A.O. Smith 30 User Manual

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Installation

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Trademarks

Liability

Warning

Read this manual carefully before starting up the water heater. Failure to read this manual and to follow the instructions in this manual may lead to accidents, personal injury, and damage to the appliance.

Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by whatsoever means, without the prior written approval of A.O. Smith water Products Company.

A.O. Smith water Products Company reserves the right to modify specifications stated in this manual.

Any brand names mentioned in this manual are registered trademarks of their respective owners.

A.O. Smith water Products Company accepts no liability for claims from third parties arising from improper use other than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven Chamber of Commerce.

Refer further to the General Conditions. These are available on request, free of charge.

Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components, the manual may nonetheless contain errors and inaccuracies.

Should you detect any errors or inaccuracies in the manual, we would be grateful if you would inform us. This helps us to further improve our documentation.

More information

If you have any comments or queries concerning any aspect related to the appliance, then please do not hesitate to contact:

A.O. Smith water Products Company

PO Box 70

5500 AB Veldhoven

Netherlands

Telephone: (free) 008008 - AOSMITH

0870 - 267 64 84

General: +31 40 294 25 00

Fax: +31 40 294 25 39

E-mail : info@aosmith.nl

Website: www.aosmithinternational.com

In the event of problems with connecting to the gas, electricity or water supply, please contact your installation's supplier/installation engineer .

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4 Instruction manual SGS

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Table of contents

1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.1 About the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9

1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.6 Forms of notation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 11

2 Working principle of the appliance- - - - - - - - - - - - - - - 13

2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

2.2 General working principle of the appliance - - - - - - - - - - - - - - - - 13

2.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - 14

2.4 Protection for the appliance - - - - - - - - - - - - - - - - - - - - - - - 16

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 17

2.6 Protection for the solar heating system - - - - - - - - - - - - - - - - - - 18

2.7 Safety of the solar heating system - - - - - - - - - - - - - - - - - - - - 19

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

3.3 Environmental conditions- - - - - - - - - - - - - - - - - - - - - - - - - 21

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 24

3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.6 Water connections, Vented- - - - - - - - - - - - - - - - - - - - - - - - 28

3.7 Water connections, Unvented - - - - - - - - - - - - - - - - - - - - - - 29

3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.9 Solar heating system- - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.10 Air supply and flue - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.11 Electrically connecting the appliance - - - - - - - - - - - - - - - - - - - 37

3.12 Electrically connecting the solar heating system controller- - - - - - - - - 40

3.13 Checking the supply pressure and burner pressure - - - - - - - - - - - - 43

4 Conversion to a different gas category - - - - - - - - - - - - 47

5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

5.1 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

5.2 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 52

5.3 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 52

5.4 Filling solar heating system- - - - - - - - - - - - - - - - - - - - - - - - 53

6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

6.1 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

6.2 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 56

6.3 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 57

6.4 Draining solar heating system - - - - - - - - - - - - - - - - - - - - - - 58

7 The control panel- - - - - - - - - - - - - - - - - - - - - - - - 59

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

7.2 Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

7.3 Meaning of icons- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

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7.4 Electronic controller ON/OFF switch - - - - - - - - - - - - - - - - - - - - 59

7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

8 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 61

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

8.5 Q/T Sensor warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

8.6 Collector temperature warning- - - - - - - - - - - - - - - - - - - - - - - 62

9 Starting and running - - - - - - - - - - - - - - - - - - - - - - 63

9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

9.2 Starting the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

9.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 63

10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 65

10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

10.2 Shut the appliance down for a brief period ("OFF mode") - - - - - - - - - - 65

10.3 Electrically isolating the appliance - - - - - - - - - - - - - - - - - - - - - 65

10.4 Shutting the appliance down for a long period - - - - - - - - - - - - - - - 65

11 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

11.2 Notational convention for menu-related instructions - - - - - - - - - - - - 67

11.3 Switching on the "ON mode" - - - - - - - - - - - - - - - - - - - - - - - 67

11.4 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - - 67

11.5 Week program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68

11.6 Starting and stopping the week program - - - - - - - - - - - - - - - - - - 68

11.7 Changing the appliance's standard week program - - - - - - - - - - - - - 68

11.8 Adding times to a week program- - - - - - - - - - - - - - - - - - - - - - 70

11.9 Deleting times from a week program- - - - - - - - - - - - - - - - - - - - 71

11.10 Extra period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71

11.11 Programming an extra period - - - - - - - - - - - - - - - - - - - - - - - 72

11.12 Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

12 Service program - - - - - - - - - - - - - - - - - - - - - - - - 75

12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75

12.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - 75

12.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 75

12.4 Displaying the appliance history - - - - - - - - - - - - - - - - - - - - - - 75

12.5 Display the selected appliance - - - - - - - - - - - - - - - - - - - - - - 76

12.6 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 76

12.7 Setting legionella prevention- - - - - - - - - - - - - - - - - - - - - - - - 76

12.8 Solar heating system configuration - - - - - - - - - - - - - - - - - - - - 76

12.9 Setting the central heating configuration - - - - - - - - - - - - - - - - - - 78

13 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 79

13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79

13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - - 80

13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - - 83

13.4 Displayed warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94

6 Instruction manual SGS

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14 Maintenance frequency - - - - - - - - - - - - - - - - - - - - 95

14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - 95

15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 97

15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97

15.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 97

15.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 99

15.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 100

15.5 Solar collector maintenance - - - - - - - - - - - - - - - - - - - - - - -100

15.6 Finalizing maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - 100

16 Warranty (certificate) - - - - - - - - - - - - - - - - - - - - - - 101

16.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

16.2 Tank warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

16.3 Conditions for Installation and use - - - - - - - - - - - - - - - - - - - - 101

16.4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102

16.5 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - 102

16.6 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -102

16.7 Obligations of A.O. Smith - - - - - - - - - - - - - - - - - - - - - - - - 102

17 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

17.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

17.2 Menu structure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104

17.3 Electrical diagram for the appliance- - - - - - - - - - - - - - - - - - - - 106

17.4 Electrical diagram, solar heating system - - - - - - - - - - - - - - - - - 108

17.5 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 111

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0063

1 Introduction

1.1 About the appliance

1.2 What to do if you smell gas

This manual describes how to install, service and use the SGS appliance. The SGS appliance is a condensing boiler with a fan in the air intake. The appliance is always supplied including a storage tank fitted with a heat exchanger connected to a solar energy source.

The SGS can be installed as either an open or room-sealed appliance. A concentric chimney connector is fitted standard to the appliance, but a parallel system can also be connected.

The alternative installation types are B23, C13, C33, C43, C53 and C63. The information in this manual applies to the: SGS 28, SGS 30, SGS 50 and

SGS 60. The appliance has been manufactured and equipped in accordance with the

European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89). The appliances are therefore compliant with the European Directive for Gas Appliances, and are entitled to bear the CE mark.

Warning

Read this manual carefully before starting up the installation. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the appliance.

Warning

If there is a gas smell:

No naked flames! No smoking!

Avoid causing sparks! Do not use any electrical equipment or switch, i.e. no telephones, plugs or bells!

1.3 Regulations

Open windows and doors!

Shut off the mains gas supply valve!

Warn occupants and leave the building!

After leaving the building, alert the gas distribution company or your installation engineer.

As the (end) user, installation engineer or service and maintenance engineer, you must ensure that the entire installation complies, as a minimum, with the official local:

• building regulations;

• energy supplier's directives for existing gas installations;

• directives and technical guidelines for natural gas installations;

• safety requirements for low-voltage installations;

• regulations governing the supply of drinking water;

• regulations governing ventilation in buildings;

• regulations governing the supply of air for combustion;

• regulations governing the discharge of products of combustion;

• requirements for installations that consume gas;

• regulations governing indoor waste water disposal;

• regulations imposed by fire brigade, power companies and municipality.

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Introduction

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Furthermore, the installation must comply with the manufacturer's instructions.

Note

Later amendments and/or additions to all regulations, requirements and guidelines published on or prior to the moment of installing, will apply to the installation.

1.4 Target groups

1.5 Maintenance

The three target groups for this manual are:

• (end) users;

• installation engineers;

• service and maintenance engineers.

Symbols on each page indicate the target groups for whom the information is intended. See the table.

Target group symbols

Symbol Target group

(End) user

Installation engineer

Service and maintenance engineer

A service should be carried out at least once a year, both on the water side and on the gas side. Maintenance frequency depends, among other things, on the water quality, the average burning time per day and the set water temperature.

Note

To determine the correct maintenance frequency, it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side within three months following installation. Based on this check, the best maintenance frequency can be determined.

Note

Regular maintenance extends the service life of the appliance.

Note

Both the end user and the service and maintenance engineer are responsible for regular maintenance. They will need to establish clear agreements on this.

Note

If the appliance is not regularly maintained, the warranty will become void.

1.6 Forms of notation

10 Instruction manual SGS

The following notation is used in this manual:

Note

Important information.

Caution

Ignoring this information can lead to the appliance being damaged.

Warning

Failure to carefully read this information may lead to personal injury and

serious damage to the appliance.

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1.7 Overview of this document

Chapter Target groups Description

Working principle of the appliance

Installation This chapter describes the installation activity to be

This chapter describes the working principle of the appliance.

completed before you start the appliance for the first time.

Conversion to a different gas category

Filling This chapter describes how to fill the appliance.

Draining This chapter describes how to drain the appliance.

The control panel This chapter describes the general control of the

Status of the appliance This chapter describes the status (mode or condition) that

Starting and running This chapter describes how to start the appliance running.

Shutting down This chapter describes how to shut the appliance down for

Main menu This chapter describes the main menu of the display. This

Service program This chapter describes the service menu. It is mainly

Troubleshooting This chapter is mainly intended for the installation

Maintenance frequency This chapter describes how to determine the optimum

This chapter describes the activities required to convert the appliance to a different gas category.

appliance using the display.

the appliance may have, and possible actions to take.

The general heating cycle of the appliance is also described.

a brief or long period of time.

is the actual menu for the user, however the installation engineer and service and maintenance engineers will also need to use this menu.

intended for the installation engineer and service and maintenance engineers. End users may also refer to this chapter for additional information about the appliance.

engineer and the service and maintenance engineer. It describes appliance errors. These errors are indicated on the display. A troubleshooting table of possible causes and solutions is provided. End users may also refer to this chapter for additional information about the appliance.

frequency at which to carry out maintenance. Both the end user and the service and maintenance engineer are responsible for regular maintenance. They need to reach clear agreement on this.

Note

If the appliance is not regularly maintained, the

warranty will become void.

Performing maintenance This chapter sets out the maintenance tasks to be carried

out during a service.

Warranty (certificate) This chapter states the warranty terms and conditions.

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2 Working principle of

the appliance

2.1 Introduction

2.2 General working principle of the appliance

Topics covered in this chapter:

• General working principle of the appliance;

• The appliance's heating cycle;

• Protection for the appliance;

• Safety of the installation;

• Protection for the solar heating system.

The figure shows a cut-away view of the appliance.

In this appliance, the cold water enters the bottom of the tank through the cold water inlet (14).

Once the appliance and the storage reservoir are completely filled with water, they are both constantly under mains water pressure. When hot water is drawn from the appliance, it is immediately replenished with hot water from the storage tank, which in turn is replenished with cold water. The water in the storage tank is heated by a heat exchanger which is connected to the solar heating system.

A gas-fired heat exchanger (11) in the appliance heats the tap water further if necessary. The air required by the latter for combustion is forced into the burner (17) by the fan (18).

The heated tap water leaves the tank through the hot water outlet (2). Once the appliance is completely filled with water, it will constantly be under mains water pressure. When hot water is drawn from the appliance, it is immediately replenished with cold water.

The gas is fed to the burner via the gas control (16). The modulated supply of gas and air ensures that the optimum gas/air mixture is always achieved. The special construction of the burner causes the mixture to form a vortex (cyclone effect) before it becomes ignited. This vorticity improves the ignition on the hot surface igniter (20), as well as ensuring optimum combustion efficiency. The special design of the heat exchanger (11) ensures that the flue gases are first led downwards via the combustion chamber, then upwards via the heat exchanger, and downwards again alongside the water in the tank. The flue gases gradually become cooler in the process. Because the cooled flue gases flow alongside the cold water lower down in the tank, they start to condense. This condensation causes latent heat energy to be transferred to the cooler water, thereby increasing the performance of the unit. The condensate yielded by this process is discharged via the siphon (23).

Heat losses are prevented by the insulating layer (24) in both the storage tank and the appliance itself. Both are enamel-coated on the inside to protect against corrosion. The anodes (9) provide extra protection against corrosion. Both are fitted with an inspection and cleaning opening (12) for maintenance purposes.

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Legend

Only applicable numbers are mentioned.

1. cover

2. hot water outlet

3. electrical connector block

4. electronic controller

5. pressure switch

6. control panel

7. temperature sensor T

8. combustion chamber

9. anode

10. tank

11. heat exchanger

12. inspection and cleaning opening

13. temperature sensor T

14. cold water inlet

15. drain valve

16. gas control

17. burner

18. fan

19. air supply hose

20. hot surface igniter

21. flame probe

22. chimney pipe

23. siphon

24. insulation layer

29. pallet

Working principle of the appliance

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Cut-away view of the appliance

2.3 The appliance's heating cycle

The net water temperature (T the gas burner and the solar heating system are started and stopped. T curve shown in the figure. The controller uses two measured values to calculate this temperature: T are used by the controller of the solar heating system. S1 is measured in the solar collector. S2 is located between the inlet and outlet of the heat exchanger of the storage tank. S

Depending on whether or not hot water is being drawn off, hot water can be pumped from the storage tank to the appliance. This happens when S higher than T causing hot water to flow from the storage tank into the appliance. The pump switches off as soon as S

The other settings that govern the control behaviour are:

(7) and T2 (13). In addition, temperatures S1, S2 and S3

is measured at the top side of the storage tank.

. Water is then pumped from the appliance to the storage tank,

net

) in the appliance is used to regulate when both

net

equals T

net

is the

net

is 5 oC

14 Instruction manual SGS

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•T

set

is the the required water temperature that has been set on the

set

appliance (11.4.1 "Setting the water temperature via the SET POINT

MENU"). As soon as T

falls below T

net

, the water heating via the solar

set

heating system is started, however, only if the temperature of the heating fluid (S measured at the appliance (sensor S2). As soon as (T

) is a certain (adjustable) value higher than the temperature

net

= T

set

= T heating via the solar heating system is stopped. There is one exception to this rule, and that is when T

solar limit

is set to a higher value than T

• Hysteresis The moment T

falls below (T

net

set

- T

- Hysteresis), the controller

solar diff

registers such a heat demand that the gas burner and the solar heating system jointly heat the water. The solar heating system is only employed when the temperature measured by S than that of S

•T

solar diff

When T

exceeds (T

net

set

- T

solar diff

is heated exclusively by the solar heating system. When T T

set

value of T

•T

solar limit

(provided

solar diff

Tse t

= T

solar limit

), the solar heating system switches off. The

is adjustable (12.8.5 "Setting the solar difference").

is a certain (adjustable) value grater

), the gas burner is shut off and the water

rises above

net

Preset (12.8.4 "Setting the solar limit temperature") water temperature at which heating via the solar heating system is stopped.

solar limit

set

Legend

A = Gas burner on B = Gas burner off

net

• = no heat demand, so water not heated

• = water heated via solar heating system

• = water heated via solar heating system and gas burner

t = time T = Temperature

C = Minimum tap water

temperature

Graphical representation of heating cycle

solar limit

set

Solar diff.

Hys.

min = 45C

Note

can rise above T

net

,. However, this is only possible if T

set

increased via the service menu.

Note

to T

set

can be lower than T

solar limit

; this will mean that T

set

solar limit

can never be equal

net

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Page 16

2.4 Protection for the appliance

2.4.1 Introduction

2.4.2 Appliance water temperature protection

Working principle of the appliance

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The electronic controller monitors the water temperature, helps ensure the safe use of the solar heating system, and ensures safe combustion. This takes place using:

• the Appliance water temperature protection

• the Gas valve

• the Fan

• the Pressure switch

• the Flame probe

The electronic controller uses temperature sensors T1 (7) and T2 to monitor several temperatures that are important for safety.

The table explains the functioning of these temperature sensors.

Temperature protection

Protection Description

Against frost:

- T1 < 5°C

- T2 < 5°C

For maximum water temperature:

- T1 > 85°C

- T2 > 85°C

For extra safety:

> 93°C

- T

> 93°C

- T

The frost protection cuts in. The water is heated to 20°C.

The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the appliance. If the high-limit safeguard is activated, the heating is stopped. This causes the water in the tank to cool down. Once the water has cooled sufficiently (T1 < 78°C), the electronic controller resets the appliance.

A lockout error of the water heater controller takes place. The controller must be manually reset before the appliance can resume operation (8.3 "Error

conditions"). The reset may only be performed if T

2.4.3 Water temperature protection for the storage tank

Using temperature sensors S2 and S3, the solar heating system controller monitors several temperatures in the storage tank that are related to safety.

Temperature protection

Protection Description

Against frost:

- S2, S3 < 5°C

For maximum water temperature:

, S3 > 85°C

- S

For extra safety:

, S3 > 93°C

- S

The frost protection cuts in. The water is heated to 20°C.

The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the storage tank. If the high-limit safeguard is activated, the heating is stopped. This causes the water in the storage tank to cool down. Once the water has cooled sufficiently (S resets the appliance.

A lockout error of the water heater controller takes place. The controller must be manually reset before the appliance can resume operation (8.3 "Error

conditions"). The reset may only be performed if S

<78°C.

< 78°C), the electronic controller

< 78°C.

2.4.4 Gas valve

The electronic controller opens the gas valve so that gas can be supplied to the burner. As a safety measure, the gas valve has a double shut-off. The double shut-off guarantees complete isolation of the appliance from the gas supply.

To help ensure smooth ignition, the gas valve opens gradually ('softlite").

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2.4.5 Fan

The fan (18) provides an optimum air supply when there is a heat demand. As a safety feature, the fan ensures that any gases present in the combustion chamber are removed, both before and after combustion. We refer to this as pre- and post-purge.

The fan speed is continuously monitored by the electronic controller (4). The electronic controller takes control if the speed of rotation varies too much from the set value.

2.4.6 Pressure switch

The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre-purge and normal running of the appliance. The default state of the pressure switch is open. When sufficient pressure difference is reached, the pressure switch closes. However, in the event of a fault, the pressure switch is tripped open, and the heating cycle is interrupted. The table shows the trip point per appliance.

Note

The trip point of the pressure switch is not adjustable.

Pressure switch trip points

2.5 Safety of the

installation

Appliance Closing pressure

difference

SGS 28 >

SGS 30 >

SGS 50 >

SGS 60 >

635 Pa < 605 Pa

855 Pa < 825 Pa

885 Pa < 855 Pa

1085 Pa < 1055 Pa

2.4.7 Flame probe

To ensure that no gas can flow when there is no combustion, the water heater is fitted with a flame probe (21). The electronic controller uses this probe to detect the presence of a flame, by means of ionisation detection. The electronic controller closes the gas control the instant it detects that there is a gas flow but no flame.

In addition to the appliance's standard built-in safety monitoring, the appliance must also be protected by an expansion vessel, expansion valve, pressure reducing valve, non-return valve and a T&P valve.

The use of an expansion vessel, expansion valve and/or pressure reducing valve depends on the type of installation: unvented or vented.

2.5.1 Unvented installation

With an unvented installation, an expansion valve valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being caused to the enamelled coating (in the appliance) or to the tank. A nonreturn valve prevents excessive pressure buildup in the water supply system. This valve also prevents water from flowing backwards from the tank into the cold water supply system. The pressure reducing valve protects the installation against an excessively high water supply pressure (> 8 bar). These components are fitted to the cold water pipe (3.6 "Water connections, Vented").

Opening pressure difference

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2.5.2 Vented installation

2.5.3 T&P valve

2.6 Protection for the solar heating system

Working principle of the appliance

gis

With a vented installation, excess pressure is taken up by the open cold water head tank. The height of the head tank determines the working pressure in the water heater, which may not exceed 8 bar. The installation must also be fitted with a vent pipe from the hot water pipe, that opens into the cold water tank.

Ideally, the vent pipe should discharge into a separate tundish/drain or otherwise to the open cold water head tank. The water heater should also be fitted on the hot water side with a stop valve (3.7.2 "Hot water side").

A T&P valve is only mandatory in an unvented installation. However, A.O. Smith also recommends the use of a T&P valve in vented installations.

A T&P (Temperature and Pressure Relief) valve monitors the pressure in the tank and the water temperature at the top of the tank. If the pressure in the tank becomes excessive (> 10 bar) or the water temperature is too high (> 97°C), the valve will open. The hot water can now flow out of the tank. Because the appliance is under water supply pressure, cold water will automatically flow into the tank. The valve remains open until the unsafe situation has been rectified. The appliance is fitted standard with a connecting point for a T&P valve (3.7.2 "Hot water side").

2.6.1 Drain-back tank

The solar heating system may optionally be equipped with a drain-back tank. The tank fills itself with the heating fluid when there is no heat demand. This avoids overheating of the solar heating system. The high insulation factor of the tank also protects the system from freezing of the fluid. The use of the drainback tank also serves to extend the useful life of the fluid.

The presence of a drain-back tank is set (12.8.1 "Setting the drain-back tank") during the installation. Refer to the solar heating system manual for more details.

2.6.2 Fluid temperature

The heat exchanger of the solar heating system may be filled with glycol. If the temperature of the heating fluid is too high, a signal is sent to the controller of the solar collector and the pump of the solar collector is switched off. This signal is passed to the controller by temperature sensor S

At present, no heating fluids other than glycol are supported. The heating fluid type is set (12.8.2 "Setting the heating fluid type in the solar heating system") during installation.

Temperature protection for solar heating system

Protection Description

Maximum temperature S heating system is filled with glycol:

- S

> 130°C

, if solar

The pump of the solar heating system switches off when the temperature of the heating fluid at S value. The solar heating system enters error mode. The error is also visible on the display of the SGS appliance

exceeds the maximum

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2.7 Safety of the solar

heating system

2.7.1 Expansion vessel

2.7.2 Expansion valve

The solar heating system must be equipped with an expansion vessel (16). An expansion vessel serves to limit pressure variations in the system. The expansion vessel in the solar heating system can withstand a maximum pressure of 6 bar. The supply pressure to the expansion vessel depends on the static head of the system.

Besides the expansion vessel, the system is protected from overpressure by an expansion valve (2.7.2 "Expansion valve").

The solar heating system is equipped with an expansion valve (23). The expansion valve monitors the pressure in the solar heating system. If the pressure is excessive (> 6 bar), then the valve will open. The hot water can now flow out of the installation. The valve remains open until the unsafe situation has passed, i.e. until the pressure has fallen back below 6 bar.

Note

Because the installation is always under pressure and is not automatically

filled, the system will again need to be replenished (5 "Filling").

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Working principle of the appliance

gis

20 Instruction manual SGS

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3 Installation

Warning

Installation work should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service.

The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations").

3.1 Introduction

3.2 Packaging

This chapter describes the installation activities to be carried out before you actually start using the appliance (9 "Starting and running"), namely:

• Packaging;

• Environmental conditions;

• Technical specifications;

• Water connections, Vented;

• Water connections, Unvented;

• Water connections, Vented;

• Gas connection;

• Solar heating system;

• Air supply and flue;

• Electrically connecting the appliance;

• Checking the supply pressure and burner pressure.

For conversion to a different gas category, see conversion (4 "Conversion to a

different gas category").

To avoid damaging the appliance, remove the packaging carefully.

We recommend unpacking the appliance at or near its intended location.

Caution

The appliance may only be manoeuvred in an upright position. Take care that the appliance is not damaged after unpacking.

3.3 Environmental conditions

Instruction manual SGS 21

The appliance is suitable for either open or room-sealed combustion. If installed as a room-sealed appliance, then the availability of the necessary external air supply will depend on the place of installation. In this event, there are no additional ventilation requirements.

If the appliance is to be installed as an open system, then it will be subject to the guidelines and ventilation regulations that are in force locally.

The alternative installation types are B23, C13, C33, C43, C53 and C63.

Caution

The appliance may not be used in rooms where chemical substances are stored or used, due to the risk of explosion and/or corrosion of the appliance. Some propellants, bleaching agents, degreasing agents etc. disperse vapours which are explosive and/or which cause accelerated corrosion. If the appliance is used in a room in which such substances are present, the warranty will be void.

Page 22

Installation

3.3.1 Air humidity and ambient temperature

The boiler room must be frost-free, or be protected against frost. The table shows the environmental conditions that must be adhered to for correct functioning of the electronics present in the appliance to be guaranteed.

Air humidity and ambient temperature specifications

Air humidity and ambient temperature

Air humidity max. 93% RV at +25°C

Ambient temperature Functional: 0 <

3.3.2 Maximum floor load

In regard to the total weight of the installation, bear in mind that the installation always comprises an appliance complete with storage tank.

Appliance maximum floor load

In connection with the appliance's weight, take account of the maximum floor loading, refer to the table.

Weight specifications related to maximum floor load

T < 60°C

Weight of the appliance filled with water

SGS 28 394 kg

SGS 30, SGS 50, SGS 60 582 kg

Maximum floor load of storage tank

Bear in mind the weight of the storage tank (completely filled with water) when considering the maximum floor load. This maximum floor load may be between 400 and 4500 kg. This depends on the type of storage tank .

3.3.3 Water composition

The appliance is intended for heating drinking water. The drinking water must comply with the regulations governing drinking water for human consumption. The table gives an overview of the specifications.

Water specifications

Water composition

Hardness (alkaline earth ions)

Conductivity > 125 µS/cm

Acidity (pH value) 7,0 < pH value < 9.5

> 1.00 mmol/l:

• German hardness > 5.6° dH

• French hardness > 10.0° fH

• British hardness > 7.0° eH

Note

If the water specifications deviate from those stated in the table, the storage

tank protection cannot be guaranteed (16 "Warranty (certificate)").

If the water hardness is greater than 4° dH, please contact A.O. Smith.

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3.3.4 Appliance working clearances

For access to the appliance, it is recommended that the following clearances are observed:

• AA: around the appliance's control column and cleaning openings: 100 cm.

• BB: all sides of the appliance: 50 cm

• Above the appliance (room to replace the anodes):

- 100 cm if using rigid anode(s), or

- 50 cm if using flexible anode(s). If the available clearance is less than 100 cm, flexible magnesium anodes

can be ordered.

Note

When installing the appliance, be aware that any leakage may cause damage to the immediate environment or floors below the level of the boiler room. If this is the case, then the appliance should be installed above a wastewater drain or in a suitable metal leak tray.

3.3.5 Storage tank working clearances

For access to the storage tank, it is recommended that the following clearances are observed:

• All sides of the storage tank: 50 cm.

• Above the storage tank (room to replace the anodes): 100 cm.

Note

When installing the storage tank, be aware that any leakage can cause damage to the immediate environment or floors below the level of the boiler room. If this is the case, then the appliance should be installed above a wastewater drain or in a suitable metal leak tray.

Working clearances

A A

IMD-0227 R2

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Installation

3.4 Technical specifications

Legend

See the table.

The appliance is supplied without accessories. Check the dimensions (3.4.1 "Dimensions of the appliance"), gas data (3.4.3 "Gas data") and other specifications (3.4.2 "General and electrical specifications") of any accessories you plan to use.

3.4.1 Dimensions of the appliance

Plan and elevation of the appliance

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Dimensions (all dimensions in mm, unless otherwise stated)

Dimen

Description SGS 28 SGS 30 SGS 50 SGS 60

sion

A Total height 1485 2005 2005 2005

C Position on pallet 490 490 490 490

D Appliance diameter 705 705 705 705

E Depth 925 925 925 925

F Width 850 850 850 850

G Diameter of chimney flue 80/125 100/150 100/150 100/150

H Height of chimney flue 1460 2000 2000 2000

Hx x position of chimney flue outlet 265 265 265 265

Hy y position of chimney flue outlet 375 375 375 375

K Height of gas/burner connection 1365 1895 1895 1895

M Height of cold water supply 265 255 255 255

N Height of hot water outlet 1485 2005 2005 2005

Ny y position of hot water outlet 205 205 205 205

P Height of cleaning opening 265 270 270 270

R Height of drain valve connection 180 170 170 170

S Height of T&P valve connection 995 1505 1505 1505

W Height of condensation drain 220 240 240 240

1 Cold water supply connection (male) R1

2 Hot water outlet (male) R11/

3 Gas control connection (female) Rp3/

4 Drain valve connection (female)

/4"

R11/

Rp3/

/4"

R11/

Rp3/

/4"

R11/

Rp3/

/4"

5 T&P valve connection (female) 1 - 11.5 NPT 1 - 11.5 NPT 1 - 11.5 NPT 1 - 11.5 NPT

6 Cleaning/inspection opening 95 x 70 95 x 70 95 x 70 95 x 70

7 Condensation drainage connection (female) Ø40 Rp 1 Rp 1 Rp 1

3.4.2 General and electrical specifications

General and electrical specifications

DESCRIPTION Unit SGS 28 SGS 30 SGS 50 SGS 60

Volume litres 217 368 368 368

Empty weight kg 177 214 214 214

Maximum operating pressure bar 8 8 8 8

Number of anodes - 4 4 4 4

Fan speed at ignition rpm 4500 4500 4500 4500

Working speed of fan rpm 5000 5400 6000 6660

Diameter of air restrictor mm 23.0 23.0 28.0 29.0

Heating-up time ∆T = 45°C minutes 22 35 24 19

Electrical power consumption W 275 275 275 275

Maximum power consumption of solar

W 700 700 700 700

heating system controller

Supply voltage (-15% +10% VAC) volts 230 230 230 230

Mains frequency Hz (± 1Hz) 50 50 50 50

IP class - 30 30 30 30

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Installation

3.4.3 Gas data

Gas data

Description II

Gas category 2H: G20 - 20 mbar

Injector orifice diameter mm 4.90 5.10 7.00 7.10

(1) = Blank plate (2) = Burner pressure regulator

Nominal load (gross calorific value) kW 32.1 34.5 52.6 63.2

Nominal output kW 30.5 32.7 48.8 59.6

Supply pressure mbar 20 20 20 20

Burner pressure mbar 8.5 8.5 8.5 11.5

Gas consumption

General 3+

Injector orifice diameter mm 2.50 2.60 3.40 3.80

(1) = Blank plate (2) = Burner pressure regulator

Gas category: G30-30 mbar (butane)

Nominal load (gross calorific value) kW 30.7 32.8 50.6 59.4

Nominal output kW 29.8 31.8 48.1 57.4

Supply pressure mbar 30 30 30 30

Burner pressure

Gas consumption

Gas category: G31-37 mbar (propane)

Nominal load (gross calorific value) kW 29.0 30.9 50.3 59.1

Nominal output kW 28.1 29.8 47.7 56.9

Supply pressure mbar 37 37 37 37

Burner pressure

Gas consumption

(*) Based on 1013.25 mbar and 15 °C. (†) If using a blank plate instead of a burner pressure regulator, it is assumed that the burner pressure is equal to

the supply pressure. In practice, however, the burner pressure will be lower.

2H3+

(*)

(†)

(*)

(†)

(*)

Unit SGS

1 or 2 2 2 2 2

m3/h 3.1 3.3 5.0 6.0

1 or 2 1 1 1 1

mbar----

kg/h 2.2 2.4 3.7 4.3

mbar----

kg/h 2.1 2.2 3.6 4.2

SGS 30

SGS 50

SGS 60

26 Instruction manual SGS

Page 27

3.5 Installation diagram

This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described.

Installation diagram

Instruction manual SGS 27

Page 28

Installation

Legend

Only applicable numbers are mentioned.

1. pressure-reducing valve (mandatory if the mains

water pressure exceeds 8 bar)

3. T&P valve (mandatory)

4. stop valve (recommended in pipe C and mandatory in

pipe A)

5. non-return valve (mandatory)

6. circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve (recommended)

12. temperature gauge (recommended)

13. condensation drainage (mandatory)

14. hot water draw-off points

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. water tank

Note

In the above diagram, there is a non-return valve in the station. This may only be used in closed (pressure) systems. In systems with drain back, it is prohibited to fit a non-return valve in the solar heating system.

19. float valve

23. pressure valve (mandatory)

26. air bleed (mandatory)

37. combined Q/T sensor (optional)

38. solar heating system pump station (modulating mandatory)

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe F. heat exchanger supply G. heat exchanger return H. overflow safety S1.collector sensor (mandatory) S2.tank sensor (mandatory) S3.top tank sensor (mandatory) S4.heat exchanger discharge sensor (optional)

3.6 Water connections, Vented

3.6.1 Cold water side

3.6.2 Hot water side

Warning

The installation should be carried out by an authorised installation engineer,

in compliance with general and local regulations (1.3 "Regulations").

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the appliance, as required by regulations (1.3 "Regulations").

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes prevents unnecessary energy loss.

1. Fit the T&P valve (3).

2. Optional: fit a temperature gauge (12) so you can check the temperature of the tap water.

3. Fit a stop valve (11) in the hot water outlet pipe for servicing.

4. If a circulation pipe is required, continue by installing the circulation pipe (3.6.3 "Circulation pipe").

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3.6.3 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort and reduces water wastage.

1. Fit a circulation pump (6) of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valve (5) behind the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for service purposes (4).

4. Connect the circulation pipe up to a connection of the storage tank.

3.7 Water connections, Unvented

3.7.1 Cold water side

3.7.2 Hot water side

Warning

The installation should be carried out by an authorised installation engineer,

in compliance with general and local regulations (1.3 "Regulations").

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side as required by applicable regulations (1.3 "Regulations").

2. The maximum working pressure of the appliance is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve (1).

3. Fit a non-return valve (5) and an expansion vessel (16).

4. Fit an expansion valve (15) and connect the overflow side to an open wastewater pipe.

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes will prevent unnecessary energy loss.

1. Optional: fit a temperature gauge (12) so you can check the temperature of the tap water.

2. Fit the T&P valve (3).

3. Fit a stop valve (11) in the hot water outlet pipe for servicing.

3.7.3 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort and reduces water wastage.

1. Fit a circulation pump (6) of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valve (5) behind the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for service purposes (4).

4. Connect the circulation pipe up to a connection of the storage tank

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Installation

3.7.4 Condensation drainage

1. Fit a sloping wastewater pipe to the siphon (13) for condensation drainage and connect this to the wastewater discharge in the boiler room.

Caution

All fittings behind the siphon must be condensation-resistant.

3.8 Gas connection

3.9 Solar heating system

Warning

The installation should be carried out by an authorised installation engineer,

in compliance with general and local regulations (1.3 "Regulations").

Caution

Make sure that the diameter and length of the gas supply pipe are large

enough to supply sufficient capacity to the appliance.

See (D) in the installation diagram (3.5 "Installation diagram").

1. Fit a manual gas valve (10) in the gas supply pipe.

2. Blow the gas pipe clean before use.

3. Close the manual gas valve.

4. Fit the gas supply pipe to the gas control.

Warning

After fitting, check for leaks.

Note

For the solar heating system connections, refer to the electrical

diagram (17.4 "Electrical diagram, solar heating system") and the table. ( "Electrical connector block")

1. Connect the supply from the solar collector to the inlet (F) of the heat exchanger (55).

2. Connect the return pipe to the solar collector to the outlet (G) of the heat exchanger (55).

3. Connect the lead from the solar heating system controller to sensor S2, see:

- electrical diagram (17.3 "Electrical diagram for the appliance") and

- connections table (3.11.2 "Preparation").

4. Connect the communication cable between the solar heating system controller and the appliance, see:

- electrical diagram (17.4 "Electrical diagram, solar heating system") and

- connections table (3.11.2 "Preparation").

Warning

The installation diagram shows a non-return valve in the pump station. This

non-return valve may be used solely in closed (pressure) systems. In systems

with a drain-back tank, it is prohibited to fit a non-return valve in the solar heating system.

3.10 Air supply and flue

3.10.1 Introduction

This section covers the following subjects:

• Requirements for flue gas discharge materials

• Concentric connections

• Parallel connections

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Page 31

3.10.2 Requirements for flue gas discharge materials

Warning

The installation should be carried out by an authorised installation engineer,

in compliance with general and local regulations (1.3 "Regulations").

Depending on the approved installation types, there are several alternatives for connecting the air supply and flue gas discharge.

The appliances are approved for installation types B23, C13, C33, C43, C53 and C63.

The figure and table give information about these appliance types. For an explanation of the possibilities, please contact the manufacturer.

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Page 32

Installation

Types of appliances

C43

B23 C33

C13 C53

IMD-0468 R0

32 Instruction manual SGS

Page 33

Explanation of type of appliance

Type of appliance Description

B23 Air for combustion is drawn from the boiler room.

C13 Concentric and / or parallel wall flue terminal

C33 Concentric and / or parallel roof flue terminal

C43 Appliances on common air supply and flue gas discharge (concentric and / or

C53 Air supply and flue terminal types mixed.

C63 Appliances supplied without flue components and / or terminal. These

3.10.3 Concentric connections

parallel) in multi-storey building.

appliances must be installed in compliance with local regulations.

Note

Make sure that the chimney discharges into an area where this is permitted

for this category of appliance.

The table shows the requirements for concentric systems.

Warning

Install flue gas discharge pipe runs with a run-off of 5 mm per metre.

Flue gas discharge requirements for concentric systems (C13, C33)

Appliance Diameter Maximum length Maximum

number of 90º bends

SGS 28 80/125 mm 40 m 7

SGS 30 100/150 mm 40 m 7

SGS 50 100/150 mm 40 m 7

SGS 60 100/150 mm 15 m 4

Caution

Both conditions stated in the table must be fulfilled.

Even if there are less bends than the stated maximum, the maximum pipe length may not be exceeded.

Even if the total pipe length is less than the stated maximum, the maximum number of bends may not be exceeded.

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Page 34

Installation

The following example illustrates how to use the table.

Practical example of concentric flue gas discharge

Example

The figure shows a SGS 30 installation. The appliance must be fitted with 25 m of concentric pipe (C13/C33) and four 90 degree bends. We need to check whether this configuration complies with the requirements stated in the table.

Appliance with concentric flue gas discharge material

According to the table, the maximum length allowed is 40 metres, and there may be up to seven 90 degree bends. Both requirements are fulfilled.

Specifications

Caution

For type C13 and C33 installations,A.O. Smith prescribes the use of a roof or wall-mounted terminal, exclusively of a type approved for the appliance. Use of an incorrect roof or wall-mounted flue terminal can cause the installation to malfunction.

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Page 35

Concentric wall flue terminal specifications C13

Specification Description

Wall flue terminal set:

• 1X Wall flue terminal (incl. wall flange & clamping ring)

• 1X Pipe 500mm

• 1X Bend 90°

Pipe material Construction Concentric

Pipe diameters Flue SGS 28

No other wall flue terminal is permitted. Use this item number to order the wall conduit set from supplier,

(1)

manufacturer or wholesaler.

Concentric roof flue terminal specifications C33

Specification Description

Roof flue terminal set:

• 1X Wall flue terminal (incl. clamping ring)

• 1X Pipe 1000mm

• 1 X Mounting flange

Pipe material Construction Concentric

Pipe diameters Flue SGS 28

No other wall flue terminal is permitted. Use this item number to order the wall conduit set from supplier,

(1)

manufacturer or wholesaler.

Art. No. SGS 28

SGS 30-50-60

Construction Concentric

Manufacturer Muelink & Grol

Model M2000 MDV SEC

Flue Thick-walled aluminium with lip ring seal

Air supply Thin-walled galvanised sheet steel

SGS 30-50-60

Air supply SGS 28

SGS 30-50-60

Art. No. SGS 28

SGS 30-50-60

Construction Concentric

Manufacturer Muelink & Grol

Model M2000 DDV HR-C

Flue Thick-walled aluminium with lip ring seal

Air supply Thin-walled galvanised sheet steel

SGS 30-50-60

Air supply SGS 28

SGS 30-50-60

0302 515 0302 504

Ø 80 mm Ø 100 mm

Ø 125 mm Ø 150 mm

0305 042 0304 423

Ø 80 mm Ø 100 mm

Ø 125mm Ø 150 mm

3.10.4 Parallel connections

The table states the maximum pipe lengths for parallel systems. The maximum pipe length depends on the chosen diameter.

Warning

Install flue component pipe runs with a run-off of 5 mm per metre.

Flue gas outlet requirements for parallel systems

Appliance Diameter

SGS 28 80mm 25m 3.9m 1.1m

SGS 30 100mm 80m 4.6m 1.2m

SGS 50 100mm 45m 4.6m 1.2m

SGS 60 100mm 25m 4.6m 1.2m

Maximum total length

equivalent

90º bend

equivalent

45º bend

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Installation

Appliance Diameter

SGS 28 100mm 100m 4.6m 1.2m

SGS 30 130mm 100m 2.4m 1.4m

SGS 50 130mm 100m 2.4m 1.4m

SGS 60 130mm 100m 2.4m 1.4m

1) Parallel systems with diameter of 130mm or 150mm. If the maximum total length for a diameter of 130mm is insufficient, 150mm diameter must be used. Any diameter enlargement must be carried out on both air supply and flue gas outlet.

You must use the longest pipe when calculating the pipe length. For example, if the chimney pipe is 35 metres and the air supply pipe is 32 metres, use 35 metres as the length for the calculation. Next, add the L and 45° bend to this 35 metres, in both the air supply and flue gas outlet. The following practical example illustrates how to use the table.

Practical example of parallel flue gas outlet

Example

The diagram shows a SGS 30. This has to be fitted with a 25m parallel pipe 100mm in diameter, plus eight 90-degree bends. The configuration must be checked for compliance with the requirements stated in the table.

Appliance with parallel flue gas discharge material

Maximum total length

equivalent

90º bend

equivalent

45º bend

for every 90°

36 Instruction manual SGS

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The longest pipe must be used to check the maximum length. In this case, the chimney pipe is the longest. This is 25 metres. This 25 metres is the sum of pipe sections 1, 2, 3, 4 and 5. The length of the transition piece can be ignored. The total number of bends used in the flue gas outlet and air supply is 8. The bend in the transition piece can be ignored. According to the table, 4.6 metres must be added for each bend. This brings the total pipe length to:

(4.6 x 8) + 25 = 36.8 + 25 = 61.8m.

This is less than the maximum length of 80 metres stated in the table. The installation therefore fulfils the requirements.

3.11 Electrically connecting the appliance

Warning

The installation should be carried out by an authorised installation engineer,

in compliance with general and local regulations (1.3 "Regulations").

3.11.1 Introduction

Topics covered in this paragraph:

• Preparation

• Connecting the mains voltage

Optionally, it is possible to connect an isolating transformer, a continuous pump, a program-controlled pump, an extra ON mode switch and an extra alarm signal to the appliance. For these options, see:

• Isolating transformer

• Connecting continuous pump

• Connecting a program-controlled pump

• Connecting an extra ON mode switch ("Tank ON")

• Connecting an extra error signal ('Alarm OUT' )

Connecting the solar heating system is also described:

• Connecting communication cable to solar heating system

Note

The optional components are not included in the rating for electrical power

consumption stated in the table (3.4.2 "General and electrical specifications").

3.11.2 Preparation

Caution

The appliance is phase-sensitive. It is absolutely essential to connect the mains phase (L) to the phase of the appliance, and the mains neutral (N) to the neutral of the appliance.

Caution

There may be no potential difference between neutral (N) and earth ( ). If this is the case, then an isolating transformer must be applied in the supply circuit (3.11.4 "Isolating transformer").

For more information or to order this isolating transformer, please contact A.O. Smith water Products Company.

The figure shows a view of the electrical connector block, and the table shows the appropriate connections.

Instruction manual SGS 37

Page 38

Legend

A. screws B. protective cap C. connector block

Installation

Connector block

IMD-0077 R2

In preparation, you must first remove the two plastic covers and the protective cap of the electrical section.

1. Undo the screws of the plastic covers.

2. Carefully remove the covers from the appliance. The electrical section is now visible.

3. Loosen the 2 screws (A) of the electrical section, and remove the protective cap (B) from the electrical section. The connector block (C) is now visible.

Note

Consult the table for the connections and consult the electrical diagram for

the electrical component connections.

Electrical connector block

BUS-

link Unuse

5X6

123456789101112131415161718192021222324

--X3X4AL5NNL4AX1X2ANL2ANL3ANL1A

Extern

ON/OF

Continuous

pump

Program-

controlled

pump

Alarm Off Isolating transformer Power

primary secondary

38 Instruction manual SGS

Page 39

3.11.3 Connecting the mains voltage

The appliance is supplied without a power cable and isolator.

Note

In order to receive electrical power, the appliance has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance. The power cable must have cores of at least 3 x 1.0 mm2.

Warning

Leave the appliance isolated until you are ready to start it up.

1. Connect phase (L), neutral (N) and earth ( ) of the power cable to terminals

22 through 24 of the connection block as indicated in the table (3.11.2 "Preparation").

2. Fit the power cable in the strain relief.

3. Connect the power cable to the isolator.

4. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

3.11.4 Isolating transformer

An isolating transformer should be used if there is a case of 'floating neutral'.

1. Refer to fitting instructions provided with the isolating transformer. (Contact

the supplier for details of the correct isolating transformer.)

2. Connect phase (L), neutral (N) and earth ( ) to terminals 16 through 21 of

the terminal block as stated in the table (3.11.2 "Preparation").

3. Fit the cables in the strain relief.

4. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

5. Connect the power cable to the isolator.

3.11.5 Connecting continuous pump

1. Connect phase (L), neutral (N) and earth ( ) to terminals 7, 8 and 9 as

stated in the table (3.11.2 "Preparation").

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

3.11.6 Connecting a program-controlled pump

1. Connect live (L), neutral (N) and earth ( ) to terminals 10, 11 and 12 as

indicated in the table (3.11.2 "Preparation"). This is for pump 8 in the diagram.

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

Instruction manual SGS 39

Page 40

Installation

3.11.7 Connecting an extra ON mode switch ("Tank ON")

Tank ON is a facility for connecting an external ON/OFF switch. In the OFF position, the programmed operating state is active. In the ON position, the programmed operating mode is overruled, and the "ON mode" is active.

1. Connect cables (X table (3.11.2 "Preparation").

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

3.11.8 Connecting an extra error signal ('Alarm OUT' )

Alarm OUT is a potential free terminal that is switched when an error is detected. This can be used to signal errors, for example with a lamp. A 230 V circuit can be directly powered. Other voltages require a relay prescribed by the manufacturer.

1. Connect the phase cables (X the table (3.11.2 "Preparation"). If required, connect earth ( ) to terminal 15.

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

and X2) to terminals 5 and 6 as indicated in the

and X2) to terminals 13 and 14 according to

3.12 Electrically connecting the solar heating system controller

3.11.9 Connecting communication cable to solar heating system

You must connect a communication cable between the controllers of the appliance and the solar heating system.

1. Connect the cables (X5 and X6) to terminals 1 and 2 as indicated in the table (3.11.2 "Preparation").

2. Fit the cable in the strain relief.

- If you do not need to make any more connections:

- Fit the cap on the terminal block.

- Fit the covers onto the appliance.

Topics covered in this paragraph:

• Preparation

• Connecting the mains power

• Connecting pump station - modulating pump

• Connecting solar collector

• Connecting tank sensor

• Connecting top tank sensor

• Connecting communication cable

Optionally you can connect an extra head pump and Q/T sensor:

• Connecting extra head pump

• Connecting Q/T sensor

40 Instruction manual SGS

Page 41

3.12.1 Preparation

Undo the screws of the cap over the terminal block of the collector. This has the following terminals:

Power n.a. Pump ON/OFF Modulating pump n.a.

LN- - - L

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

n.a.

Power 5 V

Sensor S4

1234123412341234

J3 J12 J13 J14

3.12.2 Connecting the mains power

Note

Just as with the appliance controller, the solar heating system controller must have a permanent electrical connection to the mains power supply. There must be a double-pole isolator installed in the permanent connection. This is the same double-pole isolator as installed between the mains power supply and the appliance itself. Whenever this isolator is operated, both controllers can be switched on or off.

NL2NM-------

n.a.

Flow signal

n.a.

Sensor S1

Sensor S3

Semsor S1

Sensor S2

Sensor S3

Sensor S2

1. Connect earth, live and neutral to terminals 1 through 3

2. Fit the cables in the strain relief.

3. Connect the power cable to the isolator.

4. Continue (3.12.3 "Connecting pump station - modulating pump").

3.12.3 Connecting pump station - modulating pump

The pump station contains a modulating pump (4-wire connection). You must connect this pump to the controller of the solar heating system.

1. Connect earth, live and neutral to terminals 10 through 12.

2. Connect the fourth lead to terminal 13

3. Fit the cables in the strain relief.

4. Continue (3.12.4 "Connecting solar collector").

3.12.4 Connecting solar collector

Note

This sensor must be mounted in the solar collector; refer to the solar collector installation manual.

Connect the sensor to the appliance as follows:

1. Connect the sensor to terminal 2 and 4 of J13.

2. Fit the cables in the strain relief.

3. Continue (3.12.5 "Connecting tank sensor").

Instruction manual SGS 41

Page 42

Installation

3.12.5 Connecting tank sensor

Note

This sensor is already mounted in the tank prior to delivery. The sensor is mounted between the inlet and outlet of the heat exchanger. However, you must still connect the lead to the solar heating system controller.

1. Connect the sensor lead with the blade connectors to the sensor.

2. Connect the other end to terminals 2 and 4 of J14.

3. Fit the cables in the strain relief.

4. Continue (3.12.7 "Connecting communication cable").

3.12.6 Connecting top tank sensor

1. Connect the sensor lead with the blade connectors to the sensor.

2. Connect the other end to terminals 1 and 3 of J14.

3. Fit the cables in the strain relief.

4. Continue (3.12.7 "Connecting communication cable").

3.12.7 Connecting communication cable

Note

>The communication cable must always be connected, otherwise neither the appliance nor the solar heating system controller will run.

1. Connect the double connector to J16.

2. Fit the cable in the strain relief.

3. Connect the other end of the communication cable to the terminal block of

the appliance. See:

- connecting communication cable to appliance (3.11.9 "Connecting

communication cable to solar heating system")

- electrical diagrams (17.3 "Electrical diagram for the appliance").

4. Connect the optional head pump (3.12.8 "Connecting extra head pump") or QT sensor (3.12.9 "Connecting Q/T sensor").

5. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

3.12.8 Connecting extra head pump

Note

This pump is essential if a greater head is required. When the system has

such a high resistance (>110 kPa) that the pump in the pump station is insufficient, you can connect a second (ON/OFF) pump to the solar heating system controller.

1. Connect earth ( ), live and neutral to terminals 7 through 9.

2. Fit the cable in the strain relief.

3. If you need to connect an extra head pump continue (3.12.9 "Connecting

Q/T sensor"), otherwise:

- Fit the cap on the terminal block.

- Fit the covers onto the appliance.

42 Instruction manual SGS

Page 43

3.12.9 Connecting Q/T sensor

Note

You can optionally add a Q/T sensor to the installation. This enables you to calculate the energy contribution of the system. For more information or to order the Q/T sensor, please contact your supplier.

1. Connect the 5V to J12-1.

2. Connect sensor S

3. Connect earth to J12-3.

4. Connect the "flow signal" to J12-4.

5. Fit the cable in the strain relief.

6. If you have no more connections to make:

- Fit the cap on the electrical terminal block.

- Fit the plastic covers onto the appliance.

to J12-2.

3.13 Checking the supply pressure and burner pressure

Legend

Only applicable numbers are mentioned.

1. supply pressure test nipple

2. burner pressure test nipple

3. burner pressure regulator

4. burner pressure control cap

5. burner pressure control

adjusting screw

Note

Before starting the appliance and/or checking the supply pressure and

burner pressure, you must fill (5 "Filling") the appliance.

Caution

Before starting up for the first time or after conversion, you must always

check the supply pressure and burner pressure.

Note

The easiest way to check the gas pressures is by using two pressure

gauges. This procedure assumes that these two gauges are available.

Gas control

Instruction manual SGS 43

Page 44

Installation

3.13.1 Preparation

To check the supply pressure and burner pressure, proceed as follows:

1. Isolate (10.3 "Electrically isolating the appliance") the water heater from the power supply.

2. Undo the screws of the plastic covers.

3. Carefully remove the covers from the top of the appliance. The electrical section is now visible.

3.13.2 Procedure to check pressures

1. There are two test nipples on the gas control:

- a supply pressure nipple (1)

- a burner pressure nipple (2)

Sealing screws are located inside the test nipples. Loosen both sealing screws by a few turns. Do not completely loosen them; they can be difficult to re-tighten.

2. Connect a pressure gauge to the burner pressure nipple (2).

3. Open the gas supply and vent the gas supply line with the supply pressure nipple (1).

4. Connect a pressure gauge to the supply pressure nipple (1) when gas starts to flow from this nipple.

5. Switch on the power to the appliance using the isolator on the appliance.

6. Switch the electronic controller ON by setting the 0/I switch to position I.

The display will now show go to the main menu.

INTERNAL CHECK

MENU »OFF ^ ON È WEEK PROGRAM

44 Instruction manual SGS

INTERNAL CHECK

for about 10 seconds and

Page 45

7. Activate the "ON mode" by going through the following steps:

- Press the blue arrow once ( ) to position the cursor in front of press . The display shown here will appear.

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

and

- Confirm the by pressing

The appliance is now in the "ON mode" and will ignite.

8. Once the display shows the text before reading the dynamic pressures (the fan needs this time to run up to full rotational speed).

9. Use the pressure gauge to read the supply pressure at 1nipple (1) (3.4.3 "Gas data").

Note

Consult the mains gas supply company if the supply pressure is not correct.

10. Use the pressure gauge to read the burner pressure at nipple (2) (3.4.3 "Gas data").

If the burner pressure is not correct and the appliance is fitted with a blank plate, you will not be able to adjust the pressure. Finalise (3.13.4 "Finalising"), and in this case, consult your installation engineer or supplier.

If the appliance is indeed fitted with a burner pressure regulator, the pressure can be adjusted as described in the procedure (3.13.3 "Adjusting the pressure").

3.13.3 Adjusting the pressure

1. Remove the cap (4) from the burner pressure regulator (3).

2. Correct the burner pressure by turning the adjusting screw (5), depending on the correction required:

- Adjustment screw anticlockwise: burner pressure decreases.

- Adjustment screw clockwise: burner pressure increases.

3. Cover the opening of the adjusting screw and check the burner pressure against the value given in the gas table (3.4.3 "Gas data").

4. If the pressure is not set correctly, repeat the preceding steps until the correct pressure is attained.

5. Fit the cap (4) back on the burner pressure regulator.

6. Activate the "OFF mode" of the electronic controller:

START OPERATION

RUNNING

you must wait about 1 minute

MENU »OFF ^ ON È WEEK PROGRAM

7. If the press .

- Use and to place the cursor beside

- Confirm with .

8. Wait until the fan has stopped, and switch the electronic controller off.

Caution Failure to wait until the fan stops can cause damage to the appliance.

9. Finish off (3.13.4 "Finalising").

is not displayed:

OFF

Instruction manual SGS 45

Page 46

Installation

3.13.4 Finalising

1. Shut off the gas supply.

2. Disconnect the two pressure gauges and retighten the sealing screws in the test nipples.

3. Replace the cover.

Note

Before starting-up the appliance, take time to fill in the warranty card

supplied with the appliance. This enables us to guarantee the quality of our systems, and to further enhance our warranty procedure.

Please return this card as soon as possible. Your customer will then receive a warranty certificate with our warranty conditions.

46 Instruction manual SGS

Page 47

4 Conversion to a

Legend

1. connector

2. gas coupling

3. air supply hose

4. pressure switch hose

5. gas/air distribution plate

6. stamped figures

different gas category

Caution

The conversion may only by carried out by an authorised installation

engineer.

If the appliance must operate on a family of gases (LP gas or natural gas) or other gas category than that for which the appliance has been set at the factory, the appliance will have be adapted using a special conversion kit.

Caution

You must check the supply pressure and burner pressure once the

conversion is complete.

Orifice assembly

Instruction manual SGS 47

Page 48

Conversion to a different gas category

1. Isolate the water heater from the power supply (10.3 "Electrically isolating

the appliance").

2. Shut off the gas supply.

3. Undo the screws of the plastic covers.

4. Carefully remove the covers from the top of the appliance.

5. Detach the connector (1) that connects the leads of the hot surface igniter and the flame probe to the controller.

6. Detach the three-part gas coupling (2) adjacent to the burner.

- Detach the air supply hose (3).

- Detach the pressure switch hose (4).

7. Remove the burner as complete assembly.

8. Place and fit the burner with parts from the conversion kit.

Note

The burner for LP gases can be recognised by the letter 'P' which is stamped

into the metal of the gas/air distribution plate (5).

9. Select and fit the correct orifice from the conversion kit, based on the gas table (3.4.3 "Gas data"). The injector diameter is stamped into each injector (6).

Legend

7. burner pressure regulator

8. blank plate

9. gas control connector

Conversion of gas control

48 Instruction manual SGS

IMD-0079b R2

Page 49

10. Check whether there is a burner pressure regulator (7) attached to the top of the gas control, or simply a blank plate (8).

Note

In the event of the supply pressure for a gas category being the same as the burner pressure (3.4.3 "Gas data"), the gas control must be fitted with a blanking plate with a cork gasket. A burner pressure that deviates with respect to the supply pressure requires a burner pressure regulator with rubber gasket to be used. Each conversion kit contains all the necessary components.

11. If the blank plate or burner pressure regulator need to be replaced:

- Unscrew the connector (9) from the gas control.

- If necessary, remove the blank plate or burner pressure regulator (7).

- If necessary, fit the blank plate or burner pressure regulator supplied with the conversion kit.

- Fit the gas control's connector (9).

12. Fit the connector (1) of the hot surface igniter and flame probe to the controller.

13. Fit the 3-part gas coupling (2).

14. Check the burner pressure and supply pressure (3.13 "Checking the supply

pressure and burner pressure").

15. Replace the cover.

16. Remove the sticker showing the new gas category from the conversion kit, and attach it below the appliance's rating plate. This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied.

Instruction manual SGS 49

Page 50

Conversion to a different gas category

50 Instruction manual SGS

Page 51

gis

5 Filling

5.1 Installation diagram

This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described.

Installation diagram

Instruction manual SGS 51

Page 52

Filling

gis

Legend

Only applicable numbers are mentioned.

1. pressure-reducing valve (mandatory if the mains water pressure exceeds 8 bar)

3. T&P valve (mandatory)

4. stop valve (recommended in pipe C and mandatory in pipe A)

5. non-return valve (mandatory)

6. circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve (recommended)

12. temperature gauge (recommended)

13. condensation drainage (mandatory)

14. hot water draw-off points

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. water tank

Note

19. float valve

23. pressure valve (mandatory)

26. air bleed (mandatory)

37. combined Q/T sensor (optional)

38. solar heating system pump station (modulating mandatory)

5.2 Filling unvented installations

5.3 Filling vented installations

To fill the appliance, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valves (11) between the storage tank and the appliance.

5. Open the stop valve (4) on the cold water side (A) so that cold water flows into the appliance.

6. Completely fill the appliance. When a full water jet flows from the nearest draw-off point, the appliance is full.

7. Bleed the entire installation of air, for example by opening all draw-off points.

8. The appliance is now under water supply pressure. There should be no water coming out of the expansion valve (15) or out of the P-valve (23). If there is, the cause might be:

- The water supply pressure is greater than the specified 8 bar.

Rectify this by fitting a pressure reducing valve (1).

- The expansion valve in the protected cold supply setup is defective or

incorrectly fitted.

To fill the appliance, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valves (11) between the storage tank and the appliance.

5. Open the stop valve (4) on the cold water side (A) so that cold water flows into the appliance.

52 Instruction manual SGS

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5.4 Filling solar heating system

5.4.1 Filling solar heating system with glycol

6. Completely fill the appliance. When a full water jet flows from the nearest draw-off point, the appliance is full.

7. Bleed the entire installation of air, for example by opening all draw-off points.

8. The appliance is now under water supply pressure. There should be no water coming out of the P-valve (23). If this does happen, the P-valve might be defective or incorrectly fitted.

Note

No special safety measures are required when working with the diluted glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer.

Warning

Before filling the solar heating system to replenish the heating fluid, make

certain that:

- The appliance is switched off (10.2 "Shut the appliance down for a brief period

("OFF mode")").

- The solar heating system is switched off. Refer to the documentation of the solar heating system.

- The appliance has cooled down sufficiently to prevent personal injury (burns).

Note

The filling procedure described in this manual is intended for the pump system supplied by the supplier of the appliance. For any other system, you should follow the procedure for that system.

Warning

To avoid contaminating the glycol, you should flush the solar heating system

through with water before filling.

Flushing with water

1. Connect a water supply to the filling point of the pump station.

2. Connect a drain hose to the drain point.

3. Open the taps of both supply and drain point.

4. Open the water supply tap.

5. Allow the system to spool through until no further contamination comes out

of the drain hose.

6. Then shut off the water supply.

7. Drain all remaining water from the system.

8. Now you can fill the system with glycol.

Filling with glycol

1. Insert the hose of the glycol pump into the jerry can containing the glycol.

2. Tighten the pump onto the jerry can using the swivel.

3. Connect the hose of the glycol pump to the inlet combination of the pump

station.

4. Open the valve of the inlet combination.

5. Plug the glycol pump into a mains socket.

6. Start the glycol pump using the ON/OFF switch on the glycol pump.

Instruction manual SGS 53

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Filling

gis

7. Stop the glycol pump as soon as the pressure gauge on the pump station begins to rise.

8. Completely bleed the system of air at the air bleed point (26, see installation diagram).

9. Close the air bleed when no further air comes out.

10. Repeat steps 6 through 9 until glycol runs out of the air bleed (26).

Note

The system does not need be filled to a certain pressure. The pressure in

the system will increase when the fluid heats up and expands.

11. Switch off the glycol pump.

12. Close the valve of the inlet combination and disconnect the glycol pump (including the hoses).

Note

Dispose of the residual glycol in the filler hose in an environment-friendly

manner, and according to local regulations.

Caution

The very first time the appliance is started, the correct fluid must be set (12.8.2 "Setting the heating fluid type in the solar heating system") using the Service Menu.

Note

If the system is equipped with a drain-back tank, then the system must be filled to a certain pressure. For the installation and filling of a drain-back tank, please refer to the installation and users manual of the solar collector.

54 Instruction manual SGS

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6 Draining

6.1 Installation diagram

This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described.

Installation diagram

Instruction manual SGS 55

Page 56

Draining

gis

Legend

Only applicable numbers are mentioned.

1. pressure-reducing valve (mandatory if the mains water pressure exceeds 8 bar)

3. T&P valve (mandatory)

4. stop valve (recommended in pipe C and mandatory in pipe A)

5. non-return valve (mandatory)

6. circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve (recommended)

12. temperature gauge (recommended)

13. condensation drainage (mandatory)

14. hot water draw-off points

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. water tank

Note

19. float valve

23. pressure valve (mandatory)

26. air bleed (mandatory)

37. combined Q/T sensor (optional)

38. solar heating system pump station (modulating mandatory)

6.2 Draining unvented installations

1. Activate the

MENU »OFF ^ ON È WEEK PROGRAM

2. Position the cursor in front of

3. Confirm

4. Wait until the fan has stopped. The symbol is then dimmed.

Caution Failure to wait until the fan stops purging can cause damage to the

appliance.

5. Switch the appliance OFF (position 0) using the ON/OFF switch on the control panel.

OFF

with .

OFF

56 Instruction manual SGS

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6.3 Draining vented installations

6. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0.

7. Shut off the gas supply (10).

8. Close the stop valve (11) in the hot water pipe.

9. Close the supply valve (4) in the cold water supply (A).

10. Open the drain valve (9).

11. Bleed the appliance (or installation) so that it drains completely.

1. Activate the

2. Position the cursor in front of

3. Confirm

4. Wait until the fan has stopped. The symbol is then dimmed.

Caution Failure to wait until the fan stops purging can cause damage to the

appliance.

5. Switch the appliance OFF (position 0) using the ON/OFF switch on the control panel.

OFF

with .

OFF

6. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0.

7. Shut off the gas supply (10).

8. Close the stop valve (11) in the hot water pipe.

9. Close the stop valve (4) between the water tank and the cold water inlet (A).

10. Open the drain valve (9).

11. Bleed the appliance (or installation) so that it drains completely.

Instruction manual SGS 57

Page 58

6.4 Draining solar heating system

Draining

gis

6.4.1 Draining glycol-filled system

Note

No special safety measures are required when working with the diluted glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer.

1. Activate the

MENU »OFF ^ ON È WEEK PROGRAM

2. Position the cursor in front of

3. Confirm

4. Wait until the fan has stopped. The symbol is then dimmed.

Caution Failure to wait until the fan stops purging can cause damage to the

appliance.

Warning

The fluid in the pipes and the pipes themselves can be extremely hot! Wait

therefore until the appliance has cooled down sufficiently.

Note

The draining procedure described in this manual is intended for the pump system supplied by the appliance supplier. For any other system, you should follow the procedure for that system.

1. Switch off the solar heating system.

2. Connect a hose to the lowest drain point in the solar heating system.

3. Insert the hose into the glycol jerry can.

4. Open the valve of the lowest drain point.

5. Open the air bleed point (26) of the solar heating system.

6. Close the drain point when the jerry can is full.

7. Insert the hose into a new jerry can, and connect it to the drain point.

8. Repeat steps 6 and 7 until no further glycol comes out of the system.

9. Close the air bleed point and the valve of the drain point.

10. Remove the hose.

OFF

with .

OFF

Note

Dispose of the drained glycol in an environment-friendly manner, and according to local regulations.

58 Instruction manual SGS

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7 The control panel

7.1 Introduction

Topics covered in this chapter:

• Controls;

• Meaning of icons;

• Electronic controller ON/OFF switch;

• Navigation buttons;

• PC connection.

7.2 Controls

The figure shows the electronic controller.

»START OPERATION ^ CHANGE SETPOINT È Tset=70ÉC

7.3 Meaning of icons

The table explains the meanings of the icons.

Icons and their meaning

Name Meaning

Heat demand Heat demand detected

Purge Pre- and post-purge using

fan

Pressure switch Pressure switch is closed

Glowing (Pre)glow

Gas control Gas control open/ignition

Flame detection Appliance operational

The control panel is completely menu-driven, and comprises:

• a 4-line display with 20 characters per line;

• 6 pushbuttons for operating the appliance (below the display);

• 6 graphical symbols (above the display);

• a connector for a service PC;

• an ON/OFF switch.

The pushbuttons are divided into three groups:

• Navigation buttons:

- Buttons for UP , and DOWN ;

-Enter: ;

- Reset button:

• the main menu (11 "Main menu"): ;

• the service program (12 "Service program"): . This chapter is specifically intended for the service and maintenance engineer and installation engineer.

In this manual, the display of the electronic controller is shown as in the figure, both with and without icons.

7.4 Electronic controller ON/OFF switch

The ON/OFF switch of the electronic controller is used to switch the appliance ON and OFF. Note that in the OFF position the appliance remains electrically live, in order for the continuous pump to stay running.

INTERNAL CHECK

After switching on, the text appears on the display for about 10 seconds. Themain menu (11 "Main menu") then appears. If no selection is made in the main menu, the appliance automatically switches to the OFF mode (8.2 "Operating modes").

Note

To electrically isolate the appliance, you must use the isolator between the appliance and the mains power supply.

INTERNAL CHECK

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7.5 Navigation buttons

The use of these buttons is explained with the help of the figure that shows the main menu (11 "Main

menu").

The navigation buttons are:

• Buttons for UP , and DOWN ;

• Enter: ;

• Reset button: .

The

arrows and È indicate that you can scroll up

and/or down. Use the buttons and to scroll.

MENU OFF ^»ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

The cursor » points to the option to be activated. In the display as shown in the figure, you can scroll through the main menu.

The main menu comprises:

WEEK PROGRAM, EXTRA PERIOD SETTINGS

options

The selected option is confirmed using .

Pressing the button takes you back one page in a menu and discards all options selected in the current menu.

. You have to scroll down further to see the

EXTRA PERIOD

OFF, ON

and

The control panel

and

SETTINGS

gis

Note

The button is also used to reset the

appliance following an error.

7.6 PC connection

The PC connection is solely intended to enable technicians from A.O. Smith to display the status and history of the appliance. These details can be important for troubleshooting and/or responding to complaints.

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8 Status of the

appliance

8.1 Introduction

Topics covered in this chapter:

• Operating modes;

• Error conditions;

• Service condition.

8.2 Operating modes

When running, the appliance has four basic operating modes, namely:

•

OFF

•

EXTRA

•

PROG

8.2.1

In this mode, the frost protection is activated. The figure shows the display with the following information:

• line one: the text

• line two: the time, the day and alternately (9.3 "The

• lines three and four: the text

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

8.2.2

In this mode, the appliance continually responds to the hot water demand. The figure shows the display with the following information:

• line one: the text

• line two: the time, the day and alternately (9.3 "The

• line three: the programmed water temperature

• line four: blank when the appliance is idle, or

ON 13:45 Thursday 67ÉC

OFF

;

appliance's heating cycle") T

FROST PROTECTION ACTIVATED

;

appliance's heating cycle") T

;

set

depending on the heating cycle (9.3 "The

appliance's heating cycle"), displays a text such as

HEAT DEMAND

Tset 75ÉC

and T

net

8.2.3

In this mode, one extra period is programmed and activated. In this mode, the temporarily overruled to fulfil a single period of demand. Once the period has passed, the appliance automatically returns to the previous operating mode. The figure shows the display with the following information:

• line one: the text

• line two: the time, the day and alternately (9.3 "The

• line three: the switch-on time, and the related

• line four: the text

EXTRA 12:30 Thursday 76ÉC TH 12:45 Tset 75ÉC PERIOD ACTIVATED

8.2.4

In this mode a preset week program is active, and the appliance responds continually to demand within the time periods set in the week program. There are two distinct situations possible in this mode:

PROG 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC

1. The current time falls within a set time period

PROG 12:00 Monday 76ÉC MO 11:15 PERIOD ACTIVATED

EXTRA

OFF

PROG

mode is

EXTRA

;

appliance's heating cycle") T

water temperature setting;

PERIOD ACTIVATED

PROG

of the week program.

The figure shows the display with the following

information:

- line one: the text

- line two: the time, the day and T1 and T alternately (9.3 "The appliance's heating

cycle");

- line three: the next scheduled switch-off time and the water temperature T period;

- line four: is empty, or depending on the heating cycle (9.3 "The appliance's heating

cycle"), a text such as

PROG

and T

;

HEAT DEMAND

;

net

of the active

set

net

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Status of the appliance

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2. The current time falls outside a set time period

of the week program.

The figure shows the display with the following information:

PROG

- line one: the text

- line two: the time, the day and T alternately (9.3 "The appliance's heating

cycle");

- line three: the next scheduled switch-on time;

- line four: displays the text

PERIOD ACTIVATED

In all modes, the temperature may at any moment drop below the desired temperature. The appliance then enters a heating cycle. This heating cycle is identical (9.3 "The appliance's heating cycle") for all basic operating modes.

Note

Setting and if necessary programming of the basic operating modes are described in the main menu (11 "Main menu") chapter.

;

and T

net

8.3 Error conditions

The figure shows an example of an error condition. If the appliance enters this condition, the display will show the following information:

• line one: error code comprising a letter and two

digits, followed by the error description;

• lines two to four: alternately, a brief explanation of

the error, and a brief action to resolve the error.

S04: SENSOR ERROR

CHECK

SENSOR OR DUMMY

If, as end-user, you find the appliance in an error condition, you may attempt to restart the appliance by pressing the button

However, if the error returns or occurs several times in a short time you must contact your service and maintenance engineer.

8.4 Service condition

The figure shows the message

!!! WARNING !!!

MAX. BURNING HOURS:

SERVICE REQUIRED

then the appliance is in need of a service and maintenance inspection. In that case, contact your service and maintenance engineer.

Note

The message the number of expired burning hours and the preset service interval. Should the service interval have been incorrectly selected, contact the service and maintenance engineer for instructions on how to adjust this. Information on the maintenance frequency is provided elsewhere in the manual (14 "Maintenance frequency").

.Should this message appear,

SERVICE REQUIRED

is based on

8.5 Q/T Sensor warning

This message appears if the Q/T sensor is incorrectly connected. If the message appears, you must contact your service and maintenance engineer.

!!! WARNING !!!

Q/T SENSOR NOT

CORRECTLY CONNECTED

8.6 Collector temperature warning

Caution

The displayed action to resolve the error may only

be performed by a service and maintenance engineer.

There are various types of errors:

• LOCK OUT ERRORS

When the cause has been removed, these errors require a reset with the button before the appliance can resume operation.

• BLOCKING ERRORS

These errors disappear automatically once the cause of the error has been removed, after which the appliance resumes operation by itself.

The display does not show what type of error has been detected. A comprehensive overview of the errors is provided elsewhere in the manual (13 "Troubleshooting").

This message appears whenever the collector temperature is excessive. This message disappears automatically. If the message does not disappear, you must contact your service and maintenance engineer.

!!! WARNING !!!

TEMPERATURE

COLLECTOR

TOO HIGH

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9 Starting and running

9.1 Introduction

Topics covered in this chapter:

• Starting the appliance.

• The appliance's heating cycle.

Note

The first time the appliance is started, you must enter (12.8 "Solar heating system configuration") the settings of the solar heating system

9.2 Starting the appliance

Start the appliance as follows:

1. Fill the appliance (5 "Filling").

2. Open (3.5 "Installation diagram") the manual gas

valve.

3. Switch on the power to the appliance using the

isolator between the appliance and the power supply.

4. Switch the electronic controller ON by setting the

ON/OFF switch to position I.

The display will now show about 10 seconds, and will then go to the main menu.

INTERNAL CHECK

for

INTERNAL CHECK

MENU »OFF ^ ON È WEEK PROGRAM

Note

The first time the appliance is started, you must set (12.8.2 "Setting the heating fluid type in the solar

heating system") the heating fluid type of the solar

heating system.

5. Press once on the blue arrow ( ) to position the

cursor beside

, then press :

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

6. Confirm the selection

The appliance is now in "ON mode". If there is a heat

demand, the appliance will run through the heating

cycle (9.3 "The appliance's heating cycle").

If the heating cycle is not run, then there is no

demand; should this happen, then Tset will

probably need to be set (11.4 "Setting the water

temperature").

9.3 The appliance's heating cycle

The appliance's heating cycle is activated as soon as the measured water temperature (T threshold value (T on the currently selected appliance operating mode. For example, if the appliance is in "OFF mode" (frost protection), then this value is 5°C. If the appliance is in "ON mode", then this threshold value is selectable, for example, 65°C.

The heating cycle runs in turn through the following states:

1. HEAT DEMAND;

2. PRE-PURGE;

3. PRESSURE SWITCH;

4. PRE-GLOW;

5. IGNITION;

6. RUNNING;

7. POST-PURGE.

START OPERATION

) falls below the

). This threshold value depends

set

net

with

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The complete cycle is explained in the following example, which assumes the appliance is in the basic

mode

operating modes.

Once the appliance starts, it will run through the following steps:

1. The water temperature drops below the set

Note

The same heating cycle applies to the other

temperature of (for example) 65°C. The electronic controller detects a demand and starts the heating cycle.

- The icon is activated.

- The message

HEAT DEMAND

appears.

ON Ê 13:45 Thursday 63ÉC

Tset 65ÉC

HEAT DEMAND

2. Once demand is registered, the fan is started to exhaust any gases that may be present. This phase is called pre-purge and lasts about 15 seconds.

- The icon is activated.

- The message

PRE PURGE

appears.

ON Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRE PURGE

3. During the pre-purge, the pressure switch closes.

- The icon is activated.

- The message

appears.

PRESSURE SWITCH

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRESSURE SWITCH

5. After a number of seconds pre-glow, the gas control is opened and ignition takes place.

- The icon is activated.

- The message

IGNITION

appears.

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

IGNITION

6. After ignition, the flame is detected and the appliance will be running. This means that actual heating has started. The fan speed then increases to the normal working speed, and the pressure switch closes:

- The icon is dimmed.

- The icons and are activated.

- The message

RUNNING

appears.

ON ÊÊÊ Ê 13:45 Thursday 63ÉC

Tset 65ÉC

RUNNING

7. When the water is up to temperature, the heat demand drops off and the post-purge starts. This lasts about 25 seconds.

- The icons , and are dimmed.

- The icon is activated.

- The message

POST PURGE

appears.

ON Ê Ê 13:45 Thursday 65ÉC

Tset 65ÉC

POST PURGE

8. Following the post-purge, the fan stops and the pressure switch opens:

- The icons and are dimmed.

- The message

POST PURGE

vanishes.

4. After some time, the pre-purge ceases and the electronic controller reduces the fan speed to the ignition speed. This is followed by the (pre-)glow of the hot surface igniter.

- The icons and are dimmed

- The icon is activated.

ON Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

GLOW PLUG

ON 14:05 Thursday 65ÉC

With any subsequent heat demand, the heating cycle will resume from step 1.

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10 Shutting down

10.1 Introduction

This chapter describes:

• Shut the appliance down for a brief period ("OFF

mode");

• Electrically isolating the appliance;

• Shutting the appliance down for a long period.

10.2 Shut the appliance down for a brief

period ("OFF mode")

To shut the appliance down for a brief period, you must activate the frost protection.

You can use the frost protection to prevent water freezing in the appliance.

Activate the frost protection as follows:

1. Press the button to select the main menu.

2. Use and to position the cursor in front of

Confirm with .

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

The frost protection cuts in if the water temperature

FROST

drops below 5°C. The text line one of the display. The appliance heats the water to 20°C (T

Note

These values of 5°C and 20°C cannot be adjusted.

) and drops back to the

set

will then appear on

OFF

mode.

OFF

10.3 Electrically isolating the appliance

The appliance should only be isolated from mains power in the correct way. The correct procedure is as follows:

1. Activate the

2. Position the cursor in front of

3. Confirm

OFF

with .

OFF

4. Wait until the fan has stopped. The symbol is then dimmed.

5. Switch the appliance OFF (position 0) using the ON/OFF switch on the control panel.

6. Isolate the appliance from the power supply by setting the isolator between the appliance and the

mains power supply to position 0.

10.4 Shutting the appliance down for a long

period

Drain the appliance if you are shutting it down for a long period. Proceed as follows:

1. Isolate the appliance from the power supply (10.3 "Electrically isolating the appliance").

2. Shut off the gas supply.

3. Close the stop valve in the hot water pipe.

4. Close the supply valve of the protected cold supply set-up.

5. Open the drain valve

6. Bleed the appliance (or installation) so that it drains completely.

MENU »OFF ^ ON È WEEK PROGRAM

Caution Failure to wait until the fan stops purging can

cause damage to the appliance.

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11 Main menu

11.1 Introduction

The

is reached by pressing the button on the

electronic controller.

»OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

The main menu comprises:

OFF

•

menu open, then after 30 seconds, the appliance will automatically return to the mode it was previously in.

Select this option if you wish to turn off (10 "Shutting down") the appliance for a brief period, but do not wish to drain it. In this mode, the frost protection is active. This prevents water from freezing in the appliance.

In this mode, the appliance continually responds to the hot water demand. (11.3 "Switching on the

"ON mode"")

WEEK PROGRAM

Select this option to allow the appliance to respond to demand only during pre-programmed periods (11.5 "Week program"). Outside those periods, only frost protection is active.

EXTRA PERIOD

Select this option to overrule the

PROG

mode (i.e. Week program) so that a single temporary period (11.10 "Extra period") of heat demand will be fulfilled.

SETTINGS

Select this option to set (11.12 "Settings") the language and the time. You can also use this option to display the regulation interval (temperature), and the ignition and working speeds of the fan.

Note

If you fail to make any selection with the main

OFF

mode or

11.2 Notational convention for menu-related instructions

The

( ) of the electronic controller is divided into submenus. For example, functions reached from the main menu. The

SETTINGS

menu is divided into submenus in turn.

SETTINGS

is one of the

For example,

SETTINGS LANGUAGE

notational convention:

• :

Confirm with .

This means:

1. : Activate the main menu with .

SETTINGS

SETTINGS LANGUAGE

LANGUAGE

4. Confirm with . After entering , you will have activated the

LANGUAGE

. So, for example, to select the menu, this manual uses the following

SETTINGS

: Use the and/or buttons to go to and confirm with .

: Use the and/or buttons to go to

is a submenu of

LANGUAGE

submenu.

11.3 Switching on the "ON mode"

You can switch the appliance to the ON mode from any operational mode, as follows:

1. :

Confirm with .

Note

First consult the chapter about switching

on (9 "Starting and running") too.

START OPERATION

11.4 Setting the water temperature

11.4.1 Setting the water temperature via

the SET POINT MENU

Set the water temperature via:

1. :

Confirm with .

START OPERATION ^»CHANGE SETPOINT È Tset=65ÉC

2. Use:

• to increase the value;

• to decrease the value.

• Confirm with .After confirming, the appliance enters "ONmode".

SETPOINT

CHANGE SETPOINT

» 65ÉC

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11.4.2 Setting water temperature during ON mode

The water temperature can also be directly adjusted when the appliance is in the "ON mode". Simply use:

• to increase the value;

• to decrease the value.

• Confirm with .

ON 13:45 Thursday 65ÉC

Tset»65ÉC

11.5 Week program

Using the week program, you can set the water temperature for the days and times you want.

If the appliance is running under a week program, this is indicated on the display by the line (see the figure). The second line shows the time of day, the day of the week and the temperature. The third line shows the next switching time of the week program and the programmed temperature. The fourth line shows the

PROG 07:55 Monday 64ÉC MO 08:00 Tset 75ÉC PROGRAM ACTIVATED

The appliance's default week program switches the appliance on every day at 00:00 and off at 23:59. The default water temperature setting is 65°C.

If you want, you can change every setting in the appliance's standard week program.

If the water temperature becomes too low while the week program is running, the appliance will run through the heating cycle (9.3 "The appliance's

heating cycle") and return to the week program.

This following are discussed:

• Starting and stopping the week program

• Changing the appliance's standard week program

• Adding times to a week program

• Deleting times from a week program

PROGRAM ACTIVATED

PROG

text on the first

text.

11.7 Changing the appliance's standard week program

Note

First fill-in the desired week program on the

supplied week program card.

A week program is made up of a number of programmable periods in which you can have the appliance switch on and off. A period consists of:

• switch-on time: day of the week, hours and

minutes:

• switch-off time: hours and minutes;

• the water temperature setting;

• on/off setting for a program-controlled pump.

Note

The switch-off time must always be followed by a switch-off time on the same day of the week. A maximum of three periods may be programmed per day. You can program a maximum of 21 periods.

Call up the menu for the week program as follows:

•:

WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

PROGRAM OVERVIEW

11.6 Starting and stopping the week program

The week program can be started up from any other operating mode, as follows:

1. :

A week program can be shut down simply by activating a different operating mode, for example the "ON mode".

WEEK PROGRAM

Confirm with .

START OPERATION

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The display shows the menu for the week program, see the figure below. With the default setting, the program switches on and off every day at 00:00 and 23:59 hours respectively, the water temperature is

65°C and the pump is switched on (

DAY TIME Tset ON »SU 00:00 65ÉC P OFF SU 23:59 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59 ON WE 00:00 65ÉC P OFF WE 23:59 ON TH 00:00 65ÉC P OFF TH 23:59 ON FR 00:00 65ÉC P OFF FR 23:59 ON SA 00:00 65ÉC P OFF SA 23:59

INSERT DELETE

START OPERATION

Example

As an example, we will set the switch-on time for Sunday to 08:15 hours, and the matching switch-off time to 12:45 hours. The water temperature will be set to 75 °C and the pump will run continuously. The following settings are entered one by one via the menu: the switch-on time, the switch-off time, the desired water temperature, and the mode of the program-controlled pump.

11.7.1 Week program: setting the switchon time

1. Bring the cursor to SU

Confirm with .

ON »SU 00:00 OFF SU 23:59 Tset 65ÉC PUMP ON SAVE

The day indicated by

2. Use and to set the desired day. In the example

this is

Confirm with .

ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON SAVE

The cursor moves to the hour digits, which flash.

3. Use and to set the hours. In the example, this

08.

(Sunday).

flashes.

Confirm with .

The cursor moves to the minute digits, which flash.

ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON SAVE

Note

Because the switch-off time can never be earlier than the switch-on time, the switch-off time setting is automatically adjusted with the switch-on time.

4. Use and to set the minutes. In the example,

this is

Confirm with .

The cursor moves to the switch-off hour digits,

which flash.

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON SAVE

11.7.2 Week program: setting the switch-

off time

1. Use and to set the hours. In the example, this

Confirm with .

The cursor moves to the minute digits, which flash.

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON SAVE

2. Use and to set the minutes. In the example,

this is

Confirm with .

The cursor moves to the desired water

temperature.

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON SAVE

11.7.3 Week program: setting the water

temperature

1. Use and to set the water temperature. In the

example this is 75°C.

Confirm with .

The cursor moves to

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON SAVE

PUMP ON

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11.7.4 Week program: setting the programcontrolled pump

1. If required, a pump can be controlled during the

period. Use and to set ensures a regular circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with .

The cursor moves to

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON SAVE

2. Confirm with .

The display shown in the figure will appear.

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59

3. If you wish, you can use to scroll to another day, and change more switch-on times (11.7.1 "Week

program: setting the switch-on time") and switch-

off times (11.7.2 "Week program: setting the

switch-off time").

4. After changing all desired switch-on and switch off times, you can start running the week program:

Scroll with to Confirm with .

START OPERATION

PUMP ON

SAVE

. The pump

11.8 Adding times to a week program

Call up the menu to times into a week program as follows:

1. :

WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

INSERT

switch-on and switch-off

PROGRAM OVERVIEW

The display shows the menu for the week program. The cursor points to the active period.

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

....................

OFF SA 23:59

INSERT DELETE START OPERATION

2. Scroll to

Confirm with .

The sub-menu for adding a period will appear.

ON »SU 08:15 OFFSU12:45 Tset 75ÉC PUMP ON SAVE

Example

As an example, we will program an extra period in which the switch-on time is set to 18:00 hours, and the corresponding switch-off time to 22:00 hours. The water temperature will be set to 75 °C and the pump will run continuously.

DAY TIME Tset ON »SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE START OPERATION

3. Proceed as follows:

a. Set the switch-on time (11.7.1 "Week program:

setting the switch-on time").

b. Set the switch-off time (11.7.2 "Week program:

setting the switch-off time").

c. Set the water temperature (11.7.3 "Week

program: setting the water temperature").

d. Set the program-controlled

pump (11.7.4 "Week program: setting the

program-controlled pump").

5. To activate the week program with the new period added, scroll down with to

START OPERATION

INSERT

and confirm with .

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11.9 Deleting times from a week program

All switch-on/off times are shown sequentially in the display. Assume that the switch-on/off times for the appliance are programmed as in the figure.

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59 INSERT

DELETE

START OPERATION

To delete a period, proceed as follows:

1. :

2. Scroll with to

3. Scroll with to

4. Scroll with to the day to be deleted. For

WEEK PROGRAM

Confirm with .

OFF ^»ON È WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

The display shows the menu for the week program.

Confirm with .

To warn you that you are now working in the delete sub-menu, the cursor is replaced with an exclamation mark (!) and the period settings flash.

DAY TIME Tset ON !SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59

INSERT DELETE

START OPERATION

example, the figure.

(Sunday) in the second period. See

PROGRAM OVERVIEW

DELETE

Confirm with .

DAY TIME Tset ON !SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE START OPERATION

5. The lines showing switch-on/off times are replaced by the text

Confirm with . (or use to cancel)

DAY TIME Tset ON ! DELETE OFF BLOCK? ON MO 00:00 65ÉC P

The switching period has been deleted. You will return now to the week program menu. The cursor points to the first programmed period.

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE

START OPERATION

6. Scroll with to

Confirm with .

The week program is active.

DELETE BLOCK?

START OPERATION

. See the figure.

11.10 Extra period

Use an extra period when you either want to have the appliance switch on and off for a certain period, either without modifying the active week program, or without taking the appliance out of the OFF mode (frost protection active).

If the appliance is running under an "extra period", then this is indicated in the display with the text

EXTRA

EXTRA 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC PERIOD ACTIVATED

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If the water temperature becomes too low during the extra period (11.11 "Programming an extra period"), the appliance will run through the heating cycle (9.3 "The appliance's heating cycle") and fall back into the extra period.

The same settings can be made for an extra period as for a week program (11.7 "Changing the appliance's

standard week program") period.

11.11 Programming an extra period

1. Call up the menu for entering an extra period via:

2. :

Setting the switch-on time

1. Use and to set the day. In the example this is

2. Use and to set the switch-on hour to the

than the switch-on time, the switch-off time setting is automatically adjusted with the switch-on time.

3. Use and to set the minutes. In the example,

EXTRA PERIOD

Confirm with .

ON ^ WEEK PROGRAM È»EXTRA PERIOD

The display show the settings for the extra period.

Confirm with .

The cursor moves to the hour digits, which flash.

ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON START

desired value. In the example, this is

Confirm with .

The cursor moves to the minute digits, which flash.

ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON START

Note

Because the switch-off time can never be earlier

this is 15.

Confirm with .

The cursor moves to the hour digits of the switchoff period.

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON START

08.

Setting the switch-off time

1. Use and to set the hours. In the example, this

012

Confirm with .

The cursor moves to the minute digits, which flash.

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON START

2. Use and to set the minutes. In the example, this is

Confirm with .

The cursor moves to the water temperature. See the figure

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON START

Setting the water temperature

1. Use and to set the water temperature. In the example this is 75°C.

Confirm with .

The cursor moves to

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON START

Setting the program-controlled pump

1. If required, a pump can be controlled during the period. Use and to set ensures a regular circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with .

The cursor moves to

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »START

2. Confirm with .

The extra period has been programmed.

Note

Once the extra period has completed running, the

controller returns to the mode ON, OFF or

WEEK PROGRAM

period will NOT be automatically switched on.

PUMP ON

START

. The following week, the extra

. The pump

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11.12 Settings

Using the settings and read certain appliance data:

• Adjustable settings

• Displayable appliance specifications, this

SETTINGS

- Language of the menu.

- Current day of week and time.

category is only relevant to the installation engineer and/or service and maintenance engineer

- Control range (water temperature).

- Ignition speed of fan.

- Working speed of fan.

option, you can adjust certain

11.12.1 Setting menu language

To set menu language:

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

1. Call up the menu for selecting the language as follows:

2. :

3. The cursor is positioned beside

4. Scroll with to the desired language.

The language is set.

SETTINGS

Confirm with .

The display shows the menu for settings.

SETTINGS »LANGUAGE ^ DAY/TIME È SPECIFICATIONS

Confirm with .

The display shows the language selection menu.

LANGUAGE

ENGLISH ^ NEDERLANDS È»DEUTSCH

FRANCAIS

ITALIANO

CZECH ESPANOL

Confirm with .

LANGUAGE

11.12.2 Setting day and time

To enter the time and day:

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

1. Call up the menu for entering the day and time as follows:

2. :

3. Scroll with and to

4. The cursor is positioned beside

5. The cursor moves to the hour digits, which flash.

SETTINGS

Confirm with .

The display shows the menu for settings.

Confirm with .

SETTINGS

LANGUAGE ^»DAY/TIME È SPECIFICATIONS

The display shows the sub-menu for adjusting the day.

DAY

»Sunday ^ Monday È Tuesday

Wednesday Thursday Friday Saturday

Scroll with and to the desired day.

Confirm with .

The day has been set. The display shows the submenu for adjusting the time.

TIME »00:00

Scroll with and to the current hour, for example 15.

Confirm with .

TIME 15»00

DAY/TIME

Sunday

6. The cursor moves to the minute digits, which flash.

Scroll with and to the next minute, for example

45.

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Main menu

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Confirm the minute setting with

TIME 15»45

The time has been set.

Note

The appliance takes no account of daylight saving.

11.12.3 Displaying appliance specifications

Note

This category is solely intended for the installation

engineer and/or service and maintenance engineer.

The table shows the correct settings.

SGS 28 SGS 30

Ignition fan speed (rpm)

Working speed of fan (rpm)

Regulation interval

(

4500 4500

5000 5000

40 - 80 40 - 80

The display shows the sub-menu for displaying appliance specifications.

SPECIFICATIONS

»REGULATION INTERVAL ^ IGNITION SPEED È WORKING SPEED

3. Scroll with to the section to be displayed, for example

The relevant display appears.

REGULATION INTERVAL

80ÉC

SGS 50 SGS 60

Ignition fan speed (rpm)

Working speed of fan (rpm)

Regulation interval

(

Call up the menu to display the appliance specifications as follows:

1. :

2. Scroll with to

SETTINGS

Confirm with .

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Confirm with .

SETTINGS

LANGUAGE ^ DAY/TIME È»SPECIFICATIONS

4500 4500

6660 6660

40 - 80 40 - 80

SPECIFICATIONS

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12 Service program

12.1 Introduction

The service program is used by the installation engineer or service and maintenance engineer for:

• Setting the hysteresis

• Displaying the error history

• Displaying the appliance history

• Display the selected appliance

• Setting the service interval

• Setting legionella prevention

• Solar heating system configuration

• Setting the central heating configuration

SERVICE MENU »HYSTERESE ^ HISTORY OF ERRORS È APPLIANCE HISTORY

SELECT APPLIANCE SERVICE INTERVAL ANTI LEGIONELLA SETTINGS SOLAR SETTINGS HEATING

These sub-menus are briefly described in the following paragraphs. If you are not familiar in general with how to use the displays and menus, first read the relevant chapter (7 "The control panel").

Note

The notation convention for the service menu is identical to that of the main menu (11.2 "Notational

convention for menu-related instructions"). The

difference is, you use to bring up the service program, instead of which brings up the main menu.

12.2 Setting the hysteresis

Call up the menu to set the hysteresis as follows:

HYSTERESE DOWN

12.3 Displaying the error history

Display the error history as follows:

•:

The controller will display an overview of "Blocking errors" and "Lock out errors". In both cases, the electronic controller reserves 15 lines for the last 15 error messages. If there are fewer than 15 error messages, an ellipsis (...) is displayed. The display first shows the "Blocking errors". When is pressed, the "Lock out errors" are then displayed.

The figure shows an example of "Blocking errors". In this case, the text by

HISTORY OF ERRORS(B)

È CO2 50 HZ ERROR

The figure shows an example of "Lock out errors". In this case, the text by

HISTORY OF ERRORS(L)

È ...

causes, please refer to the relevant chapter (13 "Troubleshooting").

HISTORY OF ERRORS

(B)

S04 SENSOR ERROR F06 IONIZATION

HISTORY OF ERRORS

(L)

F02 FAN F07 FLAME ERROR

Note

For an overview of all errors and the possible

is followed

12.4 Displaying the appliance history

The appliance history submenu is used to display the burning hours, the number of ignitions, the number of flame errors and the number of ignition errors.

Call up the menu for displaying the appliance history as follows:

•:

APPLIANCE HISTORY

The figure shows an example.

HYSTERESE DOWN »3ÉC

For all appliances, the range is 2...7 oC. The default setting for this value is 5 oC.

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Service program

APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021

IGNIT ERROR 000013

12.5 Display the selected appliance

Call up the menu for displaying the appliance selection as follows:

•:

SELECT APPLIANCE »5934 ^ 8576 È 3379

SELECT APPLIANCE

The appliance number can be found on the rating plate.

The appliance selection has been correctly preset in the factory.

6527

....

•:

ANTI LEGIONELLA »YES NO

•Select NO to switch legionella prevention off.

•Select

ON MO 02:00 LEG OFF MO 03:00 Tset 65ÉC »START CHANGE

•Select

ANTI LEGIONELLA

YES

to switch legionella prevention on. The

following display appears:

START

displayed.

The following display appears. This display indicates that legionella prevention is switched on.

to activate the period currently

LEG Ê Ê Ê Ê 02:45 Monday 60ÉC MO 03:00 Tset 65ÉC RUNNING

12.6 Setting the service interval

To aid servicing, the electronic controller includes a service interval which is used to set the frequency of maintenance interval (14.2 "Determining service

interval") by the service and maintenance engineer,

based on the number of burning hours.

The service interval is based on the number of burning hours. This can be set to 500, 1000 and 1500 hours. The standard setting for number of hours is 500. Once the preset number of hours is reached, a message (8.4 "Service condition"). to this effect will appear. Adjust the service interval via:

•:

SERVICE INTERVAL » 500 ^ 1000 BURNING HOURS È 1500

SERVICE INTERVAL

12.7 Setting legionella prevention

To prevent infection with legionella bacteria, the appliance heats the water to 65 °C once per week, for 1 hour. This period is adjustable. By default, this period is set to Monday from 02:00 to 03:00 hours.

12.7.1 Switching legionella prevention on and off

To switch legionella prevention on or off, select:

12.7.2 Changing legionella prevention start time

If you wish to change the start time, select:

ANTI LEGIONELLA

The following display appears.

ON ÈMO 02:00 LEG OFF MO 03:00 Tset 65 o C START

• Now set the day and time the same way as

described for setting an extra period in the week menu (11.11 "Programming an extra period"). In this case however, the pump will be automatically started.

•Select

START

to start.

YES

CHANGE

12.8 Solar heating system configuration

Use the solar heating system settings menu to reach the menus shown here:

SETTINGS SOLAR »DRAIN BACK ^ TYPE OF FLUID È DELTA T SOLAR

SOLAR DIFFERENCE SOLAR LIMIT QT SENSOR CONTRIBUTION

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12.8.1 Setting the drain-back tank

Use this menu to specify whether the solar heating system is equipped with a drain-back tank for the heating fluid. Call up the menu as follows:

•:

The default is NO.

necessary to check whether this setting corresponds with the configuration of the solar heating system.

SETTINGS SOLAR

DRAIN BACK YES »NO

Note

The first time the appliance is started, it is

DRAIN BACK

12.8.2 Setting the heating fluid type in the solar heating system

Use this menu to specify the type of heating fluid used to fill the solar heating system (2.6 "Protection for the

solar heating system"). Call up the menu as follows:

•:

You can select from is

TYPE OF FLUID »Glycol Water

necessary to check whether this setting corresponds with the configuration of the solar heating system.

SETTINGS SOLAR

Glycol

Note

The first time the appliance is started, it is

TYPE OF FLUID

and

Water

. The default

12.8.4 Setting the solar limit temperature

The solar limit temperature is the maximum water temperature obtained in the appliance via the solar heating system (measured by sensor T1).

This value can be set between 65 ... 80 °C. The default value is 65 °C.

If you set the solar limit higher than the set point (11.4 "Setting the water temperature"), then once the set point is reached, the solar pump will be started to heat the water further. However, this only makes sense if the solar heating system is actually generating heat. This makes use of the difference between the temperature at the top of the solar collector (S S

). This value is also adjustable (12.8.3 "Setting

threshold temperature of pump in solar heating system").

Call up the menu for the solar limit as follows:

•:

SOLAR LIMIT

65ÉC

) and that in the appliance (measured by

SETTINGS SOLAR

SOLAR LIMIT

12.8.5 Setting the solar difference

The solar difference is a value that influences how the heating cycle of the appliance proceeds. Call up the menu as follows:

•:

SOLAR DIFFERENCE

5ÉC

SETTINGS SOLAR

SOLAR DIFFERENCE

Note

The setting

12.8.3 Setting threshold temperature of

The pump of the solar heating system is switched on when the difference (9.3 "The appliance's heating

cycle") between the temperature at the top of the solar

collector (sensor S S2) exceeds a certain value. This value can be set to between 5 and 20 °C. Call up this menu as follows:

•:

The default value is 10 °C.

DELTA T SOLAR

10ÉC

Water

is currently not possible

pump in solar heating system

) and that in the appliance (sensor

SETTINGS SOLAR

DELTA T SOLAR

Appliance Default Range

28 7 °C. 0 ... 8 °C.

30 2 °C. 0 ... 8 °C.

50 2 °C. 0 ... 8 °C.

30 2 °C. 0 ... 8 °C.

12.8.6 Setting the QT sensor yes/no

The energy contribution of the solar heating system can be calculated (12.8.7 "Reading the energy

contribution of the solar heating system") with the aid

of the Q/T sensor. This calculation is only possible if your installation is equipped with such a Q/T sensor. If this is the case, then you must set this value to

otherwise

. Call up the applicable menu as follows:

YES

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Service program

•:

QT SENSOR YES »NO

12.8.7 Reading the energy contribution of

This option enables you to read out how much energy the solar heating system supplies. For this data to be displayed, the installation must be equipped with a QT sensor (12.8.6 "Setting the QT sensor yes/no").

3 values are reported on the display:

•

Call up this menu as follows:

•:

CONTRIBUTION ACTUAL 00000 kW LAST 24hr 00000 kJ TOTAL 00000 Mj

SETTINGS SOLAR

the solar heating system

ACTUAL

currently being supplied.

LAST 24hr TOTAL

, actual energy: the amount of energy

, energy supplied over last 24 hours.

, total energy supplied since day 1.

SETTINGS SOLAR

QT SENSOR

CONTRIBUTION

12.9 Setting the central heating configuration

Use this menu to specify whether a central heating system is connected to the installation.

Note

This function is not yet available.

•:

SETTINGS HEATING

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13 Troubleshooting

13.1 I

A distinction is made between:

• General errors

General errors are not reported on the display.

General errors are:

- Gas smell

- Display does not light up

- Insufficient or no hot water.

c t

- Water leakage

- Explosive ignition.

The manual includes a table with general

errors (13.2 "Troubleshooting table for general

errors").

• Displayed errors

Errors are reported on the display as follows:

- Line one: an error code and a brief description. The code consists of a letter and two digits.

- Lines two, three and four: a long description, alternating with a recommended action. See the figures. The first shows a possible error, the second shows the appropriate checking action.

The manual includes a table of error messages that can appear on the display (13.2 "Troubleshooting table for general

errors").

• Warnings on the display

The warnings (13.4 "Displayed warnings") can also apply to the solar heating system.

S02: SENSOR ERROR

TOP TANK SENSOR 1

NOT CONNECTED

S02: SENSOR ERROR

CHECK TOP TANK

SENSOR

There are various types of errors, all falling into one of two groups:

- LOCK OUT ERRORS When the cause has been removed, these errors require a reset with the button, before the appliance can resume operation.

- BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed, after which the appliance resumes operation by itself.

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13.2 Troubleshooting table for general errors

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

General errors

Symptom Cause Solution Remark

Gas smell Gas leak

Display is off Appliance is turned off Start the appliance up (9 "Starting and running")

No supply voltage present

Defective fuse(s) Replace fuse(s) To replace the fuses, you must contact your installation engineer.

Warning

Close the main gas valve immediately.

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

1. Check if the isolator is ON.

2. Check that there is power to the isolator.

3. Check whether the ON/OFF switch of the electronic controller is ON (position I).

4. Check whether there is power to the electrical connector block.

5. The measured voltage must be 230 VAC (-15%, +10%).

Warning

Contact your installation engineer or local gas company

immediately.

See the SGS electrical diagram (17 "Appendices") If the error persists, consult your installation engineer.

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Page 81

Symptom Cause Solution Remark

Water leakage Leakage from a water

connection (threaded)

Condensate leakage Check that the condensation water discharge is working properly.

Leakage from another nearby water appliance or pipe segment

Leakage from the appliance's tank

Explosive ignition Incorrect supply

pressure and/or burner pressure

Contaminated burner Clean the burner(s) (15.4.2 "Clean the burner(s)")

Contaminated orifice Clean the orifice(s) (15.4.3 "Clean the orifice(s)")

Hot water supply insufficient or absent

Appliance is turned off Start the appliance up (9 "Starting and running")

No supply voltage present

Hot water supply is used up

The controller is in OFF mode.

Temperature (T set too low.

set

Tighten the threaded connection If the leak persists, consult your installation engineer

Rectify if necessary

Trace the leak

Consult the supplier and/or manufacturer

Set the correct supply pressure and/or burner pressure. (3.13 "Checking the supply pressure and burner

pressure")

1. Check if the isolator is ON.

2. Check that there is power to the isolator.

3. Check whether the ON/OFF switch of the electronic controller is ON (position I).

4. Check whether there is power to the electrical connector block.

5. The measured voltage must be 230 VAC (-15%, +10%).

Reduce hot water consumption and give the appliance time to heat up.

Switch the controller to the ON mode (11.3 "Switching on the "ON

mode"")

) is

Adjust (11.4 "Setting the water temperature") temperature (T a higher value.

set

If ignition is not improved, consult your installation engineer.

See the SGS electrical diagram (17 "Appendices") If the error persists, consult your installation engineer.

If there continues to be insufficient hot water, or none at all, consult your installation engineer.

) to

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Symptom Cause Solution Remark

Glycol leakage Leakage from a fluid

connection (threaded)

Leakage from a component

Leakage from solar heating system

Tighten the threaded connection. If the leak persists or a component needs replacement, consult

your installation engineer

1. Tighten component joints

2. Any defective components must be replaced

Consult the supplier and/or manufacturer

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Page 83

13.3 Troubleshooting table for displayed errors

Displayed errors

Code + Description Cause Solution Remark

S01 (blocking error)

Open circuit from temperature sensor T2 at bottom of the tank

S02 (blocking error)

Open circuit in sensor 1 of temperature sensor T

at the top of the

(1)

tank

S03 (blocking error)

Open circuit in sensor 2 of temperature sensor T1 at the top of the tank (1).

S04 (blocking error)

Open circuit from dummy 1

S05 (blocking error)

Open circuit from dummy 2

S06 (blocking error)

Open circuit from temperature sensor S4 at bottom of storage tank

Sensor is not (correctly) connected

Damaged cable or defective sensor

Sensor is not (correctly) connected

Damaged cable or defective sensor

Sensor is not (correctly) connected

Damaged cable or defective sensor

Dummy is not (correctly) connected

Defective dummy Replace the dummy sensor To replace the necessary parts, you must contact your installation

Dummy is not (correctly) connected

Defective dummy Replace the dummy sensor To replace the necessary parts, you must contact your installation

Sensor is not (correctly) connected

Damaged cable or defective sensor

Connect the sensor lead to JP3 See the SGS electrical diagram (17 "Appendices")

Replace the sensor To replace the necessary parts, you must contact your installation

engineer

Connect the sensor lead to JP5 See the SGS electrical diagram (17 "Appendices")

Replace sensor T

Connect the sensor lead to JP5 See the SGS electrical diagram (17 "Appendices")

Replace sensor T

Connect the dummy sensor (dummy sensor 1 and 2) leads to JP4. See the SGS electrical diagram (17 "Appendices")

Connect the sensor lead to J14 (port 1 and 3) of the solar controller See the SGS electrical diagram (17 "Appendices")

Replace the sensor To replace the necessary parts, you must contact your installation

To replace the necessary parts, you must contact your installation engineer

engineer

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Page 84

Code + Description Cause Solution Remark

S07 (blocking error)

Open circuit from temperature sensor S2 at bottom of tank

S08 (blocking error)

Open circuit from temperature sensor S1 in the collector

S11 (blocking error)

Short circuit in the temp. sensor T2 at the bottom of the tank

S12 (blocking error)

Short circuit in sensor 1 of temperature sensor T

at the top of the

(1)

tank

S13 (blocking error)

Short circuit in sensor 2 of temperature sensor T1 at the top of the

(1)

tank

S14 (blocking error)

Short circuit from dummy 1

S15 (blocking error)

Short circuit from dummy 2

Sensor is not (correctly) connected

Damaged cable or defective sensor

Sensor is not (correctly) connected

Damaged cable or defective sensor

Short circuit in sensor circuit

Connect the sensor lead to J14 (port 2 and 4) of the solar controller See the SGS electrical diagram (17 "Appendices")

Replace the sensor To replace the necessary parts, you must contact your installation

engineer

Connect the sensor lead to J13 (port 2 and 4) of the solar controller See the SGS electrical diagram (17 "Appendices")

Replace the sensor To replace the necessary parts, you must contact your installation

Replace sensor T

Replace the dummy sensor

(2)

engineer

To replace the necessary parts, you must contact your installation engineer

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Page 85

Code + Description Cause Solution Remark

S16 (blocking error)

Short circuit in temp. sensor S4 at the bottom of the storage tank

S17 (blocking error)

Short circuit in temp. sensor S1 at bottom of tank

S18 (blocking error)

Short circuit in temp. sensor S1 in the collector

F01 (blocking error)

Defect in power supply circuit

F02 (lock out error)

Fan fails to run at correct speed.

Short circuit in sensor circuit.

Sensor is not (correctly) connected

Short circuit in sensor circuit

Live and neutral connected wrong way round

Condensation on the flame probe

Floating neutral Install an isolating transformer (3.11.4 "Isolating transformer") Contact your installation engineer to have an isolating transformer

Defective motor and/or rotor.

Damaged wiring 1. Check the wiring between the fan and the controller.

Replace sensor S4 To replace the necessary parts, you must contact your installation

engineer

Replace sensor S2 To replace the necessary parts, you must contact your installation

Replace sensor S1 To replace the necessary parts, you must contact your installation

Connect live and neutral correctly (3.11 "Electrically connecting the

appliance"); the appliance is phase-sensitive

1. Disconnect the lead at the flame probe

2. Ignite the appliance three times, with an interrupted ionisation circuit

3. Reconnect the ionisation lead to the flame probe

4. Ignite the appliance again

5. The repeated ignition attempts will have caused the condensation to evaporate

1. Check the motor and rotor

2. Replace the fan if the motor or rotor is defective.

3. Reset appliance controller

2. If any wires are damaged, the wiring harness must be replaced.

3. Reset appliance controller

engineer

See the SGS electrical diagram (17 "Appendices")

If errors persist, contact your installation engineer

installed

See the SGS electrical diagram (17 "Appendices")

To have the wiring replaced and a new fan fitted, you must contact your installation engineer

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Page 86

Code + Description Cause Solution Remark

Dirty or blocked fan 1. Check if the fan is dirty

2. Check that the rotor can rotate freely

3. Reset appliance controller

Because of a drop in the supply voltage, the fan is not running at the correct speed.

The F02 entries below are applicable solely to appliances that have a 3-phase fan with frequency controller.

Fun supplying insufficient pressure

Air pressure switch fails to close during prepurge.

The live (phase) wires, between freq. controller and fan are connected wrong way around

Fan speed too low 1. Check the fan speed

Air pressure switch leads

Loose air pressure switch hoses

1. Check the supply voltage, this must be 230 VAC (-15%, +10%).

2. Reset appliance controller

1. Check the wiring between the fan and the frequency controller

2. Rectify the assembly if it is incorrect

3. Reset appliance controller

2. If the fan speed is too low, check the settings

3. If the settings are correct, then replace the fan.

4. Modify the settings if incorrect

5. Reset appliance controller

1. Check the wiring between the air pressure switch and the controller. Rectify any defect:

- if any wires are damaged, replace the wiring harness

- properly connect loose or detached hoses

2. Reset appliance controller

1. Check hoses between air pressure switch and burner/fan. Rectify any defect:

- if any wires are damaged, replace the wiring harness

- properly connect loose or detached hoses

2. Reset appliance controller

See the SGS electrical diagram (17 "Appendices")

To replace the necessary parts, you must contact your installation engineer

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Page 87

Code + Description Cause Solution Remark

Heat exchanger and/or chimney flue is blocked

Defective controller 1. Check that the controller is receiving power

3. Measure the pressure differential across the air pressure switch

4. Check the values (2.4.6 "Pressure switch")

5. Check heat exchanger, condensation drainage and/or chimney flue for blockages

6. Clear any blockage that may be present.

7. Reset appliance controller

2. Check that the controller is correctly connected

3. If there is no electrical power, check the power supply to the terminal block, or replace the controller.

4. Rectify any incorrect connections.

5. Reset appliance controller

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Page 88

Code + Description Cause Solution Remark

F03 (lock out error)

The pressure switch fails to work correctly

Damaged wiring/Open circuit

Pressure switch not closing

1. Check the wiring between the pressure switch and the controller

2. If necessary, replace the wiring

1. Check the running speed of the fan (12.5 "Display the selected

appliance")

2. Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted. Refit them if necessary

3. Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner. If necessary, replace the hoses.

4. Check that the flue gas outlet is compliant (3.10 "Air supply and

flue").

5. Check for blockage in the flue gas discharge. Remove any blockage that may be present

6. Check for blockage in the condensation water discharge. Remove any blockage that may be present.

7. Measure the pressure differential across the pressure switch. See the table in Preparation for maintenance (15.2 "Preparation for maintenance"). If there is insufficient pressure differential, clean the heat exchanger. If the pressure differential is acceptable, check that the pressure switch is closing, using a multimeter.

If the error cannot be resolved or is persistent, contact your installation engineer

To replace the necessary parts, you must contact your installation engineer

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Page 89

Code + Description Cause Solution Remark

F04 (lock out error)

Three unsuccessful ignition attempts.

F05 (lock out error)

Too many flame errors have been signalled.

No gas 1. Open the main gas valve and/or the manual gas valve supplying

the water heater

2. Check the supply pressure to the gas control

3. If necessary, repair the gas supply

Air in the gas pipes Bleed the air out of the gas pipe See Checking the supply pressure and burner pressure for how to

No burner pressure 1. Check the burner pressure to the gas control

2. Check that the gas valve(s) open and shut correctly

3. If necessary, replace the gas control.

Defect in the hot surface igniter circuit

Defect in the ionisation circuit

Supply voltage too low Check the supply voltage, this must be 230 VAC (-15%, +10%).

Incorrect roof or wall conduit. Recirculating flue gases.

1. Check that the hot surface igniter is correctly connected (JP2).

2. Check the wiring of the hot surface igniter.

3. Measure the resistance across the hot surface igniter. This must lie between 2 and 5 ohms.

4. Check that the hot surface igniter lights up during ignition.

5. If necessary, replace the hot surface igniter.

1. Check that the flame probe is correctly connected (JP2)

2. Check the wiring of the flame probe

3. Measure the ionisation current. This must be at least 1.5 microamps.

4. Replace the wiring if necessary.

1. Check that the correct roof or wall flue conduit (3.10 "Air supply

and flue") has been fitted.

2. If necessary, install the correct roof or wall conduit.

3. Check that the roof or wall conduit discharges into a permitted area.

To repair the gas supply, contact your installation engineer

bleed air from the gas line, and measure the supply pressure and burner pressure. To replace the necessary parts, you must contact your installation engineer

If the error persists, contact your installation engineer. To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer

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Page 90

Code + Description Cause Solution Remark

F06 (lock out error)

Short circuit between flame probe and earth

F07 (lock out error)

A flame has been detected after the gas valve was closed.

F08 (lock out error)

Error message from safety relay

F09 (lock out error)

Water temperature safety.

Damaged cable in contact with metal surface.

Ceramic part of the flame probe is broken/cracked.

Defective gas valves 1. Check whether there is still burner pressure present after the

Flame detection before the gas valve opened.

The temperature at the top of the tank exceeds

Check the wiring of the flame probe. If necessary, replace the wiring.

1. Check that the ceramic part of the flame probe is still intact in the vicinity of the burner's air distribution plate.

2. If not, the flame probe must be replaced.

gas valves have closed.

2. Check whether a flame is still present after the gas valves have closed.

3. If this is the case, the gas control must be replaced.

1. Reset the electronic controller.

2. If the error reappears, replace the electronic controller.

1. Check that the circulation pump (if present) is working

2. Check the position of the temperature sensor T

3. Reset appliance controller

If the error persists, contact your installation engineer. To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer

Instruction manual SGS 90

Page 91

Code + Description Cause Solution Remark

F10 (lock out error)

Restriction on the number of ignition attempts based on pressure switch state changes.

F11 (blocking error)

Pressure switch not closing

Defective gas valves See F07.

1. Check the running speed of the fan (12.5 "Display the selected

appliance")

2. Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted. Refit them if necessary

3. Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner. If necessary, replace the hoses.

4. Check that the flue gas outlet is compliant (3.10 "Air supply and

flue").

5. Check for blockage in the flue gas discharge. Remove any blockage that may be present

6. Check for blockage in the condensation water discharge. Remove any blockage that may be present.

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

Flame detection with closed gas valve.

F17 (blocking error)

Communication error

No power supply at solar controller

No cable or damaged cable

1. Check that there is power to the solar heating system controller

2. The measured voltage must be 230VAC (-15%, +10%)

1. Check the wiring (communication cable) between the main controller and the solar heating system controller

2. If cable missing, connect the cable

3. If cable damaged, replace the cable

See the SGS electrical diagram (17 "Appendices") If the error persists, consult your installation engineer

See the SGS electrical diagram (17 "Appendices") For replacement of the cable, contact your installation engineer

Instruction manual SGS 91

Page 92

Code + Description Cause Solution Remark

C02 (lock out error)

Error message from the appliance controller.

Internal error message from the appliance controller.

C03 (blocking error)

Reset error

C04 (blocking error)

Appliance selection error

Incorrect reference voltage from the AD converter.

• EEPROM read error

• 50 Hz error

• Internal communication error

• Gas valve relay error

• Safety relay error

• Ignition relay error

• RAM error

• EEPROM error

• EEPROM contents do not match the software version

• Processor software error

Too many resets in too short a period.

Incorrect appliance selection / Incorrect selection resistor

1. Reset electronic controller.

2. Check that the frequency of the power supply is compliant (3.4.2 "General and electrical specifications"). If this is not the case, contact your installation engineer

3. If the frequency is correct but the error persists, replace the electronic controller.

Wait for the error to disappear (maximum 1 hour). If the error does not disappear, replace the appliance controller.

1. Check whether the correct appliance is selected (12.5 "Display

the selected appliance").

2. If the correct appliance is selected, fit the correct selection resistor.

3. If incorrect appliance selected, select the correct one.

To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

Instruction manual SGS 92

Page 93

Code + Description Cause Solution Remark

E01 (blocking error)

The temperature protection at the top of the tank has been activated.

E03 (lock-out error)

Error in temperature sensor T the tank.

E04 (lock-out error)

Error in dummy sensor

1) Temperature sensor T (2) The dummy sensor / flue gas sensor comprises dummy sensor / flue gas sensor 1 and dummy sensor / flue gas sensor 2.

at the top of

(2)

The temperature of the water at the top of the tank is > 85

The two temperature sensors in the tank detect a differential of >

C over a period of

at least 60 seconds.

The two dummy sensors in the tank detect a differential of >

C over a period of

at least 60 seconds.

is a '2 in 1' sensor, T1 contains 2 NTCs for the high-limit thermostat and safety thermostat protection.

None. This is a temporary message that may appear from time to time, but will disappear automatically.

1. Check sensor position and wiring.

2. If necessary, reset the electronic controller. Replace the sensor if the error persists.

1. Check leads from dummy 1 and dummy 2.

2. If necessary, reset the electronic controller. Replace the dummy sensor if the error persists.

To replace the necessary parts, you must contact your installation engineer

Instruction manual SGS 93

Page 94

13.4 Displayed warnings

Displayed warnings

Symptom Cause Solution Remark

Q/T sensor not correctly connected

Collector temperature excessive

Maximum burning hours: Service required

Lead(s) loosened or incorrectly connected

Temperature S1 is higher than T

max

The actual burning hours have exceeded the preset burning hours

collector

Appliance runs, but displays a warning 1. Properly connect Q/T sensor and the warning will disappear

2. If correctly wired but the warning remains, replace sensor

Note: To have the sensor connected or replaced, contact your installation engineer

The pump in the solar circuit switches off, until S1 < 70°C 1. You can let the message disappear automatically by allowing

the heating fluid to cool down

2. You can also manually eliminate the message by pressing the RESET and ENTER button simultaneously

Appliance runs, but displays a warning For maintenance to your appliance, contact your installation

engineer

Instruction manual SGS 94

Page 95

14 Maintenance

frequency

14.1 Introduction

14.2 Determining service interval

Note

Regular maintenance extends the service life of the appliance.

To determine the correct maintenance frequency, it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side, three months after installation. Based on this check, the best maintenance frequency can be determined.

To aid servicing, the electronic controller has a service interval with which the service and maintenance engineer can determine the frequency of maintenance, based on the number of burning hours.

The service interval can be set to: 500, 1000 or 1500 burning hours. The standard setting is 500 burning hours.

Example

In the first three months, the appliance has burnt 300 hours. During maintenance, it is evident that one service per year will be sufficient. Therefore, after one year, some 1200 burning hours will have elapsed. The first value below 1200 hours that can be selected is 1000 burning hours.

In this case, the service and maintenance engineer sets the interval to 1000.

In the first three months, the appliance has burned for 300 hours. During maintenance, it is evident (perhaps due to the water quality) that service will be required at least once every 6 months.

Therefore, after six months, some 600 burning hours will have elapsed. The first value below 600 hours that can be selected is 500 burning hours.

In this case, the service and maintenance engineer sets the interval to 500.

!!! WARNING !!!

MAX. BURNINGHOURS:

SERVICE REQUIRED

Once the set number of burning hours has elapsed, the message

SERVICE REQUIRED

appears, the service and maintenance engineer must be contacted.

Instruction manual SGS 95

will appear on the display. When this message

Page 96

Maintenance frequency

96 Instruction manual SGS

Page 97

15 Performing

maintenance

15.1 Introduction

15.2 Preparation for maintenance

Caution

Maintenance may only by carried out by an approved service and

maintenance engineer.

At each service, the appliance undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order.

1. Preparation for maintenance

2. Water-side maintenance

3. Gas-side maintenance

4. Solar collector maintenance

5. Finalizing maintenance

Note

Before ordering spare parts, it is important to write down the appliance type and model, and the full serial number of the appliance. These details can be found on the rating plate. Only by ordering with this information can you be sure to receive the correct spare parts.

To test whether all components are still working properly, complete the following steps:

1. Activate the

2. Use: and to place the cursor beside

3. Confirm

OFF

with .

OFF

MENU »OFF ^ ON È WEEK PROGRAM

4. Wait until the fan has stopped. The icon is then dimmed.

Caution Failure to wait until the fan stops purging can cause damage to the

appliance.

5. Switch the appliance OFF (position 0) using the ON/OFF switch on the

control panel.

Instruction manual SGS 97

Page 98

Performing maintenance

6. Switch the electronic controller ON by setting the ON/OFF switch to position I.

INTERNAL CHECK

The display will now show will then go to the main menu.

MENU »OFF ^ ON È WEEK PROGRAM

7. Activate "ON mode" by going through the following steps:

- Press once on the blue arrow ( ) to position the cursor beside

then press .

- Confirm the selection

8. If there is no heat demand, increase Tset (11.4 "Setting the water

temperature"). Note the original setting. Draw some hot water off to create

heat demand.

9. Check whether the heating cycle runs correctly (9.3 "The appliance's

heating cycle").

10. If you have adjusted T

water temperature").

11. Remove the plastic cover on the top of the appliance.

12. Check the supply and burner pressure (3.13 "Checking the supply pressure

and burner pressure"), and adjust them if necessary.

13. Check that all components of the chimney flue system are properly attached.

14. Check the pressure differential across the orifice plate of the pressure switch (see the table). If the pressure difference is too low, the heat exchanger must be cleaned (15.4.4 "Cleaning the heat exchanger").

INTERNAL CHECK

START OPERATION

, return it to the desired value (11.4 "Setting the

set

for about 10 seconds, and

with .

Pressure switch pressure differential

Appliance Observed pressure differential across

the pressure switch (Pa)

SGS 28 >

SGS 30 >

SGS 50 >

SGS 60 >

98 Instruction manual SGS

635

855

1085

Page 99

0080

15.3 Water-side maintenance

15. Test the operation of the overflow valve of the protected cold supply setup. The water should spurt out.

16. Test the overflow operation of the T&P valve. The water should spurt out.

17. Check the drain pipes from the discharge points of all valves and remove any lime buildup that may be present.

18. Drain the appliance (see Draining).

15.3.1 Introduction

The following steps must be carried out on the water side:

1. Checking the anodes.

2. Descaling and cleaning the appliance and storage tank.

3. Cleaning condensation water discharge.

15.3.2 Checking the anodes

Timely replacement of the anodes extends the service life of the appliance and storage tank. The appliance's anodes must be replaced as soon as they are 60% or more consumed (take this into consideration when determining the maintenance frequency).

1. Loosen the anodes using suitable tools.

2. Check the anodes, and if necessary, replace them.

15.3.3 Descaling and cleaning the appliance and storage tank

Scale and lime buildup prevent effective conduction of the heat to the water. Periodic cleaning and descaling prevents buildup of these deposits. This increases the service life of the appliance, and also improves the heating process.

Take the rate of scale formation into account when deciding on maintenance frequency. Scale formation depends on the local water composition, the water consumption and the water temperature setting. A water temperature setting of maximum 60°C is recommended for prevention of excessive scale buildup.

To guarantee a good, watertight seal around the cleaning opening, replace the gasket, washers, bolts and, if necessary, the lid with new parts before reassembly (see the figure). A special set is obtainable from the supplier/manufacturer.

To simplify descaling and cleaning of the appliance and storage tank, both are equipped with a cleaning opening.

IMD-

1. Remove the cover plate (1) on the outer jacket (see the figure).

2. Undo the bolts.

3. Remove the cover and the gasket.

Instruction manual SGS 99

Page 100

15.4 Gas-side maintenance

Performing maintenance

4. Inspect the tank and remove the loose scale deposits and contamination.

5. If the scale cannot be removed by hand, then the appliance will need to be descaled using a descaling agent. Contact the supplier for advice on the preferred descaling agent.

6. Close the cleaning opening. To avoid damage to the tank, tighten the bolts that fasten the lid with a torque no greater than 50 Nm. Use suitable tools for this.

15.3.4 Cleaning condensation water discharge

Regular cleaning of the condensation drain and siphon is essential for prevention of blockages.

15.4.1 Introduction

The following steps must be carried out on the gas side:

1. Clean the burner(s).

2. Clean the orifice(s).

3. Cleaning the heat exchanger.

4. Finalizing maintenance.

15.4.2 Clean the burner(s)

1. Detach the burner(s)

2. Remove all contamination present on the burner(s).

3. Fit the burner(s)

15.4.3 Clean the orifice(s)

1. Detach the orifice(s)

2. Remove all contamination present in the orifice(s).

3. Fit the orifice(s)

15.4.4 Cleaning the heat exchanger

1. Detach the burner.

2. Clean the combustion chamber of the heat exchanger using a vacuum cleaner and a soft brush.

3. Detach the flue gas discharge.

4. Clean the end of the heat exchanger using tap water.

5. Fit the burner.

6. Fit the flue gas discharge.

Note

Check the pressure differential again after cleaning. If the pressure

difference is too low following cleaning, please contact the supplier of the appliance.

15.5 Solar collector maintenance

15.6 Finalizing maintenance

100 Instruction manual SGS

See installation or users' manual for the solar collector. If this topic is not covered in the manual, then contact the supplier of the collectors.

To finalize the maintenance carry out the following steps:

1. Fill the appliance (5 "Filling").

2. Start the appliance (9 "Starting and running").

3. Erase the message then once on .

SERVICE REQUIRED

. Do this by pressing once on

A.O. Smith 30 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual