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A.O. Smith ADM - 135 Installation Manual

1. gt __ 2 ee si N dii D se LL 1 2 4 1 2 3 4 5 B ZTN D C DE l ee F H G oR i i Li NF ead I SS Li Dai pap a LNG om gi 213141515 oa a E eb ee els N O P Q 0304481 R1 1 brown 2 blue 3 yellow green 4 black 5 white flat cable 70 Instruction manual ADM ED TERMINAL STRIP CONNECTIONS Earth N Neutral L1 Phase input of controller L2 Phase input of flue gas thermostat L3 Phase output of flue gas thermostat COMPONENTS A Two pole isolator switch B Flue gas thermostat C Error signalling D Operational signalling E RESET button F Burner control G Control thermostat H Frost thermostat J Controller 0 I switch K Safety thermostat L High limit thermostat M Extra error signal connection N Gas control O Hot surface igniter P Flame probe Q High low control R Timer CONTROLLER CONNECTIONS N1 L TH GV1 MAX LG NO P NC F1 Instruction manual ADM Neutral Earth Phase input of controller Phase output to safety circuit and thermostat circuit Phase input of thermostat circuit Phase output to gas control Phase input to safety thermostat Phase output to hot surface igniter Detection of ionisation signal Normally open port of the extra error senso
2. Installation User and Service Manual IO OSM WATER PRODUCTS COMPANY A DIVISION OF A SMITH CORPORATION CE www aosmithinternational com your installer AES Read this manual carefully Trademarks Liability More information Instruction manual ADM 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 descript
3. T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 4 10 manual gas valve mandatory Y i 4 UNVENTED i 14 14 NO a w 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points c 51 4 A 15 expansion valve mandatory 16 expansion vessel mandatory Di 1 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply hot water supply circulation pipe gas supply overflow pipe overflow pipe VENTED tmoooa IMD 0466 RO Instruction manual ADM 6 1 44 6 Draining unvented installations E Some service activities require the appliance to be drained The procedure is as follows 1 Shut down the appliance by setting the ON OFF switch on the control panel to position 0 IMD 0460 RO 2 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 the hot water pipe Close the supply valve of the cold water supply A Open the drain valve 9 NOLA Bleed the appliance or installation so that it drains completely Instruction manua
4. as shown in the figure IMD 0122 R1 Instruction manual ADM ED 3 6 5 3 7 Water connections Unvented 3 7 1 3 7 2 3 7 3 3 7 4 Instruction manual ADM 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 to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve yy 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 must fit an approved pressure reducing valve 1 3 Fit a non return valve 5 and an expansion vessel 16 4 Fit an expansion valve 15 and connect the ove
5. 10 Loosen the anodes using suitable tools 11 Check the anodes and replace them if necessary 12 Now also check the flue baffles 12 4 4 Checking the flue baffles If necessary replace them 13 Place a new sealing ring on the rim of the tank and re fit the lid 14 Fit the draught diverter 3 9 2 Fitting the draught diverter 15 Feed the cable of the flue gas thermostat through the strain relief and attach the wiring to the connector block 14 2 Electrical Diagrams ADM 16 Refit the cable clamps to the appliance and draught diverter 17 Re fit the protective cover Descaling and cleaning the 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 ensure the perfectly watertight sealing of a cleaning opening the gasket 6 O ring 7 sealing rings 4 bolts 3 and possibly the lid 5 should be replaced with new components after opening see the figure A special set is obtainable from the supplier manufacturer Instruction manual
6. ADM 40 through 115 Conversion to a different gas category a ke Exchanging orifices IMD 0126 R1 1 Isolate the appliance from the power supply 10 3 Isolating the appliance from the mains 2 Shut off the gas supply Caution The burner can be hot 3 Unscrew the cover plate 1 from the burner support 4 Use a suitable tool to remove the retaining strips 2 Note that the retaining strips have very sharp edges Withdraw the retaining strips straight upwards Note The radiation shield condensation tray can be temporarily loosened to simplify disassembly of the burner 5 Remove the burners one by one from their brackets at the front To do this you first move them away from you and then downwards The orifices will now be accessible 6 Remove the orifices Instruction manual ADM ED Legend Only applicable numbers are mentioned 1 burner pressure regulator gas control connector blank plate supply pressure test nipple gas control Oro Instruction manual ADM 7 Select and fit the correct orifices from the conversion kit based on the gas data table 3 4 3 Gas data The orifice diameter is stamped on the orifice itself see 3 8 Re fit the burners back in their original position 9 Re fit the retaining strips 10 If the radiation shield condensation tray was loosened re fasten it Conversion of gas control IMD 0131 R1 11 Check
7. 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 due 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 th
8. is mounted below the burner tray This prevents overheating of the floor area below the appliance as well as serving as a collection tray for condensation water The insulation layer 24 prevents heat loss The inside of the tank is enamelled to protect against corrosion The anodes 9 offer extra protection The entire appliance is controlled by the burner control 40 and the control thermostat 41 or frost thermostat 44 The control thermostat and frost thermostat both independently measure the water temperature Twater The appliance s heating cycle is activated as soon as T water falls below the threshold value Tget The value of Tset depends on the selected mode of the appliance 8 2 Operating modes When the appliance is in OFF mode frost protection this value is determined by the frost thermostat threshold value 20 C When the appliance is in ON mode the threshold value can be set via the control thermostat 440 C 70 C As soon as T water falls below Tse the relevant thermostat control or frost will close and the burner control will register demand The gas control 16 is opened and the gas is mixed with air This mixture is ignited by the hot surface igniter 20 and the water is heated As soon as T water gets higher than Tet the thermostat opens again The demand will cease and the burner control will stop the heating cycle The thermostats have a certain margin both when closing and opening We
9. manifold test nipple cp dio IMD 0127 R1 Instruction manual ADM 29 Legend Only applicable numbers are mentioned 1 2 3 OLD 30 burner pressure regulator burner pressure regulator cap burner pressure regulator adjustment screw supply pressure test nipple gas control manifold test nipple high low control 3 11 1 Installation ye py Gas control for ADM 135 IMD 0129 R1 Preparations 1 Isolate the appliance from the power supply 10 3 Isolating the appliance from the mains There are two test nipples on the gas control Test nipple 6 is used to check the supply pressure The other test nipple on the gas control is not used The manifold test nipple 8 is used to measure the burner pressure 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 Connect a pressure gauge to the manifold test nipple 8 Open the gas supply and bleed the air from the mains gas supply via test nipple 6 Connect a pressure gauge to the manifold test nipple 6 when gas starts to flow from this nipple 6 Switch on the power to the appliance using the isolator on the appliance Set the control thermostat to the maximum temperature and start the appliance running by setting th
10. 15 Start the appliance 9 Starting and running Introduction This paragraph describes e Conversion from LP gas to natural gas e Conversion from natural gas to LP gas Conversion of gas control o pl tr L IMD 0132 R1 Instruction manual ADM EX 4 2 2 Legend Only applicable numbers are mentioned 4 timers 5 bracket 6 6 contact terminal strip 7 strain relief 8 9 contact terminal strip 9 metric strain relief 10 high low control lead Instruction manual ADM Conversion from LP gas to natural gas Installing and removing add on components IMD 0130 R1 37 4 Conversion to a different gas category yee D4 Carry out 4 1 Conversion to different category ADM 40 through 115 steps 1 through 10 2 Detach the high low control 9 3 Fit the burner pressure regulator 1 including the sealing gasket from the 10 11 12 conversion kit Attach the burner pressure regula
11. 3 4 2 General and electrical specifications General and electrical specifications DESCRIPTION Unit Capacity litres Maximum operating pressure bar Empty weight kg Heating up time AT 45 C minutes Number of anodes Number of bar burners orifices Number of flue tubes flue baffles Electrical power consumption Supply voltage 15 10 VAC Mains frequency IP class Instruction manual ADM 19 3 Installation WE 3 4 3 Gas data Gas data Description Il 43 Gas category 2H General Orifice diameter 1 Blank plate 2 Burner pressure regulator 3 High low regulator Gas category G20 20 mbar Nominal load gross calorific value Nominal output Supply pressure Burner pressure Gas consumption Gas category 3 General Orifice diameter 1 Blank plate 2 Burner pressure regulator 3 High low control Gas category G30 30 mbar Nominal load gross calorific value kW Nominal output kW Supply pressure mbar Burner pressure t mbar Gas consumption 0 kg h Gas category G31 37 mbar Nominal load gross calorific value KW Nominal output kW Supply pressure mbar 37 37 37 37 37 37 37 Burner pressure 1 mbar Gas consumption kg h 2 7 3 7 4 5 5 6 6 4 8 1 9 3 Based on 1013 25 mbar and 15 C t If u
12. 3 6 4 Installation ve py 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 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 Recirculation pipe You can install a top to bottom circulation pump to prevent water stacking in the boiler 1 Optional depending on the draw off pattern fit a recirculation pipe 22 mm a stop valve 11 and a top to bottom circulation pump 7 2 Fit a non return valve 5 3 Fit a stop valve 11 Hot water side See B in the installation diagram 3 5 Installation diagram g Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the T amp P valve 3 2 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fita stop valve 4 in the hot water outlet pipe for use when servicing 4 Ifa circulation pipe is required continue further by installing the circulation pipe 3 6 5 Circulation pipe Drain valve 1 Fit the standard drain valve 9 supplied with the appliance 2 If applicable fit a circulation pipe 3 6 5 Circulation pipe If not fit the blind threaded plug and gasket C supplied with the drain valve
13. 9 Working principle of the appliance 11 Introduction 11 General working principle of the appliance 11 The appliance s heating cycle 12 Protection for the appliance 12 Safety of the installation 13 Installation 15 Introduction 15 Packaging 15 Ambient conditions 15 Technical specifications 17 Installation diagram 21 Water connections Vented 22 Water connections Unvented 23 Gas connection 24 Chimney flue 25 Electrical connection 26 Checking the supply pressure and burner pressure 28 Conversion to a different gas category 33 Conversion to different category ADM 40 through 115 34 Conversion to a different gas category ADM 135 36 Filling gt 41 Filling unvented installations 42 Filling vented installations 42 Draining
14. ADM 12 4 Gas side maintenance Instruction manual ADM To simplify the task of descaling and cleaning the tank the appliance is equipped with two cleaning openings IMD 0235 R2 1 Remove the cover plate 1 on the outer jacket see the figure 2 Carefully remove the insulation layer 2 and set it to one side This will be needed again later Undo the bolts Remove the lid the gasket and the O ring Inspect the tank and remove the loose scale deposits and contamination on rw If the scale cannot be removed by hand descale the appliance with a descaling agent Contact the supplier manufacturer for advice on what descaling agent to use IMD 0282 R1 7 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 For the best possible watertight seal of the cleaning opening the bolts in the lid should be torqued down in the sequence shown in the figure 63 12 12 4 1 12 4 2 12 4 3 12 4 4 12 5 Finalising maintenance 64 Performing maintenance Introduction The following steps must be carried out on the gas side 1 Clean the burner s 2 Clean the orifice s 3 Checking the flue baffles 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 Re
15. OFF switch ON mode OFF mode Temperature Set water control temperature Tset Reset button Reset burner control Power LED Power indicator for burner control Error LED Burner control lockout AIN 7 4 ON OFF switch The ON OFF switch sets the appliance in ON mode or OFF mode In OFF mode the appliance is still electrically live This ensures that the frost protection is active Note To electrically isolate the appliance you must use the isolator between the appliance and the mains power supply 7 5 Control thermostat Use the rotary knob of the control thermostat to set the desired water temperature between 40 C and 70 C The range is continuous and is labeled 1 through 4 The table shows the temperatures coresponding to the numbers on the knob Temperature settings Position Temperature 40 C 50 C 60 C 70 C 47 f The control panel 7 6 Burner control reset button An error can cause the burner control to lock out When this happens the red LED on the control panel will illuminate After eliminating the cause of the error you can reset the appliance using the reset button Note Before resetting always eliminate the cause of the error The appliance s error conditions 8 3 Error conditions and how to resolve them are described in the error condition summary 11 Troubleshooting 7 7 Flue gas thermostat reset button A mal
16. 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 heaters 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 ADM EM 14 14 1 Introduction Instruction manual ADM Appendices This section gives the electrical diagrams for Electrical diagram for ADM 40 to 135 natural gas and 40 to 115 LPG e Electrical diagram 135 LP gas 67 1 4 Appendices 14 2 Electrical Diagrams ED ADM 14 2 1 Electrical diagram for ADM 40 to 135 natural gas and 40 to 115 LPG 1 C 2 L N 3 Cae a 4 nl T L N L E sla 1 2 3 4 5 6 B 3 1 2 4 4 C DE h om F ra F1 HR Lo 6 ui RITO 7 3 Bab 5500685550 asses 566 Jr s is a
17. i ro i ia l Il ETA a i JL il 4 O i akira et i cord spa bed ME M di L N NL K T 7 89 10 11 12 iatale L TOI Cn 0305471 R1 N O P 1 brown 2 blue 3 yellow green 4 black 5 white flat cable 68 Instruction manual ADM ED TERMINAL STRIP CONNECTIONS Earth N Neutral L1 Phase input of controller L2 Phase input of flue gas thermostat L3 Phase output of flue gas thermostat COMPONENTS A Two pole isolator switch B Flue gas thermostat C Error signalling D Operational signalling E RESET button F Burner control G Control thermostat H Frost thermostat J Controller 0 I switch K Safety thermostat L High limit thermostat M Extra error signal connection N Gas control O Hot surface igniter P Flame probe CONTROLLER CONNECTIONS N1 Neutral Earth L Phase input of controller L Phase output to safety circuit and thermostat circuit TH Phase input of thermostat circuit GV1 Phase output to gas control MAX Phase input to safety thermostat LG Phase output to hot surface igniter l Detection of ionisation signal NO Normally open port of the extra error sensor P Phase input of extra error sensor NC Normally closed port of the extra error sensor F1 Fuse Instruction manual ADM 69 1 4 Appendices 14 2 2 Electrical diagram 135 LP gas EX
18. 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 Feed the power cable through the metric strain relief to the top side of the control column 2 Connect the earth live L4 and neutral N of the power cable to terminals 1 through 3 in the connector block as stated in the table 3 Turn the strain relief tight to clamp the lead 4 If you do not need to make any more connections fit the protective cover onto the control column 5 Connect the power cable to the isolator 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 Instruction manual ADM EDI Legend Gas control for ADM 40 through 115 Only applicable numbers are mentioned 1 burner pressure regulator 2 burner pressure regulator cap 3 burner pressure regulator adjustment screw gas control connector blank plate O supply pressure test nipple gas control
19. refer to this margin as the hysteresis The hysteresis cannot be adjusted Introduction The burner control monitors the water temperature by means of thermostats and ensures safe combustion This takes place using the Water temperature protection e the Flue gas backflow safeguard the Flame probe Instruction manual ADM AE 2 4 2 Water temperature protection By means of the frost high limit and safety thermostats the burner control monitors three temperatures that are important for safety The table explains the working principle of the thermostats with sensors Temperature protection Protection Description Frost thermostat When the frost thermostat sensor 46 measures a temperature of 20 C or less the heating cycle 2 3 The appliance s heating cycle will start High limit thermostat When the high limit thermostat sensor 39 measures a temperature higher than 84 C the high limit thermostat will open The heat demand is terminated and the burner control halts the heating cycle until the high limit thermostats close once more At that moment the burner control will reset the appliance and the heating cycle will restart The high limit safeguard serves to prevent overheating and or excessive formation of scale in the appliance Safety thermostat When the safety thermostat sensor 38 measures a temperature higher than 93 C the safety thermostat will open The heat demand is terminated and the bur
20. the cold water enters the bottom of the tank through the cold water inlet 14 The heat of combustion is conducted to the water by the combustion chamber 8 and heat exchanger 11 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 required for combustion flows via the gas control 16 into the manifold Orifices are mounted in the manifold The gas is injected into the burner bars at pressure from these orifices 36 The burner bars together form the burner tray The injection of gas into the burner bars also draws in the primary air required for combustion The narrow opening in the orifice causes the gas flow to accelerate This in turn causes a partial vacuum It is this partial vacuum that draws in the air the Venturi effect Additional air is drawn in through the opening in the burner tray The hot surface igniter 20 ensures ignition of the gas air mixture The flue gases released by this combustion are led through the flue tubes part of 11 Flue baffles part of 11 are mounted in the flue tubes These retard the flow of the flue gases thereby increasing the thermal efficiency of the appliance The flue gases are vented from the appliance via the draught diverter 33 A radiation shield condensation tray 35
21. whether there is a burner pressure regulator 1 attached to the gas control or simply a blank plate 5 Note If the supply pressure for a gas category is the same as the burner pressure see the gas data table 3 4 3 Gas data then the gas control must be fitted with a blank plate with cork gasket A burner pressure that deviates in comparison to the supply pressure requires the use of a burner pressure regulator with rubber gasket Each conversion kit contains all the necessary components 12 If the blank plate or burner pressure regulator need to be replaced Unscrew the connector 4 of the gas control If necessary remove the blank plate or burner pressure regulator 5 or burner pressure regulator 1 If necessary fit the blank plate or burner pressure regulator supplied with the conversion kit Fit the connector 4 of the gas control 35 4 2 Conversion toa different gas category ADM 135 4 2 1 Legend Only applicable numbers are mentioned 1 burner pressure regulator 7 gas control 9 high low control 36 Conversion to a different gas category ve D4 13 Check the supply pressure and burner pressure 3 11 Checking the supply pressure and burner pressure 14 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
22. 1 1 About the appliance 0063 1 2 What to do if you smell gas 1 3 Regulations Instruction manual ADM Introduction This manual describes how to install service and use the ADM appliance The ADM appliance is a gas fired open boiler without fan ADM appliances are equipped with a flue gas backflow safeguard The ADM is an appliance of type B11ps The information in this manual applies to types ADM 40 ADM 50 ADM 60 ADM 80 ADM 90 ADM 115 and ADM 135 The appliance has been manufactured and equipped in accordance with the European standard for gas fired storage water heaters for the production of domestic hot water EN 89 The appliances are therefore compliant with the European Directive for Gas Appliances and and are entitled to bear the CE mark Wy Warning Read this manual carefully before starting up the water heater Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the appliance 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 entir
23. Instruction manual ADM Improve the air supply by providing better ventilation in the boiler room If ignition is not improved consult your installation engineer 56 11 4 ADM Troubleshooting table no hot water wy Warning Maintenance may only be performed by a qualified service and maintenance engineer No hot water Symptom Cause Precautions EX Comment Green LED OFF and Red LED ON No supply voltage present 1 Checkifthe isolator is ON Check whether there is power to the isolator Check whether there is power to the electrical connector block Check whether there is power to the burner control Check fuse in the burner control The measured voltage must be 230 VAC 15 10 See the ADM electrical diagram 14 Appendices If the error cannot be rectified contact your installation engineer Green LED ON and Red LED OFF Symptom Blockage in the flue gas discharge the flue gas thermostat has cut out Cause Trace the blockage Remove the blockage Reset flue gas thermostat 7 7 Flue gas thermostat reset button Precautions When a demand is detected the appliance will restart Comment Green LED ON and Red LED ON There are three possible causes for this error In order to determine the cause you must cause the error to appear again 1 Resetthe appliance by pressing the reset button 1x 2 If nothing happens then the reset button has been press
24. M AEX 11 11 1 Introduction 11 2 Error conditions Instruction manual ADM Troubleshooting This chapter deals with the following problems with the appliance Gas smell Water leakage Explosive ignition Poor flame profile No hot water Insufficient hot water If the water heater goes into an error condition you will be unable to draw hot water The frost protection will also be out of operation These error conditions are divided into three groups Lockout error from the flue gas thermostat The safety pushbutton on the flue gas thermostat in the draught diverter has been activated After removing the cause the pushbutton 7 6 Burner control reset button must be pressed to restart the appliance Lockout error from the flue gas thermostat When this happens the red LED on the control panel will be illuminated The burner control is locked out After eliminating the cause the appliance must be returned to service by pressing the reset button 7 6 Burner control reset button Blocking errors You can recognise this condition from the fact that the appliance does not start running even though the water temperature is lower than the setting that you have defined using the control thermostat 7 5 Control thermostat These errors disappear automatically once the cause of the error has been removed after which the appliance resumes operation by itself The following pages provide troubleshooting tab
25. Use flue gas discharge materials that comply with the regulations 1 3 Regulations Note Make sure that the chimney discharges into an area approved for this type of appliance Flue gas thermostat assembly At the top of the control column there is a plastic bag containing the flue gas thermostat with the sensor plus the associated fastenings The cable from the sensor has already been connected to the control column The thermostat bracket and sensor have yet to be fitted inside the draught diverter yy Warning If the flue gas thermostat is not or is incorrectly fitted connected the flue gas discharge will not be protected An incorrectly fitted chimney can cause flue gases to backflow into the boiler room Flue gas safety IMD 0137 R2 Fit the flue gas thermostat as follows 2 Take the bracket 1 and flue gas sensor 2 from the packaging Place the bracket in de draught diverter and screw the bracket and the sensor firmly in place 4 Bend the cable clips 3 around the flue gas thermostat lead 4 5 Screw the cable clips 3 tightly into the draught diverter and the appliance Wy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Instruction manual ADM ED 3 10 1 Legend A screws B protective cap C connector block Instruction manual ADM Preparations Caution The appliance is pha
26. appliance is in OFF mode frost protection then this value is 20 C If the appliance is in ON mode for example then this threshold value can be selected e g position 3 60 C The heating cycle runs successively through the following states HEAT DEMAND WAIT PRE GLOW IGNITION RUNNING WAIT Sr Ai OO NO Instruction manual ADM The entire cycle is explained in the example below Note The cycle has the same steps when frost protection is activated 1 The control thermostat sensor measures the temperature The water temperature falls below the set temperature of for example 60 C causing the control thermostat to close The burner control now detects a demand and starts the heating cycle 2 Following demand the wait period starts This wait ensures that the ignition is safe The wait period lasts approximately 15 seconds 3 Once the wait period has elapsed there is audible clicking of the relay in the burner control the PRE GLOW starts 4 After about 12 seconds pre glowing the gas control opens and ignition takes place 5 After ignition the flame is detected and the appliance will be running This means that actual heating has started 6 When the water reaches the set temperature the demand ceases The gas control closes and the burner tray is extinguished A new wait period of about 10 seconds starts 7 Atthe end of this wait the appliance enters the idle state and waits unt
27. ater side and on the gas side Maintenance frequency depends among other things on the water quality the average burning time per day and the set water temperature Note To determine the correct maintenance frequency it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side within three months following installation Based on this check the best maintenance frequency can be determined Note Regular maintenance extends the service life of the appliance Note Both the end user and the service and maintenance engineer are responsible for regular maintenance They will need to establish clear agreements on this Note If the appliance is not regularly maintained the warranty will become void 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 ADM AES 1 7 Overview of this The table provides an overview of the contents of this document document Contents of this document Chapter Target groups Description i Working principle of the This chapter describes how the appliance functions appliance X This chapter describes the installation activity to be completed before you actually start up the a
28. aught diverter Fitting the draught diverter The draught diverter can be positioned according to preference Once it is positioned the draught diverter is secured to the top of the appliance using two screws 6 while itis also supported on a mounting bracket 1 attached to the side of the appliance The mounting bracket parts can be found in the plastic bag attached behind the control column The assembly procedure is as follows Installing the draught diverter IMD 0123 R1 1 Take the mounting bracket out of the bag 2 Fit the mounting bracket 1 in such a way that it properly supports the draught diverter 3 Drill two holes 2 3 2 mm bit for the mounting bracket screws 4 Screw the mounting bracket tightly to the appliance 5 Place the draught diverter in the mounting bracket and mark the centres for the two holes 4 to be drilled in the top side of the appliance Remove the draught diverter from the appliance 6 Now drill two holes 4 into the top of the appliance 3 2 mm bit 7 Place the sealing ring 5 on the appliance 25 Legend 1 bracket 2 sensor 3 attachment brackets 4 cable 3 10 Electrical connection 26 3 9 3 Installation ye py 8 Screw the draught diverter tightly in place 9 Fit a45 bend 7 onto the outlet of the draught diverter followed by acorrosion resistant vertical chimney pipe 8 of at least 0 5 metres in length the remaining flue components Note
29. e ON OFF switch to position I 8 The heating cycle will start and after a short time the burner tray will ignite After the burner tray has ignited wait approximately 1 minute before reading the dynamic pressures Instruction manual ADM ED 3 11 2 3 11 3 Instruction manual ADM 10 Use the pressure gauge to read the supply pressure at test nipple 6 Refer to the gas data table 3 4 3 Gas data g Note Consult the mains gas supply company if the supply pressure is not correct 11 Use the pressure gauge to read the burner pressure at nipple 8 Refer to the gas data table 3 4 3 Gas data g Note If the burner pressure is not correct and the appliance is fitted with a blank plate or high low control you will not be able to adjust the pressure In this case consult your installation engineer or supplier If the appliance is indeed fitted with a burner pressure regulator the pressure can be adjusted 3 11 2 Adjusting the pressure Adjusting the pressure 1 Remove the cap 2 from the burner pressure regulator 2 Depending on the correction required correct the burner pressure by turning adjustment screw 3 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 thegas data table 3 4 3 Gas data 4 Ifthe pressure reading is not correc
30. e installation complies as a minimum with the Official local e building regulations energy supplier s directives for existing gas installations e directives and technical guidelines for natural gas installations e safety requirements for low voltage installations regulations governing the supply of drinking water e regulations governing ventilation in buildings e 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 governing indoor waste water disposal regulations imposed by fire brigade power companies and municipality 1 4 Target groups 1 5 1 6 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 w
31. e 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 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 65 13 4 13 5 13 6 13 7 66 13 Exclusions Scope of the warranty Claims Obligations of A O Smith Warranty certificate EN Ga X i T
32. ed too often maximum 5 times in a single heating cycle Disconnect the appliance from the mains and then restart it Seelsolating the appliance from the mains and steps 3 through 5 of Starting the appliance Decide which type of cause a or b describes the situation see tables below Instruction manual ADM If the error cannot be resolved or is persistent contact your installation engineer 57 Symptom Cause Precautions Comment a three unsuccessful start attempts in a row Symptom Cause 1 No gas Check that the gas valve is open Check whether the gas control is opening clicking of the gas control Check the leads of the gas control 2 No ignition Check whether the hot surface igniter lights up Check the electrical supply to the hot surface igniter Check the leads of the glow igniter 3 No flame detection Check that the Phase L and Neutral N are correctly connected from the mains to the appliance Check whether the flame probe is defective Check that the flame probe leads are properly connected Precautions If the error cannot be resolved or is persistent contact your installation engineer Comment b The safety thermostat has cut out Instruction manual ADM 1 The safety thermostat has cut out correctly Reset the appliance Check whether the control thermostat is working Check whether the high limit thermostat is working Check that
33. eee eee eee 43 Draining unvented installations 44 Draining vented installations 45 The control panel AT Introduction 47 Control panel 47 Explanation of icons 47 ON OFF switch 47 Control thermostat 47 Burner control reset button 48 Flue gas thermostat reset button 48 5 10 11 12 13 14 8 1 8 2 8 3 9 1 9 2 9 3 10 1 10 2 10 3 10 4 11 1 11 2 11 3 11 4 11 5 12 1 12 2 12 3 12 4 12 5 13 1 13 2 13 3 13 4 13 5 13 6 13 7 14 1 14 2 Table of contents Status of the appliance 49 Introduction 49 Operating modes 49 Error conditions 49 Starting and running 51 Introduction 51 Starting the appliance 51 The appliance s heating cycle 51 Shutting down 53 Introduction 53 Shutting down the appliance for a brief period OFF mode 53 Isolating the appliance from t
34. egory EDI Instruction manual ADM AED 5 Filling Installation diagram Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 4 10 manual gas valve mandatory Y i 4 UNVENTED i 14 14 NO a w 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points c 51 4 A 15 expansion valve mandatory 16 expansion vessel mandatory Di 1 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply hot water supply circulation pipe gas supply overflow pipe overflow pipe VENTED tmoooa IMD 0466 RO Instruction manual ADM 5 Filling 5 1 Filling unvented To fill the appliance proceed as follows AES 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 valve 4 on the cold water side A so that cold water flows into the appliance 5 Completely fill the appliance When a full water jet flows from the nearest draw off poin
35. esponds to the heat demand On the control panel the ON OFF switch is at position the water temperature can be set using the rotary knob of the control thermostat 7 5 Control thermostat the green light is lit 8 3 Error conditions If the water heater goes into an error condition you will be unable to draw hot water The frost protection will also be out of operation These error conditions are divided into three groups e Lockout error from the flue gas thermostat The safety pushbutton on the flue gas thermostat in the draught diverter has been activated After removing the cause the pushbutton 7 6 Burner control reset button must be pressed to restart the appliance Lockout error from the flue gas thermostat Instruction manual ADM When this happens the red LED on the control panel will be illuminated The burner control is locked out After eliminating the cause the appliance must be returned to service by pressing the reset button 7 6 Burner control reset button Blocking errors You can recognise this condition from the fact that the appliance does not start running even though the water temperature is lower than the setting that you have defined using the control thermostat 7 5 Control thermostat These errors disappear automatically once the cause of the error has been removed after which the appliance resumes operation by itself The cause of the error cannot be seen
36. function in the flue gas discharge e g a blockage in the chimney can lead to the flue gas thermostat locking out This state is evident when the push button on the flue gas thermostat has been activated refer to the figure Once the cause has been removed and the sensor has cooled down sufficiently press this push button to reset if the sensor is not sufficiently cooled down the flue gas thermostat will immediately lock out again The appliance will then automatically start up again if there is a demand If this is not the case please consult the error condition summary 11 Troubleshooting Note The draught diverter may be hot Figure Flue gas thermostat reset button IMD 0140 R2 48 AEX Instruction manual ADM AED 8 Status of the appliance 8 1 Introduction Topics covered in this chapter e Operating modes e Error conditions 8 2 Operating modes When running the appliance has three basic operating modes namely ELECTRICALLY ISOLATED In this mode the appliance is off and no components are live The isolator switch between the appliance and the mains power supply is off On the control panel the ON OFF switch is at position 0 the green light is dimmed OFF In this mode the frost protection is activated The isolator is at position On the control panel the ON OFF switch is at position 0 the green light is lit ON In this mode the appliance continuously r
37. he 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 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
38. he mains 53 Shutting the appliance down for a long period 53 Troubleshooting 55 Introduction 55 Error conditions 55 Troubleshooting table for general errors 56 ADM Troubleshooting table no hot water 57 Troubleshooting table insufficient hot water 59 Performing maintenance 61 Introduction 61 Preparation for maintenance 61 Water side maintenance 62 Gas side maintenance 63 Finalising maintenance 64 Warranty certificate 65 General warranty 65 Tank warranty 65 Conditions for Installation and use 65 Exclusions 66 Scope of the warranty 66 Claims 66 Obligations of A O Smith 66 Appendices 67 Introduction 67 Electrical Diagrams ADM 68 Instruction manual ADM AED 1
39. he water should spurt out 10 Test the overflow operation of the T amp P valve The water should spurt out with a strong jet 11 Check the drainpipes from the discharge points of all valves and remove any scale deposits that may be present 12 Drain the appliance 6 Draining Instruction manual ADM 61 12 12 3 Water side 62 maintenance 12 3 1 12 3 2 12 3 3 Performing maintenance Introduction The following steps must be carried out on the water side 1 Checking the anodes 2 Descaling and cleaning the tank Checking the anodes Timely replacement of the anodes extends the service life of the appliance 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 Ww Warning The draught diverter and the cover may be hot 1 Remove the protective cover from the control column by unscrewing the 4 screws in the cover 2 Detach the wiring for the flue gas thermostat from the connector block and remove the cable from the strain relief Remove the cable clamps holding the flue gas thermostat cable Disconnect the draught diverter from the flue gas discharge Undo the screws on the draught diverter Remove the draught diverter from the appliance Undo the screws of the lid in the top side of the appliance oN oa Fk amp Remove the lid from the appliance 9 Remove the sealing ring from the appliance
40. high low controller 9 including the sealing gasket from the conversion set Attach the high low control to the gas control using two small screws Detach the leads from the gas control the hot surface igniter and the flame probe to the 6contact connector strip 6 and the strain relief 7 Fit the timers 4 including cable harness plus 9contact terminal strip 6 from the conversion kit to the control column Remove the stop plug not shown from the underside of the control column and replace this with the metric strain relief 9 from the conversion kit Draw the high low control lead 10 through the strain relief and tighten the strain relief by turning it until the lead is clamped 8 Connect the high low control lead 10 plug to the high low control 9 9 Connect the cables from the timers highlow control gas control and the hot 10 38 surface igniter as shown in the electrical diagram 14 2 Electrical Diagrams ADM Check the supply pressure and burner pressure 3 11 Checking the supply pressure and burner pressure Instruction manual ADM ZX Instruction manual ADM 11 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 12 Start the appliance 9 Starting and running 39 40 Conversion to a different gas cat
41. il the water temperature once more falls below the set temperature With any subsequent heat demand the heating cycle will resume from step 1 51 52 Starting and running AES Instruction manual ADM AEX 10 Shutting down 10 1 Introduction Topics covered in this chapter e Shutting down the appliance for a brief period OFF mode e Isolating the appliance from the mains e Shutting the appliance down for a long period 10 2 Shutting down the appliance for a brief period OFF mode To shut the appliance down for a brief period you must activate frost protection using the appliance s heating cycle 2 3 The appliance s heating cycle By using the frost protection you can prevent water freezing in the appliance Frost protection is activated by setting the ON OFF switch on the control panel to position 0 10 3 Isolating the appliance from the mains The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Shut down the appliance by setting the ON OFF switch to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 10 4 Shutting the appliance down for a long period To shut the appliance down for a longer period you must drain the appliance 6 Draining Instruction manual ADM 10 Shutting down AES Instruction manual AD
42. ion of all relevant components the manual may nonetheless contain errors and inaccuracies Should you detect any errors or inaccuracies in the manual we would be grateful if you would inform us This helps us to further improve our documentation 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 0870 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 ADM 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 4 1 4 2 5 1 5 2 6 1 6 2 7 1 7 2 7 3 TA 7 5 7 6 7 7 Table of contents Introduction 7 About the appliance 7 What to do if you smell gas 7 Regulations e 7 Target groups 8 Maintenance 8 Forms of notation 8 Overview of this document
43. ion of the appliance Legend F See the table IMD 0135 R2 18 Instruction manual ADM ED Dimensions all measurements in mm unless otherwise indicated Description ADM ADM ADM ADM 40 50 60 80 Total height 1900 2100 1900 2100 Height of top of appliance 1760 1960 1760 1960 Appliance diameter 710 710 710 710 Depth 800 800 800 800 Width 1100 1100 1100 1100 Diameter of chimney flue 150 150 180 180 Heart appliance Heart chimney 660 660 660 660 flue Height of chimney flue 1840 2040 1840 2040 Height of gas connection 400 400 400 400 Height of cold water supply 565 565 565 565 Height of hot water outlet 1605 1810 1605 1810 Height of cleaning opening 730 730 730 730 Height of drain valve connection 500 515 500 515 Height of T amp P valve connection 1550 1760 1550 1760 Cold water supply connection R1 1 3 R1 1 3 R1 UA R1 UA male gt V D Ul Z Z KA Hot water outlet connection Rp1 1 3 Rp11 2 Rp1 1 2 Rp11 2 female Gas control connection female Rp3 4 Rp3 4 Rp3 4 Rp3 4 Drain valve connection female Rp1 Rp1 Rp1 5 Rp1 5 T amp P valve connection female 1 11 5 1 11 5 1 11 5 1 11 5 NPT NPT NPT NPT 6 Cleaning inspection opening 100 Z4100 Z4100 100 100 100 100
44. l ADM AE 6 2 Draining vented Some service activities require the appliance to be drained The procedure is as installations follows 1 Shut down the appliance by setting the ON OFF switch on the control panel to position 0 IMD 0460 RO 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the stop valve 4 between the cold water head tank and the cold water inlet 6 Open the drain valve 9 7 Bleed the appliance or installation so that it drains completely Instruction manual ADM 45 rainin AES Instruction manual ADM AEJK T The control panel 7 1 Introduction Topics covered in this chapter in sequence e Control panel e Explanation of icons e ON OFF switch e Control thermostat e Burner control reset button e Flue gas thermostat reset button 7 2 Control panel This figure shows the control panel The control panel 4 if Oi WATER PRODUCTS COMPANY cA E IMD 0460 RO The control panel comprises e an ON OFF switch e a reset button acontrol thermostat with rotary knob e two status LEDs 7 3 Explanation of icons The table explains the meanings of the icons Instruction manual ADM Icons and their meaning Name Explanation ON
45. lations 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 the appliance may be started up 9 Starting and running in particular e Packaging Ambient conditions e Technical specifications e Water connections Vented e Water connections Vented e Gas connection e Chimney flue e Electrical connection e Checking the supply pressure and burner pressure For a possible conversion to a different gas category see conversion 4 Conversion to a different gas category To avoid damaging the appliance remove the packaging carefully We recommend unpacking the appliance at or near its intended location Caution The appliance may only be manoeuvred in an upright position Take care that the appliance is not damaged after unpacking 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 ADM appliances are open appliances and may on
46. les for each type of error Note Footnotes referred to from within any table are shown at the bottom of the last page of that table 55 11 3 Troubleshooting table for general errors y Warning Maintenance may only be performed by a qualified service and maintenance engineer General faults and failures Symptom Precautions y Comment Gas smell Warning Close the main gas valve immediately Warning Do not operate any switches Warning No naked flames Warning Ventilate the boiler room Note Contact your installation engineer or local gas company immediately Water leakage Leakage from a water connection threaded Tighten the threaded connection Leakage from another nearby water appliance or pipe segment Trace the leak Leakage from the appliance s tank Consult the supplier and or manufacturer Condensation Before drawing too much tap water wait until the water in the boiler has reached the set temperature If the leak persists consult your installation engineer Explosive ignition Poor flame profile Incorrect supply pressure and or burner pressure Set the correct supply pressure and or burner pressure 3 11 Checking the supply pressure and burner pressure Contaminated burner Clean the burner s 12 4 2 Clean the burner s Contaminated orifice Clean the orifice s 12 4 3 Clean the orifice s Inadequate air supply
47. ly be installed in an open boiler room Their type is B11ps Air humidity and ambient temperature The boiler room must be frost free or be protected against frost The table shows the environmental conditions that must be adhered to for correct functioning of the electronics present in the appliance to be guaranteed 15 3 3 2 Installation ve py 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 connection with the appliance s weight take account of the maximum floor loading refer to the table Weight of the appliance filled with water ADM 40 ADM 50 ADM 60 ADM 115 ADM 135 504 kg 16 578 kg 3 3 3 3 3 4 507 kg 523 kg 581 kg 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 English hardness gt 7 0 eH Conductivity gt 125 uS cm Acidity pH value 7 0 lt pH value lt 9 5 Note If the water specifications deviate from those stated in the table then the tank pro
48. move all contamination present in the orifice s 3 Fit the orifice s Checking the flue baffles Wy Warning The flue baffles can be hot 1 Remove the flue baffles from the appliance N Check the flue baffles for the presence of corrosion removing this if necessary Check the flue baffles for wear and replace the flue baffles if necessary Place a new sealing ring on the rim of the tank and re fit the lid Fit the draught diverter 3 9 2 Fitting the draught diverter Feed the cable of the flue gas thermostat through the strain relief and attach the wiring to the connector block 14 2 Electrical Diagrams ADM o na 7 Refit the cable clamps to the appliance and draught diverter 8 Re fit the protective cover To finalise the maintenance carry out the following steps 1 Fill the appliance 5 Filling 2 Start the appliance 9 Starting and running Instruction manual ADM AI 13 13 1 General warranty 13 2 Tank warranty 13 3 Conditions for Installation and use Instruction manual ADM 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
49. ner control will immediately halt the heating cycle The burner control will go into a lockout error state This must be manually reset before the appliance can resume operation 2 4 3 Flue gas backflow safeguard The flue gases are discharged to the outside via the draught diverter 33 and the flue 22 To prevent the flue gases from flowing back into the boiler room the discharge ducting is monitored by a feature called the Thermal Reflux Safeguard TRS This uses a flue gas thermostat 37 with a flue gas thermostat sensor 34 that are located in the draught diverter Under normal circumstances this sensor will register the ambient temperature However if the chimney is not drawing sufficiently for example due to a blockage in the chimney the flue gases will reflux and flow back past the flue gas thermostat sensor The sensor will then detect an excessive temperature and the flue gas thermostat will open The demand will cease and the burner control will immediately stop the heating cycle The flue gas thermostat will also lock out It must be manually reset before the appliance can resume operation 2 4 4 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 burner control uses the ionisation detecting properties of this probe for flame detection The burner control closes the gas valve the instant it determines that there is a gas flow but no flame is
50. ntenance on both the water side and the gas side The maintenance must be carried out in the following order 1 Water side maintenance 2 Water side maintenance 3 Gas side maintenance 4 Finalising 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 12 2 Preparation for To test whether all components are still working properly complete the following maintenance steps 1 Set the ON OFF switch on the control panel to position 0 2 Setthe control thermostat to the highest value note the original setting and set the ON OFF switch back again to position I 3 If there is no heat demand draw off some water to create a heat demand 4 Check whether the heating cycle 9 3 The appliance s heating cycle runs correctly 5 Set the control thermostat back to the original setting and set the ON OFF switch back again to position I 6 Check the supply and burner pressure 3 11 Checking the supply pressure and burner pressure and adjust them if necessary 7 Check that all components of the chimney flue system are properly attached 8 Test the operation of the overflow valve of the protected cold supply set up The water should spurt out 9 Test the overflow operation of the T amp P valve T
51. on the control panel For a detailed overview of error conditions please refer to the error tables 11 Troubleshooting If as end user you find the appliance in an error condition you may attempt to restart the appliance by pressing the reset button once However if the error returns or occurs several times in a short time you must contact your service and maintenance engineer 49 50 Status of the appliance AED Instruction manual ADM AED 9 Starting and running 9 1 Introduction Topics covered in this chapter e Starting the appliance e The appliance s heating cycle 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 Put the appliance in ON mode by setting the ON OFF switch on the control panel to position I 5 Using the control thermostat 7 5 Control thermostat set the desired water temperature If there is a heat demand the appliance will run through the heating cycle 9 3 The appliance s heating cycle 9 3 The appliance s heating cycle The appliance s heating cycle is activated as soon as the measured water temperature Twater falls below the threshold value Tg This threshold value depends on the currently selected appliance operating mode For example if the
52. ppliance Installation Filling This chapter describes how to fill the appliance HX xx x lt 5 lt Draining This chapter describes how to drain the appliance s lt This chapter describes the general operation of the appliance and explains how to use the control panel The control panel 5 lt This chapter describes the status mode or condition that the appliance may have and possible actions to take Status of the appliance This chapter describes how to start the appliance running The general heating cycle of the appliance is also described Starting and running This chapter describes how to shut the appliance down for a brief or long period of time Shutting down 5 lt This chapter is mainly intended for the installation engineer and the service and maintenance engineer It describes appliance errors A table is included stating potential symptoms causes and solutions End users may also refer to this chapter for additional information about the appliance Troubleshooting gt e See FEE 5 lt This chapter sets out the maintenance tasks to be carried out during a service Performing maintenance Warranty certificate This chapter states the warranty terms and conditions gt zi X Instruction manual ADM 9 Introduction AES Instruction manual ADM AED 2 1 Introduction 2 2 Gene
53. present 2 5 Safety of the installation In addition to the appliance s standard built in safety monitoring the appliance must also be protected by an expansion vessel expansion valve pressure reducing valve non return valve and a T 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 2 5 1 Inlet combination and pressure reducing valve In addition to the appliance s standard built in safety monitoring the appliance must also be protected by an expansion vessel expansion valve pressure reducing valve non return valve and a T 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 Instruction manual ADM 13 14 2 5 2 2 5 3 2 5 4 Working principle of the appliance EA ial DI 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 componen
54. r Phase input of extra error sensor Normally closed port of the extra error sensor Fuse 71 72 14 Appendices ED Instruction manual ADM AES Index A M ambient temperature 15 burner pressure 28 claims 66 connect circulation piping 23 24 cold water side 22 23 electrical 26 28 gas 24 hot water side 23 shut pipe 22 23 connecting circulation pipe 23 24 connecting cold water side 22 23 connecting hot water side 23 control thermostat 47 conversion to a different gas category 33 document contents 9 draining 43 electrical connection 26 environmental conditions 15 filling 41 flame probe 13 forms of notation 8 gas category conversion to different 33 gas connection 24 general specifications 3 heating cycle 12 humidity 15 icons explanation 47 installation engineer 8 9 isolator 28 liability 3 Instruction manual ADM mains power 28 maintenance burner 64 finalising 64 gas side 63 orifice 64 perform 61 preparation 61 water side 62 operating modes 49 packaging 15 protection 12 running 51 scale 62 service check 8 service engineer 8 shunt pump 22 23 specifications 17 starting up 51 supply pressure 28 symbol installation engineer 8 service engineer 8 user 8 target groups 8 to shut down electrically isolating 53 longer period 53 short period 53 trademarks 3 user 8 warranty 65 exclusions 66 general 65 installation and conditions of use 65 scope 66
55. ral working principle of the appliance Legend Only applicable numbers are mentioned 2 hot water outlet 6 control panel 8 combustion chamber 9 anode 10 tank 11 heat exchanger 12 inspection and cleaning opening 14 cold water inlet 15 drain valve 16 gas control 20 spark igniter 21 flame probe 22 chimney pipe 24 insulation layer 33 draught diverter 34 flue gas sensor 35 radiation shield condensation tray 36 bar burners burner tray 37 flue gas thermostat 38 safety thermostat sensor 39 high limit thermostat sensor 40 burner control 41 control thermostat 42 high limit thermostat 43 safety thermostat 44 frost thermostat 45 control thermostat sensor 46 frost thermostat sensor Instruction manual ADM 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 The figure shows a cut away view of the appliance Cut away view of the appliance 1 i 4 o 10 D dd IMD 0133 R2 11 2 3 2 4 12 The appliance s heating cycle Protection for the appliance 2 4 1 Working principle of the appliance EA ial DI In this appliance
56. rflow side to an open wastewater pipe Recirculation pipe You can install a top to bottom circulation pump to prevent water stacking in the boiler 1 Optional depending on the draw off pattern fit a recirculation pipe 22 mm a stop valve 11 and a top to bottom circulation pump 7 2 Fit a non return valve 5 3 Fit a stop valve 11 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 Drain valve 1 Fit the standard drain valve 9 supplied with the appliance 2 If applicable fit a circulation pipe 3 6 5 Circulation pipe If not fit the blind threaded plug and gasket C supplied with the drain valve as shown in the figure 23 3 8 24 Gas connection 3 7 5 Installation ye py IMD 0122 R1 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 Fit a non return valve 5 behind the circulation pump
57. se sensitive It is apsolutely essential to connect the mains live L to the live of the appliance and the mains neutral N to the neutral of the appliance Caution There must also 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 For more information or to order an 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 Connector block IMD 0134 R2 1 In preparation first remove the protective cover from the control column 2 Undo the 4 screws A 3 Remove the protective cover B from the electrical part 27 3 10 2 3 11 Checking the supply 28 pressure and burner pressure Installation ve py The connector block C is now visible Note Please consult 14 2 Electrical Diagrams ADM the appropriate electrical diagram for details of the connections of the electrical components Terminal block Mains voltage Flue Gas Thermostat 1 L N Lo L3 1 2 4 5 Connecting the mains power 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
58. sing 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 20 Instruction manual ADM EDI 3 5 Installation diagram 3 5 1 Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply hot water supply circulation pipe gas supply overflow pipe overflow pipe NOarw rmooo Instruction manual ADM Installation This figure shows the installation diagram This diagram is used in the sections in which the actual connection process is described Installation diagram UNVENTED mM 14 14 ye a 1 p7 X 4 5 16 a I 9H 151 oth 10 T se VENTED IMD 0466 RO 21 3 3 6 Water connections 22 Vented 3 6 1 3 6 2 3 6 3
59. t repeat the burner pressure adjustment until the correct pressure is reached 5 Fit the cap 2 back on the burner pressure regulator 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 warranty procedure Please return this card as soon as possible Your customer will then receive a warranty certificate with our warranty conditions 31 32 Installation ED Instruction manual ADM ED 4 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 This chapter covers the following e Conversion to different category ADM 40 through 115 e Conversion from natural gas to LP gas Instruction manual ADM 33 4 Legend 1 2 3 4 1 34 cover plate retaining strips orifice with stamped figures Conversion to different category
60. t the appliance is full 6 Bleed the entire installation of air for example by opening all draw off points 7 The appliance is now under water supply pressure There should be no water coming out of the expansion valve 15 nor the T amp P valve 3 If this does happen the cause might be The water supply pressure is greater than the specified 8 bar Rectify this by fitting a pressure reducing valve 1 The expansion valve in the protected cold supply setup is defective or incorrectly fitted 5 2 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 valve 4 on the cold water side A so that cold water flows into the appliance 5 Completely fill the appliance When a full water jet flows from the nearest draw off point the appliance is full 6 Bleed the entire installation of air for example by opening all draw off points 7 The appliance is now under water supply pressure There should be no water coming out of the T amp P valve 3 If this does happen the T amp P valve might be defective or incorrectly fitted 42 Instruction manual ADM AEX 6 Draining Installation diagram Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory
61. tection cannot be guaranteed 13 Warranty certificate Working clearances For access to the appliance it is recommended that the following clearances are observed see figure 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 fixed anodes or 50 cm if using flexible anodes If the available clearance is less than 100 cm flexible magnesium anodes may be ordered g Note When installing the appliance be aware that any leakage from the tank and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this is the case the appliance should be installed above a wastewater drain or in a suitable metal leak tray The leak tray must have an appropriate wastewater drain and must be at least 5cm deep with a length and width at least 5cm greater than the diameter of the appliance Instruction manual ADM ED Working clearances Y IMD 0262 R2 3 4 Technical The appliance is supplied without accessories Check the specifications 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 Instruction manual ADM 17 3 Installation 3 4 1 Dimensions of the appliance EX Plan and elevat
62. the circulation pump if present is working 2 The safety thermostat has cut out without apparent reason Check whether the thermostat is defective Check whether the sensor of the thermostat is defective If the error cannot be resolved or is persistent contact your installation engineer 58 11 5 Troubleshooting table insufficient hot water y Warning Maintenance may only be performed by a qualified service and maintenance engineer Insufficient hot water Symptom Cause Precautions EX Comment Insufficient hot water Water temperature setting Tet is too low Set the control thermostat 7 5 Control thermostat to a higher value Hot water supply is used up Instruction manual ADM 1 Reduce hot water consumption and give the appliance time to heat up If this error persists check whether the high limit thermostat is switching If this is the case check that the circulation and or top to bottom circulation pump are working If the error has not been rectified and no other cause can be found isolate the appliance from the mains 10 3 Isolating the appliance from the mains shut off the manual gas valve and alert your installation engineer 59 Ve EX Instruction manual ADM 60 12 Performing maintenance 12 1 Introduction Caution Maintenance may only by carried out by an approved service and maintenance engineer At each service the appliance undergoes mai
63. to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connect the circulation pipe to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve 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 Instruction manual ADM EDI 3 9 Chimney flue 3 9 1 3 9 2 Legend 1 support bracket 2 holes to attach support bracket 3 screws for support bracket 4 holes to attach draught diverter 5 sealing ring 6 screws for draught diverter 7 45 bend 8 chimney pipe Instruction manual ADM Wy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Introduction The separately supplied draught diverter must be used when connecting the appliance to the chimney flue The standard flue gas thermostat and sensor that are supplied must be fitted in the dr
64. tor to the gas control using the two small screws supplied 7 Detach the leads between the 6contact terminal strip 6 and the 9contact terminal strip 8 These are the leads for the timers high low control gas control hot surface igniter and flame probe Remove the timers 4 bracket 5 wiring harness not shown and 9contact terminal strip Turn the metric strain relief 9 with the high low control lead 10 to loosen it Remove this lead Fit the stop plug from the conversion set in the place of the metric strain relief Connect the cables of the gas control the hot surface igniter and flame probe to the 6contact terminal strip as indicated in the electrical diagram 14 2 Electrical Diagrams ADM Clamp the gas control cable in one of the supplied strain reliefs 7 Do the same for the leads of the hot surface igniter and flame probe Check the supply pressure and burner pressure 3 11 Checking the supply pressure and burner pressure 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 Start the appliance 9 Starting and running 4 2 3 Conversion from natural gas to LP gas 1 Carry out steps 1 through 10 4 1 Conversion to different category ADM 40 through 115 2 Detach the burner pressure regulator 1 3 Fit the
65. ts are fitted to the cold water pipe 3 6 Water connections Vented Vented installation With vented installation excess pressure is taken up by the open cold water head tank The head height of the 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 3 6 3 Hot water side which opens into the cold water tank T amp P valve 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 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 3 Hot water side Instruction manual ADM EM 3 3 1 Introduction 3 2 Packaging 3 3 Ambient conditions 3 3 1 Instruction manual ADM Installation Wy Warning Installation work should be carried out by an approved installation engineer in compliance with the general and local regu
66. water composition 16 73 Index 0306 132 4 0 UK Instruction manual ADM

A.O. Smith ADM - 135 Installation Manual

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