Ferroli HXW User manual

HXW
WATER - WATER AND BRINE - WATER
HEAT PUMPS
FOR INDOOR INSTALLATION
INSTALLATION AND OPERATION MANUAL
i migliori gradi centigradi
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The manufacturer declines all the responsabilities regarding inaccuracies contained in this manual, if due to printing or typing mi-
stakes. The manufacturer reserves the right to apply changes and improvements to the products at any time without notice.
Dear Customer,
Thank you for having purchased a FERROLI product. It is the result of many years of experiences and of particular research studies
and has been made with top quality materials and advanced technologies. The CE mark guarantees that the products satisfy all the
applicable European Directives.
The qualitative level is kept under constant control and FERROLI products therefore offer SAFETY, QUALITY and RELIABILITY.
Due to the continuous improvements in technologies and materials, the product specication as well as performances are subject to
variations without prior notice.
Thank you once again for your preference
FERROLI S.p.A

3
TABLE OF CONTENTS
GENERAL FEATURES 4
General instructions ...................................................................................4
Declaration of conformity ...............................................................................4
Unit dataplate ........................................................................................4
Unit description.......................................................................................5
Unit identification code .................................................................................5
Description of components..............................................................................6
Control system .......................................................................................7
Options.............................................................................................8
Accessories .........................................................................................10
TECHNICAL DATA AND PERFORMANCES11
Technical data........................................................................................11
NOMINAL performances - Base setting up (AB) - Radiant plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
NOMINAL performances - Base setting up (AB) - Standard plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
HEATING performances................................................................................14
COOLING performances ...............................................................................15
Plant side hydraulic performances ........................................................................16
Source side hydraulic performances ......................................................................17
Domestic hot water side hydraulic performances.............................................................18
Operating limits.......................................................................................19
Electrical data........................................................................................20
Noise levels .........................................................................................20
Weights.............................................................................................21
Overall dimensions....................................................................................22
Minimum operating area................................................................................22
CONNECTIONS23
Hydraulic connections..................................................................................23
Electrical connections..................................................................................24
RECEIVING AND POSITIONING 25
Receiving ...........................................................................................25
Positioning ..........................................................................................25
START UP 26
Start up.............................................................................................26
CONTROL SYSTEM 27
Control system configuration ............................................................................27
Heating and cooling circuits .............................................................................28
Control system devices installation........................................................................30
Wireless devices connection ............................................................................32
Control system using ..................................................................................33
Control system programming ............................................................................36
Menu structure .......................................................................................36
Remote thermostat programming.........................................................................38
Remote control (wired o wireless) programming .............................................................38
Functions available for the use...........................................................................38
Inputs and outputs ....................................................................................40
Alarms..............................................................................................41
Alarms table .........................................................................................41
Controller technical data................................................................................42
Sensors features......................................................................................43
MAINTENANCE44
Maintenance.........................................................................................44
SAFETY AND POLLUTION45
General considerations.................................................................................45
Refrigerant safety card.................................................................................45

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GENERAL FEATURES
General instructions
Declaration of conformity
Unit dataplate
The figure shows the fields reported on the unit dataplate :
This manual and the wiring diagram supplied with the unit must be kept in a dry place for possible future consultation.
The manual provides information on installation and correct use and maintenance of the unit. Before carrying out installation,
please carefully read all the information contained in this manual, which describes the procedures necessary for correct
installation and use of the unit
Follow carefully the instructions contained in this manual and respect the safety regulations in force. The unit must be installed
in conformity with the laws in force in the country of use. Unauthorized tampering with the electrical and mechanical equipment
INVALIDATES THE WARRANTY.
Check the electrical specifications given on the dataplate before making the electrical connections. Read the instructions given in the
specific section on electrical connections.
Deactivate the equipment in case of fault or poor operation.
If the unit requires fixing, contact only specialized service centers recognized by the manufacturer and use original spare parts.
The unit must be installed outdoor and connected to a hydronic cooling and/or heating system. Any use different from that permitted
or outside the operating limits indicated in this manual is prohibited (unless previously agreed with the firm).
The manufacturer declines any responsability for damage or injury due to non-compliance with the information given in this manual.
The firm declares that the present unit complies with the requirements of the following directives :
• Machinery directive (MD) 2006/42/EC
• Pressure equipment directive (PED) 97/23/EC
• Electromagnetic compatibility directive (EMC) 2004/108/EC
• Low voltage directive (LVD) 2006/95/EC
Codice
Code B1 Rev
Ferroli Spa
Via Ritonda 78/A
(VR) Italy
A - Trademark
B - Model
B1 - Code
C - Serial number
D - Capacity in cooling at the condition W30W18
E - Capacity in heating (heat pump) at the condition W10W35
F - Power input in cooling at the condition W30W18
G - Power input in heating (heat pump) at the condition W10W35
H - Reference standard
I - Power supply
L - Maximum absorbed current
M - Refrigerant type and charge weight
N - Unit weight
O - Sound pressure level at 1 metre
P - IP protection level
Q - Maximum pressure - high pressure side
R - Maximum pressure - low pressure side
S - PED certification body

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IH 121 VB AB 0 M 1
GENERAL FEATURES
Unit description
This series of water-water heat pumps satises the heating,
cooling and domestic hot water production requirements of resi-
dential plants of small and medium size.
All the units are suitable for indoor installation and can be ap-
plied to fan coil plants, radiant oor plants and high efciency
radiators plants.
As source both water (from well, river, lake…) or brine solutions
(from geothermic probes) can be used.
The control system allows to manage not only the refrigerant
circuit but the whole plant with the possibility to choose different
solutions both for the heating and cooling plant and for the do-
mestic hot water management. The possibility of solar panels or
other heating sources integration is also available.
The heating function optimizes the ow water temperature ac-
cording both to the ambient temperature and to the outdoor tem-
perature through climatic curves adaptable to the building featu-
res. It’s possible to manage a storage tank and two independent
circuits (a direct one and a mixed one).
The domestic hot water management allows to control the th-
ree way valve, the storage tank and the anti-legionella cycles (if
necessary).
The cooling function can be realized through “passive cooling”
(free cooling), through “active cooling” (refrigerant circuit inver-
sion) or through both systems actuated in sequence. When the
unit is used in radiant oor plants, to avoid condensate genera-
tion, a room humidity sensor can be installed.
The internal programmer clock allows to dene different daily
switching programs for heating, cooling and domestic hot water
production.
The refrigerant circuit, contained in an extractable box to sim-
plify the maintenance operations, is equipped with scroll com-
pressor mounted on damper supports, brazed plate heat ex-
changers, thermostatic expansion valve and reverse cycle valve
(for reversible units). The circuit is protected by high and low
pressure switches and ow switches on both the exchangers.
The outdoor structure and the refrigerant circuit box are both
thermally and acoustically insulated in order to create a dou-
ble wall against sound propagation and to allow the installation
in domestic places.
To avoid vibration propagation towards the hydraulic circuit the
refrigerant circuit box is placed on damper supports and the con-
nection pipes are exible. Moreover all the hydraulic pipes are
thermally insulated to avoid condensate generation.
The three phase electrical power supply heat pumps are sup-
plied with phase sequence and voltage controller integrated in-
side the unit controller.
All the units are accurately built and individually tested in the
factory. Only electric and hydraulic connections are required for
installation.
Unit identification code
The codes that identify the units and the meaning of the letters used are described below.
Unit type
IH - Units suitable for hydronic plant in-
stallation operating as heat pumps
IP - Units suitable for hydronic plant
installation operating as reversible heat
pumps
Power supply
1 - 230V - 1 - 50 Hz
5 - 400V - 3N - 50 Hz
Operating range
M - Medium temperature.
The unit is suitable to produce
water at medium temperature
Refrigerant type
0 - R410A
Acoustic setting up
AB - Base setting up
Unit version
VB - Base version
N° compressors
Unit model
HXW

6
GENERAL FEATURES
Description of components
External structure Basement, lateral panels and frontal panel,
are completely thermally and acoustically insulated in order to
minimize thermal losses and noise emissions in the surroundings.
Accessibility to internal parts is possible removing the frontal
panel and the upper panel. For extraordinary manteinances also
the rear panel can be removed.
Refrigerant circuit It is contained inside an extractable box
to simplify the maintenance operations. The box is placed on
rubber vibration dampers and is connected to the hydraulic
circuit through flexible pipes in order to avoid the propagation
of the vibrations generated by the compressor outside the unit.
The hermetic scroll compressor (1) is mounted on damper
supports and is protected against overtemperatures and
overcurrents. The heat exchangers on the plant side (2) and
on the source side (3) are realized with brazed stainless steel
plates, properly insulated to avoid condensate generation and
to minimize thermal losses, and protected by a flow switch that
detects whatever water flow lack. The expansion device (4),
a thermostatic expansion valve with external equalizer, allows
the unit to adjust itself to the different operating conditions
keeping steady the set superheating. The refrigerant circuit of
each unit contains moreover solid core hermetic filter dryer (5)
to restrain impurity and moisture residuals that could be present
in the circuit, high and low pressure switches in order to
assure the compressor to operate inside the permitted limits, 4
way reverse cycle valve (6) to allow operating mode change
reversing the refrigerant flow (only for reversible heat pumps),
pressure connections SAE 5/16” - UNF 1/2” - 20 equipped
with pin, gasket and blind nut, as required for the use of R410A
refrigerant (they allow the complete check of the refrigerant
circuit : compressor inlet pressure, compressor outlet pressure,
thermostatic expansion valve upstream pressure and pressure
drops accross the filter). All the pipes of the refrigerant circuit
are properly insulated to avoid condensate generation and to
minimize thermal losses.
Hydraulic circuit Both the hydraulic circuit on the plant side
and on the source side are equipped with expansion vessel,
air vents and drain valves. All the pipes are thermally insulated
to avoid condensate generation and minimize thermal losses.
The circuit on the plant side is moreover equipped with pressure
safety valve, pressure gauge and three speed glandless pump
while the water flow rate on the source side can be adjusted by
means of a three speed glandless pump or by means of a two
way valve.
Electrical panel. It contains all the power, control and security
components necessary to guarantee the unit to work properly.
The unit is managed by a microprocessor controller to which
all the electrical loads and the control devices are connected.
The user interface, placed on the frontal panel of the unit, allows
to view and to modify, if necessary, all the parameters of the unit.
All the units are supplied with an outdoor temperature sensor,
to be installed outside, in order to realize the climatic control.

7
GENERAL FEATURES
Control system
The microprocessor controller is able to manage not only the
unit itself but also all that components of the plant which allow to
realize a complete system.
The main functions of the control system are :
- room temperature control according to the outdoor
temperature (climatic control)
- domestic hot water production (management of 3 way valve,
storage tank, anti legionella cycles…)
- management of a heating and/or cooling mixed circuit (pump
and 3 way mixing valve)
- management of a heating direct circuit (only pump)
- management of a storage tank for heating and/or cooling
- management of electrical heaters for heating and domestic
hot water (3 steps logic)
- solar panels integration
- passive cooling
- room humidity control for cooling with radiant systems
- internal programmer clock (for heating, cooling and domestic
hot water)
- digital input for electrical energy low tariff
- alarm memory management and diagnostic
- compressor and pump operating hour counter
- possibility to manage more units in cascade (maximum 16)
Besides the standard user interface present on all the units,
wired or wireless remote thermostats are available which allow
to control all the operating parameters of the unit and to acquire
the temperature in the different zones in order to realize a more
precise and comfortable control.
The unit controller is able to manage a lot of different plant
solutions enabling automatically the necessary control
algorythms according to the components which have been
connected.
The management of such components is possible through ad-
ditional expansion modules which communicate with the unit by
means of an internal bus and provide all the inputs and outputs
required to full a complete system.
The controller is able to manage up to two zones in heating
(one by means of a mixed circuit and the other by means of a
direct circuit) and one zone in cooling (by means of a mixed
circuit).
It’s possible to realize more complex plants connecting to the
heat pump controller further expansion modules in order to
extend without limits the number of zones to be managed.
For each zone the following parameters can be set :
- set point
- daily or weekly operating time table
- climatic control curve
- room control sensor : it can be in common with the other
zones or independent (in that case it’s necessary to install
an additional room thermostat)

8
GENERAL FEATURES
Options
The controller flexibility and the big number of options available
allow to get, for each model, a lot of different configurations that
integrate inside the heat pump many components of the plant
and allow to realize compact and tested installations.
In order to select the right configuration it is necessary to define
the type of plant to which the heat pump will be connected, both
for what concerning the heating and cooling circuits, and for
what concerning the domestic hot water management.
Option “Source side flow rate management”
Not reversible heat pump (IH) without options
Pump
Reversible heat pump (IP) without options
2 way valve
Source side
ow rate
management
Pump Allows the circulation of the water on the source side.
2 way valve Modulates the water ow rate on the source side when the water circulation is
assured by an external pump.
Domestic hot water
production
3 way valve Allow to divert the hot water produced by the heat pump from the heating circuit
to the domestic hot water circuit.
3 way valve with
primary heat exchanger
The hot water is diverted by the three way valve on an internal heat exchanger.
An internal pump assures a correct domestic hot water ow through the other
side of the heat exchanger.
Passive cooling Allows to use the source to cool down the plant water without activating the
compressor.
Integrative electrical heaters Integrate or replace the heating power supplied by the heat pump and are
managed by the unit controller with a 3 step logic.
Soft starter Reduces the compressor start current.

9
GENERAL FEATURES
In this configuration the heat pump can
be coupled to a domestic hot water
tank equipped with a coil designed for
a maximum water temperature between
55°C and 60°C.
The anti legionella cycles have to be
performed by means of electrical heaters
placed on the heat pump outlet (see
option “Integrative electrical heaters”) or
directly inside the tank.
In this configuration the heat pump can
be coupled to a domestic hot water tank
without coil.
The anti legionella cycles have to be
performed by means of electrical heaters
placed on the heat pump outlet (see
option “Integrative electrical heaters”) or
directly inside the tank.
Option “Domestic hot water production”
3 way valve
3 way valve with primary heat exchanger
Option “Passive cooling” Option “Integrative electrical heaters”

10
GENERAL FEATURES
Accessories
Remote thermostat Allows operating mode selection and set point adjustment. The on board temperature sensor can be used in order
to realize a climatic control.
Remote control
(wired or wireless)
Replicates all the control and visualization functionalities of the controller installed on the unit. The on board
temperature sensor can be used in order to realize a climatic control.
Wireless transmitter Connected to the unit controller, allows to communicate with wireless remote control and wireless outdoor
temperature sensor.
Wireless repeater Extends wireless operating range.
Wireless adaptor for
outdoor temperature sensor Allows to transform the wired outdoor temperature sensor, standard for all the units, in a wireless sensor.
Condensate sensor In cooling mode it allows the minimum ow temperature control when condensate generation occurs.
Room hygrostat In cooling mode it allows the minimum ow temperature control according to the room humidity.
Room humidity sensor
(with or without display)
In cooling mode it allows the minimum ow temperature control according to the room dew point, calculated from
the measured room humidity.
Rubber vibration dampers Allow to reduce the transmission to the unit support plane of the mechanical vibrations generated by the compressor
and by the fans in their normal operating mode.
Transformer
230V / 24V - 3VA It assures the correct power supply for the condensate sensor and for the room humidity sensor.
Refrigerant circuit box If a failure occurs inside the refrigerant circuit, it permits to restart the heat pump very quickly.