A.O. Smith GWV - 120, GWV - 200, GWV - 150 User Manual

120 150 200

Installation

User and

Service Manual

WATER PRODUCTS

COMPANY

A DIVISION OF A. O. SMITH CORPORATION

www.aosmithinternational.com

your installer

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Read this manual carefully

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) 0870 - 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 GWV

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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 - - - - - - - - - - - - - - - - - - - - - - 15

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

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 18

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

3.3 Environmental conditions- - - - - - - - - - - - - - - - - - - - - - - - - 20

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 22

3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

3.6 Water connections, Vented- - - - - - - - - - - - - - - - - - - - - - - - 26

3.7 Water connections, Unvented - - - - - - - - - - - - - - - - - - - - - - 28

3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

3.9 Air supply and flue - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

3.10 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

3.11 Checking the supply pressure and burner pressure - - - - - - - - - - - - 36

4 Conversion to a different gas category - - - - - - - - - - - - 41

5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

5.1 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

5.2 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 44

5.3 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 45

6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

6.1 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

6.2 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 48

6.3 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 49

7 The control panel- - - - - - - - - - - - - - - - - - - - - - - - 51

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

7.2 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

7.3 Meaning of icons- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

7.4 Electronic controller ON/OFF switch - - - - - - - - - - - - - - - - - - - 51

7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

8 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 53

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

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Table of contents

8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

8.5 Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

9 Starting and running - - - - - - - - - - - - - - - - - - - - - - 55

9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

9.2 Starting and running- - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

9.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 55

10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 59

10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

10.2 Shutting the installation down for a brief period ("OFF mode") - - - - - - - 59

10.3 Isolating the appliance from the mains - - - - - - - - - - - - - - - - - - - 59

10.4 Shutting the appliance and storage tank down for a long period - - - - - - 59

11 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

11.2 Notational convention for menu-related instructions - - - - - - - - - - - - 61

11.3 Switching on the "ON mode" - - - - - - - - - - - - - - - - - - - - - - - 61

11.4 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - - 61

11.5 Week program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

11.6 Starting and stopping the week program - - - - - - - - - - - - - - - - - - 62

11.7 Changing the appliance's standard week program - - - - - - - - - - - - - 62

11.8 Adding times to a week program- - - - - - - - - - - - - - - - - - - - - - 64

11.9 Deleting times from a week program- - - - - - - - - - - - - - - - - - - - 65

11.10 Extra period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

11.11 Programming an extra period - - - - - - - - - - - - - - - - - - - - - - - 66

11.12 Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

12 Service program - - - - - - - - - - - - - - - - - - - - - - - - 69

12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

12.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

12.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 69

12.4 Displaying the appliance history - - - - - - - - - - - - - - - - - - - - - - 69

12.5 Displaying the appliance selection - - - - - - - - - - - - - - - - - - - - - 70

12.6 Switching the pump on or off - - - - - - - - - - - - - - - - - - - - - - - 70

12.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 70

12.8 Setting the display contrast - - - - - - - - - - - - - - - - - - - - - - - - 70

12.9 Setting the display backlight switching period - - - - - - - - - - - - - - - 70

12.10 Setting the display scroll speed - - - - - - - - - - - - - - - - - - - - - - 70

12.11 Setting the stage difference for the appliance - - - - - - - - - - - - - - - 70

12.12 Setting the pump running-on time - - - - - - - - - - - - - - - - - - - - - 71

13 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 73

13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - - 74

13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - - 76

13.4 Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

14 Maintenance frequency- - - - - - - - - - - - - - - - - - - - - 87

14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87

14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - - 87

6 Instruction manual GWV

15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 89

15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

15.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 89

15.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 91

15.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 92

15.5 Finalizing maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - 92

16 Warranty (certificate) - - - - - - - - - - - - - - - - - - - - - - 93

16.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

16.2 Appliance warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

16.3 Conditions for Installation and use - - - - - - - - - - - - - - - - - - - - 93

16.4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94

16.5 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - 94

16.6 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94

16.7 Obligations of A.O. Smith - - - - - - - - - - - - - - - - - - - - - - - - 94

17 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

17.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

17.2 Electrical diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96

17.3 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 99

Instruction manual GWV 7

Table of contents

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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 GWV appliance. This appliance is a closed, gas-fired water heater with a fan in the air supply. The appliance is always supplied together with a storage tank.

The possible categories for this appliance are C13, C33, and B23.

The information in this manual applies to the: GWV 120, GWV 150 and GWV

200.

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!

Open windows and doors!

1.3 Regulations

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 GWV

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

The table provides an overview of the contents of this document.

document

Contents of this document

Chapter Target groups Description

Working principle of the appliance

Installation This chapter describes the installation activity to be

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

This chapter describes how the appliance functions.

completed before you actually start up the appliance.

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.

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

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

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

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

Troubleshooting This chapter is mainly intended for the installation

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.

Maintenance frequency This chapter describes how to determine the optimum

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.

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

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Working principle of the appliance

Cut-away view of the appliance

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654

IMD-

18 16 15 14

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Legend

1. Hot water outlet

2. Insulation layer

3. Electrical connector block

4. Aluminium strips

5. ThermoControl (electronic

controller)

6. Flue gas discharge

7. Jacket cover plate

8. Air supply

9. Gas controls

10. Fan

11. Drain valve

12. Pressure switch

13. Air distributor plate

14. Flame probe

15. Hot surface igniter/flame probe connector

16. Injectors

17. Glow plug

18. Bar burners

19. Combustion chamber

20. Heat exchanger

21. Inspection glass

In this appliance, the cold water enters the bottom of the storage tank through the cold water inlet (24). The system pump (22) ensures that the water flows into the appliance. The water is heated by the heat exchanger (20) in the combustion chamber (19).

The heated water leaves the appliance via the return valve (26) and then, once heated, flows into the storage tank (32).

To prevent condensation from forming in the appliance, the water that flows into it via the supply line (25) must not be colder than 30 the very first time, or after it has been shut down for a long period.

Once the appliance and the storage tank are completely filled with water, they are permanently pressurised by the water pipes. As hot water is drawn from the storage tank, cold water is immediately added.

Water flows into the appliance through the ribbed elements (20). This ribbing ensures better heat transfer. There are aluminium strips (4) on these elements. These slow down the flue gases, improving the yield. The air required for combustion is forcibly delivered by the fan (10).

The appliance has two identical gas controls (9) of which one will be open (partial load) or both (full load). Thanks to the modulated supply of gas and air (8), the optimum gas/air mixture is always achieved. The flue gases are removed via the flue gas outlet pipe (6). The air supply and flue gas outlet are always in parallel.

The insulation layer (2) prevents heat loss. To protect against corrosion, the storage tank is enamelled on the inside. Anodes provide extra protection against corrosion.

For maintenance, the storage tank has an aperture for inspection and cleaning.

22. System pump:

23. Temperature sensor T

24. Cold water inlet

25. Inlet line

26. Return line

27. Return valve

28. Supply valve

29. Flow-through switch:

30. Temperature sensor T

31. Temperature sensor T

32. Storage tank

33. P-valve

C. This will only be the case

2.3 The appliance's heating cycle

The appliance uses sensor T3 (23) to determine whether the water temperature set (T (T system pump on and the flow-through switch (29) will give a signal to the controller. The appliance will ignite and the water will be heated. Once T3 gets above T the heating cycle; the system pump (22) keeps running (12.12 "Setting the

pump running-on time") for a little while.

The electronic controller assumes a certain margin when ending a heat demand. We refer to this margin as the hysteresis (12.2 "Setting the

hysteresis").

) has been reached. When T3is lower than the set water temperature

set

), the electronic controller registers a "heat demand". This will switch the

set

, the demand for heat has been met and the electronic control stops

set

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Working principle of the appliance

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2.4 Protection for the appliance

2.4.1 Introduction

The electronic controller monitors the water temperature and ensures safe combustion. This is achieved by:

• the Water temperature protection

• the Gas control

• the Fan

• the Pressure switch

• the Flame probe

• the Flow-through switch

2.4.2 Water temperature protection

The electronic controller monitors the water temperature with temperature sensors T

Temperature protection

Safety Description

, T2, T3 > 98°C The appliance switches back to partial load once the heat demand has been

For additional safety

, T2, T3 > 99°C

met.

A lockout error of the appliance occurs. The controller must be manually reset before the appliance can resume operation (8.3 "Error conditions"). The reset may only be performed if T

, T2 and T3 as shown in the table.

< 90°C.

2.4.3 Gas control

When heat is required, the controller (5) opens the left-hand gas control (9) so that the gas can flow into the premix bar burners (18) of the first tray of burners. The air is mixed in with the gas at the front of the burners. The hot surface igniter (17) ignites the leftmost burner. The adjacent burners then ignite from left to right.

If more heat is demanded, the controller opens the second gas control (9) as well. There is no separate igniter for the ignition of the second tray of burners.

The gas controls have two valves as safety devices. The valves shut off the gas supply.

Smooth ignition is achieved by opening the gas controls with a delay ("softlite").

2.4.4 Fan

The fan (10) provides an optimum air supply (8) when there is a heat demand. This air comes into a separate chamber on the air distribution plate (13). Overpressure is created in the space and the air can only escape the appliance via the premix bar burners (18).

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-purge and post-purge.

The fan speed is continuously monitored by the electronic controller (5). The electronic controller takes control if the speed of rotation varies too much from the set value.

2.4.5 Pressure switch

The pressure switch (12) guarantees the air supply during pre-purging and when the appliance is operational. The standard position 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.

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Pressure measurements are made at the air distribution plate (high pressure) and in a Venturi in the burners (low pressure).

The table shows the trip point per appliance.

Note

The trip point of the pressure switch is not adjustable.

Pressure switch trip points

Appliance Closing pressure

differential

GWV 120 >

GWV 150 >

GWV 200 >

80 Pa < 66 Pa

89 Pa < 75 Pa

107 Pa < 92 Pa

2.4.6 Flame probe

To ensure that no gas can flow when there is no combustion, the water heater has a flame probe (14). The electronic controller uses this probe for flame detection, by means of ionisation detection. The electronic control closes the gas valve as soon as it detects that no flame is present.

2.4.7 Flow-through switch

the flow-through switch (29) guarantees the flow of water through the appliance (before operation and while the appliance is running). The standard position of the flow-through switch is open. When the flow is sufficient, the switch closes and the heating cycle starts. If the flow of water through the appliance gets too low, then the switch opens, which interrupts the heating cycle; this is to prevent overheating.

Flow measurement is done in the return line between the appliance and the storage tank.

Opening pressure differential

Instruction manual GWV 17

2.5 Safety of the installation

2.5.1 Unvented installation

2.5.2 Vented installation

Working principle of the appliance

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As well as the standard safeties in the appliance (2.4 "Protection for the

appliance"), it must also be protected by an inlet combination and a pressure-

reducing valve. A P-valve is also used.

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

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

Normally, the vent pipe should discharge into a separate discharge channel/drain or otherwise to the open cold water head tank. The appliance should also be fitted with a stop valve (3.6.2 "Hot water side") on the hot water side.

2.5.3 Inlet combination and pressure-reducing valve

An excessively high pressure in the storage tank can damage the enamelled layer. An inlet combination and pressure-reducing valve prevents this. The inlet combination acts as a stop valve, non-return valve and overflow valve. If the water supply pressure is too high (> 8 bar), a pressure-reducing valve must be used. Both components must be fitted in the cold water supply (3.6 "Water

connections, Vented").

2.5.4 P-valve

The appliance has a P-valve (33) as standard. A P-valve (Pressure Relief Valve) monitors the pressure in the installation. If the pressure gets too high (> 10 bar), the valve will open. The water can now flow out of the installation. Because the installation is under water supply pressure, cold water will automatically flow into the storage tank. The valve remains open until the unsafe situation (< 10 bar) has been resolved.

18 Instruction manual GWV

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;

• Installation diagram;

• Water connections, Vented,

• Gas connection;

• Air supply and flue;

• Electrical connection;

• Checking the supply pressure and burner pressure.

For a possible 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.

Instruction manual GWV 19

Installation

3.3 Environmental conditions

Caution

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

The appliance is suitable for both open and closed combustion.

For closed combustion, the air supply required is independent of the room in which it is installed. In this event, there are no additional ventilation requirements. Appliance types possible here are C13 and C33.

The appliances can also be installed as open appliances and may then only be placed in an open boiler room. The appliance type is B23.

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 <

T < 60°C

3.3.2 Maximum floor loading

Allow for the weight of the appliance and the storage tank with respect to the maximum floor loading; refer to the tables.

Specifications of the weight of the appliance, with respect to the maximum floor loads.

Weight of the appliance (kg)

GWV 120 225

GWV 150 250

GWV 200 300

Specifications of the weight of the storage tank, with respect to the maximum floor loads.

Weight of the storage tank filled with water (kg)

ST 400 505

ST 500 630

ST 600 855

ST 750 965

ST 1000 1315

20 Instruction manual GWV

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

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.

3.3.4 Working clearances

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

• Around the appliance and the storage tank: 50 cm.

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

- 100 cm if using fixed anodes, or

- 50 cm if using flexible anodes.

If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered.

> 1.00 mmol/l:

• German hardness > 5.6° dH

• French hardness > 10.0° fH

• British hardness > 7.0° eH

Note

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

Instruction manual GWV 21

Installation

3.4 Technical specifications

3.4.1 Dimensions of the appliance

Check the dimensions (3.4.1 "Dimensions of the appliance"), the gas data (3.4.3 "Gas data") and other specifications (3.4.2 "General and electrical

specifications") of the appliance.

Plan and elevation of the appliance

IMD-0483 R

22 Instruction manual GWV

Dimensions (all measurements in mm unless otherwise indicated)

Size Description GWV 120 GWV 150 GWV 200

A Overall height 835 835 835

B Height of pump connection + heat

exchanger outlet

C Length of appliance 910 1065 1465

D Length including flow switch 1230 1495 1895

E Width of appliance 625 625 625

F Air supply diameter 150 150 200

G Diameter of flue gas discharge 150 150 200

H Centre-to-centre distance between air

supply/flue gas outlet

I Air supply distance 160 240 260

J Air supply/flue gas discharge distance 185 185 185

K Height of gas connection 760 760 760

L Height of drain valve connection 345 345 345

M Length including pump 1500 1680 2100

1 Supply connection (external) R 1

2 Return connection (internal) Rp 1

3 Gas connection (external) R 1 R 1 R 1

4 Drain valve connection (internal)

5 P-valve connection (internal)

350 350 350

300 300 480

/4"

R 2 R 2

Rp 2 Rp 2

/4"

3.4.2 General and electrical specifications

Chimney data

Chimney

Not insulated (max. length) m 8 8 8

Not insulated (number of bends) - 2 2 2

Not insulated with condensation removal (max. length)

Not insulated with condensation removal (number of bends)

Insulated (max. length) m 20 20 20

Insulated (number of bends) - 2 2 2

Tap capacity (Tcold = 10°C) Unit GWV 120 GWV 150 GWV 200

Maximum temperature regulated °C 85 85 85

continuous ∆T=28°C l/h 3041 3787 4838

continuous ∆T=44°C l/h 1935 2410 3078

continuous ∆T=50°C l/h 1703 2121 2709

continuous ∆T=55°C l/h 1548 1928 2463

continuous ∆T=70°C l/h 1216 1515 1935

1) Stated lengths and bends apply for both flue gas removal and air supply

Tap capacity

Unit GWV 120 GWV 150 GWV 200

m202020

-222

Instruction manual GWV 23

Installation

Contact ratings

Unit GWV 120 GWV 150 GWV 200

Electrical power consumption W 200 210 350

Supply voltage VAC 230 (+10 -15%) - 50Hz

Operating pressure

Unit GWV 120 GWV 150 GWV 200

Operating pressure bar 8 8 8

3.4.3 Gas data

Gas data

Description II

Gas category 2H: G20 - 20 mbar

Orifice diameter mm 2,31 2,31 2,31

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

Nominal load (upper value) kW 122,2 152,1 194,3

Nominal output kW 99,0 123,3 157,5

Supply pressure mbar 20 20 20

Burner pressure mbar 2 x 8.9 2 x 9.3 2 x 8.0

Gas consumption* m

Number of burners (total) - 8 10 15

Gas category 3P: G31 – 37 mbar

Orifice diameter mm 1,50 1,50 1,50

(1) = Blank plate (2) = Burner pressure regulator (3) = High/low regulator

Nominal load (upper value) kW 111,1 138,8 216,6

Nominal output kW 90,0 112,5 175,5

Supply pressure mbar 37 37 37

Burner pressure mbar 2 x 13.3 2 x 12.7 2 x 14.5

Gas consumption kg/h 7,8 9,7 15,1

Number of burners (total) - 8 10 15

* Gas consumption at 15°C and 1013.25 mbar

2H3P

Unit GWV 120 GWV 150 GWV 200

222

/h 11,5 14,3 18,4

222

24 Instruction manual GWV

3.5 Installation diagram

Unvented

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

Installation diagram

14 14 14

Vented

IMD-0486 R2

14 14 14

IMD-0487 R2

Instruction manual GWV 25

Legend

Only applicable numbers are mentioned.

1. pressure-reducing valve (mandatory if the mains

water pressure exceeds 8 bar)

2. inlet combination (mandatory)

3. expansion valve

4. stop valve (recommended)

5. non-return valve (mandatory)

6. circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve

12. temperature gauge (recommended)

Installation

14. hot water draw-off points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

18. water tank

19. float valve

23. P-valve A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow safety

3.6 Water connections, Vented

3.6.1 Cold water side

3.6.2 Hot water side

3.6.3 Circulation pipe

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").

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.

3.6.4 System pump

The pump revs can be set using an adjuster unit. This setting depends on the length of the pipes X between the storage tank and the appliance.

26 Instruction manual GWV

Distance X

GWV 120 GWV 150 GWV 200

Pipe diameter Ø 42 (1

Distance X

/2") Ø 54 (2") Ø 54 (2")

• 0 < X < 2 metres, rev setting 1

• 2 < X < 4 metres, rev setting 2

• 4 < X < 6 metres, rev setting 3

You set the revs using the pump's adjuster unit. Proceed as follows:

1. Unscrew the pump's cap.

2. The pump's adjuster unit can be seen.

3. Take the adjuster unit out.

4. Remove the cap of the adjuster unit.

IMD-0519 R

5. Turn the adjuster unit so that the number of the rev setting required can be seen.

Instruction manual GWV 27

Installation

IMD-0520 R

6. Put the cap back on the adjuster unit.

7. Insert the adjuster unit back in the pump.

8. Fit the cap back on the pump.

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

28 Instruction manual GWV

3.8 Gas connection

3.9 Air supply and flue

3.9.1 Introduction

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 gas system.

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

Warning

After fitting, check for leaks.

This section covers the following subjects:

• Requirements for flue gas discharge materials

• Parallel connections

• Specifications

3.9.2 Requirements for flue gas discharge materials

Warning

Installation must be carried out by an authorised installation engineer, in

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

Types of appliances

The appliances are approved for appliance types C13, C33 and B23. The figure and table give information about appliance types C13 and C33. For an explanation of the possibilities, please contact the manufacturer.

Instruction manual GWV 29

0503 R0

Installation

C13: appliance with wall conduit

IMD-

C33: appliance with roof conduit

IMD-0509 R0

Note

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

for this category of appliance.

30 Instruction manual GWV

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