Ferroli RCA Series Mounting instructions

Cod. 3QE47500 - Rev. 00 - 10/2021
INSTALLATION, MAINTENANCE AND USER MANUAL
EN
RCA 195÷395
AIRCOOLED LIQUID CHILLERS AND HEAT PUMPS
WITH AXIAL FANS AND SCROLL COMPRESSORS

2

3
GENERAL 4
1.1 DOCUMENT INFORMATION 4
1.2 RESIDUAL RISK 4
1.3 RANGE 5
1.4 ACCESSORIES 5
1.5 COMPLIANCE 5
1.6 MACHINE IDENTIFICATION 5
1.7 CONNECTIONS OF THE ACCESSORIES 6
1.8 INTENDED USE 6
1.9 GENERAL PRECAUTIONS 6
1.10 BASIC SAFETY RULES 7
1.11 USER GUIDELINES 7
1.12 MACHINE DESCRIPTION 7
SHIPMENT 8
2.1 INSPECTION ON RECEIPT 8
2.2 POSITION OF THE EQUIPMENT 8
2.3 EQUIPMENT 8
2.4 STORAGE 8
2.5 HANDLING 8
2.6 UNPACKING 9
2.7 ACCESS TO INTERNAL PARTS 9
2.8 RESTING ON THE GROUND 9
INSTALLATION 10
3.1 INSTALLATION LOCATION REQUIREMENTS 10
3.2 WORK FIELDS 10
3.3 UNIT LOCATION 10
3.4 VERIFYING CLEARANCES (CLEARANCE AREA) 11
WATER CONNECTIONS 12
4.1 CONNECTION DIAGRAM 12
4.2 POSITION OF CONNECTIONS 12
4.3 HYDRAULIC DATA 12
4.4 CONNECTION TO THE SYSTEM 13
4.5 SYSTEM FILL-UP 14
4.6 DESUPERHEATER CONNECTION 14
ELECTRICAL CONNECTIONS 15
5.1 MACHINE CONNECTION 15
5.2 CONNECTIONS OF THE ACCESSORIES 15
COMMISSIONING 16
6.1 PRELIMINARY INSPECTIONS 16
6.2 FIRST START-UP OR RESTART AFTER LONG INACTIVITY 16
6.3 SHUT-DOWN 16
6.4 FLOW RATE CALIBRATION 17
CONTROL PANEL 18
7.1 USER INTERFACE 18
7.2 SWITCH ON AND OFF 20
7.3 SETTINGS 20
7.4 UNIT STATUS 23
7.5 ALARMS 25
7.6 LOGIN 27
7.7 SOFTWARE 28
MAINTENANCE 29
8.1 MAINTENANCE 29
8.2 WEEKLY CHECKS 29
8.3 MONTHLY CHECKS 29
8.4 ANNUAL CHECKS 29
8.5 WATER CIRCUIT 29
8.6 REFRIGERANT CIRCUIT 30
8.7 DECOMMISSIONING AND DISPOSING 30

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1. General
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
Document information
Residual risk
Range
Accessories
Compliance
Machine identification
Connections of the accessories
Intended use
General precautions
Basic safety rules
User guidelines
Machine description
1.1 Document information
A Chapter
B Sequence of paragraphs
C Preliminary precautions
D Operations
• The manual is divided into chapters as follows:
- General;
- Shipment;
- Installation;
- Water connections;
- Electrical connections:
- Commissioning;
- Control;
- Maintenance.
• The preliminary precautions must be read before performing any of the following operations.
This document uses the following definitions:
- Danger zones: any area inside and/or near the machine in which the presence of an
exposed person constitutes a risk to his/her own health and safety.
- Exposed person: any person who is entirely or partially in a danger zone.
- Operator/Maintenance Technician: the person/s assigned to operate, adjust, service, repair
or move the machine.
1.1.1 Symbols
• This publication contains the following symbols:
Danger Draws attention to actions that can cause serious injury if not performed
correctly.
Prohibited Draws attention to actions that impose a prohibition.
1.2 Residual risk
Description
The description of the residual risk considers the following elements:
• the type of dangers those working around the machine are subject to;
• a description of main risks;
• who could be exposed to such risks;
• what are the main safety measures adopted to reduce the risk of injury.
The guidelines for the prevention of accidents reported below, with reference to the relative areas
of residual risk, must be integrated with all the general instructions of this chapter and with the
accident prevention regulations in force in the destination country of the system.
Residual risk near the machine
• Electrocution, if the electrical connection and earthing of the machine are not carried out
correctly.
• Cuts or abrasions due to the presence of sharp edges.
• Suction of substances in the installation site and subsequent dispersion in the environment.
• Projection of any object that may fall on the fan blades.
• Leakage of water (in case of a fault).
• Formation of condensation water and ice in the area in front of the machine during the
heating operation of the heat pump machines.
• Micro-climate alteration (during operation).
• Noise emission (during operation). The sound pressure levels of the individual units are listed
in the technical booklet.
• Oil leaks (due to a fault).
• Refrigerant gas leak (due to a fault).
Refrigerant gas is a greenhouse gas effect substance. Vapours are heavier than air and they
can cause suffocation by reducing oxygen available for breathing. Rapid evaporation of the
liquid can cause freezing.
Measures to be adopted if refrigerant gas leaks
• Product type:
- R410A
First aid measures
• General information:
- do not administer anything to an unconscious person.

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• Inhalation:
- transfer outdoors.
- use oxygen or artificial respiration if needed.
- do not administer adrenaline or similar drugs.
• Contact with eyes:
- rinse thoroughly with plenty of water for at least 15 minutes and consult a doctor.
• Contact with skin:
- wash immediately with plenty of water
- immediately remove all contaminated clothing
Measures in the event of accidental spillage
• Personal precautions:
- Move all personnel to safe areas.
- Provide adequate ventilation.
- Use personal protective equipment.
• Environmental precautions:
- Intercept the emission.
• Cleaning methods:
- Use absorbent products.
Operations with removed panels
Some of the operations and/or tests described below require the removal of the panels to access
inside the unit.
There may be hot surfaces (piping, compressor, etc.) or cold (compressor, intake separator, etc.),
sharp edges (coil fins) or moving parts (fans) even with the machine stationary.
The power supply must be disconnected before removing any panel.
Operations that require the panels to be opened must only be carried out by qualified
personnel wearing personal protective equipment.
1.3 Range
1.3.1 Available versions
Cooling only
Reversible Heat Pump
Super silenced cooling only
Super silenced reversible Heat Pump
1.4 Accessories
Factory fitted accessories
IM Automatic circuit breakers
SL Unit silencement
RFM Cooling circuit shut-off valve on discharge line
RFL Cooling circuit shut-off valve on liquid line
CT Condensing control down to 0 °C
CC Condensing control down to -20 °C
BT Low water temperature kit
EC EC Inverter fans
ECH EC Inverter fans with high available static pressure
DS Desuperheater
RT Total heat recovery
TX Coil with pre-coated fins
EW External water connections
PS Single circulating pump
PSI Inverter single circulating pump
PD Double circulating pump
PDI Inverter double circulating pump
FE Antifreeze heater for evaporator
SS Soft start
IS Modbus RTU protocol, RS485 serial interface
IST Modbus TCP/IP protocol, Ethernet port
ISB BACnet MSTP protocol, RS485 serial interface
ISBT BACnet TCP/IP protocol, Ethernet port
ISL LonWorks protocol, FTT-10 serial interface
ISS SNMP protocol, Ethernet port
IAV Remote set-point, 0-10 V signal
IAA Remote set-point, 4-20 mA signal
IAS Remote signal for second set-point activation
IDL Demand limit from digital input
Loose accessories
MN High and low pressure gauges
CR Remote control panel
RP Coils protection metallic guards
AG Rubber shock absorbers
AM Spring shock absorbers
1.5 Compliance
The device complies with the following standards:
• Machinery directive 9898/37/EC - 2006/42/EC
• Electromagnetic Compatibility Directive 2004/108/EC
• Low Voltage Directive: 2006/95/EC
1.6 Machine identification
A Packaging plate
B
B Frame feature plate
RCA 195
RCA 220
RCA 245
RCA 270
RCA 300
RCA 330
RCA 360
RCA 395
RCA R AB
RCA P AB
RCA R AX
RCA P AX

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C Electrical board feature plate
The equipment can be identified from:
• Packaging plate.
- It shows the identification data of the equipment.
• Frame feature plate.
- Affixed on the machine, it shows the technical and performance data of the equipment.
• Electrical board feature plate.
- Affixed on the panel from which the electrical board is accessed, it shows the electrical
data of the equipment.
If it is lost or deteriorated, request a duplicate from Technical Support.
Tampering with, removal and deterioration of the identification plates complicate any
installation, maintenance and spare part request.
1.7 Connections of the accessories
1.7.1 Circulating pump
The circulating pump must always be connected to the control unit as indicated in the wiring
diagram. The pump must be started before the chiller is started and stopped after the chiller is
stopped (recommended minimum delay: 60 seconds).
1.8 Intended use
This unit is designed to cool water (potentially added with inhibited ethylene glycol) that
circulates in a closed circuit.
The heat pump units can cool or heat the water circuit, depending on the selected operating
cycle.
The heat recovery units can act as a sub-product, heating the water that circulates in a second
closed circuit.
The hot or cold air produced by the machine, may be used for air conditioning systems or
industrial processes.
Any other use of the machine is forbidden.
Do not use flammable products near the machine.
Do not use substances that can form explosive mixtures close to the machine.
Do not use the machine where there are problems of environmental impact.
1.9 General precautions
• These units must be installed by a qualified company that at the end of the work provides the
operator with a declaration of conformity with the regulations in force and the instructions
provided by the manufacturer in this document.
• These units must comply with their intended use in line with their performance
characteristics.
• Wear suitable and accident prevention clothing and equipment during installation and/or
maintenance. The manufacturer declines any liability for non-compliance with safety and
accident prevention regulations in force.
• All unit installation, connection, start-up and shut-down operations must only be
implemented by qualified and authorised personnel.
• Comply with the laws in force in the country where the machine is installed, concerning the
use and disposal of the packaging, the products used for cleaning and maintenance and for
the management when the unit life cycle is complete.

7
• Any repairs or maintenance must be performed by the technical support of the manufacturer
or by qualified personnel, in accordance with this publication.
• Preferably use original spare parts when replacing components.
• If the refrigerant should leak, ventilate the room. The liquid refrigerant produces toxic gas
when exposed to a flame.
• In the case of a malfunction or spill of liquid or gas refrigerant, set the main switch to "off" and
close the shut-off valves. Promptly call technical support or professional personnel. Do not
intervene personally on the unit.
• If the outside temperature can drop below zero, there is a freezing hazard and the system
must be drained or anti-freeze must be added.
• Based on CE Standard no. 842/2006 on certain fluorinated greenhouse gases, it is mandatory
to indicate the total amount of refrigerant in the installed system. This information is present
in the technical plate found in the outdoor unit.
• This unit contains fluorinated greenhouse gas covered by the Kyoto Protocol. Maintenance
and disposal must be carried out only by qualified personnel.
1.10 Basic safety rules
Using products that require electricity and water require some basic safety rules to be complied
with, such as:
It is prohibited to operate the unit before having disconnecting it from the power supply by
setting the main switch to "off".
It is prohibited to modify the safety devices or the settings without authorisation and
instructions from the manufacturer of the unit.
It is prohibited to pull, detach or twist the electrical cables coming from the unit, even if it
is disconnected from the power supply.
It is strictly prohibited to touch any moving parts, stand between them or introduce
pointed objects through the grids.
It is prohibited to use gas and water pipes to earth the unit.
It is prohibited to touch the unit when barefoot or with wet or damp parts of the body.
It is prohibited to stand on the unit, sit down on it and/or lean any type of object against it.
It is prohibited to dispose of and leave the packaging material in the reach of children as it
can be a potential source of danger.
It is prohibited for children or unassisted disabled persons to use the unit.
It is prohibited to introduce R410A in the atmosphere: R410A is a fluorinated greenhouse
gas referred to in the Kyoto Protocol with a Global Warming Potential (GWP) of 1975.
1.11 User guidelines
• Keep this manual together with the wiring diagram in a place that is accessible by the
operator.
• Take note of the unit identification data so as to provide them to the service centre when
required (see the "Machine identification" paragraph).
• It is recommended to keep track of the operations carried out on the unit, so as to facilitate any
troubleshooting.
• In case of a fault or malfunction:
- verify the type of alarm to notify the service centre;
- immediately disable the unit without resetting the alarm;
- contact an authorised service centre;
- request original spare parts.
• Request the installer to be trained on:
- switching on/shut-down;
- shutting down for long periods;
- maintenance;
- what to do/not to do in case of a fault.
1.12 Machine description
1.12.1 Features
Frame.
Self-supporting galvanised steel frame further protected with polyester powder painting.
Easy to remove panels allow access to the inside of the unit for maintenance and repair
operations.
Compressors.
Scroll with oil sight glass.
They are fitted with internal overheat protection and crankcase heater, installed on rubber shock
absorbers.
Fans.
Axial fans directly coupled to a three-phase electric motor with external rotor.
A safety fan guard is fitted on the air flow outlet.
Fans with low rpm are fitted on super silenced units and therefore some models have more fans.
Condenser.
Made up of two finned coils with copper pipes and aluminium fins. Circuits are made to create
two independent circuits.
Circuits are made so as to create two independent circuits.
Evaporator.
Evaporator AISI 316 stainless steel braze welded plates type with two independent circuits on the
refrigerant side and one on the water side, complete with water differential pressure switch. On
the Heat Pump units it is always installed an antifreeze heater.
Electrical board.
Includes: main switch with door safety interlock; fuses; overload protection for compressors and
thermocontacts for fans; interface relays; electrical terminals for external connections.
Microprocessor.
For the automatic control of the unit.
It allows the continuous display of the operational status of the unit, control set and real water
temperature and, in case of partial or total block of the unit, indication of security device that
intervened.
Cooling versions refrigerant circuit.
Each unit includes two independent refrigerant circuits.
Made of copper pipe, it includes the following components on all models: electronic thermostatic
expansion valve; filter drier; liquid and humidity indictor; high and low pressure switches (fixed
setting); safety valve in 8104P÷12240P models; liquid line shut-off valves in 8104P÷12240P
models.
Heat pump versions refrigerant circuit.
The unit in heat pump version, in addition to the components of the cooling only unit, includes
for each circuit: 4-Way inversion valve; liquid separator on the suction line; liquid receiver; check
valves; liquid line shut-off valves in 8104P÷12240P models.
Water circuit.
It includes: evaporator; temperature sensor; antifreeze sensor; manual air vent; water drain.

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2. Shipment
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Inspection on receipt
Position of the equipment
Equipment
Storage
Handling
Unpacking
Access to internal parts
Resting on the ground
2.1 Inspection on receipt
A Packaging plate
• Before accepting the delivery, check:
- That the unit has not been damaged during transport.
- That the delivered material is as specified on the shipping document when comparing the
data with the package plate 'A'.
• In case of damage or faults:
- Immediately take note of the damage on the shipping document and write: “Accepted
with reservations for evident loss/damage during transport”.
- Submit a complaint by fax and by registered mail with return receipt to the carrier and the
supplier.
2.2 Position of the equipment
A Pocket for documents
Keep the documentation in a dry place to prevent deterioration, for at least 10 years for
future reference.
Any accessories that are not factory-fitted are supplied in separate packages, with a
relevant instruction sheet.
2.3 Equipment
• Installation, operating and maintenance manual;
• Wiring diagram;
• Refrigerant diagram;
• Water diagram;
• List of parameters;
• Declaration of conformity;
• Technical data.
2.4 Storage
The room temperature in which the units are stored must be between -20 / +50°C.
2.5 Handling
• The equipment is designed for two lifting systems according to the length of the machine.
It is prohibited to use the pipes or other components of the machine as lifting points.
2.5.1 Lifting with forks
A Support
Models with a length shorter than 6700 mm
• Insert the forks from the side to avoid damaging the panels.
• Before placing the machine on the ground remove the wooden supports.

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2.5.2 Lifting with a crane
A Bar for lifting (maximum ø 63 mm)
B Hole to insert the lifting bar
C Label for holes enabled for lifting
It is recommended to use a system to prevent the belts from slipping from the bars during
lifting.
Place spacers and protectors in between prevent damaging the unit.
All models
• Insert the lifting bars into the arranged holes on the base and indicated by the relative labels.
• Lift the unit using suitable belts.
Make sure that all the equipment used for handling (belts, bars, etc.) are appropriate for
the weight of the unit.
During handling it is prohibited to exceed the maximum inclination allowed, as shown in
the figure.
2.6 Unpacking
A Wooden support
B Corner protector
C Coil protection
• Remove the wooden supports before resting it definitely on the ground.
• Remove the clear film that wraps the machine.
• Remove the corner protectors.
• Remove the coil protectors.
The machine is supplied without shock absorbers. Install any shock absorbers before
resting the machine definitely on the ground.
Only remove the packaging when set in the place of installation.
2.7 Access to internal parts
A Electrical board door
B Electrical board access panel
C Lower access panel
D Lateral access panel
E Rear access panel
• Unscrew the fixing screws and remove the panels.
To access the electrical board:
• Remove the panels of the electrical board.
• Set the disconnecting switch knob to Off.
• Open the doors of the electrical board.
2.8 Resting on the ground
The unit must be positioned on a perfectly horizontal surface that is able to withstand its weight.
Positioning must be performed slowly and so that all support points are touching the floor.

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3. Installation
3.1
3.2
3.3
3.4
Installation location requirements
Work fields
Unit location
Verifying clearances (clearance area)
3.1 Installation location requirements
The installation place must be chosen as specified in standard EN 378-1 and the requirements of
standard EN 378-3. In any case, the installation site must consider the risks associated with an
accidental leak of refrigerant gas contained in the direct expansion units. Do not install the unit
near flammable materials or others that could cause a fire. Provide specific fire-fighting measures.
3.2 Work fields
The work fields are indicative, near the operating range limits the units may choke the cooling
capacity.
Check the actual capacity by using the capacity tables or the selection software.
Operating mode: heating
Standard operation
Ta Room air temperature (°C)
To Outlet water temperature (°C)
Operating mode: cooling
Ta Room air temperature (°C)
To Outlet water temperature (°C)
Standard operation
CT Operation extension with condensation control up to 0°C
CC Operation extension with condensation control up to -20°C
BT Low water temperature kit
3.3 Unit location
The unit should be positioned far from any obstacle.
It is prohibited to place the unit under a roof, canopy or any covering in general.
The heat pump units allow ice and condensation to form that pours on to the floor in front
of the unit. Collect and drain the condensation and defrost water to prevent the floor from
becoming slippery.
It is prohibited to place the unit inside basement windows.

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3.3.1 Noise
During operation, the unit generates noise.
Avoid installation in reverberant environments.
Avoid placing the machine with the side of the coil in the direction where the noise level is
more critical.
3.3.2 Windy areas (Resting on the ground)
The wind may alter the operating conditions. Place the unit with the long side parallel to the
prevailing wind direction in order to minimise the effects.
Avoid placing it with the coil perpendicular to the direction of the main wind.
3.3.3 Resting on the ground
A Rigid rubber band
H Slab of 10-15 cm
• Place the unit on a perfectly level support surface.
• Place a rigid rubber band between the base of the machine and the support surface.
Verify that the support surface withstands the weight of the unit.
Provide a supporting slab of proportional dimensions with the unit if resting on unstable
ground.
The slab must be horizontal and able to withstand approximately 200% of the operating
weight of the machine.
If necessary, use shock absorbers (rubber or spring).
A drain for the water produced by coils defrosting must be implemented for the WP units.
3.4 Verifying clearances (clearance area)
L1 1800
L2 1800
W1 1000
W2 500
• Installation, in addition to the indicated spaces, must enable access to the authorised
personnel for maintenance operations and must take into account the safety distances from
any other equipment installed near the machine.

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4. Water
connections
4.1
4.2
4.3
4.4
4.5
4.6
Connection diagram
Position of connections
Hydraulic data
Connection to the system
System fill-up
Desuperheater connection
4.1 Connection diagram
1 Unit
ANT Anti-vibration joint (recommended)
CV Check valve
FL Flow switch (mandatory)
FTR Mesh filter (mandatory)
MN Water gauge
MP Circulating pump
RI Shut-off ball valve
RIC Automatic water filling valve
SFA Automatic air vent (mandatory)
ST Inertial tank
VE Expansion vessel
VSI Safety valve (mandatory)
Some of the components in the diagram may already be included in the unit with the
hydronic kit. Those not included must be provided by the installer.
Connection pipes must have a suitable diameter and be supported so as not to impose
their weight on the unit.
4.2 Position of connections
The position of the water connections and the inlet and outlet direction is indicated by the labels
on the connections.
4.3 Hydraulic data
4.3.1 Water volume
The machine electronic control, to protect the electrical motor, limits hourly start up of the
compressor.
This operation creates oscillations of the water temperature in the draw-off point, affecting plant
efficiency.
For a correct operation, the water volume must comply with the following formula:
For cooling only version only
M > 9,45 x k x n/N x (Qf – q)
For heat pump version only
M > 9,45 x k x n/N x (Qt – q) + 2,37 x (Qt – q)
M = Minimum water content (l);
k = Factor that takes into account the different water temperature value
between the inlet and outlet of the evaporator or condenser;
n = Partition coefficient (n=1 unit up to 4 compressors; n=2 units with more
than 4 compressors);
N = N. compressors;
Qf = Cooling capacity (kW);
Qt = Heating capacity (kW);
q = Permanent thermal load in the system (kW), (q=0 if the value is unknown).
ΔT (K) K
3 1
4 1
5 1
6 1.05
7 1.1
8 1.15
9 1.2
10 1.25
For the process application a 50% higher water content is recommended to stabilize the
outlet temperature (1.5 x M calculated with the previous formulas).
If the water volume in the circuit (V) does not reach what is indicated, installing a new inertial
storage tanks shall be required.
Storage size shall be calculated so that with its volume, added to the water quantity inside the
circuit, the value indicated in the formula is reached.

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4.3.2 Water features
Water features are important for the proper operation of the machine and for its lifetime.
Extreme water hardness leads to the formation of limestone in exchangers reducing their
performance.
The table shows some water parameters to be observed for proper operation of the machine.
Content Concentration mg/l or ppm Material
AISI 316L Copper
pH
<6 2 2
6-7.5 2 2
7.5-9 1 1
>9 1 2
Alkalinity HCO3
- <70 1 2
70-300 1 1
>300 1 2
Sulphate SO42-
<70 1 1
70-300 1 3
>300 1 3
Alkalinity/Sulphate HCO3-/SO42- >1 1 1
<1 1 3
Electrical conductivity μS/cm
<10 1 2
10-500 1 1
>500 1 2
Ammonium NH4
<2 1 1
2-20 1 2
>20 1 3
Free chlorine Cl2
<1 1 1
1-5 3 1
>5 3 3
Hydrogen Sulphide H2S <0.05 1 1
>0.05 1 3
Free Carbon Dioxide CO2
<5 1 1
5-20 1 2
>20 1 3
Nitrate NO3 <100 1 1
>100 1 2
Iron Fe <0.2 1 1
>0.2 1 2
Aluminium AL <0.2 1 1
>0.2 1 2
Manganese MN <0.1 1 1
>0.1 1 2
1 - Good corrosion resistance.
2 - If different factors of this type are present, corrosion can occur.
3 - Use not recommended.
4.3.3 Protection against freezing
If you do not wish to drain the system during periods where the machine is not used, the water
may freeze, or if the system must operate with temperatures less than 5°C, ethylene glycol must
be mixed with the water.
Adding glycol changes the physical characteristics of the water and the performance of the
machine.
The table indicates the multiplicative factors to calculate the performance change based on the
percentage of glycol used.
% G 10 20 30 40 50
Tc -4.5 -9.5 -15.5 -21.5 -32.5
CQ 0.975 0.953 0.931 0.914 0.882
CP 0.998 0.995 0.99 0.985 0.975
CG 1.01 1.04 1.08 1.14 1.2
CP 1.05 1.13 1.21 1.26 1.32
% G = Glycol percentage
Tc = Water freezing temperature (°C)
CQ = Cooling capacity correction factor
CP = Electrical power absorbed correction factor
CG = Water flow correction factor
Cp = Pressure drops correction factor
4.4 Connection to the system
4.4.1 Models without hydronic kit
A Rear panel
In these models, the connections are positioned inside the unit.
• Remove the inspection panels.
• Remove the protection caps from the connections.
• Connect the pipes to the connections.
For threaded connections:
• Fasten by holding a part in order o tighten the other part.
• It is recommended to seal with hemp and green paste.
For Victaulic connections:
• Secure by using the appropriate coupling system (not supplied).
Provide shut-off valves and anti-vibration joints on the connection pipes.
During the hydraulic connection operations, never operate with free flames near or inside
the unit.

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4.4.2 Models with hydronic kit
In these models, the connections are positioned outside the unit.
• Remove the protection caps from the connections.
• Connect the pipes to the connections.
For threaded connections:
• Fasten by holding a part in order o tighten the other part.
• It is recommended to seal with hemp and green paste.
For Victaulic connections:
• Secure by using the appropriate coupling system (not supplied).
4.5 System fill-up
A Pump drainage shut-off valve
• Before performing any operation, make sure the main switch is off.
• If the hydronic kit is installed, make sure the pump drainage shut-off valve (A) is closed.
• Make sure that the drain valves are closed and the air vent valves are open.
• Open the shut-off valves of the water system.
• Start filling.
• When the water begins to leak from the vent valves, close them and bring the water pressure
to the value required by the system (1 - 1.5 bar). Keep in mind that safety valve calibration is
6 bar.
• When the water pressure has stabilised (read the pressure gauges installed on the upper side),
close the fill-up valve and check the tightness of the various joints.
It is advisable to periodically check the pressure in the water circuits to prevent
malfunctions.
The water circuits must always be topped-up with the pumps off.
4.6 Desuperheater connection
A Rear panel
The connections are positioned inside the unit.
• Remove the inspection panels (A).
• Remove the protection caps from the connections.
• Connect the pipes to the connections.
For threaded connections:
• Fasten by holding a part in order o tighten the other part.
• It is recommended to seal with hemp and green paste.
For Victaulic connections:
• Secure by using the appropriate coupling system (not supplied).

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5. Electrical
connections
5.1
5.2
Machine connection
Connections of the accessories
5.1 Machine connection
A Pre-cut for front inlet
B Hole for bottom inlet
The unit is provided with holes for the power cables inlet. There is a pre-cut hole on the structure
and a hole on the base for any input from below.
• Remove the pre-cut.
• Insert the cables from the outside, guiding them towards the electrical board.
Avoid direct contact with non-insulated copper pipes and with the compressor.
It is forbidden to enter the device with electrical cables in positions not specifically required
in this booklet.
To set up the electrical connections:
• Unscrew the fixing screws.
• Remove the external panels.
• Set the main switch to 0.
• Turn the two fixing screws 1/4 of a turn and open the board doors.
• Use the hole for the main power cable and the hole for the cables of other external
connections.
• Make the connections as shown in the wiring diagram.
• Once the electrical connections are completed, secure the cables by using the cable glands,
close the doors of the electrical panel and reassemble the external panels by screwing the
fixing screws.
Before connecting the remote ON-OFF switch, remove the jumper from the relative
clamps.
5.2 Connections of the accessories
5.2.1 Flow switch
The chiller must only operate in the presence of water flow. The flow switch (if not already
present) must be connected as shown in the wiring diagram.
5.2.2 Circulating pump
The circulating pump must always be connected to the control unit as indicated in the wiring
diagram. The pump must be started before the chiller is started and stopped after the chiller is
stopped (recommended minimum delay: 60 seconds).
5.2.3 External consents
If you wish to enable or disable the unit remotely, connect the external consent to the contacts
listed in the wiring diagram.
Avoid placing the control cables in the same duct as the power cables. Always use a
suitable shielded cable.
The connection cables must have a minimum cross section of 1.5 mm².

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6. Commissioning
6.1
6.2
6.3
6.4
Preliminary inspections
First start-up or restart after long inactivity
Shut-down
Flow rate calibration
6.1 Preliminary inspections
6.1.1 Electrical
• Verify that the voltage on terminals L1, L2 and L3 is that shown on the plate of the unit
(tolerance allowed) ±5%, which can be checked with a tester. If voltage changes occur
frequently, please contact our technical department to choose suitable protections.
• Verify the complete tightness of the fuse holder caps.
• Verify that the crankcase heaters (if applicable) are powered correctly: to check whether the
heaters are working properly, check that the bottom of the compressor is at a temperature of
10 to 15 °C higher than the ambient temperature.
• Power and check the correct direction of rotation for the three-phase version, which should be
clockwise looking at the motor from the fan side. Otherwise, invert any two of the phase
conductors.
6.1.2 Hydraulic
• Make sure that the water circuit has been previously cleaned: it is recommended to wash the
water circuit via by-passing the unit and then check the cleanliness of the system filter.
• The machines are shipped with open vents and drains, which must be closed during
installation when filling the water circuit. Labels indicate their positions.
• In models with a hydronic kit, the water drain cap of the pump has been removed, in order to
drain the water contained in it and to avoid freezing problems during the winter season. The
cap is inside the envelope containing all documents of the unit.
• Make sure that the hydraulic system has been bled, thereby eliminating any residual air. The
operation must be performed by loading gradually and opening the venting devices set up by
the installer in the upper part of the system.
• If you are using glycol water you can move the antifreeze set-point. The value must be equal
to the value of the freezing temperature of the fluid plus 6K.
6.1.3 Cooling
• Make sure that the pressure gauges (when present) indicate an adequate pressure. Pressure
gauges can be fitted with shut-off valves. They should only be opened when necessary and
once readings are taken, they must be closed again.
• Check that there is no refrigerant leak, possibly using a leak detector.
6.2 First start-up or restart after long inactivity
6.2.1 Start-up
Activate the machine according to that described in the relative command section.
6.2.1.1 Checks during operation
• Check that the machine does not generate abnormal noise or excessive vibrations.
• After a few hours of operation verify that the crown of the liquid and humidity indicator
indicates a dry circuit.
• Verify that the machine operates within the optimum working range.
• Verify that there is no excessive presence of bubbles in the liquid indicator. If there are this
indicates low refrigerant.
• A few minutes after the compressors are started, during the summer mode cycle, make sure
that the condensing temperature is 18±4K higher than the air temperature entering the
condenser and that the average evaporating temperature is approximately 5K lower than the
water temperature leaving the utility exchanger.
• Verify that the overheating temperature of the refrigerant is between 5 and 7K. To verify:
- Measure the temperature with a contact thermometer placed on the intake pipe of the
condenser .
- Read the temperature indicated on the pressure gauge connected to the inlet.
- The difference between these temperatures provides the overheating value.
• Verify that the subcooling temperature of the refrigerant is between 4 and 8K. To verify:
- Measure the temperature with a contact thermometer placed on the outlet pipe from the
condenser.
- Read the temperature indicated on a pressure gauge connected to the liquid outlet of the
condenser.
- The difference between these temperatures provides the subcooling value.
The tests referred to above can be performed using the pressure gauges supplied with the
unit (accessories). Once the checks are complete, close the shut-off valves of the pressure
gauges.
6.2.2 Pump release procedure
• Before starting the pump, check that the moving parts rotate freely.
To release the pump:
• Remove the fan cover from the seat of the rear motor cover.
• Use a screwdriver on the present slot on the motor shaft from the fan side.
• In case of blockage, turn the screwdriver by tapping it lightly with a hammer.
• When the operations are completed, reassemble the components in reverse order.
6.3 Shut-down
6.3.1 Temporary shut-down
Disable the machine according to that described in the relative command section.
Do not disconnect the power supply by acting on the disconnecting switch on board the
machine or the main switch of the system. If no voltage is present, the crankcase heaters
and any anti-freeze heaters cannot work, thereby, posing a risk of freezing.

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6.3.2 shutting down for long periods;
Not using the unit for a long period of time requires the following operations to be performed:
• Disable the unit in any mode of operation it may be, from the control panel.
• Set the remote switch to "OFF" (if present) after having turned off the unit.
• Disable the internal terminal units by setting the switch of each unit to "off".
• Set the main switch of the system to ''off''.
• Close the water valves.
If, during the period of inactivity the temperature drops below zero, the system must be
fully empties or topped up with antifreeze liquid.
6.4 Flow rate calibration
Once the pump has started, verify that the fluid flow rate of the utilities is within the expected
values for the unit.
To verify:
• Use pressure gauges set before and after the circulating pump to measure the pressure
difference.
• Verify that the pressure difference measured is equal to the pressure drop in the system,
including the heat exchanger.
To correct:
• Turn the valve installed downstream of the pump to increase or decrease the pressure
difference.
• Mark the position of each valve to reposition it in the same position after closing for
maintenance operations.
If there are no pressure gauges:
• Verify the temperature difference between the utility fluid input and output when the unit is
operating regularly (all compressors on).
• The difference in water temperature between input and output must be between 4° and 6°C:
- If it is below 4°C, the water flow rate is too high: slightly close the discharge valve of the
pump.
- If it is more than 6°C, verify the pressure drops in the water circuit.
For units equipped with two pumps, you will have to repeat the calibration for each pump.

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7. Control Panel
7.1
7.2
7.3
7.4
7.5
7.6
7.7
User interface
Switch on and off
Settings
Unit Status
Alarms
Login
Software
7.1 User interface
7.1.1 Control panel
The control panel enables all machine functions to be performed, to display its operation and any
alarms which may be triggered.
7.1.2 Display
From the display of the control panel it is possible to see the sizes of the values set and machine
operation may be displayed through the LEDs.
Inlet water temperature
Indicates inlet water temperature.
Set-point
Indicates the Set-Point temperature.
Alarm
Indicates that a machine operation alarm has triggered.
Compressor
Indicates compressors operation:
- on, compressor active;
- flashing, compressor in standby;
- white filling, indicates the power percentage dedicated.
Pumps
Indicate pumps operation.
Fans
Indicates fan operation.

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Cooling
Indicates that the machine is operating in cooling mode.
Heating
Indicates that the machine is operating in heating mode.
Defrosting
Indicates that the machine is operating in defrosting mode.
7.1.3 Function keys
UP Function
By using the UP key it is possible to move upwards between the parameters and increase a value.
DOWN Function
By using the DOWN key it is possible to move downwards between the parameters and decrease
a value.
ENTER Function
Enter a menu and save a value by using the ENTER key.
RIGHT Function
By using the RIGHT key it is possible to move to the right within the parameters.
LEFT Function
By using the LEFT key it is possible to move to the left within the parameters.
ESC Function
By using the ESC key it is possible to exit a menu and display an alarm that has triggered.

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7.2 Switch on and off
Press the ENTER key to access the main menu in order to switch the unit on or off.
Select the start-up menu.
Press the ENTER key.
By using the UP and DOWN keys it is possible to select unit start-up and shutdown.
Press the ENTER key to confirm.
The unit can be switched on or off directly from the main screen: pushing the UP key for 5
seconds the unit switches from on to off and vice versa.
If the machine is switched off, the display will show the sign OFF.
7.3 Settings
7.3.1 Language
It is possible to select the software language.
Press the ENTER key to access the main menu.
Select the language menu.
Press the ENTER key.
Select the desired language from those available.
Press the ENTER key to confirm.
All software contents will appear translated in the language selected.
7.3.2 Date and time
The adjustment must be made while the machine is off.
Press the ENTER key to access the main menu.
Select the clock menu.
Press the ENTER key.