Robur GAHP-W Installation, Use And Maintenance Manual
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Robur GAHP-W Installation, Use And Maintenance Manual

Gahp line w and w lb series absorption heat pump for heating and cooling medium-large areas
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Installation, use and
maintenance manual
GAHP Line W and W LB Series
Absorption heat pump
for heating and cooling medium-large areas
Fired by natural gas fired/LPG and renewable energy

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Summary of Contents for Robur GAHP-W

  • Page 1 Installation, use and maintenance manual GAHP Line W and W LB Series Absorption heat pump for heating and cooling medium-large areas Fired by natural gas fired/LPG and renewable energy...
  • Page 2 GAHP-W – Installation, start-up, use and maintenance manual EDITION: 2014-08 CODE: D-LBR367 This manual was written and printed by Robur Corporation; part or total reproduction of this manual is prohibited. The original is filed in Robur Corporation. Any use of this manual other than for personal consultation must be previously authorized by Robur Corporation.

  • Page 3: Table Of Contents

    3.2 OPERATION OF THE APPLIANCE THROUGH R-W-Y CONTACTS ON THE ELECTRONIC BOARD (WITHOUT ROBUR OPTIONAL DIRECT DIGITAL CONTROLLER - DDC) 3.3 OPERATION OF THE APPLIANCE THROUGH ROBUR DIRECT DIGITAL CONTROLLER (DDC) 3.4 OPERATION OF THE GAHP-W AND W-LB SECTION 4 END USER ....................47 4.1 STARTING AND SHUTTING DOWN OF THE APPLIANCE...
  • Page 4 GAHP-W – Installation, start-up, use and maintenance manual PREFACE This manual supplies information for the installation, operation and servicing of the Robur Water-Water Gas Absorption Heat Pump GAHP-W and the Robur Water-Water Gas Absorption Heat Pump GAHP-W LB. It is strongly recommended that this manual be completely reviewed before proceeding with an installation.

  • Page 5: Section 1 Warnings

    Warnings SECTION 1 WARNINGS This manual is designed to be an installation and user’s guide for the Robur GAHP- W, Gas Absorption Heat Pumps series.This product must be installed, started up and serviced by a qualified installer. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
  • Page 6 GAHP-W – Installation, start-up, use and maintenance manual manufacturer does not accept any contractual or extra-contractual liability for any damage caused by improper use of the appliance. The appliance is not intended to be used by persons (including children) whose...
  • Page 7 Warnings FIRE HAZARD The appliance contains hot parts. Do not open the appliance or touch the flue outlet pipe. If necessary, contact a qualified service company. The appliance has a sealed circuit classified as pressure equipment, i.e. with internal pressure higher than atmospheric pressure. The fluids contained in the sealed circuits are harmful if swallowed or inhaled, or if they come into contact with the skin.
  • Page 8 GAHP-W – Installation, start-up, use and maintenance manual Edition: 2014-08...

  • Page 9: Section 2 Overview And Technical Specifications

    It can be used for heating, cooling and DHW production. • GAHP-W LB: this is a also a water-to-water gas fired absorption heat pump which has been designed to recover thermal energy from the ground through geothermal piping (not supplied) either vertically or horizontally.

  • Page 10: Gahp-W - Technical Specifications

    (1) ALL ILLUSTRATIONS AND SPECIFICATIONS CONTAINED HEREIN ARE BASED ON THE LATEST INFORMATION AVAILABLE AT THE TIME OF PUBLICATION APPROVAL. ROBUR RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE, IN MATERIALS, SPECIFICATIONS, AND MODELS OR TO DISCONTINUE MODELS.
  • Page 11 138.8 137.0 86.0 142.6 141.6 140.7 139.7 138.8 137.2 Table 3 GAHP-W heating capacity. DT is the difference between outlet and inlet temperature. GAHP-W CHILLING CAPACITY - kBtu/hr HOT WATER INLET TEMPERATURE CHILLED 77.0 86.0 95.0 104.0 113.0 113.0 WATER INLET...
  • Page 12 130.7 130.7 133.8 133.8 133.5 132.9 132.5 132.5 Table 5 GAHP-W LB heating capacity. DT is the difference between outlet and inlet temperature. GAHP-W LB CHILLING CAPACITY - kBtu/hr HOT WATER INLET TEMPERATURE CHILLED 77.0 86.0 95.0 104.0 113.0 113.0...
  • Page 13 27.00 21.00 15.00 86.0 °F Outlet 9.00 104.0 °F Outlet 122.0 °F Outlet 3.00 6.00 9.00 12.00 15.00 18.00 21.00 WATER FLOW - GPM Graph 1 GAHP-W, GAHP-W LB pressure drop – heating mode (see on page 62). Ed. 2014-08...

  • Page 14: Codes

    18.00 WATER FLOW - GPM Graph 3 GAHP-W LB pressure drop – chilling mode (see on page 62). 2.2 CODES The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These regulations shall be carefully followed in all cases.

  • Page 15: Location Of The Appliance

    The unit shall be installed such that the gas ignition system components are protected from water during operation and service. When vented vertically, the GAHP-W and GAHP-W LB units must be located as close as practical to a chimney or outside wall. If the vent terminal and/or combustion air terminal...

  • Page 16: Gahp-W And Gahp-W Lb Dimensions

    GAHP-W – Installation, start-up, use and maintenance manual 2.4 GAHP-W AND GAHP-W LB DIMENSIONS Figure 1 – GAHP-W and GAHP-W LB external dimensions. Edition: 2014-08...

  • Page 17: Placing Of The Appliance

    E – SAFETY VALVE CONNECTION " " Figure 2 – GAHP-W and GAHP-W LB connection dimensions. 2.5 PLACING OF THE APPLIANCE Do not remove packaging during handling on the installation site. Packing must only be removed upon final installation. If the appliance has to be lifted, pass slings into the openings in the base supports and use spreader bars to prevent the slings from damaging the casing during handling.
  • Page 18 GAHP-W – Installation, start-up, use and maintenance manual REQUIRED CLEARANCES FROM COMBUSTIBLE MATERIALS AND FOR SERVICE ACCESS. UNIT FRONT SIDE 18" 18" UNIT FRONT SIDE UNIT FRONT SIDE 18" 18" 18" Figure 3 - Minimum clearances; single unit installation and multiple unit installation.

  • Page 19: Venting And Combustion Air

    (CSA B149.1) must be followed. In all cases any and all applicable local installation codes must also be followed. GAHP-W and GAHP-W LB UNITS MUST receive combustion air from the space in which it is installed. The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.
  • Page 20 GAHP-W – Installation, start-up, use and maintenance manual Each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr. Figure 5 Air taken from another interior space, each of the two openings specified below should...
  • Page 21 The appliance shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel. Robur heat pumps GAHP-W and W LB are classified as a Category III appliances per CSA equipment approvals and must be installed in accordance to International and local codes that apply to Category III appliances.
  • Page 22 Table 11 - VENTING PRESSURE DROPS When the Robur GAHP-W and W LB units are vented with a horizontal discharge, it must be installed per this installation manual and the venting system manufacturer’s installation instructions. The vent system must be sealed stainless steel, per Table 12.
  • Page 23 Horizontal runs must slope downwards not less than ¼ inch per foot from the unit to the vent terminal. Robur GAHP-W and W LB units are not allowed to be vented into a common horizontal vent system, unless the common vent system is properly designed by the vent manufacturer or a qualified engineer.
  • Page 24 GAHP-W – Installation, start-up, use and maintenance manual VENT TERMINAL The terminal Must be located in accordance with ANSI Z223.1/NFPA 54 and applicable local codes. In Canada, the installation must be in accordance with CSA B149.1 and local applicable codes.
  • Page 25 Overview and technical specifacions Figure 8 INSTALLATION OF CARBON MONOXIDE DETECTORS The installing contractor shall observe that a hard-wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.

  • Page 26: Gas Supply And Piping

    Verify that the appliance is fitted for the proper type of gas by checking the rating plate. Robur GAHP-W and W LB units are designed to operate with either natural gas or L.P.G.
  • Page 27 Overview and technical specifacions The appliance and its gas connection must be leak tested before placing it in operation. Purge all air from gas lines. Do not use an open flame to check for leaks. An open flame could lead to explosion, which could result in property damage, serious injury or death.
  • Page 28 GAHP-W – Installation, start-up, use and maintenance manual MANIFOLD GAS PRESSURE ADJUSTMENT PROCEDURE Ensure that all air is properly bled from the gas line before starting the ignition sequence. Start-up without properly bleeding air from the gas line may require multiple reset functions of the ignition control module to achieve proper ignition.

  • Page 29: Water Connections

    Permanent inhibited antifreeze/glycol must be added to the hydronic loop. A minimum 10% concentration is required in all regions. Robur recommends the use of permenantlyinhibited propylene glycol. Maintaining the level of inhibitor in the glycol is also required and must be checked annually.
  • Page 30 GAHP-W – Installation, start-up, use and maintenance manual PROPYLENE GLYCOL CAPACITY CORRECTION FACTOR TABLE Percent Propylene Glycol Approximate Freezing Point In °F 25° 21° 17° 11° 5° 0° -10° Capacity Factor Multiplier * 0.98 0.96 0.95 0.93 0.92 0.91 0.89 Pressure Drop Multiplier ** 1.08...
  • Page 31 Overview and technical specifacions EXAMPLE OF TYPICAL HYDRAULIC PLANT SCHEME FOR GAHP-W APPLIANCE Figure 11 - Example of hydraulic plant diagram for GAHP-W connection Ed. 2014-08...
  • Page 32 GAHP-W – Installation, start-up, use and maintenance manual The appliance is not equipped with any expansion tank. It is necessary to install a properly sized expansion tank. The water pumps must be installed on the inlet (to the unit) water line.

  • Page 33: Ducting Of The Safety Valve

    Phone (812) 424-1800; Fax (812) 422-5117. 2.9 DUCTING OF THE SAFETY VALVE As the Robur GAHP-W and W LB units are intended for indoor installation only, it is mandatory to duct to the outdoors the safety valve in order to prevent dangerous situations inside the room.
  • Page 34 GAHP-W – Installation, start-up, use and maintenance manual Connect the ducting system to hole E (see Figure 2 at page 15) on the top panel of the unit. Do not install any valve in the ducting system. The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by improper installation of the ducting system.

  • Page 35: Section 3 Electrical Connections

    Canada. Do not rely on the gas or water piping to ground the metal parts of the Robur GAHP units. Plastic pipe or dielectric unions may isolate the Robur GAHP electrically. Service and maintenance personnel, who work on or around the unit, may be standing on wet floors and could be electrocuted by an ungrounded unit.

  • Page 36: S61 And Robur Electrical Diagram Key

    GAHP-W – Installation, start-up, use and maintenance manual 3.1 S61 AND ROBUR ELECTRICAL DIAGRAM KEY S61 electronic control board key Figure 13 - S61 electronic control board key. TOP EDGE BOTTOM EDGE OUTLET WATER TEMPERATURE FAN MOTOR ELECTRICAL SUPPLY THMF...
  • Page 37 Electrical connections Figure 14 - Internal electrical wiring diagram...
  • Page 38 GAHP-W – Installation, start-up, use and maintenance manual Robur electric diagram key SYMBOL DESCRIPTION Heating on-off switch (24 V out) Cooling on-off switch Not used (24 V out) Hot 230V Hot wire Neutral Wire GROUND Ground Capacitor Fuse On-off switch...

  • Page 39: Operation Of The Appliance Through R-W-Y Contacts On The Electronic Board (Without Robur Optional Direct Digital Controller - Ddc)

    Electrical connections 3.2 OPERATION OF THE APPLIANCE THROUGH R-W-Y CONTACTS ON THE ELECTRONIC BOARD (WITHOUT ROBUR OPTIONAL DIRECT DIGITAL CONTROLLER - DDC) Before doing any electrical connection, make sure that the unit is not powered. Do not switch on and off the unit using the main switch indicated with the symbol GS in Figure 15.
  • Page 40 GAHP-W – Installation, start-up, use and maintenance manual The operations mentioned above are not necessary if a Direct Digital Controller (DDC) is installed. The on-off signal comes directly from the DDC. Figure 16 - On-off switch connection. Connect the heating and cooling water pumps.
  • Page 41 Electrical connections • If the electrical consumption of each water pump (heating and cooling) is higher than 4A, the pumps must be connected using two relays. PY is the cooling water pump, R2 is the cooling pump relay. PW is the heating water pump, R1 is the heating pump relay. Open the jumpers J10.

  • Page 42: Operation Of The Appliance Through Robur Direct Digital Controller (Ddc)

    GAHP-W GAHP-W GAHP-W Figure 20 - Examples of CAN-bus connections One DDC can control and up to 16 GAHP-W and W-LB units. On the same CAN-bus line it is possible to connect up to three DDC’s (48 units Edition: 2014-08...
  • Page 43 CAN-bus cable specifications The CAN bus cable must meet the Honeywell SDS standard. The installation of a cable which is not compliant with the Robur specifications will void the manufacturer’s warranty. Below is a table listing the cable types which meet the Robur specifications.
  • Page 44 GAHP-W – Installation, start-up, use and maintenance manual Common signal LOW signal HIGH signal CAN BUS jumpers J1 “Terminal” node configuration - 3 wires - J1 closed “Intermediate” node configuration - 6 wires - J1 open Figure 21 - CAN-bus connection...
  • Page 45 Electrical connections • If the appliance is an “intermediate node”, connect the cable as shown in Figure 26. Respect to the sequence L, H, GND. Open jumpers J1. Fix the CAN bus cable to the clamp as indicate in Figure 24 letter C. Figure 23 - CAN-bus Connector supplied with the DDC Insulating tape protecting CAN bus cable shield...

  • Page 46: Operation Of The Gahp-W And W-Lb

    • the appliance is fitted for the proper type of gas by checking the rating plate. Robur GAHP-W and W LB units are designed to operate with either natural gas or L.P.G.
  • Page 47 Do not operate the Robur GAHP-W units if any electrical or safety components have been removed, by-passed or are not operatingdo not function correctly. The start up of the Robur GAHP-W units can only be performed by a Robur Corporation authorized service or installing Company. The guidelines provided by the manufacturer must be followed.
  • Page 48 Once the shut-down cycle is over, the cooling water pump stays on while the heating water pump stops. No priority (mode not available with the DDC): Robur unit operates whether there is a cooling or heating demand. The goals are both the cooling and the heating water set- point and the unit stops when one of them is satisfied.

  • Page 49: Section 4 End User

    End user SECTION 4 END USER 4.1 STARTING AND SHUTTING DOWN OF THE APPLIANCE Refer to the Direct Digital Controller (DDC) manual, if the appliance is controlled by a DDC. In this case it is possible to switch on and shut down the unit only through the DDC.

  • Page 50: Long Inactivity Period

    GAHP-W – Installation, start-up, use and maintenance manual If the error persists, contact an authorized Robur Service Company. c. If the ignition does not fail, the unit should be in normal operation. Switch off the appliance though the DDC (if present) or through the on/off switch connected to the electronic board (S61).
  • Page 51 End user Electronic Control Board S 61 A 4 digit DISPLAY for data and codes visualization B KNOB (encoder) to scroll/select operating data C CAN PORT for the CAN-BUS cable connection Figure 27 – S61 control board W10 that controls the heating water pump. W10 peripheral board Figure 28 –...
  • Page 52 GAHP-W – Installation, start-up, use and maintenance manual outlet cold water temperature, inlet cold water temperature, cold water ∆T outlet hot water temperature, inlet hot water temperature, hot water ∆T Example: INLET COLD WATER TEMPERATURE OUTLET COLD WATER TEMPERATURE COLD WATER ∆T...

  • Page 53: Reset

    End user 4.4 RESET In order to reset warning or error messages it is necessary to enter menu 2 of the S61 board and choose the right number. DESCRIPTION DISPLAY PARAMETER IGNITION CONTROL BOX RESET (E212) OTHER WARNINGS/ERRORS RESET EXIT Table 23 - Menu for reset operations In the electronic board main menu, press and rotate the encoder till the display...
  • Page 54 GAHP-W – Installation, start-up, use and maintenance manual HYDRAULIC PARAMETERDESCRIPTION DISPLAY COLD WATER TEMPERATURE THERMOSTAT CONTROLSELECT COLD WATER THERMOSTATING COLD WATER SET-POINT COLD WATER TEMPERATURE DIFFERENTIAL HOT WATER TEMPERATURE THERMOSTAT CONTROLSELECT HOT WATER THERMOSTATING HOT WATER SET-POINT HOT WATER TEMPERATURE DIFFERENTIAL...

  • Page 55: Unit Start Up

    START UP PROCEDURE • Check that the appliance is fitted for the proper type of gas operation by checking the rating plate. Robur GAHP-W and W LB are designed to operate with either natural gas or LPG. • Check the static gas pressure in the pipeline.
  • Page 56 GAHP-W – Installation, start-up, use and maintenance manual • Check the water pressure in the water loop. • Power on both the unit and the DDC (if present). • Set the priority/operating mode (see page 45). • Check for water leaks.

  • Page 57: Maintenance

    The static pipeline gas pressure does not comply with the Robur specifications ‐ indicated in the Robur Installation Manual (see Table 13 on page 25) and data plate. The dynamic pipeline gas pressure does not comply with the Robur specifications ‐...

  • Page 58: Change Of Gas Type

    Inspect the belt for proper belt tension, alignment or wear. Replace the beltsand pulleys after 6 years or 12,000 operation hours Check the combustion chamber and burner inside the Robur units for obstruction or leakage. Replace burner gaskets if neccesary.
  • Page 59 If the problem persists contact an authorized Robur Service Company. E 200 – Error 200 Problems in the reset circuit of the ignition control box. Switch off the power of the unit. If the problem persists contact an authorized Robur Service Company. W/E 201 – Warning or Error 201 High generator temperature.
  • Page 60 Ambient temperature lower than operational limit. W/E 207 – Warning and Error 207 High rectifier temperature. If the problem persists contact an authorized Robur Service Company. E 208 – Error 208 Burner “on” with the ignition control box locked. If the problem persists contact an authorized Robur Service Company.
  • Page 61 End user E 220 – Error 220 Rectifier temperature probe defective. If the problem persists contact an authorized Robur Service Company. E 228 – Error 228 Gas valve “on” when the ignition control box is locked. If the problem persists contact an authorized Robur Service Company.
  • Page 62 GAHP-W – Installation, start-up, use and maintenance manual Insufficient hot water flow. If the problem persists contact an authorized Robur Service Company. E 276 – Error 276 Outlet hot water temperature probe defective. If the problem persists contact an authorized Robur Service Company.

  • Page 63: Operating Codes - Troubleshooting (Firmware Release 3.023)

    Appendix A APPENDIX A IGNITION CONTROL BOX When power is supplied to the unit (to the “R” terminal on the ignition control box), ignition control will reset, perform a self check routine, flash the diagnostic LED, and enter thermostat scan state. When the control switch is closed, the electronic control board will energize the ignition control box starting the ignition sequence (24 volts applied to the “W”...
  • Page 64 GAHP-W – Installation, start-up, use and maintenance manual FC± DIAGNOSTIC LED “W” TERMINAL “R” TERMINAL Figure 31 - Ignition control box. Edition: 2014-08...
  • Page 68 Robur is dedicated to dynamic progression in research, devepment and promotion of safe, environmentally-friendly, energy-efficiency products, through the commitment and caring of its employees and partners Robur Mission Robur Corporation advanced heating and cooling technologies 827 E. Franklin Street Evansville, Indiana 47711 USA P (812) 424 1800 F (812) 422 511 7 www.robur.com/us...

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