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A-Cubed Installation Guide

1. N LEGEND DDC Direct Digital Control AL supply 4 poles connector B 1 clamp and wire for 24 Vac supply 2 clamp and wire for 0 Vac supply B B 3 clamp and wire for ground contact lel B required connection DDCTR safety transformer 230 24 Vac 50 60 Hz rt Lr 48 1234 123456 2 poyo o0o0000 Bas M P 3 DDC l DDC electric supply from external transformer The following wiring diagrams show the connection ofthe DDC to 1 appliance Figure 5 12 Connection cable CAN BUS for plants with one unit see page 48 and 2 appliances Figure 5 13 Connection cable CAN BUS for plants with more unit see page 49 respectively POTTERTON coo M MER C1 AL Figure 5 12 Connection cable CAN BUS for plants with one unit A tp x N N Lis e LI Lt Lt oq S e eee gs 3 N BS N Bc gt MMM S Si ae tret tua TIPS ME HIE i aoa Eel ae ao EE WC 7 PUMP MAN IGN h i FAN N
2. 15 33 START UP AND SHUFDONB usaspa ausqusnaqdamuqahaqahkiwhanqsqanqasqiinaqaqtaamqqadiay uqkiussas 32 ON BOARD ELECTRONICS aaa 3 3 RESET OPERATIONS AND MANUAL DEFROSTING 34 OPERATING SETTINGS saa 35 PROLONGED PERIODS OF DISUSE icd ucinnioi imde n tik n npa etin lad ciiin HYDRAULIC SYSTEM INSTALLATION TECHNICIAN 25 4 4 GENERAL INSTALLATION PRINCIPLES PRA tr REM EDU UR Lo RR EE 42 POSITION OF THE APPLIANCE aaa AS HYDRAULIC CONNECTIONS a aa AA GAS SUPPLY pieier ea EEn E 4 5 CONDENSATE DISCHARGE CONNECTION 46 FILLING OF HYDRAULIC CIRCUIT a 47 FLUEINFORMATION dtt 4 8 PROGRAMMING OF HYDRAULIC PARAMETERS ELECTRICAL SYSTEM INSTALLATION TECHNICIAN 37 5 1 ELECTRICAL DIAGRAMS OF THE APPLIANCE a tte nttnt totos natia ttt tt statt tto tts toss s esteso btts tta tts ton 5 2 HOW TO CONNECT THE APPLIANCE ELECTRICALLY 5 3 CASCADE CONTROL uu S n suu Vetere ie eee ukun mia aaa utet Wi aaa Rasa u awa BAe LYPEC Bro To Died Pdl roin NER 5 5 HOW TO REMOTELY CONTROL THE FLAME CONTROLLER RESET eese ttt tiet annassa 54 INITIAL ACTIVATION AND MAINTENANCE 57 6 1 PROCEDURE FOR INITIAL ACTIVAT
3. VJ 1 Remove the front panel by removing the fixing screws 2 Remove the cover of the electrical panel to access the knob 3 Usethespecial key through the hole to operate the knob and access the controller s menus and parameters 4 To display the menus just press the knob once the display shows the first menu 0 menu 0 5 The display shows 0 To display the other menus turn the knob clockwise The display will read in order 17 27 35 47 57 67 77 8 and E see Table 3 1 Menu of electronic board on page 17 6 To display the parameters in a given menu for example menu 0 turn the knob until it displays the menu in question in the example 0 and press the knob the display will show the first of the menu s parameters in this example 0 0 or 0 40 menu 0 parameter 0 or 40 7 In the same way turn the knob to scroll through content menus parameters actions press the knob to select confirm the content access a menu display set a parameter execute an action quit or return to the previous level For example to quit the menus turn the knob to scroll through menus 07 17 2 etc until the controller displays the quit screen E now press the knob to quit In the case of menus 0 and 1 the user can view any parameter For information about menu 2 refer to Section 3 3 RESET OPERATIONS AND MANUAL DEFROSTING on page 19 To set the parameters of menu 3 refer to Section 4 8 PROGRAMMIN
4. Tube coil heat recovery AISI 304L Air based heat exchanger with single position finned coil manufactured in steel tubing and aluminium fins e Automatic two way microprocessor controlled defrosting valve allowing the finned coil to be defrosted Installation user and maintenance manual GAHP A Control and safety components e 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 e Plant water flowmeter Sealed circuit high temperature limit thermostat manual reset e Flue temperature thermostat 120 C manual reset Sealed circuit safety relief valve e Safety by pass valve between high and low pressure sealed circuit e Antifreeze function for hydronic system e lonization flame control box Double shutter electric gas valve e Condensate siphon icing sensor 2 4 TECHNICAL DATA Table 2 1 GAHP A HT technical data 0900000009090090900909009000000000900990090000900000000900090000092000000000000000050000000000000009200000009000000000900000000900000909099 OPERATION WHEN HEATING G U E gas usage efficiency 96 152 1 OPERATING POINT A7W50 Therinal Mower kW 354 1 G U E gas usage efficiency 96 119 1 OPERATING P
5. completely unnecessary Description and general characteristics The air water gas absorption heat pump GAHP A is available in the following versions e Version HT optimised for high temperature heating systems radiators fan coils it produces hot water to 65 C for heating purposes and up to 70 C for sanitary hot water e Version LT optimised for low temperature floor heating systems it produces hot water to 4 55 C for heating purposes and up to 70 C for sanitary hot water The GAHP heat pump can be controlled with the Direct Digital Control or with a switch on the consent circuit During operation combustion products are exhausted via the flue discharge terminal at the left side of the appliance see Figure 2 1 Size Standard ventilation on page 12 or Figure 2 2 Size on page 13 The fumes outlet must be connected to a flue for further details see Section 4 7 EXHAUSTING THE COMBUSTION PRODUCTS on Page 33 The appliance is powered with 230 Vac 1N 50 Hz TECHNICAL MANUFACTURING CHARACTERISTICS The appliance is supplied with the following technical manufacturing characteristics control and safety components Steel sealed circuit treated on the outside with epoxy paint Sealed combustion chamber suited for type C installation e Metal mesh irradiation burner equipped with ignition and flame detection managed by an electronic control unit e Titanium stainless steel tube bundle water exchanger with external insulation
6. it is possible that air is present in the gas pipes In this case activation fails and the appliance reports the operating code u 12 flame controller arrest temporary see Section 8 1 MACHINE OPERATING CODES on page 67 and after a brief interval the appliance automatically launches the start up procedure again If code u_12 is signalled 4 times on successive activation attempts the code persists the appliance locks out the flame controller and displays the following operating code E 12 flame controller arrest see Section 8 1 MACHINE OPERATING CODES on page 67 In this case reset is not automatic To restore operation of the appliance carry out a reset of the flame control unit via menu 2 of the controller the procedure is illustrated in Section 3 3 RESET OPERATIONS AND 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 Shut down Switch off the appliance via the on off command placing it in the OFF position The shutdown cycle takes approximately 7 minutes to complete VISUALISING AND RESETTING OPERATING CODES Operating codes can be generated e by the S61 on board controller e by the CCP DDC if present The operating codes generated by the S61 controller are displayed on its screen and can also be viewed on the C
7. 2 ON BOARD ELECTRONICS on page 17 At the moment of installation the appliance is set up by the installation technician for best operation according to the type of plant installed Subsequently it is possible to modify the operating parameters but this is not recommended if not in possession of the necessary knowledge and experience in order to do so In any case to set new operating parameters for the appliance see Section 4 8 PROGRAMMING OF HYDRAULIC PARAMETERS on page 34 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 Disconnecting the appliance You will need the appliance connected to the power gas supply Necessary equipment and materials 1 If the appliance is in operation switch it off with the CCP if present or DDC if present or the consent switch and wait for the shutdown cycle to terminate completely approximately 7 minutes 2 Disconnecttheappliancefromthe power supply putting theexternal disconnection switch in the OFF position see GS in Figure 5 5 Electrical wiring diagram on page 41 provided in the appropriate panel by the installation technician 3 Close the gas valve Do not leave the appliance connected to power and gas supply if it is expected to remain
8. 21 If the code persists contact authorised SENSOR DEFECTIVE temperature sensor Potterton TAC E Reset may be performed from the CCI DDC or from the 61 board CONDENSER INLET TEMPERATURE Fault interruption or short circuit on condenser i E420 SENSOR DEFECTIVE inlet temperature sensor via menu 2 parameter 21 If the code persists contact authorised Potterton TAC Reset may be performed from the CCI DDC or from the 61 board E422 WATER FLOWMETER FAULT Water flowmeter fault via menu 2 parameter 21 If the code persists contact authorised Potterton TAC Reset may be performed from the CCI DDC or from the 61 board E423 AIR GAS MIXTURE SENSOR FAULT Air gas mixture sensor fault via menu 2 parameter 21 If the code persists contact authorised Potterton TAC T Reset may be performed from the CCI DDC or from the 61 board E424 bee EMPERATURE SENSOR Fumes temperature sensor fault via menu 2 parameter 21 If the code persists contact authorised Potterton TAC GAS SOLENOID VALVE EXCITED The flame controller is arrested E_12 but the gas Reset may be performed from the CCI DDC or from the S61 board E428 DURING FLAME CONTROLLER solenoid valve is excited In this case the flame via menu 2 parameter 21 If the code persists contact authorised ARREST controller is de excited E 12 resets Potterton TAC u429 GAS SOLENOID VALVE WITHOUT Gas solenoid valve is off for 5 seconds with Reset occurs automatically if the gas solenoid valve
9. H20 MAXIMUM PRESSURE OF THE COOLING CIRCUIT Front and side views dimensions in mm 2 5 DIMENSIONS AND SERVICE PANEL Figure 2 1 Size Standard ventilation 00990090009909990090009090000090009090090000000090000900090090000090990000009000900000909009000009090000009090900000900900000009990900000000000000099099 T n CL D CL TN O Y i 964 j 975 _ 1258 99090909909990000090909090090990000000909900000090900000090900909000090000009000000000000009090000000900000000909000920000909000000009090090009000090009 Installation user and maintenance manual GAHP A Figure 2 2 Size Front and side views dimensions in mm Figure 2 3 Service plate LEGEND G Gas fitting O34 F l Inlet water fitting 114 F O Outlet water fitting 14 F i i 1 1 134 ind 189 Hydraulic gas unions detail 13 3 1 A A A Installation user and maintenance manual GAHP A NORMAL OPERATION In this section you will find all the indications necessary for the activation regulation and control of operation of the appliance depending on the ty
10. L A CEEE E ELECTRICAL DIAGRAMS OF THE APPLIANCE Figure 5 4 Appliance internal wiring diagram 5 1 1e1souueu1 Wy J93UIM SL dwe 103e5Ipul NO A 8A sey jeubeuio2os 3 ME Josuas awe 4 Josuas uone1oi duund d1jneipxYH a334 JUN siou Ao ul U 70u Soponeje uoniub aqodd 1 ino 103e10de 3 VAiL Joji ede ue D J ulloJsue11 uoniub qo d seb pejsneux3 000LLd Ue NVJ duund ijneipAH aqoid e1n1ejeduJe Jo1eJouar DL 1eubeu029J 104 3e150Uu9U L WL Jamo g aqoid ainjesadwia Juaiquiy YL A 8A Dunsojjaq qA J9U0JSUEA1 J9 0 300 aqoid ainyesadwia se eArisnquuo XIWL Josuas 1972M UolesuapUuo SMD J9 0J1u02 tue 4 qo d ainjyesadwia uin1 1972M JOH 2WHL V dHV5 40
11. Sections Display and knob and How to access the menus and following To set the parameters of menu 3 You will need the appliance switched on and access to the electrical panel see Display and knob Access menu 3 The display shows the first parameter of the menu number 160 1 Turn the knob clockwise to scroll through the parameters 3 160 3 161 3 162 lastly the letter E is shown 2 Pressthe knob when a parameter is displayed to select it or when E is displayed to exit the menu 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 flashes for example 40 0 C Turn the knob to modify the value of the parameter Press the knob to confirm the value selected the display shows the current parameter again 3 161 The new value for this parameter has been set 4 lf other parameters are to be modified proceed as described previously and then exit from the menu by pressing the knob on the letter E To exit the menu turn the knob clockwise until E is displayed then press it to confirm For details regarding the codes displayed by the appliance during operation see Section 8 1 MACHINE OPERATING CODES on page 67 Installation user and maintenance manual GAHP A ELECTRICAL SYSTEM INSTALLATION TECHNICIAN This sectio
12. above operations close the electrical panel and refit the front panel of the appliance How to connect the CAN BUS cable to the DDC The CAN bus cable is connected to the specific orange connector P8 supplied with the DDC in a bag A Before working on the DDC make sure that it is electrically isolated i The DDC like the controller on the appliance has jumpers that must be moved so that it can be configured as an intermediate or terminal node The position of the jumpers on a new DDC is CLOSED Installation user and maintenance manual GAHP A To connect the CAN bus cable to a DDC Op You will need DDC to be electrically isolated 1 Depending on the type of node being configured 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 If necessary open the DDC s back panel 4 screws after jumpers J21 have been correctly positioned close the cover again and retighten the 4 screws If the DDC is an intermediate node on the network with no 6 wires in the orange connector P8 set the jumpers J21 as shown in detail B of Figure 5 10 detail wires and jumpers J21 terminal intermediate node DDC on page 46 Jumpers OPEN If the DDC is an terminal node on the network with no 3 wires in the orange con nector P8 set the jumpers J21 as shown in detail A of Figure 5 10 detail wires and jumpers J21 terminal intermediate
13. allow the information displayed to be read and not modified Via menu 0 it is possible to view the appliance operating data as detected by the board in real time Menu 1 shows the parameters that characterise the operation of the appliance and their current values Menu 7 pertains exclusively to Potterton s Commercial Engineers To view the information contained in these menus proceed as illustrated in the paragraph How to access the menus Menu 2 is an execution menu it is used to reset the flame controller reset errors and manual defrosting control To perform these procedures see Section 3 3 RESET OPERATIONS AND MANUAL DEFROSTING on page 19 Menu 3 is a settings menu it allows the values displayed to be set The correct values of these parameters for optimum performance of the appliance with the plant to be used connected have already been set during installation 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 Display and knob The controller s display can be viewed through the glass of the viewing hole on the front panel of the appliance Upon activation all of the LEDs of the display light up for approximately three seconds andthen the name of the board S61 appears After around 15 seconds afterthe applian
14. cooling Siemens O DSP005 Only for E Room unit cooling Siemens radio O DSP006 Only for E Servocontrol 230V AC for zone valves on off 90 sec O BBN000 Modulating servocontrol for 3 way valves 230V AC 150 sec O BBN001 Probe sender Siemens O DSP010 Contact probe Siemens O SND006 External probe Siemens O SND003 Immersion probe length 2 m O SND004 Solar sensor Siemens O SND005 Commissioning tool O DSP002 Communications switchboard O DSP003 ii a Cable for data communication networks for network connection POTTERTON NETBUS CAN BUS CABLE between CCI DDC and appliance O CVO008 66 Installation user and maintenance manual GAHP A 8 APPENDIX 8 1 MACHINE OPERATING CODES Table 8 1 TABLE OF OPERATING CODES generated by S61 controller firmware version 3 016 CODES DESCRIPTION TRIP CONDITIONS RESET METHOD E400 Puch um CIRCUIT OF FLAME Fault on reset circuit of flame control unit Contact authorised Potterton TAC u401 GENERATOR LIMIT TEMPERATURE High temperature detected by limit thermostat Reset limit thermostat manually operation will be restored THERMOSTAT on body of generator automatically when the cause ceases GENERATOR LIMIT TEMPERATURE u 01 code active for 1 hour or u 01 code E401 THERMOSTAT generated 3 times in 2 hours of operation Contact authorised Potterton TAC u402 FUMES THERMOSTAT High temperature detected by exhaust fume
15. current national and local regulations and the instructions supplied by Potterton Commercial Before contacting Potterton Commercial to arrange commissioning e the electricity and gas mains specifications correspond to the specifications on the nameplate e the mains gas pressure falls within the range of values specified in Table 6 1 Network gas pressure on page 59 e the gas supplied to the appliance is of the type for which it is designed e the gas supply system and water distribution system are sealed Installation user and maintenance manual GAHP A e the gas and electricity supply systems are correctly rated for the capacity required by the appliance and that they are equipped with all safety and control devices prescribed by current regulations Check that no safety and control devices are excluded by passed or not working correctly 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 Operation and maintenance of the appliance To ensure the correct operation of the appliance and to avoid failures control of the switching on and off of the appliance must be done in line with the requirements of the various types of installation e If the appliance is connecte
16. direction indicated in detail 2 of Figure 8 6 Removing the safety valve on page 72 until complete assembly as indicated in Figure 8 7 Removing the movable safety valve on page 73 paying attention not to loosen part B of the inspection valve see Figure 8 5 Particular safety valve mounted on unit on page 72 ATTENTION if a consistent ammonia leak is detected during the removal phase tighten the inspection valve immediately Installation user and maintenance manual GAHP A Figure 8 7 Removing the safety valve in 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 1 LEGEND Detail o ring View of the underside 6 Tighten part B of the inspection valve to part A see Figure 8 9 inspection valve on page 73 Figure 8 9 Inspection valve LEGEND A Fixed part B Detachable part In particular A is a fixed part and B is a removable part 7 Tighten the valve applying a torque of 62 Nm A 8 4 LEGEND A Keepfixed B Rotate clockwise Mounting the removable part 8 Testfor the absence of ammonia using a phenolphthalein test strip 9 Mount the unit upper panel WARNING DO NOT START THE APPLIANCE WITHOUT THE SAFETY VALVE NON CONDENSABLE OR NON ABSORBABLE GASES Indirect control of the presence of non condensable or non absorbable gas in the hermetic circuit or internal corrosion phenomena The presence of corrosion ph
17. electrical devices in the vicinity of the appliance such as telephones multimeters or other equipment that can cause sparks e shut off the gas supply by means of the appropriate gas tap e cut off electrical power to the appliance by means of the external disconnecting switch that the electrical system installation technician has provided in the appropriate panel e request the assistance of professionally qualified personnel from a telephone far from the appliance The appliance has a sealed circuit that may be classifled as a pressurised container i e with internal pressure higher than atmospheric pressure The fluids contained in its sealed circuits are harmful if swallowed or inhaled or if they come into contact with the skin Do not carry out any operation on the sealed circuits of the appliance or on the valves present Packing items plastic bags polystyrene foam nails etc must be kept out of the reach of children as they represent potential sources of danger The electrical safety of this appliance is assured only when it is correctly connected to an effective grounding system as detailed in current electrical safety norms Installation and regulatory references When the appliance arrives at the installation site before beginning the stages required to move it in order to position it on the site perform a visual check to ascertain that there are no evident signs of breakage or damage to the packaging or to the ext
18. inactive for a long period If you wish to disconnect the appliance during the winter one of the following three conditions must be met 1 Make sure that the hydraulic circuit connected to the appliance contains an adequate percentage of glycol antifreeze see Section 4 6 FILLING OF HYDRAULIC CIRCUIT on page 32 and Table 4 2 Percentage of monoethylene glycol on page 33 2 Empty the hydraulic circuit completely for this purpose the circuit must be provided with water drainage points that are adequately equipped sized and located to allow the water present in the circuit to drain away completely and to allow the correct disposal of any glycol antifreeze present For these operations contact a reputable hydraulic system installation technician 3 Activate the antifreeze function which runs the circulation pumps and the appliance under 6 C To do this contact your hydraulic system installation technician This function requires the appliance to be ALWAYS powered up electricity and gas and power failures excluded Otherwise the manufacturer declines all contractual and extra contractual liability for consequent damage Installation user and maintenance manual GAHP A Connecting the appliance before it is used again to be carried out by the instal lation technician Before starting this procedure the hydraulic system installation technician must e ascertain whether the appliance requires any maintenance operations contact Po
19. is restored gt m Reset may be performed from the CCI DDC or from the 61 board E410 INSUFFICIENT HOT WATER FLOW oe is repeated or code u_10 is active for via menu 2 parameter 21 If the code persists contact authorised Potterton TAC u411 INSUFFICIENT ROTAT ON OF OIL Insufficient rotation of oil pressure pump Reset occurs automatically 20 minutes after the Code is generated PAI Reset may be performed from the CCI DDC or from the S61 board E411 INSUFFICIENT ROTATION OF OIL u_11 code generated twice in 2 hours of via menu 2 parameter 21 If the code persists contact authorised PRESSURE PUMP operation Potterton TAC u412 FLAME CONTROL UNIT ARREST Failure to ignite burner Reset occurs automatically when the solenoid valve opens again new ignition attempt or if the code persists for 5 minutes Reset may be performed from the CCI DDC or from the 61 board E412 FLAME CONTROL UNIT ARREST Flame arrest signal via menu 2 parameter 20 If the code persists contact authorised Potterton TAC Reset may be performed from the CCI DDC or from the 61 board HOT OUTLET WATER TEMPERATURE Fault interruption or short circuit on hot outlet A E416 SENSOR DEFECTIVE water temperature sensor via men 2 parameter 21 If the code persists contact authorised Reset may be performed from the CCI DDC or from the 61 board E417 COLD INLET WATER TEMPERATURE Fault interruption or short circuit on inlet water via menu 2 parameter
20. node DDC on page 46 Jumpers CLOSED 2 Prepare the orange CAN bus connector from the supplied sleeve Cut a length of cable long enough to allow it to be installed without kinking 4 Remove the sheath for a length of approximately 70 80 mm taking care not to cut the shielding metallic shield and or aluminium sheet and if present the bare connector in contact with the shield and wires contained inside 5 Rollthe shielding and connect it to a 4 mm eyelet terminal as illustrated in Figure 5 9 Connection from CAN BUS to connector P8 on page 46 details C and D Now proceed as follows 6 If the DDC is an terminal node connect the three coloured wires to the orange connector P8 following the diagram provided in detail A of Figure 5 10 detail wires and jumpers J21 terminal intermediate node DDC on page 46 Observe the terminal markings L H GND on the DDC at the base of the socket P8 which are given both in Table 5 2 CAN BUS cables type on page 42 and in the example 7 f the DDC is an intermediate node repeat the operations from step 2 to step 4 for the other length of CAN bus cable required Connect the six coloured wires to the orange connector P8 following the diagram provided in detail B of Figure 5 10 detail wires and jumpers J21 terminal intermediate node DDC on page 46 Observe the terminal markings L H GND on the DDC at the base of the socket P8 which are given both in Table 5 2 CAN BUS cables type on page 42 an
21. the gas cock and check that the mains pressure has not dropped If there is no gas leak supply gas and electricity to the appliance and restart it Complete the change of gas type by checking that all gas connections are sealed including those not directly affected by this operation using soapy water or another suitable method Now check and adjust the combustion parameters as indicated in the respective paragraph Table 6 2 Gas nozzles and content of CO2 Gas type G20 G25 G25 1 G27 G2 350 G30 G31 Nozzle code 180 181 181 187 184 182 183 Nozzle diameter 47 52 52 54 5 9 3 4 3 6 Content CO2 with MAX modulation 9 196 9 296 10 196 9 096 9 096 10 496 9 896 Delta CO2 between Max and Min potential 04 0 6 0 8 0 5 0 5 0 5 04 Figure 6 2 Gas changeover 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 configured zIOmmogncov zr Installation user and maintenance manual GAHP A 63 64 Installation user and maintenance manual GAHP A 7 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 06900000009990000909090990000090900090090900090000009000000900000000909000000000000090900000090090000090090009000000
22. uo 49 uuAAO d 14 ojq PULA ISAOd eqoJd aunjesad wa AaAljap 1972M JOH 2uHL V 3 404 uo Ja aWUMO 4 W4 Je oz3u02 QLpO N DULJSIS A PA Ser DY yeIsow y UI 10 219U99 1L Je 43002 OLM e uejsisaJ edid uonesuepuo 4 yeJSOWJay SAWN enue 2L J9 0J1u02 9S e uejsiseJ uoudis uonesuepuo SH DARA plou os Sec ND S4 Sa ND aA 1 cHOS aa I ia B har ANSI NOI gt 4 H i L amp S SA T ell 4 Su z E 8 le Sk L L a l m aaa jg ci e li ILBI Pr P daB ONL N C sowuea 38 HA AE 6l Nor NI ding C Ned olai SE T ia OHT Ss 3 E CAM Ze NS sn eee j ud es a 3 M T Og c I Hels 5 E SF a AR ro i H H H H l hap INA amo a EZ I Wd a BS E J Se prnpr J t 3 XENI a i ME a gy 277888 jin SL Auld 2 EET NA noaa QT amg G uo4g err najo xpog 9 uaa p abuoug E Aat c ALMA S1 S NBI WLNDI dd M18 uLgMd XO81ND uil H2S THOS LH2S GN3531 40 Installation user and maintenance manual GAHP A 5 2 HOW TO CONNECT THE APPLIANCE ELECTRICALLY Before making the electrical connections make sure that work is not carried out on live elements si oF 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 Connect the appliance to the mains fitting in proximity to the mains a general
23. water temperature too high it ceases to apply ss FUNCTION ACTIVATED Ya function j P Lm e inet Resets automatically defrost function disabled if with only the Activati kae pl lvifth hine off In this case the antifi ip i circulator operating the hot water inlet outlet temperature rises u 479 Ctivation taxes piace oniy tr the machine off In this case the antifreeze function above 5 C at which point the circulator switches off or if also the hot module is off and the antifreeze activates the plant water circulator If this e Ee function is enabled see menu 1 temperature falls further to below 3 C the Dee le j O hens this parameter 163 function also activates the flame controller i The code remains until operating parameters are entered and completed Contact authorised Potterton TAC If the board is u 480 NCOMPLETE PARAMETERS Incomplete parameters replaced Code E 80 may appear this means that the unit s characterisation parameters have not been set Reset occurs automatically when correct parameters are entered invalid psrametersordamsoeto parameter If the code persists contact authorised Potterton TAC if the E 80 480 VALID PARAMETERS meme getop parameters are incorrect it is necessary to enter and complete the y unit operating and characterisation parameters if the memory is damaged the controller must be replaced u 481 VALID BANK 1 PARAMETERS Invalid Bank 1 data Bank 2 data OK Reset occurs automatically 5 seconds after t
24. 000009000009090000090999 ACCESSORIES es j Variable rate pump for cold and CIRCULATION PUMPS Wilo Stratos Para 25 11 O PMP004 hot water Only for E3 FILTERS Sludge filter 1 1 4 O FLT014 Sludge filter 1 1 2 O FLT015 Only for E Air separator filter 1 1 4 O FLT010 Air separator filter 1 1 2 O FLT016 Only for E BOILERS AND HYDRAULIC SEPARATORS Sanitary water boiler with oversize coil 300 I O SRB004 Only for E Sanitary water boiler with oversize coil 500 O SRB005 Only for E With integral solar coil Only for E With integral solar coil Only for E Sanitary water boiler with oversize coil 500 O SRB006 Sanitary water boiler with oversize coil 750 O SRB007 Thermal tank three fittings 300 O SRB000 Thermal tank three fittings 500 O SRB001 Thermal tank three fittings 800 O SRB002 Thermal tank three fittings 1000 O SRB003 Flow regulator valve O VLV001 3 way valve DN20 Kvs 6 3 O VLV004 3 way valve DN25 Kvs 10 O VLV005 3 way valve DN32 Kvs 16 O VLV006 3 way zone ball valve 1 1 4 O VLV002 3 way zone ball valve 1 1 2 O VLV003 GLYCOL ANTIFREEZE hone and corrosion protection for hot cold hydraulic O GLC006 Sliter tank REGULATOR COMPONENTS Radio module Siemens O DSP007 Only for E Repeater Siemens O DSP009 Only for E Sender Siemens O DSP008 Only for E Room unit basic Siemens O DSP004 Only for E Room unit
25. 22 Manual defrost 2 22 23 Timed forcing to minimum power 2 23 24 Timed forcing to maximum power 2 24 25 Regulation of power 2 25 E EXIT MENU 2 jE The general operating codes of the controller can be reset with functions 20 and 21 ctions 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 ACTION 20 Reset flame controller arrest this may be used when the appliance is first activated see Section 3 1 START UP AND SHUT DOWN on page 15 when the appliance is in a permanent locked condition or after a long period of disuse see Section 3 5 PROLONGED PERIODS OF DISUSE on page 22 Q gt You will need access to the electrical panel see Section Display and knob To reset the flame control unit select menu 2 as indicated in the Section Accessing the Menus then proceed as follows 1 The display shows 2 Press the knob to access the menu The display initially shows item 2 20 2 Pressthe knob to display the flashing reset request reS1 3 Pressthe knob again to reset the flame controller The reset request stops flashing and again the display shows 2 20 The reset operation has been performed 4 To quit the menu turn the knob clockwise until the 2 E is displayed Now press the kn
26. 2309 1 and 2 and comply with the essential requirements of the following Directives Gas Directive 90 396 EEC and subsequent modifications and additions Efficiency Directive 92 42 EEC and subsequent modifications and additions Electromagnetic Compatibility Directive 89 336 EEC and subsequent modifications and additions e Low Voltage Directive 89 336 EEC and subsequent modifications and additions e Machinery Directive 2006 42 EC e Pressurised Equipment Directive 97 23 EEC and subsequent modifications and additions UNIEN677 Specific requisites for condensation boilers with nominal thermal capacity no greater than 70 kW The absorption heat pumps of the GAHP series emit values of nitrogen oxide NOx less than 60 mg kWh Safety The appliance must only be used for the purposes for which it has been designed Any other use is considered inappropriate and therefore dangerous The manufacturer does not accept any contractual or extra contractual liability for any damage caused by improper use of the appliance Do not operate the appliance if at the moment it is to be used dangerous conditions arise odour of gas in the circuit or near to the appliance problems with the electrical gas mains or hydraulic circuit parts of the appliance submerged in water or otherwise damaged control and safety components bypassed or defective Ask professionally qualified personnel for assistance If you smell gas do not operate
27. ATION 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 On leaving the factory the appliance is reliable and tested The entire procedure for initial activation of the appliance consists in carrying out the following main operating stages 1 Preliminary verification of plant compliance 2 Checking and adjusting the combustion parameters 3 Regulating the plant operating parameters Preliminary verification of plant compliance The Potterton Commercial Engineer must Check that the whole plant has been manufactured in accordance with its design following the instructions supplied by the manufacturer and respecting current legislation The design must have been drawn up by a qualified self employed professional person Check personally that all of the connections hydraulic gas and electrical of the appliance have been made correctly e Check that the necessary conditions for plant compliance effectively exist as per the declaration consigned to the user by the qualified firm that has carried out installation of the appliance The Declaration of Compliance CERTIFIES that the plant conforms to current regulations This declaration is a compulsory document and as such must be issued by law to the owner by the qualified firm that has oversee
28. CI if present or DDC if present Operating codes generated by the controller can be cleared through the board itself or from the CCI DDC if fitted and allowed Fora description of operating codes generated by the controller and how to clear them refer to the list of operating codes contained in Section 8 1 MACHINE OPERATING CODES on page 67 The controller see Figure 5 1 Electronic board S61 on page 37 is located inside the electrical panel of the appliance and the display may be viewed through the viewing hole on the front panel of the unit itself The Machine Codes generated by the CCI DDC may only be viewed on the display of the CCI DDC and may be cleared only through the CCI DDC For the operating codes generated by the CCP DDC refer to the manuals supplied with the unit Installation user and maintenance manual GAHP A 3 2 ON BOARD ELECTRONICS The following descriptions refer to the S61 controller with firmware version 3 016 The appliance is fitted with an S61 microprocessor controller with Mod10 combustion modulation controller mounted above it see Figure 3 1 On board controller on page 17 The S61 controller in the electrical panel controls the appliance and displays data messages and operating codes Programming control and monitoring of the appliance take place by interacting with the display A and knob B shown in Figure 3 1 On board controller on page 17 The CAN BUS port connects one or seve
29. EMORY TEST UNSUCCESSFUL Processor error Contact authorised Potterton TAC E 487 MEMORY TEST UNSUCCESSFUL Processor error Contact authorised Potterton TAC E 488 MEMORY TEST UNSUCCESSFUL Processor error Contact authorised Potterton TAC E489 MEMORY TEST UNSUCCESSFUL Processor error Contact authorised Potterton TAC went Reset may be performed from the CCI DDC or from the S61 board E 490 E FEMME SENSOR Iterruprion af shart circuit of ambient via menu 2 parameter 1 If the code persists or occurs again p i contact authorised Potterton TAC One of the following is absent serial number of E491 CONTROLLER DEFECTIVE board hardware version code or encryption key Contact authorised Potterton TAC written during board test 8 2 SAFETY DEVICES ThePED Pressurised Equipment Directive prescribes thatthe unitis supplied with a hermetic circuit safety valve pos B in the Figure 8 1 units major safety devices on page 69 Installation user and maintenance manual GAHP A Figure 8 1 Major safety devices unit LEGEND A Limit thermostat B Pressure unit C Generator D By pass valve E Combustion chamber F Pump Inner parts Table 8 2 Safety valve TYPE CALIBRATION MODEL PRODUCT CODE 507 6 PSIG 35 bar ene SEALED CIRCUIT SAFETY VALVE Mechanical stop valve a 110 C VDS 2000 J VLV023A 3 imilar or simi The manufacturer guarantees the safety of operation and only when equippe
30. Figure 5 17 Electrical wiring diagram on page 53 detail CS A For the appliance to operate correctly it is ALWAYS necessary to provide a consent switch Do not use the general mains external circuit breaker GS to switch the appliance on or off Figure 5 17 Electrical wiring diagram Z LEGEND Z SCH Electronic board R Common 4 WwW Terminal consensus warming Components NOT SUPPLIED CS ON OFF command switch APE 24ac 0V 4 acl Sle E SCH p 243 electrical connections of ON OFF command switch 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 5 5 HOW TO REMOTELY FLAME CONTROLLER RESET The flame controller reset can be controlled remotely by installing a button not supplied to the flame controller inside the unit s electrical panel Connect the button as instructed below idi You will need the appliance disconnected from the electricity supply 1 The cable required to connect the reset button must be 3x0 75 mm 2 Cuta suitable length of cable 3 Connect the cable to the blind terminals A see Figure 5 18 Button connection for flame controller reset on page 55 T The cable may not be longer than 20 metres Incorrect wiring of the reset button may damage the component irreparably Check the cabling carefully before powering the u
31. G 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 Vine The special key allows the knob of the electronic board to be operated without opening the cover of the electrical panel so that operators are protected from live components When the necessary settings have been completed put away the special key replace the cap on the aperture of the electrical panel and refit the front panel of the appliance Vine There are several possible reasons why the appliance may have error status and therefore its operation arrested such an error situation does not necessarily correspond to damage or malfunction on the part of the appliance The cause that has generated the error may be temporary for example presence of air in the gas supply line or temporary power failure The appliance can be reset with controller menu 2 the Comfort Control Panel if present or the DDC if present In these two latter cases refer to their documentation Reset appliance controller The Table 3 3 Menu 2 on page 20 shows the actions available in menu 2 For regulatory reasons the flame controller reset is in a dedicated voice of menu i Table 3 3 Menu 2 ACTION REQUIRED FOR EXECUTION SHOWN ON DISPLAY AS 20 Reset flame controller arrest 2 20 21 Reset other operating codes 2 21
32. ION 6 2 MAINTENANTCE sinirini 63 CHANGE OFGAS DYPE sanctse cec erecto etes tocaba ek ieu D Rude Rea hanya anp hai ayah naye aqa Sil MACHINEOPERATING CODES I I tar rtp S ra a u ERRARE RENE Gaeta EGER URDU 67 MEOS zh bisicme er 68 83 JADDITIONAESAEETY DEVICES viisistas eE a eE iae TE E ST EAT 70 8 4 NON CONDENSABLE OR NON ABSORBABLE GASES u a 74 C OMM R Installation user and maintenance manual GAHP A PREFACE This Installation user and maintenance manual is a guide to the installation and operation of the Air Water gas absorption heat pump A CUBED GAHP A This manual is specifically intended for e final users for the use of the appliance according to their own requirements Installation technicians hydraulic and electrical for the carrying out of a correct installation of the appliance The manual also contains e a section that describes all the operations necessary for the first start up and for the gas change of the appliance as well as the main maintenance operations e an ACCESSORIES section with a description of accessories available and their respective reference codes Summary The manual has 8 sections SECTION 1 is a brief introduction to the use of the manual itself SECTION 2 is intended for use by the final user hydraulic and electrical installation technicians and the Potterton Commercial C
33. Installation on a terrace or roof Position the appliance on a levelled flat surface made of fireproof material see also SUPPORTS and LEVELLING below The structure of the building will have to support the weight of the appliance added to the weight of the supporting base The weight of the appliance is given in Table 2 1 GAHP A LT technical data on page 12 or Table 2 2 GAHP A HT technical data on page 13 Create a containing step and a suitable drainage channel for the water providing a gangway around the appliance for maintenance purposes Although the appliance produces vibrations of limited intensity the use of antivibration mounts available as accessories see Section 7 ACCESSORIES on page 65 is strongly recommended in such cases of installation on roofs or terraces in which resonance phenomena may arise In addition it is advisable to use flexible connections anti vibration joints between the appliance and the hydraulic and gas supply pipes Avoid positioning the appliance directly above rest areas or other areas that require quiet SUPPORTS and LEVELLING The appliance must be correctly levelled by placing a level on the upper part of the appliance If necessary level the appliance with metal spacers placing them appropriately in relation to the mounts do not use wooden spacers as these degrade quickly CLEARANCES Position the appliance so as to maintain minimum clearances from combustible surfaces walls or oth
34. OF HYDRAULIC PARAMETERS The operations described in this paragraph are necessary only if the appliance is not I connected to a DDC or to a CCP Ifthe appliance is connected to a DDC follow the instructions given in the DDC manuals exclusively This paragraph explains how to set the hydraulic parameters on the electronic board of the appliance Users not familiar with the basic procedures for the use of the board should refer to Section 3 2 ON BOARD ELECTRONICS on page 17 To configure the appliance access menu 3 of the electronic board With regard to the hydraulic configuration six parameters may be set select the letter E to exit to the previous menu 34 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 differential 3 162 EXIT MENU 3 E Description of parameters Select water thermostating parameter 160 this parameter may have two values 0 or 1 When the user chooses 0 the temperature that affects the activation and deactivation of the appliance is detected by the sensor on the INLET water i e water flowing into the appliance 1 the temperature that affects the activation and deactivation of the appliance is detected by the sensor on the OUTLET water i e water flowing out of the appliance e Water set point parameter 161 this parameter sets the wat
35. OINT A7W65 Thermal Dower kW 2550 G U E gas usage efficiency 96 125 OPERATING POINT A 7W50 Tliesmalipswet kW 31 5 Thermal capacity Nominal 1013 mbar 15 C kW 357 true peak kW 252 NOx emission class 5 NOx emission ppm 25 CO emission ppm 36 Hot water delivery temperature Hed for heating c 2 maximum for ACS C 70 maximum heating X 55 Hot water return temperature maximum for ACS C 60 minimum X 2 nominal Wh 3000 Hot water flow rate maximum l h 4000 minimum l h 1000 Hot water pressure drop 1 Water pressure bar 0 43 2 maximum SG 45 Ambient air temperature dry bulb intu C 200 Thermal differential nominal 5 10 methane G20 nominal m3 h 2 2 3 gas consumption G30 nominal kg h 2 03 4 G31 nominal kg h 2 00 4 ELECTRICAL SPECIFICATIONS Voltage V 230 Power supply TYPE an SINGLE PHASE Frequency subo 50 Electrical power absorption nominal kW 0 90 5 Degree of protection IP X5D INSTALLATION DATA Level of acoustic pressure at 10 meters maximum dB A 54 8 45 8 Minimum storage temperature C 30 Maximum operating pressure bar 4 Water content inside the apparatus l 4 TYPE F Water fitting thread G 11 4 Gas fitting Fume outlet TYPE thread Size Residual head Maximum condensation water flow rate Size width height depth Weight In operation GENERAL INFORMATION INSTALLATION MODE B23P B33 B53P COOLING FLUID AMMONIA R717 WATER
36. 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 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 filed at Potterton Commercial Any use of this manual other than for personal consultation must be previously authorised by Potterton Commercial The rights of those who have legitimately filed the registered trademarks contained within this publication are not affected With the aim of continuously improving the quality of its products Potterton Commercial reserves the right to modify the data and contents of this manual without prior notice Installation user and maintenance manual GAHP A INDEX OF CONTENTS OVERVIEW AND TECHNICAL CHARACTERISTICS 7 21 WARNINGS 7 2 2 NOTES ON OPERATION OF THE APPLIANCE siciscesscdetetzcssasvastensecesscecessebdabeddssebiednesovtcuaniedpartaccrisisesvaaiannesiececaasecasteaasscisetts 10 2 3 TECHNICAL MANUFACTURING CHARACTERISTICS wiasiisscesssestasccascctsascassocossssosescoaceztiaetaisseisstisdsstsanstdaresascsoussecsascodsoteaseers 10 24 TECHNICAL DATA 2 5 DIMENSIONS AND SERVICE PANEL NORMAL OPERATIONN
37. act 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 1 In the case of replacement the use of original spare parts is recommended see codes in Table 8 3 The manufacturer is exempt from any contractual or extra contractual responsibility for damage caused by the use of non original spare parts INSPECTION PROCEDURE Before starting the inspection of the generator limit thermostat the unit must be isolated from the electrical supply and gas supply after which the unit can be worked on as follows 1 Move the appliance front panel 2 Identify the thermostat which is found in the lower part of the generator pipe on the right side above the combustion chamber see figure 8 3 Inspection at generator limit thermostati on page 71 3 Disconnect the cables see Figure 8 3 Inspection at generator limit thermostati on page 71 4 Inspect or replace the component to disassemble the component turn it anti clockwise Installation user and maintenance manual GAHP A 5 n 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 connectthe cablestothe two connectors paying attention to cover the contacts completely with t
38. age caused by the use or incorrect disposal of glycol antifreeze It is equally important to recall that the use of monoethylene glycol modifies the thermophysical characteristics of the water in the plant and in particular its density viscosity and specific average heat Always check the date of expiry and or degradation of the product with the supplier In the Table 4 2 Percentage of monoethylene glycol on page 33 is shown the approximate freezing temperature of the water and the consequent increased drop in pressure of the appliance and of the circuit of the plant according to the percentage of monoethylene glycol This Table 4 2 Percentage of monoethylene glycol on page 33 should be taken into account for the sizing of the pipes and the circulation pump for calculation of internal pressure drops of the appliance refer to the Table 2 1 GAHP A HT technical data on page 11 Nevertheless it is advisable to consult the technical specifications of the monoethylene glycol used If automatic loading systems are used a seasonal check of the quantity of glycol present in the plant is also necessary Table 4 2 Percentage of monoethylene glycol 96 of MONOETHYLENE GLYCOL 10 15 20 25 30 35 40 WATER FREEZING POINT TEMPERATURE Eu 5 C 8 C 12 C 15 C 20 C 25 C PERCENTAGE OF INCREASE IN PRESSURE DROPS 6 8 10 12 14 16 LOSS OF EFFICIENCY OF UNIT 0 5 1 2 2 5 3 4 Technical data for filling the hydraulic circuit ai Ifthe per
39. agram at the base of the connector 6 Iftheappliance 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 figure 5 8 7 Fixthe CAN bus cable or two cables according to the type of node being connected to the cable fixing 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 The cables must be held firmly in place by the bracket if pulled To position the jumpers on the board according to the type of node being configured If the appliance is a terminal node on the network i e 3 wires are inserted in the orange connector on the board set the jumpers as shown in detail A of Figure 5 8 Electrical wiring diagram on page 44 If the appliance is an intermediate node on the network i e 6 wires are inserted in the orange connector on the board set the jumpers as shown in detail B of Figure 5 8 Electrical wiring diagram on page 44 Figure 5 8 Electrical wiring diagram A B LEGEND H Data signal HIGH B Detail case intermediate node 6 SCH electronic board J1 Jumper CAN BUS in board wires J1 jumper open GND Common data A Detail case terminal node 3 wires P8 Port can connector L Data signal LOW J1 jumper closed Connection cable CAN BUS to electronic board detail A case terminal node detail B case intermediate node 8 After having carried out all the
40. al reset fumes thermostat on page 31 A If the appliance is operated with the siphon empty there is a risk of leaks of combusted gas 4 6 FILLING OF HYDRAULIC CIRCUIT After having completed all the connections of the hydraulic electrical and gas supply plants the hydraulic system installation technician can proceed with filling the hydraulic circuit observing the following stages i You will need the appliance connected hydraulically and electrically 1 Activate the automatic air bleeding valves present in the plant and open all thermostatic valves 2 Fill the hydraulic circuit ensuring the minimum water content in the plant and adding if necessary to the plant water free of impurities a quantity of monoethylene glycol in proportion with the minimum winter temperature in the installation zone see table 4 2 Percentage of monoethylene glycol on page 33 3 Checkthe filter on the return pipe for impurities clean it if necessary 4 Checkthatthe siphon on the condense drain has been filled with water as indicated in the relative paragraph 5 Bring the plant to the correct pressure making sure that the water pressure is not less than 1 bar and not over 2 bar and run the circulation pump for at least 30 minutes Check the water filter again and clean it if necessary To facilitate the operation of bleeding air from the hydraulic circuit the appliance is equipped with an additional manual air bleeding valve Possible us
41. an be measured through parameters like acidity hardness conductivity chlorides content chlorine content iron content and the like A The presence of active chlorine in the water in particular can jeopardize parts of the installation and Potterton Commercial units Therefore please make sure that active chlorine content and total hardness are compliant with the allowable ranges reported in Table 4 1 Chemical and physical parameters of water on page 29 The way the installation is operated can be the cause of possible degradation of water quality Itisadvised to check regularly the water quality especially in case of automatic or periodic top up In case water treatment is needed this operation should be carried out by a professional or competent person following strictly the instructions by the manufacturer or supplier of the chemical substances for the treatment since dangers could arise for health for the environment and for Potterton Commercial appliances Several products for water treatment are available on the market Without being exhaustive Potterton Commercial can indicate the following ones e FERNOX Alphi 11 Protector Antifreeze Protective action e FERNOX F1 Protector Protective action e FERNOX AF 10 Biocide Biocide for underfloor heating systems If the system is to be chemically flushed this operation should be carried out by a professional or competent person following strictly the instructions by th
42. atically when the condition that generated the E447 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 TEMPERATURE TOO HIGH High hot water differential temperature generated E448 HOT WATER DIFFERENTIAL u 48 code generated twice in 2 hours of Reset may be performed from the CCI DDC or from the S61 board TEMPERATURE TOO HIGH operation via menu 2 parameter 21 E449 SATELLITE BOARD NOT PRESENT Satellite board not present Reset occurs automatically when the condition that generated the code ceases Defrosting function activated Defrosting is activated if at least 90 minutes has passed since the last defrosting or 180 minutes if temperature u 452 DEFROSTING FUNCTION ACTIVATED is inferior of 5 C if the flame control unit has The Code clears automatically when execution of defrosting ends been on for at least 15 minutes and if room temperature temperature of hot inlet water and ofthe evaporator require its execution Warning is generated if system operating in ae u453 WATERFLOW IN HOT PASSIVE conditioning mode and the flowmeter of the hot Reset is Ona and occurs when the condition that generated module is closed I cease to app iy OUTLET HOT WATER TEMPERATURE Reset is automatic and occurs when the condition that generated u478 TOO HIGH Outlet hot
43. ating codes and associated instructions in tabular form References If the appliance is to be connected to a Cascade VAA Direct Digital Controller DDC refer to the following documentation with which it is supplied gt INSTALLATION TECHNICIAN MANUAL book 1 for installation service technicians gt FINAL USER MANUAL book 2 for the final user of the DDC Definitions 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 A DANGER Gp WARNING ie NOTE r ide START OF OPERATING PROCEDURE REFERENCE to another part of the manual or other document 2 1 NI EN y AY Installation user and maintenance manual GAHP A OVERVIEW AND TECHNICAL CHARACTERISTICS In this section for all users you will find 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 Conformity to CE standards The absorption heat pumps of the GAHP series are certified as conforming to standard EN 1
44. bus network The CAN bus network is characterized by a series of elements appliances or DDCs called nodes connected to each other by a three wire cable The nodes are of two types terminal nodes and intermediate nodes e Terminal nodes are appliances or DDCs that are connected to one other element only e Intermediate nodes are appliances or DDCs that are connected to two other elements The diagram in Figure 5 6 Example of CAN BUS on page 42 gives an example of a CAN BUS network 3 appliances are connected to each other and to 1 DDC Appliance D and the DDC A are terminal nodes while appliances C and B are intermediate nodes as they are connected to 2 elements Itis possible to place one DDC at any point of the CAN bus network appliances and DDCs may act equally as terminal or intermediate nodes One DDC can control and monitor up to 16 appliances If there are more than 16 appliances on the network it is necessary to connect more than one DDC on the same network up to a maximum of 3 Figure 5 6 Example of CAN BUS LEGEND B C D Appliance 2 3 Intermediate nodes A CCP or DDC 1 4 Terminal nodes Terminal nodes and intermediate nodes Whatis the CAN bus cable 1 The CAN bus cable must meet the Honeywell SDS standard Table 5 2 CAN BUS cables type on page 42 gives details of some types of CAN bus cable grouped according to the maximum distance covered by each cable type Table 5 2 CAN BUS cab
45. ce powers up the appliance starts running if the required consent is available During correct operation the display shows alternately the following information outlet water temperature inlet water temperature and the difference between the two water temperatures see Table 3 2 Operating information on page 18 Table 3 2 Operating information OPERATING MODE HEATING PARAMETER THE DISPLAY SHOWS Hot outlet water temperature 50 0 Hot inlet water temperature 40 0 Differential temperature outlet inlet 10 0 Example of data visualised on display water temperature and differential If there are operating problems the display shows sequentially the operating codes corresponding to the problem detected A list of these codes with their description and the procedure to follow to bring the appliance back to correct operation is provided in Section 8 1 MACHINE OPERATING CODES on page 67 The knob is used to display or set parameters or to execute actions commands e g a function or reset when permitted 3 3 RESET OPERATIONS AND MANUAL DEFROSTING Installation user and maintenance manual GAHP A HOW TO ACCESS THE MENUS To use the knob with the special key supplied with the appliance You will need the appliance s electrical power switches set to ON the controller s display sequentially shows the operating data temperature delta T regarding the current mode e g heating and any active operating codes u E
46. ce is running can irreparably damage its internal components Type C stand alone appliance Stand alone appliances must be activated and deactivated only by means of the consent switch provided by the electrical installation technician According to requirements this consent switch may be an on off button an ambient thermostat a programmable timer or one or more volt free contacts controlled by another process For details about the type of on off command installed contact the plant s electrical installation technician The appliance must never normally be switched on and off by shutting off the power supply upstream of the Controle Device CCP DDC or consent switch before having used the latter first and waited for the shutdown cycle to end approximately 7 minutes The shutdown cycle terminates when the hydraulic pump switches off no parts in motion Shutting off the power supply while the appliance is running can irreparably damage its internal components Start up Switch on the appliance by means of the on off command placing it in the ON position When activation is successful the appliance is managed by the S61 controller in its electrical panel see Section 3 2 ON BOARD ELECTRONICS on page 17 The controller s display may be viewed through the viewing hole on the front panel of the unit itself During operation the S61 controller displays operating codes If the appliance remains inactive for a prolonged period
47. centage of glycol is gt 30 for ethylene glycol or 20 for propylene glycol P d then parameter 182 in menu 4 must be set to 1 at the installer s care 4 7 FLUE INFORMATION The appliance is approved for the connection of the combustion product flue pipes present on each single unit to a flue linked directly to the outside Each single unit is provided with a connection of 80 mm equipped with a suitable seal located on the left side see Figure 2 1 Size Standard ventilation on page 12 or Figure 2 2 Size on page 13 and outlet in a vertical position Each unit of the appliance is supplied complete with an exhaust air duct installation kit to be fitted to the appliance by the hydraulic system installation technician The exhaust air duct installation kit consists of see Figure 4 4 Fume outlet on page 34 n 1 exhaust air pipe 80mm length 300 mm with terminal e n 1rain cover e n 1 curve 90 80 mm To assemble and fit the external exhaust fumes installation kit proceed as follows 3 de You will need the appliance positioned in its installation site refer to Figure 4 4 Fume i outlet on page 34 1 Fit the rain cover C on the elbow 90 A 2 Fitthe elbow 90 A to the clamp on the left side of the appliance 3 Fitthe terminal pipe assembly B to the elbow A Figure 4 4 Fume outlet LEGEND A Elbow 90 80 B Pipe 80 Lg 300 mm w terminal C raincover 4 8 PROGRAMMING
48. 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 Plant situations that are hazardous for people and for the appliance If one of the following hazardous situations arises the Potterton Commercial Engineer must not carry out the initial activation e Appliance installed indoors Appliance installed too near combustible surfaces or in any case in conditions that do not permit access and maintenance operations in safety e Control of switching on and off of the appliance not via the CCP DDC or consent switch but via the master power switch e Situations attributable to defects or failures of the appliance that took place during its transport or installation e Smell of gas due to probable leaks from the plant itself and in any case all situations that are due to non compliant plants considered potentially hazardous Anomalous plant situations If one of the following situations exists the Potterton Commercial Engineer may carry out the initial activation at their discretion but the appliance will be left off until conditions dictated by the manufacturer are restored e Installations potentially not hazardous not carried out according to good workmanship practices not complying
49. d S61 LEGEND e 9 e 9 e 9 e 9 e 9 e 9 v 9 Bo o 9 Boog o o o o o 9 Ee J Di0 See table on page 38 THMF THRF TCN TA TG TAL TA8 SRT1 SRTe JP18 S oo oo U leo oo gt leo Eo ra U E cu S J S FSS U G lt q BK WH BR COntoct SCH1 SCH S61 Table 5 1 Electronic board S61 lectronic board S61 Auxiliary inputs Knob Fuse T 2A Fuse F 10A Fuse T 2A Fuse T 3 15A FAN BK WH BR Fan output FL water flow switch input GAHP A FS5 24V AC Controller power 24 0 24 Vac Flame controller power 230 V AC CAN BUS jumper Jumper N O contact W10 board connector on Mod10 JP10 6 pole flame controller connector JP12 Exhausted gas probe input JTAG S61 controller programming connector MAIN 230V L N S61 controller power 230 V AC N O contact Pump contact N O P7 R W Y o P8 GND L H Consent inputs CAN BUS connector PUMP 230V L N Hydraulic pump power output SPI Communication port with Mod10 controller SRT1 Hydraulic pump rotation sensor input SRT2 Hot water flowmeter input E3 A GS WS Ambient temperature probe input Input probe of evaporator output Not used Combustive air temperature probe input Exhausted gas thermostat input Gene
50. d disconnected from the gas electricity supplies Disconnect the gas pipe from the gas valve Undo the 4 bolts E shown in Figure 6 2 Gas changeover on page 63 and remove the gas valve blower assembly from the burner Protect the burner from bolts and nuts falling into it Using a CH 4 hex key undo the 4 bolts G indicated in Figure 6 2 Gas changeover on page 63 and remove the nozzle D from the gas valve Replace the nozzle and o ring C see Figure 6 2 Gas changeover on page 63 with those of the diameter suited to the new type of gas see Table 6 2 Gas nozzles and content of CO2 on page 62 The nozzle code is stamped on the nozzle itself Check that the o ring B is fitted Reassemble the gas valve to the blower with the 4 bolts G taking care that the red silicon hose between the venturi tube and the gas valve see detail F of Figure 6 2 Gas changeover on page 63 is correctly installed Replace the white gasket between the blower and the burner Reinstall the blower gas valve assembly to the burner with the 4 bolts E taking care not to damage the white gasket Reconnect the gas pipe to the gas valve Replace the sticker indicating the type of gas for which the appliance was set up detail M of Figure 6 2 Gas changeover on page 63 with one that indicates the new type of gas used Check the tightness of the installation as follows Connect a manometer to the gas intake D Figure 6 1 Gas valve on page 59 Open the gas valve e Close
51. d gas tank to reduce the pressure to 1 5 bar and a second stage pressure reducer from 1 5 to 0 03 bar near the appliance A LPG may cause corrosion The connectors between the pipes must be made of a material that is resistant to this corrosive action 4 5 ple 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 In any case provide a cut off valve cock on the gas supply line to isolate the appliance if required For data regarding hourly fuel consumption of the appliance refer to Table 2 1 GAHP A LT technical data on page 12 or Table 2 2 GAHP A HT technical data on page 13 CONDENSATE DISCHARGE CONNECTION The fumes condensate outlet is on the left of the unit The unit is supplied complete with a siphon to which a piece of pipe is attached During transport the pipe is stored inside the unit s left mounting bracket at the front of the appliance To install connect the pipe proceed as follows 1 Passthe pipe through the hole in the left mounting bracket see Figure 4 3 Position of condensate discharge and manual reset fumes thermostat on page 35 2 Connect the tube to a plastic condensate discharge manifold of the correct length 3 The connection between the pipe and the con
52. d in the example 8 Insert the orange connector P8 with the wires first into the opening prepared in the cover of the DDC and then into the appropriate socket on the DDC itself making sure it is correctly inserted 9 Usetherear cover bolts located nearthe CAN BUS socket to secure the 4 mm eyelet or 2 eyelets detail D Figure 5 9 Connection from CAN BUS to connector P8 on page 46 The cable should be secured against pulling out 5 coo M MER C1 AL Figure 5 9 Connection from CAN BUS to connector P8 LEGEND A Insulating tape to protect board shield B CAN BUS cable wires j C CANbuscable shield D terminal and screw for fixing Connection detail of cable CAN BUS Figure 5 10 detail wires and jumpers J21 terminal intermediate node DDC JUMPER JUMPER A Jel B J21 i o ololo 9j Elo o oN LEGEND DDC Direct Digital Control J21 Jumper CAN BUS in DDC board A detail case terminal node 3 wires J21 jumper closed B detail case intermediate node 6 wires J21 jumper open H LGND data signal wires Detail terminal and intermediate node jumpers position J21 closed open mE How to connect the DDC ap The DDC requires a low voltage power supply 24 V with a 230 24 V AC 50 Hz safety transformer the minimum power requirement is 20 VA For the connection use a cable with the minimum specifications 2 x 0 75 mm Connect the DDC to the transformer via the 4 pole connector provided for this
53. d to the DDC see Figure 5 3 Direct Digital Control DDC on page 39 the appliance may be switched on and off exclusively by the DDC itself e If the appliance is NOT connected to a Direct Digital Control DDC the appliance may be switched on and off exclusively by a switch on the consent circuit A The appliance must never normally be switched on and off by shutting off the power supply upstream of the Controle Device CCP DDC or consent switch before having used the latter first and waited for the shutdown cycle to end approximately 7 minutes The shutdown cycle terminates when the hydraulic pump switches off no parts in motion A Shutting off the power supply while the appliance is running can irreparably damage its internal components If the appliance fails to operate correctly with the consequent indication of the Machine code follow the instructions of Section 8 1 MACHINE OPERATING CODES on page 67 In the event of failure of the appliance and or breakage of any of its parts refrain from any attempt to repair and or restore operation of the appliance through direct action viele e Deactivate the appliance immediately if permitted and if no condition of danger exists by starting the shutdown cycle via the CCP or DDC or consent switch and waiting for it to terminate approximately 7 minutes e Disconnect the appliance from the gas and electricity mains cutting off gas supply by means of the appropriate val
54. d with original spare parts Sealed circuit safety valve characteristics INSPECTION PROCEDURE Before starting the inspection of the safety valve the unit must be switched off Remove the electric and gas power supplies and operate on each unit of the appliance as follows Electrically isolate the unit External master switch in OFF position and isolate the supply 1 Remove the front and upper panel of the unit 2 Identify the valve which lies behind the levelling chamber see Figure 8 2 Over pressure valve on page 70 3 Remove the refrigerant flexible ducting pipe by loosening in a clockwise direction 4 Once the operation has been completed re mount the flexible pipe taking it to the original position see Figure 8 2 Over pressure valve on page 70 5 Re mount the front and upper panel of the unit LEGEND Detail of the refrigerant flexible ducting pipe Position of the valve 8 3 ADDITIONAL SAFETY DEVICES The following additional safety devices are installed on the appliance e Generator limit thermostat see pos A in the Figure 8 1 on page 69 e By pass valve see pos B in the Figure 8 1 on page 69 The main features of the two devices are given in Table 8 3 on page 70 Table 8 3 Characteristics of the two devices TYPE CALIBRATION MODEL eee Thermostat single pole disc CAMPINI COREL GENERATOR Bimetallic manual reset and o o code LIMIT THERMOSTAT rapid opening ofthe contact 90 C 7 C 60R180H02 04154 UIOS Cont
55. defrosted overriding software control regarding the timing of this operation Defrosting mode is managed automatically by the on board electronics and is activated only under specific operating conditions the on board electronics verify the appropriate requirements You will need access to the electrical panel see Section Display and knob To execute the manual defrosting command select menu 2 as described in the Section how to access the menus then proceed as follows 1 The display shows 2 press the knob to access the menu The display initially shows item 2 20 2 Turn the knob clockwise to display 2 22 Press the knob to display the manual defrosting flashing request deFr 4 Press the knob again to execute the command The manual defrosting request stops flashing and the again display shows 2 22 The manual defrosting opera tion has been performed if the appropriate requirements are satisfied 5 To quit the menu turn the knob clockwise until the 2 E is displayed Now press the knob to return to menu selection 27 6 Toexitthe menu selection and return to the normal visualisation of the parameters of the appliance turn the knob clockwise until E displays press the knob to quit rad OPERATING SETTINGS The operations described require basic knowledge of the plant installed and of the S61 controller fitted to the appliance before proceeding you must acquire this information Section 3
56. densate manifold must be in a visible location Figure 4 3 Position of condensate discharge and manual reset fumes thermostat LEGEND A Condensate drain pipe B Condensate drain siphon C Manualreset fumes thermostat The condensate discharge to the sewer must be e sized so as to discharge the maximum condensation flow see Table 2 1 GAHP A LT technical data on page 12 or Table 2 2 GAHP A HT technical data on page 13 under the respective heading 31 e implemented with material capable of resisting a degree of acidity equal to 3 5 pH e 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 e implemented in such a way as to prevent the condensate icing in the expected operating conditions e mixed for example with domestic effluent washing machine dishwasher etc usually of base pH so as to form a buffer solution before discharge into the sewer i Do not discharge the condensate into the guttering since it may ice and corrode the materials normally used for gutters LOADING THE SIPHON Proceed as follows to load the siphon 1 Connect the condensate discharge pipe to a drain 2 Pour 0 2 litres of water directly into the fumes discharge pipe and check that the siphon is full detail B in Figure 4 3 Position of condensate discharge and manu
57. e manufacturer or supplier of the chemical substances for the flushing avoiding the use of substances aggressive for stainless steel or containing releasing active chlorine Please make sure the pipes are properly flushed 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 Non compliance with indications above may jeopardize the proper operation integrity and reliability of Potterton Commercial appliances invalidating the warranty The components described below are those to be always fitted in proximity to the appliance ANTIVIBRATION JOINTS in line with the water and gas connections of the appliance e MANOMETERS installed in the inlet and outlet water pipes INLET FLOW CALIBRATION VALVE either of the gate valve or the overcentre valve type installed in the water inlet pipe of the appliance only if the appliance is controller by a DDC e WATER FILTER installed in the appliance water inlet pipe e ISOLATION BALL VALVE in the water and gas pipes of the plant e 3 BAR SAFETY VALVE installed in the appliance outlet water pipe PLANT EXPANSION TANK installed in the appliance outlet water pipe e EXPANSIONTANK for individual appliance installed in the appliance water outlet pipe primary side Provide a plant expansion tank in any case s
58. e of glycol antifreeze Glycols normally used to lower the freezing point of water are substances in an intermediate state of oxidisation which in the presence of oxidising agents such as oxygen are transformed into corresponding acids Thistransformation into acids increases the corrosive nature of the fluid contained in the circuit For this reason mixtures that are commercially available almost always contain inhibiting substances that are able to 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 Most circuits however are of the non sealed type and therefore receive a more or less continuous supply of oxygen Therefore it is essential whatever type of glycol is in question to verify that itis adequately inhibited and that the necessary checks are regularly performed during its entire period of use i Antifreeze liquids for cars which do not contain inhibiting components other than ethylene glycol are not recommended for cooling and heating plants The manufacturer does not accept any contractual or extra contractual liability for dam
59. econdary side installed in the appliance water outlet pipe The appliance is not equipped with an expansion tank therefore it is necessary to install a suitable expansion tank the sizing of this vessel should be calculated by a suitably qualified heating engineer e variable rate WATER CIRCULATION PUMP FOR PLANT WITH A SINGLE APPLIANCE located on the water inlet pipe of the appliance flowing towards the appliance e variable rate WATER CIRCULATION PUMP FOR PLANT WITH SEVERAL APPLIANCES each appliance should have a pump flowing towards the appliance PLANT FILLING SYSTEM if automatic filling systems are used a seasonal check of the percentage of monoethylene glycol in the plant is recommended Theoperations 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 UN 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 The gas mains pressure must be in the range given in Table 6 1 Network gas pressure on page 59 A Supplying gas to the appliance at higher pressures than those indicated above can damage the gas valve For LPG systems fit a first stage pressure reducer of the flow necessary near the liqui
60. enomena inside the hermetic circuit has immediate effect that cause machine anomalies that can be easily recognised 1 Development of a large amount of non condensable and non absorbable gas produced of the corrosion reaction which causes an accumulation of these gases in the generator and consequently immediate overheating of the generator This is caused by the interruption of the water ammonia solution evaporation process 2 Production of rust which detaching from the internal walls of the hermetic circuit rapidly blocks the circulation of refrigerant fluid thus blocking the orifices of the restrictors This situation leads to alack of water ammonia solution to be evaporated in the generator and causes the same over heating phenomenon In both cases the over heating of the generator makes the manual rearm safety thermostat intervene which is installed on the wall of the generator As a consequence if there are no generator thermostat interventions all corrosion phenomena can be excluded and no inspection or additional action is necessary The possibility that internal corrosion phenomena are in progress must be taken into consideration only when a series of five 5 thermostat interventions are detected In this case contact the Potterton after sales service Installation user and maintenance manual GAHP A 75 PART OF BDR THERMEA Baxi Commercial Division Wood Lane Erdington Birmingham B24 9QP Email andrews ba
61. er appliances as illustrated in Figure 4 2 Clearances on page 28 Minimum clearances are necessary in order to be able to carry out maintenance operations and to ensure the correct airflow required for heat exchange with the finned coil Figure 4 2 Clearances 600 800 Position the appliance preferably out of range ofrooms 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 effect 4 3 HYDRAULIC CONNECTIONS General indications The hydraulic circuit may be created using pipes in stainless steel black steel copper or crosslinked polyethylene for heating cooling plants All water pipes and pipe connections must be adequately insulated in accordance with current regulations to prevent heat loss and the formation of condensate Topreventicing in the primary circuit in the winter the appliance is equipped with an antifreeze device that activates the external water circulation pump of the primary circuit if controlled by the appliance and the burner of the appliance itself when necessary It is therefore necessary to ensure a continuous supply of electricity and gas to the appliance throughout the whole of the winter period If it is not possible to ensure a cont
62. er temperature that when reached causes the appliance to be deactivated when the power modulation is not active parameter 181 e Water differential parameter 162 this parameter represents an interval in degrees that when added to the set point defines the temperature at which the appliance is reactivated This parameter is used only if the power modulation is NOT active parameter 181 The appliance functions by heating the water until it reaches the set point temperature At this point if the power modulation is not active parameter 181 it switches off The temperature of the water goes down again until it reaches the temperature corresponding to set point differential when this is reached the appliance switches on again Example Thermostating reading from inlet sensor Parameter 181 0 power modulation NOT active Set point 40 0 C Differential 2 0 C e The appliance is functioning the water in the plant heats up until it reaches the set point temperature 40 C e The appliance switches off the water returning from the system becomes progressively cooler until it reaches a temperature of 38 C 40 C 2 The appliance switches on again and the system water is heated up again The cycle is repeated The following procedure illustrates in detail how to configure the parameters on the electronic board inside the appliance If the procedures for how to access the knob and menus are not familiar see
63. ernal panels which would be signs that damage occurred during transport Packing materials must be removed only after the appliance has been positioned on site After removing the packing materials ensure that the appliance is intact and complete NI Installation of the appliance may only be carried out by firms that are qualified in accordance with current legislation in the country of installation i e by professionally qualified personnel Professionally qualified personnel means personnel with specific technical competence inthe sector of heating cooling plants and gas appliances Installation of the appliance must be carried out in compliance with current local and national regulations regarding the design installation and maintenance of heating and cooling plants in accordance with the manufacturer s instructions In particular current regulations regarding the following must be observed Gasequipment Electrical equipment e Heating installations and heat pumps The manufacturer does not accept any contractual or extra contractual liability for any damage caused by errors in installation and or failure to observe the above mentioned regulations and the instructions supplied by the manufacturer itself Once the appliance is installed i The firm that has undertaken the installation must provide the owner with a declaration that the installation has been carried out in compliance with proper workmanship practices
64. external bipolar circuit breaker see detail GS in Figure 5 5 Electrical wiring diagram on page 41 with 2 type T 5A fuses or a 10 A circuit breaker 3 Make the electrical connection in such a way that the ground wire is longer than the live wires In this way it will be the last wire to be pulled away if the mains cable should accidentally be pulled and will thus guarantee the earth connection E The electrical safety of the appliance is guaranteed only when it is correctly connected to an efficient earthing system executed in accordance with current safety regulations BS7671 17th edition Do not use gas pipes to ground electrical appliances Figure 5 5 Electrical wiring diagram LEGEND TER 2 f 2 TER terminal board 2 12 jte L phase L N N neutral Components NOT SUPPLIED GS general switch Example of connection of appliance to 230 V 1 N 50 Hz electricity supply 5 3 CASCADE CONTROL T This paragraph illustrates the operations to be performed when one or more appliances are connected to a Direct Digital Controller DDC In particular What is the CAN bus cable How to connect the CAN BUS cable to the appliance s controller How to connect the CAN BUS cable to the DDC How to connect the DDC How to connect the plant water circulation pump PI MS PU ct T For specific information regarding the DDC refer to the specific manuals supplied with it The appliance and the DDC communicate with each other via a CAN
65. following the diagram in Figure 5 11 DDC electric supply on page 47 Pass the cable through the opening in the cover before fixing the wires to the connector To power up the DDC proceed as follows Installation user and maintenance manual GAHP A I You will need the appliance disconnected from the electricity supply 1 Remove the DDC s back panel by undoing the 4 bolts securing it 2 Cuta suitable length of power cord minimum 2x0 75 mm 3 Passthe power cord DDC side through the hole in the DDC s cover and hook up as shown in the example with the following polarities terminal 1 24 V terminal 2 0V terminal 3 ground Make sure the grounding connection on the transformer terminal is connected to terminal 2 of the 4 pole connector EP of the DDC Terminal 2 is connected internally to terminal 3 and is thus grounded if the transformer already has one wire grounded it must be connected to this terminal Terminal 3 of the DDC s 4 pole connector must always be grounded r lt 0 10 ve 4 On completion close the DDC s back panel with the 4 bolts E 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
66. g _230V 230V BIX BK WHBRCONTACTL N LN NL Rwyo 1 2I2 11 ir ist 2I2I2I2 z C LEGEND DDC direct digital control SCH electronic board S61 J1 Jumper CAN BUS in board S61 J21 Jumper CAN BUS in board DDC A terminal nodes connection 3 wires J1 e J21 closed H L GND data signal wires rif cables table Connection cable CAN BUS between one DDC and one unit 48 Installation user and maintenance manual GAHP A Figure 5 13 Connection cable CAN BUS for plants with more unit Z M VAE E ETIAIN co s w Y os closed Ir w3awniX CooL terminal nodes connection 3 wires J1 e J21 closed direct digital control electronic board S61 Jumper CAN BUS in board S61 Jumper CAN BUS in board DDC intermediate node connection 6 wires J1 data signal wires rif cables table LEGEND H L Gnd 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 49 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 e Direct control from the controller with power absorbed by the pump less than 700 W If the power absorbed by the pump is less than 700 W make the connection as
67. he code is generated The program attempts to resolve the problem by Reset may be performed from the CCI DDC or from the 61 board E481 VALID BANK 1 PARAMETERS writing the second page over the first if after 5 via menu 2 parameter 21 If the code persists contact authorised attempts this fails the error is generated Potterton TAC u 482 VALID BANK 2 PARAMETERS Invalid Bank 2 data Bank 1 data OK Reset occurs automatically 5 seconds after the code is generated The program attempts to resolve the problem by Reset may be performed from the CCI DDC or from the 61 board E482 VALID BANK 2 PARAMETERS writing the first page over the second if after 5 via menu 2 parameter 21 If the code persists contact authorised attempts this fails the error is generated Potterton TAC Check fuses and 24 0 24 V AC electrical power connections on the FAULTY TRANSFORMER Damage to one of the 2 24 0 24 V AC transformer controller Reset may be performed from the CCI DDC or from the E484 fuses or one of 24 0 24 V AC wires to the board i CONNECTION OR 24 V AC FUSES not supplying current S61 board via menu 2 parameter 21 If the code persists or occurs pp ying i again contact authorised Potterton TAC E485 INCORRECT MODULE TYPES from The set module type from menu 6 does not Reset occurs automatically when correct parameters are entered If menu 6 correspond to the one managed by the controller the code persists contact authorised Potterton TAC E 486 M
68. he maintenance of the combustion unit the following should be done at least once yearly Burner clean and replace if visibly damaged on the surface e Electrodes check and repair in case of incorrect physical configuration alumina deposits or degraded protective ceramic and gaskets e Fumes limit thermostat and combustion unit replace only after having identified the cause of the problem and made sure that it is not due to the heat exchanger overheating If you replace it track the new component Extraordinary maintenance The operations described in this paragraph must be carried out as and when necessary Adding water and antifreeze to the hydraulic plant If it should become necessary to add water to the plant and if required to the water in the plant free of impurities glycol antifreeze of the inhibited monoethylene type for the correct execution of these procedures proceed as described in Section 4 6 FILLING OF HYDRAULIC CIRCUIT on page 32 e 1 2 e 10 11 12 13 14 15 6 3 CHANGE OF GAS TYPE A This operation must be carried out exclusively by an authorised Potterton Commercial Engineer Ifthe 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 the appliance shut off its power and gas supplies and proceed as follows i You will need the appliance switched off an
69. he two red silicone protections 7 Re mount the front panel of the unit Figure 8 3 Inspection of generator limit thermostat 99090900090990000090900990000909000900009090000000900099009009000900090990909900090009099000090900000000900900090009000000090000009090909000000909090009009 090909000909099000090209000090000000090090900090900990000090909000009090900000090990000909000009009090000000900900000092920000090090000090909000009099 Thermostat detail Figure 8 4 Safety valve kit LEGEND n 1 Safety valve n 1 ORing n 1 Litmus test 0909900090909090900909099999000090090000009909900090090000009090900009090000000090009909900000000000000090009090000000900090009909909090900099099 Necessary components The components subject of the intervention are represented in Figure 8 5 particular safety valve mounted on unit on page 72 1 2 3 LEGEND A Safetyvalve B Inspection valve C Hermetic circuit Description of components bought in Y Stop the unit and wait for the end of the switch off cycle Disconnect the unit electric power supply Remove the upper panel from the unit Position the n 2 CH22 spanners in the relevant seat see Figure 8 6 Smontaggio valvola di sicurezza on page 72 WARNING DO NOT REMOVE THE COMPONENTS DISTINGUISHED BY THE WAX SEAL Figure 8 6 Removing the safety valve LEGEND A Keep fixed B Rotate clockwise Safety valve disassembly 4 Loosen the inspection valve in the
70. inuous supply of electricity and gas to the appliance use glycol antifreeze of the inhibited monoethylene type If glycol antifreeze is to be used see Section 4 6 FILLING OF HYDRAULIC CIRCUIT on page 32 DO NOT USE galvanised pipes as they are potentially subject to corrosion phenomena in the presence of glycol e Whenrigid pipesareused to preventthetransmission of vibrations itis recommended that the appliance water inlet and outlet are connected with antivibration joints Installation user and maintenance manual GAHP A As with other heating appliances Potterton heating and cooling systems operate with water of good quality In order to prevent any possible problem of operation or reliability caused by filling or top up water please refer to codes and standards regarding water treatment for heating systems in commercial applications Parameters indicated in Table 4 1 Chemical and physical parameters of water on page 29 must be complied with Table 4 1 Chemical and physical parameters of water CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING COOLING SYSTEMS PARAMETER UNIT OF MEASUREMENT ALLOWABLE RANGE pH 65 80 Chlorides mg L 125 Total chlorine mg L 5 Total hardness CaCO f 10 15 Iron mg L 50 Copper mg L 3 Aluminium mg L 3 Langelier s index 0 HARMFUL SUBSTANCES Active Chlorine mg L lt 02 Fluorides ABSENT Sulphides ABSENT n accordance and respecting current legislation Water quality c
71. itch 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 99m i When the pump is controlled by the appliance s controller this delay is automatically applied by the board 5 4 TYPE C CONSENT SWITCH In this type of installation and control the system pump does not vary the flow rate A Before making the electrical connections make sure that work is not carried out on live elements General indications e Check that the power supply voltage is 230 V 1N 50 Hz power e Make the electrical connections as given in the following wiring diagrams Make the electrical connection in such a way that the ground wire is longer than the live wires In this way it will be the last wire to be pulled away if the mains cable should accidentally be pulled and will thus guarantee the ground connection The electrical safety of the appliance is guaranteed only when it is correctly connected to an efficient grounding system executed in accordance with current safety regulations Do not use gas pipes to ground electrical appliances How to connect the consent switch Joe You will need the appliance is electrically isolated external master power switch set to OFF 1 Connect the consent switch on off switch or ambient thermostat or timer etc to terminals R and W on the appliance s control circuit as shown in
72. lar e Fit a gas cock on the gas supply line e Fit antivibration joints on the hydraulic connections POSITION OF THE APPLIANCE Lifting the appliance and placing it in position The appliance must be kept in the same packing in which it left the factory while it is moved on site Packing must only be removed upon final installation 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 For the weight of the appliance consult Table 2 1 GAHP A LT technical data on page 12 or Table 2 2 GAHP A HT technical data on page 13 The manufacturer cannot be held responsible for any damage that occurs during the setting up of the appliance Figure 4 1 Instruction for lifting The appliance can be installed at ground level on a terrace or on a roof if compatible with its dimensions and weight The dimensions and weight of the appliance are given in Table 2 2 GAHP A HT technical data on page 13 MOUNTING BASE Always position the appliance on a f
73. lat level surface that is made of fireproof material and able to sustain the weight of the appliance itself In addition provide a small containing step that will prevent water from spreading during possible winter defrosting phases During winter operation the appliance on the basis of temperature and humidity conditions of the outside air can carry out defrosting cycles that cause the layer of frost ice on the fan coil to melt Take this possibility into consideration adopting appropriate measures for example a containing step and channelling of water into a suitable drain in order to prevent ple T d Rie w Wa 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 Installation at ground level If a horizontal support base is unavailable see also SUPPORTS and LEVELLING below it is necessary to create a flat level base in concrete which is larger than the dimensions of the base of the appliance by at least 100 150 mm on each side The dimensions of the appliance are given in Table 2 1 GAHP A LT technical data on page 12 or Table 2 2 GAHP A HT technical data on page 13 Provide a containing step and a suitable drainage channel for the water
74. les type CABLE NAME SIGNAL COLOR MAX LENGTH Note Potterton POTTERTON NETBUS H BLACK L WHITE GND BROWN 450m Ordering eode vous Honeywell SDS 1620 BELDEN 3086A na H BLACK L WHITE GND BROWN 450m DeviceNet Mid Cable In all cases the fourth conductor should not be used TURCK type 5711 H BLUE L WHITE GND BLACK 450m Honeywell SDS 2022 TURCK type 531 H BLACK L WHITE GND BROWN 200m Example types of cables used to connect the CAN network Installation user and maintenance manual GAHP A T For overall distances to cover x200 m and networks with a maximum of 6 nodes a typical example up to 5 GAHP A 1 DDC a simple shielded cable 3x0 75 mm may be used As shown in Table 5 2 CAN BUS cables type on page 42 the CAN connection requires a CAN bus cable with 3 wires If the available cable has more than 3 coloured wires use the wires with the colours indicated in 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 controller as Shown below see Figure 5 7 CAN BUS cable connection on page 43 Figure 5 7 CAN BUS cable connection LEGEND A Insulating tape to protect board shield B CAN bus cable shield C Cable fixing bracket D Connector for co
75. n illustrates the operations to perform for the correct electrical installation of the appliance and contains electrical diagrams that may be of use in the event of maintenance operations Installation of the appliance may only be carried out by firms that are qualified in accordance with current legislation in the country of installation i e by professionally qualifled personnel 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 Figure 5 1 Electronic board S61 on page 37 and Table 5 1 Electronic board S61 on page 38 detail the S61 controller s inputs and outputs The supplementary controller Mod10 is shown in detail in Figure 5 2 Mod10 controller on page 39 The appliance and the system can be controlled and regulated in one of the following ways depending on the type of installation and control system selected TYPE A NOT APPLICABLE at PRO Platform controlled by Comfort Control Panel e TYPE B controlled by DDC see Figure 5 3 Direct Digital Control DDC on page 39 e TYPE C controlled by consent switch e g on off switch ambient thermostat timer etc In Section 5 1 ELECTRICAL DIAGRAMS OF THE APPLIANCE on page 40 the Electrical diagrams of the appliance can be found Figure 5 1 Electronic boar
76. n the installation of the appliance Check that the water pressure and flow in the hydraulic circuit and the dynamic gas mains pressure are correct as indicated in Table 6 1 Check that the electrical power supply is 230V 50Hz e Check that the air flue pipes are properly connected Check that the flue condensate discharge is installed e Check that the safety clearances have been observed as shown in Figure 4 2 Clearances on page 28 If all the conditions listed above exist the Potterton Commercial Engineer can proceed with the initial activation of the appliance Ifanynon compliant elements arise during theinitial verification the Potterton Commercial Engineer may choose not to proceed with the operation of initial activation SN In this case the Potterton Commercial Engineer must e Advise the user installation technician of any installation anomaly e Inform the user installation technician of any situation that is deemed to be hazardous for the appliance and for people e Inform of any missing documentation relative to the plant e Indicate in relation to the reports made any corrective measures to be taken on the plant which the installation technician will have to carry out in order to proceed with the operation of initial activation It is the responsibility of the user installation technician to carry out any corrective measures on the plant indicated by the Potterton Commercial Engineer Following such
77. nit Installation user and maintenance manual GAHP A Figure 5 18 Button connection for flame controller reset an ss E g Bs se 2 PEE gn moon te cmq n t t gt P Q i i i i i L saa EI c l a g 3 2 X 8 a eye ew sSsic N SO Fr 00 Os ad ja am cC c So o oX 070 0 snega GE sg Oleo 80 AdIENWC SdAL VWHVe s 9g 82 858 Jo eee es 55 56 6 1 Installation user and maintenance manual GAHP A INITIAL ACTIVATION AND MAINTENANCE In this section you will find the following information e Indications required by the authorized Potterton Commercial Engineer in order to carry out the entire procedure of first start up of the appliance e Indications regarding maintenance operations of the appliance At the end of the section you will find instructions for changing the type of gas Before proceeding with theoperations described inthis section the installation technician concerned is invited to read Section 2 1 WARNINGS on page 7 in regard to switching the appliance on and off refer to Section 3 1 START UP AND SHUT DOWN on page 15 If the appliance is connected to a DDC and the DDC is in controller mode for the phases of activation and deactivation of the appliance it is necessary to refer to the two manuals dedicated to the DDC itself PROCEDURE FOR INITIAL ACTIV
78. nnect the manometer to the gas intake see detail D Figure 6 1 Gas valve on page 59 2 Openthe gas cockand check that the static mains pressure is in line with the values given in Table 6 1 Network gas pressure on page 59 A If the static mains pressure is greater than 50 mbar DO NOT switch on the _ appliance 3 Give the consent signal for operation 4 After a few seconds of operation check that the dynamic mains pressure is in line with the values given in Table 6 1 Network gas pressure on page 59 Figure 6 1 Gas valve LEGEND A Plug B Key Torx TX40 C screw adjustment CO2 D gaspressure intake Gas valve Honeywell VK 4115V Table 6 1 Network gas pressure E3 GS E3 WS E3 A GAHP GS GAHP WS GAHP A Gas supply pressure Product categories Countries of destination G20 mbar G25 mbar G30 mbar G31 mbar G25 1 mbar G27 mbar G2 350 mbar mem AT CH 20 50 50 A If the pressure reading is not in line with Table 6 1 Network gas pressure on page 59 DO m NOT activate the appliance ds Proceed with the regulation verification of the combustion parameters as stated in the next paragraph Checking and adjusting the combustion parameters After having checked the dynamic mains pressure see page 59 you may check and adjust the combustion parameters as follows 1 10 Insert the combustion products analysis probe into the vertical tract of the flue gas pipe see reference B in Figure 4 4 Fume
79. nnecting terminals of CAN bus wires E Terminals n 3 of CAN bus cable F fixing point of 2nd segment of CAN bus cable for INTERMEDIATE NODES if required Example of a single CAN bus cable connected to the board Before working on the electrical panel of the appliance make sure that it is not connected to the power supply 1 Cuta length of cable long enough to allow it to be installed without kinking 2 Having chosen one end of the length of cable remove the sheath from a length of approximately 70 80 mm taking care not to cut the shielding metallic shield and or aluminium sheet and if present the bare connector in contact with the shield and the wires contained within 3 If the cable is too thin to be held in place in the cable holder bracket detail C in Figure 5 7 CAN BUS cable connection on page 43 make it thicker by wrapping insulating tape around it on the sheath in the area adjacent to the stripped part to an approximate diameter of 12 13 mm 4 Pull back the shielding in the sheathe apply electrician s tape to the end of the shielding as pulled back detail A Figure 5 7 CAN BUS cable connection on page 43 5 f the appliance is a terminal node of the network connect the three coloured wires to the orange connector as shown in detail A of Figure 5 8 Electrical wiring diagram on page 44 Respect the correct indications L H GND provided in Table 5 2 CAN BUS cables type on page 42 on the figure and on the di
80. ob to return to menu selection 2 5 Toexitthe menu selection and return to the normal visualisation of the parameters of the appliance turn the knob clockwise until E displays press the knob to quit ACTION 21 Reset other warnings errors this is required to reset any warnings and errors that may occur during operation of the appliance zo You will need access to the electrical panel see Section Display and knob 3 4 NJ 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 Turn the knob clockwise to display item 2 21 Press the knob to display the flashing reset request rEr1 4 Presstheknob again to perform a board error reset The reset request stops flashing and the display again shows 2 21 The reset operation has been performed 5 To quit the menu turn the knob clockwise until the 2 E is displayed Now press the knob to return to menu selection 27 6 Toexitthe menu selection and return to the normal visualisation of the parameters of the appliance turn the knob clockwise until E displays press the knob to quit w ACTION 22 Manual defrosting the execution of the manual defrosting command provided that the conditions exist these are verified electronically allows the fan coil to be
81. ommissioned Engineer it gives general warnings operating instructions and constructional specifications This section also contains technical data and dimensional drawings of the appliance SECTION 3 is intended for use by the final user it provides the information necessary to use the appliance correctly according to the user s own requirements SECTION 4 is intended for use by the hydraulic installation technician it provides the indications necessary for the technician for the creation of the hydraulic circuit flue gas and gas supply system 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 verification of plant compliance initial activation and regulation of gas flow to the burners and instructions on how to change the gas type if required This section includes a summary of the main maintenance operations checks controls and cleaning operations to perform to which the appliance is subject SECTION 7 is intended for use by the final user hydraulic and electrical installation technicians and the Potterton Commercial Commissioned Engineer it contains information about accessories available for the appliance SECTION 8 is an appendix which lists the appliance s oper
82. ondensate siphon is NOT empty or blocked see Section 4 5 CONDENSATE DISCHARGE CONNECTION on page 31 6 Checkthat the air flue pipes are not blocked 7 Switch on the appliance by means of the on off command or DDC if present and in control mode or via CCP if present 24 4 1 4 2 d Heo um e Installation user and maintenance manual GAHP A HYDRAULIC SYSTEM INSTALLATION TECHNICIAN In this section you will find 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 qualified 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 GENERAL INSTALLATION PRINCIPLES Prior to installation carry out careful internal cleaning of all pipes and every other component to be used both on the hydraulic circuit and the gas supply circuit in order to remove any residues that may compromise operation of the appliance Installation of the appliance must be carried out in compliance with current regulations regarding design installation and maintenance of heating and cooling plants and must be undertaken by professionally qualified personnel in accordance with the manufacturer s instructions During the installation stage observe the following indications e Check
83. outlet on page 34 Give the unit functioning consent and wait for at least 5 minutes for normal combustion conditions With the appliance running access menu 2 parameter 24 of the unit s controller the display will flash P_H1 press to confirm forcing maximum thermal power Check that the value of CO read on the flue gas analyser coincides with the value given in Table 6 2 Gas nozzles and content of CO2 on page 62 at the Content of CO with MAX modulation line with 0 2 0 4 tolerance Example G20 gas the nominal content of CO is equal to 9 196 values in the range between 8 7 9 96 are therefore acceptable Access menu 2 parameter 23 of the unit s controller inside the electric panel the display will flash P L1 press to confirm forcing minimum thermal power Now check that the difference between the value read in point 4 and that now displayed on the flue gas analyser corresponds to the data given in the Table 6 2 Gas nozzles and content of CO2 on page 62 at the Delta CO between MAX and MIN potentiality line with tolerance of 0 3 0 0 Example G20 gas if at point 4 a content of CO equal to 9 296 was detected at point 6 there must be a value of 9 296 0 4 with tolerance of 0 3 0 0 on the delta value i e a value in the range of 8 8 8 5 If this is not the case remove cap A from the gas valve see Figure 6 1 Gas valve on page 59 and use a Torx TX40 wrench to act on screw C in Figure 6 1 Gas valve on page 59 Turn clock
84. pe of installation and control setup TYPE A NOT APPLICABLE at PRO Platform controlled by Comfort Control Panel e TYPE B controlled by DDC see Figure 5 3 Direct Digital Control DDC on page 39 TYPE C controlled by consent switch e g on off switch ambient thermostat timer etc START UP AND SHUT DOWN Before activating the appliance check that e the gas valve is open e the appliance is powered electrically e the CCP DDC are electrically powered e the installation technician has ensured that the hydraulic circuit is supplied in the correct conditions If these conditions are satisfied it is possible to proceed with activation Type A appliance connected to Comfort Control Panel CCP Type NOT APPLICABLE at PRO platform Type B appliance connected to a Direct Digital Controller DDC If the appliance is connected to a Direct Digital Controller see Figure 5 3 Direct Digital Control DDC on page 39 and the DDC is in controller mode activation and control of the appliance will occur exclusively by operating the DDC In this case refer to the manual supplied with it The appliance must never normally be switched on and off by shutting off the power supply upstream of the DDC before having used the latter first and waited for the shut down cycle to end approximately 7 minutes The shutdown cycle terminates when the hydraulic pump switches off no parts in motion Shutting off the power supply while the applian
85. ral appliances to the CCP if present or a DDC if present The Mod10 controller see detail D in Figure 3 1 On board controller on page 17 is used for combustion modulation Figure 3 1 On board controller 090000000290090009090909900000909900900909090990000009000000000900000909000009909000090090900009000900000009090000009000000090000009009090000099 9 LEGEND A 4 digit display B Knob C CAN port D Mod10 controller 099000009099000009909000000900000909000900009099000009009000009090000090000900000000009009900000009099000009020000090900909000090909900090090999 S61 Mod10 Description of menu of S61 controller The parameters and settings of the appliance are grouped in the menus shown on the controller s display Table 3 1 Menu of electronic board 9990000090990000909090900009090900000090990900009909900000099090900009099090000090900090000900990009009900000900909990000092000009009900009090990000099099 MENU MENU DESCRIPTION THE DISPLAY SHOWS Menu 0 VIEW DATA TEMPERATURE VOLTAGE PUMP SPEED ECC 0 Menu 1 VIEW ALL PARAMETERS 1 ENTER ACTIONS 2 USER SETTINGS THERMOSTATING SET POINT T DIFFERENTIAL 3 INSTALLATION TECHNICIAN SETTINGS 4 TECHNICAL ASSISTANCE CENTRE SETTINGS 5 TECHNICAL ASSISTANCE CENTRE SETTINGS MACHINE TYPE 6 VIEW DIGITAL IMPUTS 7 MENU NOT USED 8 EXIT MENU E Menu list of electronic board Menus 0 1 and 7 are Viewing Menus they only
86. rator temperature probe input Hot water delivery temperature probe input Hot water return temperature probe input SCH S61 Generator limit thermostat input Installation user and maintenance manual GAHP A Figure 5 2 Mod10 controller 090090900909900000900909000909009000900000000009090000900000900900000090009000090090009090000900090000090090000090900000909009000000000900090999 HFLUW CFLOW LEGEND HFLOW Notused CFLOW Not used J51 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 CN5 Blower control J82 W10 auxiliary controller connector J83 W10 cable shielding connection W10 CN1 Inputs 0 10V not used CREQ CAL HREQ a m lt eu Oo eu e Zz oO z oO band e J OJ OJ OJ O COMB FAN ra i 9090000909009000090909000000000000900009000090900000000900000000000000900000000000000090000000000000000900000000900000900000000009999 Mod10 controller Figure 5 3 Direct Digital Control DDC 000000090099900009099000090900000090909000000909090000000090000009090000000909000009099099000000090000099009000990000000090090909000000099000009099 LEGEND DDC Direct Digital Control 090900009090999000090092900000009900000900990000090990000090990000009000000090000000000000090099000009090090000090092000009009090000090909000009099
87. revents problems guarantees maximum operating efficiency of the appliance and allows running costs to be contained Before carrying out any operation on the appliance switch it off via the CCP DDC or consent switch and wait for the shutdown cycle to terminate When the appliance is off disconnect it from the gas and electricity mains via the external circuit breaker and the gas valve Any operation that regards internal components of the appliance must be carried out by an authorized Potterton Commercial Engineer according to the instructions supplied by the manufacturer Ordinary scheduled maintenance Perform the operations described below at least once a year If the unit is subjected to particularly heavy use 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 filters e Inspecting the condensate siphon and removing any foreign substances Checking that the oil pressure pump is operating correctly Checking the oil level e Checking the transmission belts replacement every 5 years or 10 000 hours of operation Checking the ignition and flame detector system Checking the operation of internal components safety and regulation equipment Analysis of combustion products Furthermore as regards t
88. s Reset occurs automatically when the condition that generated the thermostat code ceases Reset may be performed from the CCI DDC or from the 61 board E402 FUMES THERMOSTAT u 02 code active for 1 hour or u_02 code via menu 2 parameter 21 If codes u_02 and or E 02 occur again generated 3 times in 2 hours of operation contact authorised Potterton TAC HIGH temperature detected by ambient Reset occurs automatically when the condition that generated the E405 HIGH AMBIENT TEMPERATURE temperature sensor code ceases E406 LOW AMBIENT TEMPERATURE LOW temperature detected by ambient Reset occurs automatically when the condition that generated the temperature sensor code ceases u407 HIGH CONDENSER INLET HIGH temperature detected by condenser inlet Reset occurs automatically when the condition that generated the TEMPERATURE temperature sensor or fumes sensor code ceases Carry out appropriate checks Reset may be performed from the E407 MIGH CONDENSER INLET u07 code acie forl Kour or uar coar CCI DDC or from the S61 board via menu 2 parameter 21 If the g p code persists contact authorised Potterton TAC Carry out appropriate checks Reset may be performed from the E408 FLAME CONTROL UNIT ERROR oe s a al CCI DDC or from the S61 board via menu 2 parameter 21 If the 95y code persists contact authorised Potterton TAC u410 INSUFFICIENT HOT WATER FLOW nea water low Mh e circula eae and Reset occurs automatically when correct water flow
89. shown in Figure 5 14 Electrical wiring diagram see page 50 and checkthat the jumper J10 located at the bottom left of the controller above the NO Contact contacts is CLOSED as shown in detail A Direct control from the controller with power absorbed by the pump of more than 700 W If the power absorbed by the pump is more than or equal to 700 W make the connection as shown in Figure 5 15 Electrical wiring diagram see page 51 using a control relay In this case it is necessary to OPEN the jumper J10 located at the bottom left of the controller above the NO Contact contacts positioning it as shown in detail A of the Figure Figure 5 14 Electrical wiring diagram LEGEND SCH electronic board TER terminal board i J10 jumper closed 1 N O CONTACT clean exit normally open L phase N neutral Components NOT SUPPLIED CS ON OFF control switch PMP water pump 700W GS general switch Example of pump appliance electrical connection with 230 Vac pump with absorbed power of 700 W controlled directly by the appliance Installation user and maintenance manual GAHP A Figure 5 15 Electrical wiring diagram 4 LEGEND agers s J SCH electronic board K E TER terminal board Mii S10 decr J10 jumper open 10 s N O CONTACT clean exit normally open x a ar ND L phase TS E i CONTACT N neutral A lt m m Component NOT SUPPLIED T 230V 230V CS ON OFF control switch PMP water pump 700W KP control p
90. switches on ELECTRICAL POWER central flame control unit on again within 10 minutes with central flame control unit on er Carry out appropriate checks Reset may be performed from the E429 ELENCO WITHOUT n reed MPa 10 minutes CCI DDC or from the S61 board via menu 2 parameter 21 If the i code persists contact authorised Potterton TAC Reset may be performed from the CCI DDC or from the S61 board E436 BLOWER FAULT Blower fault via menu 2 parameter 21 If the code persists contact authorised Potterton TAC E437 LOW COMBURENT AIR Air comburent temperature equal or smaller of Reset occurs automatically when the condition that generated the TEMPERATURE 10 C code ceases CODES DESCRIPTION TRIP CONDITIONS RESET METHOD Reset may be performed from the CCI DDC or from the S61 board E444 EVAPORATORTEMPERATURE Evaporator temperature probe fault via menu 2 parameter 21 If the code persists contact authorised SENSOR FAULT Potterton TAC u 446 HOT INLET WATER TEMPERATURE Motin E E dat d Resets automatically if with the circulator on the cause resolves or TOO HIGH Op g pp pp with circulator off 20 minutes after generation of code isin operation Hot water temperature lower than lower Reset occurs automatically when cause resolves or 430 seconds u447 LOW HOT WATER TEMPERATURE operating limit of the appliance if the appliance after the code is anere is in operation 9 u_47 code generated 3 times in 1 hour of Reset occurs autom
91. thatthereisan adequate mains gas supply in accordance with the manufacturer s specifications see Table 6 1 Network gas pressure on page 59 for the correct supply pressures The appliance must be installed outdoors located in an area in which air circulates naturally and which does not require any particular protection from the weather In no case must the appliance be installed inside a room The front of the appliance must be at least 80 cm away from walls or other fixed constructions the right and left sides must have a minimum clearance of 45 cm the minimum rear clearance from walls is 60 cm see Figure 4 2 Clearances on page 28 e No obstruction or overhanging structure protruding roofs eaves balconies ledges trees must obstruct either the air flowing from the top part of the appliance or the exhaust flue outlet The appliance must be installed in such a way that the exhaust flue outlet is not in the immediate vicinity of any external air inlets of a building Respect current regulations regarding the exhaust fumes outlet Do not install the appliance close to flues chimneys or other similar structures in order to prevent hot or polluted air from being drawn by the fan through the condenser In order to function correctly the appliance must use clean air from the environment e If itis necessary to install the appliance near buildings make sure that the appliance is not in the line of water dripping from guttering or simi
92. tterton Commercial Technical Department or consult Section 6 2 MAINTENANCE on page 61 fill the hydraulic circuit if it has been emptied carrying out the instructions given in Section 4 6 FILLING OF HYDRAULIC CIRCUIT on page 32 if the hydraulic circuit has not been emptied check that the water content of the plant is correct if necessary top up the circuit to at least the minimum quantity see Section 4 6 FILLING OF HYDRAULIC CIRCUIT on page 32 if necessary add to the water of the system free of impurities inhibited monoethylene glycol antifreeze in a quantity in proportion to the MINIMUM winter temperature in the area of installation see Table 4 2 Percentage of monoethylene glycol on page 33 bring the circuit to the correct pressure making sure that the pressure of the water in the plant is not less than 1 bar and not over 2 bar You will need the appliance disconnected from the electricity gas supply 1 Open the plant gas supply valve to the appliance and make sure that there is no smell of gas indicating possible leaks 2 If no smell of gas is detected connect the appliance to the electricity supply mains via the external circuit breaker provided by the installation technician in the appropriate panel set the GS circuit breaker to the ON position see Figure 5 5 Electrical wiring diagram on page 41 3 Power up the CCP if present or DDC if present 4 Checkthat the hydraulic circuit is charged 5 Check that the c
93. ump relay GS 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 1 If several appliances are connected on the same hydraulic circuit it is always necessary to provide a safety transformer secondary SELV and a respective control relay make the connections according to the diagram in Figure 5 16 Electrical wiring diagram see page 51 Figure 5 16 Electrical wiring diagram I N Ae dH 5 H amp zis uas 2vL WL OL VI rere i zzz l zzz i ia I 3 x N tar Ba was rn um A C C IS gt p ZLS ILYS ZVL WA 91 Vl NOLAMLJMAL ree ee a youms duund sejodiq dl ATAS 19uu0Jsuea 3 Jes Yld 5 Up1IMS e u 6 S5 e 1 duund ouo dy E duund sayem dd oI GAlddNs LON slu uoduiop Sloe Jenneu N aseud J uado Ajeuuou x ues 12VINOD ON uado jeduunf OLf pieoq 3lUuo112 duos 20 iN l I NN 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 Example of pump appliance electrical connection with 230 Vac pump controlled directly by the appliance through a relay and a SELV safety transformer 52 Installation user and maintenance manual GAHP A the opening of the appliance s consent sw
94. ve and the power supply by means of the external circuit breaker provided by the electrical system installation technician on the appropriate panel Correct routine maintenance ensures the efficiency and good operation of the appliance over time Carry out maintenance operations according to the instructions supplied by the manufacturer user and maintenance manua For maintenance of the appliance s internal components contact a Potterton Commercial Engineer or qualified 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 Ifthe appliance is to be sold or transferred to another owner ensure that this Installation I is handed over to the new owner and installation technician NOTES ON OPERATION OF THE APPLIANCE The appliance uses the water ammoniac absorption thermodynamic cycle H50 NH3 to produce hot water using atmospheric air as renewable energetic source The water ammoniac thermodynamic cycle used on the unit GAHP A is implemented in a hermitically sealed circuit which has no mechanical unions and is checked directly by manufacturer to ensure the perfect seal of all joints thus making refrigerant top ups
95. wise to increase the percentage of CO and anti clockwise to decrease the percentage of CO 1 8 turn of the regulator screw reduces counterclockwise or increases clockwise the CO content by approximately 0 196 DO NOT turn the screw more than one full turn in either direction With the appliance running access menu 2 parameter 24 of the unit s controller the display will flash P_H1 press to confirm forcing maximum thermal power Check that also following a regulation intervention on screw C the value of CO corresponds to the value read in Table 6 2 Gas nozzles and content of CO2 on page 62 at the Content of CO with Max modulation line with tolerance of 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 If you have successfully calibrated the combustion parameters access menu 2 parameter 25 of the unit s controller the display will flash UnF1 press to confirm modulation of thermal power After 30 minutes of operation the appliance automatically cancels the preceding forced power mode To anticipate this timing select and execute action 25 in menu 2 6 2 Installation user and maintenance manual GAHP A 11 Switch the appliance off 12 Close the gas valve 13 Reinstall the cap A in Figure 6 1 Gas valve on page 59 14 Reinstall the front panel MAINTENANCE Correct maintenance p
96. with current national and local regulations e Installations potentially not hazardous not carried out according to good workmanship practices not complying with the instructions supplied by the manufacturer e Installations that can lead to operating anomalies of the appliance Checking and adjusting the combustion parameters During the initial activation procedure the combustion parameters must be checked and set ONLY by a Potterton Commercial Engineer In this stage NEITHER the user NOR the installation technician is authorised to perform such operations and in so doing may invalidate the guaranty of the appliance The appliance is supplied with all of its units already regulated for the type of gas for which the appliance itself is set up Thetype of gas for which the appliance is set up can be identified from the adhesive label located on the unit s internal gas pipe see detail M Figure 6 2 Gas changeover on page 63 The appliance is supplied with the nozzles required to make the gas type change to G30 and G31 Installation user and maintenance manual GAHP A During the first start up procedure it is in any case necessary to e Check the dynamic gas mains pressure e check and adjust the appliance s combustion parameters Op You will need the appliance connected to the gas and electricity supply switched off and with the gas cock closed front panel removed Check the dynamic gas mains pressure 1 Co
97. xigroup com www andrewswaterheaters co uk Sales 0845 0 0 1056 Technical 0845 0 0 105 C O M M E R C I A L

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