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Lennox ROOFTOP FLEXY FCA Series User Manual

Lennox ROOFTOP FLEXY FCA Series
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INSTALLATION
OPERATING &
MAINTENANCE MANUAL
ROOFTOP
FLEXY
English
Sept 2001
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Lennox ROOFTOP FLEXY FCA Series Specifications

General IconGeneral
Gas Heating Efficiency80% AFUE
RefrigerantR-410A
StagesSingle-stage
Heating TypeGas
Voltage208/230V or 460V
Sound Level76 dB

Summary

Transport and Handling

Delivery Checks

Checks to ensure products are in good working order upon receipt.

Storage Recommendations

Recommended procedures for units put into storage for medium to long-term.

Maintenance Key

Advice on keeping the maintenance key in an accessible place for panel access.

Rating Plate Information

Explanation of the information provided on the unit's rating plate.

Dimensions and Weights

Table detailing the dimensions and weights of various roof-top unit models.

Handling Procedures

Guidance on how to move the equipment using lifting holes and slings.

Installation Procedures

Preliminary Checks

Items to check before installing the equipment for proper operation.

Installation Device Requirements

Requirements for the installation surface and necessary clearances.

Connections Device Guidelines

Ensuring pipework is secured, insulated, and avoiding condensation.

Installation on Roof Mounting Frame

Recommendations for correct installation on a roof mounting frame.

Installation on Posts

Guidance on fitting the unit on corner posts using the provided frame.

Commissioning Process

Pre-Power Connection Checks

Checks required before connecting the unit to the power supply.

System Power-Up Procedure

Steps for powering up the system with the unit isolating switch.

Using CLIMATIC™ System

Guidance on operating and interacting with the CLIMATIC™ system.

Thermodynamic Readings and Environmental Conditions

Interpreting readings using manometers based on environmental factors.

Safety Tests

Performing various safety tests on the unit's components.

Reverse Cycle Test

Procedure for testing reversible units' cycle functionality.

Air Flow Balancing

Air Flow Balancing Test and Adjustment

Procedure for testing and adjusting airflow using pulleys and belts.

Unit and Fan Kit Reference Table

Table referencing unit/fan kits for airflow balancing purposes.

Air Flow Balancing Example

Detailed example of airflow balancing calculation and adjustment process.

Airflow Balancing for FXA/FXK Models

Specific procedure for balancing airflow on FXA/FXK models.

Filters Maintenance

Filter Status and Error Codes

Understanding error codes related to filters and their meaning.

Filter Replacement Procedure

Instructions for replacing the unit's filters, including removal and installation.

Hot Water Coils

Hydraulic Connections

Procedure for connecting the heating coil to isolating valves correctly.

Electrolytic Corrosion Warning

Warning about potential corrosion from electrolytic reaction.

Condensate Drains

Assembling and installing condensate traps for proper drainage.

Protection Against Freezing

Methods to protect the unit's water coils against freezing.

Gas Burner Operation and Maintenance

Preliminary Checks on Commissioning

Checks required before commissioning the gas burner.

Ignition Details and Sequence

Explanation of the burner ignition sequence and operation.

Pressure Reducing Valve Setting

Procedure for setting the pressure reducing valve for gas burners.

Pressure Regulator Control and Setting

Adjusting pressure regulator settings for burner tiers.

Ignition Electrode Checks

Checks for the ignition electrode tip condition and correct spacing.

Ionisation Sensor Placement

Correct placement of the ionisation sensor within the flame.

Gas Burner Service and Troubleshooting

Burner Disassembly for Service

Steps for disassembling the gas burner for service and maintenance.

Gas Burner Troubleshooting

Common problems and solutions for gas burner operation.

Burner Reassembly Procedure

Procedure for reassembling the gas burner components after service.

Belt Tensioning and Maintenance

Initial Tensioning and Checks

Initial belt tensioning and checks after 50 operating hours.

Belt Replacement Criteria

Conditions and procedure for replacing drive belts.

Pulleys and Transmission

Fan Pulley Removal

Steps to safely remove the fan pulley from the shaft.

Fan Pulley Installation

Procedure for cleaning, installing, and securing the fan pulley.

Pulley Motor Installation and Removal

Steps for installing and removing the pulley motor assembly.

Transmission Alignment

Checking transmission alignment using a ruler after pulley adjustment.

KP17 Comfort Control Display

KP17 Display Overview

Explanation of the KP17 Comfort control display interface and features.

KP17 Wiring Requirements

Requirements for connecting the KP17 remote display using recommended cable.

KP02 Maintenance Control Display

KP02 Display Callout

Identification of components and labels on the KP02 display unit.

KP02 Display Formats

Examples of display formats for hour, date, and variable values.

KP02 Operating Modes

Explanation of the four operating modes of the maintenance display.

KP02 Date Reading and Setting Modes

Procedures for reading and setting date and time modes.

KP02 Variable and Setpoint Modes

Procedures for navigating and changing variable and setpoint values.

KP02 Password Access

Procedure for accessing setpoints using a password.

KP02 Setpoint List (1st Level)

Table listing first-level setpoints with their possible ranges.

KP02 Setpoint List (2nd Level)

Table listing second-level setpoints with their possible ranges.

KP02 Variable List (1st Level)

List of variables with their corresponding numbers for the 1st level.

KP07 Graphic Control Display

KP07 Screen Keys Overview

Explanation of the KP07 display screen keys and their variable functions.

KP07 Fixed Keys Functions

Description of the 5 fixed function keys on the KP07 display.

KP07 Modification Mode

Mode for changing variable values on the active screen.

KP07 Power Status Indicator (LED 4)

Indicates when the machine is powered up.

KP07 General Fault Indicator (LED 5)

Indicates when a general fault has been detected.

KP07 Contrast Setting

How to adjust the display contrast in modification mode.

KP07 General Screen Layout

Overview of the KP07 graphic control display screen layout.

KP07 Index of Icons

Explanation of icons used for keys, sensors, conditions, and errors.

KP07 Icons: Sensors

Icons representing different sensors on the display.

KP07 Icons: Operating Conditions

Icons representing various operating conditions.

KP07 Icons: Operating Status

Icons representing different operating statuses.

KP07 Icons: Errors

Icons representing various error codes and fault states.

BMS Volt-Free Contacts Kit

Input Connections for BMS

Description of input functions for BMS connection via hard contacts.

Output Functions for BMS

Description of output functions for BMS connection.

CLIMATIC™ Parameters

ON/OFF Control

How to turn the unit ON or OFF via setpoints or remote control.

Time Slot Parameter Definition

Programming operating zones and time slots for daily control.

Parameter Descriptions

Details of parameters defined for time slots and their functions.

Advance Activation of Morning Slot

Adjusting switch time to the morning slot based on thermal inertia.

Ambient Air Regulation

Power factors for cooling/heating based on temperature difference.

Order of Components in Regulation

Sequence of component activation for cooling and heating operations.

Supply Air Regulation

Maintaining supplied air temperature using setpoint 61.

Humidity Regulation

Power factors for dehumidifying/humidifying based on hygrometry.

Blowing Regulation by Air Damper

Activating air damper regulation using setpoint 66.

Dehumidifying Regulation

Control stages and differentials for dehumidification.

Humidifying Regulation

Control of humidity using band percentage and setpoints.

Setting Fresh Air Minimum

Setting minimum fresh air damper opening percentage.

CO2 Sensor Function

Calculating fresh air minimum based on CO2 ratio.

Enthalpy Function

Using the economiser register based on air enthalpy.

Compressor-Related Functions

Anti-short cycle and equalisation of compressor operating times.

Defrost Function

Programming cycle inversion for defrosting the outside coil.

Electricity and Wiring Diagrams

Electrical Wiring Diagrams Overview

References to diagrams for selecting equipment wiring.

Diagram of Power

Diagram illustrating the unit's power supply circuit.

CLIMATIC™ Controller Wiring

Wiring diagrams for the CLIMATIC™ controller.

CLIMATIC™ Controller Outputs Wiring

Wiring diagrams for CLIMATIC™ controller outputs.

DAD Module Wiring

Wiring diagram for the DAD module.

RS 232 Interface Wiring

Wiring diagram for the RS 232 interface connection.

KP07 Wiring Diagram

Wiring diagram for the KP07 graphic control display.

GTC Wiring Diagram

Wiring diagram for the GTC system.

Electrical Wiring Diagrams List of Items

List of electrical components and their corresponding references.

Safety and Error Codes

Error Code Table

Table listing safety and error codes with their descriptions.

Detailed Error Code Explanations

Detailed explanations for specific safety and error codes.

Before Calling for Assistance

General Checks

Basic checks to perform before seeking technical assistance.

Main Operating Faults

Common operating faults, their causes, and solutions.

Planned Maintenance

Motor-Fan Assembly Maintenance

Maintenance for motor and fan assembly, including belt tension checks.

Filter Maintenance

Maintenance schedule for filters, including cleaning instructions.

Heat Exchanger Maintenance

Importance of keeping heat exchangers clean for optimal performance.

Evaporator Coil (Internal) Maintenance

Maintenance recommendations for the internal evaporator coil.

Condenser Coil (External) Maintenance

Maintenance recommendations for the external condenser coil.

Hot Water Coil Checks

Checks for the hot water coil at the start of the heating season.

Condensate Tray and Drain Trap Inspection

Inspection of condensate tray and drain trap for sediment and obstruction.

Gas Burner Annual Maintenance

Annual cleaning and checks for the gas burner and associated parts.

Electrical Terminals Check

Annual check of electrical terminals for dust and tightness.

Refrigeration Circuits Inspection

Annual inspection of refrigerant circuits and related tasks.

General Casing Maintenance

Cleaning and inspection of the equipment casing for corrosion.

Maintenance Schedule

Schedule outlining recommended maintenance tasks at different intervals.

Warranty Terms and Conditions

General Warranty Terms

General warranty terms, period, and conditions.

Anti-Corrosion Warranty for Casing

10-year warranty for rooftop casing against corrosion.

Warranty vs. Maintenance Clarification

Clarification on warranty requirements and maintenance contract obligations.

ISO 9001 Certification

CE Certification of Conformity

EU4 Filter Fire Class

33 kW Gas Burner CE Certification

60 kW Gas Burner CE Certification

120 kW Gas Burner CE Certification

180 kW Gas Burner CE Certification

Insulation Fire Class

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