Ferroli 150.4 User manual

RLA
AIR WATER HEAT PUMPS
WITH HELICAL FANS
136 ÷ 299 kW IN COOLING MODE
165 ÷ 350 kW IN HEATING MODE
TECHNICAL MANUAL
150.4
165.4
180.4
205.4
230.4
260.4
285.4
315.4
FERROLI adheres to the
EUROVENT certification
programme.
The products concerned
appear in the products guide to
www.eurovent-certification.com

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TABLE OF CONTENTS
THIS MANUAL IS DIVIDED INTO SECTIONS. THEIR NAMES APPEAR IN THE HEADING OF EACH PAGE.
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PRESENTATION OF THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
IDENTIFICATION CODE OF THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION OF THE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MECHANICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DESCRIPTION OF THE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
MECHANICAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
ELECTRICAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
COMBINATIONS OF ACCESSORIES-MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
TECHNICAL SPECIFICATIONS AND STANDARD PERFORMANCES - R407C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
TECHNICAL SPECIFICATIONS OF UNIT AB-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
NOISE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
STANDARD PERFORMANCES IN COOLING MODE AB-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
STANDARD PERFORMANCES IN HEATING MODE AB-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
TECHNICAL SPECIFICATIONS OF UNIT AS-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
NOISE LEVELS OF THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
STANDARD PERFORMANCES IN COOLING MODE AS-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
STANDARD PERFORMANCES IN HEATING MODE AS-7M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
OPERATING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
OPERATING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HOW TO SELECT THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
WATER PRESSURE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
WORKING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
MAXIMUM VOLUME OF WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
MAXIMUM VOLUME OF WATER IN THE SYSTEM WITH WET MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
OVERALL DIMENSIONS - MINIMUM SPACE REQUIRED AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
DESCRIPTION OF THE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
MINIMUM SPACE REQUIRED FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
POSITION OF WET CONNECTIONS MOD. 150-260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
POSITION OF WET CONNECTIONS MOD. 285-315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
WEIGHT DISTRIBUTION DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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Presentation of the unit
This new series of industrial chillers has been designed to meet the air conditioning requirements of
medium-large systems in the industrial, service and business sectors. Suitable for outdoor installation, they
are built for various types of system and to comply with the needs of highly qualified planning engineers.
The complete series for use in hydronic systems includes 8 sizes with refrigerating power ratings ranging
from 136 to 299 kW and heating output ratings ranging from 165 to 350 kW. When the units were desi-
gned, particular attention was also paid to sound emission in our endeavour to comply with the increasingly
more restrictive laws governing acoustic pollution: all the sizes are therefore available in both the basic and
silenced versions, to choose depending on the noise level required.
All the units can produce cold water at a temperature between 5 and 10C (summer operating mode) and
hot water from 35 to 55C (winter operating mode). As part of the standard supply, they are pre-enginee-
red for summer/winter operation at low/high outdoor air temperatures thanks to use of a condensation/eva-
poration monitoring system through continuous control of the fans by steps. All the units are equipped with
2 independent chilling circuits, each of which has two Scroll compressors. This allows the power genera-
ted by the unit to be modulated from 25% to 100%, thus adapting to the heat load of the system supplied.
All the units are equipped with a thermal barrier plate type evaporator protected by means of a differential
water pressure switch and electric antifreeze heater, coils with extended surfaces and extensive heat
exchanging areas formed by copper pipes and notched aluminium fins, electric fans with scythe-shaped
vanes to reduce the sound emission, electric panel for adjustments and controls, controller with micropro-
cessor.
The standard supply can also be integrated with a vast range of electrical and mechanical accessories. The
Water Storage Tank and Pumping Module with 1 or 2 Pumps are particularly important accessories. If both
are chosen, the tank is configured for storage on the delivery to the system or for storage on the return part of
the system, or for storage pre-engineered for the primary and secondary circuit, depending on the type of
Pumping Module selected.
The chillers have been designed for use with R407C environment-friendly refrigerant.
All the units are accurately built and tested individually. Installation only requires electrical and wet connections.
Identification code of the unit
The codes that identify the units are listed below and include the sequences of letters that determine the meanings for the various
versions and set-ups.
GENERAL SPECIFICATIONS
N of compressors= 4
IP - 285.4 - VB - AB - 7 - M - 5
AB - Basic Version
AS - Silenced Version
This version includes sound-
proofing of the compressors
and fans with reduced rotation
rate
Acoustic Version
Climatic Limits
M - Medium temperatures
The unit is suitable for
use in places with the
average temperatures
typical of temperate cli-
mates, within limits to
use up to 45-46C.
Size of
unit
150
165
180
205
230
260
285
315
VB - Base Version
Version of unit
Type of Power Supply
5- 400V - 3ph+N - 50Hz
Type of Refrigerant
7- R407C
Type of unit
IP - Unit for installation in
Hydronic systems, operating as
a reversible Heat pump on the
cooling circuit

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GENERAL SPECIFICATIONS
Description of the components
1. Fans. These are the helical type with scythe-
shaped vanes to increase efficiency and reduce
the sound emissions. The fans are directly
coupled to the threephase motor by means of an
external rotor. Thermal protection against opera-
ting faults is installed inside the winding.
2. Electric control and monitoring panel. It is
housed in a cabinet made of adequately thick
painted sheet metal suitable for outdoor installa-
tion (protection degree IP 54). The panel com-
prises the following main components:
• Main door-locking circuit-breaker.
• Disconnectable fuse holders with protection
fuses for each compressor.
•Disconnectable fuse holders with protection
fuses for the oil heaters of the compressors.
•Disconnectable fuse holders with protection
fuses for the antifreeze heater.
• Control contactor for each compressor.
•Disconnectable fuse holders with fan protection
fuses.
•Fan control contactors.
•Magnetothermic relay/s and contactor/s for the
pump/s (if one of the pumping module accessories is installed and depending on the type chosen).
• Fan speed control board.
• Insulating and safety transformer to power the auxiliaries, protected with fuses.
• Basic monitoring board with microprocessor:
the main functions of the monitoring board are: temperature regulation of the water produced by the unit, defrosting con-
trol, operating hour counting for compressors and pump, balancing of operating hours for compressors, start-up timing, param-
eter entry digitized via the keyboard, alarm diagnosis.
Functions associated with the digital inputs: high and low pressure, high temperature of compressor outlet (accessory),
correct electric power phase presence-sequence, thermal protection for compressors, thermal protection for fans, thermal pro-
tection for pump, differential water pressure switch, ON/OFF and operating mode change commands.
Functions associated with the digital outputs: compressor control, water pump control, electric antifreeze heater, general
alarm (can be remote controlled), cycle reversing valve control.
Functions associated with the analog inputs: water inlet and outlet temperatures, circuit 1 and 2 coil temperatures.
Functions associated with the analog outputs: monitoring of the fan
speed by steps in conjunction with the fan control board.
3.User interfacing terminal with display.
• On-off key.
• Operating mode selector key.
• Compressor on-off LED.
• Antifreeze heaters on LED.
• Check-control with alarm code display.
• Defrosting in progress indicator.
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34
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4. Compressors. These are the SCROLL type with orbiting coil equipped with built-in thermal protection and oil heater. As part
of the standard supply, they are positioned on rubber vibration dampers to reduce the vibrations transmitted to the base of the
unit. To lower the sound emission of silenced version AS, they are installed in a soundproofed booth made of galvanized sheet
metal coated with polyurethane powder paints and covered in soundproofing material.
5. Bearing structure made of galvanized sheet metal coated with polyurethane powder paint to ensure good protection against adver-
se weather conditions.
6. Water storage tank (accessory that must be requested when the unit is ordered) Made of adequately thick painted sheet
metal, this reduces the number of compressor start-ups and fluctuations in the temperature of the water conveyed to the users.
It is insulated with thermal barrier insulating material to prevent the formation of condensation and heat exchanges towards
the outside. In conjunction with the Pumping Module accessory, it can be supplied in 3 different configurations: Storage on the
Delivery, Storage on the Return, Storage pre-engineered for Primary and Secondary circuits. In conjunction with the Pipe Kit,
the only configuration possible is the one with Storage on the Delivery.
The water drain is installed under the tank as part of the standard supply. The water is turned on and off by a cock that allows
the unit to be drained.
7. Air vent. The automatic type, turned on and off by a cock and positioned on the highest part of the tank.
8.Water safety valve, on the rear part of the tank. It acts whenever faulty service leads to an operating pressure in the plumbing
system that exceeds the valve opening value.
9.Antifreeze heater connection. 11/4 female threaded connection pre-engineered for installation of the tanks antifreeze hea-
ter.
10. Evaporator, plate type made of braze-welded stainless steel (AISI 316), double chilling circuit and alternate water/refrige-
rant circuits. It is installed within a shell of thermal barrier insulating material to prevent the formation of condensation and heat
exchanges towards the outside. Standard supply also includes a differential pressure switch on the water supply circuit to avoid
the risk of freezing if the water flow is shut off for some reason.
11. Condensing coils, the aluminium finned pack type with shaped profile to increase the heat exchange coefficient and with
copper pipes arranged in staggered rows.
12. Covering panels, made of galvanized sheet metal coated with polyurethane powder paints to ensure the utmost ability to
withstand adverse weather conditions.
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GENERAL SPECIFICATIONS
21
19
4
18
14
15
23
17
16
15
20
4
13
9
7
22
6
8
10
2b
2a
1a
1b

Hydraulic and chilling circuit components
13. 4-way cycle reversing valves. Reverse the direction in which the refrigerant flows when the operating mode changes
(Cooling mode or Heating mode).
14.Refrigerant safety valve. (Conforms to the Directive governing pressurized vessels -PED). Installed on the delivery pipe of
the compressors. It acts if critical service faults should occur.
15.Fluid cock -Gas cock. Allow all the refrigerant in the coils to be pumped and then stored so as to carry out servicing work
or to replace all the components of the chilling circuit without having to drain it.
16.Dehydrator filter. Of the removable cartridge type. Retains impurities and traces of moisture in the circuit.
17.Fluid and humidity indicator. Signals when fluid passes through the circuit, indicating that the refrigerant charge is correct.
The fluid indicator also changes colour to show the amount of moisture in the refrigerant.
18.Low pressure switch. With fixed setting. It is installed on the intake pipe and blocks the compressors of the circuit in que-
stion if the operating pressures drop below the tolerated values. It automatically resets as the pressure increases. If it activa-
tes frequently, the circuit in question will block and can only be restarted by resetting via
the user interface terminal.
19.High pressure switch. With fixed setting. It is installed on the delivery pipe and blocks both the compressors of the circuit if
the operating pressures exceed the tolerated values. If it activates, the circuit will block and can only be restarted by resetting
via the user interface terminal.
20.Electric resistors to heat the compressor oil. Belt type, one per compressor. They activate when the compressor turns
off. Their task is to keep the temperature of the oil sufficiently high so as to prevent refrigerant from migrating during these pau-
ses.
21.Fluid receiver. One per circuit. They are plenum tanks that account for the refrigerant charge variations required by the
machine as the operating modes change (Cooling mode or Heating mode).
22.Fluid separator. One per circuit, installed on the intake part of the compressors to protect against backwashing.
23.Fluid solenoid valve.One per circuit. They shut off when both the compressors of the circuit switch off, preventing liquid refri-
gerant from flowing towards the evaporator during periods at a standstill.
One-way valves. Make the refrigerant obligatorily pass through the appropriate heat exchangers, depending on the operating
cycle.
Thermostatic valve. With external equalizer.Its task is to supply the evaporator correctly, keeping the selected degree of super-
heat at a steady level.
High temperature thermostat. One per compressor, installed on the delivery pipe to protect the compressor if the end of com-
pression temperature exceeds 130° C.
Differential water pressure switch. This is standard supply and is installed on the connections between the exchangers water
inlet and outlet. It blocks the unit if it activates.
Pressure taps: 1/4 “ SAE (7/16” UNF) type with air pump. Allow the operating pressure of both the circuits to be measured in
3 main points: compressor delivery, flow-restricting component inlet, compressor intake.
GENERAL SPECIFICATIONS
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OPTIONS AND ACCESSORIES
8
Mechanical accessories
GM (M) Pressure gauge unit. Consisting of 4 pressure gauges that display the pressure of the refrigerant fluid on the intake and
delivery of the compressors of both circuits..
GP (M) Protective grilles. Consisting of metal grilles that protect the coils with extended surfaces.
AVM (F) Spring vibration dampers. Consisting of 4 spring vibration dampers to install under the unit. They reduce the mechani-
cal vibrations generated by the compressor and fans during their normal operation, and that are then transmitted to the bearing
surface of the machine. The insulation degree provided by the vibration dampers is about 90%.
SAA (M) Water storage tank. Made of adequately thick painted sheet metal, this reduces the number of compressor start-ups
and fluctuations in the temperature of the water conveyed to the users. It is insulated with thermal barrier material to prevent the
formation of condensation and heat exchanges towards the outside. The accessory is inclusive of water safety valve, air vent,
water drain and antifreeze heater connection. In conjunction with the Pumping Module accessory, it can be supplied in 3 different
configurations: Storage on the Delivery, Storage on the Return, Storage pre-engineered for the Primary and Secondary circuit.
Pumping module with 1 o 2 Pumps (The second pump, installed in parallel to the first, allows to have one workable
pump to use if the first doesn't work).:Besides the pumps, this accessory is equipped with all the hydraulic components (water
filter, expansion tank, on-off valves, water pressure gauge) required for complete installation and easy maintenance.
Different water accumulation tank configurations are therefore available in combination with the pumping module accessory:
MP-AM : Storage on the water supply plant Delivery(1):The pump draws water from the supply plant, sends it to the plate
type heat exchanger and then to the inertial storage tank. In this configuration, when the pump operates in its nominal condi-
tions, it is able to supply the circulating water with a residual head of about 140 to 220 kPa in the Cooling mode (from 13 to 20
m.w.c.) and from 80 to 150 kPa in the Heating mode (from 14 to 22 m.w.c).
MP-AR: Storage on the water supply plant Return(1):The pump draws water from the inertial storage tank, sends it to the plate
type heat exchanger and then to the system. In this configuration, when the pump operates in its nominal conditions, it is able to
supply the circulating water with a residual head of about 140 to 220 kPa in the Cooling mode (from 13 to 20 m.w.c.) and from
80 to 150 kPa in the Heating mode (from 8 to 22 m.w.c).
MP - PS: Storage pre-engineered for the primary and secondary circuit. The pumps sole task is to allow water to circulate
around the primary circuit: this circuit includes the storage tank and plate type heat exchanger (chillers water circuit). Assembly
of the pumping section for the secondary circuit is at the installers charge and includes the storage tank (with pre-engineered
wet connections) and the system to be supplied.
KT - Pipe kit, consists of two steel pipes insulated with heat barrier material. If the Pumping Module accessory is not installed,
the pipe kit is obligatory to be taken.
Notes:
(1): Refer to the respective values given for each unit in the Technical data section.

OUT
IN
IN
OUT
9
7
OUT
IN
1
11
3
2
3
5
6
4
IN
OUT
11
1
9
7
3
2
3
5
6
4
OPTIONS AND ACCESSORIES
Description of the configurations
MP - AM 2 Pumps with Water storage tank MP - AM 2 Pumps without Water storage tank
KT with Water storage tank KT without Water storage tank
KT. - Pipe kit, consists of two steel pipes insulated with heat barrier material. Allows the water IN / OUT connections to be rou-
ted to the machine.
 MP. Pumping module. It consists of:
1 On-off ball valves. Turn components such as the water filter, surge chamber and pump on and off when they require
routine or supplementary maintenance.
2 Metal gauze water filter. Can be turned on and off and inspected. It is installed on the pump suction side. Prevents any machining
residues (dust, swarf, etc.) that may be in the water pipes from entering the pump impeller or plate-type heat exchanger.
3 Hydraulic pump. Circulates water around the system. The pumps have a high head and suit the majority of installation requi-
rements. The pump is safeguarded by a motor protector installed in the chillers electric panel.
4 Surge chamber. This is a closed, diaphragm type chamber. It absorbs the variations in the volumes of water in the system
caused by temperature variations.
5 Water filling.Manual function with control positioned on the side of the unit opposite the electric panel and turned on and off
by a cock that can be accessed by removing the rear panel.
6 Water pressure gauge. Connected to the water fill pipe. Displays the pressure of the water in the system.
7 Water safety valve. Standard supply.
8 Water outlet. Standard supply.
9 Air vent. Standard supply.
10 Antifreeze heater connection. Standard supply.
11One-way check valves. Only installed if the Pumping Module accessory with 2 pumps is installed (one valve for each pump).
NOTE: it is essential to purchase the units with either the KT or MP accessory described previously. The choice of one
automatically excludes the other. 9

10
OP - Programmer Clock. Allows the unit to be turned on and off, depending on the selected time settings (up to 14 settings
can be entered, divided as required throughout the 7 days of the week).
RAG (F) Electric antifreeze heating element on the storage tank. Plug type. It activates in parallel with the evaporators antifreeze
heating element and keeps the water at a temperature able to prevent ice from forming during the winter, when the unit is not
used.
Mechanical options
Special finned heat exchangers
• Coils with copper fins
• Coils with tin-coated copper fins
• Coils with aluminium fins with acrylic coating
Electrical options
Power source voltage rating 230V-3-50Hz
OPTIONS AND ACCESSORIES
MODE KEY
ON-OFF KEY
Selects the operating mode (waiting for start-up or operation) of
the machine.
Allows the controller to be turned on and off and resets the alarms.
MODE plus ON/OFF
KEYS
If pressed at the same time, are used to access and quit the various
menu levels.
UP KEY
DOWN KEY
When the menu is displayed, is used to scroll forwards through the
items in the menu itself, or to increase the value of a parameter.
When the menu is displayed, is used to scroll backwards through the
items in the menu itself, or to decrease the value of a parameter.
Electrical accessories
CR - Remote Control. This device consists of a remote control
which allows all the control and monitoring functions of the control
unit on the machine to be controlled up to 100 meters away from the
actual machine itself. It has been specially designed for installation
on a wall inside the building. Use a threepole. The transmission line
must be routed in a dedicated duct, separate from any electric
powering lines (230/400 V). It has four keys used to select the con-
trols on the controller installed on the machine, the only difference
being that the scroll-up and scroll-down functions have been sepa-
rated from the mode and on-off keys in order to make the control
easier to use.
During normal operation, the operating temperature (or the temperature read by the probe on the exchanger inlet) in
degrees centigrade appears on the LCD display or the alarm code, if at least one is activated. The temperatures read
by the other probes can be read by means of a few simple operations.
If faults occur during normal operation, the controller stops the machine and displays the code of the alarm in question.
After the alarm has been checked and its cause eliminated, the controller can be reset by pressing the on/off key.
The remote control has the following keys:
The controller has five LEDs on the left-hand side of the interface, that display the status functions of the machine:
•LED of compressors 1 and 2 (circuit 1).
•LED of compressors 3 and 4 (circuit 2).
•Electric antifreeze heater LED.
•HEATING mode LED
•COOLING mode LED