LENNOX BALTIC-IOM Air cooled rooftop packaged unit Installation Guide

BALTIC-IOM Air cooled rooftop packaged unit

Baltic
Air cooled rooftop packaged units Installation, Operating and Maintenance
BALTIC-IOM-2022.03-EN

CONTENTS
INSTALLATION, OPERATING & MAINTENANCE
MANUAL
Ref : BALTIC-IOM-2022.03-EN
INTRODUCTION………………………………………………………………………………………………………………………………………………. 1
GENERAL DESCRIPTION ……………………………………………………………………………………………………………………………………….. 1 COMPLIANCE WITH REGULATIONS AND DIRECTIVES………………………………………………………………………………………………..1 SAFETY CODES & REGULATIONS…………………………………………………………………………………………………………………………….1 MACHINE DESIGNATION ……………………………………………………………………………………………………………………………………… 2 AIRFLOW LIMITS………………………………………………………………………………………………………………………………………………….2 EMC DIRECTIVE COMPLIANCE ………………………………………………………………………………………………………………………………. 3 F-GAS REGULATION ……………………………………………………………………………………………………………………………………………… 3 WARRANTY………………………………………………………………………………………………………………………………………………………… 3 NOTES FOR UNIT FITTED WITH GAS BURNER …………………………………………………………………………………………………………… 4 SAFETY ……………………………………………………………………………………………………………………………………………………………… 5 LABELS ………………………………………………………………………………………………………………………………………………………………. 6 PED DIRECTIVE …………………………………………………………………………………………………………………………………………………… 7 MAIN SAFETY RECOMMENDATIONS ……………………………………………………………………………………………………………………… 8 DELIVERY CHECKS………………………………………………………………………………………………………………………………………………10 RATING PLATE …………………………………………………………………………………………………………………………………………………… 10 STORAGE …………………………………………………………………………………………………………………………………………………………. 10 MAINTENANCE KEY …………………………………………………………………………………………………………………………………………… 11 CONDENSATE DRAINS………………………………………………………………………………………………………………………………………… 11 OPERATING LIMITS……………………………………………………………………………………………………………………………………………. 12
HANDLING …………………………………………………………………………………………………………………………………………………… 13
MANDATORY HANDLING DEVICES ……………………………………………………………………………………………………………………….. 13 DIMENSIONS AND WEIGHTS ………………………………………………………………………………………………………………………………. 14 LIFTING THE UNIT ……………………………………………………………………………………………………………………………………………… 15 LIFTING THE ROOF CURBS ………………………………………………………………………………………………………………………………….. 17
INSTALLATION ……………………………………………………………………………………………………………………………………………… 18
PRELIMINARY CHECKS ……………………………………………………………………………………………………………………………………….. 18 INSTALLATION REQUIREMENTS …………………………………………………………………………………………………………………………… 18 CONNECTIONS …………………………………………………………………………………………………………………………………………………. 18 MINIMUM CLEARANCE AROUND THE UNIT ………………………………………………………………………………………………………….. 19 RECOMMENDATIONS FOR DUCTS CONNECTIONS…………………………………………………………………………………………………..20 PACKING LONG DISTANCE (OPTION) ……………………………………………………………………………………………………………………. 21 CUSTUMER WIRING ………………………………………………………………………………………………………………………………………….. 22
INSTALLATION ON A ROOFCURB……………………………………………………………………………………………………………………… 24
TYPE OF ROOFCURB ………………………………………………………………………………………………………………………………………….. 24 CURBINGAND FLASHING…………………………………………………………………………………………………………………………………….25 TRANSITION CURB …………………………………………………………………………………………………………………………………………….. 28 FOAM INSULATION INSTALLING……………………………………………………………………………………………………………………………28 FOAM GASKET INSTALLING…………………………………………………………………………………………………………………………………. 28 ELECTRICAL CONNECTION…………………………………………………………………………………………………………………………………..28 INSTALLATION ON ADJUSTABLE ROOFCURB …………………………………………………………………………………………………………. 29
HEAT RECOVERY …………………………………………………………………………………………………………………………………………… 31
SENSOR MOUNTING ……………………………………………………………………………………………………………………………………… 36
WATER CONDENSING ……………………………………………………………………………………………………………………………………. 37

SENSOR MOUNTING ……………………………………………………………………………………………………………………………………… 42
CO2 OR ADVANCED ENTHALPIC CONTROL PACK SENSOR ……………………………………………………………………………………….. 42
ECONOMISER AND EXTRACTION……………………………………………………………………………………………………………………… 43
COMMISIONING …………………………………………………………………………………………………………………………………………… 44
OPERATING LIMITS……………………………………………………………………………………………………………………………………………. 44 CASING CONDENSATION RISK …………………………………………………………………………………………………………………………….. 45 BEFORE TURNING ON THE POWER……………………………………………………………………………………………………………………….46 POWERING THE UNIT ………………………………………………………………………………………………………………………………………… 46 CLIMATICTM CONFIGURATION………………………………………………………………………………………………………………………………47 EDRIVE VENTILATION …………………………………………………………………………………………………………………………………….. 49
EDRIVETM ASSEMBLY INSTRUCTIONS & SPECIFICATION (AC VERSION) ………………………………………………………………………………………. 49 EDRIVE COUPLING DIMENSIONS (AC VERSION)………………………………………………………………………………………………………50 EDRIVETM AIRFLOW READING …………………………………………………………………………………………………………………………………….. 50 EDRIVETM FAN INVERTER CONFIGURATION (AC VERSION) ……………………………………………………………………………………………………. 50 EDRIVETM UNIT OPERATING RANGES (AC VERSION) …………………………………………………………………………………………………………… 51 GAS UNIT EDRIVETM OPERATING RANGES (AC VERSION) ……………………………………………………………………………………………………… 51 FRESH AIR WOOD …………………………………………………………………………………………………………………………………………. 52
INSTALLING ……………………………………………………………………………………………………………………………………………………… 52 WIND DIRECTION ……………………………………………………………………………………………………………………………………………… 52
FILTERS ……………………………………………………………………………………………………………………………………………………….. 53
FILTER REPLACEMENT ……………………………………………………………………………………………………………………………………….. 53
REFRIGERANT CIRCUIT …………………………………………………………………………………………………………………………………… 54
GENERIC REFRIGERANT SKETCH…………………………………………………………………………………………………………………………..54 PREHEATING OF THE CRANKCASE HEATERS ………………………………………………………………………………………………………….. 56 ELECTRONIC EXPANSION VALVE ………………………………………………………………………………………………………………………….. 56
HEATING OPTION………………………………………………………………………………………………………………………………………….. 57
HOT WATER COIL………………………………………………………………………………………………………………………………………………. 57 ELECTRIC HEATERS ……………………………………………………………………………………………………………………………………………. 58 ELECTRICAL PREHEATER …………………………………………………………………………………………………………………………………….. 59 ATMOSPHERIC GAS BURNER ………………………………………………………………………………………………………………………………. 60 PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4105 G……………………………………….. 71 LOW HEAT INJECTION PRESSURE CHECKS …………………………………………………………………………………………………………….. 72 BURNER SAFETY CHECKS ………………………………………………………………………………………………………………………………………….. 73 CONDENSING GAS BURNER………………………………………………………………………………………………………………………………… 74 RECOVERY WATER COIL …………………………………………………………………………………………………………………………………….. 84
MAINTENANCE DIAGNOSTIC…………………………………………………………………………………………………………………………… 85
MAINTENANCE PLAN …………………………………………………………………………………………………………………………………….. 89
WARRANTY………………………………………………………………………………………………………………………………………………….. 93
TERMS AND CONDITIONS……………………………………………………………………………………………………………………………………93 LIFETIME OF THE EQUIPMENT……………………………………………………………………………………………………………………………..93 DISPOSAL OF THE EQUIPMENT……………………………………………………………………………………………………………………………. 93
Original version is the English one. Other versions are translations.

INTRODUCTION
INTRODUCTION
We remind you that these instructions must be followed for operation, maintenance, repair and decommissioning of the product. Failure to follow these instructions will result in the offender assuming the manufacturer’s responsibilities.
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 parties without the prior written agreement of LENNOX.
GENERAL DESCRIPTION
The BALTIC range is an air cooled rooftop packaged unit designed for comport air conditioning.
COMPLIANCE WITH REGULATIONS AND DIRECTIVES
The units comply with the directives and regulations which apply at the time of their placing on the market. For more information, please see the product’s Declaration of Conformity.
SAFETY CODES & REGULATIONS
The unit is designed for outdoor installation only. The unit must be installed in accordance with local safety codes and regulations and can only be used in well ventilated area.
Inspections and requalification according pressure equipment directive must follow the local regulations where the unit is installed. Commissioning, monitoring, periodic verification and requalification obligations may be made mandatory in some countries. Please refer to it when installing the equipment.
You must read and be familiar with this operating manual prior to set up the equipment and commission the unit. Please closely follow the instructions. We would like to stress the importance of training with respect to the correct handling of the unit. Please consult LENNOX on the options available in this field. It is important that this manual is stored in a permanent location in the vicinity of the unit

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INTRODUCTION
MACHINE DESIGNATION
BAC065DNM5M

BA BALTIC
C Cooling only unit H Heat pump unit

M 400V/3/50
5 Revision number
H HFO GAS N Without refrigerant P R32
S 1 circuit D 2 circuits T 3 circuits F 4 circuits

Model designation

C BOX

D BOX

E BOX

E+ BOX

025 030 040 042 045 055 057 065 075 085 095 115 125

AIRFLOW LIMITS

Bo x
Model designation Minimum airflow Nominal airflow Maximum
airflow ST D
Maximum airflow
(option airflow boost)

25

30 C BOX
40

42

45

55 D BOX
57

65

75 E BOX
85

95

E+ BOX

115

125

3500 3500 3780 4140 5000 5000 5940 6660 9500 9500 12900 13800 14700

4200 5700 6300 6900 7100 8300 9900 11100 13500 14500 19500 22000 23500

5600 6800 8400 8400 9700 11200 13100 13100 17000 19000 23000 23000 24500

5600 6800 10000 10000 9700 11200 16000 16000 22000 22000 23000 23000 24500

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INTRODUCTION
EMC DIRECTIVE COMPLIANCE
WARNING:
This equipment is a “B class” according EMC Directive. In an industrial environment, this device can create radio electrical noise. In this case, the owner can be asked to take appropriated actions.
The units comply with the most stringent environmental standards according to the product’s Declaration of Conformity.
This applies to all units installed with nominal amps below <75A:
· The short-circuit rate Rsce=33 is defined in the EN61000-3-12 standard relative to the harmonics readings on the supply network. The appliances compliant with the harmonic current limits equivalent to Rsce=33 can be connected in whatever connection point of the main supply system.
· The maximal allowable impedance of the main supply system Zmax=0.30 is defined by EN 61000-3-11 standard relative to the voltage variation, fluctuation and flicker readings. The connection to the supply is a conditional connection submitted to the preliminary agreement of the power supply local provider.
The differences between the various machines are only related to the power of the compressors and equipment that are associated. For conducted and radiated emission and immunity, these differences do not alter the results.
F-Gas REGULATION
PLEASE READ THE SAFETY DATA SHEET OF THE REFRIGERANT BEFORE ANY INTERVENTION OR INSTALLATION OF THE MACHINE. Operators of refrigeration equipment’s must comply with the obligations defined in
· Regulation on Fluorinated greenhouse gases (F Gas) · Regulation on substances that deplete the ozone layer
Non-compliance with these requirements is an offence and liable of financial penalties.
Moreover, in case of problem it is mandatory to prove to the insurance company that the equipment complies with the F gas Regulation, as well as that all measures have been taken to safeguard people, environment and property.
WARRANTY
The warranty of the unit is subject to the warranty definitions as agreed upon in the order. It is expected that the design and installation of the unit utilizes good working practices. The warranty will be legally null and void if:
· Service and maintenance have not been executed in accordance with the regulations; repairs have not been carried out by LENNOX personnel or have been implemented without prior written permission by LENNOX.
· Modifications have been made to the equipment without prior written permission by LENNOX. · Settings and protections have been modified without prior written permission by LENNOX. · Non-original or other than the prescribed refrigerants or lubricants are used. · The equipment has not been installed and/or connected in accordance with the installation instructions. · The equipment is being used improperly, incorrectly, negligently or not in accordance with its nature and/or purpose. · A flow protection device is not fitted. · The unit maintenance booklet is not complete or not available.
In these circumstances LENNOX is indemnified from any product liability claims from third parties. In the event of a warranty claim the machine serial number and LENNOX order number must be quoted.
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

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INTRODUCTION
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 GAS BURNER, MINIMUM CLEARANCE AROUND THE UNIT MUST BE AT LEAST 8 M TO ALLOW A PROPER COMBUSTION FUMES DILUTION. IF NOT POSSIBLE, THE FRESH AIR INTAKE MUST BE DUCTED AT LEAST 8 M AWAY FROM THE GAS BURNER EXHAUST. PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING THIS UNIT
Switchgear must be installed on each unit in accordance with the Machine Directive and the standard EN 60204.
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

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INTRODUCTION
SAFETY
The safety information contained in this manual is provided as a guide for the safe handling of this installation. LENNOX does not vouch for the completeness of this information and can therefore not accept liability for any possible omissions. Everyone involved in the product life cycle must perform a risk analysis. This applies to manufacturers, installers, maintainers and end- users. If risks are not eliminated or remain at unacceptable levels of occurrence or severity, they must be communicated to the next party (the customer in general) through the drafting of an installation, use, maintenance guide.
In the roof tops, heat is being transported by a pressurized refrigerant, with changes in pressure and temperature. For air cooled roof tops, fans have been provided to discharge heat into the environment. The protection of operating and maintenance personnel was central in the design of the roof top. Safety features have been included to prevent excessive pressure in the system. Sheet metal parts have been fitted to prevent inadvertent contact with (hot) pipes. For air cooled roof tops, the fans are equipped with protective grids and the electrical. The service panels can only be opened using tools.

Notwithstanding that the units are equipped with extensive safety and protection features, the utmost care and attention is needed when carrying out operations on the machine. Furthermore, ear protection should be worn when working on or in the vicinity of the roof tops. All operations on the cooling circuit or electrical equipment should be carried out by authorized personnel.

It is essential to follow non exhaustive recommendations hereunder:
· Never work on a unit that is still energized. Wait 15 minutes before working on the machine after a power outage (discharge of the capacitors).
· Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorized engineer. These procedures must be carried out with the unit shut-down.
· Never work on an electrical component until the general power supply to the unit has been cut. During any maintenance operations on the unit, lock the power supply circuit in the open position ahead of the machine. If the work is interrupted, check the lock before resuming the work.
· WARNING: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuit disconnect switch is open. Refer to the wiring diagram for further details.
· In case of maintenance operations on fans (grills replacement …) ensure that the power is shut off to avoid automatic restart.
· Before the opening of the refrigerant circuit, check the pressure with manometers or pressure sensors, and purge the circuit in accordance with current environmental directives.
· Never leave a unit stopped with valves closed on the liquid line, refrigerant could be trapped and the pressure would rise. · All installation parts must be maintained by the personnel in charge, in order to avoid material deterioration and injuries
to people. Faults and leaks must be repaired immediately. The authorized technician must have the responsibility to repair the fault immediately. Each time repairs have been carried out to the unit, the operation of the safety devices must be re-checked. · Follow guidance and recommendations given in safety and machine standards such as EN378, ISO5149, etc. The use of the EN 378-2 standard provides you with the state of the art with regard to the essential safety requirements of the Machine Directives and PED. · Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances. · Never exceed the specified maximum operating pressures. · Verify the allowable maximum high- and low-side test pressures by checking the instructions in this manual and the pressures given on the unit name plate. · Do not use air for leak testing. Use only nidron or dry nitrogen. · Do not unweld or flame cut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and vapor) has been removed from roof top. Successive purges with a neutral gas (such as dry nitrogen) are recommended to remove all traces of refrigerant. Refrigerant in contact with an open flame produces toxic gases. · Do not siphon refrigerant · Wearing PPE is mandatory (glasses, cuffs, gloves, masks). Avoid splashing refrigerant on the skin or in the eyes. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, immediately and abundantly flush the eyes with water and consult a doctor

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INTRODUCTION
LABELS
The rooftop may be marked with the following warning labels to alert to potential hazards (on or near the potentially hazardous part). The rooftop may include the following labels

High temperatures

Low temperatures

Rotating parts

Sharp parts

Electrical Voltage

A2L: slightly flammable

Non-flammable liquefied gas (high pressure)

Flammable liquefied gas (high pressure)

Don’t walk on it

Wear of PPE (Personal protective equipment)

Warning Inflammable dusty filters

Don’t strap

Gravity center

Warning main switch supplied from bottom

EUROVENT certification

Protection by water filter Protection by strainer filter

mandatory

mandatory

OK to send document

Information to read

Electrical connections can loosen during transport. Please check them before start-up.

CMIM marking (Morocco)

CE marking

CA marking (UK)

EAC Marking (Russia)

Regularly check that the warning labels are still in the correct positions on the machine and replace them if necessary.

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INTRODUCTION
PED DIRECTIVE
For units covered by the Pressure Equipment Directive (see EU Declaration of Conformity).
! Warning:
1. Attention: The high-pressure safety switches are essential elements which guarantee the system remains within the admissible operating limits. Before switching on the installation, always ensure all electrical connections are correct on these elements. Carry out a test to ensure the electrical power supply is effectively turned off when the pressure switch attains its set value.
2. In case of installation in a seismic zone or in a zone which may be effected by violent natural occurrences such as storms, tornados, floods, tidal waves, etc…., the installer and/or operator will refer to valid standards and regulations in order to ensure the devices required are available as our units are not designed to operate under such conditions without prior precautions.
3. The equipment is not designed to resist fire. The installation site will therefore have to respect valid standards about protection against fire (emergency instructions, map…).
4. In case of exposure to corrosive external atmospheres or products, the installer and/or operator shall take the necessary precautions to avoid damage to the equipment and will make sure the equipment provided has the necessary and sufficient anti-corrosion protection.
5. To respect a sufficient number of supports for the piping according to their size and weight under operating conditions and to design the piping to avoid a water hammer phenomenon
6. For technical reasons, it is not possible to carry out hydrostatic tests on all our units. Our rooftops are hermetically sealed products according to the definition of the F-Gas directive and certain local regulations such as CH35 in France. Leak tests are carried out as a compensatory measure. (The entire circuit is checked using leak detectors). For machines charged with refrigerant, at the end of the test, an HP test is carried out in the factory to make sure the pressure switch is working properly.
7. Before any work is carried out on the refrigeration circuit, the dry air or nitrogen pressure our units are supplied with must be released (For units not charged with refrigerant in the factory.)
8. If a valve is fitted, the emissions of refrigerant via the safety relief valves must be channeled to the exterior of the machine room. The valve should be sized and connected in compliance with current standards.
9. Installation and maintenance of these machines must be carried out by personnel qualified to work on refrigeration equipment.
10. All interventions must be carried out in conformity with valid safety regulations (e. g.: EN 378), as well as the recommendations indicated on the labels and handbooks provided with the machine. All actions shall be taken to avoid access of unauthorized persons.
11. It is essential that any pipework or other components of the refrigeration circuit hazardous to people because of their surface temperature are insulated or identified.
12. Ensure that the installation zone (room or area) of the machine has restricted access and ensure the good condition of the covering.

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INTRODUCTION
MAIN SAFETY RECOMMENDATIONS
All work on the unit must be carried out by a qualified and authorized employee. Non-compliance with the following instructions may result in injury or serious accidents.
WORK ON THE UNIT: The risk analyses of our machines are carried out considering operation in a standard environment with unpolluted air. For other applications, which do not meet this criterion (Kitchen, industry, …) please contact your local sales representative.
· 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 authorization.
WORK ON THE REFRIGERATING CIRCUIT(S): · Monitoring of the pressures, draining and filling of the system under pressure shall be carried out using equipment designed for this purpose and suitable for the refrigerant contained in the rooftop. · 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 unbracing 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 EN1044 AG107 (minimum 30% silver).
REPLACING COMPONENTS, EQUIPMENT AND PIPING: · Replacement shall be carried out using spare parts, or using parts approved by Lennox. · Only the refrigerant shown on the manufacturer’s nameplate shall be used.
PARAMETERING AND CONTROL: · For any intervention related to parameterization, controls and unit operation management, refer to “Climatic Roof-Top and Unitary” user manual.
FILTERS: · Choose the filters fire classification’s according to local regulations

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INTRODUCTION
TRANSPORT ­ HANDLING · Never lift the unit without forklift protections · Remove the forklift protection before installation · If access to the installation is difficult, provide guard rail. This recommendation is valid for installations in general and 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 · Installation of the unit and accessibility must be compliant with the local regulations. Ensure that all access equipment allow maintenance operation in safety (electrical cabinet, main switch, panels, filter, refrigerant circuit…) · It is strictly forbidden to walk or store equipment or material on top of the rooftop unit · Equipment designed to withstand transport and handling according to the established protocol (for the handling protocol, please refer to the installation instructions for the relevant product range). · All unloading operations must be carried out with suitable equipment (crane, forklift truck, etc.). · When using a forklift truck, you must respect the positions and the direction of handling indicated on the products. · The equipment must be handled with care to avoid damage to the bodywork, pipework, condenser, etc.
ROOFTOP INSTALLATION IN HEAVY WIND LOCATIONS · The roofcurbs (vertical & horizontal) and rooftops are designed to withstand winds up to 80 km/h. Above this limit, it’s recommended to take appropriate actions to secure the installation. · Ensure the fresh air inlet does not face prevailing wind direction.
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
FAN COMPARTMENT: · Stop the power before accessing the fan compartment.
Warning: the unit is working under pressure. Never open the panels when the unit is working. Even after shutting down the unit, wait for 2 minutes until the fans are completely stopped before opening any panel.
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, it’s mandatory to ensure that the gas distribution system is compatible with the adjustment and settings of the unit.
WARNING:
· The units are not designed to resist to a fire. The installation site must comply with the standards relating to fire protection. · In case of installation of the units in an area recognized as being potentially at risk for natural phenomena (tornado,
earthquake, tidal wave, lightning…), please follow the standards and regulations, and provide the necessary devices to prevent from these risks. · In the event of fire, refrigerating circuits are liable to rise in pressure above the maximum working pressure and release refrigerant and oil. Please take this into account in your risk analyses.

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INTRODUCTION
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: +5/-5%. 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:
· year of manufacture · weight of the unit · type of refrigerant used + GWP
(Global warming potential) · required charge for each circuit · operating Pressure min/max · operating Temperature min/max

CE marking: 7 possible cases

– CE

-CE0038 or CE0094

– CE1312

-CE0038 or CE0094 + CE1312

– Absence of CE marking (outside the EC only)

This product is used for Air Conditioning. Contains fluorinated greenhouse gases covered by the Kyoto protocol. Hermetically sealed.

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 (for water condensing rooftops) . · Keep the heat exchanger protection if any. · 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. · Store the unit on an appropriate place (flat surface). · Storage temperature must be respected according to the information given on the rating plate
It is strongly recommended to store units is a dry, sheltered place (in particular for units that will be installed indoor).

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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.
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. The drains must be installed in vertical position.

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INTRODUCTION
OPERATING LIMITS
MACHINE OPERATING LIMITS The machine must work without thermodynamics with an outside air between -20°C and 50°C

THERMODYNAMIC OPERATING LIMITS
Heating mode
Outdoor air temperature °C ­

Cooling mode
Outdoor air temperature °C ­

Coil indoor inlet temperature (°C)

Coil indoor inlet temperature (°C)

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HANDLING
HANDLING
MANDATORY HANDLING DEVICES
Handling slings to guide the unit towards the roofcurb

Vacuum lifting beam to position the unit
COMPLIANT

NON COMPLIANT

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HANDLING
DIMENSIONS AND WEIGHTS

MACHINE
C BOX D BOX E BOX E+ BOX

Length (mm)
2300 +/-15 2810 +/-15 3690 +/-15 3690+/-15

Width (mm)
2260 +/-15 2260 +/-15 2260 +/-15 2260 +/-15

Height (mm)
1260 +/-15 1260 +/-15 1260 +/-15 1620+/-15

Width with hood Transport length Transport Width Transport Height

(mm)

(mm)

(mm)

(mm)

2710+/-20 2710+/-20 2710+/-20

2310 2810 3690

2309 2309 2309

1260 1260 1260

2710+/-20

3690

2364

1619

C BOX

D BOX

E BOX

E+ BOX

BAH ­ Air cooled

25

30

40

42

45

55

57

65

75

85

95

115

125

Weight of basic units without any options.

600

620

660

660

860

860

920

920 1150 1150 1350 1350 1350

Weight of basic units without any options. All weights are given in kg (+/- 5%). Individual weight of a given rooftop is indicated on the rating plate and on the sale’s offer. For each product to be lifted, check in advance the compatibility between the load and the capacity of the handling equipment.

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14

HANDLING
LIFTING THE UNIT
LIFTING THE UNIT WITH A CRANE
LIFTING SHACKLES DIMENSIONS
Use lifting shackles on each lifting lug located on each angle of the unit. Maximum diameter of the ring shaft = 20 mm
LIFTING BELTS/STRAPS LENGTH
The unit must be lifted using spacing beams to avoid the belts damages to the casing. Spacing beams must have a length equal to the machine width ­ i.e. 2250 mm.
5m
Spacer Beam

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15

HANDLING FORKLIFT PROTECTIONS

Do not remove the unit plastic cover while lifting.

NO DO NOT LIFT THIS SIDE
Do not lift the unit by the side (coil end side or drain pan outlet side). This will damage the unit. Lift the unit on the long side using a forklift with dimensions according to the figure below. Do not remove the unit plastic cover while lifting.
REMOVING THE FORKLIFT PROTECTION LOCATED UNDER THE MACHINE (Units C, D, E, E+) Before installation, remove the forklift protection which is located under machine desk.

IMPORTANT note about forklift protection removal Take care not to hurt anybody when removing the forklift rails. Locate the machine on a safe area while removing the forklift rails from the machine
WARNING: NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS REMOVE THE FORKLIFT PROTECTIONS BEFORE INSTALLATION

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16

HANDLING
LIFTING THE ROOF CURBS
Do not install the unit on the refrigeration side on Roofcurb.

DUCTING CONNECTION DETAILS The supply and return air ducts can be secured to the 30 mm flanges at the bottom of the roofcurb. Any ducting weight above 100 kg must be fixed independently to other building frames.
Minimum distance : 30 mm

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17

INSTALLATION
INSTALLATION
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
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 installing two units side by side or close to each other as this may restrict the airflow to the condensers. · Uneven surfaces are prohibited. The surface must be flat and respect a maximal flatness of 0.5mm per linear meter (in both
directions length and width). · The entire surface of the chassis must rest on a support (except for the Lennox PIED option provided for this purpose). · For the installation of a machine without the roofcurb or box supplied by Lennox, it is imperative that the load of the
machine is evenly distributed under the entire frame.
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 pipework 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
crossed premises.
NOTE: The protection sheets fitted to the finned surfaces must be removed prior to start up
The customer must provide the appropriate equipment to protect the supply line to the unit. A differential of 300 mA is recommended.
If the unit is fitted with variable speed fan condensers or variable speed pumps or compressors, a type B differential is recommended.

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INSTALLATION
MINIMUM CLEARANCE AROUND THE UNIT
Figure below shows the required clearances and service access around the unit.
NOTE: Ensure the fresh air inlet does not face prevailing wind direction
· In general, the air inlet and outlet should not be obstructed. · It is also important that there are no obstructions above the fans of the unit. · Make sure that the fresh air duct is not in the same direction as the prevailing winds. · If machine is including gas burner, minimum clearance around the unit must be at least 8 m to allow a proper gas flue
dilution. If not possible, the fresh air intake must be ducted at least 8 m away from the gas burner exhaust. · In case of extraction option, it is recommended to duct fresh air intake. In order to ensure good air quality, it is
recommended to separate fresh air and exhaust air by at least 8m. · An approach ramp must be installed if the unit’s installation requirements tell that it’s necessary to reach the main switch,
the electrical cabinet, the compressor and the ventilation compartment. This recommendation is valid for all type of installations. · It is also important to respect a minimal clearance of 3 meters above of the unit, to allow a good operation of the outdoor fans. · If you have any questions about the implementation, please contact us so that we can assist you.

*:

Add 1000 mm if the units are equipped with gas burner

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19

INSTALLATION

RECOMMENDATIONS FOR DUCTS CONNECTIONS
Some rules must be respected for the connections between ducts and unit.

Whatever the supply configuration is, respect a minimal duct’s length (D) of 2m before any elbow or any duct’s diameter change

Horizontal supply

GOOD CONNECTION

Vertical supply

GOOD CONNECTION

EXTRACTION

8m
It is recommended to sheath the exhaust air by at least 8m (according to local regulations) to escape the fresh air inlet when the input-output are on the same side.
General remarks: It is forbidden to walk on the machine. The machine must not be used to support the ducts.

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INSTALLATION
PACKING LONG DISTANCE (OPTION)
When one of the long-distance packaging options is ordered (SEI2 / SEI3), remember to remove the supports (e.g. 4-way valves) before commissioning. It is advisable to keep the supports during installation.

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INSTALLATION
CUSTUMER WIRING
VERTICAL CUSTOMER WIRING 1- Remove the indicated plate.
Drill the sheet metal to the diameter of the cable glands It is recommended to use only one cable per cable gland 2- Place the cable glands on the plate.
3- Wire through the plate. 4- Replace the plate.

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INSTALLATION Accessibility for main switch connection on C-Box (size 25-30-40-42) Accessibility for main switch connection on C-Box. In case of full options control panel, the access to connect the power cable to the main switch can be limited. Therefore a removable hatch is available at the back of the control board (accessible from the ventilation panel). When the cable connection is finished, it’s important to put the hatch back in its initial position.
HORIZONTAL CUSTOMER WIRING

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INSTALLATION ON A ROOFCURB
INSTALLATION ON A ROOFCURB
TYPE OF ROOFCURB
Non adjustable roofcurb
ADHESIVE GASKET PVC 20X14 TECNOCEL

Adjustable roofcurb
ADHESIVE GASKET PVC 20X15 TECNOCEL

Exhaust roofcurb

Multidirectionnal roofcurb

WARNING : a multidirectionnal flowcurb and horizontal extraction flowcurb must be secured to the ground using existing fixing holes on the frame.
WARNING : a roofcurb must be strongly secured to the ground. The contact to the ground must be realized with the entire contact area of the roofcurb (no discontinuous contact).

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INSTALLATION ON A ROOFCURB
CURBING AND FLASHING
Check that the insulation is continuous, counter flash and seal around the frame as shown CAUTION: To be effective, the upstream must end below the drop edge. Where pipes and electrical conduits extend through the roof, flashing must conform to local codes of practice
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.
Gasket

Rooftop

Sealing / fire bulkhead Insulation

Roofcurb

Building frame

Siding

• Check that the roofcurb height is enough to respect a sealing height of 150mm minimum (French DTU 43.3) considering the building specifications: geometry of the roof, material and thickness of the insulations and other protection layers, slope of the roof…).

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25

INSTALLATION ON A ROOFCURB
NON-ADJUSTABLE NON-ASSEMBLED ROOFCURB INSTALLATION
FRAME PARTS PACKING
Different parts are used in the assembly of this roof mounting frame. There are delivered stacked on a pallet. During assembly, all parts must be sealed with a polyurethane sealant.

ADHESIVE GASKET PVC 20X14 TECNOCEL

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INSTALLATION ON A ROOFCURB
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
ASSEMBLY

Unit floor insulation + gasket
Air duct Fixing flange

Unit support rail Roofcurb

SECURING THE FRAME To ensure proper mating with units, it is mandatory that the roof mounting frame be squared to roof structure as follows:

· With frame positioned levelled in the desired location on roof trusses, tack weld corner of frame. · Measure frame diagonally from corner to corner as shown above. These dimensions must be equal in order for the fame
to be square. · It is extremely important to sight frame from all corner to ensure it is not twisted across. Shim frame under any low
side. The maximum slope tolerance is 5mm per linear meter in any direction. · After the frame has been squared, straightened and shimmed, weld or secure the frame to the roof deck. NOTE: It must
be securely fastened to the roof as per local codes and regulations.

NOTE: The roofcurb must be attached to the framing in accordance with local regulations.

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INSTALLATION ON A ROOFCURB
TRANSITION CURB
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 WARNING: all the roofcurb must be strongly secured to the ground The contact to the ground must be realized with the entire contact area of the roofcurb (no discontinuous contact). All parts must be sealed with polyurethane sealant during assembly.
FOAM INSULATION INSTALLING
· Stick large foam pieces underneath the flat top
FOAM GASKET INSTALLING
· Stick gasket all around the curb flange’s top Let it free on 200 mm long to enable water drainage

ELECTRICAL CONNECTION
The extraction curbs are fitted with an extraction fan and a pressure sensor used to measure the flow of extracted air. The pressure sensor is directly connected to the first fan of the curb. The fan must be connected to the rooftop machine which is placed on the curb. This connection must be made once the machine is installed on the curb. A waiting wiring harness in the energy- saving compartment of the machine must be pulled to the terminal box on the curb intended for connection. For cable routing and connection to the terminal box, refer to the plan of the curb and the electrical diagram supplied with the machine.

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INSTALLATION ON A ROOFCURB
INSTALLATION ON ADJUSTABLE ROOFCURB
POSITIONING THE ROOFTOP ON ADJUSTABLE ROOFCURBS IMPORTANT note: Prior to put the machine, make sure to put a polyethylene gasket on the curb upper flange side (must be delivered in the curb package). This gasket must be put only on the internal perimeter of the curb

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INSTALLATION ON A ROOFCURB
CAUTION: · Installation of the unit and accessibility must be compliant with the local regulations. Ensure that all access equipment allow
maintenance operation in safety (electrical cabinet, main switch, panels, filter, refrigerant circuit…); this recommendation is valid for installations in general and in particular for return and curbs. · It’s advised to fix curbs and roofcurbs to the unit. Above all, ensure that all the adjustable returns are facing outward. They are usually turned inside-out for transport.

If H<430mm and <10°: Position in position A:

Transport position only
Good installation position If H>430 or <10°: Position in high position B

A

B

Place the roof mounting frame on the trimmer beam by first lining up the inlet and the outlet opening.

After levelling the frame, secure the adjustable returns on the trimmer. It is important to center the unit on the roof frame

When the frame is correctly positioned, it is essential to secure the assembly with a disconnected stitched welded seam (20 to 30 mm every 200mm) or M6 self- taping screws in pre-drilled holes along the outside:

Example with welded seam

Example with screws

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HEAT RECOVERY
HEAT RECOVERY
GENERAL DESCRIPTION Heat recovery modules (HRM) have following interests: · in winter season and heating mode, the heat in the extract air is exchanged with the fresh air ; · in summer season and cooling mode, the heat of the fresh air is transferred to the extract air. HRM are two plates heat exchanger modules, that differ from each other by their horizontal (HRMH) or vertical (HRMV) configuration.
TRMO is a thermodynamic heat recovery module, included in the machine. Its main interests are: · a variable fresh air rate from 25 to 100%, · a high COP in winter when pre-heating the fresh air due to a favorable evaporating temperature, especially with high air
flow rate; · a high EER in summer when pre-cooling the fresh air due to a favorable condensing temperature, especially with high air
flow rate.
For those reasons, TRMO will be more suitable than HRMV/HRMH in areas where the difference between indoor temperature and outdoor temperature is low. For example, in Mediterranean areas, where winter temperatures are not very cold or summer temperatures are not very high.

ELECTRICAL CONNECTIONS OF THE HEAT RECOVERY UNIT

Two components have to be connected in the space between the plate heat exchanger and the economizer:

· For the air pressure switch, connect and tighten the 2

· For the actuator, assembly the two parts of the

spade-tips on terminal 1 and 3 (no polarity):

connector:

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HEAT RECOVERY

HEAT RECOVERY INSTALLATION C, D, E BOX (ERVF + HRMV)

:

x4

2a

x6

mm

x2

1. Install the flowcurb. 2. Before installing the rooftop
a. Fix the brackets (5 pieces) on the curb by 24 screws(6x16mm);
b. ADJUST the position of the attachment bracket so that it is 5 mm above the support surface (without the foam);
c. Install the foam (25×10 mm) on the upper part of the flowcurb.

3. a. Fix the lower mounting bar of the heat

recovery module using 4 screws (6×16 mm)

3b

and remove the side doors;

b. Make sure that the foam is not damaged (20×15 mm).

4. Install the rooftop and remove the lifting covers.

3a
5. Place the two upper mounting bars through the two top slots.
6. Install the heat recovery module on the bracket by taking care to position properly the lower mounting bar.
Don’t forget to remove the lifting covers from the module.

7. Slide the ‘T’ plate into the lifting lug and place the bolt through it. On the opposite side, place also the bolt (detail A).
8. Finally tighten the heat recovery module with the 4 bolts 8x60mm to compress the foam (2 bolts on the upper mounting bars
(detail B) and the 2 bolts placed in step 7). Détail B
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Détail A
32

HEAT RECOVERY
THERMODYNAMIC HEAT RECOVERY – INSTALLATION
REFRIGERATION CIRCUIT
Frigorific components access: Compressor is located in the fix condenser part. Its access for electrical checking and pressure taps (HP and LP) is made through the screwed access door behind the hinged coil.
4-way valve, thermostatic expansion valve, dryer, and sensors are located on the eDriveTM supply compartment.
Electrical components: · For D and E-box, specific TRMO components are located in the electrical box. · For C-box, specific TRMO components are located on the back of the electrical box, and can be accessible from the supply e-DriveTM compartment.
COMMISSIONING
Electrical connections: · All wire connections are factory made.
Starting up: · CLIMATICTM configuration:
o Power the unit o Check the configuration of the CLIMATICTM with the DS in expert mode. · Flow rate settings: Make sure that both supply and exhaust air flow are balanced. See section EBHO or ERVF. Balancing is correctly set if: o with Test = ‘B.Nom 100%’: at 100% fresh air, set the exhaust Flow 3864 = supply flow 3333; o then switch Test = ‘B.Nom 0%’:
reduce coefficient 3866 until the louvers are closed; then if the flow (supply and exhaust) is far from the previous flow settings, set coefficient 3335; finally, repeat step 1 and 2 to obtain a constant flow whatever the fresh air mode. o same settings have to be realized for reduced flow – 3334 and 3865.
WARNING! During the settings, wait until the economizer is fully closed or opened, since it takes 1-2 minutes to switch.
· Start the TRMO circuit (circuit 3): switch Test=’C3–Cool’ o check the sense of rotation of the circuit 3 compressor; o check frigorific values (HP, LP, overheating and subcooling).
· Repeat the last operations with Test=’C3–Heat’

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HEAT RECOVERY
SERVICE DIAGNOSTIC
REFRIGERATION

Fault Low LP and LP cut out

Possible causes and symptoms Alarm 317: main frigorific issue
Alarm 327: too low LP

Solution
Lack of charge, obstructed components
Freezing: wait that coil is defrosted by exhaust air; Air flow too low on evaporating side (too low speed rate / fouled filter orcoil).

HP problem and HP cut out

Incorrect airflow rates Refrigerant charge too high

See also frigorific diagnostic of BALTICTM section ‘Refrigeration’.

Check fan (exhaust or supply) function of the mode (Amps) and also filter.
Check the refrigerant charge load according to the refrigerant load table.

INDOOR OR EXHAUST FAN BLOWER:
For both indoor supply fan and exhaust fan, same faults, causes and solutions are expected. See diagnostic of ‘Indoor fan blower’.

HEAT RECOVERY CONTROL
CONFIGURATION Configuration of CLIMATICTM with the DS in expert mode for TRMO (with a modulating exhaust fan):
3813 RECOV. = Comp. for TRMO 3815 EXHAUST = Modulate for both ERVF & EBHO 3816 KIT 3817 Motor to be checked function of your need 3818 Fan
USE
Protection : · Operating envelop Protection: compressor stopped during 6 minutes.
o 328: min HP = 20.5°Ccondensation; o 329: max HP = 62°C condensation; o 319: min LP = between -24.5°C and 1.6°C (function of the condensation temperature) during 5 min => freezing or
air flow on evaporator issue; o 327: max LP = 26°C. o 317: limit LP -27°C during 120 sec => frigorific failure (lack of refrigerant /closed components) · Anti-freezing Protection consist in defrosting the exhaust coil in heating mode with the extract air.
Control · No specific parameters have to be set for TRMO control. · Operation:
o TRMO runs if there is heating or cooling needs; o above 50% fresh air, TRMO compressor has priority to start; o under 15°C return or under 20% fresh air, TRMO compressor is not authorized to start.

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HEAT RECOVERY

ENERGY RECOVERY INSTALLATION (ERVF+HRMV) ON UNITS E+ BOX

2c

x4

5

2a

x6

x2

2b

1. Install the flowcurb 2. Before installing the rooftop:
a. Fix the brackets (5 pieces) on the curb by 24 screws (6x16mm);
b. ADJUST the position of the attachment bracket so that it is 5 mm above the support
surface (without the foam); c. Install the foam (25×10 mm) on the upper part of the
flowcurb.

3. a. Fix the lower mounting bar of the heat recovery module using 4 screws (6×16 mm) and remove the side doors;
b. Make sure that the foam is not damaged (20×15 mm).
4. Install the rooftop and remove the lifting covers

5. Place the two upper mounting bars through the two top slots.
6. Install the heat recovery module on the bracket by taking care to position properly the lower mounting bar
Don’t forget to remove the lifting covers from the module.

7. Slide the ‘T’ plate into the lifting lug and place the bolt through it. On the opposite side, place also the bolt.
8. Finally tighten the heat recovery module with the 4 bolts 8x60mm to compress the foam (2 bolts on the upper mounting bars (detail) and the 2 bolts placed in step 7).

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SENSOR MOUNTING
SENSOR MOUNTING
CO2 OR ADVANCED ENTHALPIC CONTROL PACK SENSOR The probe is delivered unassembled on the machine. The installer is responsible for mounting and connecting this sensor.
The device can be installed in dry surroundings (IP20) by screws on the wall surface or on the standard flush mounting box. The recommended installation height is 150…180 cm.
The device position should be selected carefully. All the error factors that can affect to the measurements should be eliminated as well as possible. The following list defines the typical measurement error factors
· direct sun light · occupant proximity · air flow coming from windows or doors · air flow coming from ventilation nozzles · air flow coming from the flush mounting box · differential temperature caused by external wall
NOTE: CO2 measurement causes a current peak to the supply voltage. This can produce an error to the analogue outputs when using long and thin cables. It is recommended to increase the wire cross section area in long cable situations (e.g. by using four-wire connection) to ensure reliable measurement signal.
WIRING WARNING:
Device wiring and commissioning can only be carried out by qualified professionals. Always make the wirings while the power is switched off
For wiring of external sensors (CO2, temperature, humidity), refer to the unit-specific electrical diagram (supplied in the unit cabinet).

AMBIENT TEMPERATURE PROBE (MATS) (C, D, E, E+ BOX)
For the wiring of the external sensors (CO2, temperature, humidity), refer to the unit-specific wiring diagram (supplied in the unit cabinet).

In- ntc Out-ntc

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36

WATER CONDENSING
WATER CONDENSING
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:
· 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 and easily accessible for maintenance. · 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 area, where the ambient temperature is likely to fall below 0°C, insulate the
piping and add an electric heater. · 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.

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WATER CONDENSING
WATER ANALYSIS
The water must be analyzed, the water circuit installed must include all items necessary for treatment of the water: filters, additives, intermediate exchangers, bleed valves, vents, isolating valves etc… Depending on the results of the water analysis

WARNING:
We do not advise operation of the units with open loops which can cause problems with oxygenation, or 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:
· 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. < 10 mg/l. · 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 < 5 mg/l with dissolved oxygen < 5 mg/l. Over those
values, it means a corrosion of steel which may generate a corrosion of copper parts under deposit 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 < 1mg/l. · Water hardness: TH >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. · 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 destabilization 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.
· pH: pH neutral at 20°C (7 < pH < 8)

If the water circuit must be emptied for longer than one month, the complete circuit must be placed under nitrogen charge to avoid any risk of corrosion by differential aeration.

ANTIFREEZE PROTECTION
Use glycol/water solution
WARNING:
ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZING
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

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38

WATER CONDENSING

Drain the installation
WARNING:
It is important to make sure that manual or automatic air bleeders are installed at all the high points of the water circuit. To enable drainage of the circuit, make sure that drain cocks are installed at all the low points of the circuit. To drain the circuit, the drain cocks must be opened and an air inlet ensured.
Note: air bleeders are not designed to admit air

Freezing of a heat exchanger due to cold weather conditions is not covered by Lennox warranty.
Electrolytic corrosion
WARNING:
We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an imbalance between earthing points.
AN EXCHANGER THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT WARRANTY

Minimum water capacity
WARNING:
The minimum volume of the water circuit must be calculated with the formula here under. If necessary, install a buffer tank. Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient

Vt Minimum water content of the installation (in liters) Q Unit cooling capacity (in kW) N Minimum power stage Dt Maximum temperature drift allowed (in K) Tmin Minimum operating time (in seconds) Wd Liquid density (in kg/m3) Cp Calorific capacity of the liquid (in kJ/(kg.K))

=

× × 1000 × × ×

Example of use of glycol/water solution in air conditioning installation: Dt=-6K (standard for an air conditioning application) Tmin=360s Liquid = glycol/water solution (Wd= 1000kg/m3 and Cp=4.18 kJ/(kg.K))
Vmini = 86 x Q / (N x Dt)

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39

WATER CONDENSING
VICTAULIC CONNECTION ASSEMBLY INSTRUCTION
Be careful not to roll or pinch the seal when installing the half-shells. This would cause a leak.
1- Install the bolts and tighten the nuts by hand on them. 2- Tighten bolts uniformly passing from one side to the other, until the pads for
the bolts are in metal-metal contact. Make sure the shoulders are well engaged in the grooves It is imperative to tighten the nuts evenly to avoid pinching the gasket.

WATER LOOP CONFIGURATION

Figures below show the 2 water configurations.
Figure 1 indicates all components used as standard:
· The electronic water flow switch · The water filter · The pressure taps and drain valves · The automatic air vent
Figure 2 shows rooftop water loop with Low Water Loop Temperature option.

Standard

3

2

Hydraulic configuration
1

Low Water Loop Temperature Option

3

2

1

6

5

4

6 5

4 7

1 All Victaulic Connections 2 Inlet Water Filter 3 Automatic Air Vent 4 Electronic Flow Switch

5 Pressure Taps and drain Valve 6 Stainless steel Exchanger 7 ElectroValve (HP control option)

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40

WATER CONDENSING

LOW WATER LOOP TEMPERATURE (OPTION)
In order to operate with low water inlet temperature in cooling mode (i.e.: 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 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.

Warning: the valve does not allow to do the balance on customer circuit. Several checks have to be done to avoid creating perturbations on customer circuit:

· Check valve pressure drop at water flow.

· Use variable speed pump.

· Adjust water flow switch set up at small water flow acceptable by the unit.

OUT

IN

WATER FILTER REPLACEMENT 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 pressurized. Observe the usual precautions when depressurizing the circuit before opening it. Failure to observe these rules could lead to accidents and cause injury to service personal

Access for cartridge

Perte de charge – Échangeur à plaque et Filtre à eau

Pressure loss (kPa)

Unit size 45 – 55 57-65-75-85

DWébaittde’reafluo(wm3(m/h3) /h)

Curve – filter A B

Curve -exchanger F F

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41

SENSOR MOUNTING
SENSOR MOUNTING
CO2 OR ADVANCED ENTHALPIC CONTROL PACK SENSOR
The probe is delivered unassembled on the machine. The installer is responsible for mounting and connecting this sensor.
The device can be installed in dry surroundings (IP20) by screws on the wall surface or on the standard flush mounting box. The recommended installation height is 150…180 cm.
The device position should be selected carefully. All the error factors that can affect to the measurements should be eliminated as well as possible. The following list defines the typical measurement error factors
· direct sun light · occupant proximity · air flow coming from windows or doors · air flow coming from ventilation nozzles · air flow coming from the flush mounting box · differential temperature caused by external wall
NOTE: CO2 measurement causes a current peak to the supply voltage. This can produce an error to the analogue outputs when using long and thin cables. It is recommended to increase the wire cross section area in long cable situations (e.g. by using four-wire connection) to ensure reliable measurement signal.
WIRING WARNING:
Device wiring and commissioning can only be carried out by qualified professionals. Always make the wirings while the power is switched off
For wiring of external sensors (CO2, temperature, humidity), refer to the unit-specific electrical diagram (supplied in the unit cabinet).

AMBIENT TEMPERATURE PROBE (MATS) (C, D, E, E+ BOX)
For the wiring of the external sensors (CO2, temperature, humidity), refer to the unit-specific wiring diagram (supplied in the unit cabinet).

In- ntc Out-ntc

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42

ECONOMISER AND EXTRACTION

ECONOMISER AND EXTRACTION
ECONOMISER Free cooling is provided through the use of fresh air which is more appropriate than excessive cooling amounts of return air. The economizer 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.

EXTRACTION Installed with economizer assembly, the gravity exhaust dampers relieve the pressure when outside air is introduced into the system. When large amount of fresh air is introduced into the system power exhaust fans can be used to equalize 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 50% open (adjustable value). It is overload protected. NOTE: When horizontal flow configuration is required, the multidirectional roof curb will be installed.

PRINCIPLE SKETCH

PRINCIPLE SKETCH MULTIDIRECTIONAL ROOFCURB

PRINCIPLE SKETCH ENERGY RECOVERY MODULE

PRINCIPLE SKETCH RETURN ROOFCURB

FRESH AIR RETURN AIR
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EXHAUST AIR SUPPLY AIR
43

COMMISIONING

COMMISIONING

The components are located inside the units or in a separate box and must be installed by a qualified engineer.

!

Note: In case of plate heat exchangers it is mandatory that a filter is installed at exchanger unit entrance.

These filters must remove all particles with a diameter greater than 1 mm

OPERATING LIMITS
Prior to any operation, please checks the operation limits of the unit These tables will give you all necessary information concerning the operating envelop of the unit.

!

WARNING: It is very important ensure the units operate well inside these envelopes..

Air Cooled Baltic

Size 25 30 40 42 45 55 57 65 75 85 95 115 125

Cooling Mode Operating Limits

Max. outdoor temp. at indoor 27°C DB/ 19°C WB

°C 48 46

Max outdoor temp with unloading °C non 50

46 45 48 46 46 46 48 48 48 48 48 50 50 non 50 50 50 50 50 50 50 50

Min. outdoor temp. at indoor

°C

20°C DB

-5

Max. entering indoor coil temp. at °C outdoor 38°C DB

35

Min. entering indoor coil temp. at °C outdoor 35°C DB

18

Heat Pump Mode Operating Limits

Min. outdoor temp. at indoor

°C

20°C DB (8)

-12

Min. entering indoor coil temp. at °C outdoor 7°C DB

5

Water Cooled Baltic Cooling Mode Operating Limits Max. inlet water temp at indoor 27°C DB/ 19°C WB Max. inlet water temp with unloading
Min. inlet water temp. at indoor 20°C DB
Max. inlet water temp 100% fresh air at outdoor 35°C Heat Pump Mode Operating Limits Min. inlet glycoled water temp. at indoor 20°C DB

45-55-57-65-75-85

°C

46

°C

48

°C

25

°C

38

45-55-57-65-75-85

°C

-15

Min outdoor temp with unloading Min. entering indoor coil temp. at outdoor 7°C DB

°C

-17

°C

7

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44

COMMISIONING
WARNING: Check that all recommendations related to the paragraph on flammable fluids are followed before commissioning. All the components must be installed by a qualified technician. Commissioning must only be carried out by trained refrigeration technician whom qualification certificates are compliant with the local regulation.
CASING CONDENSATION RISK
Depending of the ambient outdoor conditions and the supply air performance of the unit, some condensation on the outside skin of the unit casing may appear. This outside condensation doesn’t affect the good operation of the unit, but can only affect the visual aspect of the unit.
Find below graph with condensation risk limits depending on: · Outside Relative Humidity (% HR) · Delta temperature (K) between Outdoor dew point temperature and Dry supply air temperature

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45

COMMISIONING
BEFORE TURNING ON THE POWER
WARNING: ensure that the power supply includes 3 phases with no neutral
Perform a leak detection with a device suitable for the refrigerant of the machine.
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 displayed on the rating plate.
WIRE CONNECTION TIGHTNESS CHECKS
WARNING: check the wire connection tightness before powering up the unit. Some connections may have loosen during transport
Check the following wire connections for tightness: · Main switch connections · Mains wires linked to the contactors and circuit breakers · Cables in the 24V control supply circuit · All other connections of the unit
OIL CHARGE All units are delivered with a complete oil charge, and there is no need to add any oil before start-up or afterwards. Overcharging with oil can cause serious problems on an installation, particularly for the compressors. The oil type depends on compressor model that depends on the unit size. Use only oil approved and recommended by Lennox
POWERING THE UNIT
Power up the unit by closing the isolator switch. 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.
WARNING: a compressor rotating in the wrong direction will fail shortly.
If one of the components rotates in the wrong direction, disconnect the power supply at the machine’s isolator switch and reverse two of the component’s phases on the terminal within the electrical panel.
While starting the unit, fill in the check list sheet of this manual to be sure that the unit correctly installed and ready to operate.
· Check the current values per phase on each fan motor. · Check the current values per phase on each compressor motor. · Check suction and discharge pressures and compressor suction temperature. · Check chilled liquid entering and leaving temperatures if water cooled unit. · Check outdoor air temperature and indoor temperature. · Check if DAD is ON. · Check that the detector has warmed up and that the LED is green.
These verifications should be made as quickly as possible with a stable cooling load, i.e. the cooling load of the installation should be the same as the capacity developed by the unit. Measurements taken without heeding this condition will result in unusable and probably wrong values. These verifications can only be made once the proper operation of all safety devices and unit controls has been established.
Check if the customer’s air ducts are open to be sure the unit is not running with ducts closed. In addition, it is needed to check if the airflow and available static pressure are in accordance with the unit.

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46

COMMISIONING
CLIMATICTM CONFIGURATION
SETTINGS 1. Supply Air-flow adjustment (depending on customer requirements) a. 3333 = nominal air flow / pressure b. 3334 = reduced air flow / pressure c. 3332 = Manual/Automatic d. 3331 = Nominal/DeadZone/PartLoad/Pressure
2. Exhaust Air-flow adjustment (optional) a. 3864 = nominal air flow b. 3865 = reduced air flow
3. Scheduling (depending on customer requirements) a. Zones & Modes (Night/Day/Day I/ DayII) b. Setpoints per mode
4. Regulation temperature probe selection a. Select the regulation probe (DC, Return, Customer, etc.) in the Room Temp. Config screen
5. Regulation humidity sensor selection (optional) a. Select the regulation sensor (Remote, Customer) in the Room Hum. Config screen
6. Outside temperature probe selection a. Select the outdoor temp probe (Unit, Customer) in the Outside Temp. Config screen
7. Outside humidity sensor selection (optional) a. Select the outdoor hum sensor (Unit, Customer) in the Outside Hum. Config screen
8. Air quality sensor selection (optional) a. Select the air quality CO2 sensor (Remote, Customer) in the CO2 Config screen
9. Remote display configuration a. 3151 = DC simple / DC full / DM
10. Minimum fresh air a. 3121 = minimum opening %

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47

COMMISIONING

CHECK:
1. Air-flow Vs Damper

a. Test B.Nom100% : i. adjust the blower speed % (3333) to get the required airflow ii. adjust the exhaust speed % (3864) to get the required airflow
b. Test B.Nom0%: i. adjust the damper compensation (3335) to maintain the required airflow even with damper fully closed ii. adjust the damper compensation (3366) to maintain the required airflow even with damper fully closed
2. Filter safety thresholds

a. Test B.Nom100% and Test B.Nom0% : read filter P (3442) and adjust the bigger measure multiplied by 2.5 at threshold 3345 3. Frigorific circuit tests

a. Cooling mode i. Test C—Cool: (if variable speed compressor option, set speed value) 1. Check circuit pressures and temperatures 2. Check electrical consumptions
b. Heating mode i. Test C—Heat: (if variable speed compressor option, set speed value) 1. Check circuit pressures and temperatures 2. Check electrical consumptions
4. Unit option tests

a. Electrical Auxiliary heaters (Test H1-1 Full) i. Check supply temperature ii. Check electrical consumption

b. Hot Water Auxiliary heaters (Test H1-1 Full) i. Check supply temperature ii. Check valve opening
c. Gas burner heaters (Test H1-1 Full) i. Refer to gas burner chapter
d. Electrical Fresh-air pre-heaters (Test H2-1 Full) i. Check supply temperature ii. Check electrical consumption
e. Hot water eRecovery heaters (Test H2-1 Full) i. Check supply temperature ii. Check valve opening
f. TRMO i. Test C3—Cool: 1. Check circuit pressures and temperatures 2. Check electrical consumptions ii. Test C3—Heat: 1. Check circuit pressures and temperatures 2. Check electrical consumptions
g. HRMO (Rotary Wheel) i. Check wheel motor rotation
5. Advanced regulation optimization

WARNING! During the settings, wait until the economizer is fully closed or opened, since it takes 1-2 minutes to switch.

a. Compressor T i. Cooling. 1. Test C1c1 Cool: read Mix-Supply| temp and adjust compressor stage T at menu 3434 ii. Heating. 1. Test C1c1 Heat: read Mix-Supply| temp and adjust compressor stage T at menu 3444
b. Auxiliary Heaters T (Gas burner or electrical) i. Heating. 1. Test H1-1: read Mix-Supply| temp and adjust heaters stage T at menu 3734
c. Staging sequence (compressor/electrical/water/burners) i. Aux Heaters Priority 3731= Never/ Always /OutTemp ii. Pre Heaters Priority 3736= First/Last
d. Dynamic setpoint i. 3225= T between customer set point and outdoor temperature
e. Fine temperature control
i. Smooth 3231= No/ DeadZone/Comfort

Once all the settings have been adjusted, the list of parameters must be downloaded (Wizard tool), stored and signed by the customer.

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48

eDrive VENTILATION
eDrive VENTILATION

eDriveTM assembly instructions & specification (AC version)
The flexible elastomeric tire is removable without removing the plates The material is natural rubber Temperature range from -42°C to + 82°C eDriveTM assembly is designed to have no adjustment to be made inside the machine In case of vertical misalignment one could use metallic washer located under the motor to adjust height
Easy to assemble

Max angular misalignment 4°

Max radial misalignment 3mm

Max axial range 8 mm

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Vibration absorbtion
49

eDrive VENTILATION

eDRIVE COUPLING DIMENSIONS (AC VERSION)
Coupling

Machine size

Motor size kW

Motor shaft diameter mm

C-BOX

1,5

24

C-BOX

2,2

28

C-BOX

3

28

C-BOX

4

28

C-BOX

5,5

38

D-BOX

2,2

28

D-BOX

3

28

D-BOX

4

28

D&E BOX

5,5 to 7,5

38

E-BOX

9 to 11

38

Fan shaft diamete r mm

Coupling reference

25

PV40

25

PV40

25

PV40

25

PV40

25

PV60

30

PV50

30

PV50

30

PV50

30

PVP50

40

PV 60

Coupling type PP

Motor bushing ref

Fan taper Ref.

2 x Taper lock bushing
2 x Taper lock bushing
2 x Taper lock bushing
2 x Taper lock bushing
2 x Taper lock bushing
1 x Taper lock bushing + D30
1 x Taper lock bushing + D30
1 x Taper lock bushing + D30
1 x Taper lock bushing + D38
2 x Taper lock bushing

28-20 al24 28-20 al25 28-20 al28 28-20 al25 28-20 al28 28-20 al25 28-20 al28 28-20 al25 40-25 a38 40-25 al25 30-25 al28 30-25 al30 30-25 al28 30-25 al30 30-25 al28 30-25 al30
30-25 al30 40-25 al 38 40-25 al 40

eDriveTM airflow reading
eDrive is controlling the airflow within the operating range of each kit. For AC fans airflow rate calculation inputs are rpm and power absorbed output read on the inverter variable bus, while on EC fans it’s based on supply pressure reading..
eDriveTM is protecting the fan & motor against over-speed & over-amps (AC version) eDriveTM is designed to keep motor and fan in its available operating range thanks to the kit configuration selected in CLIMATICTM control. The CLIMATICTM control is limiting rpm & absorbed power. The table below shows the operating ranges per box and kit size.
eDriveTM fan inverter configuration (AC version)
eDriveTM Inverter configuration is prepared in the factory to communicate with CLIMATICTM & to be configured specifically for the customer machine. eDriveTM Fan inverter parameters are configured via the CLIMATICTM unit configuration. This configuration is selecting the proper parameters to run eDriveTM in its operating range depending on fan type & motor size.
If ever, the Inverter loose fan control (No Fan or Wrong fan speed & Compressor or Heating stay on), one may check the Inverter configuration as below:
“0.0” will be displayed in this case on the Inverter instead of the regular “0” or “xxx” rpm Switch to unlock mode: F700 = 0 F732 = 0 On Inverter, set the TYP parameter to 3 value. (reinitialize the Inverter to the default values) then configure the following setpoints: F800=1 F801=0 F802=11 F803=0 Then switch OFF the whole machine & then switch ON.

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50

eDrive VENTILATION

Then the CLIMATICTM is going to send all the proper machine configuration to Inverter (motor size, fan type, Imax, safety parameters)

eDriveTM unit operating ranges (AC version)

Box

Fan type Motor

Efficiency Kit

(kW)

Comment

Rpm min

Rpm max Qv min. Qv max. Imax

AT 15-11 S

1,5

0,80

K1

553

C BOX

AT 15-11 S

2

0,83

K2

610

– BAH BAC AT 15-11 S

3

0,85

K3

697

AT 15-11 S

4

0,85

K4

78

AT 15-11 S

5,5

0,87

K5

882

ADH 355 L

2,2

0,83

K1

581

D BOX

ADH 355 L

3

0,85

K2

660

– BAH BAC ADH 355 L

4

0,85

K3

738

ADH 355 L

5,5

0,87

K4

823

ADH 355 L

7,5

0,88

K5

938

AT 15-11 G2L 5,5

0,87

K1

Fan shaft D30

648

E BOX – BAH BAC AT 15-11 G2L 7,5

0,88

K2

Fan shaft D30

774

AT 15-11 G2L

9

0,88

K3

Fan shaft D40

880

AT 15-11 G2L

9

0,88

K4

Fan shaft D30

880

AT 15-11 G2L 11

0,89

K5

Fan shaft D40

911

962 1170 1330 1371 1417 939 1208 1396 1439 1501 1302 1385 1378 1417 1417

3600 4800 3,6 3750 6000 4,9 4500 7050 6,6 5550 8250 8,4 7200 8400 12,2 5500 6900 4,9 5500 8300 6,6 6100 9700 8,4 7100 11500 12,2 9500 13100 16,3 10000 13500 12,2 10000 16000 16,3 10000 17750 17,6 10000 19000 17,6 10000 19000 23

Gas unit eDriveTM operating ranges (AC version)

Box

Fan type Motor (kW) Efficiency Kit

Comment

AT 15-11 S

1,5

C BOX

AT 15-11 S

2

– BAH BAC AT 15-11 S

3

AT 15-11 S

4

AT 15-11 S

5,5

ADH 355 L

2,2

D BOX

ADH 355 L

3

– BAH BAC ADH 355 L

4

ADH 355 L

5,5

ADH 355 L

7,5

AT 15-11 G2L 5,5

E BOX – BAH BAC

AT 15-11 G2L

7,5

AT 15-11 G2L

9

AT 15-11 G2L

9

AT 15-11 G2L

11

0,80

K1

0,83

K2

0,85

K3

0,85

K4

0,87

K5

0,83

K1

0,85

K2

0,85

K3

0,87

K4

0,88

K5

0,87

K1

0,88

K2

0,88

K3

0,88

K4

0,89

K5

ADHE 355 ADHE 355 ADHE 355 ADHE 355 ADHE 355 Axe D30 Axe D30 Axe D30 Axe D30 Axe D30

Rpm min Rpm max Qv min. Qv max. Imax

592 690 788 907 1015 651 727 826 930 1070 760 898 994 994 1072

949 1155 1386 1449 1533 929 1206 1409 1499 1578 1310 1431 1476 1476 1525

3600 4650

3,6

3750 5700

4,9

4500 6900

6,6

5400 7950

8,4

6750

8400

12,2

5500 6500

4,9

5500 7900

6,6

6100 9300

8,4

7100 11100 12,2

8700 13100 16,3

10000 13000 12,2

10000 15250 16,3

10000 17250 17,6

10000 17250 17,6

10000 19000

23

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51

FRESH AIR WOOD
FRESH AIR WOOD
INSTALLING
The fresh air hood has to be opened and secured during commissioning. The 3 parts of the fresh air hood have to be assembled thanks to self-taping screws delivered in the spare part box Check the proper position of the black seal on the top of the hood cover. Install the remote fume hoods in a safe place without risk of aspiration of dust, grease, gas and hazardous materials.
WIND DIRECTION
The prevailing wind has to be considered while choosing the machine position on the building roof. It’s highly recommended to avoid putting the fresh air hood in the prevailing wind direction to avoid water ingress risks. If this is not possible please contact us to require specific water droplet strainer in the hood section. WARNING: the fresh air hood cover can hurt your head if you don’t pay attention while turning around the unit.

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52

FILTERS
FILTERS
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 depending on the installation. · “Airflow” in menu 2333 = 25 Pa by default · “No filter ” in menu 2334 = 50 Pa by default · “Dirty Filter” in menu 2335 = 250 Pa by default
The actual pressure drop measured across the coil can be read on the Climatic Display DS in menu 2332.
The following faults may be identified · Fault code (1) Blower, Flow Switch Cut Off, if measured P across the filter and coil is below the value set in menu 2333 · Fault code (4) Blower, Filters, Dirty if measured P across the filter and coil is above the value set in menu 2335 · Fault code (5) Blower, Filters, Missing, if measured P across the filter and coil is below the value set in menu 2334
BE CAREFUL: Choose the filters’ fire classifications according to the local regulations
BE CAREFUL: Please perform a leak detection. Please note that filters can generate static electricity and are potentially flammable.

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53

REFRIGERANT CIRCUIT
REFRIGERANT CIRCUIT
GENERIC REFRIGERANT SKETCH
Depending on the unit size or the selected options, the number of circuits and compressors can change. The specific principle diagram is at the end of the electrical diagram supplied with the unit. Some connection valves (Schrader type) are available to load/unload the circuit. C BOX :

BEVBSYPCAFDBCDBYVMGVAMRL-

Indoor coil Temperature sensor Expansion valve Check valve Filter dryer Outdoor coil Low/High pressure switch Cycle reversal valve Compressor Manual valve Suction line accumulator

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54

REFRIGERANT CIRCUIT D BOX/E/E+ BOX :
Circuit 1

Circuit 2

BEVBSYPCAFDBCDBYVMGVAMRL-

Indoor coil Temperature sensor Expansion valve Check valve Filter dryer Outdoor coil Low/High pressure switch Cycle reversal valve Compressor Manual valve Suction line accumulator

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55

REFRIGERANT CIRCUIT

PREHEATING OF THE CRANKCASE HEATERS
It’s important to avoid starting the compressors without preheating of the crankcase heaters. The crankcase heaters are regulated according to the outside temperature (< 16°C).

WARNING:
In case of extended shutdown of the unit (> 6 hours), it is mandatory to power on the unit 8 hours minimum before to start the compressors equipped with crankcase heaters

ELECTRONIC EXPANSION VALVE
Different electronic valves types can be fitted on FLEXAIR range.

C BOX

D BOX

E BOX

E+ BOX

Model designation Reference

25-30-40 42 E2V30 E3V45

45-55-57-65 E2V30

75

85 95-115-125

E2V30 E3V45

E3V45

ELECTRONIC EXPANSION VALVE ADJUSTMENTS EEV allows to control superheat in bi- flow operation (see climatic user manual).
WELDING INSTRUCTIONS Electronic expansion valves are sensitive to dust ­ strainers must be used in case of replacing.

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56

HEATING OPTION
HEATING OPTION
When a heating option is installed, it is recommended to have a pressure drop of at least 100Pa in the supply duct (for example, in the case of a short supply duct, it is recommended to add a grille at the outlet of the duct).
HOT WATER COIL
HYDRAULIC CONNECTIONS Hot water coils offer fully modulating control through the use of a 3-way valve. The hot water coil, connections and valves are all tested at pressure of 15 bars. Frost protection is provided by forcing the opening the 3-ways valve when supply temperature from hot water coil falls below 8°C and by stopping the outdoor fan when that supply temperature falls below 6°C. In addition to that, the 3-ways is also opened at 10% value if the outdoor temperature falls below an adjustable value. Hot water coils are always factory fitted, wired and fully tested, prior to shipment. Hot water coil includes automatic purge system.
The hot water coil is fitted with a three-ways proportional valve and two isolating shut off valves. Two spanners must be used to tighten the connections. One spanner must maintain the valve body when connecting the pipe-work to the main. Failure to do so may damage the pipes joints and invalidates the warranty.
Filling up and starting the system · Adjust the control for Heating by reducing the simulated ambient temperature down
to 10°C · Check that the red indicators located under the valve actuator are moving correctly with the signal. · Fill the hydraulic system and bleed the coil using the air vents. Check incoming hot water. · Check the various connections for possible leaks
FREEZE PROTECTION

1. Glycol for freeze protection Check the hydraulic system contains Glycol for protection against freezing
   GLYCOL IS THE ONLY EFFECTIVE PROTECTION AGAINST FREEZING The antifreeze must protect the unit and avoid icing under winter conditions. WARNING: Mono- ethylene glycol based fluids may produce corrosive agents when mixed with air
2. Drain the installation
   You must ensure that the manual or automatic air bleeders have been installed on all high points in the system. In order to drain the system, check that all the drain cocks have been installed on all low points of the system
   HOT WATER COILS FROZEN DUE TO LOW AMBIENT CONDITIONS ARE NOT COVERED BY THE WARRANTY
   ELECTROLYTIC CORROSION Attention is drawn to the corrosion problems resulting from electrolytic reaction created by unbalanced earth connections
   ANY COIL DAMAGED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE WARRANTY

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57

HEATING OPTION
ELECTRIC HEATERS
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 93°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 cables made of reticulated silicon rubber, resistant to temperatures up to 200°C.
WARNING: electric heater is connected heater to mains power ­ risk of electrical shock ­ switch off the unit prior to open this section Size C BOX: Standard heat: 18 kW (2 stages), High Heat (Fully modulating): 36 kW Size D BOX: Standard heat: 27 kW (2 stages), High Heat (Fully modulating): 54 kW Size E BOX: Standard heat: 27kW (2 stages), High Heat (Fully modulating): 54 kW Size E+ BOX: Standard heat: 27kW (2 stages), High Heat (Fully modulating): 54 kW

Capacity of the medium and high heat heater can be limited electronically to an exact value through the CLIMATIC To reduce installation time and hence cost, electric heaters are always factory fitted, fully wired and tested, prior to shipment

380V

400V

420V

Size of the unit
C,D,E,E+ BOX

Module size (kW)
18 27 36 54

Current (A) Current (A) Current (A)

27.3

26.0

24.7

41.0

39.0

37.1

54.7

52.0

49.5

82.0

77.9

74.2

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58

HEATING OPTION
ELECTRICAL PREHEATER
WARNING: electric pre-heater is connected heater to main power ­ risk of electrical Shock ­ switch off the unit prior to open this section Pre-heater is running only with high fresh air rate under low outdoor ambient temperature (see setpoint in CLIMATICTM section). A metallic filter is installed between air filter & electrical resistance to protect against heat radiations. WARNING: electric pre-heater metallic filter must not be plugged by dust

Size S/H

Amps per model size
S 18 kW S 24 kW S 36 kW H 36 kW H 48 kW H 72 kW

C BOX 25-30-40-42
26
52

D BOX 45-55-57-65
35
69

E BOX 75-85
52
104

E+ BOX 95-115-125
52
104

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59

HEATING OPTION

ATMOSPHERIC GAS BURNER
PRELIMINARY CHECKS BEFORE START-UP NOTE :
ANY WORK ON THE GAS SYSTEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.
THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN PLANED INSTALLATION CONDITIONS FOR OUTDOOR.

PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING A UNIT.
BEFORE COMMISSIONING A UNIT WITH GAS BURNER, IT IS MANDATORY TO ENSURE THAT THE GAS DISTRIBUTION SYSTEM (TYPE OF GAS, AVAILABLE PRESSURE…) IS COMPATIBLE WITH THE ADJUSTMENT AND SETTINGS OF THE UNIT.
THE GAS MODULE SAFETY CHAIN MUST BE CHECKED BY A PROFESSIONAL BEFORE START-UP OF THE PRODUCT.

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. · Depending on the operating conditions (prevailing winds), it may be necessary to separate the air inlets from the flue gas
outlets (excluding LENNOX supply).

SUPPLY NETWORK PIPE SIZING

MALE THREADED CONNECTION FOR GAS 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″)

UNIT SIZE S POWER H POWER

25 30 40 42 1

45 55 57 65 75 85 95 115 125

1

1

2

2

GAS FLOW – m3/h (for G20 at 20 mbar and 15°C)

UNIT SIZE S POWER H POWER

25 30 40 42 1.9 4.5

45 55 57 65 75 85

3.2

5.7

5.7

11.5

95 115 125 5.7 11.5

· The gas supply of a Rooftop gas unit must be realized according to Sound Engineering Practice and the local safety codes and rules.
· In any case the diameter of pipe-work connected to each Rooftop must not be smaller than the diameter of the connection on the Rooftop unit.
· Make sure that a shut-off isolation valve has been installed before EACH Rooftop. · Check the supply voltage to the exit of the power supply’s transformer

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60

HEATING OPTION
BLOWER PROBE AND REGULATION When the unit is equipped with a gas burner and the supply air is blown in from below (directly into the duct or with roofcurb or roofbox), the supply air temperature sensor must be a duct sensor. The position of the sensor must comply with the supplier’s recommendations and must be placed at about 2m from the unit (minimum 1.5m).
Incorrect positioning can cause damage to the burner or operation at low speed. The ductwork must comply with the installation chapter. The supply air regulation in all configurations must be a maximum of 38°C +/- 3°C.

1 2 3 4 5 6 7 8 9 1 0 1 1 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 0 4 1 4 2 4 3 4 4 4 5 4 6
398 399 400 401

STARTING UP THE GAS BURNER Purge the pipe-work near the connection on the ignition control valve for a few seconds.
· Check that the unit’s treatment “Fan” 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.
Table – Standard start-up Chronology
Time in seconds Operations Control operation sequence Extraction fan Smoke extraction fan “ON” 30 to 45 seconds pre-ventilation Fire-up spark electrode 4s Opening of the gas valve “High Heat” Flame propagation towards the ionization probe If ionization within 5s: Normal running Otherwise fault on gas ignition control block After 5minutes, fault reported on the climatic controller
If incorrect sequence, refer to the fault analysis table to identify the problem

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61

HEATING OPTION 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 press- sure port of the Gas Regulating Valve after having loosened
the screw by one turn.
INLET PRESSURE MEASURING
PORT
Check and adjust if necessary the valve inlet pressure after gas burner ignition

HIGH HEAT INJECTION PRESSURE CHECKS Check and adjust if necessary the valve outlet pressure.

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

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62

HEATING OPTION
LOW HEAT INJECTION PRESSURE CHECKS · Switch the control to Low Heat · Check and adjust if necessary the outlet pressure:

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)

Category

Supply pressure

Low Heat Injection min.

High Heat Injection

GAS VK4105 G
GAS 60 and 120kW VK4125P GAS 180 and 240kW VK4605P

G20 G25 (Groningue) G31 (GPL) G20 G25 (Groningue) G31 (GPL) G20 G25 (Groningue) G31 (GPL)

20.0 +/- 1 25.0 +/- 1.3 37.0 +/- 1.9 20.0 +/- 1 25.0 +/- 1.3 37.0 +/- 1.9 20.0 +/- 1 25.0 +/- 1.3 37.0 +/- 1.9

3.5 +/- 0.1 5.0 +/- 0.1 14.0 +/- 0.3 3.7 +/- 0.1 5.1 +/- 0.1 15.3 +/- 0.3 3,1 +/- 0.1 3,9 +/- 0.1 12,6 +/- 0.3

8.4+/- 0.2 12.3 +/- 0.2 31.4 +/- 0.6 10.4+/- 0.2 13.1 +/- 0.2 34.3 +/- 0.6
8+/- 0.2 10,4 +/- 0.2 28,3 +/- 0.6

VALVE ELECTRICAL CONTROL Check these values with an ohmmeter

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2,90 k

1,69 k

63

HEATING OPTION
BURNER SAFETY CHECKS Smoke extractor pressure switch Test.
· With the gas burner running, disconnect the flexible tube fitted to the pressure taping on the pressure switch
· The Flame must disappear and the extraction fan must carry on running.
· However, NO fault will be displayed (Gas ignition control block or CLIMATIC).
· 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.

· 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
IONISATION PROBE TEST
· With the gas burner running, disconnect the terminal plug coming from the ionization 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

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64

HEATING OPTION
GAS BURNER FIRE-UP SEQUENCE Operation from control Thermostat GAS =Closed

Supply Thermostat Limit? NO
(Auto Reset) YES

Gas Low Pressure switch?

NO

YES

Gas Ignition Control Block Signal

Extraction Fan ON

AIR Pressure Switch ON NO
Backfire Thermostat ON?
YES

Pre-Ventilation 30 seconds Fire up Electrode 4s

Gas Control alve Closes BURNER

Gas Valve Open

Gas Control

Valve Closes

Ionisation1 second after the end sparking?

NO

BURNER Fault on Gas

YES

Block

Gas Valve remains Open Normal Operation

6 Minutes Delay

NO

Air Press Switch ON or Backfire thermostat?

YES

NO

Signal from Ionisation probe still ON?

YES

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Fault on Climatic
65

HEATING OPTION

ATMOSPHERIC 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 >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.

STAGE

NORMAL OPERATION

DIAGNOSTIC TABLE FLEXAIR GAS BURNER

POSSIBLE FAULT

ACTION

POSSIBLE SOLUTION

Fault on the blower thermostat

+ Check connections on the blower thermostat.

+ Replace thermostat

Heating Requested Extraction fans start Lack of gas supply

+ Check valve’s opening & supply pressure

+ Restore gas supply

Fault on the superheat thermostat on the gas burner support bar

+ Check superheat thermostat’s operation after manual reset

+ Replace superheat thermostat

Starting of the extraction fans

After 10 seconds safety shutdown by the ignition control block
Extraction Fans are running
Nothing happens

+ Check connections of the control block on the gas valve

+ Repositioning of the control block on the valve + Replace valve

+ Check the free movement of the fan wheel + Check Electrical connection on the Gas Ignition Control Block and on EF connection Board + Check the Fan supply voltage

+ Replace fan + Replace EF connection board If necessary

Extraction Fan is ON

After 30 to 45 seconds: preventilation the fireup electrode should spark.

Continuous Ventilation without sparks from fire-up electrode

+ Check the fire-up electrode
+ Check the pressure drop at the pressure switch: It must be higher than 165 Pa +Check the good operation of the pressure switch using an Ohmmeter and by artificially creating a depression in the tube.

+ Re-position the pressure switch tube. + Change the pressure switch.

Continuous ventilation and sparks from fire up electrode.

After a few seconds the gas burner firesup

After 4 seconds the GAS Burner still not operating and safety shutdown by the Ignition Control Block.
Within 4 seconds the gas Burner fires-up BUT safety shutdown from the Ignition Control Block.

+ Check injection pressure during start-up (Value for High Heat) +Remove the control box from the gas block.
+ Check the Position and connection of the Ionization Probe. It must not be Earthed (230V). + Measure the Ionization Current: It must be higher than 1.5 microAmps. + Check the Type of GAS.

+ Remove the air from the Gas pipe- work + Adjust the injection pressure to high heat value + Change the Control Box if the Gas valve is OK.
+Check the whole electrical supply. + Adjust the supply and injection pressure if gas is different from natural gas G20 🙁 G25 Gas of Groningue for example).

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HEATING OPTION
DISASSEMBLING ATMOSPHERIC GAS BURNER FOR MAINTENANCE PURPOSES
Preliminary Safety Recommendations · Isolate 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.
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.
Disassembling the flue · Electrically disconnect the fan and remove the screws holding it in place. · Take care not to lose 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 manometer 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 & 9 · Flat Screwdrivers diameter 3 and 4, Fillips n°1 · Vacuum cleaner · Paint brush
GAS BURNER SUPPORT BAR

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67

HEATING OPTION ATMOSPHERIC NON MODULATING GAS MODULE DIAGRAM

3
11 14 13 10

12

1

Circuit breaker

2

Transformer 400/230V

3

Minimum gas pressure switch and inlet pressure plug

4

Gas valve and solenoid

5

Gas ignition control block and BG50 connection board

6

Ignition electrode

7

Ionization probe

8

Gas inshot burner

9

Gas injectors support bar

10 Backfire thermostat

11 Air pressure switch

12 Outlet pressure plug

13 Smoke exhaust chimney

14 Supply safety thermostat

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68

HEATING OPTION ATMOSPHERIC MODULATING GAS DIAGRAM (under patent inpi mai 2004)

THE ACTUATOR
The actuator receives an information 0-10v from the regulation for the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valve. Check position and operation of the actuator
Bearing surface of the actuator’s screw

Minimum opening of the actuator

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69

HEATING OPTION

STARTING UP THE ATMOSPHERIC MODULATING GAS BURNER

Disengaging for hand drive operation

Purge the pipe-work near the connection on the ignition control valve for a few seconds.

· check that the unit’s treatment fan 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.

Manual rotation of the actuator

The start of the gas burner must be done at high heat injection.

MODULATING ATMOSPHERIC GAS BURNER SAFETY CHECKS Idem non-modulating gas burner
MODULATING ATMOSPHERIC GAS BURNER TROUBLESHOUTING Idem non-modulating gas burner. If the valve’s flow is not correct, check the operation of the actuator and of the mechanical assembly. Replace the actuator if necessary
DISASSEMBLING OF MODULATING ATMOSPHERIC GAS BURNER FOR MAINTENANCE PURPOSES Idem non-modulating gas burner

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70

HEATING OPTION

PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4105 G
Pressure regulator adjustment with 300 mbar 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 of the gas regulating valve after having loosened the screw by one turn

Inlet Pressure

Low heat adjustment

High heat adjustment underneath
Check and adjust if necessary the valve inlet pressure after gas burner ignition

HIGH HEAT INJECTION PRESSURE CHECKS Check and adjust if necessary the valve OULET pressure

place the tube of the “accurate” manometer to the out port on the gas injector support bar after having loosened the screw by one turn.

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71

HEATING OPTION
LOW HEAT INJECTION PRESSURE CHECKS
· switch the control to low heat · check and adjust if necessary the outlet pressure

· 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) – NON MODULATING ATMOSPHERIC GAS BURNER

Category

Supply pressure

Low heat injection mini.

High heat injection

G20 G25 (Groningue) G31 (GPL)

20.0 +/- 1 25.0 +/- 1.3 37.0 +/- 1.9

3.5 +/- 0.1 5.0 +/- 0.1 14.0 +/- 0.3

8.4+/- 0.2 12.3 +/- 0.2 31.4 +/- 0.6

Pressure adjustments table for each type of gas (mbar) ­ MODULATING ATMOSPHERIC GAS BURNER

Category

Supply pressure

Low heat injection mini.

High heat injection

G20 G25 (Groningue) G31 (GPL)

20.0 +/- 1 25.0 +/- 1.3
NA

1.5 +/- 0.1 2.25 +/- 0.1
NA

8.4+/- 0.2 12.3 +/- 0.2
NA

VALVE ELECTRICAL CONTROL Check these values with an ohmmeter.

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2,90 k

1,69 k
72

HEATING OPTION
Burner safety checks Smoke extractor pressure switch test
· With the gas burner running, disconnect the flexible tube fitted to the pressure taping on the pressure switch.
· The flame must disappear and the extraction fan must carry on running.
· However, no fault will be displayed (gas ignition control block or CLIMATIC).
· After reconnecting of the tube, the burner will restart after a period of 30 to 45 seconds pre-ventilation.
Test de pression des gaz
· With the gas burner running, disconnect the terminal plug coming from the ionisation probe to the gas ignition control box.
· The burner stops completely. · However, no fault light will be displayed on the gas ignition control
block. After 6 minutes, the CLIMATICTM will display a fault. · Reset the CLIMATIC.

Ionisation 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

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73

HEATING OPTION
CONDENSING GAS BURNER
PRELIMINARY CHECKS BEFORE START-UP NOTE : ANY WORK ON THE GAS SYSTEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN PLANED INSTALLATION CONDITIONS FOR OUTDOOR. PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING A UNIT. BEFORE COMMISSIONING A UNIT WITH GAS BURNER, IT IS MANDATORY TO ENSURE THAT THE GAS DISTRIBUTION SYSTEM (TYPE OF GAS, AVAILABLE PRESSURE…) IS COMPATIBLE WITH THE ADJUSTMENT AND SETTINGS OF THE UNIT. THE GAS MODULE SAFETY CHAIN MUST BE CHECKED BY A PROFESSIONAL BEFORE START-UP OF THE PRODUCT.
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. · Depending on the operating conditions (prevailing winds), it may be necessary to separate the air inlets from the flue gas outlets (excluding LENNOX supply).
SUPPLY NETWORK PIPE SIZING MALE THREADED CONNECTION FOR GAS BURNER: 3/4″ ,1″ OR 1″1/4
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. Select the regulator according to the gas used, the minimum and maximum gas flow of the gas burner and the operating pressure.
WARNING: DO NOT FORGET TO CONNECT THE CONDENSATE DRAIN. THE CONDENSATES MUST ABSOLUTELY BE DRAINED AT LEAST 5 METERS FROM THE UNIT INTO AN APPROPRIATE PLACE. THE CONDENSATES ARE CORROSIVE AND COULD DAMAGE THE UNIT (OR OTHER PARTS OF THE INSTALLATION) IF THEY ARE NOT DRAINED PROPERLY.
CHIMNEY INSTALLATION Depending site configuration / local regulation, an additional chimney could be install (not included with the unit). Please refer to our Service & parts team.
CHIMNEY HORIZONTAL CONNEXION

WARNING: IT IS MANDATORY TO SEAL PROPERLY ALL EXTERNAL CONNECTIONS TO THE UNIT TO AVOID WATER INGRESS

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HEATING OPTION
SAFETY INSTRUCTIONS The gas burner can emit toxic gases (Nox, CO2, …) especially during commissioning and when starting and stopping the burner. When the unit is in operation, the technician must work away from the gas outlet chimney. A temporary work chimney to move the fumes away from the working area (see photo) must be installed during prolonged exposures near the burner.
GAS:
Before starting up the heater, make sure that: · The gas mains supply data is compatible with the data stated on the nameplate; · The combustion air intake ducts (when fitted) and the fume exhaust pipes are those specified by the manufacturer; · The combustion air is supplied in such a way to avoid even partial obstructions of the intake grille (caused by leaves etc.); · The fuel intake internal and external seal is checked during the testing stage, as required by applicable standards; · The heater is supplied with the same type of gas than that selected at purchase; · The system is correctly sized for such flow rate and is fitted with all safety and monitoring devices required by applicable standards; · The inside of the gas pipes and air distribution ducts for ducted heaters has been thoroughly cleaned; · The fuel flow rate is suitable for the power required by the heater; · The fuel supply pressure is between the range specified on the nameplate.
GAS LEAKS
If you smell gas: · Do not operate electrical switches, telephones or any other object or device that could produce sparks; · Immediately open doors and windows to create an air flow to vent the gas out of the room; · Close the gas valves; · Call for qualified staff.

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HEATING OPTION
PRODUCT RANGE
DESCRIPTION
SIZE MAXIMAL HEAT INPUT
MINIMAL HEAT INPUT

EFFICIENCY AT MAXIMAL HEAT INPUT

EFFICIENCY AT MINIMAL HEAT INPUT

Max / min gas consumption at

G20

15°C and 1013 mbar

G25

G30

G31

Supply pressure

G25

+/- 5%

G30

G20

G31

Gas inlet connection

Chimney outlet diameter Max length of gas exhaust pipe

Nominal electrical power
Operation temperature (incoming air)
Gas volume between regulator and gas burner

(*) For gases : G25 / G27 / G2.350

C

D

E

E+

25, 30, 40, 45, 55, 57, 75, 85 95, 115, 125

42

65

kW

50

70

90

110

45*

65*

kW

10

14

18

22

%

96

96

96

96

%
m3/h m3/h kg/h kg/h mbar mbar mbar mbar inch mm
m
W °C m3

109

109

109

109

1.1

1.5

1.9

2.3

5.3

7.4

9.5

11.6

1.2

1.7

2.2

2.7

6.2

8.6

11.1

13.5

0.8

1.1

1.4

1.7

3.9

5.5

7.1

8.7

0.8

1.1

1.4

1.7

3.9

5.4

7.0

8.6

20

20

20

20

25

25

25

25

37

37

37

37

37

37

37

37

3/4″

3/4″

3/4″

3/4″

100

100

100

100

5

5

5

5

65

135

173

170

-20 +40 -20 +40 -20 +40 -20 +40

0.02

0.031

0.039

0.048

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76

HEATING OPTION
GAS BURNER DETAILS
· Premix burner (venturi, gas fan, pilot group, head) gas valve · Electronic controls with display · Combustion chamber in stainless steel AISI 441 · Exchanger bundle in stainless steel AISI 441 · Safety probe · The PREMIX Technology: NO AIR=NO GAS

VENTURI

FAN

GAS VALVE

The PREMIX Technology NO AIR = NO GAS

WORKING CYCLE
· Heat is required · Burner fan starts to pre-wash combustion chamber and gas valves open to gas feed pilot burner · Start up electrode gives ignition sparks on pilot burner · Main gas valve opens to gas feed main burner · Combustion starts thanks to pilot flame ignition · The electronic boards close and stops the pilot

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HEATING OPTION ELECTRICAL CONNECTION

WARNING It is mandatory to have earth connection.

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HEATING OPTION
GAS CONNECTION The module cannot support supply pressures higher than 50 mbar (0.05 bar) otherwise it can break of the gas valve membranes.
For natural gas: always install a stabilizer on the main line. For gas GPL (Butane-Propane) gas: a pressure reducer must be installed
It is strictly forbidden to supply gas to the circuit at a pressure higher than 40 mbar. To avoid a pressure higher than 40 mbar, a minimum volume must be present between the regulator (pressure reducer) and the inlet of the gas burner, you can find these minimum values in the table “PRODUCT RANGE”. For this purpose, either a buffer cylinder must be installed (not included in our kit). Either a straight length of at least 10 m, and no pressure stabilizer should be placed between the pressure reducer and the burner. The gas filter must be present and functional . In order to respect the minimum and maximum flow rates of the regulators, it is recommended to install only one regulator per unit.
A pressure gauge must always be installed upstream and downstream of the main gas supply line visible with a scale of [0 ­ 60] mbar (0.06 bar) in order to verify any difference in upstream and downstream pressure and therefore the flow rate of the entire network.
It is also possible, by closing the general valve and turning off the module, to check the tightness of the system and gas valves, checking, after a short period, for any pressure drop on the pressure gauges.
Always connect the module with a ball valve and anti-vibration flexible gas joint.
Gas supply pressure adjustment: all modules are tested and calibrated in the factory for the pressures for which they are designed.
Do not block the electrical cabinet with the gas connection (use a flexible pipe or rigid with elbows)

Must be provided by the installer

Included in the module

POS.

DESCRIPTION

1 Manual gas shut-off ball valve

9

2 -8-11 Gas pressure intake

10

3 Gas filter

12

4 -6 Pressure gauge

13

5 Gas pressure regulator with minimum and maximum 14 pressure blocking device (outlet pressure = 0.04 bar) – For inlet pressures < 0.04 bar provide a stabilizer

7 Antivibration seal

15

Gas pressure regulator located on the appliance solenoid valve Safety solenoid valve
Burner
Ball valve with bleed
Maximum gas pressure switch with manual reset – optional
Minimum gas pressure switch – optional

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HEATING OPTION CONDENSATE DRAIN WARNING: Do not forget to connect the condensate drain (No need to add a siphon). The condensates must absolutely be drained at least 5 meters from the unit into an appropriate place. The condensates are corrosive and could damage the unit (or other parts of the installation) if they are not drained properly.
Condensate drain connection

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HEATING OPTION
COMMISSIONING
The gas module unit is supplied with settings entered and tested for the gas specified on the nameplate. Before turning on the gas module in the unit, check the following:
· Vent the gas supply line and carefully let the remaining air out of the pipes. · Restore the gas supply piping after venting and check that there are no leaks, use a soapy solution or equivalent
product, do not use open flames. · Check that electrical connections indicated in electrical diagrams attached to the unit · Check that efficient earthing connections have been completed, carried out as specified by current safety regulations; · Provide power to the heater with the general switch on the unit. · After the pre-wash time, the ignition spark occurs. After the third failed ignition attempt, the device locks up. After 10
seconds, it is possible to unlock the device by resetting the burner control equipment. · After opening the gas solenoid valve, the burner ignites. · After the stabilization of the working conditions (about 15 min.), Carry out a combustion analysis and a performance
measurement. · Recheck the combustion verification check sequence after 30 minutes of operation. · Adjust Y2
Combustion control and regulation: · Put the burner in test mode
o Start the gas burner with the H1-FULL test mode (with the DS)
o Hold the SET button until “PA” is displayed o Enter the authorization code. o Hold the SET button until “yt” is displayed o Press the button, change the value «e.g. ,,15″ » ,
for 15 minutes the burner will work in test mode. After this time, the control returns to automatic mode. Use this time to perform the combustion check.
· Verification of combustion: Procedure for changing the power of the gas burner (low / high power) o Hold the SET button until “yC” is displayed o Press the button to change the value Put «,,61″» – for high power Put «,,51″» – for low power o For the above conditions, check the exhaust gases o Check the regulation (behavior) of the burner .

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HEATING OPTION
Adjustment of Lo/Hi power with the combustion analyzer.
First in max capacity:
· Set-up (screwing Lo/ Hi as explained below in the picture) around 1.35 (it is a target) to get : o 7.8% CO2 8.9% (for G20 only) o CO 0 ppm o But if you have combustion problems (noise (whistle), turbulences, High CO), you can adjust the (air factor) from 1.2 to 1.65 to solve these problems. o > 90% o NOX < 30ppm
Then in min capacity:
· Set-up (screwing Lo/ Hi as explained below in the picture) around 1.40 (it is a target) to get: o 7.8% CO2 8.9% (for G20 only) o CO 0 ppm o But if you have combustion problems (noise (whistle), turbulences, High CO), you can adjust the from 1.2 to 1.65 to solve these problems. o > 102% o NOX < 30ppm

Y2 adjustment Parameter Y2 adjusts the power of the gas burner at start-up. This adjustment is made after the Lo/Hi power and gas supply pressure adjustments have been set. The Y2 parameter should be between 18 and 25%, by default 20%. If there is a small explosion at start-up: decrease Y2 If the flame is slow to ignite due to turbulence: increase Y2
Y2 change procedure: o Hold the SET button until “PA” is displayed. o Enter the authorization code. o Hold the SET button until “Y2″ is displayed. o Press the button and set the desired value.

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HEATING OPTION
MAINTENANCE OPERATIONS To keep the machine in efficient condition and guarantee a long lifetime of the heater, it is advisable to run some inspections every year:
NOTE: Operations at points 1 to 7 must be performed after disconnecting the heater from the electrical mains and closed the gas intake. Operations at point 8 to 11 must be done with the heater on.

1. Inspection of electrodes
   Dismantle the complete pilot flame and use a jet of compressed air to clean the mesh and nozzle. Check the integrity of the ceramic and use sandpaper to remove any oxidation on the metal parts of the electrodes. Check the correct position of the electrodes (see drawing below). It is important that the detection electrode is at a tangent to the head of the pilot and not inside it. The start-up electrode must discharge onto the mesh of the pilot burner.
2. Inspection of fume exhaust and air intake ducts
   Visually inspect where possible or examine with specific tools to learn the status of the ducts.
   Remove dust that forms on the air intake terminal.
3. Inspection and cleaning of the venturi
   Remove any dirt at the mouth of the venturi with a brush, and be careful to not let it fall inside the piece.
4. Inspection and cleaning of the exchanger and burner
   Perfect combustion in heaters prevents dirt. It is advisable, therefore, to not clean the exchanger and burner unless there are exceptional circumstances.
   An accumulation of dirt inside the exchanger could be revealed by a sizeable variation in the module gas capacity.
   Should it become necessary to clean the burner and/or exchanger, all of the gaskets mounted between the burner and the exchanger must be replaced.
5. Inspection and cleaning of the water trap
   Clean the trap every year, and check the connections. Make sure there are no traces of metallic residue. If metallic residue has formed, increase the number of inspections.
6. Inspection of the gas filter
   Remove the dirt on the gas filter. If it is too dirty, replace it.
7. Inspection of the ionization current
   With the gas burner at rest, use a multimeter, check that the current displays 20 to 30 mA at the probe terminals.
8. Inspection of intake gas pressure
   Verify that the intake pressure at the valve corresponds to the value required for the type of gas that you are using. This verification must be done with the heater on at the maximum heat capacity.
   If the gas pressure is too high at the gas inlet valve, there is a risk of ejection of the chimney. In this case, check that the gas inlet pressure regulator (if present) is working correctly
9. Check the burner settings
   Adjust with a combustion analyzer the values described in the paragraph: ” Adjustment of Lo/Hi power with the combustion analyzer.”
10. Inspection of flame monitoring equipment
    With the heater operating, close the gas tap and verify that the heater blocks, signaled on the LCD display. Reopen the gas tap, reset the block and wait for the heater to start back up.
11. Safety thermostat inspect

References

• Welcome | Lennox EMEA
• Welcome | Lennox EMEA

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