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

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SGE

Condensing Gas-Solar Water Heater

SGE - 40/60

0311 166 / 07-2013

Installation, User and Service Manual

Innovation has a name.

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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.

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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.

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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

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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

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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

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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

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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

Page 13

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

Page 15

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

Page 17

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

gis

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

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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

Page 29

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").

Page 30

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

Page 31

Installation

3.8 Gas connection

3.9 Solar heating system

Warning

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

with general and locally applicable 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 water heater.

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 valve.

Warning

After fitting, check for leaks.

Note

Please refer to the installation diagram (3.5 " diagram (17.4 " block (3.12.1 "Preparation") for details of how to connect the solar heating system.

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

exchanger.

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

exchanger.

3. Connect the lead to the solar heating system controller and sensor S

- electrical diagram (17.4 " and

- connections table (3.11.2 "Preparation").

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

- electrical diagram (17.4 "

and

- connections table (3.11.2 "Preparation").

Electrical diagram, solar heating system") and terminal

Electrical diagram, solar heating system")

Installation diagram"), electrical

, see:

Warning

28 Instruction manual SGE

Page 32

3.10 Air supply and chimney flue discharge

3.10.1 Introduction

This section covers the following topics:

• Requirements for flue gas discharge materials

• Concentric connections

• Parallel connections

3.10.2 Requirements for flue gas discharge materials

Warning

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

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

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

The water heaters are approved for installations of type B23, C13, C33, C43, C53 and C63.

This manual discusses installation types C13 and C33 in detail. If the water heater has to function in accordance with B23, C43, C53 or C63, you can obtain more information by contacting A.O. Smith.

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

Instruction manual SGE 29

Page 33

IMD-0789 R0

C43

C13 C53

B23 C33

Installation

Installation types

30 Instruction manual SGE

Page 34

Explanation of types of installation

Installation type Description

B23 Air for combustion is drawn from the boiler room.

C13 Concentric and/or parallel wall flue terminal.

C33 Concentric and / or parallel roof flue terminal

C43 Water heaters on common air supply and flue gas discharge (concentric

C53 Air supply and flue gas discharge terminal types mixed.

C63 Water heaters supplied without flue gas discharge materials and/or terminal.

3.10.3 Concentric connections

and/or parallel) in multi-storey building.

These water heaters must be installed in compliance with local regulations.

Note

Make sure that the chimney flue discharges into an area approved for this

type of installation.

The table shows the requirements for concentric systems.

Warning

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

the water heater.

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

Appliance Diameter Maximum length Maximum

number of 90 bends

SGE 40 100/150 mm 40 m 7

SGE 60 100/150 mm 40 m 7

Caution

Both conditions stated in the table must be fulfilled.

Even if you use less than the stated maximum number of bends, the maximum pipe length still may not be exceeded.

Even if you use less than the stated maximum pipe length, the maximum number of bends still may not be exceeded.

The following example illustrates how to use the table.

Practical example of concentric flue gas discharge

Example

The figure shows a SGE 60 installation. The water heater must be fitted with 10 m of concentric pipe (C13/C33) and four 90 degree bends. The configuration must be checked for compliance with the requirements stated in the table.

Instruction manual SGE 31

Page 35

Installation

Water heater with concentric flue gas discharge material

IMD-0791 R0

According to the table, the maximum permitted length is 40 metres, and 4 x 90 degree bends are permitted. Both requirements are fulfilled.

Specifications

Caution

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

Concentric wall flue terminal specifications C13

Subject Description

Wall flue terminal set:

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

• 1x pipe 500 mm

• 1x bend, 90°

Pipe material Construction Concentric

Pipe diameters Flue gas discharge Ø 100 mm

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

(1)

manufacturer or wholesaler.

Art. No. 0302 504

Construction Concentric

Manufacturer Muelink & Grol

Model M2000 MDV SEC

Flue gas discharge Thick-walled aluminium with lip ring seal

Air supply Thin-walled galvanised sheet steel

Air supply Ø 150 mm

32 Instruction manual SGE

Page 36

Concentric roof flue terminal specifications C33

Subject Description

Roof flue terminal set:

• 1x roof flue terminal (incl. clamping ring)

• 1x pipe 1000 mm

• 1x mounting flange

Pipe material Construction Concentric

Pipe diameters Flue gas discharge Ø 100 mm

No other roof flue terminal may be used. Use this item number to order the roof flue terminal set from the

(1) supplier, manufacturer or wholesalor.

Art. No. 0304 423

Construction Concentric

Manufacturer Muelink & Grol

Model M2000 DDV HR-C

Flue gas discharge Thick-walled aluminium with lip ring seal

Air supply Thin-walled galvanised sheet steel

Air supply Ø 150 mm

3.10.4 Parallel connections

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

Warning

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

the water heater.

Chimney flue requirements for parallel systems

Appliance Diameter1Maximum

total length

SGE 40 100 55 m 4.6 m 1.2 m

SGE 60 100 55 m 4.6 m 1.2 m

SGE 40 130 100 m 2.4 m 1.4 m

SGE 60 130 100 m 2.4 m 1.4 m

1) Parallel systems with diameter of 100 mm. If the maximum total length when using a diameter of 130 mm is insufficient, a diameter of 150 mm must be

used. Any diameter enlargement must be carried out on both air supply and flue gas outlet.

You must use the longest pipe when calculating the pipe length. For example, if the chimney pipe is 4 metres and the air supply pipe is 3 metres, use 4 metres as the length for the calculation. Next, add the L bend to this 4 metres, in both the air supply and flue gas outlet. The following practical example illustrates how to use the table.

L 90o bend

equivalent

for every 90° and 45°

equivalent

45o bend

Practical example of parallel flue gas discharge

Example

The figure shows a SGE 60 installation. This has to be fitted with a 4 m parallel pipe 100 mm in diameter, plus four 90-degree bends. The configuration must be checked for compliance with the requirements stated in the table.

Instruction manual SGE 33

Page 37

Installation

Appliance with parallel flue gas discharge material

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

(4.6 x 4) + 4 = 18.4 + 4 = 22.4 m.

This is less than the maximum length of 55 metres stated in the table. The installation therefore meets the requirements.

3.11 Electrically connecting the water heater

Warning

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

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

3.11.1 Introduction

This section covers the following topics:

• Preparation

• Connecting the mains power

Optionally, it is possible to connect an isolating transformer, a programcontrolled pump (a pump between the storage tank and the water heater) and an extra alarm signal to the water heater. For these options, see:

• Isolating transformer

• Connecting a program-controlled pump

• Connecting an extra ON mode switch

• Connect additional error signal

Connecting the solar heating system is also described:

• Connecting communication cable to solar heating system

Note

The optional components are not included in the electrical power consumption rating stated in the table (3.4.2 " specifications").

General and electrical

34 Instruction manual SGE

Page 38

Legend

A. screws B. cover C. terminal block

3.11.2 Preparation

Caution

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

Caution

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

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

The figure shows a view of the terminal block, and the table explains the relevant connections.

Connector block

Isolating transformer")

In preparation, you must first remove the two covers, and the cover of the electrical section.

1. Undo the screws of the covers.

2. Carefully remove the covers from the water heater.

The electrical section is now visible.

3. Loosen the 2 screws (A) and remove the cover (B) from the electrical

section. The connector block (C) is now visible.

Note

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

the electrical component connections.

Instruction manual SGE 35

Page 39

Installation

Terminal block

Mains

voltage

NL NL

12345678910111213141516 to 2021222324

Isolating transformer Alarm Out Program-

primary secondary

X1X

controlled

pump

External

ON/OFF

X3X4X5X

Bus-link

3.11.3 Connecting the mains power

The water heater is supplied without a power cable and isolator.

Note

In order to receive electrical power, the water heater has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the water heater. The power cable must have cores of at least 3 x 1.0 mm 2 .

Warning

Leave the water heater electrically isolated until you are ready to

commission it.

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

terminals 1 thru 3 of the terminal block as shown in the table (3.11.2 "Preparation").

2. Fit the power cable in the strain relief.

3. Connect the power cable to the isolator.

4. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

3.11.4 Isolating transformer

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

Note

The total power consumed by the appliance goes via the isolating transformer.

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

(Contact the supplier for details of the correct isolating transformer.)

2. Connect the neutral (N), live (L) and earth ( ) of the power cables to

terminals 4 through 9 of the connection block according to the table (3.11.2 "

3. Fit the cables in the strain relief.

4. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

5. Connect the power cable to the isolator.

Preparation").

36 Instruction manual SGE

Page 40

3.11.5 Connecting a program-controlled pump

Note

The maximum power capacity for a pump regulated by the controller

is 100W.

1. Connect neutral (N), live (L) and earth ( ) to terminals 13, 14 and 15 as indicated in the table (3.11.2 "Preparation").

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

3.11.6 Connecting an extra ON mode switch

External ON/OFF is an option for connecting an external ON/OFF switch. In the OFF position, the programmed operating mode is active. In the ON position, the programmed operating mode is overruled, and "ON mode" is active.

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

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

and X4) to terminals 21 and 22 according to the

3.11.7 Connect additional error signal

The appliance has a terminal that is switched when an error is detected. This can be used to signal errors, for example with a bulb. A 230V circuit can be powered directly. Other voltages require a relay prescribed by the manufacturer.

1. Connect the phase cables (X table (3.11.2 "Preparation"). If required, connect earth ( ) to terminal 12.

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

and X2) to points 10 and 11 according to the

3.11.8 Connecting communication cable to solar heating system

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

1. Connect the cables (X table (3.11.2 "

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

Preparation").

and X6) to terminals 23 and 24 as shown in the

Instruction manual SGE 37

Page 41

Installation

3.12 Electrical connection of the solar heating system

3.12.1 Preparation

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

LN- - - L

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

This section covers the following topics:

• Preparation

• Connecting the mains power

• Connecting pump station - modulating pump

• Connecting solar collector

• Connecting tank sensor

• Connecting communication cable

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

• Connecting extra head pump

• Connecting Q/T sensor

See Eratta. has the following terminals:

1M2M3

-------

n.a.

Power 5 V

Sensor S4

1234123412341234

J3 J12 J13 J14

3.12.2 Connecting the mains power

Note

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

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

2. Fit the cables in the strain relief.

3. Connect the power cable to the isolator.

4. Continue (3.12.3 "

3.12.3 Connecting pump station - modulating pump

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

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

2. Connect the fourth lead to terminal 13.

3. Fit the cables in the strain relief.

4. Continue (3.12.4 "

n.a.

Flow signal

Connecting pump station - modulating pump").

Connecting solar collector").

n.a.

Sensor S1

n.a.

Semsor S1

n.a.

Sensor S2

38 Instruction manual SGE

Page 42

3.12.4 Connecting solar collector

Note

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

installation manual.

Connect the sensor (S

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

2. Fit the cables in the strain relief.

3. Continue (3.12.5 "

) to the water heater as follows:

Connecting tank sensor").

3.12.5 Connecting tank sensor

Note

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

1. Connect the lead for sensor S2 with the blade connectors to the sensor.

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

3. Fit the cables in the strain relief.

4. Continue (3.12.6 "

Connecting communication cable").

3.12.6 Connecting communication cable

Note

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

1. Connect the double connector to J16.

2. Fit the cable in the strain relief.

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

the appliance. See

- connecting communication cable to the appliance (3.12.6 " communication cable").

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

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

4. Connect the optional head pump (3.12.7 "Connecting extra head pump") or Q/T sensor (3.12.8 "Connecting Q/T sensor").

5. If you do not need to make any more connections:

- Fit the cover over the controller.

Connecting

Electrical diagram for the

Instruction manual SGE 39

Page 43

Installation

3.12.7 Connecting extra head pump

Note

This pump is essential if a greater head is required. When the system has such a high resistance (>66 kPa) that the pump in the pump station is insufficient, you can connect a second (ON/OFF) pump to the solar heating system controller.

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

2. Fit the cable in the strain relief.

3. If you need to connect an extra head pump, continue (3.12.8 "

Q/T sensor"); otherwise:

- Fit the covers over the controller.

3.12.8 Connecting Q/T sensor

Note

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

Connecting

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

value

and switching pressure

3.13.1 Procedure for checking the supply pressure

1. Connect the 5V to J12-1.

2. Connect sensor S4 to J12-2.

3. Connect earth to J12-3.

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

5. Fit the cable in the strain relief.

6. If you have no more connections to make:

- Fit the covers over the controller.

Note

Before starting to use the appliance and/or checking the supply pressure and/or the CO fill (5 "Filling") the appliance.

Caution

When starting up for the first time or after conversion, you must always check the supply pressure, the gas control valve pressure, the CO the switching pressure.

Note

A CO

supply pressure, gas control valve pressure, CO2 value and switching pressure.

To check the supply pressure, proceed as follows:

1. Isolate (10.3 "

the power supply.

2. Carefully remove the covers from the appliance.

3. The electrical section is now visible.

4. There is a test nipple before the gas control valve (for natural gas

appliances) or before the pressure-reducing valve (for LPG appliances) so that the supply pressure can be measured.

value and/or the switching pressure, you should first

value and

meter and a pressure gauge must be available for checking the

Isolating the water heater from the mains") the appliance from

40 Instruction manual SGE

Page 44

IMD-1095a R0

IMD-1096a R0

This test nipple has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it as it can be difficult to retighten.

5. Open the gas supply and vent the gas supply line via the test nipple.

6. Connect a pressure gauge to the test nipple as soon as gas starts to flow from it.

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

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

The display will now show

will then go to the main menu.

INTERNAL CHECK

for about 10 seconds, and

INTERNAL CHECK

SERVICE MENU SERVICE INTERVAL »SERVICE OPERATION È ANTI LEGIONELLA

9. Select

10. Confirm with .

SERVICE OPERATION »FULL LOAD PARTIAL LOAD

11. You must wait about 1 minute after the display shows the text

SERVICE OPERATION, FULL LOAD

The display shown here will appear.

The appliance is now in "Full load mode" and will ignite.

before reading the dynamic pressures (the fan needs this time to get up to full speed, so that you can get a reliable reading).

from the service menu.

RUNNING

Instruction manual SGE 41

Page 45

Installation

12. Use the pressure gauge to read the supply pressure and compare it against the value from the gas table (3.4.3 "Gas data").

Note

Consult the mains gas supply company if the supply pressure is not correct. You cannot yet start using the appliance. You must now take the appliance out of service (10.3 "

Note

After conversion, you must check that the gas control valve is gastight.

13. Shut off the gas supply.

14. Disconnect the pressure gauge and retighten the sealing screw in the test

nipple.

15. If there is nothing else you need to check or adjust, you can put the covers

back on the appliance.

3.13.2 Procedure for checking the gas control valve pressure

The procedure for checking the gas control valve pressure is only applicable to appliances that have a pressure-reducing valve. If the appliance does not have a reducing valve, continue from adjusting the CO adjustment").

To check the gas control valve pressure, proceed as follows:

1. Isolate (10.3 "

the power supply.

2. Carefully remove the covers from the appliance.

3. The electrical section is now visible.

4. The gas control valve has a test nipple that can be used for measuring the

gas control valve pressure. This test nipple has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it as it can be difficult to retighten.

5. Open the gas supply.

6. Connect a pressure gauge to the test nipple.

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

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

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

Isolating the water heater from the mains").

value (3.13.3 "CO2

Isolating the water heater from the mains") the appliance from

INTERNAL CHECK

SERVICE MENU SERVICE INTERVAL »SERVICE OPERATION È ANTI LEGIONELLA

9. Select

42 Instruction manual SGE

SERVICE OPERATION, FULL LOAD

from the service menu.

Page 46

IMD-1096b R0

10. Confirm with .

The display shown here will appear.

SERVICE OPERATION FULL LOAD »PARTIAL LOAD

The appliance is now in "PARTIAL LOAD" mode and will ignite.

11. You must wait about 1 minute after the display shows the text before reading the dynamic pressures (the fan needs this time to get up to full speed, so that a reliable reading can be obtained).

12. Use the pressure gauge to read the pressure and compare it against the value from the gas table (3.4.3 "

13. If necessary, adjust the gas control valve pressure using the reducing valve's adjuster screw (2) until the value is within the range listed in the table

Gas control valve pressure adjustment

Gas data").

RUNNING

3.13.3 CO2 adjustment

To check the CO2 value under full load and partial load and to adjust it if necessary, proceed as follows:

1. Isolate (10.3 " the power supply.

2. Carefully remove the covers from the appliance.

3. The electrical section is now visible.

4. Place the CO gas outlet pipe.

5. Open the gas supply and vent the gas supply line.

6. Use the main switch to apply mains voltage to the appliance.

7. Start (9 "

8. Go to the :

9. Generate a heat demand by draining the appliance until it is cold or by raising the value for

Isolating the water heater from the mains") the appliance from

meter's measurement probe in the test nipple (58) of the flue

Starting the water heater") the appliance.

SERVICE OPERATION

Tset

in the

menu.

SERVICE

menu. Use for this.

Instruction manual SGE 43

Page 47

IMD-1095b R0

Installation

Full-load measurement

10. From the service menu, select:

SERVICE OPERATION

- Confirm with .

The appliance is now in "FULL LOAD mode" and will ignite.

SERVICE Ê Ê FULL LOAD 65ÉC Tset 70ÉC RUNNING

FULL LOAD

11. The appliance is now running at meter and wait until this measured value has remained stable for some time. This may take several minutes.

12. Then compare the measured CO table (3.4.3 "

Caution

The CO

in the table (3.4.3 "Gas data").

13. If necessary, adjust the CO within the range listed in the table of CO2 values. Use the Allen key supplied for this. The key can be found in the plastic bag that is attached to the appliance.

adjustment (full load)

Gas data").

value at ful l load must be within ±1.0 vol% o f th e CO2 value stated

FULL LOAD

value against the value from the

value using the adjuster screw until the value is

. Read the value from the CO2

Note

Turning to the left (anticlockwise) means more gas (higher CO2 level) and

turning to the right (clockwise) means less gas (lower CO

Note

After conversion, you must check that the gas control valve is gastight.

14. If you have increased

15. Continue with the CO

Tset

, set it back to the original value using .

measurement under partial load.

level).

44 Instruction manual SGE

Page 48

IMD-1095c R0

Partial load measurement

16. From the service menu, select:

SERVICE OPERATION

- Confirm with .

The appliance is now in "PARTIAL LOAD" mode and will ignite.

SERVICE Ê Ê PARTIAL LOAD 65ÉC Tset 70ÉC RUNNING

PARTIAL LOAD

17. The appliance is now running at meter and wait until this measured value has remained stable for some

time. This may take several minutes.

18. Compare the CO

load.

Caution

The CO

measured or adjusted under full load.

19. If necessary, adjust the CO

within 0.3 vol% of the CO2 value under full load. Then compare the measured CO

CO2 adjustment (partial load)

value at partial load must be within ±0.3 vol% of the CO2 value

value measured against the value measured under full

value against the value from the table (3.4.3 "Gas data").

PARTIAL LOAD

value using the adjuster screw until the value is

. Read the value from the

Note

Turning to the left (anticlockwise) means more less (lower CO2 level) and

turning to the right (clockwise) means more gas (higher CO2 level).

Note

After conversion, you must check that the gas control valve is gastight.

20. Remove the CO

flue gas outlet pipe.

21. Put the cap back on the measurement nipple of the flue gas outlet pipe.

22. Shut off the gas supply.

23. Replace the covers.

measurement probe from the measurement nipple of the

Instruction manual SGE 45

Page 49

Installation

3.13.4 Switching pressure measurement

To measure the switching pressure, proceed as follows:

1. Isolate (10.3 " the power supply.

2. Carefully remove the covers from the appliance.

3. The electrical section is now visible.

4. Remove the black caps from the measurement point of the pressure switch.

5. Connect the + of the pressure gauge to the H of the measurement point of the pressure switch.

6. Connect the - of the pressure gauge to the L of the measurement point of the pressure switch.

7. Zero the pressure gauge.

8. Start (9 "

9. The appliance will now run the heating cycle (9.3 " cycle").

10. Read the pressure from the meter at the moment when the appliance switches from appliance's display will show:

Isolating the water heater from the mains") the appliance from

Starting the water heater") the appliance.

PRE PURGE

PRESSURE SWITCH

The appliance's heating

. At this point, the

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRESSURE SWITCH

11. Check whether the measured value matches the value from the table (3.4.3 "

Note

If the message

must be resolved first by a qualified service engineer.

12. Shut off the gas supply.

13. Disconnect the pressure gauge.

14. Put the two black caps back on the pressure switch.

15. Replace the covers.

Gas data").

PRESSURE SWITCH

does not appear, there is a fault. This

46 Instruction manual SGE

Page 50

4 Conversion to a

different gas category

4.1 Introduction

Caution

The conversion may only by carried out by a competent person.

If the appliance has to operate on a different family of gases (liquid petroleum gas or natural gas) or gas category other than that for which the appliance has been configured at the factory, then the appliance will have be adapted using a special conversion kit. You can order the conversion kit you need from the supplier of your appliance. The conversion kit contains all the parts needed to do the conversion. A description of how to do the conversion is also delivered with the kit.

The following conversions are possible:

1. Conversion from natural gas to LPG.

2. Conversion from LPG to natural gas.

3. Conversion from natural gas to natural gas or LPG to LPG, if applicable.

Caution

After the conversion, you must check that the appliance is gastight and check the supply pressure, gas control valve pressure, the CO switching pressure.

value and the

Instruction manual SGE 47

Page 51

Conversion to a different gas category

48 Instruction manual SGE

Page 52

IMD-0783 R0

VENTED

UNVENTED

GGF

BBS

S1S

665

A45115

161638

gis

5 Filling

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 (mandatory)

17. 3-way aeration valve (recommended)

19. float switch

23. pressure valve (mandatory)

37. combined Q/T sensor (optional)

18. cold water head tank

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 S S

. collector sensor (mandatory)

. tank sensor (mandatory)

S4. heat exchanger discharge

sensor (optional)

Instruction manual SGE 49

Page 53

Filling

gis

Caution

5.1 Filling unvented installations

Caution

To fill the water heater, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves

(4) for the circulation pump (6).

2. Close the drain valve (9).

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

4. Open the valve of the inlet combination (2) so that cold water flows into the

water heater.

5. Completely fill the water heater. When a full water jet flows from the nearest

draw-off point, the water heater is full.

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

7. The water heater is now under water supply pressure. There should now be

no water coming out of the inlet combination expansion valve or out of the T&P valve (3). If there is, the cause might be:

- The water supply pressure is greater than the specified 8 bar. Rectify this by fitting a pressure reducing valve (1).

- The expansion valve in the protected cold supply set-up is defective or incorrectly fitted.

- The T&P valve is defective, or incorrectly installed.

5.2 Filling vented installations

50 Instruction manual SGE

To fill the water heater, proceed as follows:

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

2. Close the drain valve (9).

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

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

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

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

7. The water heater is now under water supply pressure. There should be no water coming out of the T&P valve (3). If this does happen, the T&P valve might be defective or incorrectly fitted.

Page 54

gis

5.3 Filling solar heating system

Note

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

Warning

Before filling the solar heating system to replenish the heating fluid, make certain that:

• The appliance is switched off (10.2 " a short period").

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

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

Note

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

Decommissioning the water heater for

Warning

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

through with water before filling.

5.3.1 Flushing with water

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

2. Connect a drain hose to the drain point.

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

4. Open the water supply tap.

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

of the drain hose.

6. Then shut off the water supply.

7. Drain all remaining water from the system.

8. Now you can fill the system with glycol.

Instruction manual SGE 51

Page 55

Filling

5.3.2 Filling met glycol

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

2. Connect the pump to the jerry can.

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

4. Open the valve of the inlet combination.

5. Plug the glycol pump into a mains socket.

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

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

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

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

10. User the service menu (12.10.2 " pump on.

Note

To ensure that the solar heating system is properly filled, the pump in the

solar heating system can be switched on for 2 minutes using the service menu.

gis

Switching on the solar pump") to switch the

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

Note

If an installation does not have a drain-back system, then it should be filled up to pressure (1.5 bar). If an installation does have a drain-back system, then it should not be pressurised. For the installation, filling and drainage of a drain-back system, please refer to the installation manual and users manual of the solar collectors.

12. Switch off the glycol pump.

13. Close the valve of the inlet combination and disconnect the glycol pump

(including the hoses).

Note

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

52 Instruction manual SGE

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IMD-0783 R0

VENTED

UNVENTED

GGF

BBS

S1S

665

A45115

161638

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6 Draining

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 (mandatory)

17. 3-way aeration valve (recommended)

19. float switch

23. pressure valve (mandatory)

37. combined Q/T sensor (optional)

18. cold water head tank

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 S S

. collector sensor (mandatory)

. tank sensor (mandatory)

S4. heat exchanger discharge

sensor (optional)

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Caution

6.1 Draining unvented installations

Some service activities require the water heater to be drained. The procedure is as follows:

1. Activate the

MENU »OFF ^ ON È WEEK PROGRAM

2. Position the cursor in front of

3. Confirm

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

Caution

Failure to wait until the fan stops can cause damage to the water heater.

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

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

7. Shut off the gas supply (10).

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

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

10. Open the drain valve (9).

OFF

with .

OFF

6.2 Draining vented installations

Some service activities require the water heater to be drained. The procedure is as follows:

1. Activate the

2. Position the cursor in front of

3. Confirm

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

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

heater.

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

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

7. Shut off the gas supply (10).

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

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

10. Open the drain valve (9).

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

OFF

with .

OFF

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6.3 Draining solar heating system

Note

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

1. Activate the

MENU »OFF ^ ON È WEEK PROGRAM

2. Position the cursor in front of

3. Confirm

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

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

heater.

Warning

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

should therefore wait until the water heater has cooled down sufficiently.

5. Switch off the solar heating system.

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

7. Insert the hose into the glycol jerry can.

8. Open the valve of the lowest drain point.

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

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

11. Insert the hose in a new jerry can.

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

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

14. Remove the hose.

OFF

with .

OFF

Note

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

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7 The control panel

7.1 Introduction

This chapter covers the following topics:

• Control;

• Explanation of icons

• ON/OFF switch on controller

• Navigation buttons;

• PC connection

;

7.2 Control

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

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

• 6 buttons for controlling the water heater (below the display);

• 6 graphical symbols (above the display);

• a connector for a service PC;

• an ON/OFF switch.

The buttons are divided into three groups:

• Navigation buttons:

- Buttons for UP , and DOWN ;

-Enter: ;

- Reset button:

• The main menu (11 "

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

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

»START OPERATION ^ CHANGE SETPOINT È Tset=70ÉC

Main menu"): ;

Service program"): .

7.3 Explanation of icons

The table explains the meanings of the icons.

Icons and their meaning

Name Explanation

Heat demand Heat demand

Purge Pre- and post-purge

Pressure switch Pressure switch is

Glow (Pre)glow

Gas control valve Gas control valve

Flame detection Water heater

Solar heating system

detected

using fan

closed

open/ignition

operational

Solar energy is heating the water

7.4 ON/OFF switch on controller

The ON/OFF switch of the controller turns the water heater ON and OFF. Note that in the OFF position the water heater remains electrically live, in order for the continuous pump to stay running.

INTERNAL CHECK

After switching on, the text appears on the display for about 10 seconds. The main menu (11 " selection is made in the main menu, the water heater automatically switches to the OFF mode (8.2 "

Note

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

Main menu") then appears. If no

Operating modes").

INTERNAL CHECK

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7.5 Navigation buttons

The use of these buttons is explained with the help of the figure showing the main menu (11 "Main menu").

The navigation buttons are:

• Buttons for UP , and DOWN ;

• Enter: ;

• Reset button: .

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

MENU OFF ^»ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

and È indicate that you can scroll up

The control panel

gis

The cursor display as shown in the figure, you can scroll through the main menu.

The main menu comprises:

WEEK PROGRAM, EXTRA PERIOD SETTINGS

options

The selected option is confirmed using .

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

Note

The button is also used to reset the water

heater following an error.

7.6 PC connection

The PC connection is exclusively intended to enable technicians from A.O.Smith to read the status and history of the water heater. These details can be important for troubleshooting and/or resolving complaints.

points to the option to be activated. In the

OFF, ON

. You have to scroll down further to see the

EXTRA PERIOD

and

SETTINGS

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8 Status of the water

heater

8.1 Introduction

This chapter covers the following topics:

• Operating modes;

• Error conditions

• Service condition;

• Anode warning

• Q/T Sensor warning

• Collector temperature warning

;

8.2 Operating modes

When running, the water heater has four basic operating modes, namely:

•

OFF

•

EXTRA

•

PROG

8.2.1

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

• line one: the text

• line two: the time, the day and T

• lines three and four: the text

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

OFF

;

.(9.3"The

appliance's heating cycle")

FROST PROTECTION ACTIVATED

8.2.2

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

• line one: the text

• line two: the time, the day and T

• line three: the programmed water temperature

• line four: is empty when the water heater is idle, or

ON 13:45 Thursday 67ÉC

8.2.3

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

• line one: the text

• line two: the time, the day and T

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

• line four: the text

;

.(9.3"The

appliance's heating cycle")

;

set

depending on the operating cycle (9.3 "

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

HEAT DEMAND

EXTRA

appliance's heating cycle")

temperature setting;

Tset 75ÉC

OFF

EXTRA

PERIOD ACTIVATED

The

PROG

mode is

;

;(9.3"The

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

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Status of the water heater

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8.2.4

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

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

1. The current time falls within a set time period

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

2. The current time falls outside a set time period

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

operating modes are described in the main menu (11 "Main menu") chapter.

PROG

of the week program.

The figure shows the display with the following information:

PROG

;

of the active

set

;(9.3"The

- line one: the text

- line two: the time, the day and T1;(9.3"The appliance's heating cycle")

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

- line four: is empty, or depending on the operating cycle (9.3 "The appliance's heating cycle") , displays a text such as

HEAT DEMAND

of the week program.

The figure shows the display with the following information:

- line one: the text

- line two: the time, the day and T appliance's heating cycle")

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

- line four: displays the text

PERIOD ACTIVATED

Note

Setting and if necessary programming of the basic

8.3 Error conditions

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

• line one: error code comprising a letter and two digits, followed by the error description;

• lines two to four: alternately, a brief explanation of the error, and a brief action to resolve the error.

S04: SENSOR ERROR

CHECK

SENSOR OR DUMMY

Caution

The displayed action to resolve the error may only

be performed by a service and maintenance engineer.

There are various types of errors:

• LOCK OUT ERRORS

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

• BLOCKING ERRORS

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

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

If, as end-user, you find the water heater in an error condition, you may attempt to re-start the water heater by pressing the button once.

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

8.4 Service condition

The figure shows the message

!!! WARNING !!!

MAX. BURNING HOURS:

SERVICE REQUIRED

water heater needs a service and maintenance inspection. In this case, contact your service and maintenance engineer.

Note

The message

the number of expired burning hours and the preset service interval. If the service interval has been incorrectly selected, contact the service and maintenance engineer for instructions on how to rectify this. Information on the frequency of maintenance is provided elsewhere in the manual (14 "Service interval").

. If this message appears, the

SERVICE REQUIRED

is based on

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8.5 Anode warning

This message appears when the anode protection is no longer active. If the message appears, you must contact your service and maintenance engineer.

!!! WARNING !!!

POWER ANODE MALFUNCTION

Note

The water heater continues to function when this

message appears.

8.6 Q/T Sensor warning

This message appears if the Q/T sensor has not been connected (properly) but has been selected in the service programme (12.10.5 "Setting the Q/T sensor"). If the message appears, you must contact your service and maintenance engineer.

!!! WARNING !!!

Q/T SENSOR NOT

CORRECTLY CONNECTED

8.7 Collector temperature warning

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

!!! WARNING !!!

TEMPERATURE

COLLECTOR

TOO HIGH

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9 Starting the water

heater

9.1 Introduction

This chapter covers the following topics:

• Starting the appliance.

• The appliance's heating cycle

Note

The first time the water heater is started, you must enter (12.10 " settings of the solar heating system.

Solar heating system configuration") the

9.2 Starting the appliance

Start the water heater as follows:

1. Fill the water heater (5 "

2. Open (3.5 "

valve.

3. Switch on the power to the water heater using the

isolator between the water heater and the power supply.

4. Switch the controller ON by setting the ON/OFF

switch to positionI.

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

Installation diagram") the manual gas

Filling").

INTERNAL CHECK

for

INTERNAL CHECK

MENU »OFF ^ ON È WEEK PROGRAM

5. Press once on the blue arrow ( ) to position the cursor beside ON, then press . The display shown in the figure will appear.

»START OPERATION ^CHANGE SETPOINT È Tset=65ÉC

6. Confirm the selection

The appliance is now in "ON mode". If there is a heat demand, the appliance will run through the heating cycle (9.3 " cycle").

If the heating cycle is not run, there is no heat demand; if this is the case, Tset will probably need to be set (11.4 "Setting the water temperature").

9.3 The appliance's heating cycle

The appliance's heating cycle is activated when the measured water temperature (T1) falls below the threshold value (T on the currently selected appliance operating mode. For example, if the appliance is in "OFF" mode (frost protection), then this value is 5°C. If the appliance is in "ON mode", this threshold value is adjustable, for example to 65°C.

The heating cycle runs successively through the following states:

1. HEAT DEMAND;

2. PRE-PURGE;

3. PRESSURE SWITCH;

4. PRE-GLOW;

5. IGNITION;

6. RUNNING;

7. POST-PURGE.

The entire cycle is explained in the following example, which assumes the water heater is in operating mode

START OPERATION

The appliance's heating

). This threshold value depends

set

with

Note

The same operating cycle applies to the other

operating modes.

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Starting the water heater

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When the water heater starts, it will run through the following steps:

1. The water temperature drops below the set

temperature of (for example) detects a heat demand and starts the operating cycle.

- The icon is activated.

- The message

ON Ê 13:45 Thursday 63ÉC

HEAT DEMAND

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

- The icon is activated.

- The message

ON Ê Ê 13:45 Thursday 63ÉC

PRE PURGE

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

- The icon is activated.

- The message

appears.

HEAT DEMAND

Tset 65ÉC

PRE PURGE

Tset 65ÉC

PRESSURE SWITCH

°C. The controller

appears.

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

- The icon is activated.

- The message

ON Ê Ê Ê 13:45 Thursday 63ÉC

IGNITION

6. After ignition, the flame is detected and the appliance will be running. This means that actual heating has started:

- The icon is dimmed.

- The icon is activated.

- The message

ON Ê Ê Ê 13:45 Thursday 63ÉC

RUNNING

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

- The icons , and are dimmed.

- The icon is activated.

- The message

IGNITION

Tset 65ÉC

RUNNING

Tset 65ÉC

POST PURGE

appears.

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRESSURE SWITCH

4. This is then followed by the (pre-)glow of the hot surface igniter.

- The icons and are dimmed

- The icon is activated.

ON Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

GLOW PLUG

ON Ê Ê 13:45:00 Thursday 65ÉC

Tset 65ÉC

POST PURGE

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

- The icons and are dimmed.

- The message

ON 14:05 Thursday 65ÉC

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

POST PURGE

vanishes.

64 Instruction manual SGE

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10 Shutting down

10.1 Introduction

This chapter describes:

• Decommissioning the water heater for a short period.

• Isolating the water heater from the mains

• Decommissioning the water heater for a long period.

;

10.2 Decommissioning the water heater for

a short period

To decommission the water heater for a short period, you must activate the frost protection.

The frost protection will prevent water from freezing in the water heater.

Activate the frost protection as follows:

1. Press button to select the main menu.

OFF

2. Using and , place the cursor beside

Confirm with .

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

The frost protection cuts in when the water temperature drops below 5°C. The text then appear on line one of the display. The water heater will heat the water to 20°C (T dropping back to mode

Note

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

Caution

The anode protection remains active when the

OFF mode is selected.

Note

If the water heater is not used for longer than two months and the water is not drained, air bubbles may form in the water heater. This can lead to air in the water pipes.

OFF

FROST

) before

set

will

10.3 Isolating the water heater from the mains

The water heater may only be isolated from mains power in the correct way. The correct procedure is as follows:

1. Activate the

2. Position the cursor in front of

3. Confirm

MENU »OFF ^ ON È WEEK PROGRAM

Caution Failure to wait until the fan stops can cause

damage to the water heater.

4. Wait until the fan has stopped. The icon is then

dimmed.

5. Switch the water heater OFF (position 0) using

the ON/OFF switch on the control panel.

6. Isolate the water heater from the power supply by

setting the isolator between the water heater and the mains power supply to position 0.

Note

Setting the main switch between the water heater and the electricity mains to 0 will switch off the power supply to the potentiostat; there is then no longer any anode protection.

OFF

with .

OFF

10.4 Decommissioning the water heater for

a long period

Drain the water heater if you are decommissioning it for a long period. Proceed as follows:

1. Isolate the water heater from the power

supply (10.3 "

mains").

2. Shut off the gas supply.

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

4. Close the supply valve of the protected cold supply

set-up.

5. Open the drain valve

6. Bleed the water heater (or installation) so that it

drains completely.

Isolating the water heater from the

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11 Main menu

11.1 Introduction

The

is reached by pressing the button on the

controller.

»OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

The main menu comprises:

OFF

•

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

Select this option if you wish to shut the water heater down (10 " period, but do not wish to drain it. In this mode, the frost protection is active. This prevents water from freezing in the water heater.

In this mode, the water heater continually responds to the hot water demand (11.3 "

WEEK PROGRAM

Select this option to allow the water heater to respond to demand only during pre-programmed periods (11.5 " periods, only frost protection is active.

EXTRA PERIOD

Select this option to overrule mode (i.e. Week program) so that a single temporary period (11.10 " demand will be fulfilled.

SETTINGS

Select this option to set (11.11 " language and the time. You can also use this option to display the regulation interval (temperature), and the ignition and working speeds of the fan.

Note

If you fail to make any selection with the main

Shutting down") for a brief

Switching to "ON mode"").

Week program"). Outside those

OFF

mode or

Extra period") of heat

Settings") the

PROG

11.2 Notation convention for menu-related instructions

The

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

SETTINGS

example, So, for example, to select menu manual employs the following convention:

• :

Confirm with .

This means:

1. : Activate the main menu with .

SETTINGS

SETTINGS LANGUAGE

LANGUAGE

4. Confirm with . After pressing ,

you will have activated sub-menu

is itself divided into sub-menus. For

LANGUAGE

SETTINGS

is a sub-menu of

LANGUAGE

: Using button and/or go to and confirm with .

: Using button and/or go to

is one of the

SETTINGS

LANGUAGE

, this

11.3 Switching to "ON mode"

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

1. :

Confirm with .

Note

Also refer to the chapter on starting the water

heater (9 "Starting the water heater").

START OPERATION

11.4 Setting the water temperature

11.4.1 Setting the water temperature via

the SET POINT MENU

Set the water temperature via:

1. :

Confirm with .

START OPERATION ^»CHANGE SETPOINT È Tset=65ÉC

CHANGE SETPOINT

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Main menu

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2. Use:

• to increase the value;

• to decrease the value.

• Confirm with .After confirming, the water heater enters "ONmode".

SETPOINT

» 65ÉC

11.4.2 Setting water temperature during

ON mode

The water temperature can also be directly adjusted when the water heater is in "ONmode". Simply use:

• to increase the value;

• to decrease the value.

• Confirm with .

ON 13:45 Thursday 65ÉC

Tset»65ÉC

11.5 Week program

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

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

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

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

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

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

The following topics are covered here:

• Starting and stopping the week program

• Changing the appliance's standard week program

• Adding times to a week program

• Deleting times from a week program

PROGRAM ACTIVATED

PROG

on the

11.6 Starting and stopping the week program

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

1. :

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

WEEK PROGRAM

Confirm with .

START OPERATION

11.7 Changing the appliance's standard week program

Note

First fill-in the desired week program on the

supplied week program card.

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

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

minutes:

• switch-off time: hours and minutes;

• the water temperature setting;

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

Note

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

Call up the menu for the week program as follows:

•:

WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

PROGRAM OVERVIEW

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The display shows the menu for the week program, see the figure below. With the default setting, the program switches on and off every day at 00:00 and 23:59 respectively, the water temperature is 65ºC and

the pump is switched on (

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

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

INSERT DELETE

START OPERATION

Example

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

11.7.1 Week program: setting the switchon time

1. Bring the cursor to SU

Confirm with .

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

The day indicated by

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

this is

Confirm with .

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

(Sunday).

blinks.

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

08.

Confirm with .

The cursor moves to the minute digits, which will blink.

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

Note

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

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

this is 15.

Confirm with .

The cursor moves to the switch-off hour digits,

which will blink.

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

11.7.2 Week program: setting the switch-

off time

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

Confirm with .

The cursor moves to the minute digits, which will

blink.

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

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

this is

Confirm with .

The cursor moves to the desired water

temperature.

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

The cursor moves to the hour digits, which will blink.

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11.7.3 Week program: setting the water temperature

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

example this is 75°C.

Confirm with .

The cursor moves to

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

PUMP ON

11.7.4 Week program: setting the programcontrolled pump

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

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

Confirm with .

The cursor moves to

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

2. Confirm with .

The display shown in the figure will appear.

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

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

3. If you wish, you can use to scroll to another day, and change more switch-on (11.7.1 " program: setting the switch-on time") and switchoff (11.7.2 " time") times .

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

Scroll with to Confirm with .

Week program: setting the switch-off

START OPERATION

SAVE

PUMP ON

. The pump

Week

11.8 Adding times to a week program

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

1. :

2. Scroll to

The submenu for adding a period will appear.

Example

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

WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

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

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

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

OFF SA 23:59

INSERT DELETE START OPERATION

Confirm with .

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

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

OFF MO 23:59

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

OFF SA 23:59

INSERT DELETE START OPERATION

INSERT

switch-on and switch-off

PROGRAM OVERVIEW

C and the pump will run

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3. Proceed as follows:

a. Set the switch-on time (11.7.1 "

setting the switch-on time").

b. Set the switch-off time (11.7.2 "

setting the switch-off time").

c. Set the water temperature (11.7.3 "

program: setting the water temperature").

d. Set the program-controlled

pump (11.7.4 " program-controlled pump").

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

START OPERATION

Week program: setting the

and confirm with .

Week program:

Week

11.9 Deleting times from a week program

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

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

OFF SU 22:00

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

OFF SA 23:59 INSERT

DELETE

START OPERATION

To delete a period, proceed as follows:

1. :

2. Scroll with to

WEEK PROGRAM

Confirm with .

OFF ^»ON È WEEK PROGRAM

Confirm with .

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

PROGRAM OVERVIEW

3. Scroll with to

Confirm with .

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

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

OFF SU 22:00

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

OFF SA 23:59

INSERT DELETE

START OPERATION

4. Scroll with to the day to be deleted. For example, SU (Sunday) in the second period. See the figure.

Confirm with .

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

OFF MO 23:59

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

OFF SA 23:59

INSERT DELETE START OPERATION

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

Confirm with . (or use to cancel)

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

DELETE

DELETE BLOCK?

. See the figure.

The display shows the menu for the week program.

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

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

OFF MO 23:59

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

OFF SA 23:59

INSERT DELETE

START OPERATION

6. Scroll with to

Confirm with .

The week program is active.

START OPERATION

11.10 Extra period

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

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

EXTRA

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

During the extra period (11.10.1 " extra period"), if the water temperature becomes too low, the water heater will run through the operating cycle (9.3 " return to the extra period.

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

The appliance's heating cycle"), then

Programming an

11.10.1 Programming an extra period

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

2. :

EXTRA PERIOD

Confirm with .

ON ^ WEEK PROGRAM È»EXTRA PERIOD

Setting the switch-on time

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

Confirm with .

The cursor moves to the hour digits, which will blink.

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

2. Use and to set the switch-on hour to the desired value. In the example, this is

Confirm with .

The cursor moves to the minute digits, which will blink.

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

Note

Because the switch-off time can never be earlier

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

3. Use and to set the minutes. In the example, this is 15.

Confirm with .

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

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

Setting the switch-off time

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

012

Confirm with .

The cursor moves to the minute digits, which will blink.

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

08.

The display show the settings for the extra period.

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2. Use and to set the minutes. In the example, this is 45.

Confirm with .

The cursor moves to the water temperature. See the figure

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

Setting the water temperature

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

Confirm with .

The cursor moves to

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

Setting the program-controlled pump

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

Confirm with .

The cursor moves to

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

2. Confirm with .

The extra period has been programmed.

Note

Once the extra period has completed running, the

controller returns to the mode ON, OFF or

WEEK PROGRAM

period will NOT be automatically switched back on.

PUMP ON

START

. The following week, the extra

. The pump

11.11 Settings

Using the option settings, and display certain water heater specifications:

• Adjustable settings

- Menu language.

- Current day of week and time.

• Displayable water heater specifications, this category is only relevant to the installation engineer and/or service and maintenance engineer

- Regulation interval (water temperature).

- Ignition speed of fan.

- Working speed of fan.

SETTINGS

you can adjust certain

11.11.1 Setting menu language

To set menu language:

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

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

2. :

3. The cursor is positioned beside

SETTINGS

Confirm with .

The display shows the menu for settings.

SETTINGS »LANGUAGE ^ DAY/TIME È SPECIFICATIONS

Confirm with .

The display shows the language selection menu.

LANGUAGE

ENGLISH ^ NEDERLANDS È»DEUTSCH

FRANCAIS

ITALIANO

CZECH ESPANOL

LANGUAGE

4. Scroll with to the desired language.

Confirm with .

The language is set.

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11.11.2 Setting day and time

To enter the time and day:

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

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

2. :

3. Scroll with and to

4. The cursor is positioned beside

SETTINGS

Confirm with .

The display shows the menu for settings.

Confirm with .

SETTINGS

LANGUAGE

^»DAY/TIME È SPECIFICATIONS

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

DAY

»Sunday ^ Monday È Tuesday

Wednesday Thursday Friday Saturday

Scroll with and to the desired day.

Confirm with .

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

TIME »00:00

DAY/TIME

Sunday

6. The cursor moves to the minute digits, which will blink.

Scroll with and to the next minute, for example

45.

Confirm the minute setting with

TIME 15»45

The time has been set.

Note

The water heater takes no account of daylight

saving.

11.11.3 Displaying water heater

specifications

Note

This category is solely intended for the installation

engineer and/or service and maintenance engineer.

Call up the menu to display the water heater specifications as follows:

1. :

2. Scroll with to

SETTINGS

Confirm with .

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Confirm with .

SETTINGS

LANGUAGE ^ DAY/TIME È»SPECIFICATIONS

The display shows the sub-menu for displaying water heater specifications.

SPECIFICATIONS

5. The cursor moves to the hour digits, which will blink.

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

Confirm with .

TIME 15»00

SPECIFICATIONS »REGULATION INTERVAL ^ IGNITION SPEED È WORKING SPEED

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

The corresponding display appears.

REGULATION INTERVAL

80ÉC

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Page 78

12 Service program

12.1 Introduction

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

• Displaying the water heater history

• Displaying the error history

• Displaying the water heater history

• Display the selected water heater

• Switching the pump on or off

• Setting the service interval

• Service mode

• Setting legionella prevention

• Solar heating system configuration

• Setting the central heating configuration

SERVICE MENU »HYSTERESIS ^ ERROR HISTORY È APPLIANCE HISTORY

SELECT APPLIANCE PUMP RELAY SERVICE INTERVAL

SERVICE OPERATION

ANTI LEGIONELLA SETTINGS SOLAR SETTINGS HEATING

These sub-menus are briefly described in the following paragraphs. If you are not generally familiar with the use of the displays and menus, first read the relevant chapter (7 "

Note

The notation convention for the service menu is identical to that of the main menu (11.2 " convention for menu-related instructions"). The difference is, you use to bring up the service program, instead of which brings up the main menu.

The control panel").

Notation

12.2 Setting the hysteresis

Call up the menu to set the hysteresis as follows:

HYSTERESIS DOWN

HYSTERESIS DOWN »3ÉC

Please refer to the table (3.4.2 "General and electrical specifications") for the regulation interval and settings for each water heater.

12.3 Displaying the error history

Display the error history as follows:

•:

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

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

(B)

ERROR HISTORY(B)

È CO2 50 HZ ERROR

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

(L)

ERROR HISTORY(L)

È ...

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

ERROR HISTORY

S04 SENSOR ERROR F06 IONIZATION

ERROR HISTORY

F02 FAN F07 FLAME ERROR

Note

For an overview of all errors and the possible

is followed by

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Page 79

12.4 Displaying the water heater history

The water heater history sub-menu is used to display the burning hours, the number of ignitions, the number of flame errors and the number of ignition errors.

Call up the menu for displaying the water heater history as follows:

•:

APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021

IGNIT ERROR 000013

APPLIANCE HISTORY

The figure shows an example.

12.5 Display the selected water heater

Call up the menu for displaying the water heater selection as follows:

•:

SELECT APPLIANCE »5934 ^ 8576 È 3379

SELECT APPLIANCE

The water heater number can be found on the rating plate.

The water heater selection has been correctly preset in the factory.

6527

....

12.6 Switching the pump on or off

If a program-controlled pump is installed (3.11.5 " pump") , it can be switched ON or OFF as follows:

•:

PUMP RELAY »ON

PUMP RELAY

The standard setting for the pump relay is OFF.

OFF

Connecting a program-controlled

12.7 Setting the service interval

The service interval is a feature of the controller to help the service and maintenance engineer set the frequency of maintenance (14.2 "Determining service interval").

The service interval is determined by the number of months that the appliance has been running. This can be set to 6, 9 and 12 months. The default service interval is 12 months . When the preset number of hours has been reached, an appropriate message

Service condition") will appear. Set the service

(8.4 "

interval as follows:

•:

SERVICE INTERVAL 6 9 Months »12

SERVICE INTERVAL

12.8 Service mode

The Installation engineer uses the

OPERATION

setting during operation.

Use :

SERVICE OPERATION

SERVICE OPERATION »FULL LOAD PARTIAL LOAD

and can be used to switch between

LOAD

If there is a heat demand, the water heater will first run through a startup cycle, then continue to operate in

FULL LOAD

If there is no heat demand, the installation engineer must create one. This can be done by draining the water heater until it is cold or by temporarily raising the set point using . After adjustment, the set point must be set back to the original value using .

if you exit the buttons are pressed for a period of 15 minutes, the water heater will revert to the original operating mode.

menu to adjust the water heater CO2

FULL LOAD

SERVICE OPERATION

menu.

and

FULL LOAD

PARTIAL LOAD

SERVICE OPERATION

SERVICE

and

PARTIAL LOAD

to display the

mode.

PARTIAL

menu or if no

If the mode active, then the setting for mode

EXTRA PERIOD

selection for the pump relay in the service menu.

Example

One of the week program periods is currently active. During this period, the pump relay setting is OFF. If the pump relay is set ON in the service menu, the pump will nonetheless remain OFF. The pump will only switch ON once the week program period has ended.

WEEK PROGRAM

has priority over the ON/OFF

EXTRA PERIOD

WEEK PROGRAM

Instruction manual SGE 76

Page 80

Temporarily raising the setpoint during

LOAD

PARTIAL LOAD

1. :>:

SERVICE OPERATION »FULL LOAD PARTIAL LOAD

2. Select

3. Confirm with .

SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 65ÉC RUNNING

4. To create a heat demand, you can temporarily

SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 70ÉC RUNNING

SERVICE OPERATION

FULL LOAD

The example below describes the situation for

FULL LOAD PARTIAL LOAD

raise the set point using to e.g. 70

PARTIAL LOAD

, which is identical to that for

FULL

12.9.1 Switching legionella prevention on and off

To switch legionella prevention on or off, select:

•:

ANTI LEGIONELLA »YES NO

• Select NO to switch legionella prevention off.

• Select

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

• Select

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

ANTI LEGIONELLA

YES

to switch legionella prevention on. The

following screen appears:

START

to activate the period currently

displayed.

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

5. Confirm with .

6. After adjusting for the CO adjustment"), you must use to restore the set point to its original value.

7. Press twice to return to the

SERVICE OPERATION

»OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

value (3.13.3 "CO2

menu via the

menu.

12.9 Setting legionella prevention

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

12.9.2 Changing legionella prevention start time

If you wish to change the start time, select:

ANTI LEGIONELLA

The following display appears.

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

• Now set the day and time the same way as

described for setting an extra period in the week menu (11.10.1 " this case however, the pump will be automatically started.

• Select

START

Programming an extra period"). In

to start.

YES

Change

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12.10 Solar heating system configuration

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

SETTINGS SOLAR »DRAIN BACK ^ TEST SOLAR PUMP È SOLAR DIFFERENCE

Q/T SENSOR SOLAR LIMIT CONTRIBUTION

TEMPERATURES

12.10.1 Setting the drain-back tank

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

•:

The default is NO.

SETTINGS SOLAR

DRAIN BACK YES »NO

DRAIN BACK

actually generating heat. This makes use of the difference between the temperature at the top of the solar collector (S (measured by S2).

Call up the menu for the solar limit as follows:

•:

SOLAR LIMIT

65ÉC

Please refer to the table (3.4.2 "General and electrical specifications") for the adjustment range and default value for each appliance.

SETTINGS SOLAR

) and that in the appliance

SOLAR LIMIT

12.10.4 Setting the solar difference

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

•:

SOLAR DIFFERENCE

SETTINGS SOLAR

SOLAR DIFFERENCE

Note

During commissioning, it is important to check whether this setting corresponds with the configuration of the solar heating system.

12.10.2 Switching on the solar pump

This menu lets you switch on the pump in the solar heating system manually. Call up this menu as follows:

•:

The following display appears.

TEST SOLAR PUMP

»START

When two minutes. Once the 2 minutes have elapsed, the pump stops running again.

SETTINGS SOLAR

START

is selected, the pump will start to run for

TEST SOLAR PUMP

12.10.3 Setting the solar limit

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

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

If you set the solar limit higher than the set point (11.4 " solar pump will be started in order to heat the water further once the set point has been reached. However, this only makes sense if the solar heating system is

Setting the water temperature"), then the

5ÉC

Please refer to the table (3.4.2 "General and electrical specifications") for the regulation interval and default value for each water heater.

12.10.5 Setting the Q/T sensor

The energy contribution of the solar heating system can be calculated (12.10.6 " using the Q/T sensor. This calculation is only possible if your installation is equipped with such a Q/T sensor. If this is the case, then you must set this value to

otherwise follows:

•:

Q/T SENSOR YES »NO

. Call up the corresponding menu as

SETTINGS SOLAR

Displaying contribution")

YES

Q/T SENSOR

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Page 82

12.10.6 Displaying contribution

This option enables you to read out how much energy the solar heating system supplies. For this data to be displayed, the installation must be equipped with a Q/T sensor (12.10.5 "

Three values are reported on the display:

•

ACTUAL

currently being supplied.

•

LAST 24hr

•

TOTAL

Call up this menu as follows:

•:

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

, actual energy: the amount of energy

, total energy supplied since day 1.

SETTINGS SOLAR

12.10.7 Displaying temperatures

This option lets you read what the solar heating system's sensors are recording. Two values are reported on the display:

•

, temperature in the collector.

•

, temperature between the inlet and outlet of the

heat exchanger in the tank.

Call up this menu as follows:

•:

SETTINGS SOLAR

Setting the Q/T sensor").

, energy supplied over last 24 hours.

CONTRIBUTION

TEMPERATURES

TEMPERATURES S1 84ÉC S2 45ÉC

12.11 Setting the central heating

configuration

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

Note

This function is not yet available.

•:

SETTINGS HEATING

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13 Errors

13.1 Introduction

A distinction is made between:

• General errors

General errors are not reported on the display. General errors are:

- Gas smell

- Display does not light up

- Insufficient or no hot water.

- Water leakage

- Explosive ignition.

The manual includes (13.2 " table with general errors.

• Displayed errors

Errors are reported on the display as follows:

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

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

S02: SENSOR ERROR

TOP TANK SENSOR 1

NOT CONNECTED

Troubleshooting table for general errors") a

S02: SENSOR ERROR

CHECK TOP TANK

SENSOR

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

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

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

The manual includes (13.3 " table of error messages that can appear on the display.

• Warnings on the display

The warnings (13.4 "

Troubleshooting table for displayed errors") a

Warnings on the display") apply to the water heater.

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Page 85

13.2 Troubleshooting table for general errors

Warning

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

General errors

Indication Cause Measure Remark

Gas smell Gas leak

Warning

Close the main gas valve at once.

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

Warning

Immediately contact your installation engineer or local gas

company.

The display is off The water heater is off Start the water heater (9 "

No supply voltage present

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

1. Check whether the isolator is ON.

2. Check that there is power to the isolator.

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

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

5. The measured voltage must be 230 V

Starting the water heater")

AC (-15%, +10%)

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

Appendices").

Instruction manual SGE 82

Page 86

Indication Cause Measure Remark

Water leakage Leakage from a water

Explosive ignition Incorrect supply

Insufficient or no hot water

connection (threaded)

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

Leakage from another nearby water water heater or pipe segment

Leakage from the water heater tank

pressure and/or CO

Contaminated burner Clean the burner (15.4.2 "

The water heater is off Start the water heater (9 "Starting the water heater")

No supply voltage present

Hot water supply is used up

The controller is in the OFF position.

Temperature (T set too low.

set

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

Rectify if necessary

Trace the leak

Consult the supplier and/or manufacturer

Set (3.13 "Check the supply pressure, gas control valve pressure, CO2 value and switching pressure") the correct supply pressure

and/or CO

1. Check whether the isolator is ON.

2. Check that there is power to the isolator.

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

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

5. The measured voltage must be 230 V

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

Switch the controller to the ON position (11.3 " mode"").

) is

Set temperature (T temperature").

Cleaning the burner")

AC (-15%, +10%)

Switching to "ON

) to a higher setting (11.4 "Setting the water

set

If ignition is not improved, consult your installation engineer.

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

If there continues to be insufficient or no hot water, consult your installation engineer.

Appendices").

Instruction manual SGE 83

Page 87

Indication Cause Measure Remark

Glycol leakage Leakage from a fluid

connection (threaded)

Leakage from a component

Leakage from solar heating system

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

your installation engineer

1. Tighten component joints

2. Any defective components must be replaced

Consult the supplier and/or manufacturer

Instruction manual SGE 84

Page 88

13.3 Troubleshooting table for displayed errors

Displayed errors

Code + description Cause Measure Remark

S01 (blocking error)

Open circuit from temperature sensor T at the bottom of the tank.

S02 (blocking error)

Open circuit from sensor 1 of temperature sensor T at the top of tank

S03 (blocking error)

Open circuit in sensor 2 of temperature sensor

at the top of the tank

(1)

S04 (blocking error)

Open circuit from dummy 1

S05 (blocking error)

Open circuit from dummy 2

(1)

Sensor is not (correctly) connected

Damaged cable and/or

defective sensor

Sensor is not (correctly) connected

Damaged cable and/or defective sensor

Sensor is not (correctly) connected

Damaged cable and/or defective sensor

Dummy is not (correctly) connected

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

Dummy is not (correctly) connected

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

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

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

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

Damaged cable and/or defective sensor To replace the necessary parts, you must contact your installation

engineer

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

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

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

engineer

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

engineer

Appendices").

Instruction manual SGE 85

Page 89

Code + description Cause Measure Remark

S07 (blocking error)

Open circuit from temperature sensor S at the bottom of the tank.

S08 (blocking error)

Open circuit from temperature sensor S1 in the collector.

S11 (blocking error)

Short circuit in temperature sensor T at the bottom of the tank.

S12 (blocking error)

Short circuit in sensor 1 of temperature sensor T

at top of tank

S13 (blocking error)

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

(1)

S14 (blocking error)

Short circuit from dummy 1

(1)

Sensor is not (correctly) connected

Damaged cable and/or

defective sensor

Sensor is not (correctly) connected

Damaged cable and/or defective sensor

Short circuit in sensor circuit

Connect the sensor lead to J14 (ports 2 and 4) of the solar controller

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

Connect the sensor lead to J13 (ports 2 and 4) of the solar controller

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

Replace the dummy sensor

(2)

See the electrical diagram (17 "

engineer

See the electrical diagram (17 "

engineer

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

Appendices").

Instruction manual SGE 86

Page 90

Code + description Cause Measure Remark

S15 (blocking error)

Short circuit from dummy 2

S17 (blocking error)

Short circuit from temperature sensor S at the bottom of the tank.

S18 (blocking error)

Short circuit from temperature sensor S in the collector.

F01 (blocking error)

Defect in power supply circuit

F02 (lock out error)

Fan fails to run at correct speed.

Short circuit in sensor circuit

Live and neutral connected wrong way around.

Condensation on the flame probe

Floating neutral Install an isolating transformer (3.11.4 "

Defective motor and/or rotor.

Replace the dummy sensor

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

Be sure to connect the live and neutral correctly (3.11 " connecting the water heater"); the water heater is phase-sensitive

1. Disconnect the lead at the flame probe

2. Ignite the water heater three times, with an interrupted ionisation circuit

3. Reconnect the ionisation lead to the flame probe

4. Ignite the water heater again

5. The repeated ignition attempts will have caused the condensation to evaporate

1. Check the motor and rotor

2. Replace the fan if the motor or rotor is defective.

3. Reset controller

(2)

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

engineer

Electrically

Isolating transformer") Contact your installation engineer to have an isolating transformer

See the electrical diagram (17 "

If errors persist, contact your installation engineer

installed

See the electrical diagram (17 "Appendices").

To have the wiring replaced and a new fan fitted, you must contact your installation engineer

Appendices").

Instruction manual SGE 87

Page 91

Code + description Cause Measure Remark

Damaged wiring 1. Check the wiring between the fan and the controller.

2. If any wires are damaged, the wiring harness must be replaced.

3. Reset controller

Contaminated or blocked fan

Because of a drop in the supply voltage, the fan will not run at the correct speed.

1. Check if the fan is dirty and repair it if necessary.

2. Check that the rotor can rotate freely

3. Reset controller

1. Check the supply voltage, this must be 230 V

2. Reset controller

AC(-15%, +10%)

If the error cannot be resolved or is persistent, contact your installation engineer

Instruction manual SGE 88

Page 92

Code + description Cause Measure Remark

F03 (lock out error)

The pressure switch fails to work correctly

Damaged wiring/Open circuit

Pressure switch not closing

1. Check the wiring between the pressure switch and the controller

2. If necessary, replace the wiring

1. Check the speed of the fan (3.4.2 " specifications").

2. Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted. Refit them if necessary

3. Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner. If necessary, replace the hoses.

4. Check whether the chimney flue is compliant (3.10 " and chimney flue discharge").

5. Check for blockage in the chimney flue. Remove any blockage that may be present

6. Check for blockage in the condensation water discharge. Remove any blockage that may be present.

7. Measure the pressure differential across the pressure switch. See the table (3.4.2 " there is insufficient pressure differential, clean the heat exchanger. If the pressure differential is acceptable, check that the pressure switch is closing, using a multimeter.

General and electrical specifications"). If

General and electrical

Air supply

If the error cannot be resolved or is persistent, contact your installation engineer

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

Instruction manual SGE 89

Page 93

Code + description Cause Measure Remark

F04 (lock out error)

Three unsuccessful ignition attempts.

F05 (lock out error)

Too many flame errors have been signalled.

No gas 1. Open the main gas supply valve and/or the manual gas supply

valve before the gas control valve

2. Check supply pressure to the gas control valve

3. If necessary, restore the gas supply

Air in the gas pipes Bleed the air out of the gas pipe (3.13 "

Defect in the hot surface igniter circuit

Defect in the ionisation circuit

Supply voltage too low Check the supply voltage, this must be 230 V

Incorrect roof or wall flue terminal. Recirculating flue gases.

gas control valve pressure, CO2 value and switching pressure")

1. Check that the hot surface igniter is correctly connected (JP2).

2. Check the wiring of the hot surface igniter.

3. Measure the resistance across the hot surface igniter. This must lie between 2 and 10 Ohm (at room temperature).

4. Check that the hot surface igniter lights up during ignition.

5. If necessary, replace the hot surface igniter.

1. Check that the flame probe is correctly connected (JP2)

2. Check the wiring of the flame probe

3. Measure the ionisation current. This must be a minimum of

1.5 microA.

4. If necessary, replace the wiring.

1. Check that the correct roof or wall flue terminal has been installed (3.10 "

2. If necessary, install the correct roof or wall flue terminal.

3. Check that the roof or wall flue terminal discharges into a permitted area.

Air supply and chimney flue discharge").

Check the supply pressure,

AC(-15%, +10%)

To restore the gas supply, contact your installation engineer

See Checking the supply pressure and burner pressure (3.13 " pressure, CO2 value and switching pressure") for how to bleed air from the gas line and how to measure the supply pressure and burner pressure.

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

If the error persists, contact your installation engineer. To replace the necessary parts, you must contact your installation

engineer

If the error cannot be resolved or is persistent, contact your installation engineer

Check the supply pressure, gas control valve

Instruction manual SGE 90

Page 94

Code + description Cause Measure Remark

F06 (blocking error)

Short circuit between flame probe and earth

F07 (lock out error)

A flame has been detected after the gas control valve was closed.

F08 (lock out error)

Error message from safety relay

F09 (lock out error)

Water temperature protection.

F11 (blocking error)

Flame detection with closed gas control valve.

F18 (blocking error)

Communication error

Damaged cable in contact with metal surface or bent flame probe.

Ceramic part of the flame probe is broken/cracked.

Defective gas control valves

Flame detection before the gas control valve opened.

Temperature at the top of the tank exceeds

Defective gas control valves

No power supply at solar controller

No cable or damaged cable

Check the wiring and the flame probe. Replace the wiring and/or flame probe if necessary.

1. Check whether the ceramic part of the flame probe is still intact, in the vicinity of the air distribution plate of the burner.

2. If not the flame probe must be replaced.

1. Check whether there is still burner pressure present, after the gas control valves have closed.

2. Check whether a flame is still present, after the gas control valves have closed.

3. If this is the case, the gas control valve must be replaced.

1. Reset controller.

2. If the error appears again, replace the controller.

1. Check that the circulation pump (if present) is working

2. Check the position of temperature sensor T

3. Reset controller

See F07.

1. Check that there is power to the solar heating system controller

2. The measured voltage must be 230 V

1. Check the wiring (communication cable) between the main controller and the solar heating system controller

2. If cable missing, connect the cable

3. If cable damaged, replace the cable

AC (-15%, +10%)

If the error persists, contact your installation engineer. To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

If the error cannot be resolved or is persistent, contact your installation engineer

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

If the error cannot be resolved or is persistent, contact your installation engineer

See the electrical diagram (17 " If the error persists, consult your installation engineer

See the electrical diagram (17 " For replacement of the cable, contact your installation engineer

Appendices").

Instruction manual SGE 91

Page 95

Code + description Cause Measure Remark

F19 (blocking error)

Power supply voltage is too low.

C02 (lock out error)

Error message from the controller.

Internal error message from the controller.

C03 (blocking error)

Reset error

There is not enough supply voltage.

Incorrect reference voltage from the AD converter.

• EEPROM read error

• 50 Hz error

• Internal communication error

• Gas valve relay error

• Safety relay error

• Ignition relay error

• RAM error

• EEPROM error

• EEPROM contents do not match the software version

• Processor software error

Too many resets in too short a period

1. Check that there is power to the controller

2. The measured voltage must be 230 V

1. Reset controller.

2. Check that the frequency of the power supply is compliant (3.4.2 " contact your installation engineer

3. If the frequency is correct but the error persists, replace the controller.

Wait for the error to disappear (maximum 1 hour). If the error does not disappear, replace the water heater controller.

General and electrical specifications"). If not,

AC (-15%, +10%)

See the electrical diagram (17 " If the error persists, consult your installation engineer

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

Appendices").

Instruction manual SGE 92

Page 96

Code + description Cause Measure Remark

C04 (blocking error)

Appliance selection error

C05 (blocking error)

Error message from the solar controller.

E01 (blocking error)

The temperature protection at the top of the tank has been activated.

E03 (lock-out error)

Error in temperature sensor T the tank.

E04 (lock-out error)

Defect in the dummy sensor

(1) Temperature sensor T (2) The dummy flue gas sensor consists of dummy flue gas sensor 1 and dummy flue gas sensor 2.

at the top of

(2)

Incorrect water heater selection/Incorrect selection resistor

• Incorrect reference voltage from the AD converter.

• EEPROM error

The temperature of the water at the top of the tank is >88

The two temperature sensors in the tank detect a difference of > 10°C over a period of at least 60 seconds.

The two temperature sensors detect a difference of >10oC over a period of at least 60 seconds.

is a 2-in-1 sensor; T1 contains 2 NTCs for maximum thermostat and safety thermostat protection.

1. Check whether the correct water heater is selected (3.4.2 "General and electrical specifications").

2. If the correct water heater is selected, fit the correct selection resistor.

3. If incorrect water heater selected, select the correct one.

1. Reset controller.

2. Check that the frequency of the power supply is compliant (3.4.2 " is not the case, contact your installation engineer.

3. If the frequency is correct but the error persists, replace the solar controller.

None. This is a temporary message that may appear from time to time, but will disappear automatically.

1. Check sensor position and wiring.

2. Reset the controller if necessary. Replace the sensor if the error persists.

1. Check the wiring of the dummy 1 and dummy 2.

2. Reset the controller if necessary. Replace the dummy sensor if the error persists.

General and electrical specifications"). If this

If the error cannot be resolved or is persistent, contact your installation engineer

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

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

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

Instruction manual SGE 93

Page 97

13.4 Warnings on the display

Warnings on the display

Situation Cause Measure Note

Maximum burning hours: Servicing required.

The actual burning hours have exceeded the preset burning hours.

Appliance runs, but displays a warning For maintenance to your appliance, please contact your installation

engineer.

Instruction manual SGE 94

Page 98

Situation Cause Measure Note

The anode protection is not working.

Solar heating system pump or Q/T sensor not correctly connected.

Collector temperature too high.

• The cables between the potentiostat and anodes are loose or have been connected incorrectly.

• The earth connection of the anodes is loose.

• The appliance is not filled with water.

Lead(s) loosened or incorrectly connected

Temperature S greater than T

max

collector

Appliance runs, but displays a warning.

Note

The appliance is functioning, but there is no anode protection for

the tank.

Appliance runs, but displays a warning 1. Connect the pump or Q/T sensor properly and the warning will

Non-drainback systems:

The solar systems pump runs at full power for 10 minutes, pumping the fluid in the solar system round. If T has elapsed, the pump will stop running for 30 minutes. After 30 minutes, the pump will start running again and the controller of the solar heating system checks whether T

Drain-back systems:

The solar system's pump stops running immediately (for 30 minutes). After 30 minutes, the pump will start running again and the controller of the solar heating system checks whether T less than T

collector max

> T

col

collector max

is less than T

col

after this

collector max

col

1. Connect the wiring up properly and the warning will disappear.

2. If the wiring is correct but the warning remains, check that the

1. If correctly wired but the warning remains, replace pump or

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

1. You can let the message disappear automatically by allowing

2. You can also manually eliminate the message by pressing the

earth connection is good and whether the tank is filled with water.

disappear.

sensor.

the heating fluid to cool down.

RESET and ENTER buttons simultaneously.

Instruction manual SGE 95

Page 99

Instruction manual SGE 96

Page 100

14 Service interval

14.1 Introduction

14.2 Determining service interval

Note

Regular maintenance extends the service life of the water heater.

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 three months after installation. Based on this check, the best service interval can be determined.

The service interval is a feature of the controller to help the service and maintenance engineer set the maintenance frequency, based on the number of months that the appliance has been running.

The service interval can be set to: 6, 9 or 12 months. The default setting is 12 months.

Once the set number of months has elapsed, the message

SERVICE REQUIRED

appears, the service and maintenance engineer must be contacted.

will appear on the display. When this message

Instruction manual SGE 97

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

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

3 Installation

5 Filling

6 Draining

7 The control panel

10 Shutting down

11 Main menu

12 Service program

13 Errors

14 Service interval