A.O. Smith SGE-40, SGE-60 User Manual

SGE

Condensing Gas-Solar Water Heater

SGE - 40/60

0311 166 / 07-2013

Installation, User and Service Manual

Innovation has a name.

your installer

A.O. Smith UK, Unit B8 Amstrong Mall, Southwood Business Park, Farnborough, Hampshire GU14 0NR www.aosmith.co.uk

“A.O. Smith Water Heaters” is a trading name of Advance Services (Sales) Ltd. Reg.

Power

n.a.

not applicable

Pump (solar)

not applicable

L N - - - -

- - L3 N L4 -

- - - - - - 1 2 3 4 5 6 7 8 9

not applicable

Sensor S

not applicable

Sensor S

not applicable

Sensor S

not applicable

Sensor S

not applicable not applicable not applicable not applicable

Power 5V

Sensor S

Flow signal not applicable not applicable

BUS-link

J13

J14

J12

J15

J16

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1

Errata

The amendments below apply to:

the preparation of the electrical connection of the solar heating control (3.12.1 "Preparation"); finishing maintenance (15.6 "Finalizing maintenance"); the electrical diagram of the solar heating control (17.4 "Electrical diagram solar heating system").

These instructions supersede the previous instructions of the solar heating control.

3.12.1

Preparation

Remove the cover (snap-on type) from the terminal block of the solar heating control. This has the following terminals:

15.6 Finalizing maintenance

To finalize the maintenance, carry out the following steps:

1. Fill the water heater (5 "Filling").

2. Start the water heater (9 "Starting the water heater").

3. Check the CO2 value (3.12.3 "CO2 adjustment").

4. Check the switching pressure of the pressure switch. (3.12.4 "Switching pressure measurement")

5. Erase the message SERVICE REQUIRED. The displayed message can be reset in either of two ways.

1. Temporary reset: To postpone the message, press RESET once. The message will reappear on the display 7 days later.

2.Full reset: To fully reset the message, press and hold both RESET and ENTER at the same time for 5 sec.

On completion of the full reset of the message, the message below will appear on the display. This message will NOT be shown after a temporary rest of the message.

17.3 Electrical diagram Electrical diagram

solar heating system

1 = brown, 2 = blue, 3 = yellow / green, 4 = black, 5 = white, 6 = grey / beige, 7 = green, 8 = yellow

TERMINAL BLOCK CONNECTIONS

Earth N Neutral L Live input of the controller L3 Live input for the solar heating system modulating pump L4 Modulating output of the solar heating system modulating pump

COMPONENTS

AA Controller BB Solar heating system pump (modulating) CC Temperature sensor (S1 - solar collector) DD Temperature sensor (S2 - tank) EE Combined Q/T sensor (incl. temperature sensor S4 - solar collector return) FF Communication between the water heater controller and the solar Heating system controller (BUS-link)

K Double-pole isolator

CONTROLLER CONNECTIONS

J12 Connection of combined Q/T sensor (1-2-3-4) J13 Connection of temperature sensor S1 (2-4) J14 Connection of temperature sensor S2 (2-4) J16 Connection of BUS-link communication

F2 Fuse (T 3.15A - 250 V)

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Read this manual carefully

Trademarks

Liability

Warning

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

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 unauthorised use, use other than that stated in this manual, and use other than in accordance with the General Conditions registered at the 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 specific aspects related to the water heater, then please do not hesitate to contact:

A.O.Smith Water Products Company

PO Box 70

5500 AB Veldhoven

The Netherlands

Telephone: 0870-AOSMITH

0870-2676484

General: +31 40 294 25 00

Fax: +31 40 294 25 39

E-mail: info@aosmith.nl

Website: www.aosmith.co.uk

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

Instruction manual SGE 3

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4 Instruction manual SGE

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Contents

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

1.1 About the water heater - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

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

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

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

1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.6 Notation conventions - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 12

2 Working principle of the water heater - - - - - - - - - - - - - 13

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

2.2 General working principle of the water heater - - - - - - - - - - - - - - - 13

2.3 Water heater operating cycle - - - - - - - - - - - - - - - - - - - - - - - 14

2.4 Protection for the water heater - - - - - - - - - - - - - - - - - - - - - - 15

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 16

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 Ambient conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 21

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

3.6 Unvented water connections - - - - - - - - - - - - - - - - - - - - - - - 26

3.7 Vented water connections - - - - - - - - - - - - - - - - - - - - - - - - 27

3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.9 Solar heating system - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.10 Air supply and chimney flue discharge - - - - - - - - - - - - - - - - - - 29

3.11 Electrically connecting the water heater- - - - - - - - - - - - - - - - - - 34

3.12 Electrical connection of the solar heating system - - - - - - - - - - - - - 38

3.13 Check the supply pressure, gas control valve pressure, CO switching pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40

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

4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

5.1 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 50

5.2 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 50

5.3 Filling solar heating system- - - - - - - - - - - - - - - - - - - - - - - - 51

6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

6.1 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 54

6.2 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 54

6.3 Draining solar heating system - - - - - - - - - - - - - - - - - - - - - - 55

value and

Instruction manual SGE 5

Contents

7 The control panel - - - - - - - - - - - - - - - - - - - - - - - - 57

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

7.2 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

7.3 Explanation of icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

7.4 ON/OFF switch on controller - - - - - - - - - - - - - - - - - - - - - - - 57

7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

8 Status of the water heater - - - - - - - - - - - - - - - - - - - 59

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

8.5 Anode warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.6 Q/T Sensor warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.7 Collector temperature warning - - - - - - - - - - - - - - - - - - - - - - - 61

9 Starting the water heater - - - - - - - - - - - - - - - - - - - - 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 Decommissioning the water heater for a short period- - - - - - - - - - - - 65

10.3 Isolating the water heater from the mains - - - - - - - - - - - - - - - - - 65

10.4 Decommissioning the water heater for a long period - - - - - - - - - - - - 65

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

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

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

11.3 Switching to "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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72

11.11 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 water heater history - - - - - - - - - - - - - - - - - - - - 76

12.5 Display the selected water heater - - - - - - - - - - - - - - - - - - - - - 76

12.6 Switching the pump on or off - - - - - - - - - - - - - - - - - - - - - - - 76

12.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 76

12.8 Service mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76

12.9 Setting legionella prevention- - - - - - - - - - - - - - - - - - - - - - - - 77

12.10 Solar heating system configuration - - - - - - - - - - - - - - - - - - - - 78

12.11 Setting the central heating configuration - - - - - - - - - - - - - - - - - - 79

6 Instruction manual SGE

13 Errors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - 82

13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - 85

13.4 Warnings on the display - - - - - - - - - - - - - - - - - - - - - - - - - 94

14 Service interval - - - - - - - - - - - - - - - - - - - - - - - - - 97

14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97

14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - 97

15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 99

15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99

15.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 99

15.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - -100

15.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - -101

15.5 Solar collector maintenance - - - - - - - - - - - - - - - - - - - - - - - 102

15.6 Finalizing maintenance - - - - - - - - - - - - - - - - - - - - - - - - - -102

16 Warranty (certificate) - - - - - - - - - - - - - - - - - - - - - - 103

16.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - -103

16.2 Tank warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -103

16.3 Collector warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

16.4 Conditions for Installation and use - - - - - - - - - - - - - - - - - - - -103

16.5 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104

16.6 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - -104

16.7 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104

16.8 Obligations of A.O.Smith - - - - - - - - - - - - - - - - - - - - - - - - - 104

17 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 105

17.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105

17.2 Menu structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106

17.3 Electrical diagram for the appliance- - - - - - - - - - - - - - - - - - - - 108

17.4 Electrical diagram, solar heating system - - - - - - - - - - - - - - - - -110

17.5 Declaration of conformity - - - - - - - - - - - - - - - - - - - - - - - - - 112

17.6 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 113

Instruction manual SGE 7

Contents

8 Instruction manual SGE

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0063

1 Introduction

1.1 About the water heater

1.2 What to do if you smell gas

This manual describes how to install, service and use the SGE water heater. The SGE water heater 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 water heater. A concentric chimney connector is fitted standard to the water heater, but a parallel system can also be connected.

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

The information in this manual applies to the: SGE 40 and SGE 60.

The water heater 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 water heaters are therefore compliant with the European Directive for Gas water heaters, and and are entitled to bear the CE mark.

Warning

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

Warning

If you smell gas:

No naked flames! No smoking!

1.3 Regulations

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

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.

Gas Safety (installations and Use) Regulations 1998 (as amended). It is law that all gas appliances are installed by competent persons, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest and that of safety, to ensure that this law is complied with.

The installation of the water heater MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, IEE Regulations and the Water Supply (water fittings) Regulations.

The installation should also be in accordance with any relevant requirements of the HSE, local gas region and local authority and the relevant recommendations of the following documents:

Instruction manual SGE 9

Introduction

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British and European Standards

• BS 6891:

Installation of low pressure gas pipework of up to 35 mm (R1¼) in domestic premises (2nd family gas) - Specification. Note: for lager installations see IGE/UP/2 below.

• BS 6798:

Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net.

• BS 6644:

Specification for installation of gas-fired hot water boilers of rated inputs between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family gases).

• BS 6700:

Design, installation, testing and maintenance of services supplying water for domestic use within buildings and their cartilages - Specifications

• BS EN 806-2:

Specification for installations inside buildings conveying water for human consumption. Part 2: Design.

• BS 5546:

Specification for installation of hot water supplies for domestic purposes, using gas-fired appliances of rated input not exceeding 70 kW.

• BS 5440:

Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases).

Part 1: Specification for installation of gas appliances to chimneys and for maintenance of chimneys.

Part 2: Specification for installation and maintenance of ventilation for gas appliances.

1.4 Target groups

Institute of Gas Engineers and Managers (IGEM) Publications

• IGE/UP/1:

Soundness testing and purging of industrial and commercial gas installations.

• IGE/UP/1A:

Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations.

• IGE/UP/2:

Gas installation pipework, boosters and compressors on industrial and commercial premises.

• IGE/UP/10:

Installation of flued gas appliances in industrial and commercial premises.

CIBSE Publications

• Guide G: Public Health Engineering.

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.

10 Instruction manual SGE

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Target group symbols

Symbol Target Group

(End) user

Installation engineer

Service and maintenance engineer

Caution

This water heater is not intended for use by persons with reduced physical, sensory or mental capacities, or who lack the necessary experience or knowledge, unless the person responsible for their safety is supervising them or has explained to them how the water heater should be used.

Caution

This water heater is not intended to be used by children. Always supervise children, and ensure that they do not play with the water heater.

1.5 Maintenance

1.6 Notation conventions

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

Note

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

Note

Regular maintenance extends the service life of the water heater.

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 water heater is not regularly serviced, the warranty will become void.

The following notation is used in this manual:

Note

Important information.

Caution

Ignoring this information can lead to the water heater being damaged.

Warning

Failure to carefully read this information may lead to danger of personal

injury, and serious damage to the water heater.

Instruction manual SGE 11

Introduction

1.7 Overview of this document

Chapter Target groups Description

Working principle of the water heater

This chapter describes the working principle of the water heater.

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Installation

Conversion to a different gas category

Filling

Draining

The control panel

Status of the water heater

Starting the water heater

Shutting down

Main menu

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

Errors This chapter is mainly intended for the installation

Service interval

This chapter describes the installation activities to be carried out before final commissioning.

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

This chapter describes how to fill the water heater.

This chapter describes how to drain the water heater.

This chapter describes the general control of the water heater using the display.

This chapter describes the status (mode or condition) that the water heater may have, and possible actions to take.

This chapter describes how to start the water heater. The general operating cycle of the water heater is also described.

This chapter describes how to decommission the water heater for a brief or long period of time.

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.

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

engineer and the service and maintenance engineer. It describes water heater errors. These errors are reported 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 water heater.

This chapter describes how to determine the optimum service interval (frequency of regular 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 water heater is not regularly serviced, the

warranty will become void.

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

out.

Warranty (certificate)

This chapter states the warranty terms and conditions.

12 Instruction manual SGE

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2 Working principle of

the water heater

2.1 Introduction

2.2 General working

principle of the water heater

This chapter covers the following topics:

• General working principle of the water heater

• Water heater operating cycle

• Protection for the water heater;

• Safety of the installation

• Protection for the solar heating system;

• Safety of the solar heating system

The water heater is fitted with a modulating premix burner system with 1:1 gasto-air ratio regulation. The air required for combustion is delivered by the fan (18). The gas is supplied via the gas control valve (16) and the venturi (30) on the intake side of the fan. The 1:1 gas-to-air ratio always guarantees the most efficient gas/air mixture.

In this water heater, 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 and a gas-fired heat exchanger (11).

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

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 condens trap (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 water heater has an inspection and cleaning opening (12) for maintenance.

;

Instruction manual SGE 13

Legend

Unused numbers are not applicable

1. cover

2. hot water outlet

3. electrical connector block

4. 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 valve

17. burner

18. fan

19. air supply hose

20. hot surface igniter

21. flame probe

22. chimney pipe

23. condens trap

24. insulation layer

29. base

55. heat exchanger (e.g. solar

heating system)

56. temperature sensor S

58. flue gas test nipple

59. pressure-reducing valve

Working principle of the water heater

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Cut-away view of the water heater

2.3 Water heater operating cycle

The water temperature (T 1) at the top of the water heater is used to control when the gas burner is started and stopped. The temperature changes in the water heater are used for switching the solar heating system on and off (using

and S2). T1 is the curve shown in the figure. In addition, temperatures S1 and

are used by the solar heating system controller. Temperature S1 is

measured in the solar collector and S exchanger (55).

The other settings that govern the control behaviour are:

•T

set

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

set

appliance (11.4.1 " MENU"). As soon as T1 falls below T heating the water, but only if the temperature of the heating fluid (S greater than the temperature measured at the appliance (sensor S given (adjustable) amount. When T1 = T heating system stops. There is one exception to this rule, which is when T

solar limit

is set to a higher value than T

Setting the water temperature via the SET POINT

between the inlet and outlet of the heat

, the solar heating system starts

set

= T

solar limit

, heating by the solar

) is

) by a

14 Instruction manual SGE

gis

solar limit

set

Solar diff.

Hys.

min = 45C

Legend

A = Gas burner on B = Gas burner off

• = No heat demand, so water

is 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

• Hysteresis The moment that T1 falls below (T

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 by the solar heating system alone. When T (provided that T value of T

•T

solar limit

solar diff

set

= T

), the solar heating system is switched off. The

solar limit

is adjustable (12.10.4 "Setting the solar difference").

is a certain (adjustable) value grater

), the gas burner is shut off and the water

rises above T

Preset (12.10.3 "Setting the solar limit") water temperature at which heating via the solar heating system is stopped.

Graphical representation of operating cycle

set

Note

can rise above T

. However, this is only possible if T

set

solar limit

is increased

via the service menu.

2.4 Protection for the water heater

2.4.1 Introduction

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

• the Water heater water temperature protection

• the Gas control valve

•the Fan

• the Pressure switch

• the Flame probe

2.4.2 Water heater water temperature protection

The controller (4) controls and monitors the safety of the water heater by means of sensors T

and T2. S2 is also used for protection of the water heater.

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.

Instruction manual SGE 15

protection Description

Against frost:

< 5°C

- T

< 5°C

- T

Against overheating of water:

> 88°C

- T

> 88°C

- T

- S2 > 88°C

For extra safety:

> 93°C

- T

> 93°C

- T

> 93°C

- S

Working principle of the water heater

Temperature protection

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 water heater. 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 < 81°C), the controller resets the water heater.

A lockout error of the water heater controller takes place. The controller must be manually reset before the water heater can resume operation (8.3 " conditions"). The reset may only be performed once T 1 <81°C.

2.4.3 Gas control valve

The controller opens the gas control valve so that gas can be supplied to the burner. As a safety measure, the gas control valve has two valves. Both valves shut off the gas supply.

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 controller (4). The controller takes control if the fan rpm varies too much from the value set.

gis

Error

2.5 Safety of the installation

2.4.5 Pressure switch

The pressure switch only guarantees the supply of air during pre-purging of the water heater. If the pressure difference during pre-purging is sufficient, the pressure switch closes. The table (3.4.2 "General and electrical specifications") shows the trip point for each water heater.

Note

The trip point of the pressure switch is not adjustable.

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 controller uses this probe to detect the presence of a flame, by means of ionisation detection. The controller closes the gas control valve the instant it detects that there is a gas flow but no flame.

Excessive pressure in the tank can damage the enamelled layer (in the water heater) or the tank itself. 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 mains pressure is too high (3.4.2 " electrical specifications"), a pressure-reducing valve must be used. Both components must be fitted in the cold water inlet (3.7 "Vented water connections").

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

General and

16 Instruction manual SGE

gis

2.5.1 Unvented installation

With an unvented installation, an expansion valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being caused to the enamel coating (in the water heater) or to the tank. A non-return valve prevents excessive pressure build-up 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 water heater against excess mains water pressure (3.4.2 " specifications"). These components are installed in the cold water inlet (3.7 "Vented water connections").

2.5.2 Vented installation

With a vented installation, excess pressure is taken up by the open cold water head tank. The level of the cold water head tank determines the maximum working pressure (3.4.2 " water heater must also be fitted with a vent pipe from the hot water pipe, which opens into the cold water head tank.

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

2.5.3 T&P valve

A T&P valve is only mandatory in unvented installations. 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 too high (3.4.2 "General and electrical specifications"), the valve will open. The hot water can now flow out of the tank. Because the water heater 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 water heater is fitted standard with a connection for a T&P valve (3.6.2 " side").

General and electrical

General and electrical specifications") in the tank. The

Hot water

2.6 Protection for the

solar heating system

2.6.1 Drain-back tank

2.6.2 Fluid temperature

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 against freezing of the fluid. The use of the drainback tank also serves to extend the useful life of the fluid.

The existence of a drain-back tank is set (12.10.1 " during the installation. Refer to the solar heating system manual for more details.

The heat exchanger of the solar heating system is 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

Setting the drain-back tank")

Instruction manual SGE 17

2.7 Safety of the solar heating system

2.7.1 Expansion vessel

2.7.2 Expansion valve

Working principle of the water heater

gis

Temperature protection for solar heating system

Protection Description

Maximum temperature:

> 130°C

- S

The solar heating system must be equipped with an expansion vessel. 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 600 kPa (6 bar). The supply pressure to the expansion vessel depends on the static head of the system.

The system is protected from overpressure by an expansion valve (2.7.1 "

The solar heating system is equipped with an expansion valve. The expansion valve monitors the pressure in the solar heating system. Should the pressure become higher than 600 kPa (6 bar), 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 to below 600 kPa (6 bar).

Expansion vessel") as well as the expansion vessel.

The pump of the solar heating system switches off when the temperature of the heating fluid at S1 exceeds the maximum value. The solar heating system enters error mode. The error is also visible on the display of the SGE water heater

Note

Because a closed system is pressurized and is not filled automatically, the system will have to be filled (5 " been activated. A system with a drain-back tank is not pressurized and does not have an expansion valve.

Filling") again when the expansion valve has

18 Instruction manual SGE

3 Installation

Warning

The installation must 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 brigade.

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 final commissioning (9 "

• Packaging

• Ambient conditions

• Technical specifications;

• Installation diagram

• Unvented water connections

• Vented water connections;

• Gas connection

• Air supply and chimney flue discharge

• Solar heating system;

• Electrically connecting the water heater

• Electrical connection of the solar heating system;

• Check the supply pressure, gas control valve pressure, CO

switching pressure.

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

To avoid damaging the water heater, remove the packaging carefully.

We recommend unpacking the water heater at or near its intended location.

Caution

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

Starting the water heater"), namely:

;

value and

3.3 Ambient conditions

The water heater is suitable for either open or room-sealed combustion. If installed as a room-sealed water heater, it is independent of the installation site for the necessary external air supply. In this event, there are no additional ventilation requirements.

If the water heater is to be installed as an open system, it must meet the locally-applicable directives and ventilation regulations for open water heaters.

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

Caution

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

Instruction manual SGE 19

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 ambient 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% RH at +25°C

Ambient temperature functionality: 0 <

3.3.2 Water heater maximum floor load

Allow for the water heater's weight and the maximum floor load; refer to the table (3.4.2 "

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

General and electrical specifications").

T < 60°C

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)").

3.3.4 Working clearances

For access to the water heater, it is recommended that the following clearances are observed (see figure):

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

• BB: all sides of the water heater: 50 cm.

• Top of the water heater: 100 cm

> 1.00 mmol/l:

• German hardness> 5.6° dH

• French hardness > 10.0° fH

• English hardness > 7.0° eH

•CaCO

> 100 mg/l

20 Instruction manual SGE

IMD-0767 R0

IMD-0772 R0

45º

44º

Working clearances

3.4 Technical specifications

The water heater is supplied without accessories. Check the dimensions (3.4 "

Technical specifications"), 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 water heater

Plan and elevation of the water heater

Legend

See the table.

Instruction manual SGE 21

Installation

Size Description Unit SGE 40 SGE 60

A Overall height mm 2055 2055

C Position on pallet mm 490 490

D Appliance diameter mm 705 705

E Depth mm 925 925

F Width mm 850 850

G Diameter of flue gas discharge mm 100 / 150 100 / 150

H Height of chimney flue mm 1995 1995

Hx x position flue gas outlet mm 260 260

Hy x position flue gas outlet mm 370 370

K Height of gas/burner connection mm 1960 1960

M Height of cold water supply mm 185 185

N Height of hot water outlet mm 2055 2055

Ny y position of hot water outlet mm 205 205

P Height of cleaning opening mm 365 365

R Height of drain valve connection mm 180 180

S Height of T&P valve connection mm 1555 1555

T Height of coil inlet mm 630 630

U Height of coil outlet mm 305 305

V Height of recirculation connection mm 1035 1035

W Height of condensation drain mm 765 765

X Height of heat exchanger supply mm 1465 1465

Y Height of heat exchanger discharge mm 855 855

Z Height of electric element connection mm 755 755

1 Cold water supply connection (external) - R 1

2 Hot water outlet (male) - R 11/

3 Gas control valve connection (external) - R 3/

4 Drain valve connection (internal) -

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

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

7 Condensation drainage connection (female) - Ø 40 Ø 40

9 Coil inlet connection (female) - Rp 1 Rp 1

10 Coil outlet connection (female) - Rp 1 Rp 1

11 Electric element connection (female) - Rp 1

12 Heat exchanger supply connector (female) - Rp 1 Rp 1

13 Heat exchanger outlet connector (female) - Rp 1 Rp 1

14 Recirculation connection (female) - Rp 1 Rp 1

/4"

R 11/

R 3/

/4"

Rp 11/

22 Instruction manual SGE

3.4.2 General and electrical specifications

General and electrical specifications

Description Unit SGE 40 SGE 60

Contents litres 370 370

Empty weight kg 245 245

Maximum floor load kg 615 615

Maximum operating pressure (vented) kPa (bar) 800 (8) 800 (8)

Maximum operating pressure, unvented kPa (bar) 550 (5,5) 550 (5,5)

Control thermostat adjustment range °C 40…80 40…80

Control thermostat and default value °C 65 65

Adjustment range for hysteresis downwards °C 2…12 2…12

Default value for hysteresis downwards °C 5 5

Adjustment range for solar differential °C 0…8 0…8

Solar differential default value °C 3 5

Adjustment range for solar limit °C 65…80 65…80

Solar limit default value °C 65 65

Number of (electrical) anodes - 2 2

Observed pressure differential across the pressure switch Pa >

Pressure differential to open the pressure switch Pa <

Heating time ΔT = 45°C at least 15 11

165 > 165

115 < 115

Description Unit SGE 40 SGE 60

Electrical power consumption of the appliance W 60 120

Electrical power consumption of the solar controller W max. 700 max. 700

Supply voltage (-15% +10% V

Mains frequency (+

IP class - IP 20 IP 20

Description Unit Value

Maximum mains pressure of cold water supply (vented) kPa (bar) 800 (8)

Maximum mains pressure of cold water supply (unvented) kPa (bar) 500 (5,5)

Maximum mains pressure of the protected cold supply setup kPa (bar) 500 (5)

T&P overflow pressure kPa (bar) 700 (7)

T&P overflow temperature °C 97

1Hz) Hz 50 50

AC) volts 230 230

Instruction manual SGE 23

Installation

3.4.3 Gas data

Gas data

description Unit SGE 40 SGE 60

2H3P

Gas category 2H: G20 - 20 mbar

Venturi injector diameter mm - -

Nominal load (gross) kW 44,4 63,3

Nominal output kW 42,8 60,4

Supply pressure mbar 20 20

(full load) Vol% 9,0 + 1,0 9,0 + 1,0

Gas consumption

Gas category 3P: G31 - 37/50 mbar

Venturi injector diameter mm 6,00 6,00

Nominal load (gross) kW 43,5 62,0

Nominal output kW 42,8 60,4

Supply pressure mbar 37 / 50 37 / 50

Gas control valve pressure mbar 12,0 +

(full load) Vol% 10,0 + 1,0 10,0 + 1,0

Gas consumption

(*) Based on 1013.25 mbar and 15°C.

(*)

m3/h 4,2 6,0

2,0 12,0 + 2,0

kg/h 3,1 4,4

24 Instruction manual SGE

IMD-0783 R0

VENTED

UNVENTED

GGF

BBS

S1S

665

A45115

161638

3.5 Installation diagram

The figure shows the Installation diagram. This diagram is referred to in the sections describing the actual connection procedure.

Installation diagram

Legend Vented and unvented

Unused numbers are not applicable

1. pressure reducing valve (mandatory)

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)

11. service stop valve (recommended)

12. temperature gauge (recommended)

13. condensation drain (mandatory)

14. draw-off points

15. expansion valve (mandatory)

16. expansion vessel

17. 3-way aeration valve

(mandatory)

(recommended)

18. cold water head tank

19. float switch

23. pressure valve (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. supply heat exchanger G. heat exchanger return H. overflow protection

. collector sensor (mandatory)

. tank sensor (mandatory)

S4. heat exchanger discharge

sensor (optional)

Instruction manual SGE 25

Installation

Caution

The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this.

3.6 Unvented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable 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 the applicable regulations (1.3 "

2. The maximum working pressure of the water heater 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 waste water pipe.

3.6.2 Hot water side

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

Note

Insulating long hot water pipes prevents 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.

Regulations").

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) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation pipe according to the installation diagram (3.5 "

3.6.4 Condensation drain

1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge.

Caution

If the condensation drain is not fitted to the waste water discharge using an

open connection, this can cause faults.

26 Instruction manual SGE

Installation diagram").

3.7 Vented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.7.1 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 between the cold water head tank (18) and the water heater, as required by applicable regulations.

3.7.2 Hot water side

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 servicing.

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

Circulation pipe").

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) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation pipe according to the installation diagram (3.5 "

Installation diagram").

3.7.4 Condensation drain

1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge.

Caution

If the condensation drain is not fitted to the waste water discharge using an

open connection, this can cause faults.

Instruction manual SGE 27

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