Rossato Air Combo 200 User manual

Heat pump air/water for domestic hot water
Technical manual
for installation, use and maintenance
AIR COMBO

Following instructions are addressed both to the installer and to the final user who need respectively to install and to use the
product. Failure to observe the indications present in this manual involves the customer in exclusion from warranty.
Following instructions contain essential and important information for a safe and perfect installation and are integral and
essential part of the product. Therefore the entire technical documentation must be always kept close to the product.
All data and instructions contained in the present manual are referred to actual technology level.
Please always consult the instructions contained in the present manual when installing the unit.
The activities described in this manual need specialistic knowledge and professional experience in installation. By consequence
it is necessary that mounting operations described are made only by personnel with indicated technical requirements.
Schemas used are only a rough guide, have no pretentions to be complete and cannot replace the project.
Even if this manual has been realized with maximum care, mistakes and updates are possible; Rossato Group Srl will not be
responsible for inaccuracies ad omissions.
Contents, images, texts and layout of this document are property of Rossato Group srl and any copy - both total or partial - is
forbidden without written authorization.

INDEX
1. General and safety instructions!4
1.1 Field of application!4
1.2 Safety warnings!4
1.3 Reference regulations!4
1.4 Explanation of symbols!5
1.5 Packing, moving and transporting!5
1.6. Disposal!5
2. Technical characteristics!6
2.1 General description!6
2.2 Components!7
2.3 Technical data!9
2.4 Pressure drops of lower exchanger!10
2.5 Fan’s characteristic curves!11
2.6 Dimensions and hydraulic connections!12
3. Installation!14
3.1 Safety recommendations!14
3.2 Place of installation and clearances!14
3.3 Unpacking!15
3.4 Installation and commissioning!15
3.5 Hydraulic connection!16
3.6 Electrical connection!18
3.7 Commissioning!19
4. Functioning and use!20
4.1 Start up!21
4.2 Control and regulation!21
4.3 List of alarms!23
5.Maintenance and cleaning!24
5.1 Cleaning!24
5.2 Maintenance!24
6. Diagnostics!26

1. General and safety instructions
1.1 Field of application
The heat pump water heater Air Combo serves only as device to prepare domestic hot water
for sanitary use and within application limits indicated in paragraph 2.3 “technical data”. For this
scope it must be hydraulically connected to a water supply net. To work it needs electrical
supply.
In order to let the unit work correctly and in safety conditions it is recommended to respect
following parameters:
rooms’ ambient temperature between 10 °C and 40°C;
maximum relative humidity: < 90 % not condensating
water hardness should not exceed 25 french degrees; otherwise it is important to install
systems for water treatment, in accordance to actual law.
It is forbidden to use Air Combo for different aims than specified. Any other use is considered
improper and not ammitted.
Rossato Group declines any responsibility in case of different uses than the ones the unit is
planned and made for and in case of possible installation mistakes and impropre uses of the
unit.
1.2 Safety warnings
The unit must be used only by adults.
Do not open or dismantle the unit in operation
Always disconnect the heat pump before cleaning and maintenance operations
1.3 Reference regulations
By affixing the mark to the unit, the manufacturer declares that the Air Combo conforms to
following relevant safety regulations:
Directive EC n. 2006/95
Low Voltage Directive (LVD)
Directive EC n. 89/336
Electromagnetic Compatibility Directive (EMC)
Corresponding documentation on conformity are kept by the manufacturer and available
upon request.
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1.4 Explanation of symbols
DANGER
This symbol indicates rules to prevent user from accidents.
Failure to observe these instructions can result in serious damage to humans, objetcs, plants or
animals.
CAUTION:
Failure to observe these instructions can result in damages to the unit or the system
NOTE:
This symbol indicates useful information
1.5 Packing, moving and transporting
Air Combo is delivered on a pallet in a paperboard packaging. Please ensure that packaging is
disposed correctly according to local laws.
NOTE:
Disposal of packaging is care of receiver who will make it in conformity with local laws of the
country where the heat pump is installed.
CAUTION:
During unit’s inactivity before commissioning, it is appropriate to position the unit at repair from
atmospheric agents.
For unloading operations use a forklift or a transpallet: they should be able to load 250 kg and
have forks 1.100 mm long.
The unit must be always kept vertical during all loading, moving and unloading operations.
CAUTION:
During unloading there must be at least two qualified technicians
NOTE:
Remove packaging only when the unit is positioned on installation’s site.
1.6. Disposal
Unit’s disposal should be made according to national laws.
Under no circumstances the unit must be disposed with ordinary household refuse.
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2. Technical characteristics
2.1 General description
Fig 1: Section AIR COMBO
The heat pump water heater Air Combo has a structure made of steel sheets, which are
thermically insulated against condensation, and covered with plastic material.
The heat pump is supported directly by the storage tank.
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air outlet
fuse holder
air inlet
electronic
control

2.2 Components
Fig. 2: refrigerant group
In the upper part of the tank is located the refrigerant group:
(1) the hermetic compressor especially realized for this kind of application allows wide
operating limits and a very high reliability.
(2) the high efficient finned evaporator is made internally by copper pipes and externally by
alluminium fins with hydrophilic treatment. The quantity of fluid coming into the evaporator is
regulated by a special thermostatic valve
(3) The tangential fan allows a possible circulation of the air taken from the ambient to heat up
water.
1
2
3
4
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The circuit is completed with a dryer filter and a liquid receiver. The copper pipes are strong
brazed together. Once finished, the circuit is tested twice to avoid any possible loss.
(4) The condenser, placed within the tank and fixed through an inspectionable flange, is made
of 3 elicoidal inlet tubes to increase the exchange surface.
There is a magnesium anode (subject to periodical replacement) to protect the tank and an
electrical heater.
Control is electronic, easy to set up and visualized through shining LEDs.
The display of thermoregulator shows water temperature, state of compressor and fan and any
alarm.
A temperature sensor on the evaporator manages defrosting in case of temperatures <7°C.
This device guarantees efficiency of the unit even with temperature close to -10°C
Safety devices are installed both on the high temperature side of refrigeration circuit and on
the compressor in order to prevent too high absorptions.
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2.3 Technical data
u.m.
Air Combo 200-300
Performances
Average COP*
> 3,5
HP yield heat power*
kW
2,03
Tot al h ea t po we r*
3,23
Electrical data
Power supply
V/Hz
230/1/50
Maximum absorption HP
kW
0,63
Absorption of e-heater + HP
kW
1,83
Electric heater (integration)
kW
1,20
Delayed action fuse
A
8
Motor protection
NTC
Operating temperatures
Minimum temperature
°C
-10
Maximum temperature
°C
50
Max temp. DHW only HP
°C
65
Max temp. DHW with e-heater
°C
90
Compressor
High efficient reciprocating hermetic
Evaporator
Battery for high heat exchange with aluminium finned coil with
hydrophilic treatment and copper tubes
Test pressure
kPa
3.000
Fan
tangential
Diameter
mm
190
Fan rotation rate RPM
300÷1300
Power
W
25/67
Condenser
Copper pipe
Nominal air flow
m3/h
350
Max available head
Pa
30
Refrigerant
R134a
Charge
g
370
Dimensions
Dimensions
Dimensions
Dimensions
Dimensions
Air Combo 200
Air Combo 200
Air Combo 300
Storage tank
Carbon steel with 2 hands vitrification (DIN 4753-3 and UNI
10025)
Carbon steel with 2 hands vitrification (DIN 4753-3 and UNI
10025)
Carbon steel with 2 hands vitrification (DIN 4753-3 and UNI
10025)
Capacity
l
225
295
295
Auxiliary coil
m2
1,5
1,5
1,5
Insulation
High density foamed PU insulation
High density foamed PU insulation
High density foamed PU insulation
Defrosting
hot gas
hot gas
hot gas
Dimensions (ø x h)
mm
640 x 1.590
640 x 1.890
640 x 1.890
Weight
kg
118
127
127
*Room air temp.: 20°C; R.H.: 70%; inlet water temp.: 15°C (according to UNI 16147)
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2.4 Pressure drops of lower exchanger
0
30
60
90
120
150
180
210
240
270
300
500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
Perdite carico scambiatore inferiore
Portata
( l/h )
P
( mbar )
water flow (l/h)
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2.5 Fan’s characteristic curves
NOTE: the fourth speed level can be used only in exceptional cases and can be activated only
by authorized personnel
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2.6 Dimensions and hydraulic connections
2.6 Dimensionali e connessioni idrauliche
Sezione Air Combo 200 con attacchi
Fig.4
Dimensioni Air Combo 200
Fig.5

Fig.3
865
765
680
345
245
165
169
280
750
855
1510
1570
640
160 160
289
259
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Section Air Combo 200 with connections Dimensions Air Combo 200
Air Combo 200-300 - upper view

Legenda
Legenda
Legenda
Legenda
Legenda
Legenda
1.
cold water inlet
1”
6.
DHW outlet
1”
2.
exchanger return
1”
7.
probe housing
ø12x70mm
3.
probe housing
ø17x70mm
8.
magnesium anode
1-1/4”
4.
exchanger inlet
1”
9.
electric heater
1-1/4”
5.
circulation
1/2”
10.
e-heater supply cable
ø 8x40mm
Sezione Air Combo 300 con attacchi
Fig. 6
Dimensioni Air Combo 300
Fig. 7
1165
965
680
680
245
165 169
280
1020
1155
1810
1870
640
160 160
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Section Air Combo 300 with connections Dimensions Air Combo 300

3. Installation
3.1 Safety recommendations
DANGER:
The unit is not planned to operate in explosive atmosphere. It is thus forbidden to install or use it in
such environment.
DANGER:
Mounting, installation and commissioning of the unit must be made only by authorized and qualified
technicians.
It is required to wear a protection equipment suitable to the operations that have to be
made
While raising and transporting the unit it is necessary to wear a safety helmet
Please ensure that the used rising means are safe and able to carry the load that has to
be carried.
Do not stop or pass underneath the unit while rising or transporting it.
3.2 Place of installation and clearances
The heat pump must be installed in a suitable place, where it is possibile to manage it for
parameter regulation, ordinary and extraordinary maintenance, to have access to all
components, to remove upper plastic cover and to control its operation. It is thus necessary to
respect the minimum clearances as indicated in the picture.
Fig. 8
500 mm
500 mm
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Moreover the place of installation must:
have a suitable electric energy supply line;
have a suitable water supply line;
be predisposed with suitable water discharge connections in case of damages on the tank,
intervention of safety valve or break of pipes/connections;
have possible containing systems in case of big water losses;
have sufficient lightening;
During operation the unit lows room temperature down: if necessary, a ventilation system
should be made so that temperature won’t be too low;
The unit is not particularly noisy, however it is recommended not to place it close to bedrooms
or living rooms.
3.3 Unpacking
NOTE:
Disposal of packaging is care of receiver who will make it in conformity with local laws of the
country where the heat pump is installed.
DANGER:
During unpacking, people incharged must wear proper equipment for individual safety, such as
safety gloves and glasses.
Demolition of packaging should be made as follows:
cutting or tacking the external packaging off;
removing the unit from the pallet.
NOTE:
After taking the packaging off please check that there is no tampering. If there is, please contact
Assistance Service.
3.4 Installation and commissioning
DANGER:
The unit is not planned to operate in explosive atmosphere. It is thus forbidden to install or use it in
such environment
DANGER:
Installation and commissioning of the unit must be made only by authorized and qualified
technicians.
The unit has to be placed on a stabile and horizontal surface that can carry enough load (for
unit’s weight see the table of technical data).
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3.5 Hydraulic connection
Fig.9
Connect cold water supply line to the relative connection on the tank.
The installer is adviced to install a gate valve, a not-return valve and a draining valve on cold
water inlet connection. Moreover an expansion vessel and a safety valve (7 bar) are mandatory.
DANGER:
Failure to install safety devices causes exclusion from warranty.
The expansion vessel must be correctly dimensioned according to storage tank’s capacity. It is
recommended to install a manometer, if it is not present anywhere else in the system.
The installer will take care to install an interception valve on hot water outlet in order to isolate
the tank from the system, in case of maintenance.
Connect a rubber pipe to condensation discharge connection, taking care not to make too high
pressure that can cause break of discharge pipe.
safety group
1. ball valve
2. not-return valve
3. manometer
4. safety valve 7 bar
5. draining valve
6. expansion vessel
Cold water inlet
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3.5.1 Integration in solar thermal system (ST)
AIR COMBO has a standard coil ready to be connected with a solar thermal system: the model
200l is suitable for a surface of solar collectors of about 2,5 m2(usually one collector); the
model 300l is suitable for a surface of solar collectors of about 5 m2(usually two collectors).
Example integration with ST
Fig.10
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3.6 Electrical connection
The unit’s electric circuit is characterized by an electronic controller that activates both the fan
and the solenoid valve for hot gas defrost. Compressor and resistance are activated through
two relais regulated by the controller itself. A fuse protects all users, unless the resistance.
Thanks to the controller the system becomes more and more efficient activating one of the
three speed levels according to ambient conditions and water temperature in the tank.
It is possible to switch the unit on through a remote control both switching off the contact
“remote ON/OFF” or selecting the second SetPoint and creating a bridge on the contact “Set2”.
In case of particularly long canalizations it is possible to use a fourth speed level of the unit,
moving the black cable coming from the controller next to the brown cable of fan.
NOTE:
A complete electric schema is drawn in the next pages.
3.6.1 Integration with photovoltaic system (PV)
AIR COMBO is suitable for small photovoltaic systems; in particular, it’s possible to switch the
unit by an external signal through the free relais “set2”, standard placed in the power panel on
board of the unit.
In this way it’s possible to exploit at the most the electrical energy instantaneously produced by
the PV system in order to store thermal energy in the tank (self consumption logic) and to avoid
that the unit works when on the contrary it would be necessary to absorb energy from the
electrical net.
Example integration PV
Fig.11
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3.7 Commissioning
DANGER:
Before starting unit’s connection, be sure that line tension corresponds to data on unit’s plate.
Proceed with following operations:
Fill the tank through the inlet tap and check that there is no water loss from gaskets or
fittings
Do not exceed the maximum available pressure indicated in the section “general technical
data”
Check all safety devices of hydraulic circuit
Check the plug connected to supply socket and that display lights up.
When plug is inserted, display shows tank’s temperature: press the button to switch AIR
COMBO on.
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4. Functioning and use
The remote programmable controller is the most suitable solution for this kind of applications: it
is completely programmable, both on regulation’s side and user interface’s side, and it’s very
easy and intuitive.
The display shows 4 red digits (incl. decimal digits) and 16 icons of different colours; keyboard
has 4 buttons.
Fig.12 Control display
UP/DOWN allows changing parameters and surfing into the menu;
SET/ENTER: pressing this button it is possible to enter the value change mode, to
confirm the selected value or to go to the next level in the menu;
STAND BY/ESC: Pressing this button for about 2 seconds, it is possible to switch the
unit on or off. If pressed inside a menu, you will go up to the higher level.
Moreover following icons are used:
Icon summer : it’s on, when compressor is working, it flashes when compressor is in
temporization before a starting.
Icon 1,2,3: identify the status of fan, indicating respectively the minimum, medium and
maximum fan’s speed;
Icon of integrative resistance : identifies the status ON of the integrative electrical
resistance: it flashes when the resistance is ON, otherwise it is off;
Icon alarm : identifies if there are alarms: it flashes when there is an alarm;
Icon defrost : identifies the status of defrosting: it is switched on when the solenoid is
open;
Icon “set2” : it’s open when system’s set2 is setted.
To set the temperature press the button “SET” for at least three seconds or until the setted set
point value is displayed and the led flashes.
NOTE:
In the first view the temperature in the upper part of the tank is displayed: this corresponds to the
temperature of water ready for withdrawal.
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