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INSTALLATION MANUAL

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3. MODELS 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Power supply 400 3 50 V ph Hz Refrigerant type R410A Compressor specifications Type capacity control SCROLL ON OFF Starting Direct Quantity 2 N Plant Exchanger Type Aluminum fins and copper tubes PS max operating pressure 1000 kPa Quantity 1 N Victaulic hydraulic connection DN65 DN65 DN65 DN65 DN65 DN65 DN65 DN65 DN65 DN65 DN65 DN Total water capacity 3 9 4 2 4 8 5 5 5 9 6 9 7 5 8 7 9 7 11 2 12 8 Electrical specifications MODELS 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Total maximum load current FLA 62 68 74 82 90 105 120 142 164 A Total maximum power input FLI 29 34 40 45 50 55 63 72 83 93 kW Total maximum starting current MIC 1 141 166 204 256 262 309 317 355 370 454 476 A NOMINAL performances Standard plants IR unit MODELS 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Cooling mode plant temperature water in 12 C out 7 C condensing temperature 50 C subcooling 5K PS 43 bar Cooling capacity 61 68 81 92 103 116 130 149 168 190 210 kW Total power input 19 4 21 4 25 8 29 3 32 9 37 2 41 5 47 2 53 0 59 9 66 8 kW EER 3 15 3 18 3 14 3 43 3 13 3 12 3 13 3 15 3 47 3 17 3 15 W W Plant Water flow rate 2 9 3 2 3 9 44 4 9 5 5 6 2 7 1 8 0 9 1 10 0 1 5
4. User system Pressure gauge Pump 6 Air vent valve ae Water filling unit Thermometer Filter tj Safety valve Three way driven valve z On off and or water i TM i flow rate regulating valve Tank Coupling Recovery water flow inlet probe Monitoring electronics Expansion tank governor 34 HYDRAULIC CONNECTIONS ISO G DN mm EXTERNAL DIAMETER OD mm A B O D T 1 25 33 7 15 875 7 137 30 226 1 600 1 651 11 4 32 42 4 15 875 7 137 38 989 1 600 1 651 11 2 40 48 3 15 875 7 137 45 085 1 600 1 651 2 50 60 3 15 875 8 738 57 150 1 600 1 651 21 2 65 76 1 15 875 8 738 72 260 1 981 2 108 3 80 88 9 15 875 8 738 84 938 1 981 2 108 4 100 114 3 15 875 8 738 110 084 2 108 2 108 5 125 139 7 15 875 8 738 135 500 2 134 2 769 6 150 168 3 15 875 8 738 163 957 2 159 2 769 8 200 219 1 19 050 11 913 214 401 2 337 2 769 1 Pipe groove inspections Check the depth and diameter of the grooves and their distance from the pipe ends Make sure that the work has been carried out with care and that the end surface of the pipes is smooth and not ovalized Make sure that there are no notches burrs or other imperfections that could impair the tightness Groove dimensions in mm A 16 B 8 C 57 2 D 1 6 2 Checking the seal and relative lubrication Make sure that the type of seal used is compatible with the nature and temperature of the flui
5. The available special versions are described below AB Standard unit The compressors are installed on rubber vibration dampers The unit has composed by basement and framework made by sheet metal with anticorrosion treatment without any closing panels AS Low noise unit Allows a noise reduction of 4 5 dB The compressors are installed on rubber vibration dampers and the unit is closed with panels made by sheet metal with anticorrosion treatment and coated with sound absorbing insulation The AS unit reaches IP54 protection degree so it can be installed outdoor AX Extra low noise unit Allows a noise reduction of 7 8 dB The compressors are installed on rubber vibration dampers and insulated with acoustic jackets the unit is closed with panels made by sheet metal with anticorrosion treatment and coated with sound absorbing insulation The AX unit reaches IP54 protection degree so it can be installed outdoor Description of the components Componenti principali 1 Electric control and monitoring panel This is housed in a metal casing in which the various electrical components are positioned on one metal plate 1a The power section includes Main door locking circuit breaker Fuse holder that can be isolated with protection fuse triad for each compressor Fuse holder that can be isolated with protection fuse for compressor oil heaters and antifreeze if installed Control contactor for each co
6. RR RO ne go ed ae Eb EE 26 Safety prescriptions 3 4 rr Tr edenrid 26 Handlings kd dor os wt b _ 26 Storage ee 26 COLLEGAMENTI FRIGORIFERI tant ane aten xe ekku da ERR CR dE EE Dei REO DU ORAS 27 Migrazione del refrigerante durante le fasi di fermata 2 eee 27 MUBAZIONW MO ORICTS EET ee dre een atd anne etter Te det 27 Dilatazione delle tubazioni e loro compensazione enden eneen eee ee 27 Scelta del diametro delle t bazioni dadel de beds a bacs ales siu kunme sm le eae d aea e 28 Esempio dicaleolOe enen enten nti sm AE En Rn nen ed eert OA 31 Procedura di installazione oes x nimme an erven dor qe KARAN SL EUR a Ea andi E deat Sana hr 32 Stima della Carica direfti erante sss konia amd harda ada ed Wed de A He naa bonu ea e E a 32 HYDRAULIC GONNECTIONS ehe xx rx ene nme bw tannin Ecke ee ek ERR RR eme ante er nano ka Ella oer 33 General UBS ne vacnr vn ohne Pare vna tn varna ebt eee dB aa SERS eee RT 33 Hydraulic layout of the System coss store a EN E O
7. discharge line Slope 2 3 Condenserless unit Remote Condenser Fig 4 discharge line Slope 2 3 F 9 Azul Remote Condenser discharge line Slope 2 3 Condenserless unit 30 REFRIGERANT CONNECTIONS Exanple of calculation It is assumed that it has been selected a condenserless unit mod IR 105 2 VB AB 5 abd the remote condenser has to be installed higher than the unit with a drop of 12 meters re Fig 4 Moreover there are 2 horizontal lines of 11 and 8 meters In nominal conditions in the section you extract Ccoling capacity 92 kW Compressors power input 29 3 kW Liquid Line From tab L2 with a capacity of 92 kW we can choice between a diametr of 28x1 interpolating the velocity calculated is 1 02m s and a diameter of 22x1 interpolating the velocity calculated is 1 74m s From tab T1 we extract d 22x1 weight of pipe 0 59 kg m R410A charge 0 28 kg m d 28x1 weight of pipe 0 76 kg m R410A charge 0 48 kg m We select diameter 22x1 that allows a velocity lower tha the admissible limit lt 2m s and moreover a saving of 22 in weight and 42 r410A charge Discharge Line Since there is a climb vertical line with that cooling capacity it is recommended a diameter 28x1 In fact from tab M3 interpolating between 90 and 100 kW we extract a velocity of 10 2 m s gt 8m s From tab M1 we extract a pressure drop of 2 3 kPa per meter and from tab M2 a DT of 0 03
8. ELECTRICAL CONNECTIONS General rules The appliance must be wired in compliance with the laws in force in the country in which it is installed The units are supplied fully wired in the factory and pre engineered for connection to the electricity main The electric panel is made in compliance with the tech nical standards in force in the European Union Structure of the electric panel All the electrical components are contained in a closed casing protected against the atmospheric agents and inspectionable by ope ning the front door after removing the front panel if present The door for accessing the power section is locked by the mechanism Access for the supply cables and earth cable PE is permitted through the opening on the botton of the electric panel Composition of the system The system comprises an electromechanical part consisting of the power circuit with disconnecting device contactors fuses or thermal cutouts transformer and another part comprising the Microprocessor control system NOTES Refer to the wiring diagram supplied with the unit for the layout of the electric panel Electrical connections All electrical connections must be carried out by qualified personnel in the absence of electric power The table below gives the elec trical specifications of the different constructional configurations of the units Standard unit UNIT 7
9. 20 Percentage Of glycol in mass volume 0 0 10 9 6 20 19 4 30 29 4 40 39 6 Freezing point C 0 3 3 7 13 21 Cooling capacity correction factor 1 0 94 0 92 CCPA Power input correction factor 1 0 95 0 93 CCQA Water flow rate correction factor 1 1 06 1 09 CCDP Water pressure drop correction factor 1 1 05 1 11 1 22 1 38 Basing on design condensing temperature and leaving water temperature of the plant exchanger evaporator DESIGN CONDITIONS from the table performances extract Cooling Capacity kWf and Compressors Power Input kWa Based on type and percentage of glycol extract CCPF CCPA CCQA CCDP Then calculate Pf_brine kWf x CCPF Pass_CP_brine kWa x CCPA Then calculate brine flow rate of the plant exchanger evaporator Q brine 5 x Pf brine KW 0 86 AT brine 3 6 where AT brine is the difference inlet outlet plant exchanger evaporator water temperature brine Twin brine Twout brine With this brine flow rate enter in abscissa on the water pressure drop of the plant exchanger evaporator then you have Ap app Finally you can calculate the actual pressure drop of the brine on plant exchanger evaporator side Ap brine CCDP x p app Fouling factors The performances supplied with the tables are referred to a fouling factory 0 44 10 m K W For different values of the fouling factory use the reduction coefficients reported in the foll
10. Water pressure drop 36 28 31 31 34 32 35 35 37 37 38 kPa The values are referred to units without options and accessories 10 IR IW UNIT PERFORMANCE Mod 70 2 105 2 Tc CONDENSING TEMPERATURE C 45 kWt kWa kWt TWe Plant exchanger evaporator outlet water temperature C Tc Condensing temperature C Subcooling 5K kWf Cooling capacity kW kWa Compressor power input kW kWt Heating capacity kW The performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger Has also been considered A 0 44 x 10 m K W fouling factor 11 IR IW UNIT PERFORMANCE Mod 120 2 170 2 Tc CONDENSING TEMPERATURE C kWt kWf TWe Plant exchanger evaporator outlet water temperature C Tc Condensing temperature C Subcooling 5K kWf Cooling capacity kW kWa Compressor power input kW kWt Heating capacity kW The performances refer to a 5 C temperature difference
11. Consult the tables in the section Dimensional data when the appliance arrives section for the venter of gravity position Use spacer bars in the top part of the unit to prevent the plastic parts covering the unit from being crushed and damaged WARNING Before proceeding with the handling operations read the information on the wrapping to ensure the safety of persons and property Also be sure to Handle the load with care Avoid stacking other objects on top of the unit Storage The units must be stored in a dry place sheltered from the run rain sand and wind The storage conditions are Do not stack the units Maximum temperature 60 C Minimum temperature 10 C Humidity 90 26 REFRIGERANT CONNECTIONS The refrigerant circuits of split systems have to be designed and built considering that When the system is stopped the refrigerant try to move to the coldest point of the system The refrigrerant pipes usually made of copper are subject to hign expansions depending on ambient temperature during the year The pipes pressure drop have to be limited since they reduce cooling capacity and efficiency of the system The refrigerant velocity has to be superior to a minimum value in order to allow oil return to the compressors both at maximum and minimum capacity To ensure a correct working of the system and so for reducing costs and environment impact it is preferable to reduc
12. high pressure high temperature on compressor supply phase presence and sequence monitoring device on power supply differential water pressure control compressors thermal protection pumps thermal protection ON Stand by remote and remote operating mode change demand limit and Economy function Digital output functions compressor start up pump start up plate heat exchanger electrical heater remote general alarm 4 way valve only IP BP unit integrative heaters Analogic input functions in and out water temperature for palnt and source sides external air temperature probe if present Analogic output functions continuous control 0 10V for 2 or 3 way valves supplied as accessory too or for inverter pumps for condensing control 2 Compressors They are the SCROLL type with orbiting coil equipped with built in thermal protection The AX unit includes an acoustic jacket for the compressors All units are equipped with two compressors connected in pairs 1 single refrigerant circuit which can operate at the same time 100 cooling capacity or individually 50 of the cooling capacity thus adapting to the different thermal loads of the system 3 Frame structure made of sheet metal with anticorrosion treatment and as option coated with epoxy powders RAL 7035 to ensure maximun protection against adverse weather conditions 2a The image refer to IR unit Mo
13. 1 190 1 200 1 210 1 255 1 300 Percentage Of glycol in mass volume 40 39 6 Freezing point C 22 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 848 0 784 0 719 0 670 0 620 0 570 0 520 CCPA Compressor power input correction factor 0 865 0 855 0 845 0 820 0 795 0 773 0 750 CCQA Water flow rate correction factor 1 116 1 114 1 112 1 110 1 108 1 107 1 105 CCDP Water pressure drop correction factor 1 230 1 275 1 320 1 375 1 430 1 500 1 570 Basing on design condensing temperature and with leaving water temperature of the plant exchanger evaporator 7 C from the table performances extract Cooling Capacity kWf and Compressors Power Input kWa Based on type and percentage of glycol extract CCPF CCPA CCQA CCDP Then calculate Pf_brine kWf x CCPF Pass_CP_brine kWa x CCPA Then calculate brine flow rate Q brine 5 x Pf brine kW 0 86 AT_brine 3 6 where AT brine is the difference between inlet outlet plant exchanger evaporator water temperature AT brine Twin brine Twout brine With this brine flow rate enter in abscissa on the water pressure drop of the plant exchanger evaporator then you have Dp app Finally you can calculate the actual pressure drop of the brine on plant exchanger evaporator side Dp brine CCDP x Dp app 15 NOISE LEVEL The noise levels refer to units operating in the nominal conditions water temperature
14. 2325 27 29 En 54 1 5 01 01 0 1 0 1 02 04 04 05 05 06 05 05 06 06 07 08 Tab 2 Cooling capacity kW 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 Y g 22x1 004 0 06 0 07 0 1 0 12 0 15 0 18 0 21 0 25 0 28 0 32 F 28x1 0 01 0 01 0 02 0 03 0 03 0 04 0 05 0 06 0 06 0 07 0 08 0 1 0 11 0 12 0 14 0 15 0 16 0 18 0 19 0 21 0 23 0 25 0 27 0 29 0 31 0 33 5 E 9 35x1 5 0 01 0 01 0 01 0 01 0 01 0 02 0 02 0 02 0 03 0 03 0 03 0 04 0 04 0 05 0 05 0 06 0 06 0 07 0 07 0 08 0 09 0 09 0 1 0 11 0 11 Pe 5 5 42 1 5 0 01 0 01 0 01 0 01 0 01 001 001 0 01 0 01 0 02 002 0 02 0 02 0 02 0 03 0 03 0 03 0 03 0 03 0 04 004 0 04 4 54 1 5 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 0 01 28 REFRIGERANT CONNECTIONS In table M3 you find the correction factors for capacity and compressors power input as a function of total pressure drop of the discharge line expressed AT in C Oil return to the compressors During standard working of the refrigerant compressors a little amount of oil mixes with the refrigerant gas so circulating into the syst
15. 47 3 kg from tab C1 unit charge 20 7 kg discharge line 1 6 kg liquid line 8 7 kg TOT estimated 31 kg When you are ready to charge it is necessary another 20 of refrigerant gas at least so the total amount necessary is 1 2 x 31 37 kg R410A For condenserless unit with thermostatic expansion valve Charge with 31 kg Start up the system Adjust the opening of thermostatic valve and the refrigerant charge in order to achieve a subcooling and a superheat of 5K 1 For condenserless unit with electronic expansion valve Charge with 31 kg Start up the system Adjust the refrigerant charge in order to achieve subcooling of 5K 1 32 HYDRAULIC CONNECTIONS General rules A mesh filter hole 500 um must be installed on the unit s water inlet otherwise warranty is immediately forfeited for units with either the standard or the complete pipe kit and MP PS The filter performs the function of blocking any foreign matter in the system s plumbing circuit shavings machining debris etc This prevents the plate exchanger water pipes from clogging then possibly freezing and therefore bursting This filter is included in the unit equipped with the hydronic kit accessory Comply with the local laws governing safety matters in order to correctly design the hydraulic circuit The following information gives suggestions on how to correctly install the unit 1 Standard supply The unit comes as standard with
16. 48 50 51 51 51 51 53 53 53 53 dB A Standard configuration type 1 horizontal air flow L d e mi A EIE NE i DEA any as M Configuration with Support Brackets accessories Type 3 vertical air flow L o e c 23 REMOTE AXIAL CONDENSER ACCESSORIES RC AS Low Noise Version Models 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Power supply 400 3 PE 50 V ph Hz Refrigerant R410A Max working pressure PS 45 bar Coils type Aluminum fins and copper tubes Gas connections 1x42 1x42 1x42 1x42 1x42 1x42 1x54 1x54 2x42 2x42 2x42 n x Liquid connections 1x35 1x35 1x28 1x35 1x35 1x35 1x42 1x42 2x35 2x35 2x35 n x Fan specification Fan 3 3 2 2 2 3 3 3 4 4 4 n Diameter 630 630 800 800 800 800 800 800 800 800 800 mm Air flow rate 22500 22500 33800 28600 26800 50700 42900 40200 54800 50800 50800 1 5 0 99 0 99 1 96 1 96 1 96 2 94 2 94 2 94 3 92 3 92 3 92 kW Current input 2 19 2 19
17. 69 65 63 59 48 76 5 71 55 45 40 190 2 71 69 70 69 65 63 59 48 76 5 71 55 45 40 2152 72 70 71 70 66 64 60 49 77 5 72 56 46 41 240 2 72 70 71 70 66 64 60 49 77 5 72 56 46 41 16 OPERATING RANGE Operating range The graph indicates the admissible working envelope of the unit The use of the unit in conditions outside the envelope will avoid the warranty Here under are reported the limits of water differential temperature for the heat exchangers of the unit Operating range standard unit AB Water thermal gradient Minimum C 3 Maximum C 10 Verify that water flow rate is inside the admissible limits NOTE the admissible limits for water flow rate on heat exchangers are indicated under the related pressure drop graph see section water pressure drop e EVAPORATOR WATER C LEAVING TEMPERATURE A AT Water 5 C 20 WE RECOMMEND THE USE OF BRINE SOLUTION EG ETHYLENE GLYCOL BRINE UNIT CONDENSER WATER LEAVING TEMPERATURE gt C 10 30 50 60 17 OOZL 0011 9 2971 LECL LOZL 096 198 087 469 Jeddn veg LG els vov 80v 08 6c 0 69 00 o NUII JOMO7 SALON AN cOvc 2912 COLL 2091 CSEL cock 290 206 208 513 JAJIEM D
18. HALVM MIS NOILONS VS N 9 3ATVA 440 LNHS SOYVHOSIC IN 5 AANA ainon TH o 3ATVA 440 1 NOILONS vu o 9 5 3HOO AVS 91 8 SISSY SSdd 3400 AVS SISSY 3409 LNOLIHM AVS t t ONILLIJ SISSY dd Oo z J HOLIMS 9UNSSJUd UJIVM Js LL HOLIMS SUNSSJUd MOJ dd x ISA Z p HOLIMS SYNSSAYd 13534 Sdd L Sdd gt 3 HOLIMS SYNSSAYd DOLIVWOLNV vvd 21 lt SSdd O YOLVOIGNI RINLSION ANY AINON YOJVYOJVAJ AJ re 8 Tu ul HALI a HOSSIHJNOI S XS HOSS3HdWOO ldo c 5 109 5 uonduoseq vg i 5 NC 5 Y H3SN3GNOO OLOIN3H 3HOJIVSN3QONOO 40 START UP General Rules To validate the contractual warranty the machine must be set at work by technicians from an authorized assistance center Before they are called check to make sure that all parts of the installation have been completed the unit levelled the wet connections made with the relative air vent and the electrical connections made MAINTENANCE General Rules Maintenance is of extreme importance if the plant is to operate in a regular way and give fade free service Have extraordinary mainte nance work done by qualified and authorized personnel Comply with the safety precautions given in the relative section of this manual and take al
19. PRESSURE SWITCH THERE ARE NO EVIDENCES ON THE DISPLAY DO NOT RESET THE PRESSURE SWITCH BEFORE YOU HAVE DONE THE FOLLOWING STEPS 1 SHUT DOWN THE UNIT 2 THEN RESET THE HIGH PRESSURE SWITCH For more details refers to section monitoring basic system Protection devices LOW PRESSURE Protection devices DISCHARGE TEMPERATURE if installed LEVEL 1 LEVEL 1 Low pressure High Temperature Device automatic switch Device Thermostat Trip out barg 4 bar Standard Version IR Trip out 135 C 9 2 bar Brine Version BR Trip in 120 C Trip in barg 6 bar Versione Standard IR 4 bar Versione Brine BR connected to electronic controller connected to electronic controller effect stop the single compressor stop the compressors and pumps of the effect source side exchanger if manager by the unit controller reset YES by keyboard after the solution of the problem that generates the alarm YES by keyboard if the low pressure reset switch has trip in and after the solution of the problem that generates the alarm For more details refers to section monitoring basic system 38 gt 2 2 c lt o 5 o lt O i TE HF z o O 4 LL ox Refrigerant flow diagram in cooling mode IR BR Asosseooe NI MIS s ueuodwoo pejejos DI
20. Safety valve Installed on the discharge pipe of the compressors this operates if extreme faults should occur in the system 9b Gas and Liquid shut off valves Allow that all the refrigerant can be pumped in the coil remote condenser when it is connected to the condenserless unit and then stored in order to carry out servicing work or to replace all the components of the refrigerant circuit without having to drain it 10 liquid Solenoid Valve It shuts off when both the compressors The image refer to IR unit Mod 90 2 of the circuit switch off preventing liquid refrigerantfrom flowing Ee towards the evaporator during periods at a standstill 11 Liquid and moisture indicator Signals if refrigerant is in liquid state so indicating that the refrigerant charge is correct The indicator light also indicates the amount of moisture in the refrigerant by changing colour Low pressure switch With fixed setting It is installed on the suction pipe and blocks the compressors if the operating pressures drop below the tolerated values Automatically resets as the pressure increases If it activates frequently the unit will block and can only be restarted by resetting via the user interface terminal High pressure switch n 2 With fixed setting Are installed on the discharge pipe and blocks the compressors if the operating pressure exceeds the tolerated values If it activates the unit will block and can only be rest
21. The manufacturer declines all responsibility for any inaccuracies in this manual due to printing or typing errors The manufacturer reserves the right to modify the products contents in this catalogue without previous notice 45 46 47 FERROLI Ferroli spa 7 37047 San Bonifacio Verona Italy 7 Via Ritonda 78 A tel 39 045 6139411 fax 39 045 6100933 www ferroli it COD 3QE29550
22. between the water entering and leaving the heat exchanger Has also been considered A 0 44 x 10 m K W fouling factor 12 IR IW UNIT PERFORMANCE Mod 190 2 240 2 Tc CONDENSING TEMPERATURE C kWt kWt kWf 200 8 132 8 206 4 137 9 211 9 142 9 TWe Plant exchanger evaporator outlet water temperature C Tc Condensing temperature C Subcooling 5K kWf Cooling capacity kW kWa Compressor power input kW kWt Heating capacity kW The performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger Has also been considered A 0 44 x 10 m K W fouling factor 13 CORRECTION FACTOR Correction factor for the use of glycol in cooling mode ETHYLENE GLYCOL with water produced between 5 20 9 C Percentage Of glycol in mass volume 0 0 10 8 9 20 18 1 30 27 7 40 37 5 Freezing point C 0 3 2 8 14 22 CCPF Cooling capacity correction factor 1 0 99 0 98 0 97 0 95 CCPA Power input correction factor 1 1 0 99 0 99 0 98 CCQA Water flow rate correction factor 1 1 04 1 08 1 12 1 16 CCDP Water pressure drop correction factor 1 1 08 1 16 1 25 1 35 PROPYLENE GLYCOL with water produced between 5
23. inlet Open field 12 C outlet 7 C Condenser water temperature inlet 30 C outlet 35 C Q 2 The acoustic pressure levels are measured 1 5 10 meters away from the outer surface of the unit operating in the free field and resting on a reflecting surface directional factor of 2 SWL Sound power levels with reference to 1x10 W 3 JL gt The Total sound power level in dB A measured in compliance with 150 9614 standards ih Zij which is therefore the only binding acoustic specification the values of the Octave bands in the table are indicative SPL Sound pressure levels with reference to 2x10 Pa The sound pressure levels are values calculated by applying the ISO 3744 relation Eu rovent 8 1 and refer to a distance of 1 meter away from the external surface of units operating in the open field with directivity factor 2 Q 2 and the units operating in nominal conditions in the cooling mode AB Standard unit SWL dB MOD Octave bands Hz Total 63 125 250 500 1000 2000 4000 8000 im 5m 10m 70 2 76 74 71 72 72 65 61 55 80 6 75 59 49 44 80 2 76 74 75 74 70 68 64 53 81 5 76 60 50 45 90 2 77 75 76 75 71 69 65 54 82 5 77 61 51 46 105 2
24. the Unit an aca eae a ar ea 6 Description of the components ss ecd 6 ACCESSORIES AND OPTIONAL EQUIPMENT sssssssssssssstsstssstsstatssereeteassrereetoss 9 GENERAL TECHNICAL SPECIFICATION sidita annen aimer miner kim mien seve men KORR dem Fave S on 10 General technical specifications aaneen eee eee 10 NOMINAL performances Standard plants onee eee 10 IR IW UNIT PERFORMANCE regu kouis date SES dente f D stn ee dd 11 CORRECTION FACTOR annen orn ne aen oen dada ne a tene KURIA EEE E A ea ed he 14 Correction factor for the use of glycol in cooling mode eneen 14 Fo lingiactOrs ro C id Sy ot Benel menen 14 BRINE UNIT BR O 15 Brine Unit BR santen img ns eat TT TTT iS drei ues nee need 15 NOISE LEVEL a nn sew Se TTT 16 AB Standard UNIE 5 ne one Eo dais andre at 16 foede Uer meer rr 16 AX Extra low MOIS SOMME xus meg od e AO SU Rer 16 OPERATING RANGE ces Rae nura _ 17 Operating RICE EORR ee ma ota PELUCHE ECCE 17 WATER PRESSURE DROP 23 zudem sedans ac A EE Paw bee AD a S Bon
25. unit 290 300 306 403 482 508 532 568 592 621 642 kg AS Low noise unit 340 350 356 465 545 571 594 630 654 683 705 AX Extra low noise unit 364 374 380 495 575 601 624 660 684 713 735 kg Operation weight Mod 70 2 80 2 90 2 105 2 120 2 135 2 1502 1702 1902 2152 2402 UM AB Standard unit 294 304 311 409 488 515 640 577 602 632 655 kg AS Low noise unit 344 354 361 471 551 577 602 639 664 694 717 kg AX Extra low noise unit 368 378 385 501 581 607 632 669 694 724 747 kg 20 DIMENSIONAL DATA Minimum space for operation Refer to the figure alongside for the dimensions of the unit To correctly install the unit comply with the measurements for the free area that must be left around the machine as shown in the figure The distances must be doubled if the unit is to be installed in a pit NOTE Allow for a clear area of not less than 0 5 meters above unit The areas installation must be doubled if multiple units are installed Refrigerant and hydraulic connections HYDRAULIC CONNECTION PLANT Mod 7 DN Type 70 240 2 DN65 Victaulic PLANT OUT HYDRAULIC CONNECTION A IN 9 24 ANI REFRIGERANT CONNECTION RE
26. 0 2 UM Power supply 400 3 PE 50 V ph Hz Refrigerant R410A working pressure PS 45 bar Coils type Aluminum fins and copper tubes Gas connections Liquid connections Fan specification Fan 2 2 3 2 2 2 2 3 3 3 3 n Diameter 630 630 630 800 800 800 800 800 800 800 800 mm Air flow rate 20000 20000 32100 42400 39200 39200 36800 63600 58800 55200 55200 1 5 Power input 1 46 1 46 2 19 4 4 4 4 6 6 6 6 kW Current input 2 7 2 7 4 05 8 6 8 6 8 6 8 6 12 9 12 9 12 9 12 9 A Internal volume 21 21 21 18 27 27 35 27 41 53 53 dm Weight 166 166 221 279 302 302 324 413 447 481 481 kg Standard configuration Dimension horizontal air flow Length L 2630 2630 3770 3230 3230 3230 3230 4580 4580 4580 4580 mm height A 1230 1230 1230 1370 1370 1370 1370 1370 1370 1370 1370 mm depth P 600 600 600 800 800 800 800 800 800 800 800 mm Dimension with Configuration with Support Brackets accessories vertical air flow Length L 2630 2630 3770 3230 3230 3230 3230 4580 4580 4580 4580 mm height A 990 990 990 1565 1565 1565 1565 1565 1565 1565 1565 mm depth P 1230 1230 1230 1370 1370 1370 1370 1370 1370 1370 1370 mm Noise level Sound Power Level 80 80 82 83 83 83 83 85 85 85 85 dB A Sound pressure level at 1mt 63 63 65 66 66 66 66 68 68 68 68 dB A Sound pressure level at 5mt 53 53 55 56 56 56 56 58 58 58 58 dB A Sound pressure level at 10mt 48
27. 0 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Power supply 400 3 50 V ph Hz TOTAL FLA 45 51 62 68 74 82 90 105 120 142 164 A TOTAL FLI 26 29 34 40 45 50 55 63 72 83 93 kW TOTAL MIC 141 166 204 256 262 309 317 355 370 454 476 A NOTES Values relative to a 400V 3 50Hz power supply voltage rating FLI Electric power draw at maximum tolerated conditions FLA Power draw at maximum tolerated conditions MIC Maximum surge current of the unit LRA Locked Rotor Amps Compressor specification UNIT 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 215 2 240 2 UM Power supply 400 3 50 V ph Hz FLA CP 1 22 6 25 6 31 0 31 0 37 0 37 0 45 0 45 0 60 0 60 0 82 0 i CP2 22 6 25 6 31 0 37 0 37 0 45 0 45 0 60 0 60 0 82 0 82 0 FLI CP 1 13 2 14 7 17 0 17 0 22 6 22 6 27 3 27 3 36 1 36 1 46 7 KW CP2 13 2 14 7 17 0 22 6 22 6 27 3 27 3 36 1 36 1 46 7 46 7 LRA CP 1 118 140 173 173 225 225 272 272 310 310 394 A CP2 118 140 173 225 225 272 272 310 310 394 394 Unit layout SCAMB IMPIANTO T Fb 25 gu 36 ELECTRICAL CONNECTIONS 1 Connection to the electricity main Power supply line The machine s power supply line must be laid by following a clearly defined route in order to make it as correct as possible any without any breaks Pass the line through the opening on the button of the electrical panel Secure the line integral with the structure of the m
28. 05 0 07 0 10 0 14 0 18 0 28 0 48 0 72 1 08 1 77 281 3 67 4 99 7 51 R410A charge per 1 meter of DISCHARGE line kg m 0 005 0 008 0 011 0 015 0 020 0 031 0 052 0 079 0 117 0 193 0 306 0 400 0 544 0 818 Expansion of the pipes and their compensation Following temperature variations the copper pipes expand In table the expansions of pipes related to temperature variation Temperature difference C 0 20 40 60 80 100 120 140 Expansion mm m 0 0 0 4 0 6 0 9 1 3 1 6 1 9 2 2 For a correct estimation of the maximum working temperature of discharge line it is enough to add 60 C to the maximum condensing temperature reached during working condtions For instance if the maximum condensing temperature is 60 C for discharge line the maximum temperature is 120 C assuming that pipes are installed with external air temp of 20 C you have to consider a temperature variation of 100 C and so provide flexible hoses or U bends to allow an appropriate expansion 27 REFRIGERANT CONNECTIONS Selection of pipes diameters The pressure drops arise on liquid and discharge lines ene Tab L1 Liquid Line H Fig 3 kPa AT The pressure drop on the liquid line cause a neglectable reductions 10 88 1 39 on capacity and efficiency of the system however they have to be lim
29. 1 1 112 CCDP Water pressure drop correction factor 1 140 1 145 1 150 1 155 1 160 1 175 1 190 Percentage Of glycol in mass volume 40 37 5 Freezing point C 22 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 884 0 827 0 770 0 710 0 655 0 598 0 547 CCPA Compressor power input correction factor 0 880 0 870 0 860 0 840 0 810 0 790 0 760 CCQA Water flow rate correction factor 1 150 1 151 1 153 1 154 1 155 1 157 1 158 CCDP Water pressure drop correction factor 1 190 1 195 1 200 1 210 1 220 1 235 1 250 PROPYLENE GLYCOL Percentage Of glycol in mass volume 20 19 4 Freezing point C 8 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 874 0 807 0 740 0 690 0 641 CCPA Compressor power input correction factor 0 945 0 935 0 925 0 900 0 875 CCQA Water flow rate correction factor 1 037 1 038 1 039 1 039 1 040 CCDP Water pressure drop correction factor 1 110 1 115 1 120 1 130 1 140 Percentage Of glycol in mass volume 30 29 4 Freezing point C 14 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 869 0 799 0 729 0 680 0 630 0 583 0 536 CCPA Compressor power input correction factor 0 935 0 923 0 910 0 888 0 865 0 838 0 810 CCQA Water flow rate correction factor 1 072 1 071 1 070 1 069 1 069 1 068 1 067 CCDP Water pressure drop correction factor 1 160 1 175
30. 2 C per meter Considering 2 syphons for the vertical line 4 standard 90 bends and 2 U bends for compensating of thermal expansions for the 2 horizontal lines From tab R1 we extract the correction factors standard 90 bend 0 8 U bend 1 2 Syphon 4 8 Equivalent length 11 12 8 4 x 0 8 2 x 1 2 2 x 4 8 462m Pressure drop of discharge line 2 3 x 46 2 106 3 kPa 0 032 x 46 2 1 48 C From tab M4 interpolating we achieve the following correction factors for cooling capacity CCPF 0 985 for compresors power input 1 02 Therefore with tis type of installation the actual capacity and power input are Cooling capacity 0 985 x 92 90 6 kW Compressors power Input 1 02 x 29 3 29 9 kW R410A charge for the lines for simplicity in the estimation of refrigerant charge it has been considere the length of straight lines only Discharge d 28x1 11 12 8 x 0 052 1 6 kg Liquid d 22x1 11 12 8 0 28 8 7 31 REFRIGERANT CONNECTIONS Installation Procedure The discharge and liquid pipe connections are identified by a label on the frame if the unit and are supplied cith female connection plugged with a plastic plug The unit is equipped with the 2 ball valves liquid and discharge CLOSED this allows to maintain the refrigerant circuit part including the compressors heat exchanger filter expansion vale ecc Gharged with NITROGEN p 1bar and so to avoid entrance of air and m
31. 5 5 5 7 5 7 5 7 5 10 10 10 A Internal volume 21 21 18 27 35 27 41 53 49 64 64 dm Weight 221 221 279 302 324 413 447 481 502 543 543 kg Standard configuration Dimension horizontal air flow Length L 3770 3770 3230 3230 3230 4580 4580 4580 3230 3230 3230 mm height A 1230 1230 1370 1370 1370 1370 1370 1370 2390 2390 2390 mm depth P 600 600 800 800 800 800 800 800 800 800 800 mm Dimension with Configuration with Support Brackets accessories vertical air flow Length L 3770 3770 3230 3230 3230 4580 4580 4580 3230 3230 3230 mm height A 990 990 1565 1565 1565 1565 1565 1565 1565 1565 1565 mm depth P 1230 1230 1370 1370 1370 1370 1370 1370 2390 2390 2390 mm Noise level Sound Power Level 75 75 76 76 76 76 76 76 77 77 77 dB A Sound pressure level at 1mt 58 58 57 57 57 59 59 59 60 60 60 dB A Sound pressure level at Smt 48 48 47 47 47 49 49 49 50 50 50 dB A Sound pressure level at 10mt 43 43 42 42 42 44 44 44 45 45 45 dB A Standard configuration type 1 horizontal air flow L pe 9 Gavan pup DO FAV DD SE SI ely Configuration with Support Brackets accessories Ty
32. 77 75 76 75 71 69 65 54 82 5 77 61 51 46 120 2 77 75 76 75 71 69 65 54 82 5 77 61 51 46 135 2 78 76 77 76 72 70 66 55 83 5 78 62 52 47 150 2 78 76 77 76 72 70 66 55 83 5 78 62 52 47 170 2 79 77 78 77 73 71 67 56 84 5 79 63 53 48 190 2 79 77 78 77 73 71 67 56 84 5 79 63 53 48 215 2 80 78 79 78 74 72 68 57 85 5 80 64 54 49 240 2 80 78 79 78 74 72 68 57 85 5 80 64 54 49 AS Low noise unit SWL dB MOD Octave bands Hz Total REAJ 63 125 250 500 1000 2000 4000 8000 dB A 1m 5m 10m 70 2 72 70 67 68 68 61 57 51 76 6 71 55 45 40 80 2 72 70 71 70 66 64 60 49 77 5 72 56 46 41 90 2 73 71 72 71 67 65 61 50 78 5 73 57 47 42 105 2 73 71 72 71 67 65 61 50 78 5 73 57 47 42 120 2 73 71 72 71 67 65 61 50 78 5 73 57 47 42 135 2 74 72 73 72 68 66 62 51 79 5 74 58 48 43 150 2 74 72 73 72 68 66 62 51 79 5 74 58 48 43 170 2 75 73 74 73 69 67 63 52 80 5 75 59 49 44 190 2 75 73 74 73 69 67 63 52 80 5 75 59 49 44 215 2 76 74 75 74 70 68 64 53 81 5 76 60 50 45 240 2 76 74 75 74 70 68 64 53 81 5 76 60 50 45 AX Extra low noise unit SWL dB MOD Octave bands Hz Total ELA 63 125 250 500 1000 2000 4000 8000 dB dB A 1m 5m 10m 70 2 68 66 63 64 64 57 53 47 72 6 67 51 41 36 80 2 68 66 67 66 62 60 56 45 73 5 68 52 42 37 90 2 69 67 68 67 63 61 57 46 74 5 69 53 43 38 105 2 69 67 68 67 63 61 57 46 74 5 69 53 43 38 120 2 69 67 68 67 63 61 57 46 74 5 69 53 43 38 135 2 70 68 69 68 64 62 58 47 75 5 70 54 44 39 150 2 70 68 69 68 64 62 58 47 75 5 70 54 44 39 170 2 71 69 70
33. A NN Lost c 06L 202 209 202 206 08 202 9 QE ey ui USAID senjeA pue eyy Aq peywijep SI eDueJ eu puooes siey ui 9 EJ MOY euy uo edy ui senjeA dosp eunsseJd ey ey JOJ sejensnii eu JUEIJ doup eunsseJd J9 8M 18 O c a c 5 0 4 ox ni ZL 94 Gl vl el 8 1 are ck LL 0L 6 8 2 0 0 0L oz 5 o toe 8 2 2 5 U 5 05 09 0 puooes seJil ui MOY JO uonounj e se edy senjeA doup Jeye eu SMOUS BUIMOJJOJ eu 1911 19 DIMENSIONAL DATA Standard unit overall dimension FRAME 1 Mod 70 2 90 2 Center distance of vibration damper holes and lifting holes o 14 mm Vibration damper fixing holes 75 mm lifting holes FRAME 2 Mod 105 2 240 2 Center distance of vibration damper holes and lifting holes 14 mm Vibration damper fixing holes 8 75 mm lifting holes Shipping weight Mod 70 2 80 2 90 2 105 2 120 2 1352 1502 1702 1902 2152 240 2 AB Standard
34. AX units the painting is extended to all closing panels so ensuring for the electrical panel a protection degree IP54 and the maximun protection against adverse weather conditions with this features the unit is suitable for outdoor installation to agree with our commercial office The units are supplied charge with NITROGEN in order to avoid entrance of air into the refrigerant circuit A variety of other accessories are available to extend the capabilities of the units All units are accurately build in compliance with the existing standards and are individually tested in factory GENERAL SPECIFICATIONS 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 EGW IR 70 2 VB AB 0 R 5 Unit type IR Unit for installation in an Hydronic system with operation as a Chiller BR Water Chiller suitable for BRINE Production Power Supply 5 400V 3ph 50Hz Condenser option Unit model N Compressor 2 R For Remote condensers Unit without Condensers suitable to be coupled with Remote condensers Acoustic Version Unit version VB Standard unit AB Standard unit Type of Refrigerant AS Low noise unit 0 R410A AX Extra low noise unit
35. E nee dead ned ee eum D walle 18 Plantexchangefs sacs nea tant enk a e gene ka A ees a ek EO erben ete sep ed 18 EE 19 DIMENSIONAL Da EKEKO a E wal BAe ee ERN lk kur e num in ajon ee ee n 20 Standard unit overall dimension sss sisas sp mia NEA NO E Ka E RS KO apre atk aang d tb arend 20 Shipping weight bed ___ dass 20 Operation ceterae ete ze dek ECO dae 20 Minimum space for 8 0 21 Refrigerant and hydraulic connections onee eee 21 Mibration damper installation s s a snama tr A ace ees oni nea eet Deum A EVE eene 21 REMOTE AXIAL CONDENSER ACCESSORIES 0 2 eee eee nnn 22 Description ln eee aed ebb aad hawt eel _ 22 VerSlON siete Aaa enal hats Re 23 AS Low Noise Version use ces reme hex em ded ade Rea VE Ge Pl A DEA eee bee ae OK a ee 24 AX Extra L w Version nz sss ena 25 RECEPTION AND POSITIONING zn ane ze sur sio Re ERE EE ESROS KAAS REA wee OKA ENEN KAO EN Ka meres 26 Inspections on
36. FORMATION ON REGULATIONS The product must not be labelled according to Directive 1999 45 EC Comply with the regulations given below and the relevant applicable updates and amendments Circulars no 46 79 and 61 81 of the Ministry of Labour Risks related to the use of products containing aromatic amines Leg Decree no 133 92 Regulations on the discharge of hazardous substances in waters Leg Decree no 277 91 Protection of workers against noise lead and asbestos Law 256 74 Decree 28 1 92 Leg Decree no 52 dated 3 2 97 Decree dated 28 4 97 as amended Classification packing and labelling of hazardous substances and preparations Decree no 175 88 as amended Activities with significant accident risks Seveso Law Decree no 203 88 Emissions into the atmosphere Decree no 303 56 Work hygiene Decree no 547 55 Regulations on accident prevention Leg Decree no 152 dated 11 5 99 Protection of waters 16 OTHER INFORMATION Recommended uses Refrigerant Can cause suffocation in high concentration Keep in a well ventilated place Do not breathe the gas The risk of suffocation is often underestimated and must be clearly explained during the training of operators Ensure compliance with all the national and regional regulations Before using this product in any new process or trial an in depth study on safety and compatibility of the product with the materials must be carried out The above information is based on our current know how and de
37. FRIGERANT CONNECTION Mod DISCHARGE UM 70 190 42 ODS mm 215 240 42 ODS mm Mod LIQUID uM d 70 190 28 005 mm 215 240 35 005 mm NB The measures are in mm Vibration damper installation To prevent the operating unit from tran smitting vibrations to the bearing struc F A m ture vibration dampening materials should be inserted under the bearing 4 TIT N points o EN n The unit be supplied with the rub m N n ber or spring vibration dampening ac E cessory This must be mounted by the installer Mod A B D E 70 2 240 2 95 35 122 124 150 21 REMOTE AXIAL CONDENSER ACCESSORIES RC Description This new series of Remote Axial Condensers uses copper pipes with special internal riffling and a high efficiency fin The fin has been specially designed to guarantee a high thermal exchange coefficient with low air pressure drops By combining both special tubes and fins the following features can be achieved Maximum capacity related to the heat exchanger s dimensions Minimum refrigerant charge The most strict environment standards for sound pollution can be met This new series of axial condensers is equipped with fans with scythe shaped blades to reduce the sound emission From the noise level point of view all models can be supplied as basic version AB low noise version AS or extra low noise version AX To guarantee solidity stre
38. Ferroli EGW CONDENSERLESS WATER CHILLERS Ne 61 40 kW in cooling mode INSTALLATION MANUAL Dear Customer Thank you for having purchased a FERROLI Idustrial coolers It is the result of many years experience particular research and has been made with top quality materials and higlly advanced technologies The CE mark guaranteed thats the appliances meets Euro pean Machine Directive requirements regarding safety The qualitative level is kept under constant surveillance FERROLI products therefore offer SAFETY QUALITY and RELIABILITY Due to the continuous improvements in technologies and materials the product specification as well as performances are subject to variations without prior notice NL CE DECLARATION OF CONFORMITY We the undersigned hereby declare under our responsibility that the machine in question complies with the provisions established by Directives EG KONFORMITATSERKLARUNG Wir die Unterzeichner dies er Erklarung erklaren unter unseren ausschlie Blichen Verantworfung die genannte Maschine den Bestimmungen der folgenden EG Richtlinien entspricht DECLARATION CE DE CONFORMITE Nous soussign s d clarons sous notre enti re responsabilit que la machine en objet est conforme aux prescriptions des Directives DICHIARAZIONE CE DI CONFORMITA Noi sottoscritti dichiariamo sotto la nostra respon sabilita che la macchina in que
39. N Ea ee DA E 33 Precautions for the Winter s sus a a sla Repeat Eque Red e n ee px aid e Robo Cea Rv osx ih n 33 Basic diagram Basic Version VB USER SYSTEM SIDE ees en 34 ELECTRICAL CONNECTIONS gt hk eee zegt man o rado Ser Cae MEER REFERS ERE EE ES kanal 36 General UES _________ 36 Structure of electric panel sssssssssisssissstesstastessesstastesssestesstesstestos 36 Composition of the SYSTEM nn vergaren neden ___ _________ petu ob Ra reas 36 Electrical connections en sas 4 eku jukas ek vii ee inano A Ede akalo 36 R410A PROTECTION DEVICES insomnia RUN Ree Re o ER ende RS E ln 38 REFRIGERANT FLOW DIAGRAM STANDARD UNIT VB oon oee eeen eee 39 Refrigerant flow diagram in cooling mode IR BR eneen eee 39 Refrigerant flow diagram in cooling mode IR BR with electronic valve eee 40 START UP to Re vare eod ae REM UNES GR aed cee EE P UE QUEUE ane eed E Une 41 General RUES zn arora ETT TITT ee ate kesh at 41 MAINTENANCE Rp iR BUR A Rn a ne ad 41 General RUES PPP 41 Routine maintenance ze ses ca smaak zaate
40. YMBATOTHTAxX EE mov vroypapovpe Tv TOPOVOO nXovoupe vxo Tv OMOKAELOTIKT ELBLVN OTI pgnxoavnuo a ot IZJAVA O CE SUGLASNOSTI Mi potpisani izjavljujemo pod na om odgovorno u da ova Ma ina odgovara zahtijevima iz Direktiva DEKLARACJA ZGODNOSCI CE My ni ej podpisani o wiadczamy z pelna odpowiedzialno ci e ni ej wymienione urz dzenie w pe ni odpowiada postanowieniom przyj tym w nast puj cych Dyrektywach ll rAp entan Dar ali The manufacturer declines all responsibility for any inaccuracies in this manual due to printing or typing errors The manufacturer reserves the right to modify the products contents in this catalogue without previous notice TABLE OF CONTENTS THIS MANUAL IS DIVIDED INTO SECTIONS THEIR NAMES APPEAR IN THE HEADING OF EACH PAGE GENERAL SPEGIFICATIONS 52 2 eee Ga eee rud ete kna aika NR kape e kja aki weer ee eld RU 5 General Specifications sss sus Bee Fada NE hae 4 European oss ot Baw deh beta 4 identification plate of the Units issi sas sss rtas edo se reme ere oe de ee eee ee n ddl ot oae ae re mae d 4 Presentatiomof the Umit amos sede tl 5 Identification code of
41. a differential pressure switch located between the entrance and exit of water plant exchanger and for IP and BP units another one for the source water exchanger to prevent freezing problems in case of lack of water flow The intervention is calibrated to a DP of 80 5 mbar while the reset occurs with a DP of 105 5 mbar The differential pressure switch contact opens and stop the unit when you reduce the water flow and so DP lt 80 mbar 5 The differential pressure switch closes and then the unit can restart when the water flow increases and so Dp 2 105 mbar 5 2 With hydronic kit accessory Besides the standard accessories the unit is equipped with all the hydraulic components as specified in the Options and accessories section Hydraulic layout of the system General suggestions The pipes must have the least possible number of bends to minimize load losses and must be adequately supported in order to prevent the connections of the unit from being excessively stressed Install on off valves near components that need to be serviced to isolate them when maintenance work needs to be done and to allow them to be replaced without having to discharge the system Before isolating the pipes and charging the system carry out preliminary inspections to make sure that there are no leaks Isolate all the chilled water pipes to prevent condensation from forming along the pipes themselves Make sure that the material used is t
42. achine Then continue inside the panel and connect the conductors directly to the input terminals of the main disconnecting device of the machine Power supply system The power cables of the machine s supply line must be taken from a system of symmetrical three phase voltages and of a separate protection conductor V 400V 10 f 50 Hz Protection on supply side An automatic switch must be installed on the supply side of the side in order to protect against any overcurrents and indirect contacts that could occur when the machine is operating It is advisable to install an automatic current limiter switch in order to limit the effective short circuit current in the connecting point of the machine This allows a protection device with a lower breaking capacity than that required in the connection point to be sized like the main circuit breaker of the machine The line and switch must be coordinated in compliance with the current laws governing electrical safety matters regarding the type of installation and environmental conditions in which the machine must operate Protection conductor ground wire The protection conductor from the feeder line must be connected straight to the ground screw identified by code PE which ensures the equipotential connection of all metal grounding points and structural parts of the machine 2 Electric panel Protection degree The electric panel casing is made from sheet metal and h
43. aired for any reason this must only be done by a specialized assistance center recognized by the manufacturer and using geuine spare parts The manufacturer also declines all liability for any damage to persons or property deriving from failure of the information in this manual to correspond to the actual machine in your possession Proper uses this series of chillers is designed to produce cold or hot water for use in hydronic systems for conditioning heating purposes The units are not suitable for the production of domestic hot water Any use differing from this proper use or beyond the operating limits indicated in this manual is forbidden unless previously agreed with the manufacturer The prevention of the risk of fire at the installation site is the responsiblity of the end user European Directives The company hereby declares that the machine in question complies with the matters prescribed by the following Directives Machine Directive 2006 42 CE Directive governing pressurized vessels PED 97 23 Electromagnetic compatibility Directive EMC 2004 108 CE Low voltage Directive LVD 2006 95 CE Any other Directives have to be considered not applicable Identification plate of the Unit A The figure on the left depicts the identification plate of the uni
44. and source exchanger and safety valve and the water pumps Pipes in general Ice burns Leaking refrigerant Do not pull on the pipes Electrical cables metal parts Electrocution serious burns Defective cable insulation live metal Adequate electrical protection cor parts rectly ground the unit c Pollution The unit contains refrigerant gas and lubricating oil When scrapping the unit these fluids must be recovered and disposed of in com pliance with the regulations in force in the country where it is installed The unit must not be abandoned during the scrapping stage 42 SAFETY AND POLLUTION General recommendations about the R410A refrigerant used 1 SUPPLIER COMPANY AND PRODUCT IDENTIFICATION Card No Product Supplier company identification FRIG 8 R 410A RIVOIRA SpA 2 COMPOSITION INFORMATION ON INGREDIENTS Substance Preparation Components Impurities EEC No Trade name 3 IDENTIFICATION OF HAZARDS Identification of hazards 4 FIRST AID MEASURES Inhalation Contact with eyes Contact with skin Swallowing 5 FIRE PREVENTION MEASURES Specific hazards Dangerous fumes Fire extinguishing means usable Specific methods Special protection equipment Preparation Contains the following components Difluoromethane R32 50 in weight Pentafluoroethane R125 50 in weight Non applicable for mixtures Pu Liquefied gas The vapours are heavier than air and can cause suffocation
45. arted by resetting via the user interface terminal Pressure taps 5 16 SAE Allow the operating pressure of the system to be measured compressor discharge expansion valve inlet compressor suction Pressure taps 1 4 SAE 7 16 UNF type with schraeder pin Allow the charge discharge of the refrigerant gas from the system ACCESSORIES AND OPTIONAL EQUIPMENT RC F Remote Condensers It is possible to supply several types of air cooled remote condensers following different project specification as for instance different noise levels standard low noise eXtra low noise coils with coated or copper fins ecc The remote condensers can be equipped with specific accessories as for instance sheet metal support for horizontal installation electrical wiring box electrical panel CE marked fans speed control by cut of phase for head pressure control Specifical accessories for condenserless units PAN Covering panels M accessory only for AB unit made of galvanized sheet metal if painting option VER is selected the panels are provided coated with epoxidic powder paint RAL 7035 to ensure maximun protection against adverse weather conditions AVG Rubber vibration dampers F Consisting of 4 rubber vibration dampers to fit under the unit Reduce the transmission of the mechanical vibrations generated by the compressors and pumps during normal operation to the basement of the unit The insulating degree of the vibration dampers is abo
46. as IP22 protection rating at the doors directly accessible from the outside The other parts of the casing guarantee a protection degree that is at least equivalent to IP22 as established by the current laws in force this has been achieved since the panel has further protection against the penetration of solid foreign bodies and atmospheric agents thanks to the machine structure in which it is housed If the unit is equipped with panels the protection degree for the electrical panel becomes IP54 Starting and stopping function The red handle on the panel door directly acts on the main circuit breaker The handle also acts as a door lock since it ensures that the machine is only powered when the door is shut The stopping function carried out by the main circuit breaker is classified as type 0 since the machine is stopped by immediately cutting off the power supply 3 Reference standards The provisions established by the following Directives have been complied with to ensure the safety of the electrical products placed on the European Union market Low Voltage Directive 2006 95 EEC which also includes the following harmonized standards CEI EN 60335 1 and 60335 2 40 Classification CEI EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General rules Directive 2004 108 EEC concerning Electromagnetic compatibility 4 User connection In the electrical board are available on terminals a comman
47. d 90 2 GENERAL SPECIFICATIONS 4 Plant Exchanger made of brazed stainless steel plates AISI 316 It is installed in a shell of heat 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 circuit to avoid the risk of freezing if the water flow is shut off for some reason It can be equipped with antifreeze heater Covering panels for AS and AX units or as accessory for AB unit made of galvanized sheet metal if painting option VER is selected the panels are provided coated with epoxidic powder paint RAL 7035 to ensure maximun protection against adverse weather conditions 5 Dehydrator filter Mechanical type Retains impurities and traces of moisture in the circuit Hermetic type for models 70 90 cartridge type for models 105 240 6 Water differential pressure switch It is installed on the connections between the water inlet and outlet of the exchanger It stops the unit if it activates 7 Thermostatic expansion valve With external equalizer this feeds the evaporator correctly keeping the selected superheat degree at a steady level Electronic Expansion valve optional feeds the evaporator correctly keeping the selected superheat degree at a steady level it guarantees an effective and quick response to the load modifications so increasing the efficiency at partial load 8 Refrigerant
48. d Signal green EPDM seals are used Apply a film of grease to the seal on the back on the side flanks and on the inner lips that contact the pipe Work in conditions of the utmost cleanliness as particles of dirt could damage the seal Always and only use synthetic grease Greasing makes it easier to fit the seal on the pipe and improves the tightness It also allows the seal to slide within the connection avoiding tensions and projections near the bolts 3 How to fit the seal Fully insert the seal into the end of a pipe Make sure that the seal lips adhere to the pipe itself VON o MV a A sro 4 Alignment Align the pipes and move their ends near to each other Now push the seal centering iton the two pipe ends The seal must remain inside the grooves NS 5 Joint assembly Remove one bolt and loosen without removing the other one Seat part of the body of the joint the bottom between the pipe ends inserting and edges of the grooves Now seat the other part of the body at the top on the two ends and close the joint Make sure that the parts of the body of the joint NS touch each other IA 6 Nut torquing Fit the previously removed bolt back in place and tighten both nuts by hand Now torque them with the relative wrench tightening them alternately a few turns WARNING If one nut is fully tightened at a time the seal could slip between the jaws of the opposite side of the joint
49. d for water circulation pump available one rel free contact and relative thermal protection b digital input for remote ON Stand by of the unit free voltage contact for general alarm NO d command for remote condenser fans available one rel free contact and relative thermal protection For more details refer to the wiring diagram of the unit 37 R410A PROTECTION DEVICES Protection devices HIGH PRESSURE The unit is protected against risk of overpressure by means of 3 levels protection chain Each circuit is equipped with 1 high pressure automatic switch connected to electronic controller 2 high pressure manual switch connected to compressor contactor command and to electronic controller 3 high pressure safety valve Protection devices technical data LEVEL 1 2 3 penco High pressure High pressure High pressure automatic switch manual switch safety valve Trip out barg 41 0 43 0 45 0 Trip in barg 29 5 31 0 41 0 connected to electronic controller compressor contactor command discharge pipe compressor Discharge the refrigerant effect stop the compressors stop the compressors to atmosphere to reduce the system pressure By keyboard if the Press the button high pressure switch has present on the manual reset trip in and after the solution pressure switch Not necessary of the problem that generates the alarm CAUTION CAUTION IN CASE OF COMPRESSORS TRIP OUT BY MANUAL RESET HIGH
50. e to the minimum the refrigerant charge Refrigerant migration during standstill periods compresors stopped During standstill periods with stopped compressors the refrigerant try to move to the coldest point of the system During nighttime or during winter for systems with condenserless units and remote condenser the coldest point becomes the condenser subject to external air temp so all the refrigerant condenses becoming liquid into the coil of remote condenser In order to avoid that compressors were flooded by liquid it is necessary to provide shutoff devices automatic as for instance liquid solenoid valve and manuals as for instance shutoff valves on liquid and discharge pipes and for specific cases to install a liquid receiver of appropriate volume Note if the system has not to work during wintertime it is preferable shutoff the valves on liquid and discharge pipes Refrigerant pipes The refrigerant lines have to be bulit with pipes usually copper with thickness adequate to the maximum working pressure PS In table some technical features of copper refrigerant pipes usually available Tab T1 External diameter mm 10 12 14 16 18 22 28 35 42 54 67 76 89 108 Thickness mm 1 1 1 1 1 1 1 15 15 2 2 2 25 25 Weight per 1 meter of line kg m 0 25 0 31 0 36 0 42 0 48 0 59 0 76 1 41 1 70 2 92 3 65 4 15 6 07 7 40 pu meter of LIQUID kg m 0
51. em The oil not still mixed with the refrigerant reaches the condenser where is dissolved completely into the liquid and so returnig to the unit compressors The oil return can be achieved for gravity or drag The problem does not arise if the condenser is installed at same Fig 1 or lower level fig 2 3 than condenserless unit instead if installed at higher level Fig 4 it is necessary sizing the discharge line so ensuring particularly when the unit has to work at partial capacity a minimum refrigerant velocity to achieve the oil drag To guarantee an effective oil return it is recommended to size the diameter to have a velocity with unit at full capacity of minimum 4m s for the horizontal lines and 8m s for the vertical lines For very long vertical lines you have to provide some siphons For horizontal lines it is however suggested to install the discharge pipe with an adequate slope 2 3 towards the condenser Tab M3 AT A cooling capacity 96 CP power input 96 0 1 1 0 5 0 993 1 010 1 0 985 1 02 1 5 0 978 1 030 2 0 97 1 04 2 5 0 963 1 050 3 0 955 1 06 3 5 0 948 1 070 4 0 94 1 08 Tab M4 Cooling capacity kW 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 22
52. es vertical air flow Length L 3230 3230 3230 3230 4580 4580 4580 3230 3230 4580 4580 mm height A 1565 1565 1565 1565 1565 1565 1565 1565 1565 1565 1565 mm depth P 1370 1370 1370 1370 1370 1370 1370 2390 2390 2390 2390 mm Noise level Sound Power Level 68 68 68 68 70 70 70 71 71 73 73 dB A Sound pressure level at 1mt 51 51 51 51 53 53 53 54 54 56 56 dB A Sound pressure level at Smt 41 41 41 41 43 43 43 44 44 46 46 dB A Sound pressure level at 10mt 36 36 36 36 38 38 38 39 39 41 41 dB A Standard configuration type 1 horizontal air flow roj l Sl CIS AD aera SAE WEISE CIN CI Configuration with Support Brackets accessories Type 3 vertical air flow L o 25 RECEPTION AND POSITIONING Inspections on arrival As soon as the unit is consigned it is essential to make sure that all the ordered items have been received and that the dispatch is complete Carefully check that the load has not been damaged If visible damage is discovered immediately inform the haulage contractor and write Collected with reserves owing to evident damage on the consignment note Delivery at the plant means t
53. ess Discharge line Ap kPa for 1 meter of pipe The pressure drop on discharge line leads to an increase of compressor condensing pressure with a reduction of capacity and an increase of power input The pressure drop is expressed in kPa but usually it is converted in an increase of condensing saturation temperature and so expressed as a AT ref tab M1 and M2 Moreover you have to consider the concntrted pressure drop due to bends TEE siphons or other components mufflers oil separtor shutoff valves etc Respect to commercial componets refer to features declared by the manufacturer instead referring the fitiings use table R1 to calculate the equivalent length Tab M1 Cooling capacity kW 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 B g 22x1 27 39 5 3 6 9 87 10 1 12 2 14 5 17 1 19 8 22 2 F 5 28x1 07 1 14 18 23 27 33 39 46 53 59 67 76 85 95 10 2 11 2 12 3 13 5 14 7 158 17 1 184 19 8 21 3 226 as 9 8 35x1 5 04 06 08 4 4 12 14 17 2 21 24 27 3 34 36 4 44 48 52 55 59 64 69 74 79 i 5 5 42 1 5 03 04 05 06 07 08 08 09 1 12 13 13 14116 17 19 2 22
54. hat any damages will be reimbursed by the insurance company as established by law Safety prescriptions Comply with the current safety provisions in relation to the equipment used to handle the unit and the ways in which these operations are carried out Handling Before moving the unit check its weight on the data plate with the general specifications of the appliance and consult the Main Fea tures section of this manual Make sure that the unit is handled with care that it is not jolted in any way and that none of its functional parts is damaged Comply with the following instructions when lifting and positioning the unit e Handling with a lift truck or similar The unit has four wooden bases so that it can be transported in a longitudinal and sideways direction Do not allow the unit or any of its parts to drop on to the ground Remember that the heaviest part is the one where the compressor is installed electric panel side Fig 1 Refer to the data plates Part 3 Fig 1 that identify the center of gravity position applied to the 4 sides of the base Fig 1 Fig 2 Fig 3 Lu Lifting and handling with crane or similar Position metal tubes of an adequate thickness in the holes on the base of the unit in order to lift it The ends of the tubes must project to an adequate extent to allow safety components to be inserted and the lifting belts to be fitted
55. he steam barrier type failing this cover the insulation with an appropriate protection Also make sure that the air venting valves can be accessed through the insulation Do not forget to install or at least allow for the installation of pressure and temperature reading instruments on the inlet and outlet parts of the hydraulic circuit These instruments will allow you to monitor the operation of the system The circuit can be kept under pressure by means of an expansion tank with which the unit is equipped if the hydronic kit accessory is installed and a pressure reducer A plant filling unit can also be used in order to automatically charge the system and keep it at the desired pressure if it drops below a certain pressure value Install manual or automatic values in the highest point of the system to eliminate air from the circuit Fit manual or automatic valves at the highest point in the circuit in order to vent air from the circuit Depending on the chosen accessory there may be Victaulic type joints for hooking up to the unit The joints allow the pipes to ex pand due to changes in temperature and in addition the elastomer gasket and the specified play help insulate and absorb noise and vibration If anti vibration mounts are installed under the unit it is recommended to use flexible couplings before and after the water circulation pump and near the unit Install a cock on the outlet of the unit in order to regulate the wate
56. ited to avoid the refrigerant rievaporation that can generate 24 a non correct feed of expansion valve bubbles on liquid sight 30 265 4 32 glass placed upstream the xpansion valve so making the system 40 354 5 85 unstable and possible cause of liquid return to the compressors On sizing the liquid line diameter it must take care particularly when remote condenser is placed at a level lower than condenserless unit since that difference turns on a loss of subcooling ref tab L1 With R410A is not recommended level difference higher than 20 meters The diameter selection is strictly related to cooling capacity to achieve a velocity of 1 1 5 m s with thiese velocities the pressure drop of the liquid line are neglectable However so reducing the refrigerant charge it s possible to use a minor diameter paying attention to limit the velocity under 1 8 2 m s 8 tab L2 Tab L2 Cooling capacity KW 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 1220 230 240 250 260 270 280 290 300 22x1 09 1 1 1 3 15 1 7 1 9 21 23 28x1 06 0 7 08 0 9 1 0 1 1 12 13 14 16 1 7 18 19 20 21 22 a 35x1 5 0 5 0 6 0 7 0 7 0 8 09 09 1 0 1 1 12 12 13 14 15 15 16 1 7 18 1 8 19 20 21 21 22 42x1 5 05 0 6 0 6 0 7 0 8 0 8 0 9 0 9 1 0 10 11 11 12 12 13 13 14 14 15 ipe v m s diameter x thickn
57. l the necessary precautions The following information is only a guide for the end user Routine maintenance The inspections described below to which the unit must be subjected do not require specific technical know how They merely include a few simple inspections involving certain parts of the unit Call an authorized assistance center if actual maintenance work is required The table below gives a recommended list of inspections which should be carried out at the indicated intervals DESCRIPTION WEEKLY MONTHLY EVERY SIX MONTHS Visual inspection of the unit Inspection of hydraulic circuit Inspection of electrical system Inspection of condensing system M Inspection and adjustment of operat parameters Visual inspection of the structure of the unit When checking the condition of the parts that form the structure of the unit pay particular attention to the parts liable to rust If traces of rust are noted they must be treated with rust inhibitor paint in order to eliminate or reduce the problem Check to make sure that the external panels of the unit are well fixed Bad fixing gives rise to noise and abnormal vibrations Inspection of hydraulic circuit Check visually to make sure that there are no leaks in the hydraulic circuit If the pumping module accessory is installed it is advisable to make sure that the water filter is clean Inspection of electrical system Make sure that
58. llation or indoor installation in rooms that during winter can reach very low ambient temperature RB Compressors suction shut off valve M Made by a ball valve installed on compressors suction allows a quick replacement of the compressor in case of failure VER Framework and panels if present made by sheet metal with anticorrosion treatment painted RAL7035 with epoxy powders to ensure the maximum resistance to adverse weather conditions EEV M Electronic Expansion valve standard for IP and BP units feeds the evaporator correctly keeping the selected superheat degree at a steady level it guarantees an effective and quick response to the load modifications so increasing the efficiency at partial load SS Soft Starter M Soft starter on compressors riduce the inrush current and reduce the vibrations transmitted to the pipes and basic frame during the start up phase RIF Capacitors for power factor corrections M Capacitors for power factor corrections increase power factor cos gt 0 91 MTC Magnetothermic switch M Magnetothermic switch on all loads in place of fuses NOTES M only installed in the factory F supplied for installation by the customer Other power source voltage rating contact our technical department GENERAL TECHNICAL SPECIFICATION General technical specifications
59. mpressor Contactor and magnetothermic switch to protect the pump if installed Phase presence and sequence monitoring device on power supply 1b The auxiliary section includes Fuses on the auxiliary transformer Electromagnetic noise filter Insulating and safety transformer to power the auxiliary circuit GENERAL SPECIFICATIONS 1c The microprocessor monitoring section includes User interfacing terminal with display On off key Operating mode selector key e Compressor on off display LED Operational mode LED Antifreeze heaters activated indicator LED Source Pump s on off display LED Plant Pumps on off display LED Check control with fault code display e Stand by remote Summer Winter remote selection IW IP BW BP units only Control system main functions temperature control of the water produced by the unit compressor and pump operating hour counter timing and cycling of start ups input parameters by keyboard alarms management operating mode change IW IP BW BP units only dynamic set point climatic control scheduling and integrative heaters control If installed the hydronic kit these functions are enabled antifreeze with pump start up cycle after prolonged inactivity antisticking if the hydronic kit installed has 2 pumps there is a cycling between each pump to ensure an equivalent lifetime Digital input functions low pressure
60. n experiments on animals Rapid evaporation of the fluid can cause freezing Can cause cardiac arrhythmia 43 SAFETY AND POLLUTION 12 ECOLOGICAL INFORMATION Effects linked to ecotoxicity Pentafluoroethane R125 Potential global warming with halocarbides HGWP R 11 1 0 84 Potential impoverishment of the ozone ODP R 11 1 0 13 CONSIDERATIONS ON DISPOSAL General Do not dispose of where accumulation can be hazardous Usable with reconditioning The depressurised containers must be returned to the supplier Contact the supplier if instructions for use are deemed necessary 14 INFORMATION FOR TRANSPORT Designation for transport LIQUEFIED GAS N A S DIFLUOROMETHANE PENTAFLUOROETHANE UN No 3163 Class Div 2 2 ADR RID No 2 2nd A ADR RID hazard no 20 ADR label Label 2 non toxic non flammable gas CEFIC Groupcard 20939 A Other information for transport Avoid transport on vehicles where the loading zone is not separate from the cab Make sure the driver is informed about the potential risk of the load and knows what to do in case of accident or emergency Before starting transport make sure the load is properly secured and make sure the valve of the container is closed and does not leak make sure the blind cap of the valve when provided is correctly fitted make sure the cap when provided is correctly fitted and that there is an adequate ventilation passage ensure compliance with the current provisions 15 IN
61. ngth and the maximum resistance to atmospheric agents the bearing and the casing are manufactured with galvanized steel and oven painted with a polyurethane resin the standard colour is RAL 7035 All models can be equipped with several accessories as Condensing Control using a cut of phase regulator AB e AS by step AX Electrical Wiring Box allows a fast and safe electrical installation of the unit since all wires and thermal protections of the fans are connected inside a waterproof box IP54 to a terminal block where the installer connect the electrical supply 400V 3 PE 50Hz and the fans thermal switches signal Electrical Panel CE this accessory like the electrical wiring box allows a fast and safe electrical installation and moreover simplify the standard and non standard maintenance of the unit The accessory is in fact composed by main electrical switch fuses and contactors of the fans transformer to supply an alarm auxiliary rel terminal block for remote ON OFF i e sent by the condenserless unit Rubber Vibrations Dampers Support Brackets As special options it is possible supply Special fins Copper Painted Aluminium ecc Special motors 22 REMOTE AXIAL CONDENSER ACCESSORIES RC AB Basic Version Models 70 2 80 2 90 2 105 2 120 2 135 2 1502 170 2 1902 215 2 24
62. oisture Note the ball valves if open lead to the leak of nitrogen with risk of air entrance For making the connection between condenserless unit and remote condenser proceed as following descrive 1 Install the refrigerant pipes from the remote condenser toward the condenserless unit 2 Braze the pipe to the discharge connection of the unit 3 Arrange in advance the liquid connection in order to reduce to minimum the time necessary to the following brazing 4 Connect the vacuum pump to the provided points in the condenserless unit some pressure taps 1 4 SAE and 5 15 SAE with needle are available ref to refrigerant diagram 5 Open the liquid ball valve discharging the nitrogen of the condenserless unit 6 In the shortest possible time max 15 minutes make the brazing of the liquid pipe 7 Switch on the vacuum pump 8 Open the discharge ball valve 9 Switch off the vacuum pump 11 Check the tightness of the system 12 Charge with refrigerant gas Estimation of the refrigerant charge Roughly it is necessary the amount of refrigerant indicated in tab C1 and to add the amount calculated for the lines moreover it is necessary a back up amount of another 20 at least For instance for mod 105 2 with reference to the calculation example MODELS 70 2 80 2 90 2 105 2 120 2 135 2 150 2 170 2 190 2 2152 240 2 UM Estimated charge 13 7 15 3 18 2 20 7 23 2 26 1 29 3 33 5 37 8 42 8
63. owing table Evaporator Faning m K W 0 44 x 10 1 1 m K W 0 86 x 10 0 98 0 99 K W 1 72 x 104 0 93 0 98 F c PF Correction Factor for Cooling capacity F c PA Correction Factor for compressor power Input 14 BRINE UNIT BR Brine Unit BR Correction factors to apply to the basic version data ETHYLENE GLYCOL Percentage Of glycol in mass volume 20 18 1 Freezing point C 8 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 912 0 855 0 798 0 738 0 683 CCPA Compressor power input correction factor 0 967 0 957 0 947 0 927 0 897 CCQA Water flow rate correction factor 1 071 1 072 1 073 1 075 1 076 CCDP Water pressure drop correction factor 1 090 1 095 1 100 1 110 1 120 Percentage Of glycol in mass volume 30 27 7 Freezing point C 14 Leaving water temperature 4 2 0 2 4 6 8 Cooling capacity correction factor 0 899 0 842 0 785 0 725 0 670 0 613 0 562 CCPA Compressor power input correction factor 0 960 0 950 0 940 0 920 0 890 0 870 0 840 Water flow rate correction factor 1 106 1 107 1 108 1 109 1 110 1 11
64. pe 3 vertical air flow L 24 REMOTE AXIAL CONDENSER ACCESSORIES AX Extra Low Noise Version Models 70 2 80 2 90 2 105 2 120 2 135 2 1502 1702 1902 2152 240 2 UM 400 3 50 V ph Hz Refrigerant R410A Max working pressure PS 45 bar Coils type Aluminum fins and copper tubes Gas connections 1x42 1x42 1x42 1x42 1x42 1x54 1x54 2x42 2x42 2x42 2x42 m x O Liquid connections 1x28 1x28 1x35 1x35 1x35 1x42 1x42 2x35 2x35 2x35 2x35 n x Fan specification Fan 2 2 2 2 3 3 3 4 4 4 4 n Diameter 800 800 800 800 800 800 800 800 800 800 800 mm Air flow rate 24400 24400 22000 20200 36600 33000 30300 41600 38400 69600 69600 ls Power input 1 18 1 18 1 18 1 18 1 77 1 77 1 77 2 36 2 36 2 36 2 36 Current input 2 5 2 5 2 5 2 5 3 75 3 75 3 75 5 5 5 5 A Internal volume 18 18 27 35 27 41 53 49 64 49 49 dm Weight 279 279 302 324 413 447 481 502 543 680 680 kg Standard configuration Dimension horizontal air flow Length L 3230 3230 3230 3230 4580 4580 4580 3230 3230 4580 4580 mm height A 1370 1370 1370 1370 1370 1370 1370 2390 2390 2390 2390 mm depth P 800 800 800 800 800 800 800 800 800 800 800 mm Dimension with Configuration with Support Brackets accessori
65. r flow Precautions for the Winter The water could freeze and damage the exchanger of the unit and other parts of the system during the winter period if the system was to remain at a standstill This problem can be obviated in 3 different ways 1 Drain the system completely taking care to drain the plate exchangers in order to drain the unit s plumbing system completely open the water drain ball valves and the air vent valves and centrifugal pumps 2 Operate with glycol water taking account depending on the of glycol of the factor of correction of the refrigerating capacity power input water flow rate and losses of head see the Correction factor for the use of glycol section 3 If it is certain that the unit will always be powered throughout the winter the unit is able to protect itself from freezing down to a temperature of 20 C this is possible thanks to the low temperature kit accessory composed by 2 antifreeze heaters installed on the water exchangers and to a intelligent control of the water pumps that must be governed by the microprocessor board see the Electric Connections section 33 HYDRAULIC CONNECTIONS Basic diagram Basic Version VB USER SYSTEM SIDE The following figures represent connections to the evaporator circuit IMPORTANT There must be a constant flow of water to the exchanger
66. reducing the oxygen available for brea thing Rapid evaporation of the fluid can cause freezing Can cause cardiac arrhythmia Do not administer anything if the person has fainted Take the person outdoors Use oxygen or artificial respiration if necessary Do not administer adrenaline or similar substances Rinse thoroughly with plenty of water for at least 15 minutes and see a doctor Wash immediately with plenty of water Immediately remove all contaminated garments Increase in pressure Halogen acids traces of carbonyl halides All the known fire extinguishing means can be used Cool the containers tanks with water sprays Use self contained breathing apparatus in confined spaces 6 MEASURES AGAINST ACCIDENTAL SPILLING OF THE PRODUCT Personal protection Protection for the environment Product removal methods 7 HANDLING AND STORAGE Handling and storage Incompatible products Evacuate personnel to safe areas Provide for adequate ventilation Use personal protection equip ment It evaporates It evaporates Ensure an adequate air change and or extraction in the workplaces Only use well ventilated rooms Do not breathe vapours or aerosols Carefully close the containers and keep them in a cool dry and well ventilated place Keep in the original containers Explosives flammable materials organic peroxides 8 CONTROL OF EXPOSURE PERSONAL PROTECTION Personal protection Control parameters Respiratory trac
67. rom 5 to 20 C The units can be supplied for brine production BR that allow brine production from 10 to 5 C To increase the seasonal efficiency index ESEER and so further containing power input and operation cost the units can be supplied with electronic expansion valve Great attention has been dedicated to achieve low sound levels in order to meet the increasingly restrictive laws in terms of noise upon request you can choose for a Standard Unit AB or Low noise unit AS or Extra low noise unit AX The low noise unit AS provides sound attenuation thanks to panels with sound absorbing insulation The extra low noise unit AX provides a further sound attenuation thanks to panels with sound absorbing and acoustic jackets for compressors The basic unit AB is an essential structure made by sheet metal with anti corrosion treatment not painted and without any closing panels so suitable ONLY for indoor installation All the units are equipped with 2 scroll compressors arranged in pairs tandem on 1 circuit operating with environmental friendly R410A gas brazed plate heat exchangers on plant side evaporator completely insulated and protected on water side with a differential pressure control electrical panel complete with electronic controller and display phase presence and sequence control device as standard As option the unit can be selected with painted structure epoxy powders RAL 7035 For low noise AS and extra low noise
68. s MODE key used to select the operating mode sees ON OFF key used to turn the unit ON OFF and to reset the alarms 45 B Mode ON OFF keys used to access and quit the various menu levels UP key scrolls forwards through the menu items or increases the value of a parameter Sao Tasto DOWN scrolls backwards through the menu items or decreases the value of a parameter oK D Programmer clock Allows the unit to be turned on and off depending the programmed time setting up to 14 switching actions can be programmed as required throughout the 7 days of the week TAT High Temperature Thermostat M Two thermostats in series on compressors discharge pipes preserve operation not allowing temperature to rise up than a specified fixed value INT Serial interface M F Allows serial communication on RS485 via MODBUS protocol CSF Voltage monitor and sequence meter M F The device enables control of the correct sequence of power phases and the lack of any phases It also ensures that the unit works within 10 the rated voltage MIN 360 RATED 400V MAX 440V It blocks the unit if the voltage is outside the limits provided for the condensation pressure inside the correct operating limits KBT Low temperature M Consisting of antifreeze electrical heaters for plate heat exchangers and oil crankcase heaters for compressors It is particularly suggested for outdoor insta
69. scribes the product according to the safety requirements It does not however repre sent a guarantee and assurance of the qualities in a legal sense Each person responds personally for compliance with such regulations 44 SAFETY AND POLLUTION First aid Move the victim away from the toxic source keep him warm and allow him to rest Administer oxygen if necessary Proceed with artificial respiration if necessary Give heart massage in the case of heart failure Immediately seek medical help Contact with the skin Immediately thaw the affected parts under running lukewarm water Remove contaminated clothing garments may stick to the skin in the case of ice burns if they have not adhered to the skin Seek medical assistance if necessary Contact with the eyes Immediately rinse the eyes with physiologic eyewash or clean water at least 10 minutes with the eyelids pulled open Seek medical assistance if necessary Swallowing Do not make the victim vomit If the victim is conscious have him rinse his mouth out with clean water and then drink 200 300 ml of water Immediately seek medical help Do not administer adrenaline or sympathomimetic drugs after exposure owing to the risk of cardiac arrhythmia For further information about the characteristics of the refrigerant consult the technical briefs that can be obtained from manufactu rers of refrigerant products
70. stione conforme alle prescrizioni delle Direttive DECLARACION CE DE CONFORMIDAD Quienes subscribimos la presente declaracion declaramos baio nuestra exclusiva responsabilidad que la maquina en objeto respeta lo prescrito par las Directivas DECLARAC O CE DE CONFORMIDADE N s signat rios da presente declaramos sob a nassa exclusiva responsabilidade que a m quina em quest o est em conformidade com as prescri es das Directrizes EG CONFORMITEITSVERKLARING Wij ondergetekenden verklaren hierbij op uitsluitend eigen verantwoording dat de bovengenoemde machine conform de voorschriften is van de Richtlijnen 2006 42 EC 97 23 2004 108 2006 95 3QE22170 rev 03 Thank you once again for your preference PL FERROLI S p A CE OVERENSSTEMMELSESERKLERING Underfegnede forsikrer under eget ansvar al den ovenneevnte maskine er i overensstemmelse med vilkarene i direktiveme FORSAKRAN OM CE OVERENSSTAMMELSE Underfecknade f rs krar under eget ansvar alt ovann mnda maskinskinen er i overensstemmelse med vilkarene i direktivene BEKREFTELSE OVERENSSTEMMELSE Underfegnede forsikrer under eget ansvar al den ovennevnte maskinen er overensstemmelse med vilkarene i direktivene CE VAATIMUSTENMUKAISUUSVAKUUTUS Allekirjoittaneet vakuutamme omalla vastuullamme ett yll mainittu kone noudattaa ehtoja direkti iveiss AHAQXH X
71. t affixed to the outer left hand side of the Electric Panel Modelo B A description of the data is given below cos B1 Standard versions se Trademark Coding B Model B1 Code Cooling Heating Serial number ho E w G D Cooling Capacity RIE norma H Heating Capacity Aimeniazone F Power input in COOLING mode l V Ph Hz G Power input in HEATING mode orent max JL H Reference standard DN Electric power supply wem M L Maximum load current Weight N Type of refrigerant and charge N Shipping weight of the unit O Sound pressure level at 1m and EI P IP Level Protection te Tile Q Maximum pressure High Side Max pressure Q MPa R rasta E R Maximum pressure Side iay A S PED certification authority S GENERAL SPECIFICATIONS Presentation of the unit This new series of industrial condenserless units has been designed to meet the demands of global markets in the small medium power industrial and commercial plants Units are compact and highly configurable built to fit different types of plants so to meet the needs of highly qualified engineers Units are only cooling IR suitable for indoor installation and if equipped with painted structure and panels option they are suitable for outdoor installation too This series is composed of 11 models and two sizes with nominal cooling capacity from 61 to 210 Kw The units produce cold water f
72. t protection Eye protection Hand protection Hygiene measures 9 CHEMICAL PHYSICAL PROPERTIES Relative density gas air 1 Solubility in water mg l Appearance Odour Fire point 10 STABILITY AND REACTIVITY Stability and reactivity Materials to be avoided Hazardous products of decomposition 11 TOXICOLOGICAL INFORMATION Local effects Long term toxicity Specific effects Ensure adequate ventilation especially in closed areas Difluoromethane R32 Recommended exposure limits AEL 8h and 12h TWA 1000 ml m3 Pentafluoroethane R125 Recommended exposure limits AEL 8h and 12h TWA 1000 ml m3 For rescue and for maintenance works in tanks use self contained breathing apparatus The vapours are heavier than air and can cause suffocation reducing the oxygen available for breathing Total protection glasses Rubber gloves Do not smoke Heavier than air Not known but deemed very low Colourless liquefied gas Similar to ether Does not ignite No decomposition if used according to the special instructions Alkali metals alkali earth metals granulated metal salts Al Zn Be etc in powder Halogen acids traces of carbonyl halides Concentrations substantially above the value TLV 1000 ppm can cause narcotic effects Inhalation of highly concentrated products of decomposition can cause respiratory insufficiency pulmonary oedema No carcinogenic teratogenic or mutagenic effects have been recorded i
73. the power cable that connects the unit to the distribution panel is not torn cracked or damaged in a way that could impair its insulation MAINTENANCE General considerations The machine has been designed with a view to reducing the risks to persons and the environment in which it is installed to the mi nimum To eliminate residue hazards it is therefore advisable to become as familiar as possible with the machine in order to avoid accidents that could cause injuries to persons and or damage to property a Access to the unit Only qualified persons who are familiar with this type of machine and who are equipped with the necessary safety protections fo otwear gloves helmet etc may be allowed to access the machine Moreover in order to operate these persons must have been authorized by the owner of the machine and be recognized by the actual Manufacturer b Elements of risk The machine has been designed and built so as not to create any condition of risk However residue hazards are impossible to elimi nate during the planning phase and are therefore listed in the following table along with the instructions about how to neutralize them Part in question Residue hazard Mode Precautions Compressor and delivery Burns Contact with the pipes and or com Avoid contact by wearing pipe pressor protective gloves Turn off the machine Delivery pipes check the high pressure switch Explosion Excessive pressure plant
74. ut 85 90 GM Pressure gauge unit M Consisting of 2 pressure gauges that display the pressure values of the refrigerant on the suction and discharge of the compressors AV Victaulic Connections F Consisting of 2 Victaulic brackets and 2 pipe Victaulic Welding CV Victaulic Elbows F Consisting of 2 brackets and 2 elbows Victaulic Victaulic Water valves F Consisting of 2 brackets and 2 water valves Victaulic to shut off the unit from the plant or from the source F Victaulic Water Filter F Consisting of 1 bracket and 1 Victaulic water filter of Y shape Can be turned on and off and inspected It prevents that machining residues dust swarf etc in the water pipes can enter into the plate type heat exchanger FLS Flow switch F Paddle flow switch on the water circuit to avoid the risk of freezing if the water flow is shut off for any reason For a quick connection to the unit the accessory is completed with grooved pipe on wich install the flow switch and victaulic bracket CR Remote control F This can be used to select all the monitoring and display functions of the control unit on the machine ata maximum distance of 100 meters away It must be installed by using a cable with three strands or three wires in PVC of the NO7 VK type with a 1mmz section The transmission line must be installed in a raceway separate from any electric powering wires 230 400 V The control unit has the following button
75. wie de vedan te el Rank Dice Ej eh ee ut raj 41 General corisiderations ns ss sk ka kona d ss Rte 42 SAFETY AND POL EU TION ete SEKAR E ER eten ele ki BUS DEOR le ei engin keeren A 43 General recommendations about the R410A refrigerant used oee eee 43 First AIG cT 45 GENERAL SPECIFICATIONS General specifications This manual and the wiring diagram supplied with the unit must be kept in a dry place and ready to hand for future consultation when required This manual has been compiled to ensure that the unit is installed in the correct way and to supply comprehensive information about how to correctly use and service the appliance Before proceeding with the installation phase please carefully read all the information in this manual which describes the procedures required to correctly install and use the unit Strictly comply with the instructions in this manual and conform to the current safety standards The appliance must be installed in accordance with the laws in force in the country in which the unit is installed Unauthorized tampering with the electrical and mechanical equipment will VOID THE WARRANTY Check the electrical specifications on the identification plate before making the electrical connections Read the instructions in the specific section where the electrical connections are described Ifthe unit must be rep
76. x1 9 2 11 12 9 14 7 16 6 18 4 20 2 22 1 23 9 25 8 27 6 52 28x1 5 5 6 6 77 88 9 9 10 9 12 113 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 8 22 9 24 25 1126 2127 3 8 35 15 3 6 43 5 5 8 6 5 7 2 7 9 86 94 10 1 10 8 11 5 12 2 13 13 7 14 4 15 1 15 8 16 6 17 3 18 18 7 19 4120 220 9 21 6 3 G 42x15 24 29 3 4 38 4 3 48 5 3 5 8 6 2 6 7 7 3 7 8 83 88 9 2 9 7 10 2 10 7 11 2 11 6 12 1 12 6 13 1 13 6 14 14 5 gt 54x1 5 4 3 4 6 4 9 5 2 5 4 5 7 6 63 66 68 7 73 7 6 7 8 8 1 8 5 Tab R1 factors for calculation of the equivalent length d ext mm 12 16 18 22 28 35 42 54 67 bend 90 standard 0 4 0 48 0 5 0 6 0 8 1 12 1 5 1 7 bend 90 wide radius 0 3 0 3 0 3 0 4 0 5 0 7 0 8 1 1 2 elbow a 90 0 7 0 76 0 8 1 1 2 1 7 1 9 2 5 2 9 bend a 45 0 2 0 24 0 28 0 3 0 4 0 5 0 6 0 8 0 97 elbow a 45 0 3 0 4 0 4 0 5 0 6 0 9 1 1 4 1 6 bend a 180 0 7 0 76 0 8 1 1 2 1 7 1 9 2 5 2 9 siphon 2 8 3 3 2 4 4 8 6 8 7 6 10 11 6 TEE 0 3 0 3 0 3 0 4 0 5 0 7 0 8 1 1 2 TEE with reduction 0 4 0 48 0 5 0 6 0 8 1 1 2 1 5 1 8 29 REFRIGERANT CONNECTIONS discharge line Slope 2 3 Remote Condenserless unit Condenser 15 2 BOTTOM LEVEL discharge line Slope 2 3 Condenserless unit gt 6m H valvola NR Additional liquid receiver Remote Condenser Fig 3 BOTTOM LEVEL

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