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Potterton A-Cubed Installation, User And Maintenance Manual

Gas absorption heat pump
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August 2010
A-Cubed
Gas absorption heat pump
Installation, user and maintenance manual
Working towards
a cleaner future

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Summary of Contents for Potterton A-Cubed

  • Page 1 This manual must be kept with the appliance August 2010 A-Cubed Gas absorption heat pump Installation, user and maintenance manual Working towards a cleaner future...
  • Page 2 Revision: A This manual has been drawn up and printed by Potterton Commercial; whole or partial reproduction of this manual is prohibited. The original is fi led at Potterton Commercial. Any use of this manual other than for personal consultation must be previously authorised by Potterton Commercial.

  • Page 3: Table Of Contents

    Installation, user and maintenance manual – GAHP-A INDEX OF CONTENTS PREFACE ......................5 OVERVIEW AND TECHNICAL CHARACTERISTICS .........7 WARNINGS ....................................... 7 NOTES ON OPERATION OF THE APPLIANCE ........................10 TECHNICAL MANUFACTURING CHARACTERISTICS......................10 TECHNICAL DATA ..................................11 DIMENSIONS AND SERVICE PANEL ............................12 NORMAL OPERATION ..................15 START UP (AND SHUT DOWN) ..............................15 ON-BOARD ELECTRONICS ................................17 RESET OPERATIONS AND MANUAL DEFROSTING ......................19...

  • Page 5: Preface

    SECTION 5 is intended for use by the electrical installation technician; it provides the information required to hook up the appliance electrically. SECTION 6 is intended for use by the Potterton Commercial Commissioned Engineer; it provides the indications necessary to carry out the entire initial activation procedure (preliminary verifi cation of plant compliance, initial activation, and regulation of gas fl ow to the burners) and instructions on how to change the gas type, if required.
  • Page 6 Defi nitions, terms and icons APPLIANCE: this term refers to the A-Cubed Air-Water gas absorption heat pump "GAHP-A". CCP: "Comfort Control Panel". CCI: "Comfort Control Interface" device. DDC: digital control panel (Direct Digital Controller). The icons present in the margin of the manual have the following meanings:...

  • Page 7: Overview And Technical Characteristics

    Installation, user and maintenance manual – GAHP-A OVERVIEW AND TECHNICAL CHARACTERISTICS In this section, for all users, you will fi nd general warnings, the operating principle of the appliance and its manufacturing characteristics. This section also contains technical data and dimensional drawings of the appliance. WARNINGS This manual constitutes an integral and essential part of the product and must be delivered to the user together with the appliance.
  • Page 8 Potterton Commercial. Before contacting Potterton Commercial to arrange commissioning: • the electricity and gas mains specifi cations correspond to the specifi cations on the nameplate;...
  • Page 9 Commissioning The entire procedure for commissioning the appliance must be carried out exclusively by Potterton Commercial and according to the instructions supplied by the manufacturer. To carry out the entire procedure correctly, follow the instructions in Section 6.1 PROCEDURE FOR INITIAL ACTIVATION on page 59.

  • Page 10: Notes On Operation Of The Appliance

    Commercial Engineer or qualifi ed technician; for other maintenance requirements, see Section 6.2 MAINTENANCE on page 61. Any repair of the appliance must be carried out by an authorised Potterton Commercial Engineer, using only original parts. Failure to observe the indications given above may compromise the operation and safety of the appliance, and may invalidate its guarantee, if active.

  • Page 11: Technical Data

    Installation, user and maintenance manual – GAHP-A Control and safety components • S61 controller with integrated microprocessor and LCD display and control knob, complete with "Mod10" supplementary combustion modulation controller (see Figure 5.1 Electronic board S61 on page 37 and Figure 5.2 Mod10 controller on page 39).

  • Page 12: Dimensions And Service Panel

    GAHP-A HT GAHP-A HT S TYPE Gas fi tting thread " G Size Fume outlet Residual head Maximum condensation water fl ow rate width 848 (6) Size height 1281 (6) 1537 (6) depth 1258 Weight In operation GENERAL INFORMATION INSTALLATION MODE B23P, B33, B53P AMMONIA R717 COOLING FLUID...
  • Page 13 Installation, user and maintenance manual – GAHP-A Figure 2.2 – Size Front and side views (dimensions in mm). Figure 2.3 – Service plate LEGEND Gas fi tting Ø ¾” F Inlet water fi tting Ø 1¼” F Outlet water fi tting Ø 1¼” F Hydraulic/gas unions detail...

  • Page 15: Normal Operation

    Installation, user and maintenance manual – GAHP-A NORMAL OPERATION In this section you will fi nd all the indications necessary for the activation, regulation and control of operation of the appliance depending on the type of installation and control setup. •...
  • Page 16 MANUAL DEFROSTINGon page 19. After it is reset, the appliance will make a new attempt to activate. If the appliance locks out several times, contact a Potterton Commercial Engineer by calling the Technical Department of Potterton (tel. 0845 070 1057).

  • Page 17: On-Board Electronics

    Installation, user and maintenance manual – GAHP-A ON-BOARD ELECTRONICS The following descriptions refer to the S61 controller with fi rmware version 3.016. The appliance is fi tted with an S61 microprocessor controller with Mod10 combustion modulation controller mounted above it (see Figure 3.1 On-board controller on page 17).
  • Page 18 In any case, to set new values for the parameters, see Section 4.8 PROGRAMMING OF HYDRAULIC PARAMETERS on page 34. Menus 4, 5, 6 and 7 exclusively concern the installation technician and Potterton Commercial Engineer. Menu 8 may currently be selected, but not used.

  • Page 19: Reset Operations And Manual Defrosting

    19. To set the parameters of me nu 3, refer to Section 4.8 PROGRAMMING OF HYDRAULIC PARAMETERS on page 34. The other menus are not for the User: the information in these menus is dealt with in the sections dedicated to the installation technician or Potterton Commercial Technical Department.
  • Page 20 "23", "24" and "25" are used to regulate the combustion parameters or for gas type changeovers, and are thus for use only by the installation technician or Potterton Commercial Technical Department (for other information refer to Section 6.1 PROCEDURE FOR INITIAL ACTIVATION on page 57).

  • Page 21: Operating Settings

    Installation, user and maintenance manual – GAHP-A To reset the controller errors, select menu 2, as indicated in the Section "Accessing the Menus"; Then: 1. The display shows: "2." press the knob to access the menu. The display initially shows item "2. 20". 2.

  • Page 22: Prolonged Periods Of Disuse

    PROLONGED PERIODS OF DISUSE When the appliance is to be inactive for a long period, it is necessary to disconnect the appliance before the period of disuse and reconnect it before it is used again. To carry out these operations, contact a reputable hydraulic system installation technician.
  • Page 23 Before starting this procedure, the hydraulic system installation technician must: • ascertain whether the appliance requires any maintenance operations (contact Potterton Commercial Technical Department or consult Section 6.2 MAINTENANCE on page 61); • fi ll the hydraulic circuit if it has been emptied, carrying out the instructions given in Section 4.6 FILLING OF HYDRAULIC CIRCUIT on page 32;...

  • Page 25: Hydraulic System Installation Technician

    Installation, user and maintenance manual – GAHP-A HYDRAULIC SYSTEM INSTALLATION TECHNICIAN In this section you will fi nd all the instructions necessary for installing the appliance from a hydraulic viewpoint. Before proceeding with operations to create the hydraulic and gas supply plant of the appliance, the professionally qualifi ed personnel concerned are advised to read Section 2.1 WARNINGS on page 7: it provides important information regarding installation safety and references to current regulations.
  • Page 26 If the appliance has to be lifted, connect braces to the openings provided on the base bar, and use suspension and spacer bars to prevent these braces from damaging the panels during moving operations (see Figure 4.1 Instruction for lifting on page 26). The lifting crane and all accessory devices (braces, cables, bars) must be suitable sized for the load to be lifted.
  • Page 27 Installation, user and maintenance manual – GAHP-A “uncontrolled” spread of water around the appliance and the consequent risk that a layer of ice will form (with the danger of falls on the part of passing people). The manufacturer may not be held responsible for any damage arising from the failure to observe this warning.

  • Page 28: Hydraulic Connections

    Figure 4.2 – Clearances Position the appliance preferably out of range of rooms and/or environments where strict silence is required, such as bedrooms, meeting rooms, etc. Evaluate the acoustic impact of the appliance on the basis of the installation site: avoid locating the appliance in positions (corners of buildings, etc.) that could amplify the noise it produces (reverb eff ect).
  • Page 29 Please make sure the pipes are properly fl ushed in order to remove any residue of chemical substances from the pipes. Potterton Commercial is not liable for ensuring that water quality is always compliant with what reported in Table 4.1 Chemical and physical parameters of water on page 29.

  • Page 30: Gas Supply

    The operations necessary for commissioning the appliance must be carried out exclusively by Potterton Commercial. These operations are described in Section 6 INITIAL ACTIVATION AND MAINTENANCE on page 57. The products' warranty is void if commissioning is not carried out by a Potterton Commercial Engineer. GAS SUPPLY SYSTEM The installation of gas supply pipes must be carried out in compliance with current regulations in force.

  • Page 31: Condensate Discharge Connection

    Installation, user and maintenance manual – GAHP-A Vertical gas pipes must be equipped with a siphon and provided with a drain for the con- densate that may form inside the pipe during cold periods. It may also be necessary to insulate the gas pipe to prevent the formation of excessive condensate.

  • Page 32: Filling Of Hydraulic Circuit

    • implemented with material capable of resisting a degree of acidity equal to 3 - 5 • sized to ensure a slope of 10mm per metre of length; if this slope cannot be achieved, a condensate pump (available as an accessory) must be installed near to the discharge - see Section 7 ACCESSORIES on page 65;...

  • Page 33: Flue Information

    Installation, user and maintenance manual – GAHP-A control the pH of the solution. A necessary condition for the oxidisation of the glycol, and therefore its degradation, is the presence of an oxidising agent such as oxygen. In closed circuits in which there is no replenishment of water, and therefore of oxygen, occurs over the course of time, once the oxygen initially present has reacted, the degenerative phenomenon of glycol is hugely inhibited.

  • Page 34: Programming Of Hydraulic Parameters

    The exhaust air duct installation kit consists of (see Figure 4.4 Fume outlet on page 34): • n. 1 exhaust air pipe Ø 80mm (length 300 mm) with terminal; • n. 1 rain cover; • n. 1 curve 90° Ø 80 mm. To assemble and fi t the external exhaust fumes installation kit, proceed as follows: You will need: the appliance positioned in its installation site (refer to Figure 4.4 Fume outlet on page 34).
  • Page 35 Installation, user and maintenance manual – GAHP-A Table 4.3 – Menu 3 parameters HYDRAULIC PARAMETER THE DISPLAY SHOWS Hot water thermostat control selection 3.160 Hot water setpoint 3.161 Hot water temperature diff erential 3.162 (EXIT MENU) 3. E Description of parameters: •...
  • Page 36 3. For example, to set parameter 161 (hot water set-point), proceed as follows: · Select the parameter: turn the knob until the display shows 3.161; · Press the knob to access the value of the parameter; the display shows the previously set value, which fl ashes, for example 40.0 °C;...

  • Page 37: Electrical System Installation Technician

    Installation that is incorrect or that does not comply with current legislation may cause damage to people, animals or the appliance; Potterton Commercial is not responsible for any damage caused by installation that is incorrect or that does not comply with current legislation.
  • Page 38 Table 5.1 – Electronic board S61 CODE DESCRIPTION SCH1 Electronic board S61 SCH3 Mod10 electronic controller (see fi gure for further details) A1, A2 Auxiliary inputs Knob Fuse T 2A Fuse F 10A Fuse T 2A Fuse T 3.15A FAN (BK, WH, BR) Fan output water fl ow switch input (GAHP-A) FS5 (24V AC)
  • Page 39 Installation, user and maintenance manual – GAHP-A Figure 5.2 – Mod10 controller LEGEND HFLOW Not used CFLOW Not used SPI connector HPMP Primary circuit hot water pump control output (0-10 V) [E3 A/GS/WS] CPMP Cold side water pump control output [E3 GS/WS] NC1-C1 Status indication of locking warnig/error...

  • Page 40: Electrical Diagrams Of The Appliance

    ELECTRICAL DIAGRAMS OF THE APPLIANCE Figure 5.4 – Appliance internal wiring diagram...

  • Page 41: How To Connect The Appliance Electrically

    Installation, user and maintenance manual – GAHP-A HOW TO CONNECT THE APPLIANCE ELECTRICALLY Before making the electrical connections, make sure that work is not carried out on live elements. You will need: the appliance in its permanent location. 1. Prepare a cable of the FG7(O)R 3Gx1.5 type for the power supply to the appliance. 2.
  • Page 42 Table 5.2 – CAN BUS cables type CABLE NAME SIGNAL / COLOR MAX LENGTH Note Potterton Ordering Code O-CVO008 POTTERTON NETBUS H= BLACK L= WHITE GND= BROWN 450 m Honeywell SDS 1620 BELDEN 3086A H= BLACK...
  • Page 43 Table 5.2 CAN BUS cables type on page 42 and cut the remaining ones. The POTTERTON NETBUS cable is available as an accessory, see Section 7 ACCESSORIES on page 65. How to connect the CAN BUS cable to the appliance's controller The CAN BUS cable must be connected to the special socket on the machine’s on-board...
  • Page 44 6. If the appliance is an intermediate node repeat the operations from step 2 to step 5 for the other length of cable required. As shown in Detail "B" of fi gure 5.8. 7. Fix the CAN bus cable (or two cables, according to the type of node being connected) to the cable fi xing bracket in the upper part of the inside of the electrical panel so that the rolled-back sheathing makes solid contact with the metal bracket.
  • Page 45 Installation, user and maintenance manual – GAHP-A To connect the CAN bus cable to a DDC: You will need: DDC to be electrically isolated. 1. Depending on the type of node being confi gured, set the DDC's jumpers J21 as shown in detail "A" or detail "B" in Figure 5.10 detail wires and jumpers J21 - terminal/intermediate node DDC on page 46.
  • Page 46 Figure 5.9 – Connection from CAN BUS to connector P8 LEGEND Insulating tape to protect board/shield CAN BUS cable wires CAN bus cable shield terminal and screw for fi xing Connection detail of cable CAN BUS. Figure 5.10 – detail wires and jumpers J21 - terminal/intermediate node DDC LEGEND Direct Digital Control Jumper CAN-BUS in DDC board...
  • Page 47 The DDC is equipped with a backup battery which retains the memory settings in case of power failure. The backup battery lasts approximately 7 years, after which time it must be replaced by an authorised Potterton Commercial Technical Engineer. Figure 5.11 – DDC - electric supply...
  • Page 48 Figure 5.12 – Connection cable CAN BUS for plants with one unit LEGEND direct digital control electronic board S61 Jumper CAN-BUS in board S61 Jumper CAN-BUS in board DDC terminal nodes connection - (3 wires; J1 e J21 = "closed") H,L,GND data signal wires (rif.
  • Page 49 Installation, user and maintenance manual – GAHP-A Figure 5.13 – Connection cable CAN BUS for plants with more unit Connexion cable CAN BUS between one DDC and more unit How to connect the plant water circulation pump It is possible to control the pump of the plant either from the appliance's controller or independently.
  • Page 50 Controlling the pump from the appliance's controller Control of the plant water circulation pump from the appliance's controller depends on the power rating of the pump itself. 2 cases may be distinguished: • Direct control from the controller with power absorbed by the pump less than 700 W.
  • Page 51 Installation, user and maintenance manual – GAHP-A Figure 5.15 – Electrical wiring diagram LEGEND electronic board terminal board jumper open N.O. CONTACT clean exit normally open phase neutral Component NOT SUPPLIED ON/OFF control switch water pump =700W control pump relay general switch Example of pump/appliance electrical connection with 230 Vac pump (with absorbed power equal or more than 700 W), controlled directly by the appliance through a relay...
  • Page 52 Figure 5.16 – Electrical wiring diagram Example of pump/appliance electrical connection with 230 Vac pump, controlled directly by the appliance through a relay and a SELV safety transformer Independent control of the pumps If it is intended to manage the operation of the plant water circulation pump separately, it is necessary to provide a delayed relay, with a de-excitation time of 10 minutes: after...

  • Page 53: Type C (Consent Switch)

    Installation, user and maintenance manual – GAHP-A the opening of the appliance's consent switch contacts, the circulation pump will thus continue to circulate the water in the plant for a further 10 minutes, thereby ensuring the complete dispersal of the heating energy produced. When the pump is controlled by the appliance's controller, this delay is automati cally applied by the board.

  • Page 54: How To Remotely Control The Flame Controller Reset

    How to connect the plant water circulation pump For how to connect the system pumps, see the section with this title in Section 5.3 TYPE B (DDC) on page 41. HOW TO REMOTELY FLAME CONTROLLER RESET The fl ame controller reset can be controlled remotely by installing a button (not supplied) to the fl ame controller inside the unit’s electrical panel.
  • Page 55 Installation, user and maintenance manual – GAHP-A Figure 5.18 – Button connection for fl ame controller reset...

  • Page 57: Initial Activation And Maintenance

    PROCEDURE FOR INITIAL ACTIVATION The entire procedure for the initial activation of the appliance must only be carried out by an authorised Potterton Commercial Engineer. The product's guaranty may be void if the procedure is not carried out by a Potterton Commercial Engineer.
  • Page 58 Potterton Commercial Engineer. Following such corrective measures performed by the installation technician, the Potterton Commercial Engineer will assess the plant again. At this point, if, in the opinion of the Potterton Commercial Engineer, safety and compliance conditions exist, the Potterton Commercial Engineer must carry out the "initial activation".
  • Page 59 Installation, user and maintenance manual – GAHP-A During the fi rst start-up procedure it is in any case necessary to: • check the dynamic gas mains pressure • check and adjust the appliance’s combustion parameters You will need: the appliance connected to the gas and electricity supply: switched off and with the gas cock closed;...
  • Page 60 +0.2 -0.4. If you cannot calibrate the CO percentage after the second attempt, DO NOT activate the appliance; contact Potterton Commercial technical department on 0845 070 1057. 10. If you have successfully calibrated the combustion parameters, access menu 2 parameter 25 of the unit's controller: the display will fl ash "unF1", press to confi rm...

  • Page 61: Maintenance

    (for example in processing plants or in other conditions of continuous operation), these maintenance operations must be performed more often. Maintenance operations that the user may NOT carry out (operations for a Potterton Commercial Engineer). • Check cleansing of the water fi lters.

  • Page 62: Change Of Gas Type

    CHANGE OF GAS TYPE This operation must be carried out exclusively by an authorised Potterton Commercial Engineer). If the appliance is to be used with a type of gas other than that indicated on the sticker inside the appliance (see detail M in Figure 6.2 Gas changeover on page 63), switch off...
  • Page 63 Installation, user and maintenance manual – GAHP-A Figure 6.2 – Gas changeover LEGEND Gas valve O-ring O-ring Gas nozzle Fixing screws Red silicon pipe Fixing screws Manual reset fumes thermostat Sticker stating type of gas for which appliance is confi gured Gas changeover...

  • Page 65: Accessories

    Installation, user and maintenance manual – GAHP-A ACCESSORIES This section contains a list of the accessories that are available for the installation and use of the appliance. To order these accessories, contact Potterton on 0845 070 1057. Table 7.1 – Accessories ACCESSORIES...

  • Page 67: Appendix

    CCI/DDC (or from the S61 board via menu 2, parameter 21). If the TEMPERATURE generated 12 times in 2 hours of operation. code persists, contact authorised Potterton TAC. Carry out appropriate checks. Reset may be performed from the E_12 on unit and condenser inlet temperature...

  • Page 68: Safety Devices

    Reset occurs automatically when the condition that generated the E 447 LOW HOT WATER TEMPERATURE operation of the circulator. code ceases. If the code persists, contact authorised Potterton TAC. HOT WATER DIFFERENTIAL Reset occurs automatically 20 minutes after the operating code is u 448 High hot water diff erential temperature.
  • Page 69 Installation, user and maintenance manual – GAHP-A Figure 8.1 – Major safety devices unit LEGEND Limit thermostat Pressure unit Generator By-pass valve Combustion chamber Pump Inner parts Table 8.2 – Safety valve TYPE CALIBRATION MODEL PRODUCT CODE SAMI INSTRUMENTS 507.6 PSIG (35 bar) code SEALED CIRCUIT SAFETY VALVE Mechanical stop valve...

  • Page 70: Additional Safety Devices

    J-TLT015 LIMIT THERMOSTAT rapid opening of the contact . 60R180H02/04154 Contact N.C. (normaly closed) or similar* Potterton. BY-PASS VALVE Mechanical stopper valve 25,5 +0/-2 bar code H-VLV105 * The manufacturer guarantees the safety of operation and only when equipped with original spare parts In the case of replacement, the use of original spare parts is recommended (see codes in Table 8.3).
  • Page 71 Installation, user and maintenance manual – GAHP-A 5. In the case of replacement, before re-mounting the new thermostat, spread an adequate quantity of thermal grease on the lower part of the thermostat in order to ensure correct heat conductivity; 6. Re-connect the cables to the two connectors, paying attention to cover the contacts completely with the two red silicone protections;...
  • Page 72 Figure 8.5 – Safety valve mounted on unit LEGEND Safety valve Inspection valve Hermetic circuit Description of components bought in Stop the unit and wait for the end of the switch-off cycle. 1. Disconnect the unit electric power supply. 2. Remove the upper panel from the unit. 3.
  • Page 73 Installation, user and maintenance manual – GAHP-A Figure 8.7 – Removing the safety valve Removing the safety valve 5. Replace the o-ring as indicated in Figure 8.8 O-ring on page 73. Figure 8.8 – o-ring LEGEND Detail o-ring View of the underside 6.

  • Page 74: Non-Condensable Or Non-Absorbable Gases

    The possibility that internal corrosion phenomena are in progress must be taken into consideration only when a series of fi ve (5) thermostat interventions are detected. In this case, contact the Potterton after-sales service.
  • Page 75 Installation, user and maintenance manual – GAHP-A...
  • Page 76 Sales: Baxi Commercial Division 0845 070 1056 Wood Lane, Erdington, Birmingham B24 9QP Technical: Email: andrews@baxigroup.com 0845 070 1057 www.andrewswaterheaters.co.uk...

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