A.O. Smith GWV - 120 Installation And Service Manual Download

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Instruction manual GWV

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

Vented

1 5

6
5

IMD-0486 R2

6
5

IMD-0487 R2

Summary of Contents for GWV - 120

Page 1: ...120 150 200 WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION Installation User and Service Manual Installation User and Service Manual ...

Page 2: ...www aosmithinternational com your installer ...

Page 3: ...ther 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 inaccurac...

Page 4: ...4 Instruction manual GWV gis ...

Page 5: ...l specifications 22 3 5 Installation diagram 25 3 6 Water connections Vented 26 3 7 Water connections Unvented 28 3 8 Gas connection 29 3 9 Air supply and flue 29 3 10 Electrical connection 33 3 11 Checking the supply pressure and burner pressure 36 4 Conversion to a different gas category 41 5 Filling 43 5 1 Installation diagram 43 5 2 Filling unvented installations 44 5 3 Filling vented installa...

Page 6: ...s standard week program 62 11 8 Adding times to a week program 64 11 9 Deleting times from a week program 65 11 10 Extra period 65 11 11 Programming an extra period 66 11 12 Settings 67 12 Service program 69 12 1 Introduction 69 12 2 Setting the hysteresis 69 12 3 Displaying the error history 69 12 4 Displaying the appliance history 69 12 5 Displaying the appliance selection 70 12 6 Switching the ...

Page 7: ... maintenance 92 15 5 Finalizing maintenance 92 16 Warranty certificate 93 16 1 General warranty 93 16 2 Appliance warranty 93 16 3 Conditions for Installation and use 93 16 4 Exclusions 94 16 5 Scope of the warranty 94 16 6 Claims 94 16 7 Obligations of A O Smith 94 17 Appendices 95 17 1 Introduction 95 17 2 Electrical diagram 96 17 3 Week program card 99 ...

Page 8: ...Table of contents 8 Instruction manual GWV ...

Page 9: ...you smell gas 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 1 3 Regulations As the end user instal...

Page 10: ... 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 s...

Page 11: ...y 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 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 This ch...

Page 12: ...Introduction 12 Instruction manual GWV 1 gis ...

Page 13: ...1 Introduction Topics covered in this chapter General working principle of the appliance The appliance s heating cycle Protection for the appliance Safety of the installation 2 2 General working principle of the appliance The figure shows a cut away view of the appliance ...

Page 14: ...Working principle of the appliance 14 Instruction manual GWV 2 gis Cut away view of the appliance IMD 0500 R1 8 7 6 5 4 3 2 20 19 1 13 11 12 10 9 31 30 29 33 28 27 32 22 21 17 18 16 15 14 24 25 26 23 ...

Page 15: ...on layer 2 prevents heat loss To protect against corrosion the storage tank is enamelled on the inside Anodes provide extra protection against corrosion For maintenance the storage tank has an aperture for inspection and cleaning 2 3 The appliance s heating cycle The appliance uses sensor T3 23 to determine whether the water temperature set Tset has been reached When T3is lower than the set water ...

Page 16: ...g the gas controls with a delay softlite 2 4 4 Fan The fan 10 provides an optimum air supply 8 when there is a heat demand This air comes into a separate chamber on the air distribution plate 13 Overpressure is created in the space and the air can only escape the appliance via the premix bar burners 18 As a safety feature the fan ensures that any gases present in the combustion chamber are removed...

Page 17: ... closes the gas valve as soon as it detects that no flame is present 2 4 7 Flow through switch the flow through switch 29 guarantees the flow of water through the appliance before operation and while the appliance is running The standard position of the flow through switch is open When the flow is sufficient the switch closes and the heating cycle starts If the flow of water through the appliance ...

Page 18: ...g pressure in the appliance which may not exceed 8 bar The appliance must also be fitted with a vent pipe from the hot water pipe which opens into the cold water tank Normally the vent pipe should discharge into a separate discharge channel drain or otherwise to the open cold water head tank The appliance should also be fitted with a stop valve 3 6 2 Hot water side on the hot water side 2 5 3 Inle...

Page 19: ...arried out before you actually start using the appliance 9 Starting and running namely Packaging Environmental conditions Technical specifications Installation diagram Water connections Vented Gas connection Air supply and flue Electrical connection Checking the supply pressure and burner pressure For a possible conversion to a different gas category see conversion 4 Conversion to a different gas ...

Page 20: ... may then only be placed in an open boiler room The appliance type is B23 3 3 1 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 Air humidity and ambient temperature specifications 3 3 2 Maximu...

Page 21: ...ge tank it is recommended that the following clearances are observed Around the appliance and the storage tank 50 cm Above the storage tank 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 Note When installing the appliance and storage tank be aware that any leakage can ...

Page 22: ... the dimensions 3 4 1 Dimensions of the appliance the gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of the appliance 3 4 1 Dimensions of the appliance Plan and elevation of the appliance C M I H G J 1 2 3 5 4 F D B L E K A IMD 0483 R0 ...

Page 23: ...185 K Height of gas connection 760 760 760 L Height of drain valve connection 345 345 345 M Length including pump 1500 1680 2100 1 Supply connection external R 11 2 R 2 R 2 2 Return connection internal Rp 11 2 Rp 2 Rp 2 3 Gas connection external R 1 R 1 R 1 4 Drain valve connection internal 3 4 3 4 3 4 5 P valve connection internal 3 4 3 4 3 4 Chimney1 Unit GWV 120 GWV 150 GWV 200 Not insulated ma...

Page 24: ... 2 Nominal load upper value kW 122 2 152 1 194 3 Nominal output kW 99 0 123 3 157 5 Supply pressure mbar 20 20 20 Burner pressure mbar 2 x 8 9 2 x 9 3 2 x 8 0 Gas consumption m3 h 11 5 14 3 18 4 Number of burners total 8 10 15 Gas category 3P G31 37 mbar Orifice diameter mm 1 50 1 50 1 50 1 Blank plate 2 Burner pressure regulator 3 High low regulator 2 2 2 Nominal load upper value kW 111 1 138 8 2...

Page 25: ...on diagram This diagram is used in the sections in which the actual connection process is described Installation diagram Unvented Vented A 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 D 10 9 9 12 B C IMD 0486 R2 4 4 14 14 14 6 5 4 23 3 11 11 11 D 10 9 9 12 B A 4 18 19 E H 17 C IMD 0487 R2 ...

Page 26: ...f hot water is required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fit a circulation pump 6 of the correct capacity for the length and resistance of the circulation system 2 Fit a non return valve 5 behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connect the circulatio...

Page 27: ... revs using the pump s adjuster unit Proceed as follows 1 Unscrew the pump s cap 2 The pump s adjuster unit can be seen 3 Take the adjuster unit out 4 Remove the cap of the adjuster unit 5 Turn the adjuster unit so that the number of the rev setting required can be seen GWV 120 GWV 150 GWV 200 Pipe diameter Ø 42 1 1 2 Ø 54 2 Ø 54 2 IMD 0519 R0 ...

Page 28: ... expansion valve 15 and connect the overflow side to an open wastewater pipe 3 7 2 Hot water side See B in the installation diagram 3 5 Installation diagram 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 Fit the T P valve 3 3 Fit a stop valve 11 in the hot water outlet pipe for serv...

Page 29: ...the gas system 4 Fit the gas supply pipe to the gas system Warning After fitting check for leaks 3 9 Air supply and flue 3 9 1 Introduction This section covers the following subjects Requirements for flue gas discharge materials Parallel connections Specifications 3 9 2 Requirements for flue gas discharge materials Warning Installation must be carried out by an authorised installation engineer in ...

Page 30: ...on manual GWV 3 is C13 appliance with wall conduit C33 appliance with roof conduit Note Make sure that the chimney discharges into an area where this is permitted for this category of appliance B A IMD 0503 R0 A C B IMD 0509 R0 ...

Page 31: ... bends Caution Contact the supplier for the installation of an insulated pipe maximum number of 45 or 90 bends allowed is 2 If you make use of horizontal piping then this must slope towards the appliance at a minimum of 5 mm per metre running length The transition piece to convert the air supply and flue gas discharge from parallel to concentric must be placed immediately before the roof or wall f...

Page 32: ...120 Ø 150 mm GWV 150 Ø 150 mm GWV 200 Ø 200 mm 1 No other wall flue terminal is permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler Subject Description Roof flue terminal set 1x roof flue terminal incl transition piece 1x adhesive sheet 1x clamping ring 2x pipe 1000 mm 1x bend 90 Item No GWV 120 0308 239 1 GWV 150 0308 239 1 GWV 200 0308 240 1 Cons...

Page 33: ...OUT Sensor wiring 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 3 10 2 Preparation Caution The appliance is phase sensitive It is absolutely essential to connect the mains live L to the live of the appliance and the mains neutral N to the neutral of the appliance The figure shows a view o...

Page 34: ...al section 1 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 Legend A screws B protector plate C connector block A B C 19 1 IMD 0504 R1 ...

Page 35: ...elief 2 Connect the cable to terminals 1 2 3 of the DIN rail 3 Connect the power cable to the double pole isolator 4 If you do not need to make any more connections Fit the protector plate onto the electrical connector block 3 10 4 Connecting a program controlled pump 1 Pass the cable through the third strain relief from the right 2 Connect the cable to terminals 7 8 9 of the DIN rail 3 Connect th...

Page 36: ...by AO Smith is required 1 Pass the lead through the strain relief 2 Connect the phase cables X2 and X3 up to terminals 12 and 13 according to the table on page 34 If required connect earth to terminal 11 3 Connect the wires up to the fault sensor 4 If you do not need to make any more connections Fit the protector plate onto the electrical connector block 3 10 7 Sensor wiring Four connectors are fi...

Page 37: ... Do no completely undo them as it may be awkward retightening them 2 Connect a pressure gauge to the burner pressure nipple 2 3 Open the gas supply and vent the gas supply line through 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 the isolator on the appliance 6 Switch th...

Page 38: ...the pressure gauge to read the supply pressure at the test nipple 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 you can adjust the pressure according to the procedure 3 11 3 Adjusting the pressure 3 11 3 Adjusting the pressure 1 R...

Page 39: ... and switch the electronic controller off Caution Failure to wait until the fan stops can cause damage to the appliance 9 Finish off 3 11 4 Finalising 3 11 4 Finalising 1 Shut off the gas supply 2 Disconnect the two pressure gauges and retighten the sealing screws in the test nipples in the gas controls 3 Put the front panel back Note Before starting the appliance up take time to fill in the warra...

Page 40: ...Installation 40 Instruction manual GWV 3 is ...

Page 41: ... 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 The conversion instructions are not part of this manual Contact A O Smith if conversion is needed ...

Page 42: ...Conversion to a different gas category 42 Instruction manual GWV 4 is ...

Page 43: ...llation 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 A 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 D 10 9 9 12 B C IMD 0486 R2 ...

Page 44: ...ll 7 Bleed the entire installation of air for example by opening all draw off points 8 Bleed the pump Vented Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory if the mains water pressure exceeds 8 bar 2 inlet combination mandatory 3 expansion valve 4 stop valve recommended 5 non return valve mandatory 6 circulation pump optional 9 drain valve 10 manual gas valve mand...

Page 45: ...n 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 of...

Page 46: ...Filling 46 Instruction manual GWV 5 gis ...

Page 47: ...allation 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 A 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 D 10 9 9 12 B C IMD 0486 R2 ...

Page 48: ... 1 pressure reducing valve mandatory if the mains water pressure exceeds 8 bar 2 inlet combination mandatory 3 expansion valve 4 stop valve recommended 5 non return valve mandatory 6 circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 18 w...

Page 49: ...raining vented installations Some service activities require the appliance to be drained The procedure is as follows 1 Activate the MENU with 2 Position the cursor in front of OFF 3 Confirm OFF with 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 s...

Page 50: ...ning 50 Instruction manual GWV 6 gis 9 Close the stop valve 4 between the water tank and the cold water inlet A 10 Open the drain valve 9 11 Bleed the appliance or installation so that it drains completely ...

Page 51: ... is shown as in the figure both with and without icons 7 3 Meaning of icons The table explains the meanings of the icons Icons and their meaning 7 4 Electronic controller ON OFF switch The ON OFF switch of the electronic controller is used to switch the appliance ON and OFF After switching on the text INTERNAL CHECK appears on the display for about 10 seconds Themain menu 11 Main menu then appears...

Page 52: ...oll down further to see the EXTRA PERIOD and SETTINGS texts Press to confirm the selected option With the button you go back one page in a menu and all options selected in the current menu are discarded Note The button is also used to reset the appliance after a fault 7 6 PC connection The PC connection is solely intended to enable technicians from A O Smith to display the status and history of th...

Page 53: ... 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 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 PROG line two the time the day and T1 and T3 alternately 2 3 ...

Page 54: ...rrors LOCK OUT ERRORS When the cause has been removed these errors require a reset with the 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 The display does not show what type of error has been detected A comprehensive overview of the errors is pr...

Page 55: ...ycle 2 3 The appliance s heating cycle If the heating cycle is not run there is no heat demand if this is the case Tset will probably need to be set 11 4 Setting the water temperature 9 3 The appliance s heating cycle The appliance s heating cycle is activated when the measured water temperature T3 falls below the threshold value Tset This set point value depends on the currently selected applianc...

Page 56: ...at actual heating has started The rotational speed of the fan then increases to the normal running speed for the partial load phase and the pressure switch closes The icon is removed The and icons are activated The RUNNING 1 message appears 7 If the temperature difference between Tset and T3 is greater than the downward hysteresis plus the stage difference then second gas control full loaf gas con...

Page 57: ...and icons are removed The icon is activated The message POST PURGE appears 11 Following the post purge the fan stops and the pressure switch opens The and icons are removed The POST PURGE message is removed With any subsequent heat demand the heating cycle will resume from step 1 ON Ê Ê 13 45 Thursday 65ÉC Tset 65ÉC POST PURGE ON 14 05 Thursday 65ÉC a a ...

Page 58: ...Starting and running 58 Instruction manual GWV 9 gis ...

Page 59: ...ated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 2 Position the cursor in front of OFF 3 Confirm OFF with Caution Failure to wait until the fan stops purging can cause damage to the appliance 4 Wait until the fan has stopped The icon then goes out 5 Switch the appliance OFF position 0 using the ON OFF switch on the control panel 6 Isolate the ap...

Page 60: ...Shutting down 60 Instruction manual GWV 10 gis ...

Page 61: ...e appliance will automatically return to the mode it was previously in 11 2 Notational convention for menu related instructions The MENU of the electronic controller is divided into submenus For example SETTINGS is one of the functions reached from the main menu The SETTINGS menu is divided into submenus in turn For example LANGUAGE is a submenu of SETTINGS So for example to select the LANGUAGE me...

Page 62: ...e 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 2 3 The appliance s heating cycle and return to the week program This following are discussed Starting and stopping the week program Changing the appliance s standard week prog...

Page 63: ...witch on time the switch off time setting is automatically adjusted with the switch on time 4 Use and to set the minutes In the example this is 15 Confirm with The cursor moves to the switch off hour digits which flash 11 7 2 Week program setting switch off time 1 Use and to set the hour In the example this is 12 Confirm with The cursor moves to the minute digits which flash 2 Use and to set the m...

Page 64: ...e period 2 Scroll to INSERT Confirm with The submenu for adding a period will appear Example Asan example we will program an extra period in which the switch on time is set to 18 00 and the switch off time to 22 00 The water temperature will be set to 75ºC and the pump will run continuously 3 Do the following a Set the switch on time 11 7 1 Week program setting the switch on time b Set the switch ...

Page 65: ...ff for a certain period either without modifying the active week program or without taking the appliance out of the ON or OFF mode frost protection active If the appliance is running an extra period this is indicated in the display with EXTRA If the water temperature becomes too low during the extra period the appliance will run through the heating cycle 2 3 The appliance s heating cycle and fall ...

Page 66: ...inutes In the example this is 45 Confirm with The cursor moves to the water temperature See the figure 11 11 3 Setting the water temperature 1 Use and to set the water temperature In the example this is 75 C Confirm with The cursor moves to PUMP ON 11 11 4 Setting the program controlled pump 1 If required a pump can be controlled during the period Use and to set PUMP ON The pump ensures a regular ...

Page 67: ... Setting day and time To enter the time and day 1 Call up the menu for entering the day and time as follows 2 SETTINGS Confirm with The display shows the menu for settings 3 Scroll to DAY TIME using and Confirm with The display shows the submenu for adjusting the day 4 The cursor is positioned in front of Sunday Scroll to the desired day using and Confirm with The day has been set The display show...

Page 68: ... display shows the submenu for displaying appliance specifications 3 Scroll with to the section to be displayed for example REGULATION INTERVAL The relevant display appears TIME 15 45 GWV 120 Ignition rotation speed rpm 1620 Working revs 1 partial load rpm 2040 Working revs 2 full load rpm 2340 Adjustability o C 40 85 GWV 150 GWV 200 Ignition rotation speed rpm 1500 1800 Working revs 1 partial loa...

Page 69: ...esis The hysteresis can be set DOWN negative hysteresis The hysteresis can be adjusted between 2 C and 7 C Set the hysteresis DOWN as follows HYSTERESIS DOWN The figure shows an example 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 reserv...

Page 70: ... 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 4 Service condition to this effect will appear Adjust the service interval via SERVICE INTERVAL 12 8 Setting the display contrast Set the display contrast as follows DISPLAY CONTRAST The default setting i...

Page 71: ...n the stage difference The stage difference can be adjusted between 2 C and 8 C The default stage difference is 5 C You can set the stage difference using STAGE DIFFERENCE The figure shows an example 12 12 Setting the pump running on time Once the heat demand has been met the heating cycle stops but the pump continues to run for a short time The run on time can be set to 45 90 or 180 seconds The d...

Page 72: ...Service program 72 Instruction manual GWV 12 is ...

Page 73: ... See the figures The first shows a possible error the second shows the appropriate checking action There are various types of errors all falling into one of two groups LOCK OUT ERRORS When the cause has been removed these errors must be reset with the button before the appliance can resume operation BLOCKING ERRORS These errors disappear automatically when the cause of the error is removed after w...

Page 74: ... 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 I 4 Check whether there is power to the electrical connector block 5 The measured voltage must be 230 VAC 15 10 See the GWV electrical diagram 17 Appendices If the error persists consult your installation engineer Defective fuse s Replace ...

Page 75: ...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 I 4 Check whether there is power to the electrical connector block 5 The measured voltage must be 230 VAC 15 10 See the GWV electrical diagram 17 Appendices If the error persists consult your installation engineer Hot water supply is used u...

Page 76: ...nect the sensor lead to JP5 See the GWV electrical diagram 17 Appendices Damaged cable or defective sensor Replace sensor T2 1 To replace the necessary parts you must contact your installation engineer S04 blocking error Open circuit in dummy 1 Dummy is not correctly connected Connect the dummy sensor dummy sensor 1 and 2 leads to JP4 See the GWV electrical diagram 17 Appendices Defective dummy Re...

Page 77: ...re sensor T2 outlet of heat exchanger Short circuit in sensor circuit Replace sensor T2 1 To replace the necessary parts you must contact your installation engineer S14 blocking error Short circuit from dummy 1 Short circuit in sensor circuit Replace the dummy sensor 2 To replace the necessary parts you must contact your installation engineer S15 blocking error Short circuit from dummy 2 Short cir...

Page 78: ...ition attempts will have caused the condensation to evaporate If the error persists contact your installation engineer F02 lock out error Fan fails to run at correct speed Damaged wiring 1 Check the wiring between the fan and the controller 2 If any wires are damaged the wiring harness must be replaced 3 Reset appliance controller See the GWV electrical diagram 17 Appendices To have the wiring rep...

Page 79: ...the running speed of the fan 12 5 Displaying the appliance selection 2 Check that the hoses are fitted correctly to the pressure switch and the ventilator s air supply hose Refit them if necessary 3 Check for cracks in the hoses on the pressure switch and in the air supply hose for the fan If necessary replace the hoses 4 Check that the flue gas outlet is compliant 3 9 Air supply and flue 5 Measur...

Page 80: ... 2 Check the wiring of the hot surface igniter 3 Measure the resistance across the hot surface igniter This must lie between 2 and 5 ohms 4 Check that the hot surface igniter lights up during ignition 5 If necessary replace the hot surface igniter If the error persists contact your installation engineer To replace the necessary parts you must contact your installation engineer Defect in the ionisa...

Page 81: ... 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 1 Reset electronic controller 2 If the error appears again replace the electronic controller 3 If this is the case the gas contr...

Page 82: ...al is acceptable check that the pressure switch is closing using a multimeter 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 F16 lock out error Flow switch does not close Component is not correctly conn...

Page 83: ... appliance controller EEPROM read error 50 Hz error Internal communication error Internal error message from the appliance controller Gas valve relay error Safety relay error Ignition relay error RAM error EEPROM error EEPROM contents do not match the software version Processor software error C04 blocking error Appliance selection error Incorrect appliance selection Incorrect selection resistor 1 ...

Page 84: ...nd dummy 2 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 E05 lock out error Controller too long in a blocking error The controller has been in a blocking error for at least 20 hours 1 Resolve the blocking error and press RESET to remove the lock out error To resolve the blocki...

Page 85: ...tent contact your installation engineer To replace the necessary parts you must contact your installation engineer The display shows the text WARNING TEMPERATURE DIFFERENCE HEAT EXCHANGER TOO LARGE see note 1 Defective pump Check that the pump is working correctly To replace the necessary parts you must contact your installation engineer Blocked or bunged up pipe system 1 Replace blocked or distor...

Page 86: ...Troubleshooting 86 Instruction manual GWV 13 gis ...

Page 87: ...et to 500 1000 or 1500 burning hours The standard setting is 500 burning hours Example In the first three months the appliance has burned for 300 hours During maintenance it is evident that one service per year will be 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 an...

Page 88: ...Maintenance frequency 88 Instruction manual GWV 14 is ...

Page 89: ...ce 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 15 2 Preparation for maintenance To test whether all components are still working properly complete the following steps 1 Activate the MENU with 2 Use and to position the cursor in front of OFF 3 Confi...

Page 90: ...ove the sheeting from the front of the appliance 12 Check the supply and burner pressures 3 11 Checking the supply pressure and burner pressure and adjust these where necessary 13 Check that all components of the flue gas 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 flue gas o...

Page 91: ...e 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 spec...

Page 92: ... on the burner s 3 Fit the burner s 15 4 3 Clean the injector s 1 Dismantle the injector s 2 Remove all contamination present in the injector s 3 Fit the injector s then the manifold and then the flexible gas hose 15 4 4 Cleaning the aluminium strips 1 Dismantle the flue gas outlet 2 Use a vacuum cleaner to clean the aluminium strips 15 5 Finalizing mainte nance To finalize the maintenance carry o...

Page 93: ... under the following conditions a The appliance is installed under strict adherence to the installation instructions of A O Smith for the specific model and the relevant local authority installation and building codes rules and regulations in force b The appliance remains installed at the original site of installation c The appliance is exclusively used with drinking water which at all times can f...

Page 94: ...ty provided do not extend beyond delivery free of charge from the warehouse of the parts or components or appliance to be replaced transport labour installation and other costs associated with the replacement will not be borne by A O Smith 16 6 Claims A claim on grounds of the specified warranty must be submitted to the dealer from whom the appliance was purchased or to another authorised dealer f...

Page 95: ...Instruction manual GWV 95 is 17 Appendices 17 1 Introduction This appendix contains Electrical diagram 17 2 Electrical diagram Week program card ...

Page 96: ...29 J34 JP5 JP4 JP3 J21 J19 J20 J33 X JP2 F1 F3 J38 X X X X X JP11 X X J2 X F 3 1 2 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 5 5 2 2 2 2 2 2 2 2 6 6 3 3 3 3 7 4 4 4 4 8 3 3 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4 3 6 5 7 7 6 6 5 5 5 U T S R V W X 18 17 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 2 2 2 2 2 2 1 1 1 1 6 4 5 7 1 G C B 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 1 1 2 1 1 3 4 4 4 4 4 4 4 4 4 4 4 4 4 ...

Page 97: ...rature sensor T3 Tank U Temperature sensor T2 heat exchanger outlet V Selection resistor W Air pressure switch X Flow through switch CONTROLLER CONNECTIONS J2 Connection for controller power J19 Connection for system pump and alarm signal J20 Connection for gas controls J21 Program controlled pump connection J29 n a J33 Fan connection J36 Connection of display to controller JP2 Flame probe and hot...

Page 98: ...Appendices 98 Instruction manual GWV 17 is ...

Page 99: ... OFF OFF 5 ON C ON OFF OFF 6 ON C ON OFF OFF 7 ON C ON OFF OFF 8 ON C ON OFF OFF 9 ON C ON OFF OFF 10 ON C ON OFF OFF 11 ON C ON OFF OFF Period DAY TIME Tset Pump 1 ON MO 14 30 70 C ON OFF OFF MO 16 15 Period DAY TIME Tset Pump 12 ON C ON OFF OFF 13 ON C ON OFF OFF 14 ON C ON OFF OFF 15 ON C ON OFF OFF 16 ON C ON OFF OFF 17 ON C ON OFF OFF 18 ON C ON OFF OFF 19 ON C ON OFF OFF 20 ON C ON OFF OFF 2...

Page 100: ...Instruction manual GWV 100 ...

Page 101: ... 41 general specifications 3 H heating cycle 15 humidity 20 I icons pre glow 51 explanation 51 flame detection 51 gas control 51 heat demand 51 installation diagram 25 43 47 installation engineer 10 L language setting 67 liability 3 M maintenance finalising 92 gas side 92 perform 89 mode ERROR 54 SERVICE REQUIRED 54 N navigation buttons 51 O ON mode 61 P packaging 19 PC connection 52 protection 16...

Page 102: ...0307 971 4 0 UK Index Instruction manual GWV ...

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