Ferroli RCI 35-40 Mounting instructions

Cod. 3QE47110 - Rev. 00 - 10/2021
INSTALLATION, MAINTENANCE AND USER MANUAL
EN
RCI 35-40
A CLASS ENERGY EFFICIENCY AIRCOOLED LIQUID CHILLERS AND HEAT PUMPS
WITH AXIAL FANS, INVERTER SCROLL COMPRESSOR AND EC INVERTER

2

3
GENERAL 4
1.1 DOCUMENT INFORMATION 4
1.2 RANGE 4
1.3 ACCESSORIES 4
1.4 COMPLIANCE 5
1.5 MACHINE IDENTIFICATION 5
1.6 RESIDUAL RISK 5
1.7 INTENDED USE 6
1.8 GENERAL PRECAUTIONS 6
1.9 BASIC SAFETY RULES 7
1.10 USER GUIDELINES 7
1.11 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 9
2.6 UNPACKING 9
2.7 ACCESS TO INTERNAL PARTS 10
2.8 RESTING ON THE GROUND 10
INSTALLATION 11
3.1 INSTALLATION LOCATION REQUIREMENTS 11
3.2 WORK FIELDS 11
3.3 UNIT LOCATION 11
3.4 VERIFYING CLEARANCES (CLEARANCE AREA) 13
WATER CONNECTIONS 14
4.1 CONNECTION DIAGRAM 14
4.2 POSITION OF CONNECTIONS 14
4.3 HYDRAULIC DATA 14
4.4 CONNECTION TO THE SYSTEM 15
4.5 SYSTEM FILL-UP 15
ELECTRICAL CONNECTIONS 16
5.1 MACHINE CONNECTION 16
5.2 CONNECTIONS OF THE ACCESSORIES 16
COMMISSIONING 17
6.1 PRELIMINARY INSPECTIONS 17
6.2 FIRST START-UP OR RESTART AFTER LONG INACTIVITY 17
6.3 SHUT-DOWN 17
6.4 FLOW RATE CALIBRATION 17
6.5 FLOW RATE BALANCE 18
CONTROL PANEL 19
7.1 USER INTERFACE 19
7.2 ON, OFF, STAND-BY 22
7.3 SETTINGS 22
7.4 ALARMS 30
MAINTENANCE 32
8.1 MAINTENANCE 32
8.2 WEEKLY CHECKS 32
8.3 MONTHLY CHECKS 32
8.4 DECOMMISSIONING AND DISPOSING 32
8.5 ANNUAL CHECKS 32
8.6 WATER CIRCUIT 33
8.7 REFRIGERANT CIRCUIT 33

4
1. General
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
Document information
Range
Accessories
Compliance
Machine identification
Residual risk
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 panel;
- Maintenance.
- Attached.
• 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 Range
Models with plate evaporator
RCI 35
RCI 40
1.2.1 Available versions
RCI R Cooling only
RCI P Reversible Heat Pump
1.3 Accessories
Factory fitted accessories
BT Low water temperature kit
TX Coil with pre-coated fins
TXB Coil with epoxy treatment
PS Single circulating pump
FE Antifreeze heater for evaporator
Loose accessories
CR Remote control panel
IS Modbus RTU protocol, RS485 serial interface
RP Coils protection metallic guards
AG Rubber shock absorbers

5
1.4 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
1.5 Machine identification
A Packaging plate
B Frame feature plate
C Electric board 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.
The loss of the label may compromise CE compliance. 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.
1.6 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.

6
Measures to be adopted if refrigerant gas leaks
• Product type:
- R410A
First aid measures
• General information:
- do not administer anything to an unconscious person.
• 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.
1.7 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 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.
1.8 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.
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.
This unit contains fluorinated greenhouse gas covered by the Kyoto Protocol. Maintenance
and disposal must be carried out only by qualified personnel.
The feature plate of the machine indicates the total quantity of refrigerant present in the system.

7
1.9 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 release R410A in the atmosphere: R410A is a fluorinated greenhouse gas
referred to in the Kyoto Protocol with a Global Warming Potential (GWP) = 2088.
1.10 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.
• 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.
In case of a fault or malfunction:
- immediately disable the unit without resetting the alarm;
- verify the type of alarm to notify the service centre;
- contact an authorised service centre;
- request original spare parts.
1.11 Machine description
1.11.1 Features
Frame.
Self-supporting frame in peraluman and galvanized steel frame, featuring rubber shock absorbers
on the base. Stainless steel screws.
Compressors.
Scroll DC Inverter three phase with oil sight glass. They are fitted with internal overheat protec
tion and crankcase heater, installed on rubber shock absorbers.
Fans.
Axial fan type with low rpm and special wing profile, directly coupled to external rotor motors.
A safety fan guard is fitted on the air flow discharge.
Condenser.
Made of a finned coil with copper pipes and aluminium fins. Complete with drain pan for hea
t pump version only.
Evaporator.
AISI 316 stainless steel braze welded plate evaporator. On the heat pump units an antifreeze he
ater is installed by standard.
Electrical board.
The electrical board includes: main switch with door safety interlock; fuses; thermal protection
relays on compressors; thermocontacts for fans; remote ON/OFF; summer/winter switching;dom
estic hot water and external 3-way valve management.
Microprocessor.
For the automatic control of the following functions: water temperature regulation, antifreeze
protection, compressor time control, alarms reset, alarms management and operating led, ala
rm cumulative contact for remote signal, local or remote cooling/heating cycle switching on he
at pump units, visual system with digital display: running cycle (cooling or heating), com
pressordemand/on, outlet water temperature, set point and differential setting, alarm code.
Proportional electronic device.
It attenuates the sound level of the unit using a continuous regulation of fan rotation speed.
This device also allows the cooling operation of the unit to outdoor air temperatures of -20 °C.
Control logic of the Inverter Scroll compressor.
Through the Inverter it adjusts the power supplied by the compressor as a function of the
system’s thermal load, the condensing pressure and the outdoor air temperature.
The control system, thanks to the Inverter technology, continuously monitors and adapts the
performance of the Inverter compressor, circulator and fans in order to grant the best operating
conditions of the unit. Thanks to Inverter logic, they are able to operate also with low water
content in the unit, thus making the use of the inertial tank superfluous.
Circuito frigorifero versione solo freddo.
Made of copper pipe, it includes the following components on all models: electronic thermostatic
expansion valve; filter drier; liquid and humidity indicator; high pressure switch (with fixed
setting); high and low pressure transducers.
Circuito idraulico versione solo freddo.
It includes: evaporator; temperature sensor; antifreeze sensor; water differential pressure switch;
manual air vent; high efficiency EC Inverter circulator; expansion vessel; water drain; safety valve.
Circuito frigorifero versione pompa di calore.
The heat pump version, in addition to the components installed on the cooling only version,
includes: 4-way reversing valve; suction liquid separator; liquid receiver; check valves.
Circuito idraulico versione pompa di calore.
It includes: evaporator; temperature sensor; antifreeze sensor; water differential pressure switch;
manual air vent; high efficiency EC Inverter circulator; expansion vessel; water drain; safety valve.

8
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 corresponds to what is indicated on the transport document
comparing the data with the packaging plate.
• 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
Removing the front panel provides access to the pocket containing the documentation.
A Front panel
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.
2.4 Storage
The room temperature in which the units are stored must be between -20 / +50°C.

9
2.5 Handling
• The equipment is designed for two lifting systems.
It is prohibited to use the pipes or other components of the machine as lifting points.
During moving it is forbidden to pass the maximum inclination consented as indicated in
the figure.
2.5.1 Lifting with forks
A Support
• Insert the forks from the side;
• Before placing the machine on the ground remove the wooden supports.
2.5.2 Lifting with a crane
A Lifting bar
B Hole for the insertion of the bar
C Indication of enabled holes
• Insert the lifting bars into the arranged holes on the base and indicated by the relative labels.
• Lift the unit using suitable belts.
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.
Make sure that all the equipment used for handling (belts, bars, etc.) are appropriate for
the weight of the unit.
2.6 Unpacking
A Wooden support
B Corner protector
C Coil protection
D Shrink
Before positioning the unit in the right installation place, remove the protective packing.
• Cut and remove the heat-shrink coating.
• Remove the corner protectors.
• Remove the protection from the coil.

10
• Lift the unit and remove the wooden supports.
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 Front panel
B Rear panel
To access to internal parts of the unit:
• Turn off power to the machine.
• Remove the front panel.
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.