Potterton A-Cubed Operating instructions

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A-Cubed
Gas absorption heat pump
Installation, user and maintenance manual
This manual must be kept with the appliance August 2010

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 led 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 led the registered trademarks contained within this
publication are not aected.
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
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INDEX OF CONTENTS
1 PREFACE ............................................................................................................5
2 OVERVIEW AND TECHNICAL CHARACTERISTICS .........................................7
2.1 WARNINGS....................................................................................................................................................................................... 7
2.2 NOTES ON OPERATION OF THE APPLIANCE ......................................................................................................................10
2.3 TECHNICAL MANUFACTURING CHARACTERISTICS.........................................................................................................10
2.4 TECHNICAL DATA ........................................................................................................................................................................11
2.5 DIMENSIONS AND SERVICE PANEL .......................................................................................................................................12
3 NORMAL OPERATION ....................................................................................15
3.1 START UP (AND SHUT DOWN)................................................................................................................................................15
3.2 ON-BOARD ELECTRONICS........................................................................................................................................................17
3.3 RESET OPERATIONS AND MANUAL DEFROSTING ...........................................................................................................19
3.4 OPERATING SETTINGS ...............................................................................................................................................................21
3.5 PROLONGED PERIODS OF DISUSE ........................................................................................................................................22
4 HYDRAULIC SYSTEM INSTALLATION TECHNICIAN ....................................25
4.1 GENERAL INSTALLATION PRINCIPLES ..................................................................................................................................25
4.2 POSITION OF THE APPLIANCE ................................................................................................................................................25
4.3 HYDRAULIC CONNECTIONS ....................................................................................................................................................28
4.4 GAS SUPPLY...................................................................................................................................................................................30
4.5 CONDENSATE DISCHARGE CONNECTION..........................................................................................................................31
4.6 FILLING OF HYDRAULIC CIRCUIT ...........................................................................................................................................32
4.7 FLUE INFORMATION...................................................................................................................................................................33
4.8 PROGRAMMING OF HYDRAULIC PARAMETERS ...............................................................................................................34
5 ELECTRICAL SYSTEM INSTALLATION TECHNICIAN....................................37
5.1 ELECTRICAL DIAGRAMS OF THE APPLIANCE ....................................................................................................................40
5.2 HOW TO CONNECT THE APPLIANCE ELECTRICALLY.......................................................................................................41
5.3 CASCADE CONTROL...................................................................................................................................................................41
5.4 TYPE C (Consent switch)...........................................................................................................................................................53
5.5 HOW TO REMOTELY CONTROL THE FLAME CONTROLLER RESET..............................................................................54
6 INITIAL ACTIVATION AND MAINTENANCE..................................................57
6.1 PROCEDURE FOR INITIAL ACTIVATION................................................................................................................................57
6.2 MAINTENANCE.............................................................................................................................................................................61
6.3 CHANGE OF GAS TYPE ..............................................................................................................................................................62
7 ACCESSORIES..................................................................................................65
8 APPENDIX .......................................................................................................67
8.1 MACHINE OPERATING CODES ................................................................................................................................................67
8.2 SAFETY DEVICES..........................................................................................................................................................................68
8.3 ADDITIONAL SAFETY DEVICES...............................................................................................................................................70
8.4 NON-CONDENSABLE OR NON-ABSORBABLE GASES .....................................................................................................74

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Installation, user and maintenance manual – GAHP-A
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1 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 specically intended for:
• nal 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:
• a section that describes all the operations necessary for the“rst start-up”and for the
“gas change” of the appliance, as well as the main maintenance operations;
• 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 nal user, hydraulic and electrical installation
technicians and the Potterton Commercial Commissioned Engineer; it gives general
warnings, operating instructions and constructional specications. This section also
contains technical data and dimensional drawings of the appliance.
SECTION 3 is intended for use by the nal 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 ue 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 verication of plant compliance, initial activation, and regulation of gas ow
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 nal 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 operating 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:
INSTALLATION TECHNICIAN MANUAL - book 1: for installation/service technicians
FINAL USER MANUAL - book 2: for the nal user of the DDC

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Denitions, terms and icons
APPLIANCE: this term refers to the A-Cubed Air-Water gas absorption heat pump
"GAHP-A".
CCP: "Comfort Control Panel".
CCI: "Comfort Control Interface" device.
DDC: digital control panel (Direct Digital Controller).
The icons present in the margin of the manual have the following meanings:
= DANGER
= WARNING
= NOTE
= START OF OPERATING PROCEDURE
= REFERENCE to another part of the manual or other document

Installation, user and maintenance manual – GAHP-A
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2 OVERVIEW AND TECHNICAL CHARACTERISTICS
In this section, for all users, you will nd general warnings, the operating principle of the
appliance and its manufacturing characteristics. This section also contains technical data
and dimensional drawings of the appliance.
2.1 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 certied as conforming to standard EN
12309-1 and -2 and comply with the essential requirements of the following Directives:
• Gas Directive 90/396/EEC and subsequent modications and additions.
• Eciency Directive 92/42/EEC and subsequent modications and additions.
• Electromagnetic Compatibility Directive 89/336/EEC and subsequent modications
and additions.
• Low Voltage Directive 89/336/EEC and subsequent modications and additions.
• “Machinery Directive” 2006/42/EC.
• Pressurised Equipment Directive 97/23/EEC and subsequent modications and
additions.
• UNI EN 677 Specic 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
qualied personnel for assistance.
If you smell gas:
• do not operate electrical devices in the vicinity of the appliance, such as telephones,
multimeters or other equipment that can cause sparks;
• shut o the gas supply by means of the appropriate gas tap;
• cut o electrical power to the appliance by means of the external disconnecting
switch that the electrical system installation technician has provided in the
appropriate panel;
• request the assistance of professionally qualied personnel from a telephone far
from the appliance.

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The appliance has a sealed circuit that may be classied as a pressurised container, i.e.
with internal pressure higher than atmospheric pressure. The uids 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
eective 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 external 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.
Installation of the appliance may only be carried out by rms that are qualied in
accordance with current legislation in the country of installation, i.e. by professionally
qualied personnel.
"Professionally qualied personnel" means personnel with specic technical competence
in the 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:
• Gas equipment.
• Electrical equipment.
• 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
The rm 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, current national and local regulations, and the instructions supplied by
Potterton Commercial.
Before contacting Potterton Commercial to arrange commissioning:
• the electricity and gas mains specications correspond to the specications on the
nameplate;
• the mains gas pressure falls within the range of values specied in Table 6.1 Network
gas pressure on page 59;
• the gas supplied to the appliance is of the type for which it is designed;
• the gas supply system and water distribution system are sealed;

Installation, user and maintenance manual – GAHP-A
9
• 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 o of the appliance must be done in line with the requirements of the
various types of installation.
• If the appliance is connected to the DDC (see Figure 5.3 Direct Digital Control
(DDC) on page 39), the appliance may be switched on and o exclusively by the
DDC itself.
• If the appliance is NOT connected to a Direct Digital Control (DDC) the appliance
may be switched on and o exclusively by a switch on the consent circuit.
The appliance must never normally be switched on and o by shutting o the power
supply upstream of the Controle Device (CCP, DDC or consent switch) before having used
the latter rst and waited for the shutdown cycle to end (approximately 7 minutes). The
shutdown cycle terminates when the hydraulic pump switches o (no parts in motion).
Shutting o 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.
• 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);
• Disconnect the appliance from the gas and electricity mains, cutting o gas supply
by means of the appropriate valve 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 eciency and good operation of the appliance
over time.
Carry out maintenance operations according to the instructions supplied by the
manufacturer.

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For maintenance of the appliance’s internal components, contact a Potterton
Commercial Engineer or qualied technician; for other maintenance requirements, see
Section 6.2 MAINTENANCE on page 61.
Any repair of the appliance must be carried out by an authorised Potterton Commercial
Engineer, using only original parts.
Failure to observe the indications given above may compromise the operation and safety
of the appliance, and may invalidate its guarantee, if active.
If the appliance is to be sold or transferred to another owner, ensure that this“Installation,
user and maintenance manual” is handed over to the new owner and installation
technician.
2.2 NOTES ON OPERATION OF THE APPLIANCE
The appliance uses the water/ammoniac absorption thermodynamic cycle (H20 – 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
completely unnecessary.
Description and general characteristics
The air-water gas absorption heat pump GAHP-A is available in the following versions:
• 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.
• Version LT: optimised for low temperature oor heating systems; it produces hot
water to +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 ue 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 ue (for further
details, see Section 4.7 EXHAUSTING THE COMBUSTION PRODUCTS on Page 33).
The appliance is powered with 230 Vac 1N - 50 Hz.
2.3 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.
• Metal mesh irradiation burner equipped with ignition and ame detection managed
by an electronic control unit.
• Titanium stainless steel tube bundle water exchanger, with external insulation.
• Tube coil heat recovery (AISI 304L ).
• Air-based heat exchanger with single-position nned coil, manufactured in steel
tubing and aluminium ns.
• Automatic two-way microprocessor-controlled defrosting valve, allowing the nned
coil to be defrosted.