Lochinvar GAHP-A HT STD, GAHP-A HT S1 Installation, Use And Maintenance Manual
Installation, Use and
Maintenance Manual
GAHP-A
powered by gas and renewable energies
Air-Water gas absorption heat pump
Revision: B
Code: D-LBR724
This Manual has been drawn up and printed by Lochinvar; whole or partial reproduction of this Manual is
forbidden.
The original is led at Lochinvar.
Any use of this Manual other than for personal referencing must be previously authorised by Lochinvar.
The rights of those who have legitimately led the registered trademarks contained within this publication are not
aected.
With the aim of improving the quality of its products, Lochinvar reserves the right to modify the data and contents
of this Manual without prior notice.
Installation, Use and Maintenance Manual – GAHP-A
3
INDEX OF CONTENTS
I INTRODUCTION ...............................................4
II SYMBOLS AND DEFINITIONS .........................4
II.1 Key to symbols ...................................................................... 4
II.2 Terms and denitions .........................................................4
III WARNINGS .......................................................4
III.1 General and safety warnings ........................................... 4
III.2 Conformity .............................................................................6
III.3 Exclusions of liability and warranty ............................... 6
1 FEATURES AND TECHNICAL DATA ................6
1.1 Features ...................................................................................6
1.2 Dimensions ............................................................................7
1.3 Components ..........................................................................9
1.4 Electrical wiring diagram ............................................... 12
1.5 Electronic boards .............................................................. 13
1.6 Operation mode ................................................................ 15
1.7 Controls ................................................................................ 16
1.8 Technical characteristics ................................................. 16
2 TRANSPORT AND POSITIONING .................18
2.1 Warnings .............................................................................. 18
2.2 Handling ............................................................................... 18
2.3 Appliance positioning ..................................................... 19
2.4 Minimum clearance distances...................................... 20
2.5 Mounting base ................................................................... 20
3 HEATING ENGINEER ......................................20
3.1 Warnings .............................................................................. 20
3.2 Installation ........................................................................... 21
3.3 Hydraulic connections .................................................... 21
3.4 Water circulation pump .................................................. 21
3.5 Anti-icing function............................................................ 21
3.6 Anti-icing liquid ................................................................. 21
3.7 System water quality ....................................................... 22
3.8 Installation lling .............................................................. 22
3.9 Fuel gas supply .................................................................. 22
3.10 Combustion products exhaust .................................... 23
3.11 Flue gas condensate discharge .................................... 24
3.12 Defrosting water drainage ............................................. 24
4 ELECTRICAL INSTALLER ...............................24
4.1 Warnings .............................................................................. 24
4.2 Electrical systems .............................................................. 25
4.3 Electrical power supply ................................................... 26
4.4 Set-up and control ............................................................ 27
4.5 Water circulation pump .................................................. 30
5 FIRST STARTUP ............................................33
5.1 Preliminary checks ............................................................ 33
6 NORMAL OPERATION ...................................34
6.1 Warnings .............................................................................. 34
6.2 Switch on and o .............................................................. 34
6.3 Messages on the display ................................................ 34
6.4 Electronic adjustment on the machine – Menus
and parameters of the S61 board ............................... 35
6.5 Modifying settings ............................................................ 36
6.6 Restarting a locked-out unit - Reset ........................... 36
6.7 Eciency .............................................................................. 37
7 MAINTENANCE ..............................................37
7.1 Warnings .............................................................................. 37
7.2 Pre-emptive maintenance ............................................. 37
7.3 Scheduled routine maintenance ................................. 38
7.4 Periods of inactivity .......................................................... 38
8 DIAGNOSTICS ................................................38
8.1 Operative codes................................................................. 38
APPENDICES ........................................................41
1 Declaration of Conformity ............................................. 41
2 Product che....................................................................... 42
I Introduction
4
I INTRODUCTION
Manual
This Manual is an integral part of the GAHP-A unit and
must be handed to the end user together with the
appliance.
Recipients
This Manual is intended for:
▶
end user, for appropriate and safe use of the appliance;
▶
qualied installer, for correct appliance installation;
▶
planner, for specic information on the appliance.
Control device
In order to be able to work, the GAHP-A unit needs a control
device (DDC, CCP/CCI or external requests), which must be connected by the installer.
II SYMBOLS AND DEFINITIONS
II.1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
II.2 TERMS AND DEFINITIONS
GAHP Appliance/Unit = equivalent terms, both used to des-
ignate the gas powered absorption heat pump GAHP (Gas Absorption Heat Pump).
TAC = Technical Assistance Centre authorised by Lochinvar.
External request = generic control device (e.g. thermostat,
clock or any other system) equipped with a voltage-free NO contact and used as control to start/stop the GAHP unit.
CCI Controller (Comfort Controller Interface) = optional adjust-
ment device Lochinvar which lets you manage up to three modulating heat only GAHP units (A, WS, GS).
CCP Controller (Comfort Control Panel) = adjustment device
Lochinvar which lets you manage in modulation mode up to
three GAHP units and all system components (probes, diverter/mixing valves, circulating pumps), including any integration
boiler.
DDC Control (Direct Digital Controller) = optional Robur device
to control one or more Lochinvarappliances (GAHP heat pumps,
GA chillers and AY boilers) in ON/OFF mode.
RB100/RB200 Devices (Robur Box) = optional interface devices
complementary to DDC, which may be used to broaden its functions (heating/cooling/DHW production service demands, and
control of system components such as third party generators,
adjustment valves, circulating pumps, probes).
Heat generator = equipment (e.g. boiler, heat pump, etc..) producing heating and/or DHW.
GUE (Gas Utilization Eciency) = eciency index of gas heat
pumps, equal to the ratio between the thermal energy produced and the energy of the fuel used (relative to LCV, lower
caloric value).
First start-up = appliance commissioning operation which may
only and exclusively be carried out by a TAC.
S61/Mod10/W10 Boards = electronic boards on the GAHP unit,
to control all functions and to provide interface with other devices and with the user.
III WARNINGS
III.1 GENERAL AND SAFETY WARNINGS
Installer's qualications
Installation must exclusively be performed by a Qualied Firm and by Skilled Personnel, with specic knowledge on heating, cooling, electrical systems and gas
appliances, in compliance with the laws in force in the
Country of installation.
Declaration of Conformity
Upon completing installation, the installing rm shall
issue to the owner/client the appliance's Workmanlike
Conformity Declaration, according to national/local
regulations in force and the manufacturer's instructions/
provisions.
Misuse
The appliance must only be used for the purposes for
which it has been designed. Any other use is deemed
hazardous. Incorrect use may aect operation, duration
and safety of the appliance. Adhere to the manufacturer's instructions.
Hazardous situations
▶
Do not start the appliance in hazardous conditions,
such as: gas smell, problems with the plumbing/electrical/gas system, parts of the appliance under water
III Warnings
Installation, Use and Maintenance Manual – GAHP-A
5
or damaged, malfunctioning, disabling or bypassing
control and safety devices.
▶
In case of danger, request intervention by skilled
personnel.
▶
In case of danger, switch o the electrical power and
gas supplies only if this can be done in total safety.
▶
Do not entrust children, persons with physical, sensory or mental disabilities or persons with poor knowledge and experience with use of the appliance.
Gas component tightness
▶
Before performing any operation on gas ducting
components, close the gas cock.
▶
Upon completing any procedure, perform the tightness test according to regulations in force.
Gas smell
If you smell gas:
▶
Do not use electrical devices such as telephones,
multimeters or other equipment that may cause
sparks next to the appliance.
▶
Shut o the gas supply by turning the cock o.
▶
Disconnect electrical power supply by means of the
external isolation switch in the power supply electrical panel.
▶
Use a telephone away from the appliance to ask for
intervention from skilled personnel.
Poisoning
▶
Ensure the ue gas ducts are tightness and compliant with the regulations in force.
▶
Upon completing any procedure, ensure components are tightness.
Moving parts
The appliance contains moving parts.
▶
Do not remove guards during operation, and in any
case prior to disconnecting the power supply.
Burn hazard
The appliance contains very hot parts.
▶
Do not open the appliance and do not touch internal
components before the appliance has cooled down.
▶
Do not touch the ue gas exhaust before it has
cooled down.
Pressure vessels
The appliance has a sealed circuit classied as pressure vessel, the tightness of which is tested by the
manufacturer.
▶
Do not carry out any intervention on the sealed circuit or on the appliance's valves.
Water-ammonia solution
The GAHP unit uses the ammonia-water absorption
cycle. The water-ammonia solution is contained in the
sealed circuit. The solution is harmful for health if it is
ingested, inhaled or comes in contact with the skin.
▶
In the event of coolant leak keep away and disconnect the power and gas supply (only if it is possible
to do so with no danger).
▶
Request assistance from the TAC.
Electrocution hazard
▶
Disconnect the electrical power supply before any
work/procedure on appliance components..
▶
For electrical connections exclusively use compliant
components and according to the specications provided by the manufacturer.
▶
Ensure the appliance cannot be accidentally
switched back on.
Earthing
Electrical safety depends on eective earthing system,
correctly connected to the appliance and installed according to the regulations in force.
Distance from combustible or ammable materials
▶
Do not store ammable materials (paper, solvents,
paint, etc.) in the vicinity of the appliance.
Limescale and corrosion
Depending on the chemical/physical properties of the
system water, limescale or corrosion may damage the
appliance (Paragraph 3.7p.22).
▶
Check system tightness.
▶
Avoid frequent top-ups.
Chloride concentration
The concentration of chlorides or free chlorine in the
system water must not exceed the values in Table
3.2p.22.
Aggressive substances in air
Halogenated hydrocarbons containing chlorine and
uorine compounds cause corrosion. The supply/ventilation air of the appliance must be free from aggressive
substances.
Acid ue gas condensate
▶
Discharge the acid condensate of combustion ue
gas, as indicated in Paragraph 3.11p. 24, in compliance with current exhaust regulations.
Switching the appliance o
Disconnecting the power supply while the appliance
is running may cause permanent damage to internal
components.
▶
Except in the case of danger, do not disconnect the
power supply to switch o the appliance, but always
and exclusively act through the control device provided (DDC, CCP/CCI or external request).
1 Features and technical data
6
In the event of failure
Operations on internal components and repairs may
exclusively be carried out by a TAC, only using original
parts.
▶
In the event of failure of the appliance and/or breakage of any component, do not attempt to repair and/
or restore and immediately contact the TAC.
Routine maintenance
Proper maintenance assures the eciency and good
operation of the appliance over time.
▶
Maintenance must be performed according to the
manufacturer's instructions (see Chapter 7 p. 37)
and in compliance with current regulations.
▶
Appliance maintenance and repairs may only be
entrusted to rms legally authorised to work on gas
appliances and systems.
▶
Enter into a maintenance contract with an authorised specialised rm for routine maintenance and for
servicing in case of need.
▶
Only use original parts.
Decommissioning and disposal
If the appliance is to be disposed of, contact the manufacturer for its disposal.
Keep the Manual
This "Installation, Use and Maintenance Manual" must
always accompany the appliance and must be handed to the new owner or installer in the event of sale or
removal.
III.2 CONFORMITY
EU Directives and standards
The absorption heat pumps of the GAHP series are certied as
conforming to standard EN 12309-1 and -2 and comply with the
essential requirements of the following Directives:
▶
2009/142/EC "Gas Appliances Directive" as amended and
added.
▶
2004/108/EC "Electromagnetic Compatibility Directive" as
amended and added.
▶
2006/95/EC "Low Voltage Directive" as amended and added.
▶
2006/42/EC "Machine Directive" as amended and added.
▶
97/23/EEC "Pressure Equipment Directive" as amended and
added.
Furthermore, they comply with the requirements of the following standards:
▶
UNI EN 677 Specic requirements for condensing boilers
with nominal heating capacity up to 70 kW.
▶
EN 378 Refrigerating systems and heat pumps.
Other applicable provisions and standards
The design, installation, operation and maintenance of the systems shall be carried out in compliance with current applicable
regulations, depending on the Country and location, and in accordance with the manufacturer's instructions. In particular, regulations regarding the following shall be complied with:
▶
Gas systems and equipment.
▶
Electrical systems and equipment.
▶
Heating and air conditioning systems, and heat pumps.
▶
Environmental protection and combustion products exhaust.
▶
Fire safety and prevention.
▶
Any other applicable law, standard and regulation.
III.3 EXCLUSIONS OF LIABILITY AND
WARRANTY
Any contractual or extra-contractual liability of the
manufacturer for any damage caused by incorrect installation and/or improper use and/or failure to comply
with regulations and with the manufacturer's directions/instructions shall be disclaimed.
In particular, the warranty on the appliance may be rendered void by the following conditions:
▶
Incorrect installation.
▶
Misuse.
▶
Failure to comply with the manufacturer's indications on installation, use and maintenance.
▶
Alteration or modication of the product or any part
thereof.
▶
Extreme operational conditions or however outside of the operational ranges set forth by the
manufacturer.
▶
Damages caused by external agents such as salts,
chlorine, sulphur or other chemical substances contained in the installation water or present in the air of
the installation site.
▶
Abnormal actions transmitted by the plant or installation to the appliance (mechanical stresses, pressure, vibrations, thermal dilations, power surges...).
▶
Accidental damages or due to force majeure.
1 FEATURES AND TECHNICAL DATA
1.1 FEATURES
Operation
Based on the thermodynamic water-ammonia absorption cycle
(H20–NH3), the appliance produces hot water using outdoor air
as a renewable energy source (cold source) and natural gas (or
LPG) as primary energy.
The thermodynamic cycle takes place within a hermetically
sealed circuit, in welded construction, perfectly tight, factory-tested, which does not require any maintenance or coolant
top-ups.
Mechanical and thermo-hydraulic components
▶
steel sealed circuit, externally treated with epoxy paint;
1 Features and technical data
Installation, Use and Maintenance Manual – GAHP-A
7
▶
sealed combustion chamber (type C) suitable for outdoor
installations;
▶
metal mesh radiant burner equipped with ignition and ame
detection device, controlled by an electronic control unit;
▶
titanium stainless steel shell-and-tube water heat exchanger, externally insulated;
▶
stainless steel, ue gas latent heat recovery exchanger;
▶
air exchanger with nned coil, with steel pipe and aluminium ns;
▶
automatic microprocessor-controlled nned coil automatic
defrosting valve;
▶
standard or S1 silenced fan (reduction of electrical consumption and reduction of sound emission).
Control and safety devices
▶
S61 electronic board with microprocessor, LCD display and
knob;
▶
Mod10 additional electronic board (integrated in S61);
▶
auxiliary W10 electronic board
▶
installation water owmeter;
▶
generator limit thermostat, with manual reset;
▶
ue gas temperature thermostat, with manual reset;
▶
generator n temperature sensor;
▶
sealed circuit safety relief valve;
▶
by-pass valve, between high and low pressure circuits;
▶
ionisation ame controller;
▶
gas solenoid valve with double shutter;
▶
anti-icing function for water circuit;
▶
condensate discharge obstruction sensor.
Standard or silenced fan
According to the type of fan the GAHP-A unit is available in two
versions:
▶
standard fan, for applications that do not require a special
degree of noiselessness;
▶
silenced fan, for applications that require a high degree of
noiselessness;
1.2 DIMENSIONS
Figure 1.1 – Service plate
Hydraulic/gas unions detail
LEGEND
G Gas tting Ø ¾” F
B Inlet water tting Ø 1¼” F
A Outlet water tting Ø 1¼” F
1 Features and technical data
8
Figure 1.2 – Size (Standard ventilation)
Figure 1.3 – Dimensions (low consumption silenced fan)
1 Features and technical data
Installation, Use and Maintenance Manual – GAHP-A
9
1.3 COMPONENTS
Figure 1.4 – Internal components - front view
1
2
4
5
6
7
3
10
12
11
8
9
LEGEND
1. Fan (S1 version)
2. Flue gas tapping point
3. Gas valve
4. Combustion air inlet
5. Blower
6. Ignition transformer
7. Tmix Probe
8. Oil pump
9. Water return tting: “G 1”¼ F
10. Water inlet connection: “G 1”¼ F
11. Gas connection
12. TA Probe
1 Features and technical data
10
Figure 1.5 – Internal components - left side view
LEGEND
1. Flue gas thermostat reset
2. Flue gas thermostat sensor
3. Ø 80mm ue gas drain
4. Generator n temperature sensor
5. Switch on and detection electrodes
6. Condensate sensor
1 Features and technical data
Installation, Use and Maintenance Manual – GAHP-A
11
Figure 1.6 – Internal components - right side view
LEGEND
1. TG Probe
2. Safety valve
3. Delivery pipe owmeter
4. Delivery temperature probe
5. Limit thermostat
6. Defrosting valve
7. Return temperature probe
8. Teva Probe
1 Features and technical data
12
1.4 ELECTRICAL WIRING DIAGRAM
Figure 1.7 – Wiring diagram of the appliance with low consumption fan (S1)
LEGEND
SCH1 S61 circuit board
SCH2 W10 circuit board
SCH3 Mod10 circuit board
TER Appliance power terminal block
CNTBOX Flame controller
PWRTR Board transformer
BLW Blower
PMP Hydraulic pump
IGNTR Ignition transformer
IGN Ignition electrodes
FLS Flame sensor
LS Gas valve ON indicator lamp
GV Gas solenoid valve
TC Manual fumes thermostat
TL Generator limit thermostat
FM Flowmeter
CWS Condensation water sensor
VD Defrosting valve
FAN Fan
CF Filter capacitor
FS Condensate hose heating element
THRC Hot water return temperature sensor
THMC Hot water delivery temperature sensor
TMIX Combustion air temperature sensor
TA Ambient air temperature sensor
TG Generator temperature sensor
TF Fumes temperature sensor or genera-
tor n sensor
TEVA Evaporator outlet temperature sensor
TK Condensate discharge heating element
thermostat
MA Terminal block
REED Hydraulic pump rotation sensor
1 Features and technical data
Installation, Use and Maintenance Manual – GAHP-A
13
Figure 1.8 – Wiring diagram of the appliance with standard fan
LEGEND
SCH1 S61 circuit board
SCH2 W10 circuit board
SCH3 Mod10 circuit board
TER Appliance power terminal block
CNTBOX Flame controller
PWRTR Board transformer
BLW Blower
PMP Hydraulic pump
IGNTR Ignition transformer
IGN Ignition electrodes
FLS Flame sensor
LS Gas valve ON indicator lamp
GV Gas solenoid valve
TC Manual fumes thermostat
TL Generator limit thermostat
FM Flowmeter
CWS Condensation water sensor
VD Defrosting valve
FAN Fan
C Fan condenser
(not present on silenced units)
FS Condensate hose heating element
THRC Hot water return temperature sensor
THMC Hot water delivery temperature sensor
TMIX Combustion air temperature sensor
TA Ambient air temperature sensor
TG Generator temperature sensor
TF Fumes temperature sensor or genera-
tor n sensor
TEVA Evaporator outlet temperature sensor
TK Condensate discharge heating element
thermostat
MA Terminal block
REED Hydraulic pump rotation sensor
1.5 ELECTRONIC BOARDS
Electronic boards (S61+Mod10)
The unit's electrical board contains:
▶
Electronic Board S61 (Figure 1.9 p. 14), with micropro-
cessor, it controls the appliance and displays data, messages
and operative codes. The appliance is monitored and programmed by interacting with the display and knob.
▶
Auxiliary Mod10 electronic board (Figure 1.10 p. 15),
overlapping S61, it handles power modulation of the burner,
fan and water circulation pump.
▶
Satellite W10 electronic board (Figure 1.11p. 15), inter-
connected to the S61 board and located next to it, used to
control defrosting operations of the GAHP unit.
1 Features and technical data
14
Figure 1.9 – Electronic board S61
LEGEND
SCH1 Electronic board S61
SCH3 Electronic board Mod10 (see specic
picture for more details)
A1, A2 Auxiliary inputs
ENC Knob
F1 Fuse T 2A
F2 Fuse T 10A
F3 Fuse T 2A
F4 Fuse T 3,15A
FAN (BK, WH, BR) Fan output
FS5 (24V AC) Board power supply 24-0-24
Vac
IGN.BOX (L, N) Flame control unit power supply
230 Vac
J1 Jumper CAN BUS
J10 Jumper N.O. contact
J82 Board connector W10 (on Mod10)
JP10 6 pole ame control unit connector
JP12 Flue gas probe input or generator n
probe
JTAG Connector for board programming S61
MAIN 230V (L, N) Board power supply S61
230 Vac
CONTACT Normally open pump contact
P7 (R, W, Y, O) Enable input
P8 (GND, L, H) Connector CAN BUS
PUMP 230V (L, N) Oil hydraulic pump power
supply output
SPI Communication port with board
Mod10
SRT1 Oil hydraulic pump rotation sensor
input
SRT2 Hot water ow meter input
TA Ambient air temperature probe
TA1 Evaporator output probe input
TA2 Not used
TCN Combustive air temperature probe
input
TF Flue gas thermostat input
1 Features and technical data
Installation, Use and Maintenance Manual – GAHP-A
15
Figure 1.10 – Mod10 controller
Mod10 controller
Figure 1.11 – W10 electronic controller
1.6 OPERATION MODE
ON/OFF or modulating operation
The GAHP unit may work in two modes:
▶
mode (1) ON/OFF, i.e. On (at full power) or O, with circulating pump at constant or variable ow;
▶
mode (2) MODULATING, i.e. at variable load from 50% to
100% of power, with circulating pump at variable ow.
LEGEND
HFLOW Not used
CFLOW Condensation water sensor control
J51 SPI connector
HPMP Primary circuit hot water pump control
output (0-10 V )
CPMP Low consumption fan control output
(0-10V)
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)
LEGEND
FS1 Defrosting valve contact
JP1 Communication with S61/Mod10
Loading...