Strebel S-WG 100, S-WG 80, S-WG 120, S-WG 150, S-WG 180 Installation, Operating And Maintenance Manual

STREBEL

S-WG

80 - 100 - 120 - 150 - 180

Wall hung high efficiency water heater

Installation, Operating and Maintenance Manual

2015-05-06 v2.1

E09.012.246 Manual S-WG

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TABLE OF CONTENTS

INTRODUCTION ……………………….………………………..........................................................................................................5

1 SAFETY GUIDELINES ................................................................................................................................................................. 5

1.1 GENERAL ...................................................................................................................................................................... 5

1.2 IMPORTANT TECHNICAL WARNINGS AND GUIDELINES ........................................................................................................ 6

2 TECHNICAL DATA S-WG WATER HEATERS .......................................................................................................................... 10

3 DIMENSIONS ............................................................................................................................................................................. 12

3.1 WATER HEATERS S-WG80 – S-WG120 ........................................................................................................................ 12

3.2 WATER HEATERS S-WG150 AND S-WG180.................................................................................................................. 13

3.3 S-WG TANKS ............................................................................................................................................................... 14

3.4 CASCADE FRAMES S-WG80 – S-WG180 ...................................................................................................................... 16

4 ACCESSORIES AND UNPACKING ........................................................................................................................................... 18

4.1 ACCESSORIES ............................................................................................................................................................. 18

4.2 UNPACKING ................................................................................................................................................................. 18

5 INSTALLATION OF THE S-WG ................................................................................................................................................. 19

5.1 GENERAL NOTES ................................................................................................ ................................ .......................... 19

5.2 MOUNTING THE WATER HEATER AND TANK .................................................................................................................... 20

5.2.1 Water heater mounting ........................................................................................................................................... 20

5.2.2 Tank positioning ..................................................................................................................................................... 21

6 FLUE GAS AND AIR SUPPLY SYSTEM ................................................................................................................................... 22

6.1 GENERAL .................................................................................................................................................................... 22

6.2 AIR SUPPLY ................................................................................................................................................................. 22

6.3 FLUE TERMINAL............................................................................................................................................................ 22

6.4 FLUE SYSTEM CLASSIFICATION B23P ............................................................................................................................ 23

6.5 FLUE SYSTEM CLASSIFICATION C63 .............................................................................................................................. 23

6.6 COMBUSTION AIR QUALITY ............................................................................................................................................ 24

6.7 FLUE GAS & AIR INLET CALCULATION EXAMPLES (NEXT PAGES) ....................................................................................... 24

7 ELECTRICAL INSTALLATION .................................................................................................................................................. 32

7.1 GENERAL .................................................................................................................................................................... 32

7.2 ELECTRICAL CONNECTIONS .......................................................................................................................................... 32

7.3 SENSOR VALUES .......................................................................................................................................................... 33

7.4 ELECTRICAL SCHEMATICS ............................................................................................................................................. 34

8 THE S-WG WATER HEATER .................................................................................................................................................... 36

8.1 WATER QUALITY........................................................................................................................................................... 36

8.2 FROST PROTECTION ..................................................................................................................................................... 36

8.3 LEGIONELLA PROGRAM................................................................................................................................................. 36

8.4 FLOW MONITORING ...................................................................................................................................................... 37

8.5 WATER PRESSURE SWITCH ........................................................................................................................................... 37

9 THE S-WG SANITAIRY SYSTEM: INSTALLATION INSTRUCTIONS ...................................................................................... 38

9.1 THE S-WG SYSTEM ..................................................................................................................................................... 38

9.1.1 Stand-alone set-up ................................................................................................................................................. 38

9.1.2 Cascade set-up ...................................................................................................................................................... 39

9.1.3 Control general ....................................................................................................................................................... 41

9.1.4 Cascade control ..................................................................................................................................................... 41

9.2 WATER HEATER AND TANK: CONNECTIONS AND CONNECTION SIZES ................................................................................ 42

9.2.1 Connecting the tank to the water heater ................................................................................................................. 42

9.2.2 To connect the tank to your DHW installation ......................................................................................................... 43

9.2.3 Condensate drain connection ................................................................................................................................. 44

9.3 CASCADE SYSTEMS: ASSIGNING PIPE CODES ................................................................................................................. 45

9.3.1 Pipe codes water heater side ................................ ................................................................................................ . 45

9.3.2 Pipe codes at the tanks’ side .................................................................................................................................. 46

9.3.3 Equivalent length .................................................................................................................................................... 46

9.4 CONNECTION COMPONENT TABLES – DIAMETERS AND LENGTHS ..................................................................................... 47

9.4.1 Water manifolds ..................................................................................................................................................... 47

9.4.2 Tank headers ......................................................................................................................................................... 48

9.4.3 Interconnecting pipes – diameters and equivalent length ....................................................................................... 50

9.5 PUMP CHOICE AND PUMP CONTROL ............................................................................................................................... 51

9.5.1 Pump choice .......................................................................................................................................................... 51

9.5.2 Nominal flow per water heater type ........................................................................................................................ 52

9.5.3 Pump control .......................................................................................................................................................... 52

9.5.4 Pump: maximum electrical power ........................................................................................................................... 53

9.6 ELABORATED EXAMPLES .............................................................................................................................................. 54

9.6.1 One S-WG20 water heater with one 450-litres tank ............................................................................................... 54

9.6.2 Two S-WG100 water heaters with two 450-litres tanks .......................................................................................... 55

9.6.3 Three S-WG180 water heaters with five 750-litres tanks ........................................................................................ 56

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10 USER INTERFACE .................................................................................................................................................................... 58

10.1 CONTROL PANEL / DISPLAY UNIT ................................................................................................................................... 58

10.2 CONTROL PANEL MENU STRUCTURE .............................................................................................................................. 59

10.3 DISPLAY DURING OPERATION ........................................................................................................................................ 60

10.4 MONITOR SCREENS ...................................................................................................................................................... 61

10.5 SERVICE FUNCTION ...................................................................................................................................................... 63

10.6 SWEEPER FUNCTION .................................................................................................................................................... 64

10.7 PROGRAMMING IN STANDBY MODE ................................................................................................................................ 65

10.8 SETTING THE TIME & DATE ............................................................................................................................................ 65

10.9 SET POINTS ................................................................................................................................................................. 66

10.10 SETTING THE TIMER PROGRAMS.................................................................................................................................... 67

10.11 CHECKING THE OPERATING HISTORY ............................................................................................................................. 70

10.12 CHECKING THE FAULT HISTORY ..................................................................................................................................... 71

10.13 SETTING THE MAINTENANCE SPECIFICATIONS ................................................................................................ ................ 72

10.14 SETTING THE USER LOCK ................................................................................................................................ .............. 75

10.15 SETTING THE PARAMETERS WITH THE DISPLAY MENU ..................................................................................................... 76

10.16 FAULT CODES DISPLAY ................................................................................................................................................. 84

10.16.1 Lock-out codes ................................................................................................................................................... 84

10.16.2 Blocking codes .................................................................................................................................................... 86

10.16.3 Messages ........................................................................................................................................................... 88

11 CONTROLLING OPTIONS AND SETTINGS ................................................................ ............................................................. 89

11.1 WATER HEATER OPTIONS ............................................................................................................................................. 89

11.1.1 0-10 VDC remote flow temperature set point.......................................................................................................... 89

11.1.2 anti-Legionnaires’ disease (pasteurisation) function ............................................................................................... 90

11.2 GENERAL .................................................................................................................................................................... 91

11.2.1 Max cooling time .................................................................................................................................................... 91

11.2.2 temperature display on/off ...................................................................................................................................... 91

11.2.3 Gas type selection ................................................................................................................................ .................. 91

11.2.4 Soft start option ...................................................................................................................................................... 92

11.2.5 Pump mode (EC technology) ................................................................................................................................. 92

11.2.6 Tank sensor sensitivity ........................................................................................................................................... 92

12 COMMISSIONING THE WATER HEATER ................................................................................................................................ 93

12.1 FIRST: FLUSHING THE WATER HEATER WITH WATER ....................................................................................................... 93

12.2 SECOND: FILLING & VENTING THE WATER HEATER AND THE SYSTEM ............................................................................... 93

12.3 THIRD: CHECK THE WATER FLOW .................................................................................................................................. 93

13 STARTING THE WATER HEATER ............................................................................................................................................ 95

13.1 GENERAL .................................................................................................................................................................... 95

13.2 FIRING FOR THE FIRST TIME .......................................................................................................................................... 95

14 ADJUSTING AND SETTING THE BURNER .............................................................................................................................. 96

14.1 INTRODUCTION ............................................................................................................................................................ 96

14.1.1 Adjustment tables ................................................................................................................................................... 96

14.1.2 Setting screws gas valve(s): drawings .................................................................................................................... 97

14.1.3 Adjustment actions: general scheme ...................................................................................................................... 99

14.2 ADJUSTING IN CASE OF A NEW WATER HEATER, OR AFTER SERVICE (CASE A) ................................................................ 100

14.2.1 General remark .................................................................................................................................................... 100

14.2.2 Adjusting at maximum load .................................................................................................................................. 100

14.2.3 Adjusting at minimum load ................................................................................................................................... 100

14.3 ADJUSTING AFTER GAS VALVE REPLACEMENT, OR IN CASE OF GAS CONVERSION (CASE B) ............................................. 100

14.3.1 General remarks .................................................................................................................................................. 100

14.3.2 Adjusting at maximum load S-WG80 / S-WG100 ................................................................................................. 100

14.3.3 Adjusting at minimum load S-WG80 / S-WG100 .................................................................................................. 100

14.3.4 Checking and adjusting at maximum load S-WG120 / S-WG150 / S-WG180....................................................... 100

14.3.5 Checking and adjusting at minimum load S-WG120 / S-WG150 / S-WG180 ....................................................... 101

14.4 ADJUSTING PROCEDURES ........................................................................................................................................... 102

15 PUTTING THE WATER HEATER OUT OF OPERATION ........................................................................................................ 103

16 FAULT CODES, BLOCKING CODES ...................................................................................................................................... 104

16.1 LOCK-OUT CODES ...................................................................................................................................................... 104

16.2 BLOCKING CODES ...................................................................................................................................................... 112

16.3 MAINTENANCE ATTENTION FUNCTION .......................................................................................................................... 116

17 MAINTENANCE ....................................................................................................................................................................... 117

17.1 GENERAL .................................................................................................................................................................. 117

17.3 INSPECTION & MAINTENANCE ...................................................................................................................................... 118

18 USER INSTRUCTIONS ............................................................................................................................................................ 121

19 INDEX ....................................................................................................................................................................................... 122

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INTRODUCTION

This manual is written for:

 the installer  system design engineer  the service engineer

abbreviations

NB

NOTICE

symbols

Warning: important information related to the safety of persons and/or the appliance

terminology

Flow Return

Water heater hot water out Water heater cold water in

1 SAFETY GUIDELINES

1.1 General

Read all these instructions before commencing installation.

Keep this user manual near the water heater for quick reference. The appliance should be installed by a skilled installer according to all applicable standards and regulations.

Failure to comply with these regulations could deem the warranty invalid. Without written approval of the manufacturer the internals of the water heater may not be changed. When these

changes are executed without approval, the water heater certification is invalid. Commissioning, maintenance and repair must be done by a skilled installer/engineer, according to all applicable

standards and regulations. What should one do when there is the smell of gas:

 Do NOT use any electrical equipment  Do NOT press any switches  Close the gas supply  Ventilate the room (open the windows and/or outside plant room doors)  Warn the installer immediately

The manufacturer/supplier is not liable for any damage caused by inaccurately following of these instructions. Only original parts may be used when carrying out any repair or service works.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

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1.2 Important technical warnings and guidelines

For FAULT CODES in this manual see Ch. 16 on page 104 The STREBEL Domestic Hot Water systems will, for a long period, comfortably meet your requirement of hot

water of the right temperature at the right hour, provided that a few important conditions have been fulfilled regarding the installation. Please follow all instructions and recommendations presented in this manual by STREBEL, especially the ones concerning the next important topics:

- Water quality (also see § 8.1 on page 36) A first necessary condition is the quality of the water to be heated in the DHW water heater. Three values

matter: hardness, total amount of dissolved solids and acidity. If water quality does NOT meet the requirements, the system may be seriously damaged.

 Hardness should not exceed 205 PPM CaCO3 (11.5°dH)  TDS (Total Dissolved Solids) should not exceed 450 PPM  Hardness and TDS together may not exceed 450 PPM  pH-value should be between 6.5 and 7.5, measured cold

The actual values can be retrieved by contacting your local water supplier.

If water quality doesn’t meet the abovementioned requirements, a water treatment installation should be installed to improve water quality to the required levels, if possible.

- Water flow velocity and pump choice (see § 9.5 on page 51) For a given combination of water heaters and tanks, pump choice is very important with respect to the re-

quired flow velocity. STREBEL has done the calculations and provides a number of tables in which you can find the right pump type suitable for your particular installation.

- Water flow velocity and piping diameters and lengths (see § 9.4 from page 47 on) The arguments that hold for pump choice, hold for piping design as well: all piping components added up are

giving a certain total resistance which should not exceed a critical value at which the pump cannot realize the required flow velocity anymore. STREBEL has done the calculations and provides a number of tables in which you can find the piping requirements suitable for your particular installation.

Following the instructions and recommendations given in the referred paragraphs will highly improve the functioning and considerably lengthen the life time of your STREBEL DHW system.

Furthermore, for all STREBEL appliances the next instructions and recommendations apply:

! Never use aluminium or aluminium containing flue gas outlet ! Always fill the siphon before commissioning the water heater ! Always set the gas valves during commissioning the water heater, for the first time and after mainte-

nance and/or installation changes

! Never change the parameters P2LC, P2LD, P2ML en P5BI ! Never place an isolation valve between the safety valve and the water heater ! In a log, keep track of all situations regarding the appliance:

what, when , by whom , what actions and/or changes, what communication has been performed

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Warnings and guidelines (continuation)

STREBEL is not liable for any damage caused by inaccurately following these mounting instructions. Only STREBEL parts may be used when carrying out any repair or service works.

Do not use chlorine based products for brazing. When commissioning the water heater, the running of the water heater pump must be checked before

leaving the installation. By pressing the service button for approximately 5 seconds the water heater can be fired independently from the thermostat circuit. Firing the water heater without water flow (but filled with water) will cause a boiling noise.

The flow and return temperatures are checked continuously. The temperature difference may not exceed the programmed value belonging to the actual power mode. If it does, the water heater will go in a lockout.

The applied DHW pump must be controlled by the S-WG water heater control. If, for any reason, an external pump control is applied without written approval of STREBEL, the complete warranty on the S-WG water heater and all supplied parts will become invalid.

Minimum water pressure 1 bar.

Fuel used should have sulphur rates that comply with the next values: a maximum annual peak over a short period of time of 150 mg/m3 and an annual average of 30 mg/m3 maximum.

Combustion air must be free of contents of chlorine, ammonia, alkali agents. The air near a swimming pool, a washing machine or a laundry is containing these a.m. contents.

The water heater is used in combination with a hot water tank without any other heat exchanger; the water heater should be equipped with a safety relief valve. The tank should be equipped with a T&P relief valve. Always apply all applicable installation standards and regulations.

The connection for a remote DHW Stat is based on an OpenTherm bus system or an on/off timer. For correct connections of the thermostat see page 32.

At first installation, the built-in automatic air vent should be open.

LEGIONNAIRES’ DISEASE

An anti-Legionella function is present in the software but is default turned OFF. See § 8.3 on page 36 and for the programming options § 11.1.2 on page 90.

BUTANE GAS

If butane gas is to be used for this water heater, the fan speed must be reduced by altering parameter P4BD. See § 11.2.3 on page 91.

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TAKE NOTICE !

Between the water heater and the safety valve, DO NOT install an isolation valve or any other form of narrowing, because this might disturb the correct functioning of the safety valve.

The correct safety valve has been supplied together with the S-WG water heater.

water heater

safety valves

Part number

S-WG 80

27112 Prescor B ¾ - 10 bar - 150 kW

E04.015.090

S-WG 100

27112 Prescor B ¾ - 10 bar - 150 kW

E04.015.090

S-WG 120

27112 Prescor B ¾ - 10 bar - 150 kW

E04.015.090

S-WG 150

27112 Prescor B ¾ - 10 bar - 150 kW

E04.015.090

S-WG 180

29007 Prescor B 1 - 10 bar - 250 kW

E04.015.091

The S-WG water heater and tank should be installed by a skilled installer according to all applicable standards and regulations for tap water installations. Use the next scheme as guideline. When multiple water heaters and tanks are applied, every combination has to be equipped with its own safety valve.

Scheme on next page 

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A) Cold water inlet B) Hot water circulation flow C) Circulation flow return

1) Pressure relief valve (mandatory in case service water pressure is too high)

2) Inlet combination with valve (mandatory)

3) Apply filter if necessary (recommended)

4) A suitable safety valve must be mounted near the water heater (mandatory) This safety valve may never be isolated from the water heater by means of a ball valve

5) Mount remote pipe sensor as close as possible to the tank

6) Drain valve (recommended)

7) Hot and cold water mixers

SAFETY COMPONENTS

NB! The picture shows an example of a functional installation. The safety components as

shown in the picture are NOT necessarily conform the applicable standards and regulations.

ALWAYS have the installation installed by a skilled installer. Safety must be added according to all applicable standards and regulations.

1

2

3

A

B

C

4

7

A

5

6

PUMP

NON RETURN VALVE

VALVE

SAFETY VALVE

AUTOMATIC VENT

FILTER

INLET COMBINATION

- Overflow

- Controllable return valve

- Valve

PRESSURE REGULATING VALVE

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2 TECHNICAL DATA S-WG WATER HEATERS

GENERAL

Product Identification number CE 0063 BR3190

Classification

II2H3P

Gas Appliance Type

B23; B23P; C13X, C23X, C33X, C43X, C53X, C63X, C83X

Type water heater

S-WG80

S-WG100

S-WG120

S-WG150

S-WG180

Dimensions (h x w x d)

mm

842 x 476 x 486

898 x 476 x 677

Water content est.

Litre

5.0

6.5

8.3

10.4

12.9

Weight dry

kg

68

73

78

87

96

In- and outlet water connection union

inch

1½ 2 2 2 2

Gas connection

inch

R ¾

R 1

Flue duct flue/air inlet

mm

80/125

100/150

Parallel connection

mm

80-80

100-100

130-130

DOMESTIC HOT WATER

Nominal input min./max. (Net)

kW

14.6 - 74.3

17.2 - 92.2

26.0 - 111

34.0 - 138

45.0 - 166

Nominal input min./max. (gross) (G20 G25)

kW

16.2 - 82.5

19.1 - 102

28.9 - 123

37.8 - 153

50.0 - 184

Nominal input min./max. (gross) (G31)

kW

15.9 - 80.8

18.7 - 100

28.3 - 121

37.0 - 150

48.9 - 180

Nominal input min./max. (gross) (G30)

kW

15.8 - 80.2

18.6 – 99.7

34.7 - 120

36.8 - 150

48.8 - 180

Nom. output 80/60 at 100%

kW

14.0 - 71.2

16.5 - 88.4

24.7 - 106

32.6 - 132

43.3 - 180

Nom. output 50/30 at 100%

kW

15.2 - 77.5

18.0 - 96.2

27.2 - 116

35.5 - 144

47.3 - 160

Nom. output 37/30 at 30%

kW

15.7 - 80.1

18.6 - 99.5

28.1 - 120

36.7 - 149

48.5 - 175

Efficiency 40/30ºC DIN 4702-8

%

up to 110.6 % within the S-WG range

GAS CONSUMPTION [EN437]

Natural gas G25 min - max

m³st/h

1.80 - 9.14

2.12 - 11.35

3.20 - 13.66

4.18 - 16.98

5.54 - 20.43

Natural gas G20 min - max

m³st/h

1.54 - 7.86

1.82 - 9.76

2.75 - 11.75

3.60 - 14.60

4.76 - 17.57

Propane gas G31 min - max

m³st/h

0.60 - 3.04

0.70 - 3.77

1.06 - 4.54

1.39 - 5.65

1.84 - 6.79

Butane gas G30 min - max 1 (B/P)

m³st/h

0.45 - 2.29

0.53 - 2.85

0.99 - 3.44

1.05 - 4.28

1.40 - 5.15

Gas supply pressure nom. G25 2

mbar

25

Gas supply pressure nom. G20 2

mbar

20

Gas supply pressure nom. G31 2

mbar

30/37

Gas supply pressure nom. G30 2

mbar

50

EMISSION

CO2 flue gas G25/G20 min - max 3

%

8.7 - 9.0

CO2 flue gas G31 min - max 3

%

9.3 - 10.3

9.3 - 10.4

9.3 - 10.5

CO2 flue gas G30 min - max 3

%

9.3 - 10.4

9.3 - 10.5

9.3 - 10.6

NOx emission at 0% O

2

max.80/60 4

ppm

32.2

37.8

32.2

34.3

NOx emission at 0% O

2

max.80/60 4

mg/kWh

57.9

67.9

57.9

61.9

NOx - class [EN483 / EN15420]

-

5

Temperature flue gas estimated @ combustion air temp 20ºC

°C

85-95

Available pressure for the flue system 5

Pa

200

INSTALLATION

Max. water temperature

°C

75

Pressure WW-system min./max.

bar

1.0-6.0

Hydraulic resistance of the water heater at T = 17 K between in- and outlet

Head mWC

5.8

4.7

4.1

6.0

5.5

ELECTRIC

Power consumption

W

170

190

250

Power supply

V / Hz

230 / 50

Protection class

IPX4D

NOTES

1

Using propane G31 or butane G30, maximum fan

speed needs to be reduced (parameter P4BD).

2

Below a table is given in which the min. and max.

gas supply pressures are mentioned acc. to EN437.

p nominal

[mbar]

p min

[mbar]

p max [mbar]

G25

25

20

30

G20

20

17

25

G31

30

25

35

37

25

45

G30

50

43

57

3

CO2 of the unit measured/set without the water heater

door in place.

4

Emissions measured during unit certification.

5

Maximum combined resistance of flue gas and air supply

piping at high fire.

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The S-WG water heater is standard set for Natural gas G20

Gases used must meet the European standard EN 437.

Water heater control includes the next programmable features:

 Cascade control for up to twelve water heaters  Remote operation and heat demand indication from each water heater  Anti-Legionnaires’ disease function  0-10 VDC remote flow temperature (set point) control

0-10 VDC connection available

The water temperature can be controlled by an external 0-10 VDC signal. When a number of water heaters are cascaded, the signal should be directed to the master only. Less than 1 Volt will switch off the water heater(s).

Time program

Time programs with three programmable periods per day are available. These time programs are activated at the control panel and offer great flexibility in controlling the water heater’s day and night temperatures as well as the anti-Legionella settings.

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3 DIMENSIONS

3.1 Water heaters S-WG80 – S-WG120

TWIN PIPE CONCENTRIC

Connections

(mm/ ” )

twin pipe

concentric

S-

WG80

S-

WG100

S-

WG120

S-

WG80

S-

WG100

S-

WG120

FG

flue gas

Ø80

Ø100

Ø80

Ø100

AI

air inlet

Ø80

Ø100

Ø125

Ø150

I

cold water inlet

R 1½”

(swivel)

R 2”

(swivel)

R 1½”

(swivel)

R 2” (swivel)

O

hot water outlet

R 1½”

(swivel)

R 2”

(swivel)

R 1½”

(swivel)

R 2” (swivel)

G

gas

R ¾” (male)

C

condensate

flexible hose Ø25/21 x 750 mm.

dimension "D"

175

160

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3.2 Water heaters S-WG150 and S-WG180

TWIN PIPE CONCENTRIC

Connections

(mm/ ” )

twin pipe

concentric

S-WG 150 -180

FG

flue gas

Ø130

Ø100

AI

air inlet

Ø130

Ø150

I

cold water inlet

Rp 2”

(swivel)

Rp 2”

(swivel)

O

hot water outlet

Rp 2”

(swivel)

Rp 2”

(swivel)

G

gas (male)

R 1”

C

condensate

flexible hose Ø25/21 x 750 mm.

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3.3 S-WG tanks

300 Ltr. 450 Ltr.

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750 Ltr.

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3.4 Cascade frames S-WG80 – S-WG180

Frames for two, three and four water heaters S-WG80 up to S-WG180

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water heaters S-WG 150 - 180

4

1980

133

160

235

317

Rp 2

R 1"

590

1080

1570

935

3

1520

133

160

235

317

Rp 2

R 1"

605

1110

n.v.t.

935

2

1015

133

160

235

317

Rp 2

R 1"

605

n.v.t.

935

935 1 510

133

160

235

317

Rp 2

R 1"

n.v.t.

935

water heaters S-WG 100 - 120

4

1980

133

160

177

314

Rp 2

R ¾"

590

1080

1570

990

3

1520

133

160

177

314

Rp 2

R ¾"

605

1110

n.v.t.

990

2

1015

133

160

177

314

Rp 2

R ¾"

605

n.v.t.

990

1

510

133

160

177

314

Rp 2

R ¾"

n.v.t.

990

water heaters S-WG 80

4

1980

133

175

177

310 Rp 1½

Rp 1½

R ¾"

590

1080

1570

990

3

1520

133

175

177

310 Rp 1½

Rp 1½

R ¾"

605

1110

n.v.t.

990

2

1015

133

175

177

310 Rp 1½

Rp 1½

R ¾"

605

n.v.t.

990

990 1 510

133

175

177

310 Rp 1½

Rp 1½

R ¾"

n.v.t.

990

Number of water

heaters cascaded

L (frame)

B1 (return)

B2 (return/flow)

B3 (gas)

C (water/gas)

D1 (flow)

D2 (return)

D3 (gas)

E1 (gas 2nd water

heater)

E2 (gas 3rd water

heater)

E3 (gas 4th water

heater)

H1 (flow/return)

H2 (gas)

E09.012.246 Manual S-WG

18

4 ACCESSORIES AND UNPACKING

4.1 Accessories

Depending on the selected way of controlling the system, the following items can be supplied with the water heater. Ask your supplier for the specifications.

Item

Part no.

1

External DHW-Tank temperature sensor 10kOhm@25°C, to be mounted on the tank outlet to the water heater

E04.016.304

2

S-WG 80 water heater: Conversion set for concentric to parallel flue and air terminal (80/125→80-80)

E61.001.163

3

S-WG 80 water heater: Conversion set for parallel to concentric flue-air terminal (80-80→80/125)

E61.001.170

4

S-WG 100 - 120 water heater: Conversion set for concentric to parallel flue and air terminal (100/150→100-100)

E61.001.164

5

S-WG 100 - 120 water heater: Conversion set for parallel to concentric flue-air terminal (100-100→100/150)

E61.001.171

6

S-WG 150 - 180 water heater: Conversion set for concentric to parallel flue and air terminal (100/150→130-130)

E61.001.179

7

S-WG 150 - 180 water heater: Conversion set for parallel to concentric flue-air terminal (130-130→100/150)

E61.001.180

8

Remote control DHW temperature ‘Open Therm’ RCW (modulating)

E04.016.645

9

Software set for diagnose, programming and temperature read out

E09.000.105

10

Hot water tank, stainless steel, 300 litres

E66.000.203

11

Hot water tank, stainless steel, 450 litres

E66.000.204

12

Hot water tank, stainless steel, 750 litres

E66.000.205

13

Interface cable between water heater control and computer (laptop) with USB connection

E04.016.586

4.2 Unpacking

The S-WG water heater will be supplied with the following documents and accessories:

 One “Installation, Operating and Maintenance Manual”  One suspension bracket with locking plate and bolts  Attached to a connection tube:

~ One safety relief valve, to be mounted conform the applicable standards and regulations

 Attached to the front of the gas valve:

~ Three spare nuts for mounting the burner plate ~ Two spare fuses for the water heater control ~ One sticker for propane or butane operation

 Bottom part of the siphon, temperature sensor and connector  Two nipples with gaskets for inlet/outlet connections of the water heater

NB! A pump is separately supplied, it’s not included in the water heater supply. For pump choice, see § 9.5. After delivery, immediately check the water heater package to see if it is complete and without any defects. Re-

port any imperfections immediately to your supplier.

E09.012.246 Manual S-WG

19

5 INSTALLATION OF THE S-WG

5.1 General notes

At every side of the water heater at least 50 mm of clearance should be applied to walls or wall units, 350 mm above the top side of the water heater and 250 mm from the bottom of the water heater.

The installation area/room must have the following provisions:

 230 V - 50 Hz power source socket with earth connection.  Open connection to the sewer system for draining condensing water:

Note:

The wall used for mounting the water heater must be able to hold the weight of the water heater. If this is not the case it is recommended to mount the water heater on a (cascade) frame.

Other considerations related to the water heater location:

 The ventilation of the plant room must meet all applicable standards and regulations, regardless of the

selected supply of fresh air to the water heater location.

 Both the air supply and the flue gas tubes must be connected to the outside wall and/or the outside roof.  The installation area must be dry and frost-free.  The water heater has a built-in fan that will generate noise, depending on the total heat demand. The wa-

ter heater location should minimise any disturbance this might cause. Preferably it is suggested to mount the water heater on a brick wall.

 There must be sufficient lighting available in the plant room to work safely on the water heater.  Remind the positioning of electrical components in relation to the temperature sensitivity.  Make sure there is an open connection with the sewer to drain the condensate. This connection should

be lower than the condensate drain level of the water heater.

The water heater must be positioned and installed by a certified installer in accordance with all applicable standards and regulations. Commissioning of the water heater must be done by a skilled service/commissioning engineer.

E09.012.246 Manual S-WG

20

5.2 Mounting the water heater and tank

5.2.1 WATER HEATER MOUNTING

Before mounting and installing the water heater the following connections should be considered:

 Flue gas system and the flue gas pipe connections  Air supply system and connections  ‘Cold in’ and ‘hot out’ pipe connection  Condensate and pressure relief valve drainage  Power supply (preferably the power connection is positioned above the water heater)

All lines/piping must be mounted free of tension. The weight of all the installation components should be supported separately from the water heater so there will be no standing force on the connections. This might influence the mounting position of the water heater.

Determine the position of the flow and return pipes by using the included suspension bracket or a suspension frame (when supplied). While marking the holes, ensure that the suspension bracket or frame is perpendicular and the water heater does not lean forward. If necessary adjust the position with the adjusting bolts at the lower rear side of the back panel (see drawing). When the adjusting bolts aren’t sufficient, fill the gap behind the bolts to get the water heater in position. The exact water heater position lies between the water heater hanging level and hanging slightly backwards.

The water heater should not lean forward in the mounted position. Lock the suspension bracket with the security cover before making any other connections to the water heater.

This security cover will prevent the water heater from falling off the bracket. Don't use excessive force during the mounting of the water heater connections.

3. Lock water heater with locking plate and two bolts

1. Attach mounting bracket to wall

with inclined side facing upwards

2. Suspend water heater with suspen-

sion bracket on mounting bracket

4. Level water heater using adjusting bolts

E09.012.246 Manual S-WG

21

Detailed drawing of the water heater mounting and the fixation of the locking plate.

5.2.2 TANK POSITIONING

The tank can be placed at will* on a stable floor, but not too far from the water heater(s). See § 9.4.3, ‘Interconnecting pipes – equivalent length’, on page 50.

* NB! This floor must be able to hold the weight of the water filled tank(s).

E09.012.246 Manual S-WG

22

6 FLUE GAS AND AIR SUPPLY SYSTEM

6.1 General

The water heater has a positive pressure flue system. The available combined pressure drop for the inlet and outlet system, for a single water heater, is 200 Pa for the complete water heater range. For a multiple water heater installation, always contact the manufacturer for advice.

Notice:

 Install the horizontal flue components with an angle of 3° downwards in the direction of the water heater

(roughly equal to five centimetres for every linear meter). When not installed accordingly, it may result in condensate building-up in the flue gas tube, eventually causing component failure.

 Wall flue terminals are generally used up to 80 kW. Using these terminals with larger capacities will give

unpleasant large condensate clouds.

 When using a wall terminal, there is the possible risk of ice building-up on surrounding parts/structures,

because the condensate will freeze. This risk should be taken into account during the design phase of the DHW installation.

Note:

Because the flue gases can have a relatively low temperature, the water heater needs to have a high efficiency approved stainless steel or plastic flue system. These materials should be usable for the applied pressure in the flue gas system, be condensate proof and have a temperature class of T-120.

6.2 Air supply

When an air supply duct is connected from the outside of the building to the water heater, the water heater will operate as a room-independent water heater (closed water heater).

The air supply duct can be made of:

 PVC / PPs  Thin-walled aluminium  Stainless steel

NOTICE: When the supply duct will be placed in a plant room with moist air (for example: greenhouses), a sufficiently insulated duct must be used to prevent the possible condensation at the outside of the duct. It is not possible to insulate the internal air pipes of the water heater and therefore condensation at the internal air canals must be prevented. The air supply duct needs to be protected against rain falling on top of the roof, so no rain water will enter the water heater.

6.3 Flue terminal

Never use aluminium (containing) flue gas materials for this water heater

The flue terminal duct can be made of:

 Stainless steel with T-120 gaskets  PPs temperature class T-120

E09.012.246 Manual S-WG

23

Height A

This is the height of the air inlet. A rain hood should prevent rainwater entering the air supply system.

When the inlet and outlet are mounted on a flat roof, the inlet should be at least 60 cm above the roof surface and at least 30 cm above the maximum snow level.

Example 1:

When the maximum snow level on the roof surface is 45 cm then the air inlet should be at 45+30=75 cm. 75 cm is more than the minimum 60 so the height will be 75 cm.

Example 2: When the maximum snow level on the roof surface is 15 cm then the air inlet should be at 15+30=45 cm. 45 cm is less than the minimum 60 cm so the height will be 60 cm.

Height B This is the height of the flue outlet related to the air inlet.

The flue gas outlet should be at least 70 cm above the air inlet. It is advised to be equipped with a conical outlet.

A single flue outlet should be situated at least 100 cm above the roof surface.

Distance C The horizontal distance between the flue gas pipe and air

inlet pipe at roof level.

This distance should be at least 70 cm.

6.4 Flue system classification B23P

Overpressure flue gas systems

For classification B23P and for overpressure flue gas systems the minimum requirements of the flue gas material for S-WG appliances can be determined in a designation string according to the EN1443 (see table).

CE string flue gas material (B23P)

European standard

Temperature class

Pressure class

Resistance to condensate

Corrosion resistance class

Metal: liner specifications

Soot fire resistance class

Distance to combustible material

Plastics: location

Plastics: fire behaviour

Plastics: enclosure

min. requirement PPs

EN 14471

T120

P1 W 1 O

30

I or E

C/E

L

min. requirement StS

EN 1856-1

T120

P1 W 1

L20040 O 40

A few examples of flue gas material suitable for S-WG water heaters:

CE String for Plastic PPs: EN14471 T120 P1 W 2 O(30) I C/E L CE String for Stainless Steel: EN1856-1 T250 P1 W V2-L50040 )(50) When selecting flue gas systems, be aware that the minimum requirements are met. So only select flue gas materials having the same or better properties than this table.

6.5 Flue system classification C63

In general, appliances are certified with their own flue gas material. If a water heater is C63 certified, no specific type flue gas material has been certified in combination with the water heater. In this case the flue gas material does not need to be certified in combination with the water heater but should be fit for purpose, and comply with the applicable European standards. It must be able to handle the condensate forming and transport, overpressure and must have a minimum temperature class of T120.

E09.012.246 Manual S-WG

24

6.6 Combustion air quality

Combustion air must be free of contaminants. For example: chlorine, ammonia and/or alkali agents, dust, sand and pollen. Remind that installing a water heater near a swimming pool, a washing machine, laundry or chemical plants does expose combustion air to these contaminants.

6.7 Flue gas & air inlet calculation examples (next pages)

For several flue gas & air inlet combinations the maximum length of the pipes will be calculated using the given table:

A: Twin pipe system with separate pipes for flue gas and air supply B: Twin pipe system with separate pipes and concentric roof terminal C: Single pipe for flue gas outlet only (air supply from plant room)

E09.012.246 Manual S-WG

25

Flue gas and air supply resistance table

NOTICE: This table can only be used for a single flue/air system for one water heater. Do NOT use this table for common flue/air systems with cascaded water heaters.

FLUE GAS PIPING

RESISTANCE [Pa]

Ø [mm] *

S-

WG80

S-

WG100

S-

WG120

S-

WG150

S-

WG180

straight tube/m

80

8.0 - - - -

100

3.5

4.0

6.5 - -

130

0.8

1.2

1.8

3.8

6.0

150

-

0.5

0.8

1.7

3.0

45° bend

80

4.0 - - - -

100

1.7

2.0

3.2 - -

130

0.4

0.6

0.8

1.9

3.0

150

-

0.2

0.4

0.8

1.5

90° bend

80

8.0 - - - -

100

3.5

4.0

6.5 - -

130

0.8

1.2

1.8

3.8

6.0

150

-

0.5

0.7

1.7

3

Flue outlet zeta=0.05

80

1.2 - - - -

100

0.5

0.8

1.1 - -

130

0.18

0.3

0.4

0.6

0.9

150

-

0.15

0.2

0.35

0.5

Flue outlet zeta=1.0

80

24 - - - -

100

9.8

15.2

22.1 - -

130

3.5

5.3

7.8

12

17.3

150

-

3.0

4.4

6.8

9.8

Flue outlet zeta=1.5

80

36 - - - -

100

14.8

22.8

33.2 - -

130

5.2

8.0

11.6

18

26

150

-

4.5

6.6

10.2

14.7

AIR SUPPLY PIPING

RESISTANCE [Pa]

Ø [mm] *

S-

WG80

S-

WG100

S-

WG120

S-

WG150

S-

WG180

straight tube/m

80

7.5 - - - -

100

3.0

3.5

4.0 - -

130

0.75

0.8

1.1

1.2

2.0

150

-

0.3

0.4

0.6

1.2

45° bend

80

3.5 - - - -

100

1.5

1.7 2 -

-

130

0.4

0.5

0.6

1.0

150

-

0.15

0.2

0.3

0.6

90° bend

80

7.0 - - - -

100

3.0

3.5

4.0 - -

130

0.7

0.8

1.1

1.2

2.0

150

-

0.3

0.4

0.6

1.2

Air inlet zeta=1.0

80

18.1 - - - -

100

7.4

11.4

16.7 - -

130

2.6

4.0

5.8

9.1

13.1

150

-

2.3

3.3

5.1

7.4

CONCENTRIC PARTS

RESISTANCE [Pa]

Ø [mm] *

S-

WG80

S-

WG100

S-

WG120

S-

WG150

S-

WG180

roof terminal

80/125

61 - - - -

100/150

-

39

45

69

86

130/200

- - -

15

23

outside wall terminal

80/125

22 - - - -

100/150

-

19

24

40

48

straight tube/m

80/125

12 - - - -

100/150

-

8.0

10

14

16

45° bend conc.

80/125

7 - - - -

100/150

-

8.0

9.0

14

16

90° bend conc.

80/125

13 - - - -

100/150

-

11

13

22

28

conc./par. adaptor

80/125

14 - - - -

100/150

-

16

22

40

56

* Do not reduce pipe diameters relative to water heater connections

Roof

FLUE GAS OUTLET

AIR INLET

CONCENTRIC

Wall

H

D

H/D=1,0

zeta=1,0

AIR INLET

H

D

H/D=0,5

zeta=1,5

H

D

H/D=1,0 zeta=1,0

conical outlet

zeta=0,05

FLUE GAS OUTLET

open outlet

zeta=0

zeta = 0.0 open outlet

zeta = 0.05 conical outlet

H/D = 1.0 zeta = 1.0

H/D = 0.5 zeta = 1.5

H/D = 1.0 zeta = 1.0

Roof

Wall

FLUE GAS OUTLET

AIR INLET

CONCENTRIC

FLUE GAS OUTLET

AIR INLET

E09.012.246 Manual S-WG

26

A: Twin pipe system with separate pipes for flue gas and air supply.

Example A

The total resistance is less than 200 Pa. This flue gas/air supply system is functional.

180

4m

2m

5m

Water heater type:

S-WG 180

Flue gas

Diameter: 130 mm.

Number

Pa

Pa total

Straight tube m¹

total 9 6

54

Bend

90° 2 6

12

Flue outlet

conical

1

0.9

Total resistance flue gas outlet:

66.9

Air supply

Diameter: 130 mm.

Number

Pa

Pa total

Straight tube m¹

total 8 2

16

Bend

90° 2 2

4

Air inlet

H/D = 1.0

1

13.1

Total resistance air supply:

33.1

Total resistance flue gas outlet and air supply:

100 Pa

E09.012.246 Manual S-WG

27

B: Twin pipe system with separate pipes and concentric roof terminal.

Example B

The total resistance is less than 200 Pa. This flue gas/air supply system is functional.

120

2m

Water heater type:

S-WG 120

Flue gas

Diameter: 100 mm.

Number

Pa

Pa total

Straight tube m¹

total

6

6.5

39

Bend

90° 2 6.5

13

Roof terminal

concentric

150/100

1

45

Adaptor conc./par.

150/100

1

22

Total resistance flue gas outlet:

119

Air sup-

ply

Diameter: 100 mm.

Number

Pa

Pa total

Straight tube m¹

total 6 4

24

Bend

90° 2 4

8

Total resistance air supply:

32

Total resistance flue gas outlet and air supply:

151 Pa

E09.012.246 Manual S-WG

28

C: Single pipe for flue gas outlet only (air supply from plant room).

Example C

The total resistance is less than 200 Pa. This flue gas/air supply system is functional.

100

4m

2m

3m

2

m

2m

Water heater type:

S-WG 100

Flue gas

Diameter: 100 mm.

Number

Pa

Pa total

Straight tube m¹

total

13 4 52

Bend

90° 2 4

8

Bend

45° 2 2

4

Flue outlet

H/D = 1.0

1

15.2

Total resistance flue gas outlet:

79.2

E09.012.246 Manual S-WG

29

Twin pipe system: flue gas and air supply positions.

Example A

water heater type 

S-WG80

S-WG100

S-WG120

S-WG150

S-WG180

Diameter air inlet

80

100

130

Diameter flue outlet

80

100

130

Diameter roof terminals

80

100

130

Maximum pipe length

(inlet + outlet together)

18.0

31.5

24.0

44.5

30.0

Example B

water heater type 

S-WG80

S-WG100

S-WG120

S-WG150

S-WG180

Diameter air inlet

80

100

130

Diameter flue outlet

80

100

130

Concentric roof terminal

80/125

100/150

130/200

Maximum pipe length

(inlet + outlet together)

12.0

23.0

16.5

40.5

25.5

Concentric roof terminal

Air inlet

Flue outlet

Example A

Example B

concentric/parallel adaptor

E09.012.246 Manual S-WG

30

Single pipe system: flue gas positions:

Example C

water heater type 

S-WG80

S-WG100

S-WG120

S-WG150

S-WG180

Diameter air inlet

80

100

130

Diameter flue outlet

80

100

130

Diam. roof terminal

80

100

130

Maximum pipe length

(total outlet length)

21.5

46.5

27.5

49.5

30.0

Example C

Vented area

Air inlet

Flue outlet

E09.012.246 Manual S-WG

31

Concentric pipe system: flue gas positions:

Example D

water heater type 

S-WG80

S-WG100

S-WG120

S-WG150

S-

WG180

Diameter concentric pipe

80/125

100/150

NOT

RECOMMENDED

(choose B, C or E)

Concentric roof terminal

80/125

100/150

Maximum pipe length

7.0

14.5

10.0

Example E

water heater type 

S-WG80

S-WG100

S-WG120

S-WG150

S-

WG180

Diameter concentric pipe

80/125

100/150

Concentric wall terminal

80/125

100/150

Maximum pipe length

12.5

20.0

15.0

8.5

6.5

Concentric roof terminal

Concentric wall terminal

Example D

Example E

E09.012.246 Manual S-WG

32

7 ELECTRICAL INSTALLATION

7.1 General

All the wiring is connected to a separate connector that is fitted in a socket. The connector can be taken from the sockets without loosening the wiring. The connections are placed on top of the display panel and can be accessed by removing the water heater front door and the connector protection cover.

 For operation the water heater needs a power supply of 230 Vac 50Hz.  The water heater connections are not life/neutral sensitive (the water heater is not phase-sensitive).  The wiring for the connections can be entered at the bottom of the water heater through the cable glands.  NOTICE: Before starting to work on the water heater, it must be switched off and the power supply to the

water heater must be disconnected.

 Electrical wiring should be installed according to all applicable standards and regulations.  Working on the water heater should only be done by a skilled service engineer/installer and according to

all applicable standards and regulations.

7.2 Electrical connections

The following table describes the function of all connections of the water heater.

1-2

DO NOT USE

Do not connect any cable to these connections

3-4

TANK SENSOR

This external flow sensor measures the flow temperature at the system side. The sensor must be mounted on the supply pipe at the system side, close to the tank. NOTICE: The sensor must be used when several water heaters are cascaded with the internal cascade manager. PARAMETER: No parameter settings needed.

5-6

DO NOT USE

Do not connect any cable to these connections

7-8

GENERAL BLOCKING

A heat demand that will start the burner will be blocked when terminals 7 and 8 are not bridged. This connection is for the use of external safety devices (terminals must be bridged for allowing burner to fire).

9-10

EMPTY

Table is continued 

DO NOT

USE

TANK

SENSOR

DO NOT

USE

GENERAL

BLOCKING

EMPTY

EXTERNAL

WPS

ON/OFF STAT

OR

OPEN THERM

0 -10

VDC

CASCADE

CONNECTION

LOCK-OUT

BURNER

BURNING

HEAT

DEMAND

CIRCULATION

PUMP P3

DO NOT USE

MAINS 230 VAC

CONNECTIONS

E09.012.246 Manual S-WG

33

11-12

EXTERNAL WATER PRESSURE SWITCH

A water pressure switch is mounted in the water heater. As an option an external water pressure switch can be wired to the terminals. In this case remove connectors from ‘internal water pressure switch’. When terminals 11-12 are not bridged, the water heater will lock-out. PARAMETER: A parameter change is needed.

13-14

ON/OFF STAT OR OPENTHERM WATER TANK

OPTION 1: an ON/OFF thermostat can be connected. The water heater will use the set/programmed tank temperature when these terminals 13 and 14 are bridged. OPTION 2: an OpenTherm (OT) controller can be connected to the terminals 13 and 14. The water heater software will detect and use this OpenTherm signal automatically.

15-16

0-10 VDC CONTROL SIGNAL

These terminals are used for an external 0-10 VDC control signal. PARAMETER: A parameter change is needed. NOTICE: Terminal 15 [+] (positive) and terminal 16 [-] (negative).

17-18

CASCADE CONNECTION

These connections are used when water heaters are cascaded with the internal cascade manager for controlling the total cascade. NOTICE: Connect all terminals 17 and all terminals 18 together, do not switch between these terminals.

19-20

LOCK-OUT OR PUMP ON/OFF

This contact is N.O. (normally open). When the unit is in lock-out this contact will close. This contact can also be used for the switching of a pump with a separate control input connection. (PARAMETER: A parameter change is needed).

21-22

BURNER ACTIVE OR EXTRA WATER HEATER OR PUMP ON/OFF

This contact is N.O. (normally open). When the unit starts the burner and detects the flame, this contact will be closed. This contact can also be used to control an external (extra) water heater. This contact can also be used for the switching of a pump with a separate control input connection. (PARAMETER: A parameter change is needed).

23-24

BURNER DEMAND OR PUMP ON/OFF

This contact is N.O. (normally open). When the unit receives any heat demand this contact will close. This contact can also be used for the switching of a pump with a separate control input connection. (PARAMETER: A parameter change is needed).

25-26-27

CIRCULATION PUMP P3

Each boiler should be installed with an external pump.

Make use of a relay between this pump and terminal 25-27, when the pump consumes more than 450 Watt.

Pump is switched off, when there is no heat demand, after post running time.

28-29-30-31

DO NOT USE

Do not connect any cable to these connections.

TAKE CARE! 230 V electric voltage on these connections

32-33-34

POWER SUPPLY

The power supply connection of the unit. 32 = phase wire; 33 = ground wire; 34 = neutral wire.

7.3 Sensor values

SENSOR

SENSOR TYPE

SENSOR VALUE

S1

Internal flow sensor

NTC-10K

S2

Internal return sensor

NTC-10K

S3

Tank sensor

NTC-10K

S6

Flue gas sensor

NTC-10K

Conversion table: temperature vs. resistance for all sensors NTC-10k

Temperature

(°C)

Resistance

(Ω)

Temperature

(°C)

Resistance

(Ω)

Temperature

(°C)

Resistance

(Ω)

Temperature

(°C)

Resistance

(Ω)

-30

175203

20

12488

70

1753

120

387

-25

129289

25

10000

75

1481

125

339

-20

96360

30

8059

80

1256

130

298

-15

72502

35

6535

85

1070

135

262

-10

55047

40

5330

90

915

140

232

-5

42158

45

4372

95

786

145

206

0

32555

50

3605

100

677

150

183

5

25339

55

2989

105

586

155

163

10

19873

60

2490

110

508

160

145

15

15699

65

2084

115

443

165

130

E09.012.246 Manual S-WG

34

7.4 Electrical schematics

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35

E09.012.246 Manual S-WG

36

8 THE S-WG WATER HEATER

8.1 Water quality

In direct water heating appliances the water flows directly through the heat exchanger of the water heater. Because all the time fresh water, containing dissolved minerals, is heated, scaling may occur. To prevent this, water quality must meet a number of standards. The values are the following:

Water temperature max. = 70°C Maximum allowed water hardness is 205 PPM or 205 mg/L CaCO3 (= 11.5°dH) TDS (total dissolved solids) may not exceed 450 PPM Water hardness and TDS together may not exceed 450 PPM The pH value of the water may not be under 6.5 and not above 7.5 (measured cold) If water hardness is too high a water softening system is necessary. If TDS alone or the combined value is higher than the abovementioned, the water should be heated by means of an indirect water heating appliance. Minimum water hardness = 80 PPM or 80 mg/L CaCO3 Minimum TDS = 100 PPM

Water that’s under these minimum values normally has a pH value which is aggressive and

corrosive.

NEVER install a direct heated water system in an area where water quality does not comply with abovementioned values.

If the water hardness is too high, a water treatment installation should be installed reducing the water hardness within acceptable level.

8.2 Frost protection

The water heater has a built-in frost protection, that is automatically activating the pump when the water heater return (water) temperature drops below 5°C (programmable). When the water heater return temperature drops below 3°C (programmable), the burner is also ignited. The pump and/or burner will shut down as soon as the return temperature has reached 10°C (programmable). The abovementioned temperatures are related to the temperatures measured by the RETURN sensor of the water heater. This frost protection function will not fire up the water heater in case of a “general blocking” of the burner demand.

NOTICE:

- This frost protection function is only protecting the water heater and not the whole sanitary system.

- This frost protection function is only useable provided that water circulation through the system is possible - if not, the water heater goes in a lock-out.

- Because it concerns a programmable setting, a water heater damaged by frost is not covered under warranty.

8.3 Legionella program

To avoid contamination of the water with Legionnaires’ disease, a special anti-Legionella program is present in the software of the water heater control, the settings of which are freely programmable. NB! This option is default turned ‘OFF’, the responsibility for a Legionella-free installation lies with the end-user. See § 11.1.2 on page 90 for an extensive explanation of how to use this option.

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37

8.4 Flow monitoring

Flow

In the control of the water heater an extensive flow monitoring function has been implemented. If the temperature difference between incoming cold water and outgoing hot water gets too high, this indicates a too small water flow through the appliance.

Safety actions

- If the temperature difference exceeds the maximum at a certain load, for a longer time than specified in the

software, the display will show ‘Delta direct block’ and the appliance will block: it switches immediately to

reduced power. Power is then slowly increased to the required level again. The fourth time, so after three of these blockings, the water heater will go in lock-out (F16) and the display shows ‘FlowReturn dt fault’.

- At very bad flow rates (temperature difference for 10 seconds exceeding a certain entered safety value), the

appliance will skip the blockings and immediately go in lock-out: F16, display ‘FlowReturn dt fault’.

- In Service mode the appliance will immediately go in lock-out when the maximum value corresponding to the applied power is exceeded, skipping the blocking procedures that apply at normal operation. Again F16, display ‘FlowReturn dt fault’.

NB! All values of this flow monitoring have been programmed by STREBEL in order to get the best performance

combined with a long life time.

8.5 Water pressure switch

Water pressure getting too low indicates a blocking of the water flow. If that is the case, heat from the flue gases cannot be transferred and will flow away through the flue gas channels. Also overheating of the heat exchanger and/or other parts of the system could occur, if no measures would have been taken. For this reason a water pressure switch, WPS, has been integrated in all S-WG system models.

Operating values

The water pressure switch has one Normally Open (NO) contact, meaning the contact is open in rest position when no pressure is applied. As soon as the system has been filled and the pressure exceeds 0.85 bar, the switch closes, enabling operation. If, by any cause, the pressure drops under 0.75 bar, the system will be blocked.

In this case the display will show:

Display message W a t e r p r e s s u r e f a u l t 9 9 9 , 5 h r

s

Reason

Water pressure is too low or high.

Check if there is any leakage or maybe the pressure in the service pipe has dropped down. See also § 16.2 ‘Blocking codes’, from page 112 on.

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9 THE S-WG SANITAIRY SYSTEM: INSTALLATION INSTRUCTIONS

9.1 The S-WG system

The system as a whole is set up as shown in the next two examples, the first showing a combination of one water heater and one tank, the second showing a combination of three water heaters and two tanks. Other combinations are possible as well.

SAFETY COMPONENTS NB! The pictures in §§ 9.1.1 and 9.1.2 show examples of functional installations. The safety components as

shown in these pictures are NOT necessarily conform the applicable standards and regulations. ALWAYS have the installation installed by a skilled installer. Safety must be added according to all applicable

standards and regulations.

9.1.1 STAND-ALONE SET-UP

The basic form of a S-WG installation is one water heater with one tank. Shown in the picture are the principle components and connections.

Example of a combination of one water heater and one tank

PUMP

NON RETURN VALVE

VALVE

SAFETY VALVE

AUTOMATIC AIR VENT

FILTER

INLET COMBINATION

- Overflow

- Controllable return valve

- Valve

PRESSURE REGULATING VALVE

Extra explanation:

1) Pressure relief valve (mandatory in case water pressure is too high)

2) Inlet combination with valve (mandatory)

3) Apply filter if necessary (recommended)

4) A suitable safety valve must be mounted near the water heater (mandatory) 1

This safety valve may never be isolated from

the water heater by means of a ball valve

5) Mount remote pipe sensor as close as possible to the tank

6) Drain valve (recommended)

7) Hot and cold water mixers

A) Cold water inlet (service pipe) B) Hot water circulation flow C) Circulation return

1

Always apply safety components according to

all applicable standards and regulations.

1

2

3

A

B

C

4

7

A

5

6

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39

9.1.2 CASCADE SET-UP

S-WG water heaters and tanks can be installed cascaded in a number of possible combinations cf. the instructions in the next paragraphs.

For the installation of cascaded water heaters and tanks, always consult the tables in § 9.4. All requirements concerning pipe diameters and lengths as well as pump choice are presented orderly here. By applying these you’ll improve both the well-functioning and the life time of your S-WG installation.

PUMP

NON RETURN VALVE

VALVE

SAFETY VALVE

AUTOMATIC AIR VENT

FILTER

INLET COMBINATION

- Overflow

- Controllable return valve

- Valve

PRESSURE REGULATING VALVE

Example of a combination of three water heaters and two tanks

Notes:

 Connections on the water heater side should always be executed as drawn.  In the inlet (return) connection of the water heater no check valve is recommended.  All designs and tables in the next paragraphs go up to eight water heaters max. If needed, the water

heater control can handle up to twelve water heaters.

B

C

B

C

7

3

1

2

A

5

6 6

6 6 6 6 6 6

Extra explanation:

1) Pressure relief valve (mandatory in case water pressure is too high)

2) Inlet combination with valve (mandatory)

3) Apply filter if necessary (recommended)

4) A suitable safety valve must be mounted near the water heater (mandatory) 1

This safety valve may never be isolated from

the water heater by means of a ball valve

5) Mount remote pipe sensor as close as possible to the tank

6) Drain valve (recommended)

7) Hot and cold water mixers

A) Cold water inlet (service pipe) B) Hot water circulation flow C) Circulation return

1

Always apply safety components according to

all applicable regulations.

E09.012.246 Manual S-WG

40

 For large capacity installations (more than two water heaters) consult STREBEL.

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41

9.1.3 CONTROL GENERAL

 There is no need for a sensor in the tank, because when the pump starts to run, the inlet sensor of the water

heater is measuring the water temperature of the tank.

 When there is no drawing water from the tank, the inlet sensor is measuring the water temperature in the

tank.

 After ending a heat demand, the pump has a post turning time.  On the control panel, the tank or hot water temperature can be set.  When a remote wall controller is connected to the wire terminal (13) and (14), the setting of the tank tem-

perature can be done with this controller (Open Therm bus), also the night or weekend reduction of tank temperature.

 During a period of no tapping, the temperature inside the tank is maintained at the Setting temperature

automatically.

 A safety control stops the water heater from firing, when the temperature difference between flow and return

gets higher than allowed at the actual load (flow monitoring, ΔT function).

 Parameters: the default of the parameters of the water heater control have been set for this type of tanks.

9.1.4 CASCADE CONTROL

 Up to twelve water heaters can be cascaded.  One water heater has to be appointed master, the other water heaters are appointed slaves, each with

his own address in the software.

 The slaves are connected with two wires to the master.  Every individual water heater has a connection for a pump.  An external temperature sensor is placed at the inlet tube of the system (S3), sensing the temperature of

the inlet water of the water heaters: the sensor has to be placed close to the connection of the tank.

 At a heat demand, the master water heater controls the heat output of the slaves, on base of the mea-

sured temperature of the external sensor.

 When a slave stops burning, the pump connected to this slave has a post turning time.  When one water heater in the cascade installation is burning, the fans of the other water heaters are

turning at a low speed, preventing recirculation of the flue gases.

 Flow monitoring cf. § 8.4 (page 37) remains active in every separate water heater of the cascade.

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42

9.2 Water heater and tank: connections and connection sizes

9.2.1 CONNECTING THE TANK TO THE WATER HEATER

 Connect the pump by means of couplings and a piece of copper pipe to connection A of the water heater

(note the flow direction of the pump).

 Connect the inlet of the pump to the upper of the two close above each other located connections of the

tank, labelled ‘return to water heater’.

 Connect connection B of the water heater to the lower of the two close above each other located connec-

tions of the tank, labelled ‘flow from water heater’. Also make a tap point in this line at the lowest point.

WATER HEATER CONNECTIONS

A = inlet cold water B = outlet hot water C = overpressure safety valve D = gas

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43

9.2.2 TO CONNECT THE TANK TO YOUR DHW INSTALLATION

(see picture on next page )

 Connect the fresh water supply to the single connection C, labelled ‘cold in’, opposite to A and B which

were used for connecting the water heater. For the application of inlet combination, (control) valves, etc. all applicable regulations should be met.

 Connect the DHW connection on top of the tank, labelled ‘hot out’, to your DHW installation.  Connect the recirculation line to connection F, labelled ‘circulation return’, on the side of the tank, at the

same height as inlet C.

The STREBEL tanks have the following DHW connections:

 COLD IN for inlet of fresh water  HOT OUT for outlet of DHW  water heater return for connection to inlet of water heater  water heater flow for connection to outlet of water heater  CIRCULATION RETURN for recirculation of DHW from installation to tank

Besides there are connections for:

 Thermometer (on side on ± ¾ of height of the tank)  Connection for T&P valve (mounted on top) according to the applicable standards and regulations. Even

if a T&P valve has to be applied, the safety at the water heater’s side, on position C ( see previous page), should be maintained at all times!

Tank connection sizes:

Code

Connection

M / F

Remarks

300 L

450 L

750 L

A

return water heater

M

incl. reducing ring

R 2"

excl. reducing ring

R 1½"

B

flow water heater

M

incl. reducing ring

R 2"

excl. reducing ring

R 1½"

C

cold water inlet

M

incl. reducing ring

R 2"

excl. reducing ring

R 1½"

D

DHW outlet

M

incl. reducing ring

R 2"

excl. reducing ring

R 1½"

E

free connection (T&P valve)

F

incl. plug

Rp 1½"

F

circulation return

M

incl. cap

R ¾"

G

bleed valve

-

- - -

-

H

thermometer connection

F

incl. plug

Rp ½"

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44

9.2.3 CONDENSATE DRAIN CONNECTION

The condensate drain is placed at the centre at the bottom of the water heater and has a ¾ inch hose discharge. Connect this flexible hose to the sewer system. Use only plastic parts with the condensate drain. Metal lines are not allowed.

Blockage of this drain might damage the water heater. The drain connection is correct when the condensate can be seen flowing away, e.g. using a funnel. Any damage that might occur, when the drain is not installed correctly, is not covered by the warranty of the water heater.

There should be an open connection between the condensate hose and the sewage system, to make sure that any pressure difference between the two can never affect the condense water level and hence the functioning of the water heater:

When mounting the bottom part of the siphon, before commissioning the water heater and/or after maintenance, it must ALWAYS be completely filled with water.

This is a safety measure: the water in the siphon keeps the flue gases from entering the plant room via the condensate drain.

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9.3 Cascade systems: assigning pipe codes

With the tables in § 9.4 (from page 47 onwards) the diameters of the several connection pipes can be assessed, so that there will always be sufficient flow. For using the tables in a straightforward manner, water heaters and pipes need to be numbered, where water heater-1 is the one that‘s situated the furthest away from the tanks. The pipe codes are set as pointed out below:

9.3.1 PIPE CODES WATER HEATER SIDE

The codes of the piping in the picture are used in the installation tables in section 9.4 to determine the right installation diameters.

Hot water out

These pipes get codes F1 to FF (where FF = F(last)) (F for flow) The hot water connections directly to the water heaters get the next codes:

 for an installation containing one water heater:

code FF (see § 9.4.1, pick the table of the corresponding water hea-ter type)

 for all cascades of more than one water heater:

code F1 = Ø 54 mm (standard tube 541.5) The (‘continuous’) hot water pipe that’s connected to this ‘water heater flow pipe’ is numbered after the corresponding water heater: F1 at water heater-1, F2 at water heater-2, etc.

Cold water in

These pipes get codes R1 to RR (where RR = R(last)) (R for return) The return connections directly to the water heaters get the next codes:

 for an installation containing one water heater:

code RR (see § 9.4.1, pick the table of the corresponding water heater type)

 for all cascades of more than one water heater:

code R1 = Ø 54 mm (standard tube 541.5) The (‘continuous’) return pipe that’s connected to this ‘water heater return pipe’ is numbered ‘reversely’ to the corresponding water heater:

 R1 at water heater-last, R2 at water heater-last but one, etc.

Main connections:

- The main connections from cascade to tank(s) are not called F(number-last) and R(number-last) but FF and

RR.

- For every type of cascade F1=R1, F2=R2, …, FF=RR. On the next page the procedure will be summarized 

F1R1F1R1F1R1F1R1

R2 R1R3

RR FF

F5F3 F4

R1F1

R4

F2

R1

RR R5

F1

R1 F1

R6

F6

R1 F1

F7

R7

1 2 3 4 5 6 7 8

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46

9.3.2 PIPE CODES AT THE TANKS’ SIDE

The codes of the piping in the picture are used in the installation tables in section 9.4 to determine the right installation diameters.

Numbering

Tank numbering may be useful to install flow and return connections in the right way, but doesn’t affect pipe diameters. Only numbers of tanks and water heater type do (see tables § 9.4.2).

Encoding

Tank connections: A1 and B1 (entrance and exit). The values are found in the tank tables (§ 9.4.2) Pipes between these connections: FF and RR, values from the water heater tables (§ 9.4.1). For a given cascade, A1 equals B1.

9.3.3 EQUIVALENT LENGTH

Piping between (cascaded) water heaters and one or more tanks. Equivalent length. Piping connecting the water heaters’ cascade with the tanks may not be too long, and moreover, every extra component, such as bends and the like, contributes to the so-called ‘equivalent length’, see table ‘Equivalent lengths’ in § 9.4.3 on page 50.

ELABORATED EXAMPLES At the end of this chapter, in § 9.5.4, three elaborated examples will be given demonstrating how to apply the tables and values given in §§ 9.4 and 9.5.

FF

B1A1 B1A1

RR

FF

A1 B1

RR RR

FF

A1B1

FF

B1A1

RR

B1 A1

RR

FFFF

1 2 3 4 5 6 7

B1

RR

A1

FF

A1B1

8

RR

FF

COLDIN

RR

FF

COLD WATER IN (SERVICE PIPE)

SUMMARY ENCODING PIPES WATER HEATER SIDE:

Assigning codes to a one water heater installation:

- There’s only one flow pipe, encoded FF, and one return pipe, encoded RR. For the right diameters see § 9.4.1, pick the table of the corresponding water heater type.

Assigning codes to cascades: two or more water heaters to connect:

- First number the water heaters: water heater-1 is the one that‘s situated the furthest away from the tank(s).

- Connections directly to the water heaters: F1 = R1 = 541,5 (mmmm)

- Number the horizontal flow pipes between water heaters: from F1 at water heater-1 to FF at water heater-number-last.

- Number the horizontal return pipes between water heaters ‘reversely’: from R1 at water heaternumber-last to RR at water heater-1.

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47

9.4 Connection component tables – diameters and lengths

General remark: diameters may at any time be chosen LARGER than specified in the tables, but never SMALLER. Flow must remain guaranteed. The pipe tables in this section are numbered after capacity: Water heater tables WH-80, WH-100 etc. up to WH-180 and tank headers T-80, T-100 etc. up to T-180.

9.4.1 WATER MANIFOLDS

Numbering:

- Water heater-1 is the one that is situated the furthest away from the tanks

- For the hot water flow pipes start numbering (F1) at water heater-1

- For the cold water return pipes start numbering (R1) at water heater-nr. last

The figures in the tables refer to diameterwall thickness (mmmm) of the corresponding pipe

S-WG80

Nr. of cascaded

water heaters

FF/RR

F1/R1

F2/R2

F3/R3

F4/R4

F5/R5

F6/R6

F7/R7

1

421.4

---

2

671.9

541.5

---

3

802.1

541.5

671.9

---

4

802.1

541.5

671.9

802.1

---

5

932.3

541.5

671.9

802.1

---

6

1062.5

541.5

671.9

802.1

932.3

---

7

1062.5

541.5

671.9

802.1

932.3

1062.5

---

8

1332.8

541.5

671.9

802.1

932.3

1062.5

table WH-80

S-WG100

Nr. of cascaded

water heaters

FF/RR

F1/R1

F2/R2

F3/R3

F4/R4

F5/R5

F6/R6

F7/R7

1

541.5

---

2

671.9

541.5

---

3

802.1

541.5

671.9

---

4

932.3

541.5

671.9

802.1

---

5

1062.5

541.5

671.9

802.1

932.3

---

6

1062.5

541.5

671.9

802.1

932.3

1062.5

---

7

1332.8

541.5

671.9

802.1

932.3

1062.5

---

8

1332.8

541.5

671.9

802.1

932.3

1062.5

1332.8

table WH-100

S-WG120

Nr. of cascaded

water heaters

FF/RR

F1/R1

F2/R2

F3/R3

F4/R4

F5/R5

F6/R6

F7/R7

1

541.5

---

2

802.1

541.5

---

3

932.3

541.5

802.1

---

4

1062.5

541.5

802.1

932.3

---

5

1332.8

541.5

802.1

932.3

1062.5

---

6

1332.8

541.5

802.1

932.3

1062.5

1332.8

---

7

1332.8

541.5

802.1

932.3

1062.5

1332.8

---

8

1593.0

541.5

802.1

932.3

1062.5

1332.8

table WH-120

to be continued 

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48

(Water manifolds continued (§ 9.4.1))

S-WG150

Nr. of cascaded

water heaters

FF/RR

F1/R1

F2/R2

F3/R3

F4/R4

F5/R5

F6/R6

F7/R7

1

541.5

---

2

802.1

541.5

---

3

932.3

541.5

802.1

---

4

1062.5

541.5

802.1

932.3

---

5

1332.8

541.5

802.1

932.3

1062.5

---

6

1332.8

541.5

802.1

932.3

1062.5

1332.8

---

7

1593.0

541.5

802.1

932.3

1062.5

1332.8

---

8

1593.0

541.5

802.1

932.3

1062.5

1332.8

1593.0

table WH-150

S-WG180

Nr. of cascaded

water heaters

FF/RR

F1/R1

F2/R2

F3/R3

F4/R4

F5/R5

F6/R6

F7/R7

1

671.9

---

2

932.3

541.5

---

3

1062.5

541.5

932.3

---

4

1332.8

541.5

932.3

1062.5

---

5

1332.8

541.5

932.3

1062.5

1332.8

---

6

1593.0

541.5

932.3

1062.5

1332.8

---

7

1593.0

541.5

932.3

1062.5

1332.8

1593.0

---

8

Di>160

541.5

932.3

1062.5

1332.8

1593.0

table WH-180

9.4.2 TANK HEADERS

The numbers in the tables are diameter  wall thickness (mm  mm) of the corresponding pipe

S-WG80

Pipe diameter A1/B1 to the water tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

421.4

351.3

281.2

221,1

221.1

2

671.9

421.4

351.3

351,3

281.2

221.1

3

802.1

541.5

421.4

421,4

351.3

281.2

4

802.1

671.9

541.5

421,4

421.4

351.3

5

932.3

671.9

541.5

541,5

421.4

351.3

6

1062.5

802.1

671.9

541,5

541.5

421.4

7

1062.5

802.1

671.9

541,5

541.5

421.4

8

1332.8

802.1

671.9

671,9

541.5

421.4

table T-80

S-WG100

Pipe diameter A1/B1 to the water tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

541.5

351.3

281.2

281,2

221.1

2

671.9

541.5

421.4

351,3

351.3

281.2

3

802.1

541.5

421,4

351.3

281.2

4

932.3

671.9

541.5

541,5

421.4

351.3

5

1062.5

802.1

671.9

541,5

541.5

421.4

6

1062.5

802.1

671.9

541,5

541.5

421.4

7

1332.8

932.3

671.9

671,9

541.5

421.4

8

1332.8

932.3

802.1

671,9

671.9

541.5

table T-100

to be continued 

E09.012.246 Manual S-WG

49

(Tank headers continued (§ 9.4.2))

S-WG120

Pipe diameter A1/B1 to the water tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

541.5

421.4

351.3

281,2

281.2

221.1

2

802.1

541.5

421.4

421,4

351.3

281.2

3

932.3

671.9

541.5

541,5

421.4

351.3

4

1062.5

802.1

671.9

541,5

541.5

421.4

5

1332.8

802.1

671.9

671,9

541.5

421.4

6

1332.8

932.3

802.1

671,9

671.9

541.5

7

1332.8

1062.5

802.1

671,9

671.9

541.5

8

1593.0

1062.5

932.3

802,1

671.9

541.5

table T-120

S-WG150

Pipe diameter A1/B1 to the water tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

541.5

421.4

351.3

281,2

281.2

221.1

2

802.1

541.5

421,4

351.3

281.2

3

932.3

671.9

541.5

541,5

421.4

351.3

4

1062.5

802.1

671.9

541,5

541.5

421.4

5

1332.8

932.3

802.1

671,9

541.5

6

1332.8

932.3

802.1

671,9

671.9

541.5

7

1593.0

1062.5

932.3

802,1

671.9

541.5

8

1593.0

1062.5

932.3

802,1

802.1

671.9

541.5

table T-150

S-WG180

Pipe diameter A1/B1 to the water tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

671.9

541.5

421.4

351,3

351.3

281.2

2

932.3

671.9

541.5

541,5

421.4

351.3

3

1062.5

802.1

671.9

541,5

541.5

421.4

4

1332.8

932.3

802.1

671,9

671.9

541.5

5

1593.0

1062.5

802.1

802,1

671.9

541.5

6

1593.0

1062.5

932.3

802,1

802.1

671.9

541.5

7

Di>160

1332.8

1062.5

932,3

802.1

671.9

8

Di>160

1332.8

1062.5

932,3

802.1

671.9

table T-180

E09.012.246 Manual S-WG

50

9.4.3 INTERCONNECTING PIPES – DIAMETERS AND EQUIVALENT LENGTH

When the water heaters and tanks are separated over some distance, the interconnecting pipes may only have a certain maximum length, dependent of the number of bends and the like components. For every applied component a so-called ‘equivalent length’ is deducted from the total allowed.

The meaning of the connection ‘VL’ can be seen in the drawing below. The diameter of this connection VL should meet at least the specified pipe diameter FF/RR. For this pipe connection the maximum straight length of flow and return part added * has been specified in the table below.

* The real available maximum distance VL between water heaters and tanks is therefore half of the

length specified in the table!

Drawing, explaining pipe connection ‘VL’:

Each component that’s added to the straight pipes is contributing to the total resistance, and will therefore cause a necessary reduction of straight length. The table contains a number of commonly used components and their equivalent length:

Copper

pipe

diameter

Maximum

straight length

flow + return

equiv. length

90° elbow

R=0.5D

equiv. length

90° elbow

R=1.0D

equiv. length

45° bend

R=1.0D

fully

ported

ball valve

RR/FF

m

m/elbow

m/bend

m/valve

541.5

24.2

2.8

1.0

0.6

0.4

671.9

26.1

3.3

1.1

0.7

0.5

802.1

28.5

3.8

1.3

0.8

0.6

932.3

31.9

4.6

1.6

0.9

0.7

1062.5

36.7

5.7

2.0

1.1

0.9

1332.8

44.3

7.5

2.6

1.5

1.1

1593.0

58.2

10.8

3.8

2.2

1.6

table EL

Example: Suppose, for a project the diameter FF/RR has been specified the value 1062.5, so the maximum allowed straight length is 36.7 m (see table). In the connection is added

- 4  bend 90°, R=0.5D

- 2  fully ported ball valve This gives a reduced allowed straight length of:

36.7  ( 45.7 )  ( 20.9 ) = 12.1 m With this component configuration one may only use 12.1 m straight length.

 The distance between water heater main connections and tank main connections in this example is therefore ~6 m at max.

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51

9.5 Pump choice and pump control

Pump choice is of very great importance, because, in combination with the system’s total resistance, it sets the water velocity in water heater and pipes. The right water velocity is essential for correct functioning and a long life time of the system.

9.5.1 PUMP CHOICE

Select the pump for your S-WG-installation using the following tables, by looking up, in the table that relates to the S-WG water heater type you installed, the applied combination of numbers of cascaded water heaters and tanks. 1

P1 = Wilo TOP Z 25/10 (1.5")

P2 = Grundfos UPS 32-100N

S-WG 80

Number of tanks

cascaded

units

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

P1

P1 2 P2

P1

P1 3 x

P1

P1 4 x

P2

P1

5

x

P2

P1

6

x x P2

P1

P1 7 x x P2

P1

P1 8 x x P2

P2

P1

P2 = Grundfos UPS 32-100N

P4 = Wilo TOP Z 30/10 (2") when not available P4 is replaced by P2

S-WG100

Number of tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

P4

2

P2

P4

P4 3 x

P4

P4 4 x

P2

P4

P4 5 x x P4

P4

P4 6 x x P2

P4

P4 7 x x P2

P4

8

x x x

P2

P4

P2 = Grundfos UPS 32-100N

S-WG120

Number of tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

P2

P2 2 x

P2

P2 3 x x P2

P2

P2 4 x x P2

P2

5

x x x

P2

6

x x x x P2

P2

P2 7 x x x x P2

P2

P2 8 x x x x x

P2

E09.012.246 Manual S-WG

52

P2 = Grundfos UPS 32-100N

S-WG150

Number of tanks

Nr. of cascaded

water heaters

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

P2

P2 2 x x P2

P2

P2 3 x x x

P2

P2 4 x x x x P2

P2

P2 5 x x x x x

P2

6

x x x x x x x

P2

7

x x x x x x x x 8

x x x x x x x

x

P3 = UPS 40-120 FB

S-WG180

Number of tanks

cascaded

units

1 tank

2 tanks

3 tanks

4 tanks

5 tanks

6 tanks

7 tanks

8 tanks

1

P3

P3 2 x

P3

3

x x P3

P3

4

x x x

P3

P3 5 x x x x P3

P3

P3 6 x x x x x

P3

P3 7 x x x x x x P3

P3

8

x x x x x x x

P3

1

NB! An x in the pump tables doesn’t necessarily mean that the corresponding installation cannot be built. If it

can, it will need specific design effort and pump choice. Please consult STREBEL for advice.

STREBEL part numbers

Water heater

Pump

Part nr.

S-WG 80

Pump Top-Z 25/10

E09.000.064

S-WG 100

Pump Top-Z 30/10

E09.000.065

S-WG 100/120/150

DHW pump UPS 32-100N

E09.000.112

S-WG 180

DHW pump UPS 40-120 FB

E09.000.115

9.5.2 NOMINAL FLOW PER WATER HEATER TYPE

Water heater

Flow [m3/h]

S-WG 80 S-WG 100 S-WG 120 S-WG 150 S-WG 180

3.97

4.77

6.36

7.15

8.89

9.5.3 PUMP CONTROL

The applied pump must be controlled by the S-WG water heater control. If, for any reason, an external pump control is applied without written approval of STREBEL, then the complete warranty on the S-WG water heater and all delivered parts will become invalid.

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53

9.5.4 PUMP: MAXIMUM ELECTRICAL POWER

General

- The inrush current of a conventional pump is approximately 2½ x its nominal current.

- The maximum current, that the relay on the PCB can switch, is 5 A. The conclusion from this is that nominal currents of pumps, controlled by the PCB, may not exceed 2 A.

S-WG pump.

The nominal current of the pump must be equal to or lower than 2 A. All pumps of § 9.5.1 fulfil this condition.

Warning (EC pumps):

In case of using an electronic commutating pump, the relays 1, 2 or 3 may not be used for the power connection, because of the inrush current of the electronics of the pump. Directly connect the pump to the mains of the water heater and use the cable kit from STREBEL. Control connections of an EC pump can be established in several ways, set by parameter P5BN. See § 11.2.5 on page 92.

E09.012.246 Manual S-WG

54

9.6 Elaborated examples

To work out the examples in this section, the rules of page 46 are given again:

9.6.1 ONE S-WG120 WATER HEATER WITH ONE 450-LITRES TANK

Water heater and tank connections:

For this system rule 1 must be applied, so only one pipe size is needed. No numbering of water heaters, tanks and connections is required. From table WH-120: for 1 water heater is FF = RR = 541.5 [mmmm] From table T-120: for 1 tank is A1 = B1 = 541.5 [mmmm]

For this system pipes sized at least 541.5 [mmmm] are required for all connections.

Equivalent length:

From table EL: The maximum total length of flow and return pipes 541.5 [mmmm] is 24.2 m. So when 541.5 [mmmm] is applied, the physical distance between water heaters and tanks may be half of this, so ~ 12 m, at max. In case bends and/or valves are used, this distance becomes less than 12 m. Use the table.

tank 450 L

boiler SWG120

FF

RR

1

RR

FF

KOUDIN

1

B1 A1

1. Assigning codes to a one water heater installation:

 There’s only one flow pipe, encoded FF, and one return pipe, encoded RR. For the right diameters

see § 9.4.1, pick the table of the corresponding water heater type.

2. Assigning codes to cascades: two or more water heaters to connect:

 First number the water heaters: water heater-1 is the one that‘s situated the furthest away from the

tank(s).

 Connections directly to the water heaters: F1 = R1 = 541.5 (mmmm)  Number the horizontal flow pipes between water heaters: from F1 at water heater-1 to FF at water

heater-number-last.

 Number the horizontal return pipes between water heaters ‘reversely’: from R1 at water heater-

number-last to RR at water heater-1.

3. Assigning codes to tank connections:

- Tank connections: A1 and B1 (entrance and exit). The values are found in the tank tables (§ 9.4.2)

- Pipes between these connections: FF and RR, values from the water heater tables (§ 9.4.1).

Example 1

COLD IN

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55

9.6.2 TWO S-WG100 WATER HEATERS WITH TWO 450-LITRES TANKS

Water heater connections, assigning codes:

For this system rule 2 must be applied. Number the water heaters: water heater-1 is the water heater furthest from the tank(s), see picture. Number de connection pipes directly connected to the water heaters: F1 en R1, see picture. Number de horizontal connection pipes:

- flow pipes starting at water heater-1: F1 t/m FF (here only an F1 and an FF), see picture.

- return pipes starting at water heater-last (= water heater-2): R1 t/m RR (same remark), see picture.

Pipe sizes, water heater side:

From table WH-100, 2nd row:

- All pipes F1 and R1 in the picture must measure at least 541,5 [mmmm] (column F1/R1)

- The pipes FF and RR must measure 671.9 [mmmm] (column FF/RR).

Tank connections:

From table T-100, 2nd row: for 2 tanks A1 = B1 = 541.5 [mmmm] is sufficient.

So for this system pipes sized at least 541.5 [mmmm] are to be applied for all connections directly on water heaters and tanks, and pipes sized at least 671.9 [mmmm] for the flow and return connections between them.

Equivalent length:

From table EL: The maximum total length of flow and return pipes 671.9 [mmmm] is 26.1 m. So when 671.9 [mmmm] is applied, the physical distance between water heaters and tanks may be half of this, so ~ 13 m, at max. In case bends and/or valves are used, this distance becomes less than 13 m. Use the table.

2 boilers S-WG100

2 tanks 450 L

F1R1F1R1

R1

FFF1

RR

1 2

FF

B1 A1 B1 A1

RR FF

KOUDIN

1 2

Example 2

COLD IN

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56

9.6.3 THREE S-WG180 WATER HEATERS WITH FIVE 750-LITRES TANKS

Water heater connections, assigning codes:

For this system rule 2 must be applied. Number the water heaters: water heater-1 is the water heater furthest from the tank(s), see picture. Number de connection pipes directly connected to the water heaters: F1 en R1, see picture. Number de horizontal connection pipes:

- flow pipes starting at water heater-1: F1, F2, FF, see picture.

- return pipes starting at water heater-last (= water heater-3): R1, R2, RR, see picture.

Pipe sizes, water heater side:

From table WH-180, 3rd row:

- All pipes F1 and R1 in the picture must measure at least 541,5 [mmmm] (column F1/R1)

- The pipes F2 and R2 must measure 932.3 [mmmm] (column F2/R2).

- The pipes FF and RR must measure 1062.5 [mmmm] (column FF/RR).

-

Tank connections: From table T-180, 3rd row: for 5 tanks A1 = B1 = 541.5 [mmmm] is sufficient again.

Resulting set-up see next page 

5 tanks 750 L

FF

B1 A1 B1 A1

RR

FF

A1B1

RR RR

FF

A1B1

FF

B1 A1

RR

FF

1 2 3 4 5

KOUDIN

3 ketels S-WG180

F1R1F1R1R1

R2 R1

RR

FFF2F1

RR

F1

1 2 3

RR FF

tanks

Example 3

COLD IN

E09.012.246 Manual S-WG

57

So for this system, sizes of at least 541.5 [mmmm] are to be applied for all pipes directly connected to the water heaters and tanks, and pipes sized at least 1062.5 [mmmm] for the flow and return connections between the cascaded water heaters and the tanks. The pipes F2 and R2 must be at least 932.3 [mmmm].

Equivalent length:

From table EL: The maximum total length of flow and return pipes 1062,5 [mmmm] is 36,7 m. So when 1062,5 [mmmm] is applied, the physical distance between water heaters and tanks may be half of this, so ~ 18 m, at max. In case bends and/or valves are used, this distance becomes less than 18 m. Use the table.

1 2 3

= 54 x 1.5 = 93 x 2.3

= 106 x 2.5

1 2 3 4 5

R

F

R

F

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58

10 USER INTERFACE

10.1 Control panel / Display unit

DISPLAY

2 rows / each 20 characters

MENU

ON/OFF

RESET

ENTER

SERVICE

COMM. PORT

ON/OFF RESET ENTER

Press and hold for 6 seconds to switch water heater on/off. Is also used as RESET button and ENTER button when programming.

Connector for connecting computer cable

Buttons can be pushed to open menu. [ hold for 1 second ]

Buttons to toggle through measured temperatures. These are also used for navigating through the menus and used for changing values.

Button to activate service function. [ hold for 3 seconds ]

Schornsteinfeger function (only for Germany).

Light: will light up when controller sees good flame signal. Lights when burner is burning.

SERVICE

MENU

COMM. PORT

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59

10.2 Control panel menu structure

BASE SCREEN : (appears during operation)

WTRHTR : No demand / Standby / burning > > > : 1 1 8 ° C ( 1 2 5 ° C )

CONFIRMATION CHANGE

When changes are being made in the menus within this dashed rectangle, the user presses ENTER to confirm the changes. To prevent customers making changes by accident the following happens when changes are made: Step 1: The user presses "ENTER" to confirm the change made or [MENU] to leave the menu without changes.

HINT: First programme all changes planned, then only press

[ENTER]

Step 2: The display asks the user to be sure to make these changes. The user can cancel and confirm by using the left and right arrows. CANCEL = ◄ CONFIRM = ►

press [ON/OFF] for 3 s. to programme in standby mode

By pressing (◄ ►) one can toggle though the available menus.

press: MENU

view data

"TIME/DATE/DAY" menu

In this menu one can set the time and the date.

"MONITOR" screens

One can toggle through the measured values and status of the heater. Pressing "ON/OFF, RESET, ENTER" briefly will cause the display to go back to the base menu. When no button has been pressed for 3 minutes the display will automatically go to the BASE DISPLAY. (This period can be set by a parameter)

"SETPOINT" menu

In this menu one can change temperature settings without the need for a password.

- Hot water set point Calorifier or water heater (depends on heater type) tank temperature

- Hot water reduced

The amount of degrees diff. relative to "Hot water set point" during night reduction.

- Local set point water heater The temperature of the hot water supply from the DHW appliance to the tank is set here.

press: ◄ ►

Display shows 2x20 digit message for 3 seconds. Message can be set in parameters.

example:

Company name City, Country

"PROGRAM" menu

In this menu one can set the DHW and Anti-legionella program.

press: ▲

"OPERATING HISTORY" menu

Shows burning hours DHW, etc.

Display shows for 3 seconds:

- Heater type

- Time, date and day

example:

Z-FG 550 13:51 US (or EU) 06 / 01 / 2010 Wed

After this message the display shows for 3 seconds:

- Software version and

- Cascade designation

example:

Firmware : Mk 00197 Address : 0

"FAULT HISTORY" menu

Reading last 10 faults (only reading!).

press: ▼

"MAINTENANCE" menu

By pressing (◄ ► ) one can set the following options:

- Maintenance reset

- Maintenance Mode

- All

- Date

- Ignition cycles

- Burning hours

- Mainten Off

These three messages will also show when:

- Heater is connected to the power

- When heater is turned ON

- When heater is turned OFF sequence: The messages will show from TOP to BOTTOM each for three seconds.

"USER LOCK" menu In this menu one can lock the menu for users

0= UNLOCKED 1= LOCKED

When un-locked the user can enter the "MENU" by pressing the menu button and all submenus will show. When locked the user has to push the : MENU and simultaneously press ▼ for 6 seconds to get access to all submenus. This is to prevent accidental changes! NOTE: The parameters sub menu can always be accessed.

"PARAMETERS" menu In this menu one can change parameters. The possible access

depends on the password that is used.

Enter password:

Password "LEVEL 1"

entered

Password "LEVEL 2"

entered

3 second message confirming access:

"LEVEL 1"

3 second message confirming access:

"LEVEL 2"

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60

10.3 Display during operation

During normal operation the text in the display shows the status of the water heater. In the following graphs the several displays during normal operation are explained.

Display at WATER HEATER / HOT WATER DEMAND

Heat demand type:

Actual status:

W A T R H T R : S T A N D

- B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

cascade communication indicator

temp. set point water temp.

measured temp.control.sens. showing the measured temp. Can be turned off by P5 BJ

Explanation "Actual status" screen

Actual status:

B o i l e r o f f

When water heater is switched off (only text in the display during this status).

N o d e m a n d

No heat demand signal coming from the room themostat and calorifier sensor (open).

S t a n d

- b y

Room themostat & calorifier sensor/themostat detect heat demand but set point is reached.

P r e

- p u r g e

The fan is purging before a burner start attempt.

P r e

- i g n i t i o n

Ignition starts before opening of the gas valve.

I g n i t i o n

The igniter is igniting.

P o s t - p u r g e

The fan is purging after burner is switched off.

B u r n i n g 1 0 0

%

When the burner is firing, also the actual rpm% is shown.

Explanation "Cascade communication indicator" NO CASCADE COMMUNICATION

> > >

no.1

Always showing the fixed ">>>"

CORRECT CASCADE COMMUNICATION

> >

no.1 no.2

>

Showing alternating no.1 & no.2 with 1 second interval.

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10.4 Monitor screens

During normal operation and standby, the “◄” and “►” buttons can be used to show some water heater information, including measured temperatures, settings and data. In the following graphs is explained which values can be shown in the display. When no button is activated for three minutes, the display will return to its status display.

Pressing [◄] or [►] while being at the "operating screen" toggles through the screens below. When pressing [ON/OFF, RESET, ENTER] or [MENU] at any time the display returns to the base menu.

SCREEN: 1

T 1 F l o w 1 2 3 , 9 °

C

Measured value by the internal flow sensor.

T 2 R e t u r n 1 2 3 , 9 °

C

Measured value by the internal return sensor.

O p e n

Shown when controller doesn’t detect this sensor.

S h o r t e d

Shown when sensor wires or sensor itself is shorted.

SCREEN: 2

T 3 E x t e r n a l 1 2 3 , 9 °

C

Measured value by the external sensor.

T 4 C a l o r i f i 1 2 3 , 9 °

C

Measured value by the calorifier sensor.

O p e n

Shown when controller doesn’t detect this sensor.

S h o r t e d

Shown when sensor wires or sensor itself is shorted.

SCREEN: 3

T 5 O u t d o o r 1 2 3 , 9 °

C

Measured value by the outdoor sensor.

T 6 F l u e 1 2 3 , 9 °

C

Measured value by the flue gas sensor.

O p e n

Shown when controller doesn’t detect this sensor.

S h o r t e d

Shown when sensor wires or sensor itself is shorted.

SCREEN: 4

d T F l o w R e t u r n 1 2 3 , 9 °

C

Temp. difference between internal flow & return.

d T F l u e R e t u r n 1 2 3 , 9 °

C

Temp. difference between flue gas & internal return.

SCREEN: 5

Temp. difference between external & internal return (ΔT LLH).

d T E x t R e t u r n 1 2 3 , 9 ° C S i g n a l P o w e

r

External supplied 0-10 Volt dc signal.

S e t p o

i

"Power" = power input control or "Setpoi" = set point control.

SCREEN: 6

F a n s p e e d 9 9 9 9 r p

m

Actual fan speed in rpm.

F a n s p e e d 1 0 0

%

Actual fan speed % of maximum allowable fan speed.

SCREEN: 7

F l a m e s i g n a l 1 0 0 μ

A

Flame signal given in μA.

W a t e r P r e s s u r 1 , 0 b a

r

Shows water pressure when sensor is connected.

SCREEN: 8

P u m p 1 H e a t e r O f f

Pump 1 (HEATER PUMP) On or Off.

P u m p 1 S i g n a l 1 0 0 %

Modulating signal Pump 1 in (%).

SCREEN: 9

P u m p 2 C a l o r i O f f

Shows when the calorifier pump is "ON" or "OF".

3 - w a y V a l v e H e a t i n g

Signal to the 3-way valve: "HEATING" or "HOTWATER".

SCREEN: 10

P u m p 3 S y s t e m O f f

Shows when the system pump is "ON" or "OF".

h h : m m D D / M M / Y Y Y Y D a y

hh=hour; mm=minutes; DD=day; MM=month; YYYY=yr; Day of the week

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SCREEN: 11

C a s c D e s i g n 0

0 = MASTER, 1 ..... 11 = SLAVES

C a s I n f 0 1 2 3 4 5 6 7 8 9 A

B

Displays number, priority and state of cascade water heaters.

DESCRIPTION "CASCINFO" Screen 11

Shows the number of water heaters connected with the cascade. The master/lead water heater is designated as

0. Slave/lag water heaters will be designated 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B. When a “-“ is used instead of a number, then that water heater is either not connected, or in a lockout mode and not available for the cascade. When an “x“ is used instead of a number, then that water heater is connected, but in lockout mode. When the number is flashing, then that water heater is providing heat to the cascade. When the leading water

heater is changed according to the set priority change time, then that water heater’s address will be shown first in

the row of numbers. Example 1: "3 4 5 - - - - - - 0 1 2"

There are six water heaters present and nr. 3 has priority. Example 2: "3 4 x - - - - - - 0 1 2"

There are six water heaters present and nr. 3 has priority. Water heater 5 is present, but in a lock-out.

SCREEN: 12

C a s c P o w e r 9 9 9 % 9 9 9

%

% heat demand of total (cascade) power available (%).

D u a

l B u r n e r :

N o

One heat exchanger equipped with two burners: "Yes" or "No".

SCREEN: 13

M a x T h e r m O p e n

Status of the maximum thermostat: "Open" or "Closed".

G e n B l o c k C l o s e

d

Status of the general blocking contact: "Open" or "Closed".

SCREEN: 14

S i p h o n p r e s s C l o s e

d

Status of the siphon pressure switch: "Open" or "Closed".

N R V C o n t a c t

O p e n

Status of the non-return valve contact: "Open" or "Closed".

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10.5 Service function

The following graphs describe how to use the service function.

Operating screen:

W A T R H T R : S T A N D - B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [SERVICE] and hold for 3 seconds. The burner will start and show the display below.

Operating screen:

W A T R H T R : S e r v i c e 2 6

%

> > > 7 5 . 0 ° C ( 6 0 . 0 ° C

)

"WATRHTR": It is an appliance for DHW. "Service": It is operating in service mode. "26%": The burner is firing at 26%. "75,0oC": Max. allowable water temp. during service. "60,0oC": Actual measured water temp. (when P5BJ active).

Press [SERVICE] to exit. The unit will go to the operating screen. Press 3 s. [ON/OFF] to exit. The unit will be switched off.

By using the [▲] & [▼] buttons the burner firing rate% can be

changed.

Press [MENU] to access the main menu. Press [MENU] to return to the service menu.

Use [◄] & [►] buttons to browse through the monitor screens. Press [MENU] to go to the operation menu of the service mode.

Press [SERVICE] to exit the service mode. The unit will return to the standard operation display.

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10.6 Schornsteinfeger function

The purpose of this function is to have an easy interface for the "Schornsteinfegers" in Germany, to be able to do their required testing on the water heater. This is a simplified function similar to the normal service function of the water heater.

When the "Schornsteinfeger" button is pressed for 3 seconds: the heater will fire at minimum firing rate (%) In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : M i n i m u m

When the button is pressed (briefly) again: the heater will fire at 50% firing rate In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : 5 0 %

When the button is pressed (briefly) again: the heater will fire at maximum firing rate (%) In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : M a x i m u m

When the button is pressed briefly again: the heater will return to the normal operation mode. The "Schornsteinfeger" function is switched off.

NOTES:

When the heater is burning during Schornsteinfeger function (when top display line shows "Flue service mode") and no button is pressed for 12 minutes, the water heater will return automatically to the normal operation mode. The "Schornsteinfeger" function will be switched off.

The "Schornsteinfeger function" can be activated for the user by programming a parameter (P5 BK)

All regular temperature safety controls remain active and the water heater pump and system pump are running.

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10.7 Programming in standby mode

Standby

Use the standby mode for modifying water heater settings without interaction with the water heater control. Changes are effectuated by leaving standby mode.

Properties of standby mode:

 Keys are active and the menu is accessible.  Burner does NOT respond to an external heat demand.  All control functions are ON: pumps, fans and cascade are operational, recirculation and frost protection

are active.

How to programme the water heater:

 Disconnect or shut down the room thermostat and/or other external controllers from the water heater.

The CH pump and fan will stop after a short time.

 Switch the water heater in standby mode by pressing [ON/OFF] for three seconds.  The next display screen should appear:

Display message W A T R H T R : b o i l e r o f f

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

 Program the water heater at the control panel (see the following sections).  Terminate programming mode by pressing [MENU], or [ENTER] and NO ◄ or YES ►.  Reactivate the water heater by pressing [ON/OFF] for three seconds again.

10.8 Setting the time & date

The following graphs describe how to program the time and date of the unit.

Operating screen:

W A T R H T R : S T A N D - B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [MENU]

Main menu screen:

M a i n M e n u

C l o c k

The display shows "CLOCK" press [ENTER]

Setting Time and Date:

S e t t i m e / d a t e 0 8 : 3 3 3 0 / 0 3 / 2 0 1 0 T u e

The day is now blinking/selected and can be changed.

Use [▲] & [▼] to change the value. Use [◄] & [►] to select another value.

Press [ENTER] for the confirmation screen after all changes are done.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (display goes back to operating screen).

Press [►] to confirm the changes made. The time and day will start blinking for a few seconds. After this, the display returns to its operating screen.

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10.9 Set points

The following graphs describe how to program the hot water set points.

Heating set point normal/day time: (parameter P4 AA = 1/2)

D H W s e t p o i n t

6 0 ° C

This is the water temperature set point that is active during the programmed DHW periods (parameter P4 AA = 1/2)

DHW set point reduction: (parameter P4 AA = 1/2)

D H W R e d u c e

1 0 ° C

The reduction of the normal/day time set point. This reduction is used outside the programmed CH periods.

DHW setpoint reduction: (parameter P4 AA = 2 and P5 DJ&DK =1)

H e a t i n g s e t p o i n t

7 5 ° C

This parameter is the local setpoint of the water heater and is regulated on sensor S1 (parameter P4 AA = 2, P5 DJ = 1 and P5 DK =1 ).

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10.10 Setting the timer programs

Two different programs can be set with the water heater, these are:

 DHW program  Anti-legionnaires’ disease (pasteurisation) program

START PROGRAMMING

Three programmed periods each day can be set (period 1, 2 and 3). During this period the unit will use the normal DHW set point. Outside the programmed period(s) the unit will use the reduced temperature as set point. When no time is programmed for a period, it will not be used. (Example no time programmed in period 3 on Monday > "Mon 3 --:-- ---:--").

Operating screen:

W A T R H T R : S T A N D - B Y > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [MENU]

Select "Timer" using [◄] & [►] and press [ENTER]

Main menu screen:

M a i n M e n u

T i m e r

Press [ENTER]

Setting CH program times:

P r o g r a m C H M o n 1 0 6 : 0 0 - 2 3 : 0 0

Press [◄] for next SCREEN

> > > Continue on next page HOT WATER program < < <

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HOT WATER PROGRAM

> > > From previous page < < <

Setting DHW program times:

P r o g r a m D H W

M o n 1 0 6 : 0 0 - 2 3 : 0 0

Press [►] to browse through the values that can be set at the bottom line. The blinking value can be changed.

Press [▲] & [▼] to change the selected (blinking) value.

Press [ENTER] for confirmation screen when all settings are done.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Press [►] to confirm the changes. The last alternation will be blinking for a few seconds and return to base menu.

Press [MENU] to exit. The water heater will reset and go to the operating screen.

Press [◄] for next SCREEN

Copy programmed day for DHW:

C o p y f r o m : D H W M o

n

C o p y t o : D H W T u

e

Press [►] to switch between "Copy from" and "Copy to". The blinking day is selected and can be changed.

Press [▲] & [▼] to change the selected (blinking) value.

Press [ENTER] for confirmation screen when all settings are done.

Confirmation screen:

A r e y o u s u r e < C a n c e l ; > C o n f i r m Press [◄] to cancel the changes made (unit will reset).

Press [►] to confirm the changes. The two days will blink for a moment.

Press [MENU] to exit. The water heater will reset and go to the operating screen.

Press [◄] for next SCREEN

> > > Continue on next page LEGIONELLA program < < <

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ANTI LEGIONNAIRES’ DISEASE PROGRAM

See the following description. The standard factory setting for this function is “OFF”.

> > > From previous page with HOT WATER part < < <

Setting legionella program (day and time):

P r o g r a m L e g i o n e l l a

M o n 0 9 : 5 1

Press [►] to browse through the values that can be set at the bottom line. The blinking value can be changed.

Press [▲] & [▼] to change the selected (blinking) value.

Press [ENTER] for confirmation screen when all settings are done.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m Press [◄] to cancel the changes made (unit will reset).

Press [►] to confirm the changes. The last alternation will be blinking for a few seconds and return to base menu.

Press [MENU] to exit. The water heater will reset and go to the operating screen.

Press [◄] for next SCREEN

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10.11 Checking the operating history

The following graphs describe how to check the operating history of the water heater.

Operating screen:

W A T R H T R : S T A N D - B Y > > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [MENU]

Select "Operate" using [◄] & [►] and press [ENTER]

Main menu screen:

M a i n M e n u

O p e r a t e

Press [◄] & [►] to browse through the 5 screens.

Press [MENU] or [ENTER] to exit. The unit will return to the operating screen.

SCREEN: 1

O p e r a t i n g h i s t o r y

P o w e r O n h r s 1 3 1 4 0 0

Top line: Shows the operating history menu is activated.

Bottom line: Total hours the water heater is connected to power supply and switched on.

SCREEN: 2

h r s C h T o t 1 0 0 0 0 0 0 h r s D h w T o t 1 0 0 0 0 0

0

Top line: Total burning hours for heating.

Bottom line: Total burning hours for domestic hot water.

SCREEN: 3

h r s C h < 5 0 % 1 0 0 0 0 0 0 h r s C h = > 5 0 % 1 0 0 0 0 0

0

Top line: Burning hours for heating while the burner was firing less than 50%.

Bottom line: Burning hours for heating while the burner was firing equal or higher than 50%.

SCREEN: 4

h r s D h w < 5 0 % : 1 0 0 0 0 0 0 h r s D h w = > 5 0 % : 1 0 0 0 0 0

0

Top line: Burning hours for hot water while the burner was firing less than 50%.

Bottom line: Burning hours for hot water while the burner was firing equal or higher than 50%.

SCREEN: 5

T i a 1 0 0 0 0 0 F i a 1 0 0 0 0 0 S s l 1 0 0 0 0 0 S s t 1 0 0 0 0 6

Top line: Shows Total Ignition Attempts (Tia) & Failed Ignition Attempts (Fia)

Bottom line: Shows Soft Starts last (Ssl) & Soft Starts Total (Sst)

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10.12 Checking the fault history

The following graphs describe how to check the fault history of the water heater.

Operating screen:

W A T R H T R : S T A N D - B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

) Press [MENU]

Select "Faulthist" using [◄] & [►] and press [ENTER]

F a u l t h i s t N o . 0

1

2 1 / 0 4 / 2 0 1 0 W e d 2 2 : 2 3

A

▲ blinking ▼

S i p h o n S w i t c h

S v 9 9 9 / C U M 9 9 9 / R 9 9 9 9 ,

5 Press [◄] & [►] to browse through the last 10 faults.

Press [MENU] or [ENTER] to exit. The unit will return to

The fault menu shows the last 10 faults. For each fault the

display blinks between the two screens shown above. The top line of the top screen shows the fault number and the bottom line of the top screen shows the date, day and time the fault occurred.

On the top line of the bottom screen the fault type is displayed. The bottom line shows the following:

SV: The total amount of this fault that has occurred after the last time that the service history was erased (after service was done).

CUM: The total amount of this fault. The total amount cannot be erased after service, this shows the fault history of the water heater (electronics) since the start of operation.

R: Shows the elapsed time in hrs between the moment the fault occurred and the moment it was reset.

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10.13 Setting the maintenance specifications

MAINTENANCE SETTINGS

The unit can be programmed in such a way that an automatic maintenance message is displayed. There are three options that can be selected. A maintenance message appears after: * A programmed date is reached. * An amount of burning hours is reached. * An amount of ignition cycles is reached. A single option can be activated or all three options.

Operating screen:

W A T R H T R : S T A N D - B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [MENU]

Select "Maintenan" using [◄] & [►] and press [ENTER]

Operating screen:

M a i n t e n R e s e t

Press [▲] to reset the:

Counter for the total amount of burning hours. Counter for the total amount of ignition cycles. (The text will blink once briefly after resetting).

Operating screen:

M a i n t e n M o d e

Blinking second line.

What is blinking at the second line (before a selection is made) is the active maintenance option.

Press [▲] or [▼] to change the selected blinking option.

Screen: Selecting of all maintenance options.

M a i n t e n M o d e

A l l

Press [►] to set: The option that is blinking can be changed using by [▲] & [▼]

* Date for the Maintenance message. * Total amount of burning hours for the Maintenance message. * Total amount of ignition cycles for the Maintenance message. After selecting one of these values the water heater returns to the maintenance operating screen.

Press [ENTER] to confirm the changes.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the changes. Hereafter the water heater returns to the operating screen.

Go to next page

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From previous page

Screen: Selecting message at certain date.

M a i n t e n M o d e

D a t e

Press [►] to set: The date for the maintenance message.

Press [◄] to: Return to maintenance mode selection.

Press [►] to browse through the values that can be set at the bottom line. The blinking value can be changed with [▲] & [▼]

Press [ENTER] to confirm the changes.

Confirmation screen:

A r e y o u s u r e < C a n c e l ; > C o n f i r

m

Press [◄] to cancel the changes or [►] to confirm the changes. Hereafter the water heater returns to the operating screen.

Screen: Message after total amount of ignition cycles.

M a i n t e n M o d e

I g n i t i o n c y c l e s

Press [►] to set: The total amount of ignition cycles for the Maintenance message.

Press [◄] to: Return to maintenance mode selection.

The blinking value can be changed with [▲] & [▼]

Press [ENTER] to confirm the changes.

Confirmation screen:

A r e y o u s u r e < C a n c e l ; > C o n f i r

m

Press [◄] to cancel the changes or [►] to confirm the changes. Hereafter the water heater returns to the operating screen.

Go to next page

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From previous page

Screen: Message after total amount of burning hours.

M a i n t e n M o d e

B u r n i n g h o u r s

Press [►] to set: The total amount of burning hours for the maintenance message.

Press [◄] to: Return to maintenance mode selection.

The blinking value can be changed with [▲] & [▼]

Press [ENTER] to confirm the changes.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the changes. Hereafter the water heater returns to the operating screen.

Screen: No maintenance message will be displayed.

M a i n t e n M o d e

M a i n t e n O f f

Press [ENTER] to confirm the changes.

Confirmation screen:

A r e y o u s u r e < C a n c e l ; > C o n f i r

m

Press [◄] to cancel the changes or [►] to confirm the changes. Hereafter the water heater returns to the operating screen.

Note: The [MENU] button will return the display to the operating screen.

BE AWARE: This function is standard turned OFF. We offer this programmable function to the installer to use as a reminder. Because it concerns a free programmable function the use of it cannot be used as an argument in warranty cases. Our units must be maintained every twelve months whatever the settings/working of this function.

It is and remains the responsibly of the end user to have the unit maintained every twelve months.

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10.14 Setting the user lock

The following graphs describe how to activate the user lock of the display. The standard factory setting for this function is “OFF”.

The "USER LOCK" menu.

In this menu the water heater can be locked for (end-)users. 0 = UNLOCKED 1 = LOCKED

When the water heater is unlocked, the user can enter the MENU by pressing the menu button and all screens will show up.

When the water heater is locked, the user has to push the: [MENU] button together with the [▼] button for 5 s. to access all menu screens.

This function is to prevent accidental changes!

NOTICE: The PARAMETER screen always accessible.

Operating screen:

H E A T I N G : S T A N D

- B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Press [MENU]

Select "User lock" using [◄] & [►] and press [ENTER]

User lock screen:

S e t U s e r l o c k = 0 0

The "0" is now blinking/selected and can be changed.

Use [▲] & [▼] to change the value.

0 = User lock function OFF 1 = User lock function ON

Press [ENTER] for the confirmation screen after the selection has been made.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes (the unit will reset and the

display returns to the operating screen).

Press [►] to confirm the changes. The changed value will be blinking for a few seconds. After this, the display returns to the operating screen.

NOTICE:

Using the [MENU] button during the User lock display, will reset the water heater and the water heater will return to the operating screen. Changes will be neglected in this case.

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10.15 Setting the parameters with the display menu

The functions of the controller are embedded in de electronics. The values and settings that are being used for these controlling functions can be changed by programming these values. This can be done by a skilled and trained service engineer with the help of a computer, the correct software and an interface cable. The values and settings that are used for these controlling functions are called parameters. A selection of these parameters can be programmed on the unit itself, without the use of a computer. These settings can easily be done at the control panel of the water heater.

The following table gives a list of these parameters that can be programmed by the display. All parameters that are shown in the display, can be changed. NOTICE: Only the password for level 1 is issued in this manual. When other “more advanced” parameters needs to be programmed, it can only be done by a skilled and trained service engineer, who has access to level 2.

PASSWORD: 1342

PASSWORD:

MENU

SOFTW.

PARAM

DESCRIPTION

UNITS

TEXT DISPLAY

LEVEL 1

LEVEL 2

Display

Modify

Display

Modify

HEATING

A

1

P5BE

Step modulation (1=on 0=off)

-

S t e p m o d u

l

yes

no

yes

yes 2 P5AO

Blocking offset flow temperature control

°C

H E s O f f 1

3

yes

yes 3 P5AP

Proportional range temperature control

°C

H E s P r b 1

3

yes

no

yes

yes 4 P5AL

Hysteresis CH Flow temperature control

°C

H E s c D i f 1

3

yes

yes 5 P2IC

Integration time temperature control

s

H E s I n t 1

3

yes

no

yes

yes 6 P2MI

Blocking offset System CH temperature control

°C

H E c O f f

3

yes

yes 7 P2MJ

Proportional range System CH temperature control

°C

H E c P r b

3

yes

no

yes

yes 8 P2MK

Integration time CH temperature control

s

H E c I n t

3

yes

no

yes

yes 9 P5AB

Timer Contact (1=on)

-

T i m e r C o n t

yes

DHW

B

1

P4AB

DHW Pump Config 0=Pump 1=TWV

-

D H i p m p / t w

v

yes

yes yes

yes 2 P5CB

Flow temperature DHW tank low

°C

D H i f l o w L

O

yes

yes 3 P5CK

Flow temperature DHW tank hi

°C

D H i f l o w H

I

yes

yes 4 P5CL

Low Flow temperature time DHW

min

D H i L O t i m

e

yes

yes 5 P5CD

Legionella temperature

°C

L e g i o t e m

p

yes

no

yes

yes 6 P5CI

Legionella hyst DHW tank temperature

°C

L e g i o h y s

t

yes

no

yes

yes 7 P5CJ

Legionella hold time (0=off)

min

L e g i o h o l

d

yes

no

yes

yes 8 P2KI

CH interrupt by Legionella (0=yes)(1=no)

-

L e g i o i n t

r

yes

no

yes

yes 9 P2LC

Regulation temperature offset DHWd

°C

D H d s c O f f 2

yes

yes A P2LE

Proportional range DHWd modulation

°C

D H d s c P r b 2

3

yes

no

yes

yes B P2LD

Regulation temperature hysteresis DHWd

°C

D H d s c D i f 2

yes

yes C P2LF

integration time DHWd modulation

s

D H d s c I n t 2

3

yes

no

yes

yes D P2ML

Sys temp blocking offset DHW tank

°C

D H d s c O f f 3

yes

yes E P2MM

Sys temp blocking hysteresis DHW tank

°C

D H d s c D i f 3

yes

yes F P5CA

Hysteresis DHW tank temperature

°C

D H i s c D i f 4

yes

yes G P2KH

Gradient heat demand detect DHW tank temperature

°C

D H i d e t g r a

d

yes

CASCADE

C

1

P2MA

Max number extra water heaters

-

M a x C a s c U n

t

yes

no yes

yes 2 P5DA

Bus address water heater

-

B u s a d r e s

s

yes

no

yes

yes 3 P5DC

Dhw on entire cascade(0) only master(1)

-

D H i c a s / m a

s

yes

no

yes

yes 4 P5DE

Extra Water heater output enable(1)

-

E x t r a u n i

t

yes

yes 5 P5DF

Cascade detection (0=standalone 1=Leader)

-

C a s S i / M a

yes

no

yes

yes 6 P5BL

Power off total cascade (1)

-

P w r O f f T o C

a

yes

no

yes

yes 7 P5DB

Number of water heaters with common flue 0=None

-

C o m F l u N u m

yes

no

yes

GENERAL

D

1

P5BB

Analogue input Config (0=off 1=temp 2=power)

-

A n I n p C o

n

yes

yes yes

yes 2 P5AI

Minimum Temperature 0-10V input

°C

0 - 1 0 M i n T m

p

yes

yes 3 P5BI

Altitude (in amounts of 100 ft.)

ft*100

A l t * 1 0 0 f

t

yes

yes 4 P2LK

Max cooling time

min

M a x C o o l T i

m

yes

yes 5 P5BJ

Temperature display 1=on

-

T e m p O n D i s

p

yes

yes 6 P4AA

DHW 0=off 1=Indirect 2=Direct

-

D H W 1 = i 2 =

d

yes

no

yes

7

P4AD

pressure 0=off 1=sensor and 2=switch

-

c o n f i g

yes

no

yes

yes 8 P4BD

Gas type values 0-2

-

g a s t y p e

yes

no

yes

yes 9 P4BE

Soft start type values 0-2

-

c o n f i g

yes

no

yes

yes A P5BN

Pump modes 0-4

-

c o n f i g

yes

no

yes

In the parameter table shown above one can see all the parameters that can be set on the unit without the use of a laptop/computer.

In the following chapter “Controlling options and settings” the controlling options for hot water and cascading are

explained. In the explanation of these options there is a reference of all relevant parameters which are shown in the table above and can be set on the unit.

IMPORTANT:

Do not change the parameters P2LC, P2LD, P2ML, P2MM and P5BI; they are present in the controller for different purposes than DHW control. Changing these parameters may affect water heater operation negatively!

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The following graphs describe how to program the parameters by using the display:

Operating screen:

W A T R H T R : S T A N D - B Y

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

) Press [MENU]

Select "Parameter" using [◄] & [►] and press [ENTER]

Parameter menu:

I n s t a l l e r c o d e

0 0 0 0

Enter the 4-digit code with the [◄] & [►] and the [▲] & [▼] buttons and select [ENTER]

The code will blink a few seconds and when entered correctly, the following parameters will be displayed.

NOTICE: These codes are user based and give access to a selected amount of parameters, which can be changed (Installer level 1/2).

Menu A: Heating

A 1 S t e p m o d u l

1

Function to activate the step modulation: 0 = Off 1 = On

Menu A: Heating

A 2 H E s o f f 1 3 4 ° C

CH supply temperature setting. This parameter is the offset of the programmed CH temperature.

Menu A: Heating

A 3 H E s P r b 1 3

2 5 ° C

Select the CH supply temperature control. This parameter is the proportional range of the selected CH supply temperature.

Menu A: Heating

A 4 H E s c D i f 1 3

1 0 ° C

Select the CH supply temperature control. This parameter is the hysteresis of the selected CH supply temperature.

Menu A: Heating

A 5 H E s l n t 1 3

6 0 S e c

Select the CH supply temperature control. This parameter is the integration time of the selected CH supply temperature.

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu A: Heating

A 6 H E c O f f 3 4 ° C

Select the cascaded boilers supply temperature control. This parameter is the offset of the selected CH supply temperature of EACH boiler of the total cascade.

Menu A: Heating

A 7 H E c P r b 3 2 5 ° C

Select the cascaded boilers supply temperature control. This parameter is the proportional range of the selected CH supply temperature of EACH boiler of the total cascade and of the external (cascade) sensor.

Menu A: Heating

A 8 H E c l n t 3

8 0 S e c

Select the cascaded boilers supply temperature control. This parameter is the integration time of the selected CH supply temperature of EACH boiler of the total cascade and of the external (cascade) sensor.

Menu A: Heating

A 9 T i m e r C o n t 0

Function to activate "external time controller": 0 = Off 1 = On Connect to 13-14. Contact closed = daytime setting, Contact open = night-time setting.

Menu B: Hot water

B 1 D H i p m p / t w v 1

Hot water function of the boiler by: 0 = pump 1 = 3-way valve

Menu B: Hot water

B 2 D H i f l o w L O 2 5 ° C

Hot water function of the boiler. This parameter is the CH supply temperature LOW level with an indirect hot water demand.

Menu B: Hot water

B 3 D H i f l o w H I 8 5 ° C

Hot water function of the boiler. This parameter is the CH supply temperature HIGH level with an indirect hot water demand.

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu B: Hot water

B 4 D H i L O t i m e

1 M i n

Hot water function of the boiler. This parameter is the selectable time period after which the boiler switches from LOW to HIGH set point with an indirect hot water demand.

Menu B: Hot water

B 5 L e g i o t e m p 8 5 ° C

Pasteurisation function of the boiler. This parameter is the selected hot water temperature during the pasteurisation function of the boiler.

Menu B: Hot water

B 6 L e g i o h y s t 2 ° C

Pasteurisation function of the boiler. This parameter is the selected hysteresis during the pasteurisation function of the boiler.

Menu B: Hot water

B 7 L e g i o h o l d

2 M i n

Pasteurisation function of the boiler. This parameter is the selected time period for the pasteurisation function of the boiler.

Menu B: Hot water

B 8 L e g i o i n t r

0

Pasteurisation function of the boiler. This parameter controls if the CH demand can be interrupted by the pasteurisation function of the boiler. 0 = Yes 1 = No

Menu B: Hot water

B 9 D H d s c O f f 2 4 ° C

Function for the direct hot water boiler. This parameter is de off set of the selected HW temperature of the boiler.

Menu B: Hot water

B A D H d s c P r b 2 3

2 0 ° C

Function for the direct hot water boiler. This parameter is the proportional range of the selected HW temperature of the boiler.

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu B: Hot water

B B D H d s c D i f 2 1 0 ° C

Function for the direct hot water boiler. This parameter is the hysteresis of the selected HW temperature of the boiler.

Menu B: Hot water

B C D H d s c l n t 2 3 2 0 0 S e c

Function for the direct hot water boiler. This parameter is the integration time of the selected HW temperature of the boiler.

Menu B: Hot water

B D D H d s c O f f 3 4 ° C

Function for the cascaded direct hot water boilers. This parameter is the offset of the selected HW temperature of the cascaded boilers.

Menu B: Hot water

B E D H d s c D i f 3 8 ° C

Function for the cascaded direct hot water boilers. This parameter is the hysteresis of the selected HW temperature of the cascaded boilers.

Menu B: Hot water

B F D H i s c D i f 4 5 ° C

Function for the indirect hot water supply of the boiler (tank). This parameter is the hysteresis of the selected HW temperature of the calorifier/tank.

Menu B: Hot water

B G D H i d e t g r a d 3 ° C

Function for the indirect hot water supply of the boiler (tank). This parameter detects an (an accelerated) hot water demand, when a larger (water) amount is being used.

Menu C: Cascade

C 1 M a x C a s c U n t 1 1

Function for the cascading of the boiler(s). This parameter sets the total amount of cascaded boilers. (Max. 12 boilers).

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu C: Cascade

C 2 B u s a d r e s s 0

Function for the cascading of the boiler(s). This parameter determines the address of the boiler for the total cascading control. Master = 0, Slave 1 = 1 etc.

Menu C: Cascade

C 3 D H i c a s / m a s 0

Function for the cascading of the boiler(s). This parameter determines if only the Master boiler or all boilers of the cascade are used for indirect hot water. 0 = All 1 = Master

Menu C: Cascade

C 4 E x t r a u n i t 0

Function for the cascading of the boiler(s). This parameter is activated when an external (extra) boiler is connected to the Master boiler. Connect to the Master connections 21-22.

Menu C: Cascade

C 5 C a s S i / M a 0

Function for the cascading of the boiler(s). This parameter sets the function of the boiler at a cascade alignment 0 = Single / Slave unit 1 = Master unit

Menu C: Cascade

C 6 P w r O f f T o C a

0

Function for the cascading of the boiler(s). This parameter determines the function of the Slave boilers when the Master boiler is switched off. 0 = Slave boiler(s) continue operation 1 = Slave boiler(s) switch off

Menu C: Cascade

C 7 C o m F l u N u m 0

Function for the cascading of the boiler(s). This parameter determines the number of cascaded boilers, that are implemented with a common flue system.

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu D: General

D 1 0 - 1 0 V c o n t r 0

Function for the external control of the boiler by using a 0-10 Volt signal (Connections 15-16). 0 = No external control 1 = Control based on temperature setting 2 = Control based on power setting

Menu D: General

D 2 0 - 1 0 M i n T m p 2 0 ° C

Function for the external control of the boiler by using a 0-10 Volt signal (Connections 15-16). Control based on temperature (setting 1). The minimum (desired) CH water temperature when supplying a 1 Volt signal.

Menu D: General

D 3 A l t * 1 0 0 f 0

Function for setting the location height (above sea level) of the boiler. NOTICE: dimensions in English feet. One unit = 100 ft. Use this function only in consultation with the supplier/manufacturer.

Menu D: General

D 4 M a x C o o l T i m

2 M i n

Function for setting the maximum overrun time of the fan (Maximum 10 minutes). 0 = Switch off

Menu D: General

D 5 T e m p O n D i s p

1

Function to show the (measured) temperature of the boiler at the display.

Menu D: General

D 6 D H W 1 = i 2 = d 1

Function to set up the CH and HW boiler options. 0 = CH only (direct) 1 = CH/HW function (indirect) 2 = HW only (direct)

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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Menu D: General

D 7

c o n f i g

Function for the setting of the water pressure. Up to 4 bar a sensor is used, up to 6 bar a switch. 0 = off 1 = sensor 2 = switch

Menu D: General

D 8

g a s t y p e

Function to select the gas type 0 = standard 1 = G31* 2 = B/P G30*/G31*

* (cf. EN437)

Menu D: General

D 9

c o n f i g

Function for setting the 'soft start' option 0 = normal start-up 1 = reduced fan ramp-up speed (I) 2 = reduced fan ramp-up speed (II)

Menu D: General

D A

c o n f i g

Function: Pump mode 0 = normal 1 = relay 1, connector 19 and 20 (lock-out) 2 = relay 2, connector 21 and 22 (burner burning) 3 = relay 3, connector 23 and 24 (heat demand) 4 = relay CN10, connector 9 and 18

The screen texts on these pages are standard part of the software and apply to CH systems (boilers) and/or DHW devices (water heaters).

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10.16 Fault codes display

The following graphs describe the lock out codes of the water heater. A lock out code can only be removed by a manual reset of the water heater. NOTICE: Before resetting the water heater always check the water heater, DHW system and all components corresponding to the related lock out description. Never just reset the water heater, before analysing the possible cause of failure.

10.16.1 LOCK-OUT CODES

Having a lockout means that the water heater needs a manual reset to start operating again. When the water heater is in lockout the backlight of the display is blinking on and off.

Explanation >

9 9 9 , 5 : h r s

= time elapsed after fault & message.

Explanation >

P u m p 1 o

n

= status of the pump during fault.

Display message

F0

F l o w s e n s o r e r r o r p u m p o n 9 9 9 , 5 h r

s

Reason

Flow sensor not detected by the water heater caused by faulty connection/sensor.

Display message

F1

F l o w h i g h T e m p

p u m p o n 9 9 9 , 5 h r

s

Reason

Flow temperature exceeds the limit which has been set in the parameters.

Display message

F1

R e t u r n h i g h T e m p

p u m p o n 9 9 9 , 5 h r

s

Reason

The maximum return temperature as set in the parameters is exceeded.

Display message

F2

L a c k o f w a t e r p u m p o n

9 9 9 , 5 h r s

Reason

The general required gradient water lack has failed.

Display message

F3

R e t u r n s e n s o r e r r o r

p u m p o n 9 9 9 , 5 h r

s

Reason

Return sensor not detected by the water heater caused by faulty connection / sensor.

Display message

F5

N o n R e t u r n V a l v e

p u m p o n

9 9 9 , 5 h r s

Reason

Contact signal of the non-return valve failed.

Display message

F6

F l u e s e n s o r e r r o r p u m p o n 9 9 9 , 5 h r

s

Reason

Flue gas sensor not detected by the water heater caused by faulty connection / sensor.

Display message

F7

F l u e t e m p t o o h i g h

p u m p o n 9 9 9 , 5 h r s Reason

Flue gas temperature exceeds the limit which has been set in the parameters.

Display message

F8

F a i l e d b u r n e r s t a r t p u m p o n 9 9 9 , 5 h r s Reason

Water heater is not starting after the programmed starting attempts.

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Display message

F9

F l a m e l o s t p u m p o n 9 9 9 , 5 h r s Reason

Flame detected during normal operation, but was lost while running.

Display message

F10

F a l s e f l a m e s i g n a l p u m p o n

9 9 9 , 5 h r s

Reason

Flame signal is detected while it cannot be expected.

Display message

F11

F a n s p e e d i n c o r r e c t

p u m p o n

9 9 9 , 5 h r s

Reason

The controller does not detect a correct fan speed.

Display message

F12

p r o g r a m m i n g e n d p u m p o n

9 9 9 , 5 h r s

Reason

Software parameters have been programmed.

Display message

F13

P a r a m / H a r d w f a u l t p u m p o n

9 9 9 , 5 h r s

Reason

Fault during programming of the water heater software parameters.

Display message

F14

H i g h G a s F a i l

p u m p o n

9 9 9 , 5 h r s

Reason

Gas supply pressure is too high.

Display message

F15

C l i x o n F a

u l t p u m p o

n

9 9 9 , 5 h r s

Reason

Rear wall thermostat (clixon) detects a too high temperature.

Display message

F16

F l o w R e t u r n d t f a u l t p u m p o n 9 9 9 , 5 h r

s

Reason

Temperature difference T1-T2 has exceeded the blocking value. Programmed at the parameters P2 CO, P2 CR until P2 CV.

Display message

F17

W a t e r h i g h l i m i t

p u m p o n

9 9 9 , 5 h r s

Reason

Maximum thermostat (clixon) measured a too high flow temperature.

Display message

F19

S i p h o n s w i t c h p u m p o n

9 9 9 , 5 h r s

Reason

The pressure switch detects a high pressure in the flue/siphon system.

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The following graphs describe the blocking codes of the water heater. A blocking code is only a temporary blocking of the water heater, because of an extraordinary situation. The water heater will continue to operate after stabilisation of this situation.

10.16.2 BLOCKING CODES

The display is not blinking, but is lightened up during the blocking period. The water heater is blocking an action because of an extraordinary situation. This action will be continued after stabilisation of the situation.

Display message

A n t i c y c l e t i m e

9 9 9 , 5 h r

s

Reason

The controller received a new heat demand too quick after the last ended demand.

Display message

F l u e t e m p h i g h

9 9 9 , 5 h r

s

Reason

The flue gas temperature has exceeded the limit, as set in the parameters.

Display message

F l o w t e m p h i g h 9 9 9 , 5 h r

s

Reason

The flow temperature has exceeded the blocking temperature, as set in the parameters

Display message

R e t u r n t e m p h i g h 9 9 9 , 5 h r

s

Reason

The return temperature has exceeded the blocking temperature, as set in the parameters, but the return temperature has not exceeded the lock-out value.

Display message

T 1 - T 2 h i g h

9 9 9 , 5 h r

s

Reason

Temperature difference T1-T2 has exceeded the blocking value as set in the parameters.

Display message

D e a i r a t i o n

9 9 9 , 5 h r

s

Reason

The water heater starts its deairation function and after will return to normal operation. This function can be activated by parameter P4AJ.

Display message

D e l t a D i r e c t b l o c k 9 9 9 , 5 h r

s

Reason

Temperature difference T1-T2 has exceeded the blocking value, as set in the parameters P2CQ-P2CV.

Display message

H e a t e x c h a n g a t r i s k

9 9 9 , 5 h r

s

Reason

Temperature difference T1-T2 has exceeded the blocking value more than three times, as set in the parameters P2CQ-P2CV.

Display message

G a s p r e s s u r e l o w 9 9 9 , 5 h r

s

Reason

Gas supply pressure is (too) low.

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Display message W a t e r p r e s s u r e f a u l t 9 9 9 , 5 h r

s

Reason

Water pressure is too low or too high.

Display message

O u t d o o r s e n s o r f a i l

9 9 9 , 5 h r

s

Reason

Outdoor temperature has exceeded the blocking temperature which is set in the parameters.

Display message

d T B l o c k

9 9 9 , 5 h r

s

Reason

Temperature difference between flow and return exceeds the blocking value but not the lock out value.

Display message

C a s c a d e B l o c k

9 9 9 , 5 h r

s

Reason

One of the cascaded water heaters causes an error, because of a lock out.

Display message

A P S f a u l t 9 9 9 , 5 h r

s

Reason

The activation of the air pressure switch.

Display message

N R V o r F a n f a u l t 9 9 9 , 5 h r

s

Reason

Non return valve contact signal activated, > 15 seconds will cause a lock-out.

Display message

L i n e f a u l t

9 9 9 , 5 h r s

Reason

Wrong electrical power supply is connected (Not 50 or 60Hz, 220-240 Volt).

Display message

G e n B l o c k

9 9 9 , 5 h r s

Reason

The general blocking circuit is activated during operation = contact 7-8

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10.16.3 MESSAGES

The following graphs describe the messages at the water heater display. Depending on the selected and activated options for the water heater, it is possible that some messages will show up at the display of the water heater. For example a maintenance message after a certain programmed date has been reached. The water heater will operate independently of these messages.

MAINTENANCE ATTENTION MESSAGE

The display shows alternating the base screen and this message, while the backlight is blinking. The water heater is operating, but will count the exceeding hours. A parameter must be changed, after service, to remove this message.

Display message N e e d s M a i n t e n a n 0 . 0 I g n i t i o n c y c l e s h r s Reason

Maintenance option of total amount of ignition cycles has been reached.

Display message N e e d s M a i n t e n a n 0 .

0

D a t e h r s

Reason

Maintenance option of the date has been reached.

Display message N e e d s M a i n t e n a n 0 .

0

B u r n i n g h o u r s h r s

Reason

Maintenance option of total amount of burning hours has been reached.

Display message N e e d s M a i n t e n a n 0 .

0

A l l h r s

Reason

One of the abovementioned maintenance options has been reached.

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11 CONTROLLING OPTIONS AND SETTINGS

11.1 Water heater options

11.1.1 0-10 VDC REMOTE FLOW TEMPERATURE SET POINT

The hot water temperature is controlled by connecting an external 0-10 VDC signal to the water heater (connections 15-16).

P5BB Analogue input Config (0=off 1=temp) (display D1). This parameter must be set at "1" so the supplied 0-10 V dc signal will control the temperature set point. Possible settings are:

0 = 0-10V control off 1 = 0-10V temperature set point control active

See also the following graph for the relation between the temperature and the control signal.

offset Legionella hysteresis Legionella Legionella temp. max. setpoint

min. setpoint

0-10V DC control signal [V]

Temperature set point [°C]

off

on

max

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11.1.2 ANTI-LEGIONNAIRES’ DISEASE (PASTEURISATION) FUNCTION

To prevent Legionnaires’ disease, the water heater (software) provides a function for heating up the hot water storage tank (once a week or every day) to a higher water temperature than the normal active hot water set point. Also the period, that this “higher” water temperature function must be active, can be programmed in P7BV start time (0:00) and P7BW (8) and is standard switched off.

Also an external 0-10Vdc signal can be used to activate the pasteurisation function this can be done by making the 0-10V signal higher than 10,2V.

NOTICE: The standard factory setting for this Legionnaires’ disease (pasteurisation) function is “OFF”. To act i-

vate this Legionnaires’ disease function some parameters must be programmed by the manufacturer/supplier.

The starting day and starting time of this Legionnaires’ disease function can be programmed by the control panel

of the water heater and by using a computer, interface cable and the water heater software. Several parameters are used for this function. Three of these parameters are shown in the following graph.

The settings of these parameters P5CI, P5CJ and P5CD must be programmed according to all applicable anti Legionnaires’ disease preventing regulations.

The setting of these parameters can only be done by the manufacturer/supplier of the water heater and is possible by the control panel of the unit without the use of a computer.

NOTICE: The use and activation of this function won’t guarantee a Legionnaires’ disease free installation. The responsibility for a Legionnaires' disease free installation remains at the end-user/owner.

P5CI = 5°C This is the bandwith within which the Legionnaires' temperature must stay during the programmed duration time period. In this example the temperature is allowed to fluctuate between 65°C and 70°C during the anti Legionnaires' function.

P5CJ = 80 min.

This is the duration within which the water tempera-

ture must be between the 65°C and 70°C.

P5CD = 70 °C This is the maximum temperature during anti Legionnaires' disease function period.

Normal setting

water temperature.

Start of the anti Legionnaires'

disease program (start day and

time can be programmed).

Normal setting

water temperature.

Time (10 min steps)

Water temperature

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11.2 General

The following sections describe some general functions of the water heater and their possible use.

11.2.1 MAX COOLING TIME

The fan will cool down the heat exchanger according to the temperature settings (parameters) of the software. With this cooling parameter the maximum run time of the fan can be programmed.

P2LK Max cooling time (display D4) [min.]

The fan will cool the heat exchanger according to parameter P2 LJ, but the fan will never run for cooling longer than the period programmed with this parameter P2 LK. “0” = cooling function off. For S1 > local set point P6BA – P2LJ  fan starts after 1 minute and stops after 3 minutes During post pump circulation, no post ventilation takes place.

11.2.2 TEMPERATURE DISPLAY ON/OFF

Selection for showing the measured temperatures in the operation display of the water heater.

P5BJ Temperature display 1=on (display D5)

The measured temperature in the operation display. 0 = not visible

1 = visible

11.2.3 GAS TYPE SELECTION

Settings for gas types: natural gas, propane or butane-propane mixture (B/P). P4 BD Gas type (0=standard, 1=propane , 2=butane/propane (B/P)) (display D8).

This parameter is set 0 for the common used gas types such as natural gas G20 or G25. By setting this parameter 1 for propane, fan speed is reduced. Set this parameter 2 for B/P.

0 = standard gas (e.g: natural gas) 1 = propane 2 = B/P

By each setting, the relevant Soft start settings are automatically adjusted, depending on its main setting P4BE, see next section § 11.2.4.

In case of gas conversion, paste the corresponding sticker at the appropriate position in the boiler and mark the square for the used gas type. Also mark the square, indicating that the correct value has been set for parameter P4BD.

(In the example on the right, ‘propane’ and ‘P4BD = 1’ have been marked).

PROPANE

PROPAN

PROPANO

PROPAAN

BUTANE/PROPANE

BUTAN/PROPAN

BUTANO/PROPANO

BUTAAN/PROPAAN

P4BD = 1

P4BD = 2

G31

G30/G31

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11.2.4 SOFT START OPTION

Start parameters can be modified to achieve better start behaviour, in case of noise or other difficulties. This is done by reducing the fan ramp-up speed. Two reduced settings are available (I and II).

P4BE Soft start (0=normal, 1=reduced fan ramp-up speed (I), 2= reduced fan speed ramp-up (II))

(display D9).

0 = normal start-up 1 = reduced fan ramp-up speed (I) 2 = reduced fan ramp-up speed (II)

11.2.5 PUMP MODE (EC TECHNOLOGY)

When using a pump with Electronic Commutation technology and start-stop function, with a separate control connection, this parameter determines the relay for switching the pump on and off.

P5 BN Pump mode (0=modulating, 1=relay1, 2= relay2, 3= relay3, 4= external relay) (display DA).

Do not use the 230 Vac relay for the main power supply of the pump, but directly connect the pump to the mains of the boiler.

A modulating pump with PWM control: the power supply is directly connected to the mains, the PWM connection is connected to CN10, contacts 9 and 18.

Pumps with an on/off control can be switched by one of the relay connections “lock-out”, “burner burning” or “heat demand”. Choose a connection which is not yet used.

If all these connections are already used, an external 24 V relay can be connected to the PMW output connec-

tion (CN10, 9 + 18). By setting the parameter 4, the PMW signal becomes a start/stop signal: ‘pump ON’ by

PMW 100% (so constantly 24 V). This way, the pump can be controlled via the relay. 0 = PWM 0-100% modulating pump, connection CN10, connector 9 and 18

1 = Start-stop through relay 1, connector 19 and 20 (lock-out) 2 = Start-stop through relay 2, connector 21 and 22 (burner burning) 3 = Start-stop through relay 3, connector 23 and 24 (heat demand) 4 = Start-stop through PWM and external relay, connection CN10, connector 9 and 18

11.2.6 TANK SENSOR SENSITIVITY

P2KH Gradient heat demand detection DHW tank temperature (display BG) [0.1°C]

With S3 in use as tank sensor, it is possible to detect a fast cooling down of the tank through a large DHW flow. The sensitivity of this sensor can be set in parameter P2KH in tenths of degrees.

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12 COMMISSIONING THE WATER HEATER

12.1 First: flushing the water heater with water

After installation of the water heater the first step, before commissioning, is to flush the water heater and the whole DHW installation with fresh water to remove pollution, debris and other materials that might cause a blocking. This must also be done with installations, where only the water heater is replaced.

12.2 Second: filling & venting the water heater and the system

After flushing the water heater and the installation the system can be filled with fresh water by opening the water supply valve of the system and opening all the taps that are on the system. The water pressure of the system should be between a minimum of 1 bar and a maximum of 10 bar, also depending on the applied pressure safety valve.

The water heater has an automatic air vent situated on top of the water heater (at the roof panel). This vent must be opened during the filling of the water heater and the DHW system to make sure that no air/oxygen is trapped in the heat exchanger of the water heater. NOTICE: Check that the screw cap has been loosened at least one twist.

Make sure that, during flushing and filling, no water can reach any electrical parts of the water heater.

12.3 Third: check the water flow

Before the water heater will be started, be sure that the pump is functioning and that there is a water flow over the heat exchanger. Check the electrical power supply of the water heater. When this is connected correctly, the display will show:

Display message B o i l e r o f f

Reason

Water heater is not active. To activate the water heater press [ON/OFF] button for 6 seconds.

Display message W A T R H T R : b o i l e r o f f

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Reason

Water heater is not active. To activate the water heater press [ON/OFF] button for 6 seconds.

Activate the water heater by pressing the ON/OFF button for at least 6 seconds. After this the following display will appear:

Display message W A T R H T R : N o d e m a n d

> > > : 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Reason

Water heater is active, but there is no heat demand.

When there is no water present in the water heater or the water pressure is too low, the water heater will go into lock-out and will show a corresponding message in the display.

Display message W a t e r p r e s s u r e f a u l t 9 9 9 , 5 h r

s

Reason

Water pressure is too low or too high.

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By pressing the [SERVICE] button of the water heater, the water heater can be started without a heating demand. The water heater will start to fire and also the pump will start to run. Firing of the water heater without a

water flow (but filled with water!) will cause the so called “boiling noises”. Check during this “service function”

operation also the flow and return temperatures of the water heater by pressing the [◄] button once. The temperature difference of the flow and return must be at least 13ºC and maximum 25ºC. This temperature difference indicates that there is a (enough) water flow over the water heater; this water flow prevents the heat exchanger of possible damage caused by a thermal overload.

Flow monitoring

Another safety feature of the water heater, to make sure that there is enough water flow over the water heater, is the monitoring of the flow and return temperatures (T1 and T2). When the temperature difference (delta T) between flow and return exceeds a certain (set) value (load dependent), the following warning messages will be shown in the display.

Display message

T 1 - T 2 h i g h

9 9 9 , 5 h r

s

Reason

Temperature difference T1-T2 has exceeded the blocking value, as set in the parameters.

Display message

D e l t a D i r e c t b l o c k

9 9 9 , 5 h r

s

Reason

The temperature difference between flow and return has exceeded the blocking value

When this temperature difference exceeds the lock-out setting, the water heater will switch off and the following lock out code will be shown at the display.

Display message

F l o w R e t u r n d t f a u l t F16 p u m p o n 9 9 9 , 5 h r s

Reason

Temperature difference between flow and return has exceeded the blocking value. Parameters P2CO, P2CR until P2CV.

When these messages appear and/or the water heater will lock out, it means that there is not enough flow over the water heater. In this case check the functioning of the pump.

The water heater has a built in water pressure switch. If water pressure of the system drops under a certain limit, the water heater will go in a lock-out.

During and after the commissioning of the water heater, the operation of the water heater pump must be checked, before leaving the installation room.

NOTICE: Always check the running of the pump before firing the water heater.

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13 STARTING THE WATER HEATER

13.1 General

Check the gas pressure available at the gas connection pipe of the water heater. Use the pressure nipple (3) of the gas safety valve for this measurement. The gas pressure for the water heater, to operate properly under the correct load, must be at least 20 mbar.

The graphs below show the position of the pressure nipple (3) for the complete water heater range.

13.2 Firing for the first time

After the commissioning of the water heater and the described previous actions, the water heater display will show the following graph.

Display message W A T R H T R : N o d e m a

n

d > > > 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Reason

Water heater is active, but there is no heat demand.

The display describes:

 The actual operation  If a heat demand is activated  The temperature setting  The temperature measured

When mounting the bottom part of the siphon, before commissioning the water heater and/or after maintenance, the siphon must ALWAYS be completely filled with water.

This is a safety measure: the water in the siphon keeps the flue gases from leaking out of the heat exchanger via the condensate drain.

When the water heater receives a heat demand the electronics will start the operation of the water heater. Before the water heater is used, the water heater burner must be adjusted and set at the minimum and maximum load.

80 & 100

P

I

L

O

T

9-I

IN OUT AIR I N

EV 2

EV 1

3

1

2

The siphon must always be filled with water to the edge before placing back on the unit

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14 ADJUSTING AND SETTING THE BURNER

Before carrying out any adjusting of the burner, carefully read this complete chapter.

14.1 Introduction

The burner must always be adjusted in the next situations:

A. - A new water heater is installed

- As part of a service/maintenance check, in case the CO2 values turn out to be incorrect

Adjustment procedures for situation A are described in § 14.2. B. - The gas control safety valve has been (re)placed

- Another type of gas is applied: gas conversion

Adjustment procedures for situation B are described in § 14.3.

In either of the four cases described in A and B, always check the gas/air ratio of the combustion figure (CO2) at maximum and minimum input. First set the water heater at maximum load and subsequently at minimum load,

and repeat if necessary. Set-up of this chapter:

First, all necessary values are given in three tables in § 14.1.1. A drawing of the gas valve(s) and setting screws is given in § 14.1.2 on the next page. In § 14.1.3 a general scheme, conform which the adjustments must be carried out, is presented in table form. After that, in §§ 14.2 and 14.3, a thorough description is given of how to proceed in cases A and B respectively. In § 14.4, finally, two main procedures used in the previous sections are described in detail.

14.1.1 ADJUSTMENT TABLES

Tables 2 and 3 see next page 

Maximum fan speed has to be reduced to convert the water heater into a butane (B/P) appliance.

For adjustment use CO2 tolerance of ± 0.1 % (for O2 this is ± 0.2 %).

Table 1

gas type:

water heater type

load

output

nat.gas G20 1/ G25 1

propane G31 1

butane (B/P) G30

1, 3

S-WG 80-120 2

max. load

CO2 (%)

9.0

10.3

10.4

O2 (%)

4.8

5.2

5.3

min. load

CO2 (%)

8.7

9.3

O2 (%)

5.3

6.7

6.9

S-WG 150 2

max. load

CO2 (%)

9.0

10.4

10.5

O2 (%)

4.8

5.0

5.2

min. load

CO2 (%)

8.7

9.3

O2 (%)

5.3

6.7

6.9

S-WG 180 2

max. load

CO2 (%)

9.0

10.5

10.6

O2 (%)

4.8

4.7

4.9

min. load

CO2 (%)

8.7

9.3

O2 (%)

5.3

6.7

6.9

1

Cf. EN437

2

All values are measured without front panel.

3

Fan settings must be changed by altering parameter P4BD (display D8) (only by a skilled mechanic)

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Table 2

pre adjustment settings gas valve for BIC water heaters

water heater type

number of turns open (counter clockwise)

nat. gas G20 / G25

propane G31

butane G30

S-WG 80

1.5

0.75

0.5

SWG100

3.5

1.5

1.25

SWG120

2.25 *

1 *

0.75 *

SWG150

2.25 *

1 *

0.75 *

SWG180

4.25 *

2.25 *

2 *

* Both gas valves must be opened this number of turns.

Table 3

Contact your supplier for the right settings when converting to a not mentioned type of gas.

Pressure adjustment settings LEFT valve

water heater type

“p-out” pressure at gas valve

nat. gas G20 / G25

propane G31

butane G30

S-

WG120

-2 to 0 Pa

-4 to -2 Pa

-5 to -3 Pa

S-

WG150

-2 to 0 Pa

-7 to -5 Pa

-8 to -6 Pa

S-

WG180

-2 to 0 Pa

-7 to -5 Pa

-8 to -6 Pa

The maximum fan speed has to be reduced to convert the water heater into a butane (B/P) appliance. Set parameter P4BD.

14.1.2 SETTING SCREWS GAS VALVE(S): DRAWINGS

NOTICE: Do NOT mistake the screw marked ‘PILOT’ for screw 2.  Screw 2 is the SMALL screw immediately next to the pilot screw.

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80 & 100

150 & 180

120

P

I

L

O

T

9-I

IN OUT AIR IN

EV2

EV1

P

I

L

O

T

9-I

IN OUT AIR IN

EV2

EV1

P

I

L

O

T

9-I

IN OUT AIR IN

EV2

EV1

P

I

L

O

T

9-I

IN OUT AIR IN

EV2

EV1

P

I

L

O

T

9-I

IN OUT AIR IN

EV2

EV1

3

1

2

3

1

2

3

1

2

4 1

1

4

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14.1.3 ADJUSTMENT ACTIONS: GENERAL SCHEME

General scheme for adjustment of the gas valve(s). Check this scheme for an overview. To complete all necessary adjustments in right order, follow case A or B top-down through the scheme (B involves a few extra steps (grey fields)):

GENERAL SCHEME SETTING STEPS

case A

case B

continue ↓

first close (both*) screw(s) [2], then set

them in accordance with table 2

SWITCH TO SERVICE MODE

continue ↓

If burner doesn’t start, open (RIGHT*)

screw[2] ¼ turn extra

setting at maximum load

procedure 1

[▲] set burner at maximum load

measure CO2 at flue gas outlet;

use (RIGHT*) screw [2] to

match value with table 1

setting at minimum load

continue ↓

only  SWG120, 150, 180

[▼] set burner at minimum

load

use LEFT screw [1] to match “p-out” with table 3

procedure 2

[▼] set burner at minimum load

measure CO2 at flue gas outlet;

use (RIGHT*) screw [1] to

match value with table 1

repeat procedure 1

repeat procedure 2

keep repeating until values match table values best

Water heater returns to NORMAL MODE after 40 min. OR by pressing [SERVICE] button

* in case of a double valve (S-WG120, 150 and 180) For an extensive description consult the next two sections (choose which is applicable, A or B):

CO2

[2]

CO2

[2]

CO2

[1]

CO2

[1]

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14.2 Adjusting in case of a new water heater, or after service (case A)

14.2.1 GENERAL REMARK

For all adjusting steps under A the following must be applied: as long as measured CO2 values differ less than

0.3% from the table values, no adjustment is necessary, because this deviation is typical for the process (O2 values: ± 0.5%). If, however, larger deviations are measured, adjustment now must be made until the table value is reached within max. 0.1% deviation (O2 values: ± 0.2%).

14.2.2 ADJUSTING AT MAXIMUM LOAD

Adjust at maximum load by carrying out procedure 1, see p.102 .

14.2.3 ADJUSTING AT MINIMUM LOAD

Adjust at minimum load by carrying out procedure 2, see p.102.

14.3 Adjusting after gas valve replacement, or in case of gas conversion (case B)

The maximum fan speed has to be reduced to convert the water heater into a butane (B/P) appliance (set parameter P4BD).

14.3.1 GENERAL REMARKS

In case B, a distinction is made between the setting of boilers containing a single valve (S-WG80-S-WG100) and boilers containing a double valve (S-WG120-S-WG180). All adjustments must result in CO2 percentages within a bandwidth of max. ± 0.1% deviation from the table values (O2 values: ± 0.2%).

14.3.2 ADJUSTING AT MAXIMUM LOAD S-WG80 / S-WG100

The water heaters S-WG80 and S-WG100 all have single gas valves, see the drawings on page 97.  First, turn setting screw [2] of the gas valve clockwise until you feel resistance. This means that the valve

is closed, do not try to tighten the screw any further.

 Now turn screw [2] counter clockwise (open), according to the number of turns in table 2 for the used wa-

ter heater and gas type.

After this, adjust at maximum load by carrying out procedure 1 on p.102. If the burner doesn’t start up in service mode, turn screw [2] a quarter turn counter clockwise further open, and try again.

14.3.3 ADJUSTING AT MINIMUM LOAD S-WG80 / S-WG100

Adjust at minimum load by carrying out procedure 2 on p.102. IMPORTANT: Toggle between high fire and low fire to make fine-tuning adjustments (adjusting the minimum

setting affects the maximum setting and contrariwise).

14.3.4 CHECKING AND ADJUSTING AT MAXIMUM LOAD S-WG120 / S-WG150 / S-WG180

The water heaters S-WG120, S-WG150 and S-WG180 all have double gas valves, see the drawings on page

97. First connect a manometer to “p-out” = measuring point [4] of the left gas valve (see drawing).

 Now, turn setting screws [2] of both gas valves clockwise until you feel resistance. This means that the

valves are closed, do not try to tighten the screws any further in the closed position.

 After this, turn screws [2] of both left and right hand gas valve counter clockwise (open), according to the

number of turns in table 2 for the used water heater and gas type.

From now on only use the right hand gas valve for adjustments on high fire. Adjust the right hand valve at maximum load by carrying out procedure 1 on p.102.

If the burner doesn’t start up in service mode, turn screw [2] a quarter turn counter clockwise further open, and try again.

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14.3.5 CHECKING AND ADJUSTING AT MINIMUM LOAD S-WG120 / S-WG150 / S-WG180

Adjusting these water heaters at minimum load in case B involves extra measurements, to get both valves balanced:

Use the [▼] button to decrease the actual load of the service (percentage) to the minimum. The following screen

will appear:

Display message W A T R H T R : S e r v i c e 2 6

%

> > > 1 2 3 . 4 ° C ( 1 2 3 . 4 ° C

)

Water heater is activated and operates at service mode at 26% (minimum).

See table 3 for pressure settings “p-out” gas valve for the used water heater and gas type. Use screw [1] on the left hand gas valve to adjust the measured pressure at “p-out” to the right value according to table 3. Be sure the manometer has been zeroed out prior to making this setting. Below, the influence of turning screw [1] is described.

Turning counter clockwise Turning clockwise

  less gas

more gas

  a drop in CO2

a rise in CO2

  a drop in measured pressure at “p-out”

a rise in measured pressure at “p-out”

After “p-out” has been set cf. table 3, use only the right hand screw [1] for setting the CO2 at low fire.

Adjust the right hand valve at minimum load by carrying out procedure 2 on p.102. Again, toggle between high fire and low fire to make fine-tuning adjustments (adjusting the minimum setting affects the maximum setting and contrariwise).

If the valves have been set correctly, “p-out“ left should equal “p-out“ right. As an additional test, one could check this by measuring “p-out“ at the RIGHT valve, i.e. at measuring point 4 on the right valve (not denoted in the drawings on page 97). This pressure should be in the same range of pressure as the left valve, so in accordance with table 3 again.

If, after all setting steps have been carried out properly, the values of left and right “p-out“ are still very different, contact your supplier.

In case of gas conversion, paste the corresponding sticker at the appropriate position in the boiler and mark the square for the used gas type. Also mark the square, indicating that the correct value has been set for parameter P4BD.

(In the example on the right, ‘propane’ and ‘P4BD = 1’ have been marked).

PROPANE

PROPAN

PROPANO

PROPAAN

BUTANE/PROPANE

BUTAN/PROPAN

BUTANO/PROPANO

BUTAAN/PROPAAN

P4BD = 1

P4BD = 2

G31

G30/G31