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A.O. Smith SGS - 100 Installation Manual

1. C43 B23 C33 n I j val ia ae EA Yaa Eas ti n 2 i I e Lg o C13 C53 W Cs ER ee le ya DZ nr g cat T eA__ Elma HS Ta T ka 0 ED Type of appliance Explanation of type of appliance Description B23 Air for combustion is drawn from the boiler room C13 Concentric and or parallel wall flue terminal C33 Concentric and or parallel roof flue terminal C43 Appliances on common air supply and flue gas discharge concentric and or parallel in multi storey building C53 Air supply and flue terminal types mixed C63 3 10 3 Instruction manual SGS Appliances supplied without flue components and or terminal These appliances must be installed in compliance with local regulations Note Make sure that the chimney discharges into an area where this is permitted for this category of appliance Concentric connections The table shows the requirements for concentric systems Wy Warning Install flue gas discharge pipe runs with a run off of 5 mm per metre Flue gas discharge requirements for concentric systems C13 C33 Appliance Diameter Maximum length Maximum number of 90 bends 130 200mm 3 130 200mm 3 Caution Both conditions stated in the table must be fulfilled Even if there are less bends than the stated maximum the maximum pipe length may not be exceeded Ev
2. 13 General working principle of the appliance 13 The appliance s heating cycle 14 Protection for the appliance 15 Safety of the installation 17 Installation 19 Introduction 19 Packaging ee ee ee eee 19 Environmental conditions 19 Technical specifications 22 Installation diagram 25 Water connections Vented 26 Water connections Unvented 27 Gas connection 28 Solar heating system 28 Air supply and flue 28 Electrical connection 35 Electrically connecting the solar heating system controller 38 Checking the supply pressure and burner pressure 41 Conversion to a different gas category 45 Filling gt AT Installation diagram 47 Filling unvented installations 48 Filling vented installations 48 Filling solar heating system 49 Draining
3. OH WEEE PROGRAM 2 Position the cursor in front of OFF 3 Confirm OFF with ENTER 4 Wait until the fan has stopped The symbol is then dimmed Caution Failure to wait until the fan stops purging can cause damage to the appliance 5 Switch the appliance OFF position 0 using the ON OFF switch on the control panel XeSmith IMD 0588 RO Instruction manual SGS AE 6 3 Draining vented installations Instruction manual SGS 6 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 7 Shut off the gas supply 10 8 Close the stop valve 11 in the hot water pipe 9 Close the supply valve 4 in the cold water supply A 10 Open the drain valve 9 11 Bleed the appliance or installation so that it drains completely 1 Activate the MEHLI with c 2 Position the cursor in front of OFF 3 Confirm OFF with ENTER 4 Wait until the fan has stopped The symbol amp is then dimmed Caution Failure to wait until the fan stops purging can cause damage to the appliance 5 Switch the appliance OFF position 0 using the ON OFF switch on the 8 9 10 11 XeSmith control panel IMD 0588 RO Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 Shut off the gas supply 10 Close the stop valve 11 in
4. Height of drain valve connection 225 225 Height of T amp P valve connection 1425 1425 Height of condensation drain 240 240 Cold water supply connection external R1 5 R1 Hot water outlet external R1 R1 5 Gas control connection internal Rp Rp 4 Drain valve connection internal T oie T amp P valve connection internal 1 11 5 NPT 1 11 5 NPT Cleaning inspection opening 95x70 95x70 N a alo N gt sl wa v z Condensation drainage connection internal Rp1 3 4 2 General and electrical specifications General and electrical specifications DESCRIPTION Unit Rp1 SGS 100 Capacity litres 460 Empty weight kg Maximum operating pressure bar Number of anodes Fan speed at ignition rpm Working speed of fan rpm Diameter of air restrictor mm Heating up time AT 45 C minutes Electrical power consumption W Power consumption of solar heating system controller max W Supply voltage 15 10 VAC Mains frequency IP class Instruction manual SGS 23 3 Installation WE 3 4 3 Gas data Gas data Description Ilo1434 SGS 100 Natural gas Gas category G20 20 mbar Orifice diameter Nominal load gross calorific value Nominal output Supply pressure Burner pres
5. 15 blocking error Short circuit from dummy 2 Short circuit in sensor circuit Instruction manual SGS Replace the dummy sensor To replace the necessary parts you must contact your installation engineer 80 Code Description Solution ae De S16 blocking error Short circuit in temp sensor S4 atthe bottom of the storage tank Short circuit in sensor circuit Replace sensor S4 To replace the necessary parts you must contact your installation engineer 17 blocking error Short circuit in temp sensor S1 at bottom of tank Sensor is not correctly connected Replace sensor S2 To replace the necessary parts you must contact your installation engineer 18 blocking error Short circuit in temp sensor S1 in the collector Short circuit in sensor circuit Replace sensor S1 To replace the necessary parts you must contact your installation engineer F01 blocking error Defect in power supply circuit Live and neutral connected wrong way round Connect live and neutral correctly 3 11 Electrical connection the appliance is phase sensitive See the SGS electrical diagram 17 Appendices Condensation on the flame probe Disconnect the lead at the flame probe 2 Ignite the appliance three times with an interrupted ionisation circuit 3 Reconnect the ionisation lead to the flame probe Ignite the appliance again 5 The repeated ig
6. 11 S 4 IMD 0582 R2 Instruction manual SGS 51 6 Legend i ARR 19 float valve Only applicable numbers are mentioned 23 pressure valve mandatory 1 pressure reducing valve mandatory if the mains 26 air bleed mandatory water pressure exceeds 8 bar 3 T amp P valve mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating 4 stop valve recommended in pipe C and mandatory in mandatory pipe A 5 non return valve mandatory 6 circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve recommended 12 temperature gauge recommended 13 condensation drainage mandatory 14 hot water draw off points 16 expansion vessel mandatory cold water supply hot water supply circulation pipe gas supply overflow pipe heat exchanger supply heat exchanger return overflow safety S1 collector sensor mandatory S2 tank sensor mandatory TOMMOO0A gt 17 3 way aeration valve recommended S3 top tank sensor mandatory 18 water tank 6 2 Draining unvented installations 52 S4 heat exchanger discharge sensor optional Note In the above diagram there is a non return valve in the station This may only be used in closed pressure systems In systems with drain back it is prohibited to fit a non return valve in the solar heating system 1 Activate the MEHU with MENU 0FF
7. 51 Installation diagram 51 Draining unvented installations 52 Draining vented installations 53 Draining solar heating system 54 The control panel 55 Introduction 55 Controls 55 Meaning of icons 55 Electronic controller ON OFF switch 55 Navigation buttons 56 5 10 11 12 13 14 7 6 8 1 8 2 8 3 8 4 8 5 9 1 9 2 9 3 10 1 10 2 10 3 10 4 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 9 11 10 11 11 11 12 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 13 1 13 2 13 3 13 4 14 1 14 2 Table of contents PC connection 56 Status of the appliance 57 Introduction 57 Operating modes 57 EXTEA 57 Error conditions 58 Service condition 58 Starting and running 59 Introduction 59 Starting the appliance 59 The appliance s heating cycle 59
8. Check that the controller is receiving power Check that the controller is correctly connected If there is no electrical power check the power supply to the terminal block or replace the controller Rectify any incorrect connections Reset appliance controller Instruction manual SGS 83 Code Description Solution Remark F03 lock out error Damaged wiring Open 1 Check the wiring between the pressure switch and the If the error cannot be resolved or is persistent contact your circuit controller installation engineer To replace the necessary parts you must contact your installation engineer The pressure switch fails to work correctly If necessary replace the wiring Pressure switch not Check the running speed of the fan 12 5 Display the selected closing appliance Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted Refit them if necessary Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner If necessary replace the hoses Check that the flue gas outlet is compliant 3 10 Air supply and flue Check for blockage in the flue gas discharge Remove any blockage that may be present Check for blockage in the condensation water discharge Remove any blockage that may be present Measure the pressure differential across the pressure switch See the table in Preparation for
9. Installation User and Service Manual Te Smith CE www aosmithinternational com your installer AES Read this manual carefully Trademarks Liability More information Instruction manual SGS Ww Warning Read this manual carefully before starting up the water heater Failure to read this manual and to follow the instructions in this manual may lead to accidents personal injury and damage to the appliance Copyright 2008 A O Smith water Products Company All rights reserved Nothing from this publication may be copied reproduced and or published by means of printing photocopying or by whatsoever means without the prior written approval of A O Smith water Products Company A O Smith water Products Company reserves the right to modify specifications stated in this manual Any brand names mentioned in this manual are registered trademarks of their respective owners A O Smith water Products Company accepts no liability for claims from third parties arising from improper use other than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven Chamber of Commerce Refer further to the General Conditions These are available on request free of charge Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components the manual may nonetheless contain errors and inaccuracies Shoul
10. maintenance 15 2 Preparation for maintenance If there is insufficient pressure differential clean the heat exchanger If the pressure differential is acceptable check that the pressure switch is closing using a multimeter Instruction manual SGS 84 Code Description F04 lock out error Three unsuccessful ignition attempts Solution 1 Open the main gas valve and or the manual gas valve supplying the water heater 2 Check the supply pressure to the gas control 3 If necessary repair the gas supply y De To repair the gas supply contact your installation engineer Air in the gas pipes Bleed the air out of the gas pipe No burner pressure Check the burner pressure to the gas control Check that the gas valve s open and shut correctly If necessary replace the gas control See Checking the supply pressure and burner pressure for how to bleed air from the gas line and measure the supply pressure and burner pressure To replace the necessary parts you must contact your installation engineer Defect in the hot surface igniter circuit Check that the hot surface igniter is correctly connected JP2 Check the wiring of the hot surface igniter 1 2 3 1 2 3 Measure the resistance across the hot surface igniter This must lie between 2 and 5 ohms Check that the hot surface igniter lights up during ignition If necessary replace the hot surface igniter
11. 16 on the intake side of the fan The gas air mixture is then blown into the burner The modulated supply of gas and air ensures that the optimum gas air mixture is always achieved A gas fired heat exchanger 11 in the appliance heats the tap water further if necessary The air required by the latter for combustion is forced into the burner 17 by the fan 18 The heated tap water leaves the tank through the hot water outlet 2 Once the appliance is completely filled with water it will constantly be under mains water pressure When hot water is drawn from the appliance it is immediately replenished with cold water The gas is fed to the burner via the gas control 16 The modulated supply of gas and air ensures that the optimum gas air mixture is always achieved The special construction of the burner causes the mixture to form a vortex cyclone effect before it becomes ignited This vorticity improves the ignition on the hot surface igniter 20 as well as ensuring optimum combustion efficiency The special design of the heat exchanger 11 ensures that the flue gases are first led downwards via the combustion chamber then upwards via the heat exchanger and downwards again alongside the water in the tank The flue gases gradually become cooler in the process Because the cooled flue gases flow alongside the cold water lower down in the tank they start to condense This condensation causes latent heat energy to be transferred to the
12. To enter the time and day MEHL WEEK PROGRAM EXTRA PERIOD 5ETTIHOS 1 Call up the menu for entering the day and time as follows 2 ca SETTINGS Confirm with ENTER The display shows the menu for settings 3 Scroll with 4 and to GAY TIME Confirm with ENTER SETTINGS LAHGUAGE 0AYTIME SPECIFICATIONS The display shows the sub menu for adjusting the day DAY Surndau Monday Tuesday Hegdnesdad Thuradas Friday Satuedoa Hi 4 The cursor is positioned beside Sunda Scroll with and to the desired day Confirm with ENTER The day has been set The display shows the sub menu for adjusting the time 5 The cursor moves to the hour digits which flash Scroll with and to the current hour for example 15 Confirm with ENTER 6 The cursor moves to the minute digits which flash Scroll with and to the next minute for example 45 69 1 1 Main menu Confirm the minute setting with ENTER The time has been set Note The appliance takes no account of daylight saving 11 12 3 Displaying appliance specifications Note This category is solely intended for the installation engineer and or service and maintenance engineer The table shows the correct settings SGS 100 Ignition fan speed 3120 rpm Working speed of fan 5700 rpm Regulation interval 40 80 C Call up the menu to display the appliance specifica
13. pre and post purge The fan speed is continuously monitored by the electronic controller 4 The electronic controller takes control if the speed of rotation varies too much from the set value 16 Instruction manual SGS AE 2 5 Safety of the installation Instruction manual SGS 2 4 6 2 4 7 2 5 1 2 5 2 2 5 3 Pressure switch The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre purge and normal running of the appliance The default state of the pressure switch is open When sufficient pressure difference is reached the pressure switch closes However in the event of a fault the pressure switch is tripped open and the heating cycle is interrupted The table shows the trip point per appliance Note The trip point of the pressure switch is not adjustable Pressure switch trip points Appliance Closing pressure difference Opening pressure difference SGS 80 gt 1005 Pa lt 975 Pa SGS 100 gt 1145 Pa lt 1115 Pa Flame probe To ensure that no gas can flow when there is no combustion the water heater is fitted with a flame probe 21 The electronic controller uses this probe to detect the presence of a flame by means of ionisation detection The electronic controller closes the gas control the instant it detects that there is a gas flow but no flame In addition to the appliance s standard built in safety monitoring the appliance m
14. setting the switch off time 1 Use t and to set the hours In the example this is 12 Confirm with ENTER The cursor moves to the minute digits which flash OH OFF mo Tset PLIMP mo EP LI 2 Use and to set the minutes In the example this is 45 Confirm with ENTER The cursor moves to the desired water temperature OH SU esis OFF SU 15545 Tset 65 C PUMP OH SAJE 11 7 3 Week program setting the water temperature 1 Use 4 and to set the water temperature In the example this is 75 C Confirm with ENTER The cursor moves to F LIMP OH OH OFF Tset FUMF 40H SANE 65 11 11 7 4 Week program setting the program controlled pump Main menu 1 If required a pump can be controlled during the period Use tand amp to set FHMF OH The pump ensures a regular circulation of hot water in the hot water pipes You can skip this step if you there is no pump in your hot water circuit Confirm with ENTER The cursor moves to SAE OH OFF Tset PUMP 0H SANE 2 Confirm with ENTER The display shown in the figure will appear DAY TIME OH 50 02 13 OFF SU 12545 0H MO Bel ae OFF MO 26559 OH TU Bela OFF Til 23 59 3 If you wish you can use to scroll to another day and change more switch on times 11 7 1 Week program setting the switch on time and switch off times 11 7 2 Week program setting the switch off time 4 After changing all desired
15. Defect in the ionisation circuit Check that the flame probe is correctly connected JP2 Check the wiring of the flame probe Measure the ionisation current This must be at least 1 5 microamps 4 Replace the wiring if necessary Supply voltage too low Check the supply voltage this must be 230 VAC 15 10 If the error persists contact your installation engineer To replace the necessary parts you must contact your installation engineer F05 lock out error Too many flame errors have been signalled Incorrect roof or wall conduit Recirculating flue gases Instruction manual SGS 1 Check that the correct roof or wall flue conduit 3 10 Air supply and flue has been fitted If necessary install the correct roof or wall conduit 3 Check that the roof or wall conduit discharges into a permitted area If the error cannot be resolved or is persistent contact your installation engineer 85 Code Description F06 lock out error Short circuit between flame probe and earth Damaged cable in contact with metal surface Solution Check the wiring of the flame probe If necessary replace the wiring Ceramic part of the flame probe is broken cracked Check that the ceramic part of the flame probe is still intact in the vicinity of the burner s air distribution plate If not the flame probe must be replaced Remark If the error persists contact your in
16. Finalizing maintenance Note Before ordering spare parts it is important to write down the appliance type and model and the full serial number of the appliance These details can be found on the rating plate Only by ordering with this information can you be sure to receive the correct spare parts To test whether all components are still working properly complete the following steps 1 Activate the MEHLI with c amp 2 Use and amp to place the cursor beside OFF 3 Confirm OFF with ENTER MENU OFF gt ole WEEE PROGRAM 4 Wait until the fan has stopped The icon is then dimmed Caution Failure to wait until the fan stops purging can cause damage to the appliance 5 Switch the appliance OFF position 0 using the ON OFF switch on the control panel 93 94 15 Performing maintenance XeSmith IMD 0588 RO 6 Switch the electronic controller ON by setting the ON OFF switch to position I INTERHAL CHECK The display will now show IHTERHMAL CHECK for about 10 seconds and will then go to the main menu MENU 0FF jH WEEE PROGRAM 7 Activate ON mode by going through the following steps Press once on the blue arrow to position the cursor beside OH then press ENTER Confirm the selection THET OFERATION with ENTER 8 If there is no heat demand increase Tset 11 4 Setting the water temperature Note the original setting Draw some hot water off to
17. ON 37 Connect Alarm OUT 38 connecting air supply 28 connecting cold water side 26 27 connecting condensation drainage 28 connecting flue gas discharge 28 connecting hot water side 27 connecting isolating transformer 37 connecting Tank ON 37 connecting the program controlled pump 37 controls 63 conversion to a different gas category 45 dimensions 23 display 55 displaying error history 71 draining 51 electrical connection 35 electrical connector block 35 environmental conditions 19 error 58 extra period 57 operating mode 57 settings 68 fan 16 filling 47 flame probe 17 floor loading 20 forms of notation 10 frost protection 57 Instruction manual SGS gas category conversion to different 45 gas connection 28 gas control 16 general specifications 3 heat demand 59 heating cycle 14 59 humidity 20 icons pre glow 55 explanation 55 flame detection 55 gas control 55 heat demand 55 ignition 59 installation diagram 25 47 51 installation engineer 10 isolator 37 language setting 69 liability 3 mains power 37 maintenance burner 96 condensation water discharge 96 finalising 96 gas side 96 heat exchanger 96 orifice 96 water side 95 mode ERROR 58 EXTRA 57 HEAT DEMAND 59 IGNITION 59 OFF 57 ON 57 POST PURGE 59 PRE GLOW 59 PRE PURGE 59 PRESSURE SWITCH 59 PROG 57 RUNNING 59 SERVICE REQUIRED 58 navigation buttons 56 off 57 on 57 ON mode 63 109 Index on off switch 55 softlite 16
18. The water temperature drops below the set temperature of for example amp 3 C The electronic controller detects a demand and starts the heating cycle The icon Wis activated The message HEAT GCEMANE appears T00dA00 OH u 15545 Thursday Ts HEAT GEMAHD 2 Once demand is registered the fan is started to exhaust any gases that may be present This phase is called pre purge and lasts about 15 seconds The icon Gis activated The message FRE PURGE appears o e B a Bw OH na 15545 Thur coos PRE PURGE 3 During the pre purge the pressure switch closes The icon Gis activated Themessage PRESSURE SWITCH appears OH an 13 45 Thur PRESSURE Sul 4 After some time the pre purge ceases and the electronic controller reduces the fan speed to the ignition speed This is followed by the pre glow of the hot surface igniter The icons and are dimmed The icon Eis activated PAR Say tal OH F 7 13 45 Thursday 63 C Tse 65 BLOW FLUG 60 AEX 5 After a number of seconds pre glow the gas control is opened and ignition takes place The icon lis activated The message ISHITIOH appears 0 eoo gaw OH 15 49 rin IGHITIOH 6 After ignition the flame is detected and the appliance will be running This means that actual heating has started The fan speed then increases to the normal working speed and
19. WEEE PROGRAM EXTRA PERIOD SETTINGS The cursor points to the option to be activated In the display as shown in the figure you can scroll through the main menu The main menu comprises OFF OH WEEK PROGRAM EXTRA PERIGE and SETT IMG You have to scroll down further to see the options ESTEA PERIOD and SETTINGS The selected option is confirmed using ENTER Pressing the RESET button takes you back one page in a menu and discards all options selected in the current menu Note The RESET button is also used to reset the appliance following an error 7 6 PC connection The PC connection is solely intended to enable technicians from A O Smith to display the status and history of the appliance These details can be important for troubleshooting and or responding to complaints 56 Instruction manual SGS AEJK 8 Status of the appliance 8 1 Introduction Topics covered in this chapter e Operating modes e Error conditions e Service condition 8 2 Operating modes When running the appliance has four basic operating modes namely e OFF e CH ESTRA PROG 8 2 1 DFF In this mode the frost protection is activated The figure shows the display with the following information line one the text OFF linetwo the time the day and alternately 9 3 The appliance s heating cycle T4 and Thet lines three and four the text FROST PROTECTION ACTIUATED OFF 13 45 Thursday 6 C
20. and supply pressure 3 13 Checking the supply pressure and burner pressure 9 Replace the cover 10 Remove the sticker showing the new gas category from the conversion kit and attach it below the appliance s rating plate This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied 11 Start 9 Starting and running the appliance Instruction manual SGS AED 5 Filling 5 1 Installation diagram This figure shows the installation diagram This diagram is used in the sections in which the actual connection process is described Installation diagram UNVENTED Si rd VENTED 11 Ss ROD A 4 IMD 0582 R2 Instruction manual SGS 47 5 AES Legend 19 float valve Only applicable numbers are mentioned 23 pressure valve mandatory 1 pressure reducing valve mandatory if the mains 26 air bleed mandatory 6 9 10 11 service stop valve recommended 12 temperature gauge recommended 13 condensation drainage mandatory water pressure exceeds 8 bar T amp P valve mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating stop valve recommended in pipe C and mandatory in mandatory pipe A non return valve mandatory circulation pump optional drain valve manual gas valve mandatory cold water supply hot water supply
21. appliance is switched off 10 2 Shut the appliance down for a brief period OFF mode The solar heating system is switched off Refer to the documentation of the solar heating system The appliance has cooled down sufficiently to prevent personal injury burns Note The filling procedure described in this manual is intended for the pump system supplied by the supplier of the appliance For any other system you should follow the procedure for that system Wy Warning To avoid contaminating the glycol you should flush the solar heating system through with water before filling Flushing with water 1 Connect a water supply to the filling point of the pump station Connect a drain hose to the drain point Open the taps of both supply and drain point Open the water supply tap ak oN Allow the system to spool through until no further contamination comes out of the drain hose 6 Then shut off the water supply 7 Drain all remaining water from the system 8 Now you can fill the system with glycol Filling with glycol 1 Insert the hose of the glycol pump into the jerry can containing the glycol 2 Tighten the pump onto the jerry can using the swivel 3 Connect the hose of the glycol pump to the inlet combination of the pump station 4 Open the valve of the inlet combination 5 Plug the glycol pump into a mains socket 6 Start the glycol pump using the ON OFF switch on the glycol pump 49 m ARR 7 Stop
22. circulation pipe gas supply overflow pipe heat exchanger supply heat exchanger return overflow safety TOMMOO0A gt 14 hot water draw off points S1 collector sensor mandatory 16 expansion vessel mandatory S2 tank sensor mandatory 17 3 way aeration valve recommended S3 top tank sensor mandatory 18 water tank S4 heat exchanger discharge sensor optional Note In the above diagram there is a non return valve in the station This may only be used in closed pressure systems In systems with drain back it is prohibited to fit a non return valve in the solar heating system 5 2 Filling unvented To fill the appliance proceed as follows installations 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6 2 Close the drain valve 9 3 Open the nearest hot water draw off point 14 4 Open the stop valves 11 between the storage tank and the appliance 5 Open the stop valve 4 on the cold water side A so that cold water flows into the appliance 6 Completely fill the appliance When a full water jet flows from the nearest draw off point the appliance is full 7 Bleed the entire installation of air for example by opening all draw off points 8 The appliance is now under water supply pressure There should be no water coming out of the expansion valve 15 or out of the P valve 23 If there is the cause might be The water supply pressure is greater tha
23. cuts in if the water temperature drops below 5 C The text FROST will then appear on line one of the display The appliance heats the water to 20 C Tet and drops back to the FF mode Note These values of 5 C and 20 C cannot be adjusted 10 3 Electrically isolating the appliance The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 23 2 Position the cursor in front of FF 3 Confirm OFF with ENTER MENU 0FF PO WEEE PROGRAM Caution Failure to wait until the fan stops purging can cause damage to the appliance Instruction manual SGS 4 Wait until the fan has stopped The symbol is then dimmed 5 Switch the appliance OFF position 0 using the ON OFF switch on the control panel IMD 0588 RO 6 Isolate the appliance from the power supply by setting the isolator between the appliance and the mains power supply to position 0 10 4 Shutting the appliance down for a long period Drain the appliance if you are shutting it down for a long period Proceed as follows 1 Isolate the appliance from the power supply 10 3 Electrically isolating the appliance 2 Shut off the gas supply 3 Close the stop valve in the hot water pipe 4 Close the supply valve of the protected cold supply set up 5 Open the drain valve 6 Bleed the appliance or installation so that it drains completely 61 10 S
24. running 5 lt This chapter describes how to start the appliance running The general heating cycle of the appliance is also described Shutting down Main menu al elelee gel i Pel fe el l el feel 5 lt x lt Pel De Delle pe X This chapter describes how to shut the appliance down for a brief or long period of time This chapter describes the main menu of the display This is the actual menu for the user however the installation engineer and service and maintenance engineers will also need to use this menu Service program X This chapter describes the service menu It is mainly intended for the installation engineer and service and maintenance engineers End users may also refer to this chapter for additional information about the appliance Troubleshooting gt Fe I ge XI This chapter is mainly intended for the installation engineer and the service and maintenance engineer It describes appliance errors These errors are indicated on the display A troubleshooting table of possible causes and solutions is provided End users may also refer to this chapter for additional information about the appliance Maintenance frequency gt x This chapter describes how to determine the optimum frequency at which to carry out maintenance Both the end user and the service and maintenance engineer are responsible for regular maintenance They need to reach clea
25. salt water or corrosive water d The tank is safeguarded against harmful scaling and lime buildup by means of periodic maintenance e The water temperatures in the heater do not exceed the maximum setting of the thermostats which form a part of the water heater f The water pressure and or heat load do not exceed the maximum values stated on the water heater rating plate g The water heater is installed in a non corrosive atmosphere or environment h The water heater is connected to a protected cold supply arrangement which is approved by the relevant authority with sufficient capacity for this purpose supplying a pressure no greater than the working pressure stated on the water heater and where applicable by a likewise approved temperature and pressure relief valve fitted in accordance with installation instructions of A O Smith applying to the specific model of water heater and further in compliance with the government and local authority installation and building codes rules and regulations 97 16 4 16 5 16 6 16 7 98 16 Exclusions Scope of the warranty Claims Obligations of A O Smith Warranty certificate EN Ga X i The appliance is at all times fitted with cathodic protection If sacrificial anodes are used for this these must be replaced and renewed when and as soon as they are 60 or more consumed When electric anodes are used it is important to ensure that they continue
26. service and maintenance engineer Note The message SERUTICE REGUTREDIs based on the number of expired burning hours and the preset service interval Should the service interval have been incorrectly selected contact the service and maintenance engineer for instructions on how to adjust this Information on the maintenance frequency is provided elsewhere in the manual 14 Maintenance frequency Instruction manual SGS AED 9 Starting and running 9 1 Introduction Topics covered in this chapter e Starting the appliance The appliance s heating cycle Note The first time the appliance is started you must enter 12 8 Solar heating system configuration the settings of the solar heating system 9 2 Starting the appliance Start the appliance as follows 1 Fill the appliance 5 Filling 2 Open 3 5 Installation diagram the manual gas valve 3 Switch on the power to the appliance using the isolator between the appliance and the power supply 4 Switch the electronic controller ON by setting the ON OFF switch to position I IMD 0588 RO The display will now show IHTERHAL CHECK for about 10 seconds and will then go to the main menu 900000 INTERHAL CHECK T00dA00 MENU 0FF ON WEEK PROGRAM Instruction manual SGS Note The first time the appliance is started you must set 12 8 2 Setting the heating fluid type in the solar heating system the heating f
27. sufficient Therefore after one year some 1200 burning hours will have elapsed The first value below 1200 hours that can be selected is 1000 burning hours In this case the service and maintenance engineer sets the interval to 1000 In the first three months the appliance has burned for 300 hours During maintenance it is evident perhaps due to the water quality that service will be required at least once every 6 months Therefore after six months some 600 burning hours will have elapsed The first value below 600 hours that can be selected is 500 burning hours In this case the service and maintenance engineer sets the interval to 500 11 WARHIHO MAS BURN IMGHOURS SERVICE REQUIRED Once the set number of burning hours has elapsed the message SERUICE REQUIRED will appear on the display When this message appears the service and maintenance engineer must be contacted 91 92 14 Maintenance frequency ED Instruction manual SGS 15 15 1 Introduction 15 2 Preparation for maintenance Instruction manual SGS Performing maintenance Caution Maintenance may only by carried out by an approved service and maintenance engineer At each service the appliance undergoes maintenance on both the water side and the gas side The maintenance must be carried out in the following order 1 Preparation for maintenance Water side maintenance Gas side maintenance Solar collector maintenance a fF ON
28. the hot water pipe Close the stop valve 4 between the water tank and the cold water inlet A Open the drain valve 9 Bleed the appliance or installation so that it drains completely 53 6 4 54 6 Draining solar heating system 6 4 1 ae ARR Draining glycol filled system Note No special safety measures are required when working with the diluted glycol solution specified by the manufacturer For more information about the fluid please contact the manufacturer 1 Activate the MEHU with MENU 0FF jH WEEE PROGRAM 2 Position the cursor in front of OFF 3 Confirm OFF with ENTER 4 Wait until the fan has stopped The symbol l amp is then dimmed Caution Failure to wait until the fan stops purging can cause damage to the appliance y Warning The fluid in the pipes and the pipes themselves can be extremely hot Wait therefore until the appliance has cooled down sufficiently Note The draining procedure described in this manual is intended for the pump system supplied by the appliance supplier For any other system you should follow the procedure for that system Switch off the solar heating system Connect a hose to the lowest drain point in the solar heating system Insert the hose into the glycol jerry can Open the valve of the lowest drain point 1 2 3 4 5 Open the air bleed point 26 of the solar heating system 6 Close the drain point when the jerry can is ful
29. to work properly The warranty set out in articles 1 and 2 will not apply in the event of a damage to the water heater caused by an external factor b misuse neglect including frost damage modification incorrect and or unauthorised use of the water heater and any attempt to repair leaks contaminants or other substances having been allowed to enter the tank d the conductivity of the water being less than 125 uS cm and or the hardness alkaline earth ions of the water being less than 1 00 mmol litre 3 3 3 Water composition e unfiltered recirculated water flowing through or being stored in the water heater f any attempts at repair to a defective water heater other than by an approved service engineer The obligations of A O Smith pursuant to the specified warranty do not extend beyond free delivery from the Veldhoven warehouse of the replacement sections parts or water heater respectively Shipping labour installation and any other costs associated with the replacement will not be accepted by A O Smith A claim on grounds of the specified warranty must be submitted to the dealer from whom the water heater was purchased or to another authorised dealer for A O Smith water Products Company products Inspection of the water heater as referred to in articles 1 and 2 shall take place in one of the laboratories of A O Smith water Products Company A O Smith grants no other warranty or guarantee over its water he
30. 2 5 3 12 6 Instruction manual SGS Connecting the mains power Note Just as with the appliance controller the solar heating system controller must have a permanent electrical connection to the mains power supply There must be a double pole isolator installed in the permanent connection This is the same double pole isolator as installed between the mains power supply and the appliance itself Whenever this isolator is operated both controllers can be switched on or off Connect earth live and neutral to terminals 1 through 3 Fit the cables in the strain relief Connect the power cable to the isolator Pa _ NS Continue 3 12 3 Connecting pump station modulating pump Connecting pump station modulating pump The pump station contains a modulating pump 4 wire connection You must connect this pump to the controller of the solar heating system 1 Connect earth live and neutral to terminals 10 through 12 2 Connectthe fourth lead to terminal 13 3 Fit the cables in the strain relief 4 Continue 3 12 4 Connecting solar collector Connecting solar collector Note This sensor must be mounted in the solar collector refer to the solar collector installation manual Connect the sensor to the appliance as follows 1 Connectthe sensor to terminal 2 and 4 of J13 2 Fit the cables in the strain relief 3 Continue 3 12 5 Connecting tank sensor Connecting tank sensor Note This sensor is already moun
31. FROST PROTECTIOH ACTIVATED 8 2 2 OH In this mode the appliance continually responds to the hot water demand The figure shows the display with the following information line one the text OH e line two the time the day and alternately 9 3 The appliance s heating cycle T4 and Thet e line three the programmed water temperature Tset e line four blank when the appliance is idle or depending on the heating cycle 9 3 The appliance s heating cycle displays a text such as HEAT DEMAND OH 15 45 Thurada IE Hd ut Instruction manual SGS 8 3 EXTEA In this mode one extra period is programmed and activated In this mode the OFF orFECE mode is temporarily overruled to fulfil a single period of demand Once the period has passed the appliance automatically returns to the previous operating mode The figure shows the display with the following information line one the text EXTRA line two the time the day and alternately 9 3 The appliance s heating cycle T4 and The line three the switch on time and the related water temperature setting line four the text PER TOD ACTIVATED ESTEA 12 38 Thursday TEC TH 12 45 Taet 75 C PERIOD SCTIVETED 8 3 1 PROG In this mode a preset week program is active and the appliance responds continually to demand within the time periods set in the week program There are two distinct situations possible in this mode PROG 16 66 Mo
32. Fit the cable in the strain relief 3 If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appliance 3 11 8 Connecting communication cable to solar heating system You must connect a communication cable between the controllers of the appliance and the solar heating system 1 Connect the cables X5 and X6 to terminals 1 and 2 as indicated in the table 3 11 2 Preparation 2 Fit the cable in the strain relief If you do not need to make any more connections Fit the cap on the terminal block Fit the covers onto the appliance 3 12 Electrically Topics covered in this paragraph connecting the solar heating system controller Preparation e Connecting the mains power e Connecting pump station modulating pump e Connecting solar collector e Connecting tank sensor Connecting top tank sensor e Connecting communication cable Optionally you can connect an extra head pump and Q T sensor e Connecting extra head pump e Connecting Q T sensor 3 12 1 Preparation Undo the screws of the cap over the terminal block of the collector This has the following terminals Pump ON OFF Modulating pump L N JL Lo M 8 9 10 11 13 09 pen O D c oO N Flow signal Sensor S1 Semsor S1 Sensor S3 Sensor S2 38 Instruction manual SGS ED 3 12 2 3 12 3 3 12 4 3 1
33. N Confirm with ENTER A week program can be shut down simply by activating a different operating mode for example the ON mode 64 AE 11 7 Changingthe appliance s standard week program Note First fill in the desired week program on the supplied week program card A week program is made up of a number of programmable periods in which you can have the appliance switch on and off A period consists of e switch on time day of the week hours and minutes e switch off time hours and minutes e the water temperature setting e on off setting for a program controlled pump Note The switch off time must always be followed by a switch off time on the same day of the week A maximum of three periods may be programmed per day You can program a maximum of 21 periods Call up the menu for the week program as follows ce WEEK PROGRAM PROGRAM QUERUTEM Confirm with ENTER WEEK PROGRAM START OPERATION FPROGRAM QVERVIEU Instruction manual SGS ARES The display shows the menu for the week program see the figure below With the default setting the program switches on and off every day at 00 00 and 23 59 hours respectively the water temperature is 65 C and the pump is switched on F DAY TIME OM SU BE ee OFF SU 23559 OM MO Be ae OFF MO 0H TU OFF TH OH We OFF ME OM TH DFF CH DFF CH OFF SA Za INSERT DELETE START OPERATION Oe ied gh gL nu uun nu nn m Mu Pe mi
34. Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fit a stop valve 11 in the hot water outlet pipe for servicing 4 Ifa circulation pipe is required continue by installing the circulation pipe 3 6 3 Circulation pipe Instruction manual SGS ED 3 7 Water connectio Unvented Instruction manual SGS 3 6 3 ns 3 7 1 3 7 2 3 7 3 Circulation pipe See C in the installation diagram 3 5 Installation diagram If an immediate flow of hot water is required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fita circulation pump 6 of the correct capacity for the length and resistance of the circulation system 2 Fita non return valve 5 behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connect the circulation pipe up to a connection of the storage tank wy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Cold water side See A in the installation diagram 3 5 Installation diagram 1 Fit an approved stop valve 4 on the cold water side as required by applicable regulations 1 3 Regulations 2 The maximum working pressure of the appliance is 8 bar Because the pressure in the water pipe at times can exceed 8 bar you
35. START 2 Use ft and to set the switch on hour to the desired value In the example this is Hi Confirm with ENTER The cursor moves to the minute digits which flash OW OFF Tset FUMF Note Because the switch off time can never be earlier than the switch on time the switch off time setting is automatically adjusted with the switch on time 3 Use t and to set the minutes In the example this is 15 Confirm with ENTER The cursor moves to the hour digits of the switch off period mot Al SERI e Oo oo E Li feb pete LIO LI iN di th I a we 68 AE Setting the switch off time 1 Use t and to set the hours In the example this is Biz Confirm with ENTER The cursor moves to the minute digits which flash z c mo gf if 2 Use f and to set the minutes In the example this is 5 Confirm with ENTER The cursor moves to the water temperature See the figure DFF Tset 65 0 PUMP OH START Setting the water temperature 1 Use and to set the water temperature In the example this is 75 C Confirm with ENTER The cursor moves to FLINF OH OH OFF Tset PUMP 0H Setting the program controlled pump 1 If required a pump can be controlled during the period Use and to set FUMNF OH The pump ensures a regular circulation of hot water in the hot water pipes You can skip this step if you there is no pump in your h
36. Shutting down 61 Introduction 61 Shut the appliance down for a brief period OFF mode 61 Electrically isolating the appliance 61 Shutting the appliance down for a long period 61 Main menu 63 Introduction 63 Notational convention for menu related instructions 63 Switching on the ON mode 63 Setting the water temperature 63 Week program 64 Starting and stopping the week program 64 Changing the appliance s standard week program 64 Adding times to a week program 66 Deleting times from a week program 67 Extra period e 67 Programming an extra period 68 Settings 69 Service program 71 Introduction 2 2 2 rs ani eet eee aan ee ariana es ne eet ona 71 Setting the hysteresis 71 Displaying the error history 71 Displaying the appliance history 71 Display the selected appliance 72 Setting the s
37. T Tset FA C 7 3 Meaning of icons The table explains the meanings of the icons Icons and their meaning Name Meaning Heat demand Heat demand detected Purge Pre and post purge using fan oje Pressure switch Pressure switch is closed Glowing Pre glow Gas control Gas control open ignition b O Flame detection Appliance operational 7 4 Electronic controller ON OFF switch The ON OFF switch of the electronic controller is used to switch the appliance ON and OFF Note that in the OFF position the appliance remains electrically live in order for the continuous pump to stay running INTERMHAL CHECK After switching on the text THTERHAL CHEDE appears on the display for about 10 seconds Themain menu 11 Main menu then appears If no selection is made in the main menu the appliance automatically switches to the OFF mode 8 2 Operating modes Note To electrically isolate the appliance you must use the isolator between the appliance and the mains power supply 55 f The control panel 7 5 Navigation buttons AEX The use of these buttons is explained with the help of the figure that shows the main menu 11 Main menu The navigation buttons are e Buttons for UP and DOWN Enter ENTER e Reset button RESET The arrows and indicate that you can scroll up and or down Use the buttons and to scroll MENU DEF 0H
38. a od di Poe I LI I Lo ata Li ZENZERO G Real l 1 1 I I 1 I 1 I 1 I 1 Poe rey ea 1 Primair Secundair 1 L J ni r Ki vl LU ii LI I 1 l I NL 0308920a RO 230VAC 50Hz 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 7 red 8 dark green 9 yellow 102 Instruction manual SGS EDI Main control components Controller Flame probe Main controller terminal strip BUS link Hot surface igniter Gas control Potentiostat Burner earth connection Program controlled pump Continuous pump Frequency controller External error signal connection Isolating transformer COIN OD Cds WIND gt External ON OFF Double pole isolator Controller 0 I switch Display Program controlled pump Fan Temperature sensor T2 bottom of tank Dummy Extra error signal connection Temperature sensor T1 top of tank Selection resistor Pressure switch Isolating transformer primary Potentiostat Frequency controller RS 485 interface Isolating transformer secondary Electrical anodes Signalling for electrical anodes Mains choke and EMC filter N lt X S lt C 7 O V O Z Z T A T TW m O O w gt Solar heating system controller BUS link F1 Fuse F3 Fuse Instruction manual SGS 103 1 f Appendices 17 4 Electrical diagram Elec
39. alve A T amp P valve is only mandatory in an unvented installation However A O Smith also recommends the use of a T amp P valve in vented installations A T amp P Temperature and Pressure Relief valve monitors the pressure in the tank and the water temperature at the top of the tank If the pressure in the tank becomes excessive gt 10 bar or the water temperature is too high gt 97 C the valve will open The hot water can now flow out of the tank Because the 17 18 2 5 4 2 5 5 Working principle of the appliance EA ial DI appliance is under water supply pressure cold water will automatically flow into the tank The valve remains open until the unsafe situation has been rectified The appliance is fitted standard with a connecting point for a T amp P valve 3 7 2 Hot water side Protection for the solar heating system Drain back tank The solar heating system may optionally be equipped with a drain back tank The tank fills itself with the heating fluid when there is no heat demand This avoids overheating of the solar heating system The high insulation factor of the tank also protects the system from freezing of the fluid The use of the drain back tank also serves to extend the useful life of the fluid The presence of a drain back tank is set 12 8 1 Setting the drain back tank during the installation Refer to the solar heating system manual for more details Fluid temperature The heat exchan
40. appliance is in the ON mode Simply use to increase the value to decrease the value Confirm with ENTER OH 11 5 Week program Using the week program you can set the water temperature for the days and times you want If the appliance is running under a week program this is indicated on the display by the FFM text on the first line see the figure The second line shows the time of day the day of the week and the temperature The third line shows the next switching time of the week program and the programmed temperature The fourth line shows the PROGRAM ACTIVATED text PROG Griso Monday 64 C MO BS ae Tset FS C PROGRAM ACTIVATED The appliance s default week program switches the appliance on every day at 00 00 and off at 23 59 The default water temperature setting is 65 C If you want you can change every setting in the appliance s standard week program If the water temperature becomes too low while the week program is running the appliance will run through the heating cycle 9 3 The appliance s heating cycle and return to the week program This following are discussed e Starting and stopping the week program e Changing the appliance s standard week program e Adding times to a week program e Deleting times from a week program 11 6 Starting and stopping the week program The week program can be started up from any other operating mode as follows 1 ca WEEE FROGRAMN START OPERATIO
41. aters nor the sections or parts of water heaters supplied for replacement other than the warranty expressly set out in this Certificate Under the terms of the supplied warranty A O Smith is not liable for damage to persons or property caused by sections or parts or the glass lined steel tank of a replacement water heater that it has supplied Instruction manual SGS EM 17 17 1 Introduction Instruction manual SGS Appendices This appendix contains e Menu structure of the main menu 17 2 Menu structure e Appliance electrical diagram 17 3 Electrical diagram for the appliance e Electrical diagram solar heating system 17 4 Electrical diagram solar heating system e Week program card 99 1 f Appendices 17 2 Menu structure CONTROL SERVICE MENU MAIN MENU HYSTERESE OFF HYSTERESE DOWN HISTORIE OF ERRORS START OPERATION CHANGE SETPOINT APPLIANCE HISTORY WEEK PROGRAM SELECT APPLIANCE START OPERATION SERVICE INTERVAL PROGRAM OVERVIEW ANTI LEGIONELLA EXTRA PERIOD SOLAR CONFIGURATION SETTINGS DRAIN BACK LANGUAGE FLUID TYPE DAY TIME DELTA T SOLAR SPECIFICATIONS SOLAR LIMIT TEMPERATURE REGULATION INTERVAL SOLAR DIFFERENCE IGNITION SPEED Q T SENSOR WORKING SPEED CONTRIBUTION HEATING CONFIGURATION HEATING CONNECTED HEATING SETPOINT 100 Instruction manual SGS EDI Instruction manual SGS 101 17 17 3 Electrical diagram for the appliance A
42. ault value is 10 C DELTA T SOLAR 16 C 12 8 4 Setting the solar limit temperature The solar limit temperature is the maximum water temperature obtained in the appliance via the solar heating system measured by sensor T4 This value can be set between 65 80 C The default value is 65 C If you set the solar limit higher than the set point 11 4 Setting the water temperature then once the set point is reached the solar pump will be started to heat the water further However this only makes sense if the solar heating system is actually generating heat This makes use of the difference between the temperature at the top of the solar collector S4 and that in the appliance measured by S32 This value is also adjustable 12 8 3 Setting threshold temperature of pump in solar heating system Call up the menu for the solar limit as follows gt gt SETTINGS SOLAR SOLAR LIMIT SOLAR LIMIT L 6 12 8 5 Setting the solar difference The solar difference is a value that influences how the heating cycle of the appliance proceeds Call up the menu as follows SETTINGS SOLAR SOLAR DIFFERENCE SOLAR DIFFERENCE The range is 65 80 C The standard setting for this margin is 5 C 12 8 6 Setting the QT sensor yes no The energy contribution of the solar heating system can be calculated 12 8 7 Reading the energy contribution of the solar heating system with the aid of the Q T s
43. block Fit the plastic covers onto the appliance Connecting extra head pump Note This pump is essential if a greater head is required When the system has such a high resistance gt 110 kPa that the pump in the pump station is insufficient you can connect a second ON OFF pump to the solar heating system controller 1 Connect earth live and neutral to terminals 7 through 9 Fit the cable in the strain relief If you need to connect an extra head pump continue 3 12 9 Connecting Q T sensor otherwise Fit the cap on the terminal block Fit the covers onto the appliance Connecting Q T sensor Note You can optionally add a Q T sensor to the installation This enables you to calculate the energy contribution of the system For more information or to order the Q T sensor please contact your supplier Connect the 5V to J12 1 Connect sensor Sy to J12 2 Connect earth to J12 3 Connect the flow signal to J12 4 Fit the cable in the strain relief Oo Oe ON a If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appliance Instruction manual SGS EDI 3 13 Checking the supply pressure and burner pressure Legend Only applicable numbers are mentioned 1 supply pressure test nipple burner pressure test nipple burner pressure regulator burner pressure control cap burner pressure control adjusting screw ak wn 3 13 1 In
44. ce and storage tank 3 Cleaning condensation water discharge Checking the anodes Timely replacement of the anodes extends the service life of the appliance and storage tank The appliance s anodes must be replaced as soon as they are 60 or more consumed take this into consideration when determining the maintenance frequency 1 Loosen the anodes using suitable tools 2 Check the anodes and if necessary replace them Descaling and cleaning the appliance and storage tank Scale and lime buildup prevent effective conduction of the heat to the water Periodic cleaning and descaling prevents buildup of these deposits This increases the service life of the appliance and also improves the heating process Take the rate of scale formation into account when deciding on maintenance frequency Scale formation depends on the local water composition the water consumption and the water temperature setting A water temperature setting of maximum 60 C is recommended for prevention of excessive scale buildup To guarantee a good watertight seal around the cleaning opening replace the gasket washers bolts and if necessary the lid with new parts before reassembly see the figure A special set is obtainable from the supplier manufacturer To simplify descaling and cleaning of the appliance and storage tank both are equipped with a cleaning opening IMD 0080 R1 Remove the cover plate 1 on the outer jacket see the figure U
45. cooler water thereby increasing the performance of the unit The condensate yielded by this process is discharged via the siphon 23 Heat losses are prevented by the insulating layer 24 in both the storage tank and the appliance itself Both are enamel coated on the inside to protect against corrosion The anodes 9 provide extra protection against corrosion Both are fitted with an inspection and cleaning opening 12 for maintenance purposes 13 Legend Only applicable numbers are mentioned cover hot water outlet electrical connector block electronic controller pressure switch control panel temperature sensor T4 combustion chamber 9 anode 10 tank 11 heat exchanger 12 inspection and cleaning opening 13 temperature sensor T2 14 cold water inlet 15 drain valve 16 gas control 17 burner 18 fan 19 air supply hose 20 hot surface igniter 21 flame probe 22 chimney pipe 23 siphon 24 insulation layer 25 mains power choke 26 EMC filter 27 frequency controller 28 potentiostat 29 pallet 2 3 ON Oa RON gt The appliance s heating cycle 14 Working principle of the appliance Cut away view of the appliance IMD 0219 R2 The net water temperature Thet in the appliance is used to regulate when both the gas burner and the solar heating system are started and stopped The is the curve shown in the figure The controller u
46. create heat demand 9 Check whether the heating cycle runs correctly 9 3 The appliance s heating cycle 10 If you have adjusted Tg return it to the desired value 11 4 Setting the water temperature 11 Remove the plastic cover on the top of the appliance 12 Check the supply and burner pressure 3 13 Checking the supply pressure and burner pressure and adjust them if necessary 13 Check that all components of the chimney flue system are properly attached 14 Check the pressure differential across the orifice plate of the pressure switch see the table If the pressure difference is too low the heat exchanger must be cleaned 15 4 4 Cleaning the heat exchanger Pressure switch pressure differential Appliance Observed pressure differential across the pressure switch Pa SGS 80 gt 1005 SGS 100 gt 1145 15 Test the operation of the overflow valve of the protected cold supply setup The water should spurt out 16 Test the overflow operation of the T amp P valve The water should spurt out Instruction manual SGS 15 3 Water side maintenance 15 3 1 15 3 2 15 3 3 Instruction manual SGS 17 Check the drain pipes from the discharge points of all valves and remove any lime buildup that may be present 18 Drain the appliance see Draining Introduction The following steps must be carried out on the water side 1 Checking the anodes 2 Descaling and cleaning the applian
47. ctrical diagram 17 Appendices Damaged cable or defective sensor Replace the sensor To replace the necessary parts you must contact your installation engineer S08 blocking error Open circuit from temperature sensor S1 in the collector Sensoris not correctly connected Connect the sensor lead to J13 port 2 and 4 of the solar controller See the SGS electrical diagram 17 Appendices Damaged cable or defective sensor Replace the sensor To replace the necessary parts you must contact your installation engineer S11 blocking error Short circuit in the temp sensor T2 at the bottom of the tank Short circuit in sensor circuit Replace sensor T To replace the necessary parts you must contact your installation engineer S12 blocking error Short circuit in sensor 1 of temperature sensor T at the top of the tank Short circuit in sensor circuit Replace sensor T To replace the necessary parts you must contact your installation engineer 13 blocking error Short circuit in sensor 2 of temperature sensor T1 at the top of the tank Short circuit in sensor circuit Replace sensor T4 To replace the necessary parts you must contact your installation engineer 14 blocking error Short circuit from dummy 1 Short circuit in sensor circuit Replace the dummy sensor To replace the necessary parts you must contact your installation engineer
48. d you detect any errors or inaccuracies in the manual we would be grateful if you would inform us This helps us to further improve our documentation If you have any comments or queries concerning any aspect related to the appliance then please do not hesitate to contact A O Smith water Products Company PO Box 70 5500 AB Veldhoven Netherlands Telephone free 008008 AOSMITH 0870 267 64 84 General 31 40 294 25 00 Fax 31 40 294 25 39 E mail info aosmith nl Website www aosmithinternational com In the event of problems with connecting to the gas electricity or water supply please contact your installation s supplier installation engineer AES AES Instruction manual SGS 1 1 1 2 1 3 14 1 5 1 6 1 7 2 1 2 2 2 3 24 2 5 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 5 1 5 2 5 3 5 4 6 1 6 2 6 3 6 4 7 1 7 2 7 3 TA 7 5 Table of contents Introduction 9 About the appliance 9 What to do if you smell gas 9 Regulations 9 Target groups 10 Maintenance 10 Forms of notation 10 Overview of this document 11 Working principle of the appliance 13 Introduction
49. display the burning hours the number of ignitions the number of flame errors and the number of ignition errors Call up the menu for displaying the appliance history as follows APPLIAHCE HISTORY The figure shows an example 71 12 Service program APPLIANCE HISTORY BURHIMGHOURS GGGdia TEHITIOHS FLAME ERRORS Beas IGHIT ERROR GGGGLS BE1 888 12 5 Display the selected appliance Call up the menu for displaying the appliance selection as follows gt gt SELECT APPLIANCE The appliance number can be found on the rating plate The appliance selection has been correctly preset in the factory SELECT APPLIANCE 12 6 Setting the service interval To aid servicing the electronic controller includes a service interval which is used to set the frequency of maintenance interval 14 2 Determining service interval by the service and maintenance engineer based on the number of burning hours The service interval is based on the number of burning hours This can be set to 500 1000 and 1500 hours The standard setting for number of hours is 500 Once the preset number of hours is reached a message 8 5 Service condition to this effect will appear Adjust the service interval via o SERVICE INTERVAL SERVICE INTERVAL 388 BURHIHG HOURS 12 7 Setting legionella prevention To prevent infection with legionella bacteria the appliance heats the water to 65 C once per week
50. drain back tank Use this menu to specify whether the solar heating system is equipped with a drain back tank for the heating fluid Call up the menu as follows e S 5ETTINGS SOLAR DEATN BACK The default is H DRAIN BACK WES HO Note The first time the appliance is started it is necessary to check whether this setting corresponds with the configuration of the solar heating system 12 8 2 Setting the heating fluid type in the solar heating system Use this menu to specify the type of heating fluid used to fill the solar heating system 2 5 4 Protection for the solar heating system Call up the menu as follows SETTINGS SOLAR TYPE OF FLUID You can select from amp 14201 and Water The default is Glucel FS le FIHINE blucol Lisp Note The first time the appliance is started it is necessary to check whether this setting corresponds with the configuration of the solar heating system Note The setting Water is currently not possible 12 8 3 Setting threshold temperature of pump in solar heating system The pump of the solar heating system is switched on when the difference 9 3 The appliance s heating cycle between the temperature at the top of the solar collector sensor S4 and that in the appliance sensor S2 exceeds a certain value This value can be set to between 5 and 20 C Call up this menu as follows e SETTIHGS SOLAR DELTA T SOLAR Instruction manual SGS The def
51. e Caution There may be no potential difference between neutral N and earth If this is the case then an isolating transformer must be applied in the supply circuit 3 11 4 Isolating transformer For more information or to order this isolating transformer please contact A O Smith water Products Company The figure shows a view of the electrical connector block and the table shows the appropriate connections 35 Legend A screws B protective cap C connector block Frequency controller Installation ve ay Connector block 7 WOR e IMD 0224 R3 In preparation you must first remove the two plastic covers and the protective cap of the electrical section 1 Undo the screws of the plastic covers 2 Carefully remove the covers from the appliance The electrical section is now visible 3 Loosen the 2 screws A of the electrical section and remove the protective cap B from the electrical section The connector block C is now visible Note Consult the table for the connections and consult the electrical diagram for the electrical component connections Electrical connector block Alarm Off Isolating transformer Program controlled pump primary secondary L4 is 4 N L3 36 11 17 18 19 20 Instruction manual SGS ED 3 11 3 3 11 4 3 11 5 3 11 6 Instruction manual SGS Conn
52. e If the water specifications deviate from those stated in the table the storage tank protection cannot be guaranteed 16 Warranty certificate If the water hardness is greater than 4 dH please contact A O Smith Instruction manual SGS ED Instruction manual SGS 3 3 4 3 3 5 Appliance working clearances For access to the appliance it is recommended that the following clearances are observed e AA around the appliance s control column and cleaning openings 100 cm BB all sides of the appliance 50 cm e Above the appliance room to replace the anodes 100 cm if using rigid anode s or 50cm if using flexible anode s If the available clearance is less than 100 cm flexible magnesium anodes can be ordered g Note When installing the appliance be aware that any leakage may cause damage to the immediate environment or floors below the level of the boiler room If this is the case then the appliance should be installed above a wastewater drain or in a suitable metal leak tray Storage tank working clearances For access to the storage tank it is recommended that the following clearances are observed e All sides of the storage tank 50 cm e Above the storage tank room to replace the anodes 100 cm Note When installing the storage tank be aware that any leakage can cause damage to the immediate environment or floors below the level of the boiler room If this is the case then the appliance sh
53. e adhered to for correct functioning of the electronics present in the appliance to be guaranteed Air humidity and ambient temperature specifications Air humidity and ambient temperature Air humidity max 93 RV at 25 C Ambient temperature Functional 0 lt T lt 60 C Maximum floor load In regard to the total weight of the installation bear in mind that the installation always comprises an appliance complete with storage tank Maximum floor load Allow for the appliance s weight with respect to the maximum floor load refer to the table Weight specifications related to maximum floor load Weight of the appliance filled with water SGS 80 SGS 100 940 kg Maximum floor load of storage tank Bear in mind the weight of the storage tank completely filled with water when considering the maximum floor load This maximum floor load may be between 400 and 4500 kg This depends on the type of storage tank Water composition The appliance is intended for heating drinking water The drinking water must comply with the regulations governing drinking water for human consumption The table gives an overview of the specifications Water specifications Water composition Hardness gt 1 00 mmol l alkaline earth ions German hardness gt 5 6 dH e French hardness gt 10 0 fH e British hardness gt 7 0 eH Conductivity gt 125 uS cm Acidity pH value 7 0 lt pH value lt 9 5 Not
54. e to manufacturing and or material defects then A O Smith shall repair or replace this section or part If within 3 years of the original installation date of a water heater supplied by A O Smith following inspection and at the sole discretion of A O Smith the glass lined steel tank proves to be leaking due to rust or corrosion occurring on the water side then A O Smith shall offer to replace the defective water heater with an entirely new water heater of equivalent size and quality The warranty period given on the replacement water heater shall be equal to the remaining warranty period of the original water heater that was supplied Notwithstanding that stated earlier in this article in the event that unfiltered or softened water is used or allowed to stand in the water heater the warranty shall be reduced to one year from the original installation date The warranty set out in article 1 and 2 will apply solely under the following conditions a The water heater is installed under strict adherence to A O Smith installation instructions for the specific model and the relevant government and local authority installation and building codes rules and regulations in force at the time of installation b The water heater remains installed at the original site of installation c The appliance is exclusively used with drinking water which at all times can freely circulate a separately installed heat exchanger is mandatory for heating
55. eak persists or a component needs replacement consult connection threaded your installation engineer Symptom Solution Remark Leakage from a 1 Tighten component joints component 2 Any defective components must be replaced Leakage from solar Consult the supplier and or manufacturer heating system Instruction manual SGS 78 13 3 Troubleshooting table for displayed errors Displayed errors Code Description 01 blocking error Open circuit from temperature sensor T2 at bottom of the tank Sensor is not correctly connected Solution Connect the sensor lead to JP3 y De Remark See the SGS electrical diagram 17 Appendices Damaged cable or defective sensor Replace the sensor To replace the necessary parts you must contact your installation engineer S02 blocking error Open circuit in sensor 1 of temperature sensor T4 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5 See the SGS electrical diagram 17 Appendices Damaged cable or defective sensor Replace sensor T To replace the necessary parts you must contact your installation engineer S03 blocking error Open circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5 See the SGS electrical diagram 17 Appendices Damaged cable or defective sen
56. ecting the mains voltage The appliance is supplied without a power cable and isolator Note In order to receive electrical power the appliance has to be connected to the mains power by means of a permanent electrical connection A double pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance The power cable must have cores of at least 3 x 1 0 mm Wy Warning Leave the appliance isolated until you are ready to start it up 1 Connect phase L neutral N and earth of the power cable to terminals 22 through 24 of the connection block as indicated in the table 3 11 2 Preparation 2 Fit the power cable in the strain relief Connect the power cable to the isolator 4 If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appliance D Isolating transformer An isolating transformer should be used if there is a case of floating neutral 1 Refer to fitting instructions provided with the isolating transformer Contact the supplier for details of the correct isolating transformer 2 Connect phase L neutral N and earth to terminals 16 through 21 of the terminal block as stated in the table 3 11 2 Preparation 3 Fit the cables in the strain relief 4 If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appl
57. ed in the flue gas discharge and air supply is 8 The bend in the transition piece can be ignored According to the table 2 4 metres per bend must be added This brings the total pipe length to 2 4 x 8 35 19 2 35 54 2m This is less than the maximum length of 60 metres stated in the table The installation therefore fulfils the requirements Instruction manual SGS EDI 3 11 Electrical connection 3 11 1 3 11 2 Instruction manual SGS Wy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Introduction Topics covered in this paragraph e Preparation e Connecting the mains voltage Optionally itis possible to connect an isolating transformer a continuous pump a program controlled pump an extra ON mode switch and an extra alarm signal to the appliance For these options see e Isolating transformer Connecting a program controlled pump e Connecting an extra ON mode switch Tank ON e Connecting an extra error signal Alarm OUT Note The optional components are not included in the rating for electrical power consumption stated in the table 3 4 2 General and electrical specifications Preparation Caution The appliance is phase sensitive It is absolutely essential to connect the mains phase L to the phase of the appliance and the mains neutral N to the neutral of the applianc
58. en if the total pipe length is less than the stated maximum the maximum number of bends may not be exceeded The following example illustrates how to use the table 31 Installation ve a 28 Practical example of concentric flue gas discharge Example The figure shows a SGS 100 installation The appliance must be fitted with 12m of concentric pipe C13 C33 and three 90 degree bends We need to check whether this configuration complies with the requirements stated in the table Appliance with concentric flue gas discharge material IMD 0590 RO According to the table the maximum length allowed is 15 metres and there may be up to three 90 bends Both requirements are fulfilled Specifications Caution For type C13 and C33 installations A O Smith prescribes the use of a roof or wall mounted terminal exclusively of a type approved for the appliance Use of an incorrect roof or wall mounted flue terminal can cause the installation to malfunction Instruction manual SGS Subject Concentric wall flue terminal specifications C13 Description Wall flue terminal set Item No 0302 326 1 e 1x wall flue terminal incl wall flange amp Construction clamping ring e 1x pipe 500mm 1x bend 90 Concentric Manufacturer Muelink amp Grol Type M2000 MDV SEC Pipe material Construction Concentric Flue gas discharge Thick walled aluminium with lip ring seal Air sup
59. ensor This calculation is only possible if your installation is equipped with such a Q T sensor If this is the case then you must set this value to YES otherwise H Call up the applicable menu as follows 73 1 2 Service program SETTINGS SOLAR OT SEHSOR OT SEHSOR HES EJA HO 12 8 7 Readingthe energy contribution of the solar heating system This option enables you to read out how much energy the solar heating system supplies For this data to be displayed the installation must be equipped with a QT sensor 12 8 6 Setting the QT sensor yes no 3 values are reported on the display e METLUFIL actual energy the amount of energy currently being supplied e LAST 24hr energy supplied over last 24 hours e TOTAL total energy supplied since day 1 Call up this menu as follows S SETTINGS SOLAR CONTRIBUTIOH CONTRIBLTICOH ACTUAL LAST 24hr AGAGG kJ TOTAL RRAA Mi 12 9 Setting the central heating configuration Use this menu to specify whether a central heating system is connected to the installation Note This function is not yet available SETTINGS HEATING SETTINGS HEATING 74 Instruction manual SGS AEX 13 13 1 Introduction A distinction is made between e General errors General errors are not reported on the display General errors are Gas smell Display does not light up Insufficient or no hot water Water leakage Explosive ignitio
60. enu 11 2 Notational convention for menu related instructions The difference is you use D to bring up the service program instead of amp which brings up the main menu 12 2 Setting the hysteresis Call up the menu to set the hysteresis as follows gt HYSTERESE GOW HYSTERESE DOWN 43 C For all appliances the range is 2 7 C The default setting for this value is 5 C Instruction manual SGS 12 3 Displaying the error history Display the error history as follows HISTORY OF ERRORS The controller will display an overview of Blocking errors and Lock out errors In both cases the electronic controller reserves 15 lines for the last 15 error messages If there are fewer than 15 error messages an ellipsis is displayed The display first shows the Blocking errors When ENTER is pressed the Lock out errors are then displayed The figure shows an example of Blocking errors In this case the text HISTORY OF ERRORS is followed by Ee HISTORY OF ERRORS B2 564 SENSOR ERROR Fee IONIZATIOH COZ 36 HZ ERROR The figure shows an example of Lock out errors In this case the text HISTORY OF ERRORS is followed by Li HISTORY OF ERRORSCLI Fae FAH Fay FLAME ERROR Fon Note For an overview of all errors and the possible causes please refer to the relevant chapter 13 Troubleshooting 12 4 Displaying the appliance history The appliance history submenu is used to
61. ervice interval 72 Setting legionella prevention 72 Solar heating system configuration 72 Setting the central heating configuration 74 Troubleshooting 75 Introduction 75 Troubleshooting table for general errors 76 Troubleshooting table for displayed errors 79 Displayed warnings 90 Maintenance frequency 91 Introduction 91 Determining service interval 91 Instruction manual SGS 15 16 17 Instruction manual SGS 15 1 15 2 15 3 15 4 15 5 15 6 16 1 16 2 16 3 16 4 16 5 16 6 16 7 17 1 17 2 17 3 17 4 17 5 Performing maintenance 93 Introduction 93 Preparation for maintenance 93 Water side maintenance 95 Gas side maintenance 96 Solar collector maintenance 96 Finalizing maintenance 96 Warranty certificate 97 General warranty 97 Tank warranty 97 Conditions for Installation and u
62. et the correct supply pressure and or burner pressure 3 13 Checking the supply pressure and burner pressure Contaminated burner Clean the burner s 15 4 2 Clean the burner s Contaminated orifice Clean the orifice s 15 4 3 Clean the orifice s If ignition is not improved consult your installation engineer Hot water supply insufficient or absent Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 Check if the isolator is ON 2 Check that there is power to the isolator 3 Check whether the ON OFF switch of the electronic controller is ON position 4 Check whether there is power to the electrical connector block 5 The measured voltage must be 230 VAC 15 10 See the SGS electrical diagram 17 Appendices If the error persists consult your installation engineer Hot water supply is used up Reduce hot water consumption and give the appliance time to heat up The controller is in OFF mode Switch the controller to the ON mode 11 3 Switching on the ON mode Temperature Tg is set too low Instruction manual SGS Adjust 11 4 Setting the water temperature temperature Tse to a higher value If there continues to be insufficient hot water or none at all consult your installation engineer TI EM Glycol leakage Leakage from a fluid Tighten the threaded connection If the l
63. for 1 hour This period is adjustable By default this period is set to Monday from 02 00 to 03 00 hours 12 7 1 Switching legionella prevention on and off To switch legionella prevention on or off select 72 ED e SANTI LEGIONELLA ANTI LEGIONELLA VES Ho e Select H to switch legionella prevention off e Select WES to switch legionella prevention on The following display appears OH MO 2 00 LEG OFF WHO 83 88 Tset 65 C START CHANGE e Select THET to activate the period currently displayed The following display appears This display indicates that legionella prevention is switched on D eA o a aA LEG u uu u Azid Monday 66 MO BE B6 Tset RUM TH 12 7 2 Changing legionella prevention start time If you wish to change the start time select gt AHTI LESTOHELLA YES CHAHGE The following display appears OH MO 62 66 LEG OFF MO 63 66 Tset 65 o START e Now set the day and time the same way as described for setting an extra period in the week menu 11 11 Programming an extra period In this case however the pump will be automatically started Select THET to start 12 8 Solar heating system configuration Use the solar heating system settings menu to reach the menus shown here SETTINGS SOLAR DRAIH BACK Pya ME POEN DELTA T SOLAR SOLAR DIFFERENCE SOLAR LIMIT GT SENSOR CONTRIBLTICH Instruction manual SGS EDI 12 8 1 Setting the
64. gas category see conversion 4 Conversion to a different gas category To avoid damaging the appliance remove the packaging carefully We recommend unpacking the appliance at or near its intended location Caution The appliance may only be manoeuvred in an upright position Take care that the appliance is not damaged after unpacking The appliance is suitable for either open or room sealed combustion If installed as a room sealed appliance then the availability of the necessary external air supply will depend on the place of installation In this event there are no additional ventilation requirements If the appliance is to be installed as an open system then it will be subject to the guidelines and ventilation regulations that are in force locally The alternative installation types are B23 C13 C33 C43 C53 and C63 Caution The appliance may not be used in rooms where chemical substances are stored or used due to the risk of explosion and or corrosion of the appliance Some propellants bleaching agents degreasing agents etc disperse vapours which are explosive and or which cause accelerated corrosion If the appliance is used in a room in which such substances are present the warranty will be void 19 20 3 3 1 3 3 2 3 3 3 Installation ye py Air humidity and ambient temperature The boiler room must be frost free or be protected against frost The table shows the environmental conditions that must b
65. ger of the solar heating system may be filled with glycol If the temperature of the heating fluid is too high a signal is sent to the controller of the solar collector and the pump of the solar collector is switched off This signal is passed to the controller by temperature sensor S4 At present no heating fluids other than glycol are supported The heating fluid type is set 12 8 2 Setting the heating fluid type in the solar heating system during installation Temperature protection for solar heating system Protection Description Maximum temperature S4 if solar The pump of the solar heating system heating system is filled with switches off when the temperature of the glycol heating fluid at S4 exceeds the maximum S4 gt 130 C value The solar heating system enters error mode The error is also visible on the display of the SGS appliance Safety of the solar heating system Expansion vessel The solar heating system must be equipped with an expansion vessel 16 An expansion vessel serves to limit pressure variations in the system The expansion vessel in the solar heating system can withstand a maximum pressure of 6 bar The supply pressure to the expansion vessel depends on the static head of the system Besides the expansion vessel the system is protected from overpressure by an expansion valve Expansion valve Expansion valve The solar heating system is equipped with an expansion valve 23 The ex
66. he isolator on the appliance 6 Switch the electronic controller ON by setting the 0 I switch to position I XeSmith IMD 0588 RO The display will now show IHTERHAL CHECK for about 10 seconds and go to the main menu INTERHAL CHECK MEHU 0FF On WEEK PROGRAM 7 Activate the ON mode by going through the following steps Press the blue arrow once to position the cursor in front of AH and press ENTER The display shown here will appear 35 7ART OPERATIOM CHANGE SETPOINT TseL 65 C Confirm the ENTERby pressing THET OPERATION The appliance is now in the ON mode and will ignite 8 Once the display shows the text RUMHIHG amp you must wait about 1 minute before reading the dynamic pressures the fan needs this time to run up to full rotational speed Instruction manual SGS EDI 3 13 3 3 13 4 Instruction manual SGS 9 Use the pressure gauge to read the supply pressure at 1nipple 1 3 4 3 Gas data Note Consult the mains gas supply company if the supply pressure is not correct 10 Use the pressure gauge to read the burner pressure at nipple 2 3 4 3 Gas data If the burner pressure is not correct and the appliance is fitted with a blank plate you will not be able to adjust the pressure Finalise 3 13 4 Finalising and in this case consult your installation engineer or supplier If the appliance is indeed fitted with a burner pressure regulator the press
67. hutting down AES Instruction manual SGS AMEN 11 Main 11 1 Introduction The EHL is reached by pressing the 22 button on the electronic controller MENU 0FF OH WEEE PROGRAM EXTRA PERIOD SETTIMGS The main menu comprises e OFF Select this option if you wish to turn off 10 Shutting down the appliance for a brief period but do not wish to drain it In this mode the frost protection is active This prevents water from freezing in the appliance e OH In this mode the appliance continually responds to the hot water demand 11 3 Switching on the ON mode WEEK PROGRAM Select this option to allow the appliance to respond to demand only during pre programmed periods 11 5 Week program Outside those periods only frost protection is active ETRE PERIODO Select this option to overrule the FF mode or FROG mode i e Week program so that a single temporary period 11 10 Extra period of heat demand will be fulfilled SETTINGS Select this option to set 11 12 Settings the language and the time You can also use this option to display the regulation interval temperature and the ignition and working speeds of the fan Note If you fail to make any selection with the main menu open then after 30 seconds the appliance will automatically return to the mode it was previously in 11 2 Notational convention for menu related instructions The HEHU 22 of the electro
68. iance 5 Connect the power cable to the isolator Connecting a program controlled pump 1 Connect live L neutral N and earth to terminals 10 11 and 12 as indicated in the table 3 11 2 Preparation This is for pump 8 in the diagram Fit the cable in the strain relief If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appliance Connecting an extra ON mode switch Tank ON Tank ON is a facility for connecting an external ON OFF switch In the OFF position the programmed operating state is active In the ON position the programmed operating mode is overruled and the ON mode is active 1 Connect cables X and X32 to terminals 5 and 6 as indicated in the table 3 11 2 Preparation Fit the cable in the strain relief If you have no more connections to make Fit the cap on the electrical terminal block Fit the plastic covers onto the appliance 37 3 Installation Xx 3 11 7 Connecting an extra error signal Alarm OUT Alarm OUT is a potential free terminal that is switched when an error is detected This can be used to signal errors for example with a lamp A 230 V circuit can be directly powered Other voltages require a relay prescribed by the manufacturer 1 Connect the phase cables X and X3 to terminals 13 and 14 according to the table 3 11 2 Preparation If required connect earth to terminal 15 2
69. l 7 Insert the hose into a new jerry can and connect it to the drain point 8 Repeat steps 6 and 7 until no further glycol comes out of the system 9 Close the air bleed point and the valve of the drain point 1 0 Remove the hose Note Dispose of the drained glycol in an environment friendly manner and according to local regulations Instruction manual SGS AED T The control panel 7 1 Introduction Topics covered in this chapter e Controls e Meaning of icons e Electronic controller ON OFF switch e Navigation buttons e PC connection 7 2 Controls The figure shows the electronic controller IMD 0588 RO The control panel is completely menu driven and comprises e a4 line display with 20 characters per line 6 pushbuttons for operating the appliance below the display e 6 graphical symbols above the display e aconnector for a service PC e an ON OFF switch The pushbuttons are divided into three groups e Navigation buttons Buttons for UP and DOWN Enter ENTER Reset button RESET e the main menu 11 Main menu 4 e the service program 12 Service program gt gt This chapter is specifically intended for the service and maintenance engineer and installation engineer In this manual the display of the electronic controller is shown as in the figure both with and without icons Instruction manual SGS T00d00 START OPERATION CHANGE SETPOIN
70. lay will show the following information e line one error code comprising a letter and two digits followed by the error description e lines two to four alternately a brief explanation of the error and a brief action to resolve the error S84 SEHSOR ERROR CHECE SEHSOR OF DUMMY Caution The displayed action to resolve the error may only be performed by a service and maintenance engineer There are various types of errors e LOCK OUT ERRORS When the cause has been removed these errors require a reset with the button RESET before the appliance can resume operation e BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed after which the appliance resumes operation by itself The display does not show what type of error has been detected A comprehensive overview of the errors is provided elsewhere in the manual 13 Troubleshooting 58 AE If as end user you find the appliance in an error condition you may attempt to restart the appliance by pressing the RESET button However if the error returns or occurs several times in a short time you must contact your service and maintenance engineer 8 5 Service condition The figure shows the message Pit WARM IMG Hee MAS BURM IMG HOURS SERVICE REQUIRED SERUICE REQUIRED Should this message appear then the appliance is in need of a service and maintenance inspection In that case contact your
71. lps ensure the safe use of the solar heating system and ensures safe combustion This takes place using e the Appliance water temperature protection e the Gas valve e the Fan e the Pressure switch the Flame probe 15 2 Working principle of the appliance AE 2 4 2 Appliance water temperature protection The electronic controller uses temperature sensors T4 7 and T to monitor several temperatures that are important for safety The table explains the functioning of these temperature sensors Temperature protection Protection Description Against frost The frost protection cuts in The water is heated to 20 C Ty lt 5 C Ta lt 5 C For maximum water temperature The high limit safeguard serves to prevent overheating and or excessive T4 gt 85 C formation of scale in the appliance If the high limit safeguard is activated the T2 gt 85 C heating is stopped This causes the water in the tank to cool down Once the water has cooled sufficiently T4 lt 78 C the electronic controller resets the appliance For extra safety A lockout error of the water heater controller takes place The controller must T4 gt 93 C be manually reset before the appliance can resume operation 8 4 Error T2 gt 93 C conditions The reset may only be performed if T4 lt 78 C 2 4 3 Water temperature protection for the storage tank Using temperature sensors S gt and S4 the solar heating sy
72. luid type of the solar heating system 5 Press once on the blue arrow to position the cursor beside H then press ENTER T00dA00 5TART OFERATIOH CHANGE SETPOINT Tset 65 C 6 Confirm the selection STHET OPERATION with ENTER The appliance is now in ON mode If there is a heat demand the appliance will run through the heating cycle 9 3 The appliance s heating cycle If the heating cycle is not run then there is no demand should this happen then Tset will probably need to be set 11 4 Setting the water temperature 9 3 The appliance s heating cycle The appliance s heating cycle is activated as soon as the measured water temperature Thet falls below the threshold value Tse This threshold value depends on the currently selected appliance operating mode For example if the appliance is in OFF mode frost protection then this value is 5 C Ifthe appliance is in ON mode then this threshold value is selectable for example 65 C The heating cycle runs in turn through the following states HEAT DEMAND PRE PURGE PRESSURE SWITCH PRE GLOW IGNITION RUNNING POST PURGE NQaPF WON gt 59 9 The complete cycle is explained in the following example which assumes the appliance is in the basic mode fH Starting and running Note The same heating cycle applies to the other operating modes Once the appliance starts it will run through the following steps 1
73. main gas valve immediately Warning Do not operate any switches Warning No naked flames Warning Ventilate the boiler room Remark yy Warning Contact your installation engineer or local gas company immediately Display is off Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 2 3 4 5 Check if the isolator is ON Check that there is power to the isolator Check whether the ON OFF switch of the electronic controller is ON position Check whether there is power to the electrical connector block The measured voltage must be 230 VAC 15 10 See the SGS electrical diagram 17 Appendices If the error persists consult your installation engineer Defective fuse s Instruction manual SGS Replace fuse s To replace the fuses you must contact your installation engineer 76 Symptom Water leakage Leakage from a water connection threaded Solution Tighten the threaded connection Condensate leakage Check that the condensation water discharge is working properly Rectify if necessary Leakage from another nearby water appliance or pipe segment Trace the leak Leakage from the appliance s tank Consult the supplier and or manufacturer ae De If the leak persists consult your installation engineer Explosive ignition Incorrect supply pressure and or burner pressure S
74. measured voltage must be 230VAC 15 10 See the SGS electrical diagram 17 Appendices If the error persists consult your installation engineer No cable or damaged cable Instruction manual SGS Check the wiring communication cable between the main controller and the solar heating system controller If cable missing connect the cable If cable damaged replace the cable See the SGS electrical diagram 17 Appendices For replacement of the cable contact your installation engineer 87 Code Description Solution Remark C02 lock out error Incorrect reference Reset electronic controller To replace the necessary parts you must contact your installation voltage from the AD engineer converter Check that the frequency of the power supply is compliant 3 4 2 General and electrical specifications If this Error message from the is not the case contact your installation engineer appliance controller If the frequency is correct but the error persists replace the Internal error message EEPROM read electronic controller from the appliance error controller 50 Hz error Internal communication error Internal error message Gas valve relay from the appliance error controller Safety relay error Ignition relay error RAM error EEPROM error EEPROM contents do not match the software version Processor software error C03 blocking error Too many rese
75. must fit an approved pressure reducing valve 1 3 Fit a non return valve 5 and an expansion vessel 16 Fit an expansion valve 15 and connect the overflow side to an open wastewater pipe Hot water side See B in the installation diagram 3 5 Installation diagram g Note Insulating long hot water pipes will prevent unnecessary energy loss 1 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 2 Fitthe T amp P valve 3 3 Fita stop valve 11 in the hot water outlet pipe for servicing Circulation pipe See C in the installation diagram 3 5 Installation diagram If an immediate flow of hot water is required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fita circulation pump 6 of the correct capacity for the length and resistance of the circulation system 2 Fita non return valve 5 behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connect the circulation pipe up to a connection of the storage tank 27 3 8 3 9 3 7 4 Gas connection Solar heating system 3 10 Air supply and flue 28 3 10 1 Installation ye py Condensation drainage 1 Fit a sloping wastewater pipe to the siphon 13 for condensation drainage and connect this to the wastewater discharge in the boiler room Caution All fittings behind the
76. n The manual includes a table with general errors 13 2 Troubleshooting table for general errors Displayed errors Errors are reported on the display as follows Line one an error code and a brief description The code consists of a letter and two digits Lines two three and four a long description alternating with a recommended action See the figures The first shows a possible error the second shows the appropriate checking action SENSOR ERROR TOF TAHKE SENSOR 1 HOT CONMECTED S82 SENSOR ERROR CHECK TOF TAHKE SENSOR There are various types of errors all falling into one of two groups LOCK OUT ERRORS When the cause has been removed these errors require a reset with the RESET button before the appliance can resume operation BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed after which the appliance resumes operation by itself Instruction manual SGS Troubleshooting The manual includes a table of error messages that can appear on the display 13 2 Troubleshooting table for general errors Warnings on the display The warnings 13 4 Displayed warnings can also apply to the solar heating system 15 13 2 Troubleshooting table for general errors y Warning Maintenance may only be performed by a qualified service and maintenance engineer General errors Symptom Gas smell Solution Warning Close the
77. n the specified 8 bar Rectify this by fitting a pressure reducing valve 1 The expansion valve in the protected cold supply setup is defective or incorrectly fitted 5 3 Filling vented To fill the appliance proceed as follows installations 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6 2 Close the drain valve 9 3 Open the nearest hot water draw off point 14 4 Open the stop valves 11 between the storage tank and the appliance 5 Open the stop valve 4 on the cold water side A so that cold water flows into the appliance 48 Instruction manual SGS AED 5 4 Filling solar heating system Instruction manual SGS 5 4 1 6 Completely fill the appliance When a full water jet flows from the nearest draw off point the appliance is full 7 Bleed the entire installation of air for example by opening all draw off points 8 The appliance is now under water supply pressure There should be no water coming out of the P valve 23 If this does happen the P valve might be defective or incorrectly fitted Filling solar heating system with glycol Note No special safety measures are required when working with the diluted glycol solution specified by the manufacturer For more information about the fluid please contact the manufacturer Wy Warning Before filling the solar heating system to replenish the heating fluid make certain that The
78. nda FEC Tset FSC MO 11 15 1 The current time falls within a set time period of the week program The figure shows the display with the following information line one the text FECE line two the time the day and T4 and Thet alternately 9 3 The appliance s heating cycle line three the next scheduled switch off time and the water temperature Tet of the active period line four is empty or depending on the heating cycle 9 3 The appliance s heating cycle a text such as HEAT DEMAHD PROG 12 66 Hondas MO ilsi5 PERIOD ACTIVATED 57 8 Status of the appliance 2 The current time falls outside a set time period of the week program The figure shows the display with the following information line one the text FROG line two the time the day and T and Thet alternately 9 3 The appliance s heating cycle line three the next scheduled switch on time line four displays the text PERIOD ACTIVATED In all modes the temperature may at any moment drop below the desired temperature The appliance then enters a heating cycle This heating cycle is identical 9 3 The appliance s heating cycle for all basic operating modes Note Setting and if necessary programming of the basic operating modes are described in the main menu 11 Main menu chapter 8 4 Error conditions The figure shows an example of an error condition If the appliance enters this condition the disp
79. ndo the bolts Remove the cover and the gasket PONS Inspect the tank and remove the loose scale deposits and contamination 95 15 4 15 5 15 6 96 15 Gas side maintenance Solar collector maintenance Finalizing maintenance 15 3 4 15 4 1 15 4 2 15 4 3 15 4 4 Performing maintenance 5 If the scale cannot be removed by hand then the appliance will need to be descaled using a descaling agent Contact the supplier for advice on the preferred descaling agent 6 Close the cleaning opening To avoid damage to the tank tighten the bolts that fasten the lid with a torque no greater than 50 Nm Use suitable tools for this Cleaning condensation water discharge Regular cleaning of the condensation drain and siphon is essential for prevention of blockages Introduction The following steps must be carried out on the gas side 1 Clean the burner s 2 Clean the orifice s 3 Cleaning the heat exchanger 4 Finalizing maintenance Clean the burner s 1 Detach the burner s 2 Remove all contamination present on the burner s 3 Fit the burner s Clean the orifice s 1 Detach the orifice s 2 Remove all contamination present in the orifice s 3 Fit the orifice s Cleaning the heat exchanger 1 Detach the burner 2 Clean the combustion chamber of the heat exchanger using a vacuum cleaner and a soft brush Detach the flue gas discharge Clean the end of the heat exchanger usi
80. ng tap water Fit the burner Oy ON RO Fit the flue gas discharge Note Check the pressure differential again after cleaning If the pressure difference is too low following cleaning please contact the supplier of the appliance See installation or users manual for the solar collector If this topic is not covered in the manual then contact the supplier of the collectors To finalize the maintenance carry out the following steps 1 Fill the appliance 5 Filling 2 Start the appliance 9 Starting and running 3 Erase the message SERUICE REGUTFED Do this by pressing once on RESET then once on ENTER Instruction manual SGS AE 16 16 1 General warranty 16 2 Tank warranty 16 3 Conditions for Installation and use Instruction manual SGS Warranty certificate To register your warranty you should complete and return the enclosed warranty card after which a warranty certificate will be sent to you This certificate gives the owner of a appliance supplied by A O Smith water Products Company B V of Veldhoven The Netherlands hereinafter A O Smith the right to the warranty set out below defining the commitments of A O Smith to the owner If within one year of the original installation date of a water heater supplied by A O Smith following verification and at the sole discretion of A O Smith a section or part with exclusion of the tank proves to be defective or fails to function correctly du
81. ng the RESET and ENTER button simultaneously Maximum burning hours Service required The actual burning hours have exceeded the preset burning hours Instruction manual SGS Appliance runs but displays a warning For maintenance to your appliance contact your installation engineer 90 EM 14 14 1 Introduction 14 2 Determining service interval Instruction manual SGS Maintenance frequency A service should be carried out at least once a year both on the water side and on the gas side Maintenance frequency depends among other things on the water quality the average burning time per day and the set water temperature Note Regular maintenance extends the service life of the appliance To determine the correct maintenance frequency it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side three months after installation Based on this check the best maintenance frequency can be determined To aid servicing the electronic controller has a service interval with which the service and maintenance engineer can determine the frequency of maintenance based on the number of burning hours The service interval can be set to 500 1000 or 1500 burning hours The standard setting is 500 burning hours Example In the first three months the appliance has burnt 300 hours During maintenance it is evident that one service per year will be
82. nic controller is divided into submenus For example SETT THES is one of the functions reached from the main menu The SETTIHES menu is divided into submenus in turn Instruction manual SGS menu For example LAMGUAGE is a submenu of SETTINGS So for example to select the LAHGUAGE menu this manual uses the following notational convention SETTINGS LANGUAGE Confirm with ENTER This means 1 Activate the main menu with lt 2 SETTINGS Use the 4 and or buttons to go to SETTINGS and confirm with ENTER 3 LANGUAGE Use the and or buttons to go to LANGUAGE 4 Confirm with ENTER After entering ENTER you will have activated the LAHGUAGE submenu 11 3 Switching on the ON mode You can switch the appliance to the H mode from any operational mode as follows 1 ce OH START OPERATION Confirm with ENTER Note First consult the chapter about switching on 9 Starting and running too 11 4 Setting the water temperature 11 4 1 Setting the water temperature via the SET POINT MENU Set the water temperature via 1 cee OW CHANGE SETPOINT Confirm with ENTER START OPERATION CHAHGE SETPOINT Tset 65 C 2 Use e to increase the value e to decrease the value e Confirm with ENTER After confirming the appliance enters ONmode SERIE 63 1 1 Main menu 11 4 2 Setting water temperature during ON mode The water temperature can also be directly adjusted when the
83. nition attempts will have caused the condensation to evaporate If errors persist contact your installation engineer Floating neutral Install an isolating transformer 3 11 4 Isolating transformer Contact your installation engineer to have an isolating transformer installed F02 lock out error Fan fails to run at correct speed Defective motor and or rotor 1 Check the motor and rotor 2 Replace the fan if the motor or rotor is defective 3 Reset appliance controller Damaged wiring Check the wiring between the fan and the controller N Reset appliance controller If any wires are damaged the wiring harness must be replaced See the SGS electrical diagram 17 Appendices To have the wiring replaced and a new fan fitted you must contact your installation engineer Instruction manual SGS 81 Code Description Solution Remark Dirty or blocked fan Check if the fan is dirty Check that the rotor can rotate freely Reset appliance controller Because of a drop in the supply voltage the fan is not running at the correct speed DN Check the supply voltage this must be 230 VAC 15 10 Reset appliance controller The F02 entries below are applicable solely to appliances that have a 3 phase fan with frequency controller Fun supplying insufficient pressure Air pressure switch fails to close during pre purge The live pha
84. nty procedure Please return this card as soon as possible Your customer will then receive a warranty certificate with our warranty conditions 43 44 Installation EX Instruction manual SGS ED Legend Unused numbers are not applicable 2 three part gas coupling 6 orifice with stamped figures Instruction manual SGS Conversion to a different gas category Caution The conversion may only by carried out by an authorised installation engineer If the appliance must operate on a family of gases LP gas or natural gas or other gas category than that for which the appliance has been set at the factory the appliance will have be adapted using a special conversion kit Caution You must check the supply pressure and burner pressure once the conversion is complete Orifice assembly IMD 0225 R2 1 Isolate the appliance from the power supply 10 3 Electrically isolating the appliance 2 Shut off the gas supply 3 Undo the screws of the plastic covers 4 Carefully remove the covers from the appliance 45 46 Conversion to a different gas category ye ke 5 Detach the 3 part gas coupling 2 adjacent to the burner 6 Select and fit the correct orifice from the conversion kit based on the gas table 3 4 3 Gas data The injector diameter is stamped into each injector 6 7 Refit the 3 part gas coupling 2 8 Check the burner pressure
85. op tank sensor S3 4 Tank sensor S2 J15 1 n a 2 n a 3 n a J16 1 BUS link 2 J17 1 n a 2 n a 105 106 17 Appendices DX Instruction manual SGS 17 5 Week program card You can cut the week program card out and keep it near the appliance Period Pump Period Pump Ci CH OH OFF 12 DEF Lal DFF OH OFF CH CH OH OFF 13 DEF sani DFF OH OFF GH CH _ 2 OM OFF 14 Las OFF OFF OH OFF Ci CH OH OFF 15 OFF a OFF OH OFF CH CH OH OFF 16 OFF nee Te OH OFF CH CH OH OFF 17 OFF RES DFE OH OFF OH OH ON OFF 18 EE se AEE OH OFF Ci CH OH OFF 19 FE das SEE OH OFF CH CH OH OFF 20 OFF da FEE OH OFF CH CH be OH OFF OFF OFF OH OFF OH OFF Example Pump OH OFF Instruction manual SGS OH OFF 107 108 17 Appendices DX Instruction manual SGS AES Index ambient temperature 20 appliance displaying history 71 displaying selection 72 types 9 19 burner pressure 41 claims 98 connect 28 air supply 28 Alarm OUT 38 cold water side 26 27 condensation drainage 28 electrical 35 flue gas discharge 28 gas 28 hot water side 27 isolating transformer 37 program controlled pump 37 Tank
86. operating modes specifications 22 EXTRA 57 supply pressure 41 general 57 symbol OFF 57 installation engineer 10 ON 57 service engineer 10 PROG 57 user 10 P T packaging 19 target groups 10 PC connection 56 ThermoControl 55 post purge 59 controls 55 power cable 37 ON OFF switch 55 pre glow 59 to shut down pre purge 59 electrically isolating 61 pressure switch 17 59 longer period 61 prog 57 short period 61 protection 15 trademarks 3 push buttons 55 U R user 10 running 59 Ww S warranty 97 scrolling 56 exclusions 98 service check 10 91 general 97 service engineer 10 installation and conditions of use 97 service required 58 scope 98 setting date 69 week program 57 setting service interval 72 0308 853 1 UK Instruction manual SGS
87. ot water circuit Confirm with ENTER The cursor moves to THET Poi OH START 2 Confirm with ENTER The extra period has been programmed Note Once the extra period has completed running the controller returns to the mode ON OFF or WEEK PROGRAM The following week the extra period will NOT be automatically switched on Instruction manual SGS AES 11 12 Settings Using the SETTINGS option you can adjust certain settings and read certain appliance data e Adjustable settings Language of the menu Current day of week and time e Displayable appliance specifications this category is only relevant to the installation engineer and or service and maintenance engineer Control range water temperature Ignition speed of fan Working speed of fan 11 12 1 Setting menu language To set menu language MEHL WEEK PROGRAM ESTER FERIOD 5ETTIHOS 1 Call up the menu for selecting the language as follows 2 ca SETTINGS Confirm with ENTER The display shows the menu for settings SETTINGS LAHGUAGE DAYTIME SPECIFICATIONS 3 The cursor is positioned beside LAHGUAGE Confirm with ENTER The display shows the language selection menu LAHGUAGE EHGL ISH HEDERLAHDS DEUTSCH FRENCHIS ITALTAHO CZECH ESPANOL 4 Scroll with to the desired language Confirm with ENTER The language is set Instruction manual SGS 11 12 2 Setting day and time
88. ould be installed above a wastewater drain or in a suitable metal leak tray Working clearances 53 IMD 0227 R2 21 3 3 4 Technical specifications 3 4 1 Legend See the table 22 Installation yee ay The appliance is supplied without accessories Check the dimensions 3 4 1 Dimensions of the appliance gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan to use Dimensions of the appliance Plan and elevation of the appliance IMD 0220 R4 Instruction manual SGS Dimensions all measurements in mm unless otherwise indicated Description SGS 80 SGS 100 Total height 2060 2060 Position on pallet 530 530 Appliance diameter 850 850 Depth 1000 1000 Width 900 900 Diameter of flue gas outlet 130 200 130 200 Height of flue gas outlet air supply 2015 2015 x position of flue gas outlet 310 310 y position of flue gas outlet 440 440 Height of gas connection 1855 1855 Height of cold water supply 225 225 zZ Height of hot water outlet 2060 2060 y position of hot water outlet lt 205 205 Height of cleaning opening 290 290
89. overning indoor waste water disposal e regulations imposed by fire brigade power companies and municipality 1 4 Target groups 1 5 1 6 10 Maintenance Forms of notation ia Ae Furthermore the installation must comply with the manufacturer s instructions Note Later amendments and or additions to all regulations requirements and guidelines published on or prior to the moment of installing will apply to the installation The three target groups for this manual are end users e installation engineers e service and maintenance engineers Symbols on each page indicate the target groups for whom the information is intended See the table Target group symbols Symbol Target group End user Installation engineer Service and maintenance engineer Delo A service should be carried out at least once a year both on the water side and on the gas side Maintenance frequency depends among other things on the water quality the average burning time per day and the set water temperature Note To determine the correct maintenance frequency it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side within three months following installation Based on this check the best maintenance frequency can be determined Note Regular maintenance extends the service life of the appliance Note Both the end user and the ser
90. p E ag Gp sgt Gp gtr ghia i gh sgt gh gl i 4 Example As an example we will set the switch on time for Sunday to 08 15 hours and the matching switch off time to 12 45 hours The water temperature will be set to 75 C and the pump will run continuously The following settings are entered one by one via the menu the switch on time the switch off time the desired water temperature and the mode of the program controlled pump 11 7 1 Week program setting the switch on time 1 Bring the cursor to SU Confirm with ENTER OH 50 da OFF SU 23 55 Tset 65 C PUMP OH SANE The day indicated by flashes 2 Use and amp tosetthe desired day In the example this is SLI Sunday Confirm with ENTER ON SU 66 GG OFF SU GG 59 Tsel 65 C PUMP OH SANE The cursor moves to the hour digits which flash 3 Use and to set the hours In the example this is AS Instruction manual SGS Confirm with ENTER The cursor moves to the minute digits which flash Note Because the switch off time can never be earlier than the switch on time the switch off time setting is automatically adjusted with the switch on time 4 Use t and to set the minutes In the example this is 15 Confirm with ENTER The cursor moves to the switch off hour digits which flash ON DFF a LO de LR ins Oo 00 nno na ni LI LI Li n I Tset PUMP mo Cha Li Sf cel 11 7 2 Week program
91. pansion valve monitors the pressure in the solar heating system If the pressure is excessive gt 6 bar then the valve will open The hot water can now flow out of the installation The valve remains open until the unsafe situation has passed i e until the pressure has fallen back below 6 bar Note Because the installation is always under pressure and is not automatically filled the system will again need to be replenished 5 Filling Instruction manual SGS EM 3 3 1 Introduction 3 2 Packaging 3 3 Environmental conditions Instruction manual SGS Installation Wy Warning Installation work should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas water and power supply companies and the fire service The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations 1 3 Regulations This chapter describes the installation activities to be carried out before you actually start using the appliance 9 Starting and running namely e Packaging e Environmental conditions e Technical specifications e Water connections Vented e Water connections Unvented e Water connections Vented e Gas connection Solar heating system e Air supply and flue Electrical connection e Checking the supply pressure and burner pressure For conversion to a different
92. ply Thin walled galvanised sheet steel Pipe diameters Flue gas discharge 130mm Air supply 200mm T No other wall flue terminal is permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler Subject Concentric roof flue terminal specifications C33 Description Roof flue terminal set e 1x wall flue terminal incl clamping ring e 1x pipe 1000mm e 1x mounting flange Item No 0306 855 1 Construction Concentric Manufacturer Muelink amp Grol Type M2000 DDV SEC Pipe material Construction Concentric Flue gas discharge Thick walled aluminium with lip ring seal Air supply Thin walled galvanised sheet steel Pipe diameters Flue gas discharge 130mm Air supply 200mm 1 No other wall flue terminal is permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler 3 10 4 Parallel connections The table states the maximum pipe lengths for parallel systems The maximum pipe length depends on the chosen diameter Wy Warning Install flue component pipe runs with a run off of 5 mm per metre Table of pipe lengths equivalent Appliance Diameter Maximum equivalent total length 90 bend 45 bend 130mm 115m 2 4m 1 4m 130mm 60m 2 4m 1 4m SGS 80 SGS 100 Instruction manual SGS 33 34 Installation A
93. ppendices Electrical diagram EX A T D 3 3 Q X x 2 OT o Jo x J33 24 6 IT xj s li OO E D x a 1 i 712 uP z aao up3 x _ x x x x 1m O O gt x JP4 J21 x xe P x x x ESS i x J19 JP5 x X Q x x x x 435 e Ee o To ele J34 e s xTx SI R OLI xi J29 2 JP6 aa 5 x V x x x eli 7 gre s W A x om ssa xfx x PIE o gga N go X OP CH U sae x7 x7 x 337 x HER oaoa 7 Vv aa M LIL j Py NLT bi ebed TTI LEG x f LG aa a a oo aao a o oo d dle a 1 2 9 10 11 12 13 14 15 18 19 20 21 22 23 24 TTI T T T N L T T 4 N x ij i I I I 1 I L tl pa es
94. ppliance SGS 80 Diameter 150mm Maximum total length 115m equivalent 90 bend 2 6m ED Lequivalent 45 bend 1 6m SGS 100 150mm 100m 2 6m 1 6m 1 Parallel systems with diameter of 130mm or 150mm If the maximum total length for a diameter of 130mm is insufficient 150mm diameter should be used Any diameter enlargement must be carried out on both air supply and flue gas discharge You must use the longest pipe when calculating the pipe length For example if the chimney pipe is 35 metres and the air supply pipe is 32 metres then 35 metres should be taken as the length for calculation Next add the Lequivalent for every 90 and 45 bend to this 35 metres in both the air supply and flue gas discharge The following practical example illustrates how to use the table Practical example of parallel flue gas discharge Example The figure shows a SGS 100 installation This has to be fitted with a 35m parallel pipe 130mm in diameter plus eight 90 bends We need to check whether this configuration complies with the requirements stated in the table Appliance with parallel flue gas discharge material IMD 0589 RO The longest pipe must be used to check the maximum length In this case the chimney pipe is the longest This is 35 metres This 35 metres is the sum of pipe sections 1 2 3 4 and 5 The length of the transition piece can be ignored The total number of bends us
95. r agreement on this Note If the appliance is not regularly maintained the warranty will become void Performing maintenance x This chapter sets out the maintenance tasks to be carried out during a service Warranty certificate Instruction manual SGS This chapter states the warranty terms and conditions 11 Introduction AES Instruction manual SGS AED 2 1 Introduction 2 2 General working principle of the appliance Instruction manual SGS Working principle of the appliance Topics covered in this chapter e General working principle of the appliance e The appliance s heating cycle e Protection for the appliance e Safety of the installation e Protection for the solar heating system The figure shows a cut away view of the appliance In this appliance the cold water enters the bottom of the tank through the cold water inlet 14 Once the appliance and the storage reservoir are completely filled with water they are both constantly under mains water pressure When hot water is drawn from the appliance it is immediately replenished with hot water from the storage tank which in turn is replenished with cold water The water in the storage tank is heated by a heat exchanger which is connected to the solar heating system The appliance is equipped with a gas air premix burner 17 The air is drawn in through the fan 18 The gas is supplied via the gas control
96. r gas fired storage water heaters for the production of domestic hot water EN 89 The appliances are therefore compliant with the European Directive for Gas Appliances and are entitled to bear the CE mark y Warning Read this manual carefully before starting up the installation Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the appliance Wy Warning If there is a gas smell No naked flames No smoking Avoid causing sparks Do not use any electrical equipment or switch i e no telephones plugs or bells Open windows and doors Shut off the mains gas supply valve Warn occupants and leave the building After leaving the building alert the gas distribution company or your installation engineer As the end user installation engineer or service and maintenance engineer you must ensure that the entire installation complies as a minimum with the Official local e building regulations e energy supplier s directives for existing gas installations e directives and technical guidelines for natural gas installations safety requirements for low voltage installations e regulations governing the supply of drinking water e regulations governing ventilation in buildings regulations governing the supply of air for combustion e regulations governing the discharge of products of combustion requirements for installations that consume gas e regulations g
97. ram menu The cursor points to the first programmed period D A hi OH 51 Sl FCI MO INSERT DELETE START OPERATION 6 Scroll with to START OPERATION Confirm with ENTER The week program is active 11 10 Extra period Use an extra period when you either want to have the appliance switch on and off for a certain period either without modifying the active week program or without taking the appliance out of the OFF mode frost protection active If the appliance is running under an extra period then this is indicated in the display with the text ES TRA ESTER l HG Hondas MO 11515 Tset PERIOD ACTIVATED 67 1 1 Main menu If the water temperature becomes too low during the extra period 11 11 Programming an extra period the appliance will run through the heating cycle 9 3 The appliance s heating cycle and fall back into the extra period The same settings can be made for an extra period as for a week program 11 7 Changing the appliance s standard week program period 11 11 Programming an extra period 1 Call up the menu for entering an extra period via 2 GS ESTRA PERIOD Confirm with ENTER MEHL OH WEEE PROGRAM EXTER PERIOD The display show the settings for the extra period Setting the switch on time 1 Use and to set the day In the example this is SU Confirm with ENTER The cursor moves to the hour digits which flash SUFHE Be SU Goa 59 Ok
98. re gauge recommended 13 condensation drainage mandatory 14 hot water draw off points 16 expansion vessel mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating cold water supply hot water supply circulation pipe gas supply overflow pipe heat exchanger supply heat exchanger return overflow safety S1 collector sensor mandatory S2 tank sensor mandatory TOMMOO0AO gt 17 3 way aeration valve recommended S3 top tank sensor mandatory 18 water tank 3 6 Water connections Vented 26 3 6 1 3 6 2 S4 heat exchanger discharge sensor optional Note In the above diagram there is a non return valve in the station This may only be used in closed pressure systems In systems with drain back it is prohibited to fit a non return valve in the solar heating system y Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Cold water side See A in the installation diagram 3 5 Installation diagram 1 Fitan approved stop valve 4 on the cold water side between the cold water head tank 18 and the appliance as required by regulations 1 3 Regulations Hot water side See B in the installation diagram 3 5 Installation diagram Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the T amp P valve 3 2
99. return valve in the pump station This non return valve may be used solely in closed pressure systems In systems with a drain back tank it is prohibited to fit a non return valve in the solar heating system Introduction This section covers the following subjects e Requirements for flue gas discharge materials Concentric connections e Parallel connections Instruction manual SGS ED 3 10 2 Instruction manual SGS Requirements for flue gas discharge materials Wy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Depending on the approved installation types there are several alternatives for connecting the air supply and flue gas discharge The appliances are approved for installation types B23 C13 C33 C43 C53 and C63 The figure and table give information about these appliance types For an explanation of the possibilities please contact the manufacturer 29 Installation Types of appliances
100. roll down with to START OFERATION and confirm with ENTER Instruction manual SGS AED 11 9 Deleting times from a week program All switch on off times are shown sequentially in the display Assume that the switch on off times for the appliance are programmed as in the figure TIME Tset aGri5 75 0 P INSERT DELETE START OPERATION To delete a period proceed as follows 1 ca WEEE PROGRAM PROGRAM QUERUTEL Confirm with ENTER MENU OFF 20H WEEE PROGRAM 2 Scroll with 6 to FEOGRAM QUERNTEN Confirm with ENTER WEEK FROGRAN START OFERATION 3PROGRAM CVERUTEL The display shows the menu for the week program 3 Scroll with amp to DELETE Confirm with ENTER To warn you that you are now working in the delete sub menu the cursor is replaced with an exclamation mark and the period settings flash DAY TIME OH ISU Be SU INSERTO DELETE START OPERATION 4 Scroll with to the day to be deleted For example Sunday in the second period See the figure Instruction manual SGS Confirm with ENTER DAY TIME Tset OH ISU 16 60 75 0 P OFF SU 22 00 OH MO Bara 65 C P OFF MO 2359 5 Thelines showing switch on off times are replaced by the text DELETE BLOCK See the figure Confirm with ENTER or use RESET to cancel TIME Tset DELETE BLOCK BEIGE 65 C P The switching period has been deleted You will return now to the week prog
101. se 97 Exclusions 98 Scope of the warranty 98 Claims 98 Obligations of A O Smith 98 Appendices 2222222222228 99 Introduction 99 Menu structure 100 Electrical diagram for the appliance 102 Electrical diagram solar heating system 104 Week program card 107 7 Table of contents Instruction manual SGS AED 1 1 1 About the appliance 0063 1 2 What to do if you smell gas 1 3 Regulations Instruction manual SGS Introduction This manual describes how to install service and use the SGS appliance The SGS appliance is a condensing boiler with a fan in the air intake The appliance is always supplied including a storage tank fitted with a heat exchanger connected to a solar energy source The SGS can be installed as either an open or room sealed appliance A concentric chimney connector is fitted standard to the appliance but a parallel system can also be connected The alternative installation types are B23 C13 C33 C43 C53 and C63 The information in this manual applies to the SGS 80 and SGS 100 The appliance has been manufactured and equipped in accordance with the European standard fo
102. se wires between freq controller 1 Check the wiring between the fan and the frequency controller and fan are connected 2 Rectify the assembly if it is incorrect wrong way around 3 Reset appliance controller Fan speed too low 1 Check the fan speed 2 Ifthe fan speed is too low check the settings 3 Ifthe settings are correct then replace the fan 4 Modify the settings if incorrect 5 Reset appliance controller Air pressure switch 1 Check the wiring between the air pressure switch and the leads controller Rectify any defect if any wires are damaged replace the wiring harness properly connect loose or detached hoses 2 Reset appliance controller Loose air pressure 1 Check hoses between air pressure switch and burner fan switch hoses Rectify any defect if any wires are damaged replace the wiring harness properly connect loose or detached hoses 2 Reset appliance controller See the SGS electrical diagram 17 Appendices To replace the necessary parts you must contact your installation engineer Instruction manual SGS 82 EX Code Description Solution Heat exchanger and or 3 Measure the pressure differential across the air pressure switch Chiare Aldo 1S PIGCKEG Check the values 2 4 6 Pressure switch Check heat exchanger condensation drainage and or chimney flue for blockages Clear any blockage that may be present Reset appliance controller Defective controller
103. ses two measured values to calculate this temperature T4 7 and T 13 In addition temperatures S4 So and S3 are used by the controller of the solar heating system S is measured in the solar collector Sz is located between the inlet and outlet of the heat exchanger of the storage tank S3 is measured at the top side of the storage tank Depending on whether or not hot water is being drawn off hot water can be pumped from the storage tank to the appliance This happens when S3 is 5 C higher than They Water is then pumped from the appliance to the storage tank causing hot water to flow from the storage tank into the appliance The pump switches off as soon as S equals Thet The other settings that govern the control behaviour are Tset Tse is the the required water temperature that has been set on the appliance 11 4 1 Setting the water temperature via the SET POINT MENU As soon as Thet falls below Tse the water heating via the solar heating system is started however only if the temperature of the heating Instruction manual SGS AE Legend A Gas burner on B Gas burner off Thet BE a no heat demand so water not heated e water heated via solar heating system ___ water heated via solar heating system and gas burner t time T Temperature 45 C Minimum tap water temperature 2 4 Protection for the appliance 2 4 1 Instruction manual SGS fluid S4 is a certain adjus
104. siphon must be condensation resistant Ww Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Caution Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the appliance See D in the installation diagram 3 5 Installation diagram 1 Fit a manual gas valve 10 in the gas supply pipe 2 Blow the gas pipe clean before use 3 Close the manual gas valve 4 Fit the gas supply pipe to the gas control Wy Warning After fitting check for leaks Note For the solar heating system connections refer to the electrical diagram 17 4 Electrical diagram solar heating system and the table Electrical connector block 1 Connectthe supply from the solar collector to the inlet F of the heat exchanger 55 2 Connect the return pipe to the solar collector to the outlet G of the heat exchanger 55 3 Connect the lead from the solar heating system controller to sensor S2 see electrical diagram 17 3 Electrical diagram for the appliance and connections table 3 11 2 Preparation 4 Connect the communication cable between the solar heating system controller and the appliance see electrical diagram 17 4 Electrical diagram solar heating system and connections table 3 11 2 Preparation wy Warning The installation diagram shows a non
105. sor Replace sensor T To replace the necessary parts you must contact your installation engineer 04 blocking error Open circuit from dummy 1 Dummy is not correctly connected Connect the dummy sensor dummy sensor 1 and 2 leads to JP4 See the SGS electrical diagram 17 Appendices Defective dummy Replace the dummy sensor To replace the necessary parts you must contact your installation engineer 05 blocking error Open circuit from dummy 2 Dummy is not correctly connected Connect the dummy sensor dummy sensor 1 and 2 leads to JP4 See the SGS electrical diagram 17 Appendices Defective dummy Replace the dummy sensor To replace the necessary parts you must contact your installation engineer S06 blocking error Open circuit from temperature sensor S4 at bottom of storage tank Sensor is not correctly connected Connect the sensor lead to J14 port 1 and 3 of the solar controller See the SGS electrical diagram 17 Appendices Damaged cable or defective sensor Instruction manual SGS Replace the sensor To replace the necessary parts you must contact your installation engineer 79 Code Description 07 blocking error Open circuit from temperature sensor S2 at bottom of tank Sensor is not correctly connected Solution Connect the sensor lead to J14 port 2 and 4 of the solar controller Remark See the SGS ele
106. stallation engineer To replace the necessary parts you must contact your installation engineer F07 lock out error A flame has been detected after the gas valve was closed Defective gas valves Check whether there is still burner pressure present after the gas valves have closed Check whether a flame is still present after the gas valves have closed If this is the case the gas control must be replaced If the error cannot be resolved or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F08 lock out error Error message from safety relay Flame detection before the gas valve opened Reset the electronic controller If the error reappears replace the electronic controller If the error cannot be resolved or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F09 lock out error Water temperature safety The temperature at the top of the tank exceeds 93 C Instruction manual SGS Check that the circulation pump if present is working 2 Check the position of the temperature sensor T4 Reset appliance controller If the error cannot be resolved or is persistent contact your installation engineer 86 Code Description F10 lock out error Restriction on the number of ignition attempts based on pressure
107. stem controller monitors several temperatures in the storage tank that are related to safety Temperature protection Protection Description Against frost The frost protection cuts in The water is heated to 20 C Sa S3 lt 5 C For maximum water temperature The high limit safeguard serves to prevent overheating and or excessive So S3 gt 85 C formation of scale in the storage tank If the high limit safeguard is activated the heating is stopped This causes the water in the storage tank to cool down Once the water has cooled sufficiently S3 lt 78 C the electronic controller resets the appliance For extra safety A lockout error of the water heater controller takes place The controller must So S3 gt 93 C be manually reset before the appliance can resume operation 8 4 Error conditions The reset may only be performed if S3 lt 78 C 2 4 4 Gas valve The electronic controller opens the gas valve so that gas can be supplied to the burner As a safety measure the gas valve has a double shut off The double shut off guarantees complete isolation of the appliance from the gas supply To help ensure smooth ignition the gas valve opens gradually softlite 2 45 Fan The fan 18 provides an optimum air supply when there is a heat demand As a safety feature the fan ensures that any gases present in the combustion chamber are removed both before and after combustion We refer to this as
108. struction manual SGS Note Before starting the appliance and or checking the supply pressure and burner pressure you must fill 5 Filling the appliance Caution Before starting up for the first time or after conversion you must always check the supply pressure and burner pressure Note The easiest way to check the gas pressures is by using two pressure gauges This procedure assumes that these two gauges are available Gas control IMD 0260 R1 Preparation To check the supply pressure and burner pressure proceed as follows 1 Isolate 10 3 Electrically isolating the appliance the water heater from the power supply 2 Undo the screws of the plastic covers 3 Carefully remove the covers from the top of the appliance The electrical section is now visible 41 Installation ye pe 3 13 2 Procedure to check pressures 1 There are two test nipples on the gas control a supply pressure nipple 1 a burner pressure nipple 2 Sealing screws are located inside the test nipples Loosen both sealing screws by a few turns Do not completely loosen them they can be difficult to re tighten 2 Connect a pressure gauge to the burner pressure nipple 2 3 Open the gas supply and vent the gas supply line with the supply pressure nipple 1 4 Connect a pressure gauge to the supply pressure nipple 1 when gas starts to flow from this nipple 5 Switch on the power to the appliance using t
109. sure Gas consumption LP gas Gas category G31 37mbar propane Orifice diameter mm 4 70 5 10 Nominal load gross calorific value kW 84 8 103 3 Nominal output kW 81 9 99 8 Supply pressure mbar 37 37 Burner pressure 1 mbar 13 13 Gas consumption kg h 6 1 7 4 Based on 1013 25 mbar and 15 C t If using a blank plate instead of a burner pressure regulator it is assumed that the burner pressure is equal to the supply pressure In practice however the burner pressure will be lower 24 Instruction manual SGS EDI 3 5 Installation diagram This figure shows the installation diagram This diagram is used in the sections in which the actual connection process is described Installation diagram UNVENTED 26 Si l cip CONTROL Rao a VENTED H he l 4 IMD 0582 R2 Instruction manual SGS 25 3 Installation ye py Legend 19 float valve Only applicable numbers are mentioned 23 pressure valve mandatory 1 pressure reducing valve mandatory if the mains 26 air bleed mandatory water pressure exceeds 8 bar 3 T amp P valve mandatory 4 stop valve recommended in pipe C and mandatory in mandatory pipe A 5 non return valve mandatory 6 circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve recommended 12 temperatu
110. switch on and switch off times you can start running the week program Scroll with amp to START OPERATION Confirm with ENTER 11 8 Adding times to a week program Call up the menu to THSEET switch on and switch off times into a week program as follows 1 ca WEEE PROGRAM PROGRAM QUERUTELE Confirm with ENTER WEEK FROGRAM START OFERATIOH FROGRAM OVERVIEW r 66 AE The display shows the menu for the week program The cursor points to the active period DAY TIME Tset OM 5U 63 15 s DELETE START OPERATION 2 Scroll to INSERT Confirm with ENTER The sub menu for adding a period will appear OM 50 02 13 OFF SU 123545 Tset PSPC PUMP OH SAWE Example As an example we will program an extra period in which the switch on time is set to 18 00 hours and the corresponding switch off time to 22 00 hours The water temperature will be set to 75 C and the pump will run continuously DRY TIME Tset OH 511 15 60 OFF SH DELETE START OPERATION 3 Proceed as follows a Set the switch on time 11 7 1 Week program setting the switch on time b Setthe switch off time 11 7 2 Week program setting the switch off time c Set the water temperature 11 7 3 Week program setting the water temperature d Set the program controlled pump 11 7 4 Week program setting the program controlled pump 5 To activate the week program with the new period added sc
111. switch state changes Pressure switch not closing Solution Check the running speed of the fan 12 5 Display the selected appliance Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted Refit them if necessary Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner If necessary replace the hoses Check that the flue gas outlet is compliant 3 10 Air supply and flue Check for blockage in the flue gas discharge Remove any blockage that may be present Check for blockage in the condensation water discharge Remove any blockage that may be present Measure the pressure differential across the pressure switch See the table in Preparation for maintenance 15 2 Preparation for maintenance If there is insufficient pressure differential clean the heat exchanger If the pressure differential is acceptable check that the pressure switch is closing using a multimeter ae De If the error cannot be resolved or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F11 blocking error Flame detection with closed gas valve Defective gas valves See F07 F17 blocking error Communication error No power supply at solar controller 1 Check that there is power to the solar heating system controller The
112. table value higher than the temperature measured at the appliance sensor S2 As soon as Thet Tset Tsolar limit heating via the solar heating system is stopped There is one exception to this rule and that is when Tolar limit iS Set to a higher value than Tse e Hysteresis The moment Thet falls below Tset Tsolar diff Hysteresis the controller registers such a heat demand that the gas burner and the solar heating system jointly heat the water The solar heating system is only employed when the temperature measured by S4 is a certain adjustable value grater than that of Sp Tsolar diff When Thet exceeds Tset Tsolar diff the gas burner is shut off and the water is heated exclusively by the solar heating system When Thet rises above Tset provided 7set Tsolar limit the solar heating system switches off The value of Tolar diff iS adjustable 12 8 5 Setting the solar difference Tsolar limit Preset 12 8 4 Setting the solar limit temperature water temperature at which heating via the solar heating system is stopped Graphical representation of heating cycle ui Tsolar limit Tset Solar diff Trin 45 C Note Thet Can rise above Tse However this is only possible if Tolar limit iS increased via the service menu Note Tolar limit Can be lower than Tyg this will mean that Thet can never be equal to Tset Introduction The electronic controller monitors the water temperature he
113. ted in the tank prior to delivery The sensor is mounted between the inlet and outlet of the heat exchanger However you must still connect the lead to the solar heating system controller Connect the sensor lead with the blade connectors to the sensor Connect the other end to terminals 2 and 4 of J14 Fit the cables in the strain relief e O ia Continue 3 12 7 Connecting communication cable Connecting top tank sensor 1 Connect the sensor lead with the blade connectors to the sensor 2 Connect the other end to terminals 1 and 3 of J14 3 Fit the cables in the strain relief 4 Continue 3 12 7 Connecting communication cable 39 40 3 12 7 3 12 8 3 12 9 Installation ve py Connecting communication cable Note gt The communication cable must always be connected otherwise neither the appliance nor the solar heating system controller will run 1 Connect the double connector to J16 Fit the cable in the strain relief 3 Connect the other end of the communication cable to the terminal block of the appliance See connecting communication cable to appliance 3 11 8 Connecting communication cable to solar heating system electrical diagrams 17 3 Electrical diagram for the appliance 4 Connect the optional head pump 3 12 8 Connecting extra head pump or QT sensor 3 12 9 Connecting Q T sensor 5 If you have no more connections to make Fit the cap on the electrical terminal
114. the glycol pump as soon as the pressure gauge on the pump station begins to rise 8 Completely bleed the system of air at the air bleed point 26 see installation diagram 9 Close the air bleed when no further air comes out 10 Repeat steps 6 through 9 until glycol runs out of the air bleed 26 Note The system does not need be filled to a certain pressure The pressure in the system will increase when the fluid heats up and expands 11 Switch off the glycol pump 12 Close the valve of the inlet combination and disconnect the glycol pump including the hoses Note Dispose of the residual glycol in the filler hose in an environment friendly manner and according to local regulations Caution The very first time the appliance is started the correct fluid must be set 12 8 2 Setting the heating fluid type in the solar heating system using the Service Menu Note If the system is equipped with a drain back tank then the system must be filled to a certain pressure For the installation and filling of a drain back tank please refer to the installation and users manual of the solar collector Instruction manual SGS AEX 6 Draining 6 1 Installation diagram This figure shows the installation diagram This diagram is used in the sections in which the actual connection process is described Installation diagram UNVENTED 26 Si itinere CONTROL VENTED 23 Ve
115. the pressure switch closes The icon Edis dimmed The icons and are activated The message RUMMTHG appears 190086 OH 13 45 Thur RUA IHG 7 When the water is up to temperature the heat demand drops off and the post purge starts This lasts about 25 seconds The icons W and are dimmed The icon is activated The message POST PURGE appears HeaeBew aH Li 15545 Thur Hd POST FURGE 8 Following the post purge the fan stops and the pressure switch opens The icons and are dimmed The message POST FURGE vanishes 0 eeg aw OH 14 GS Thursday With any subsequent heat demand the heating cycle will resume from step 1 Instruction manual SGS AE 10 Shutting down 10 1 Introduction This chapter describes e Shut the appliance down for a brief period OFF mode e Electrically isolating the appliance Shutting the appliance down for a long period 10 2 Shut the appliance down for a brief period OFF mode To shut the appliance down for a brief period you must activate the frost protection You can use the frost protection to prevent water freezing in the appliance Activate the frost protection as follows 1 Press the button to select the main menu 2 Use t and to position the cursor in front of DFF Confirm with ENTER OFF 13 45 Thursday 6 C FROST PROTECTION ACTIUATED The frost protection
116. tions as follows 1 c SETTINGS Confirm with ENTER MEHL WEEK PROGRAM EXTRA PERIOD 5ETTIHOS 2 Scroll with amp to SFECTFICATIONS Confirm with ENTER SETTINGS LANGUAGE DAYTIME v 5PECIFICATIOHS The display shows the sub menu for displaying appliance specifications SPECIFICATIOHS FEGULATION THTERWAL gt NEO MEl SFIESE WORETHG SPEED 3 Scroll with to the section to be displayed for example REGULATION THTERUAL 70 AE The relevant display appears REGULATION INTERVAL 4a 30 C Instruction manual SGS ED 12 Service program 12 1 Introduction The service program is used by the installation engineer or service and maintenance engineer for Setting the hysteresis e Displaying the error history e Displaying the appliance history e Display the selected appliance Setting the service interval Setting legionella prevention Solar heating system configuration e Setting the central heating configuration SERVICE MEHU FHV STERESE gt HISTORY OF ERRORS APPLIANCE HISTORY SELECT SPPLIAHCE SERUTCE INTERUAL AHTI LEGIONELLA SETTINGS SOLAR SETTINGS HEATING These sub menus are briefly described in the following paragraphs If you are not familiar in general with how to use the displays and menus first read the relevant chapter 7 The control panel Note The notation convention for the service menu is identical to that of the main m
117. trical diagram solar heating system J16 L BB CC DD EE HH FF 230VAC 50Hz 0308920b RO 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 7 red 8 dark green 9 yellow 104 Instruction manual SGS EDI 17 4 1 Solar system electrical diagram legend Solar heating system control components Controller Extra head pump for solar heating system ON OFF Solar heating system pump modulating Temperature sensor S1 solar collector Temperature sensor S2 storage tank Combined Q T sensor incl temperature sensor S4 solar collector return Controller BUS link Temperature sensor S3 top storage tank F2 Fuse Instruction manual SGS Solar heating system controller terminal strip 1 n 2 L Power 3 N 4 n a 5 n a 6 n a 7 a 8 L1 Extra head pump for solar heating system ON OFF 9 N 10 4 11 L2 Solar heating system pump modulating 12 N 13 M 14 n a 15 n a 16 n a 17 n a 18 n a 19 n a 20 n a J3 1 n a 2 n a 3 n a 4 n a J12 1 Power 5V 2 Solar collector return sensor 84 3 Earth 4 Flow signal J13 1 n a 2 Solar collector sensor S1 3 n a 4 Solar collector sensor S1 J14 1 Top tank sensor S3 2 Tank sensor S2 3 T
118. ts in too Wait for the error to disappear maximum 1 hour If the error does To replace the necessary parts you must contact your installation short a period not disappear replace the appliance controller engineer Reset error C04 blocking error Incorrect appliance Check whether the correct appliance is selected 12 5 Display If the error cannot be resolved or is persistent contact your selection Incorrect the selected appliance installation engineer Appliance selection selection resistor To replace the necessary parts you must contact your installation If the correct appliance is selected fit the correct selection error resistor engineer If incorrect appliance selected select the correct one Instruction manual SGS 88 Code Description E01 blocking error The temperature protection at the top of the tank has been activated The temperature of the water at the top of the tank is gt 85 C Solution None This is a temporary message that may appear from time to time but will disappear automatically De E03 lock out error Error in temperature sensor T4 at the top of the tank The two temperature sensors in the tank detect a differential of gt 10 C over a period of at least 60 seconds 1 Check sensor position and wiring If necessary reset the electronic controller Replace the sensor if the error persists To replace the necessary parts
119. ure can be adjusted as described in the procedure 3 13 3 Adjusting the pressure Adjusting the pressure 1 Remove the cap 4 from the burner pressure regulator 3 2 Correct the burner pressure by turning the adjusting screw 5 depending on the correction required Adjustment screw anticlockwise burner pressure decreases Adjustment screw clockwise burner pressure increases 3 Cover the opening of the adjusting screw and check the burner pressure against the value given in the gas table 3 4 3 Gas data 4 If the pressure is not set correctly repeat the preceding steps until the correct pressure is attained Fit the cap 4 back on the burner pressure regulator 6 Activate the OFF mode of the electronic controller MENU 0FF jH WEEE PROGRAM 7 Ifthe MEHU is not displayed press a Use and 4 to place the cursor beside OFF Confirm with ENTER 8 Wait until the fan has stopped and switch the electronic controller off Caution Failure to wait until the fan stops can cause damage to the appliance 9 Finish off 3 13 4 Finalising Finalising 1 Shut off the gas supply 2 Disconnect the two pressure gauges and retighten the sealing screws in the test nipples 3 Replace the cover g Note Before starting up the appliance take time to fill in the warranty card supplied with the appliance This enables us to guarantee the quality of our systems and to further enhance our warra
120. ust also be protected by an expansion vessel expansion valve pressure reducing valve non return valve and a T amp P valve The use of an expansion vessel expansion valve and or pressure reducing valve depends on the type of installation unvented or vented Unvented installation With an unvented installation an expansion valve valve and expansion vessel prevent the buildup of excessive pressure in the tank This prevents damage being caused to the enamelled coating in the appliance or to the tank A non return valve prevents excessive pressure buildup in the water supply system This valve also prevents water from flowing backwards from the tank into the cold water supply system The pressure reducing valve protects the installation against an excessively high water supply pressure gt 8 bar These components are fitted to the cold water pipe 3 6 Water connections Vented Vented installation With a vented installation excess pressure is taken up by the open cold water head tank The height of the head tank determines the working pressure in the water heater which may not exceed 8 bar The installation must also be fitted with a vent pipe from the hot water pipe that opens into the cold water tank Ideally the vent pipe should discharge into a separate tundish drain or otherwise to the open cold water head tank The water heater should also be fitted on the hot water side with a stop valve 3 7 2 Hot water side T amp P v
121. vice and maintenance engineer are responsible for regular maintenance They will need to establish clear agreements on this Note If the appliance is not regularly maintained the warranty will become void The following notation is used in this manual Note Important information Caution Ignoring this information can lead to the appliance being damaged Wy Warning Failure to carefully read this information may lead to personal injury and serious damage to the appliance Instruction manual SGS AES 1 7 Overview of this document Chapter Target groups Description Working principle of the appliance XI This chapter describes the working principle of the appliance Installation ie This chapter describes the installation activity to be completed before you start the appliance for the first time Conversion to a different gas category eal This chapter describes the activities required to convert the appliance to a different gas category Filling FXI 5 lt This chapter describes how to fill the appliance Draining 5 lt This chapter describes how to drain the appliance The control panel 5 lt This chapter describes the general control of the appliance using the display Status of the appliance This chapter describes the status mode or condition that the appliance may have and possible actions to take Starting and
122. you must contact your installation engineer E04 lock out error Error in dummy sensor The two dummy sensors in the tank detect a differential of gt 10 C over a period of at least 60 seconds 1 Check leads from dummy 1 and dummy 2 If necessary reset the electronic controller Replace the dummy sensor if the error persists To replace the necessary parts you must contact your installation engineer 1 Temperature sensor T4 is a 2 in 1 sensor T4 contains 2 NTCs for the high limit thermostat and safety thermostat protection 2 The dummy sensor flue gas sensor comprises dummy sensor flue gas sensor 1 and dummy sensor flue gas sensor 2 Instruction manual SGS 89 13 4 Displayed warnings Displayed warnings Symptom Cause Solution Remark Q T sensor not correctly connected Lead s loosened or incorrectly connected Appliance runs but displays a warning 1 Properly connect Q T sensor and the warning will disappear 2 If correctly wired but the warning remains replace sensor Note To have the sensor connected or replaced contact your installation engineer Collector temperature excessive Temperature S1 is higher than Tcollector max The pump in the solar circuit switches off until S1 lt 70 C 1 You can let the message disappear automatically by allowing the heating fluid to cool down 2 You can also manually eliminate the message by pressi

A.O. Smith SGS - 100 Installation Manual

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