A.O. Smith SGE Installation Manual
40
60
Installation
Installation
User and
User and
Service Manual
Service Manual
www.aosmithinternational.com
your installer
gis
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.
Copyright © 2008 A.O. Smith water Products Company
All rights reserved.
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 .
Instruction manual SGE 3
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4 Instruction manual SGE
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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 - - - - - - - - - - - - - - - - - - - - - - - 15
2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.6 Protection for the solar heating system - - - - - - - - - - - - - - - - - - 17
2.7 Safety of the solar heating system - - - - - - - - - - - - - - - - - - - - 18
3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.3 Environmental conditions- - - - - - - - - - - - - - - - - - - - - - - - - 19
3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 22
3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
3.6 Water connections, Unvented - - - - - - - - - - - - - - - - - - - - - - 27
3.7 Water connections, Vented- - - - - - - - - - - - - - - - - - - - - - - - 28
3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
3.9 Air supply and flue - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
3.10 Solar heating system- - - - - - - - - - - - - - - - - - - - - - - - - - - 35
3.11 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
3.12 Electrically connecting the solar heating system controller- - - - - - - - - 38
3.13 Checking the supply pressure and burner pressure - - - - - - - - - - - - 41
4 Conversion to a different gas category - - - - - - - - - - - - 45
5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
5.1 Filling the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
5.2 Filling solar heating system- - - - - - - - - - - - - - - - - - - - - - - - 51
6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
6.1 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 54
6.2 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 55
6.3 Draining solar heating system - - - - - - - - - - - - - - - - - - - - - - 55
7 The control panel- - - - - - - - - - - - - - - - - - - - - - - - 57
7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.2 Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.3 Meaning of icons- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
7.4 Electronic controller ON/OFF switch - - - - - - - - - - - - - - - - - - - 57
7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
Instruction manual SGE 5
Table of contents
8 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 59
8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
8.5 Collector temperature warning- - - - - - - - - - - - - - - - - - - - - - - 60
8.6 Q/T Sensor warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
9 Starting and running - - - - - - - - - - - - - - - - - - - - - - 61
9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
9.2 Starting the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
9.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 61
10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 63
10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
10.2 Shut the appliance down for a brief period ("OFF mode") - - - - - - - - - - 63
10.3 Electrically isolating the appliance - - - - - - - - - - - - - - - - - - - - - 63
10.4 Shutting the appliance down for a long period - - - - - - - - - - - - - - - 63
11 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
11.2 Notational convention for menu-related instructions - - - - - - - - - - - - 65
11.3 Switching on the "ON mode" - - - - - - - - - - - - - - - - - - - - - - - 65
11.4 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - - 65
11.5 Week program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
11.6 Starting and stopping the week program - - - - - - - - - - - - - - - - - - 66
11.7 Changing the appliance's standard week program - - - - - - - - - - - - - 66
11.8 Adding times to a week program- - - - - - - - - - - - - - - - - - - - - - 68
11.9 Deleting times from a week program- - - - - - - - - - - - - - - - - - - - 69
11.10 Extra period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
11.11 Programming an extra period - - - - - - - - - - - - - - - - - - - - - - - 70
11.12 Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
12 Service program - - - - - - - - - - - - - - - - - - - - - - - - 73
12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
12.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
12.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 73
12.4 Displaying the appliance history - - - - - - - - - - - - - - - - - - - - - - 73
12.5 Display the selected appliance - - - - - - - - - - - - - - - - - - - - - - 74
12.6 Switching the pump on or off - - - - - - - - - - - - - - - - - - - - - - - 74
12.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 74
12.8 Setting legionella prevention- - - - - - - - - - - - - - - - - - - - - - - - 74
12.9 Solar heating system configuration - - - - - - - - - - - - - - - - - - - - 75
12.10 Setting the central heating configuration - - - - - - - - - - - - - - - - - - 76
13 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 77
13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - - 78
13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - - 81
13.4 Displayed warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
14 Maintenance frequency- - - - - - - - - - - - - - - - - - - - - 91
14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - - 91
6 Instruction manual SGE
15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 93
15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
15.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 93
15.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 95
15.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 96
15.5 Solar collector maintenance - - - - - - - - - - - - - - - - - - - - - - - 96
15.6 Finalizing maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - 96
16 Warranty (certificate) - - - - - - - - - - - - - - - - - - - - - - 97
16.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
16.2 Tank warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
16.3 Collector warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
16.4 Conditions for Installation and use - - - - - - - - - - - - - - - - - - - - 97
16.5 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98
16.6 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - 98
16.7 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98
16.8 Obligations of A.O. Smith - - - - - - - - - - - - - - - - - - - - - - - - 98
17 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
17.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
17.2 Menu structure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100
17.3 Electrical diagram for the appliance- - - - - - - - - - - - - - - - - - - - 102
17.4 Electrical diagram, solar heating system - - - - - - - - - - - - - - - - - 104
17.5 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 107
Instruction manual SGE 7
Table of contents
8 Instruction manual SGE
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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 SGE appliance. The
SGE appliance is a condensing boiler with a fan in the air intake. The water is
heated partly by means of an external heat exchanger that can be connected to
e.g. a solar energy source.
The SGE 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: SGE 40 and SGE 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 and are entitled to bear the CE mark.
Warning
Read this manual carefully before starting up the water heater. 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.
Instruction manual SGE 9
1
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 SGE
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.
gis
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.
Instruction manual SGE 11
1
Introduction
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12 Instruction manual SGE
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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). The water is heated by means of a heat exchanger (55)
connected to a solar heating system (2.6 "Protection for the solar heating
system") and a gas-fired heat exchanger (11). 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. As hot water is drawn from the appliance, cold water is immediately
added.
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).
The insulation layer (24) prevents heat loss. The inside of the tank is enamelled
to protect against corrosion. The anodes (9) provide extra protection against
corrosion.
The appliance has an inspection and cleaning opening (12) for maintenance.
Instruction manual SGE 13
2
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
55. heat exchanger (e.g. solar
heating system)
56. temperature sensor S
1
2
2
Working principle of the appliance
gis
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
used by the solar heating system controller. S1 is measured in the solar
collector and S2 between the inlet and outlet of the heat exchanger (55).
The other settings that govern the control behaviour are:
•T
set
T
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
heating system is started, however, only if the temperature of the heating
fluid (S
measured at the appliance (sensor S2). As soon as (T
heating via the solar heating system is stopped. There is one exception to
this rule, and that is when T
) is a certain (adjustable) value higher than the temperature
1
(7) and T2 (13). In addition, temperatures S1 and S2 are
1
) in the appliance is used to regulate when both
net
falls below T
net
solar limit
, the water heating via the solar
set
= T
set
= T
net
is set to a higher value than T
is the
net
solar limit
.
set
14 Instruction manual SGE
),
gis
Legend
A = Gas burner on
B = Gas burner off
T
:
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
o
45
C = Minimum tap water
temperature
• 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
.
2
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 (12.9.5 "Setting the solar difference").
is a certain (adjustable) value grater
1
), the gas burner is shut off and the water
rises above
net
Preset (12.9.4 "Setting the solar limit temperature") water temperature at
which heating via the solar heating system is stopped.
•
Graphical representation of heating cycle
T
solar limit
T
set
Solar diff.
Hys.
T
min = 45C
Note
can rise above T
T
net
,. However, this is only possible if T
set
solar limit
is
increased via the service menu.
Note
to T
T
set
can be lower than T
solar limit
.
; this will mean that T
set
can never be equal
net
2.4 Protection for the
appliance
2.4.1 Introduction
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
Instruction manual SGE 15
2
Working principle of the appliance
2.4.2 Appliance water temperature protection
The electronic controller (4) controls and monitors the safety of the appliance by
means of sensors T1 and T2 . S2 is also used for protection of the appliance.
However, this is primarily intended for control of the solar heating
system (2.6 "Protection for the solar heating system").
The table explains the functioning of these temperature sensors.
Temperature protection
Protection Description
Against frost:
- T1 < 5°C
< 5°C
- T
2
For maximum water temperature:
> 85°C
- T
1
> 85°C
- T
2
> 85°C
- S
2
For extra safety:
> 93°C
- T
1
- T
> 93°C
2
> 93°C
- S
2
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 (T
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
gis
< 78°C), the electronic controller resets the
1
<78°C.
1
2.4.3 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").
2.4.4 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.
2.4.5 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
Appliance Closing pressure
difference
SGE 40
SGE 60 >
675 Pa < 645 Pa
Opening pressure
difference
16 Instruction manual SGE
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2.5 Safety of the
installation
2.4.6 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 (3.7 "Water connections, Vented").
2.5.2 Vented installation
2.5.3 T&P valve
2.6 Protection for the
solar heating system
2.6.1 Drain-back tank
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 (3.6.2 "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 (3.6.2 "Hot water side").
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 (12.9.1 "Setting the drain-back tank")
during the installation. Refer to the solar heating system manual for more
details.
Instruction manual SGE 17
2
2.6.2 Fluid temperature
2.7 Safety of the solar
heating system
Working principle of the appliance
gis
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 (12.9.2 "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
1
, if solar
1
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 SGE appliance
.
1
exceeds the maximum
1
2.7.1 Expansion vessel
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").
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").
18 Instruction manual SGE
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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;
• Electrical connection;
• 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 SGE 19
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.
3
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 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
Weight (kg) of the appliance filled with water
SGE 40 and 60 615
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.
is
T < 60°C
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, then the
tank protection cannot be guaranteed (16 "Warranty (certificate)").
> 1.00 mmol/l:
• German hardness> 5.6° dH
• French hardness > 10.0° fH
• English hardness > 7.0° eH
20 Instruction manual SGE
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3.3.4 Working clearances
For access to the appliance, it is recommended that the following clearances
are observed (see figure):
• 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 fixed anodes, or
- 50 cm if using flexible anodes.
If the available clearance is less than 100 cm, flexible magnesium anodes
may be ordered.
Note
When installing the appliance, be aware that any leakage from the tank
and/or connections can cause damage to the immediate environment or floors
below the level of the boiler room. If this is the case, the appliance should be
installed above a wastewater drain or in a suitable metal leak tray.
The leak tray must have an appropriate wastewater drain and must be at least
5cm deep with a length and width at least 5cm greater than the diameter of the
appliance.
Working clearances
Instruction manual SGE 21
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Installation
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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
22 Instruction manual SGE
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Dimensions (all dimensions in mm, unless otherwise stated)
Dime
nsion
A Total height 2055
C Position on pallet 490
D Appliance diameter 705
E Depth 925
FWidth 755
G Diameter of chimney flue 100 / 150
H Height of chimney flue 1995
Hx x position of chimney flue outlet 260
Hy y position of chimney flue outlet 370
K Height of gas/burner connection 1945
M Height of cold water supply 185
N Height of hot water outlet 2055
Ny y position of hot water outlet 205
P Height of cleaning opening 365
R Height of drain valve connection 180
S Height of T&P valve connection 1485
T Height of coil inlet 630
U Height of coil outlet 305
V Height of recirculation connection 1035
W Height of condensation drain 765
X Height of heat exchanger supply 1465
Y Height of heat exchanger discharge 855
Z Height of electric element connection 755
1 Cold water supply connection (male) R 1
2 Hot water outlet (male) R 11/
3 Gas control connection (female) R 3/
4 Drain valve connection (female)
5 T&P valve connection (female) 1 - 11.5 NPT
6 Cleaning/inspection opening 95 x 70
7 Condensation drainage connection (female) Rp 1
9 Coil inlet connection (female) Rp 1
10 Coil outlet connection (female) Rp 1
11 Electric element connection (female) R 1
12 Heat exchanger supply conn. (female) Rp 1
13 Heat exchanger discharge conn. (female) Rp 1
14 Recirculation connection (female) Rp 1
Description SGE 40 SGE 60
3
/4"
1
/
2
2
4
1
/
2
Instruction manual SGE 23
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Installation
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3.4.2 General and electrical specifications
General and electrical specifications
DESCRIPTION Unit SGE 40 SGE 60
Capacity litres 370
Empty weight kg 245
Maximum operating pressure bar 8
Maximum temperature of control thermostat °C 80
Number of anodes - 4
Fan speed at ignition rpm 4920
Working speed of fan rpm 6300
Diameter of air restrictor mm 34.0
Heating-up time ∆T = 45°C minutes 11
Electrical power consumption W 275
Power consumption of solar heating system controller W 700
Supply voltage
(-15% +10% VAC)
Mains frequency Hz (± 1Hz) 50
IP class - 30
volts 230
3.4.3 Gas data
Gas data
Description II
Gas category 2H: G20 - 20 mbar
Orifice diameter mm - 8.70
(1) = No burner pressure regulator
(2) = Burner pressure regulator
Nominal load (upper value) kW - 63.2
Nominal output kW - 59.7
Supply pressure mbar - 20
Burner pressure
Gas consumption
Gas category 3+: G30 - 30mbar
Orifice diameter mm - 4.00
(1) = No burner pressure regulator
(2) = Burner pressure controller
Nominal load (upper value) kW - 61.7
Nominal output kW - 59.7
Supply pressure mbar - 30
Burner pressure
Gas consumption
2H3+
(†)
(*)
(†)
(*)
Unit SGE
40
1 or 2 2
mbar - 10.0
m³/h - 6.0
1 or 2 - 1
mbar - -
kg/h - 4.5
SGE
60
24 Instruction manual SGE
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Description II
Gas category 3+: G31 - 37 mbar
Orifice diameter mm - 4.00
(1) = No burner pressure regulator
(2) = Burner pressure controller
Nominal load (upper value) kW - 61.8
Nominal output kW - 59.7
Supply pressure mbar - 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 SGE
40
1 or 2 - 1
mbar - -
kg/h - 4.5
SGE
60
Instruction manual SGE 25
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Installation
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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
26 Instruction manual SGE
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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 (mandatory)
10. manual gas valve (mandatory)
20. pressure valve (mandatory)
26. air bleed (mandatory)
3.6 Water connections,
Unvented
in compliance with general and local regulations (1.3 "Regulations").
3.6.1 Cold water side
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
2. The maximum working pressure of the appliance is 8 bar. Because the
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
11. service stop valve (recommended)
12. temperature gauge
(recommended)
13. condensation drainage
(mandatory)
14. hot water draw-off points
15. expansion valve (mandatory)
16. expansion vessel (mandatory)
17. 3-way aeration valve
(recommended)
18. water tank
19. float valve
23. pressure valve (mandatory)
37. combined Q/T sensor (optional)
Warning
The installation should be carried out by an authorised installation engineer,
applicable regulations (1.3 "Regulations").
pressure in the water pipe at times can exceed 8 bar, you must fit an
approved pressure-reducing valve (1).
wastewater pipe.
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)
S4.heat exchanger discharge sensor
(optional)
3.6.2 Hot water side
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.
3.6.3 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 to the cold water supply pipe.
Instruction manual SGE 27
3
Installation
is
3.6.4 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.
3.7 Water connections,
Vented
3.7.1 Cold water side
3.7.2 Hot water side
3.7.3 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 (4) in the hot water outlet pipe, for use when servicing.
4. If a circulation pipe is required, continue further 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 to the cold water supply pipe.
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.
28 Instruction manual SGE
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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 manual gas valve.
4. Fit the gas supply pipe to the gas control.
Warning
After fitting, check for leaks.
This section covers the following subjects:
• Requirements for flue gas discharge materials
• Concentric connections
• Parallel connections
3.9.2 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.
Instruction manual SGE 29
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Installation
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Types of appliances
30 Instruction manual SGE
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