A.O. Smith SGE - 40 Installation, User And Service Manual Download

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Instruction manual SGE

109

TERMINAL STRIP CONNECTIONS

COMPONENTS

CONTROLLER CONNECTIONS

Earth

Neutral

Live input of controller

Live input of isolating transformer (primary
side)

Live output of isolating transformer
(secondary side)

Live input of program-controlled pump

Control

Flame probe

Hot surface igniter

Gas control valve

Burner earth connection

Extra ON mode switch

Program-controlled pump (max. 100W)

Extra error signal connection

Isolating transformer

Double-pole isolator

Controller 0/I switch

Display

Fan

Temperature sensor (T

- bottom of tank)

Dummy

Temperature sensor (T

- top of tank)

Selection resistor

Push button

Electrical anodes

Signalling for electrical anodes

Potentiostat

Communication between the appliance
controller and the solar system (BUS
connection)

Solar system controller

Power connection for controller

J19

Extra error signal connection

J20

Gas control valve connection

J21

Program-controlled pump connection

J29

Power connection for the fan

J36

Controller display connection

J40

Regulator connection for the fan

JP2

Flame probe and hot surface igniter
connection

JP3

Temperature sensor T

connection

JP4

Dummy connection

JP5

Temperature sensor T

connection

JP6

Selection resistor and pressure switch
connection

JP8

Extra ON mode switch connection

Fuse (T 3.15A - 250 V)

Summary of Contents for SGE - 40

Page 1: ...0311 166 07 2013 Innovation has a name Installation User and Service Manual Condensing Gas Solar Water Heater SGE 40 60 SGE ...

Page 2: ...your installer A O Smith UK Unit B8 Amstrong Mall Southwood Business Park Farnborough Hampshire GU14 0NR www aosmith co uk A O Smith Water Heaters is a trading name of Advance Services Sales Ltd Reg ...

Page 3: ...licable not applicable not applicable Power 5V Sensor S 4 Flow signal not applicable not applicable BUS link BUS link J13 J14 J3 J12 J15 J16 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 15 6 Finalizing maintenance To finalize the maintenance carry out the following steps 1 Fill the water heater 5 Filling 2 Start the water heater 9 Starting the water heater 3 Check the CO2 value 3 12 3 CO2 adjustment 4 ...

Page 4: ...E2 17 3 Electrical diagram Electrical diagram solar heating system 1 brown 2 blue 3 yellow green 4 black 5 white 6 grey beige 7 green 8 yellow ...

Page 5: ...ture sensor S1 solar collector DD Temperature sensor S2 tank EE Combined Q T sensor incl temperature sensor S4 solar collector return FF Communication between the water heater controller and the solar Heating system controller BUS link K Double pole isolator CONTROLLER CONNECTIONS J12 Connection of combined Q T sensor 1 2 3 4 J13 Connection of temperature sensor S1 2 4 J14 Connection of temperatur...

Page 6: ...an that stated in this manual and use other than in accordance with the General Conditions registered at the Chamber of Commerce Refer further to the General Conditions These are available on request free of charge Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components the manual may nonetheless contain errors and inaccuracie...

Page 7: ...4 Instruction manual SGE gis ...

Page 8: ...9 3 2 Packaging 19 3 3 Ambient conditions 19 3 4 Technical specifications 21 3 5 Installation diagram 25 3 6 Unvented water connections 26 3 7 Vented water connections 27 3 8 Gas connection 28 3 9 Solar heating system 28 3 10 Air supply and chimney flue discharge 29 3 11 Electrically connecting the water heater 34 3 12 Electrical connection of the solar heating system 38 3 13 Check the supply pres...

Page 9: ...Decommissioning the water heater for a long period 65 11 Main menu 67 11 1 Introduction 67 11 2 Notation convention for menu related instructions 67 11 3 Switching to ON mode 67 11 4 Setting the water temperature 67 11 5 Week program 68 11 6 Starting and stopping the week program 68 11 7 Changing the appliance s standard week program 68 11 8 Adding times to a week program 70 11 9 Deleting times fr...

Page 10: ...enance 100 15 4 Gas side maintenance 101 15 5 Solar collector maintenance 102 15 6 Finalizing maintenance 102 16 Warranty certificate 103 16 1 General warranty 103 16 2 Tank warranty 103 16 3 Collector warranty 103 16 4 Conditions for Installation and use 103 16 5 Exclusions 104 16 6 Scope of the warranty 104 16 7 Claims 104 16 8 Obligations of A O Smith 104 17 Appendices 105 17 1 Introduction 105...

Page 11: ...Contents 8 Instruction manual SGE ...

Page 12: ...lure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater 1 2 What to do if you smell gas Warning If you smell gas 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 buildi...

Page 13: ...es of rated input not exceeding 70 kW BS 5440 Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net 1st 2nd and 3rd family gases Part 1 Specification for installation of gas appliances to chimneys and for maintenance of chimneys Part 2 Specification for installation and maintenance of ventilation for gas appliances Institute of Gas Engineers and Managers IGEM Publicatio...

Page 14: ...he correct service interval it is recommended to arrange for the service and maintenance engineer to check the water heater on both the water and gas side within three months following installation Based on this check the best service interval can be determined Note Regular maintenance extends the service life of the water heater Both the end user and the service and maintenance engineer are respo...

Page 15: ...n menu This chapter describes the main menu of the display This is the actual menu for the user However the installation engineer and service and maintenance engineers will also need to use this menu Service program 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 additiona...

Page 16: ... system and a gas fired heat exchanger 11 The heated tap water leaves the tank through the hot water outlet 2 Once the water heater is completely filled with water it will constantly be under mains water pressure As hot water is drawn from the water heater cold water is immediately added The special design of the heat exchanger 11 ensures that the flue gases are first led downwards via the combust...

Page 17: ...OINT MENU As soon as T1 falls below Tset the solar heating system starts heating the water but only if the temperature of the heating fluid S1 is greater than the temperature measured at the appliance sensor S2 by a given adjustable amount When T1 Tset Tsolar limit heating by the solar heating system stops There is one exception to this rule which is when Tsolar limit is set to a higher value than...

Page 18: ...However this is only possible if Tsolar limit is increased via the service menu 2 4 Protection for the water heater 2 4 1 Introduction The controller monitors the water temperature helps ensure the safe use of the solar heating system and ensures safe combustion This takes place using the Water heater water temperature protection the Gas control valve the Fan the Pressure switch the Flame probe 2 ...

Page 19: ...ation detection The controller closes the gas control valve the instant it detects that there is a gas flow but no flame 2 5 Safety of the installation Excessive pressure in the tank can damage the enamelled layer in the water heater or the tank itself An inlet combination and pressure reducing valve prevents this The inlet combination acts as a stop valve non return valve and overflow valve If th...

Page 20: ...wever A O Smith also recommends the use of a T P valve in vented installations A T P Temperature and Pressure Relief valve monitors the pressure in the tank and the water temperature at the top of the tank If the pressure in the tank becomes too high 3 4 2 General and electrical specifications the valve will open The hot water can now flow out of the tank Because the water heater is under water su...

Page 21: ...ith an expansion valve The expansion valve monitors the pressure in the solar heating system Should the pressure become higher than 600 kPa 6 bar the valve will open The hot water can now flow out of the installation The valve remains open until the unsafe situation has passed i e until the pressure has fallen back to below 600 kPa 6 bar Note Because a closed system is pressurized and is not fille...

Page 22: ...on to a different gas category 3 2 Packaging To avoid damaging the water heater remove the packaging carefully We recommend unpacking the water heater at or near its intended location Caution The water heater may only be manoeuvred in an upright position Take care that the water heater is not damaged after unpacking 3 3 Ambient conditions The water heater is suitable for either open or room sealed...

Page 23: ...s governing drinking water for human consumption The table gives an overview of the specifications Water specifications Note If the water specifications deviate from those stated in the table then the tank protection cannot be guaranteed 16 Warranty certificate 3 3 4 Working clearances For access to the water heater it is recommended that the following clearances are observed see figure AA around ...

Page 24: ...ications gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan to use 3 4 1 Dimensions of the water heater Plan and elevation of the water heater IMD 0767 R0 AA AA B B Legend See the table IMD 0772 R0 3 5 5 P M 6 11 1 4 R Z S K N A 4 D G 2 2 3 6 H U T W Y V X F Hy C E Ny 45º 45º 44º 7 10 9 13 14 12 Hx ...

Page 25: ...et mm 630 630 U Height of coil outlet mm 305 305 V Height of recirculation connection mm 1035 1035 W Height of condensation drain mm 765 765 X Height of heat exchanger supply mm 1465 1465 Y Height of heat exchanger discharge mm 855 855 Z Height of electric element connection mm 755 755 1 Cold water supply connection external R 11 2 R 11 2 2 Hot water outlet male R 11 2 R 11 2 3 Gas control valve c...

Page 26: ...Adjustment range for solar limit C 65 80 65 80 Solar limit default value C 65 65 Number of electrical anodes 2 2 Observed pressure differential across the pressure switch Pa 165 165 Pressure differential to open the pressure switch Pa 115 115 Heating time ΔT 45 C at least 15 11 Description Unit SGE 40 SGE 60 Electrical power consumption of the appliance W 60 120 Electrical power consumption of the...

Page 27: ...kW 42 8 60 4 Supply pressure mbar 20 20 CO2 full load Vol 9 0 1 0 9 0 1 0 Gas consumption m3 h 4 2 6 0 Gas category 3P G31 37 50 mbar Venturi injector diameter mm 6 00 6 00 Nominal load gross kW 43 5 62 0 Nominal output kW 42 8 60 4 Supply pressure mbar 37 50 37 50 Gas control valve pressure mbar 12 0 2 0 12 0 2 0 CO2 full load Vol 10 0 1 0 10 0 1 0 Gas consumption kg h 3 1 4 4 Based on 1013 25 mb...

Page 28: ...ture gauge recommended 13 condensation drain mandatory 14 draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 cold water head tank 19 float switch 23 pressure valve mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating mandatory A cold water supply B hot water supply C circulation pipe D gas supply E ...

Page 29: ...rflow side to an open waste water pipe 3 6 2 Hot water side See B in the installation diagram 3 5 Installation diagram Note Insulating long hot water pipes prevents unnecessary energy loss 1 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 2 Fit the T P valve 3 3 Fit a stop valve 11 in the hot water outlet pipe for servicing 3 6 3 Circulation pipe See C in the ...

Page 30: ... a circulation pipe is required continue by installing the circulation pipe 3 6 3 Circulation pipe 3 7 3 Circulation pipe See C in the installation diagram 3 5 Installation diagram If an immediate flow of hot water is required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fit a circulation pump 6 of the correct capacity for the length and ...

Page 31: ...rminal block 3 12 1 Preparation for details of how to connect the solar heating system 1 Connect the supply from the solar collector to the inlet F of the heat exchanger 2 Connect the return pipe to the solar collector to the outlet G of the heat exchanger 3 Connect the lead to the solar heating system controller and sensor S2 see electrical diagram 17 4 Electrical diagram solar heating system and...

Page 32: ... applicable regulations 1 3 Regulations Depending on the approved installation types there are several alternatives for connecting the air supply and chimney flue The water heaters are approved for installations of type B23 C13 C33 C43 C53 and C63 This manual discusses installation types C13 and C33 in detail If the water heater has to function in accordance with B23 C43 C53 or C63 you can obtain ...

Page 33: ...Installation 30 Instruction manual SGE 3 is Installation types IMD 0789 R0 C43 C13 C53 B23 C33 ...

Page 34: ...rates how to use the table Practical example of concentric flue gas discharge Example The figure shows a SGE 60 installation The water heater must be fitted with 10 m of concentric pipe C13 C33 and four 90 degree bends The configuration must be checked for compliance with the requirements stated in the table Installation type Description B23 Air for combustion is drawn from the boiler room C13 Con...

Page 35: ...nal can cause the installation to malfunction Concentric wall flue terminal specifications C13 IMD 0791 R0 Subject Description Wall flue terminal set 1x wall flue terminal incl wall flange clamping ring 1x pipe 500 mm 1x bend 90 Art No 0302 504 1 Construction Concentric Manufacturer Muelink Grol Model M2000 MDV SEC Pipe material Construction Concentric Flue gas discharge Thick walled aluminium wit...

Page 36: ... four 90 degree bends The configuration must be checked for compliance with the requirements stated in the table Subject Description Roof flue terminal set 1x roof flue terminal incl clamping ring 1x pipe 1000 mm 1x mounting flange Art No 0304 423 1 Construction Concentric Manufacturer Muelink Grol Model M2000 DDV HR C Pipe material Construction Concentric Flue gas discharge Thick walled aluminium...

Page 37: ...Electrically connecting the water heater Warning The installation should be carried out by a competent person in compliance with general and locally applicable regulations 1 3 Regulations 3 11 1 Introduction This section covers the following topics Preparation Connecting the mains power Optionally it is possible to connect an isolating transformer a program controlled pump a pump between the stora...

Page 38: ...isolating transformer please contact A O Smith Water Products Company The figure shows a view of the terminal block and the table explains the relevant connections Connector block In preparation you must first remove the two covers and the cover of the electrical section 1 Undo the screws of the covers 2 Carefully remove the covers from the water heater The electrical section is now visible 3 Loos...

Page 39: ...4 If you have no more connections to make Fit the cover on the terminal block Fit the covers onto the water heater 3 11 4 Isolating transformer An isolating transformer should be used if there is a case of floating neutral Note The total power consumed by the appliance goes via the isolating transformer 1 Refer to the fitting instructions provided with the isolating transformer Contact the supplie...

Page 40: ...cover on the terminal block Fit the covers onto the water heater 3 11 7 Connect additional error signal The appliance has a terminal that is switched when an error is detected This can be used to signal errors for example with a bulb A 230V circuit can be powered directly Other voltages require a relay prescribed by the manufacturer 1 Connect the phase cables X1 and X2 to points 10 and 11 accordin...

Page 41: ... installed between the mains power supply and the water heater itself Whenever this isolator is operated both controllers can be switched on or off 1 Connect earth live and neutral to terminals 1 through 3 2 Fit the cables in the strain relief 3 Connect the power cable to the isolator 4 Continue 3 12 3 Connecting pump station modulating pump 3 12 3 Connecting pump station modulating pump The pump ...

Page 42: ...inals 2 and 4 of J14 3 Fit the cables in the strain relief 4 Continue 3 12 6 Connecting communication cable 3 12 6 Connecting communication cable Note The communication cable must always be connected otherwise neither the appliance nor the solar heating system controller will run 1 Connect the double connector to J16 2 Fit the cable in the strain relief 3 Connect the other end of the communication...

Page 43: ... you have no more connections to make Fit the covers over the controller 3 13 Check the supply pressure gas control valve pressure CO2 value and switching pressure Note Before starting to use the appliance and or checking the supply pressure and or the CO2 value and or the switching pressure you should first fill 5 Filling the appliance Caution When starting up for the first time or after conversi...

Page 44: ...ng the 0 I switch to position I The display will now show INTERNAL CHECK for about 10 seconds and will then go to the main menu 9 Select SERVICE OPERATION FULL LOAD from the service menu 10 Confirm with The display shown here will appear The appliance is now in Full load mode and will ignite 11 You must wait about 1 minute after the display shows the text RUNNING before reading the dynamic pressur...

Page 45: ...ng valve If the appliance does not have a reducing valve continue from adjusting the CO2 value 3 13 3 CO2 adjustment To check the gas control valve pressure proceed as follows 1 Isolate 10 3 Isolating the water heater from the mains the appliance from the power supply 2 Carefully remove the covers from the appliance 3 The electrical section is now visible 4 The gas control valve has a test nipple ...

Page 46: ...rol valve pressure adjustment 3 13 3 CO2 adjustment To check the CO2 value under full load and partial load and to adjust it if necessary proceed as follows 1 Isolate 10 3 Isolating the water heater from the mains the appliance from the power supply 2 Carefully remove the covers from the appliance 3 The electrical section is now visible 4 Place the CO2 meter s measurement probe in the test nipple ...

Page 47: ...l of the CO2 value stated in the table 3 4 3 Gas data 13 If necessary adjust the CO2 value using the adjuster screw until the value is within the range listed in the table of CO2 values Use the Allen key supplied for this The key can be found in the plastic bag that is attached to the appliance CO2 adjustment full load Note Turning to the left anticlockwise means more gas higher CO2 level and turn...

Page 48: ...under full load 19 If necessary adjust the CO2 value using the adjuster screw until the value is within 0 3 vol of the CO2 value under full load Then compare the measured CO2 value against the value from the table 3 4 3 Gas data CO2 adjustment partial load Note Turning to the left anticlockwise means more less lower CO2 level and turning to the right clockwise means more gas higher CO2 level Note ...

Page 49: ...oint of the pressure switch 7 Zero the pressure gauge 8 Start 9 Starting the water heater the appliance 9 The appliance will now run the heating cycle 9 3 The appliance s heating cycle 10 Read the pressure from the meter at the moment when the appliance switches from PRE PURGE to PRESSURE SWITCH At this point the appliance s display will show 11 Check whether the measured value matches the value f...

Page 50: ...cial conversion kit You can order the conversion kit you need from the supplier of your appliance The conversion kit contains all the parts needed to do the conversion A description of how to do the conversion is also delivered with the kit The following conversions are possible 1 Conversion from natural gas to LPG 2 Conversion from LPG to natural gas 3 Conversion from natural gas to natural gas o...

Page 51: ...Conversion to a different gas category 48 Instruction manual SGE 4 is ...

Page 52: ...ts 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 cold water head tank 19 float switch 23 pressure valve mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating mandatory A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe F supply heat exchanger G heat exchanger return H overflo...

Page 53: ...rom the nearest draw off point the water heater is full 6 Bleed the entire installation of air for example by opening all draw off points 7 The water heater is now under water supply pressure There should now be no water coming out of the inlet combination expansion valve or out of the T P valve 3 If there is the cause might be The water supply pressure is greater than the specified 8 bar Rectify ...

Page 54: ... Flushing with water 1 Connect a water supply to the filling point of the pump station 2 Connect a drain hose to the drain point 3 Open the taps of both supply and drain point 4 Open the water supply tap 5 Allow the system to spool through until no further contamination comes out of the drain hose 6 Then shut off the water supply 7 Drain all remaining water from the system 8 Now you can fill the s...

Page 55: ...12 10 2 Switching on the solar pump to switch the pump on Note To ensure that the solar heating system is properly filled the pump in the solar heating system can be switched on for 2 minutes using the service menu 11 Repeat steps 6 through 9 until glycol runs out of the air bleed 26 Note If an installation does not have a drain back system then it should be filled up to pressure 1 5 bar If an ins...

Page 56: ...ts 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 cold water head tank 19 float switch 23 pressure valve mandatory 37 combined Q T sensor optional 38 solar heating system pump station modulating mandatory A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe F supply heat exchanger G heat exchanger return H overflo...

Page 57: ...or between the water heater and the mains power supply to position 0 7 Shut off the gas supply 10 8 Close the stop valve 11 in the hot water pipe 9 Close the supply valve 4 in the cold water inlet A 10 Open the drain valve 9 6 2 Draining vented installations Some service activities require the water heater to be drained The procedure is as follows 1 Activate the MENU with 2 Position the cursor in ...

Page 58: ...es can be extremely hot You should therefore wait until the water heater has cooled down sufficiently 5 Switch off the solar heating system 6 Connect a hose to the lowest drain point in the solar heating system 7 Insert the hose into the glycol jerry can 8 Open the valve of the lowest drain point 9 Open the air bleed point 26 of the solar heating system 10 Close the drain point when the jerry can ...

Page 59: ...Draining 56 Instruction manual SGE 6 gis ...

Page 60: ...7 3 Explanation of icons The table explains the meanings of the icons Icons and their meaning 7 4 ON OFF switch on controller The ON OFF switch of the controller turns the water heater ON and OFF Note that in the OFF position the water heater remains electrically live in order for the continuous pump to stay running After switching on the text INTERNAL CHECK appears on the display for about 10 sec...

Page 61: ...in menu The main menu comprises OFF ON WEEK PROGRAM EXTRA PERIOD and SETTINGS You have to scroll down further to see the options EXTRA PERIOD and SETTINGS The selected option is confirmed using Pressing the button takes you back one page in a menu and discards all options selected in the current menu Note The button is also used to reset the water heater following an error 7 6 PC connection The PC...

Page 62: ...one the text ON line two the time the day and T1 9 3 The appliance s heating cycle line three the programmed water temperature Tset line four is empty when the water heater is idle or depending on the operating cycle 9 3 The appliance s heating cycle displays a text such as HEAT DEMAND 8 2 3 EXTRA In this mode one extra period is programmed and activated In this mode the OFF orPROG mode is tempora...

Page 63: ...de comprising a letter and two digits followed by the error description lines two to four alternately a brief explanation of the error and a brief action to resolve the error Caution The displayed action to resolve the error may only be performed by a service and maintenance engineer There are various types of errors LOCK OUT ERRORS When the cause has been removed these errors require a reset with...

Page 64: ...s not been connected properly but has been selected in the service programme 12 10 5 Setting the Q T sensor If the message appears you must contact your service and maintenance engineer 8 7 Collector temperature warning This message appears whenever the collector temperature is too high This message disappears automatically If the message does not disappear you must contact your service and mainte...

Page 65: ...Status of the water heater 62 Instruction manual SGE 8 gis ...

Page 66: ...pliance is now in ON mode If there is a heat demand the appliance will run through the heating cycle 9 3 The appliance s heating cycle If the heating cycle is not run there is no heat demand if this is the case Tset will probably need to be set 11 4 Setting the water temperature 9 3 The appliance s heating cycle The appliance s heating cycle is activated when the measured water temperature T1 fall...

Page 67: ... takes place The icon is activated The message IGNITION appears 6 After ignition the flame is detected and the appliance will be running This means that actual heating has started The icon is dimmed The icon is activated The message RUNNING appears 7 When the water is up to temperature the heat demand ceases and the post purge starts This takes about 25 seconds The icons and are dimmed The icon is...

Page 68: ...ng the water heater from the mains The water heater may only be isolated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 2 Position the cursor in front of OFF 3 Confirm OFF with Caution Failure to wait until the fan stops can cause damage to the water heater 4 Wait until the fan has stopped The icon is then dimmed 5 Switch the water heater OFF posit...

Page 69: ...Shutting down 66 Instruction manual SGE 10 gis ...

Page 70: ... fail to make any selection with the main menu open then after 30 seconds the water heater will automatically return to the mode it was previously in 11 2 Notation convention for menu related instructions The MENU of the controller is divided into sub menus For example SETTINGS is one of the functions reached from the main menu The menu SETTINGS is itself divided into sub menus For example LANGUAG...

Page 71: ...The appliance s heating cycle and return to the week program The following topics are covered here Starting and stopping the week program Changing the appliance s standard week program Adding times to a week program Deleting times from a week program 11 6 Starting and stopping the week program The week program can be started up from any other operating mode as follows 1 WEEK PROGRAM START OPERATIO...

Page 72: ... the minute digits which will blink Note Because the switch off time can never be earlier than the switch on time the switch off time setting is automatically adjusted with the switch on time 4 Use and to set the minutes In the example this is 15 Confirm with The cursor moves to the switch off hour digits which will blink 11 7 2 Week program setting the switch off time 1 Use and to set the hours I...

Page 73: ...rm with 11 8 Adding times to a week program Call up the menu to INSERT switch on and switch off times into a week program as follows 1 WEEK PROGRAM PROGRAM OVERVIEW Confirm with The display shows the menu for the week program The cursor points to the active period 2 Scroll to INSERT Confirm with The submenu for adding a period will appear Example As an example we will program an extra period in wh...

Page 74: ... OVERVIEW Confirm with The display shows the menu for the week program 3 Scroll with to DELETE Confirm with To warn you that you are now working in the delete sub menu the cursor is replaced with an exclamation mark and the period settings will blink 4 Scroll with to the day to be deleted For example SU Sunday in the second period See the figure Confirm with 5 The lines showing switch on off times...

Page 75: ...via 2 EXTRA PERIOD Confirm with The display show the settings for the extra period Setting the switch on time 1 Use and to set the day In the example this is SU Confirm with The cursor moves to the hour digits which will blink 2 Use and to set the switch on hour to the desired value In the example this is 08 Confirm with The cursor moves to the minute digits which will blink Note Because the switc...

Page 76: ...ttings Using the option SETTINGS you can adjust certain settings and display certain water heater specifications Adjustable settings Menu language Current day of week and time Displayable water heater specifications this category is only relevant to the installation engineer and or service and maintenance engineer Regulation interval water temperature Ignition speed of fan Working speed of fan 11 ...

Page 77: ...ith The time has been set Note The water heater takes no account of daylight saving 11 11 3 Displaying water heater specifications Note This category is solely intended for the installation engineer and or service and maintenance engineer Call up the menu to display the water heater specifications as follows 1 SETTINGS Confirm with 2 Scroll with to SPECIFICATIONS Confirm with The display shows the...

Page 78: ...s follows HYSTERESIS DOWN Please refer to the table 3 4 2 General and electrical specifications for the regulation interval and settings for each water heater 12 3 Displaying the error history Display the error history as follows ERROR HISTORY The controller will display an overview of Blocking errors and Lock out errors In both cases note that the controller reserves 15 lines for the last 15 erro...

Page 79: ...ture of the controller to help the service and maintenance engineer set the frequency of maintenance 14 2 Determining service interval The service interval is determined by the number of months that the appliance has been running This can be set to 6 9 and 12 months The default service interval is 12 months When the preset number of hours has been reached an appropriate message 8 4 Service conditi...

Page 80: ...legionella prevention on or off select ANTI LEGIONELLA Select NO to switch legionella prevention off Select YES to switch legionella prevention on The following screen appears Select START to activate the period currently displayed The following display appears This display indicates that legionella prevention is switched on 12 9 2 Changing legionella prevention start time If you wish to change th...

Page 81: ...at the water further once the set point has been reached However this only makes sense if the solar heating system is actually generating heat This makes use of the difference between the temperature at the top of the solar collector S1 and that in the appliance measured by S2 Call up the menu for the solar limit as follows SETTINGS SOLAR SOLAR LIMIT Please refer to the table 3 4 2 General and ele...

Page 82: ... menu as follows SETTINGS SOLAR CONTRIBUTION 12 10 7 Displaying temperatures This option lets you read what the solar heating system s sensors are recording Two values are reported on the display S1 temperature in the collector S2 temperature between the inlet and outlet of the heat exchanger in the tank Call up this menu as follows SETTINGS SOLAR TEMPERATURES 12 11 Setting the central heating con...

Page 83: ...Instruction manual SGE 80 is ...

Page 84: ...ecommended action 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 require a reset with the button before the water heater can resume operation BLOCKING ERRORS These errors disappear automatically once the cause of the er...

Page 85: ...ation engineer or local gas company The display is off The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check that there is power to the isolator 3 Check whether the ON OFF switch of the controller is ON position I 4 Check whether there is power to the electrical connector block 5 The measured voltage must be ...

Page 86: ...ing the burner Insufficient or no hot water The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check that there is power to the isolator 3 Check whether the ON OFF switch of the controller is ON position I 4 Check whether there is power to the electrical connector block 5 The measured voltage must be 230 VAC 15 ...

Page 87: ...ed connection If the leak persists or a component needs replacement consult your installation engineer Leakage from a component 1 Tighten component joints 2 Any defective components must be replaced Leakage from solar heating system Consult the supplier and or manufacturer Indication Cause Measure Remark ...

Page 88: ...ou must contact your installation engineer S03 blocking error Open circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5 See the electrical diagram 17 Appendices Damaged cable and or defective sensor Replace the cable and or sensor To replace the necessary parts you must contact your installation engineer S04 blocking...

Page 89: ...contact your installation engineer S11 blocking error Short circuit in temperature sensor T2 at the bottom of the tank Short circuit in sensor circuit Replace the cable and or sensor To replace the necessary parts you must contact your installation engineer S12 blocking error Short circuit in sensor 1 of temperature sensor T1 at top of tank 1 Short circuit in sensor circuit Replace the cable and o...

Page 90: ...11 Electrically connecting the water heater the water heater is phase sensitive See the electrical diagram 17 Appendices Condensation on the flame probe 1 Disconnect the lead at the flame probe 2 Ignite the water heater three times with an interrupted ionisation circuit 3 Reconnect the ionisation lead to the flame probe 4 Ignite the water heater again 5 The repeated ignition attempts will have cau...

Page 91: ...cked fan 1 Check if the fan is dirty and repair it if necessary 2 Check that the rotor can rotate freely 3 Reset controller If the error cannot be resolved or is persistent contact your installation engineer Because of a drop in the supply voltage the fan will not run at the correct speed 1 Check the supply voltage this must be 230 VAC 15 10 2 Reset controller Code description Cause Measure Remark...

Page 92: ...correctly fitted Refit them if necessary 3 Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner If necessary replace the hoses 4 Check whether the chimney flue is compliant 3 10 Air supply and chimney flue discharge 5 Check for blockage in the chimney flue Remove any blockage that may be present 6 Check for blockage in the condensation water discha...

Page 93: ... Measure the resistance across the hot surface igniter This must lie between 2 and 10 Ohm at room temperature 4 Check that the hot surface igniter lights up during ignition 5 If necessary replace the hot surface igniter If the error persists contact your installation engineer To replace the necessary parts you must contact your installation engineer Defect in the ionisation circuit 1 Check that th...

Page 94: ...e from safety relay Flame detection before the gas control valve opened 1 Reset controller 2 If the error appears again replace the controller If the error cannot be resolved or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F09 lock out error Water temperature protection Temperature at the top of the tank exceeds 93o C 1...

Page 95: ...n engineer 3 If the frequency is correct but the error persists replace the controller To replace the necessary parts you must contact your installation engineer Internal error message from the controller EEPROM read error 50 Hz error Internal communication error Internal error message from the controller Gas valve relay error Safety relay error Ignition relay error RAM error EEPROM error EEPROM c...

Page 96: ...ontact your installation engineer E01 blocking error The temperature protection at the top of the tank has been activated The temperature of the water at the top of the tank is 88o C None This is a temporary message that may appear from time to time but will disappear automatically E03 lock out error Error in temperature sensor T1 at the top of the tank The two temperature sensors in the tank dete...

Page 97: ...gs on the display Situation Cause Measure Note Maximum burning hours Servicing required The actual burning hours have exceeded the preset burning hours Appliance runs but displays a warning For maintenance to your appliance please contact your installation engineer ...

Page 98: ... warning remains replace pump or sensor To replace the necessary parts you must contact your installation engineer Collector temperature too high Temperature S1 is greater than Tcollector max Non drainback systems The solar systems pump runs at full power for 10 minutes pumping the fluid in the solar system round If Tcol Tcollector max after this has elapsed the pump will stop running for 30 minut...

Page 99: ...is Instruction manual SGE 96 ...

Page 100: ...ntenance engineer to check the water heater on both the water and gas side three months after installation Based on this check the best service interval can be determined 14 2 Determining service interval The service interval is a feature of the controller to help the service and maintenance engineer set the maintenance frequency based on the number of months that the appliance has been running Th...

Page 101: ...Service interval 98 Instruction manual SGE 14 is ...

Page 102: ...tant to write down the installation type water heater model and the full serial number of the water heater 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 t...

Page 103: ... and switching pressure and adjust them where necessary 13 Check that all components of the chimney flue system are properly attached 14 Check the pressure differential across the pressure switch 3 13 4 Switching pressure measurement and if this is too low the heat exchanger should be cleaned 15 4 3 Clean heat exchanger 15 Test the operation of the overflow valve of the protected cold supply setup...

Page 104: ...e the figure 2 Undo the bolts 3 Remove the cover and the gasket 4 Inspect the tank and remove the loose scale deposits and contamination 5 If the scale cannot be removed by hand descale the water heater with a descaling agent Contact the supplier manufacturer for advice on what descaling agent to use 6 Close the cleaning opening To avoid damage to the tank tighten the bolts that fasten the lid wit...

Page 105: ...tial is too low following cleaning please contact the supplier of the water heater 15 5 Solar collector maintenance See installation or users manual for the solar collector If this topic is not covered in the manual then contact the supplier of the collectors 15 6 Finalizing maintenance See Eratta 1 Fill the water heater 5 Filling 2 Start the water heater 9 Starting the water heater 3 Check the CO...

Page 106: ...nstallation date 16 3 Collector warranty For warranty and installation and conditions of use please see the manual included with the collectors 16 4 Conditions for Installation and use The warranty set out in articles 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 ...

Page 107: ...tive water heater other than by an approved service engineer 16 6 Scope of the warranty The obligations of A O Smith by virtue of the warranty provided do not extend beyond delivery free of charge from the warehouse of the parts or components or water heater to be replaced transport labour installation and other costs associated with the replacement shall not be borne by A O Smith 16 7 Claims A cl...

Page 108: ...cture of the main menu 17 2 Menu structure Appliance electrical diagram 17 3 Electrical diagram for the appliance Electrical diagram solar heating system 17 4 Electrical diagram solar heating system Declaration of conformity 17 5 Declaration of conformity Week program card 17 6 Week program card ...

Page 109: ... SOLAR DIFFERENCE IGNITION SPEED DRAIN BACK DAY TIME TEST SOLAR PUMP SPECIFICATIONS SERVICE OPERATION SETTINGS SOLAR CONFIGURATION LANGUAGE ANTI LEGIONELLA FULL LOAD PARTIAL LOAD START OPERATION PUMP RELAY PROGRAM OVERVIEW SERVICE INTERVAL EXTRA PERIOD CHANGE SETPOINT APPLIANCE HISTORY WEEK PROGRAMMA SELECT APPLIANCE HYSTERESE DOWN ON HISTORY OF ERRORS START OPERATION CONTROL SERVICE PROGRAM MAIN ...

Page 110: ...Instruction manual SGE 107 is ...

Page 111: ... X X X 2 J20 1 4 JP5 JP4 X 6 6 X 6 6 X X 6 6 X X 6 JP3 JP11 X 6 6 X F3 X 3 X 2 F1 1 X J2 Q P O S 6 6 12 11 16 15 14 13 19 18 17 20 24 21 22 23 J33 A R J38 J37 X X J34 J35 J39 J36 4 4 M X X 4 X 2 1 3 2 1 1 2 3 1 2 3 4 2 1 1 5 6 2 3 7 8 4 5 1 5 1 1 6 2 1 4 1 2 5 6 3 6 1 2 4 3 1 7 1 1 2 9 7 5 3 1 11 13 15 10 4 2 8 6 16 12 14 7 1 6 2 4 5 1 3 5 1 3 1 2 4 5 5 7 4 4 2 0 I 2 1 1 L N 3 2 1 X X X X 2 4 3 1 ...

Page 112: ...nk P Dummy Q Temperature sensor T1 top of tank R Selection resistor S Push button T Electrical anodes U Signalling for electrical anodes V Potentiostat W Communication between the appliance controller and the solar system BUS connection AA Solar system controller J2 Power connection for controller J19 Extra error signal connection J20 Gas control valve connection J21 Program controlled pump connec...

Page 113: ... black 5 white 6 grey beige 7 green 8 yellow 0309 686b R0 1 2 3 4 5 6 10 7 8 9 12 11 16 15 14 13 19 18 17 20 X X X X 4 3 1 2 J13 X X X X 4 3 1 2 J14 X X X X 4 3 1 2 J3 X X X X 4 3 1 2 J12 J17 X X X 1 2 3 X X J15 1 2 X X 2 1 J16 F2 N L N L1 M M1 M N L3 4 DD EE K 230VAC 50Hz SWL BB CC 3 1 2 3 1 2 3 1 7 5 6 6 6 6 AA 1 7 8 5 F Q T FF GG 5 5 2 3 M M M 5 6 ...

Page 114: ...ating pump AA Control PS Extra head pump for solar heating system ON OFF CC Solar heating system pump modulating DD Temperature sensor S1 solar collector EE Temperature sensor S2 tank FF Combined Q T sensor incl temperature sensor S4 solar collector return GG Communication between the appliance controller and the solar system BUS connection K Double pole isolator J12 Connection of combined Q T sen...

Page 115: ...Appendices 112 Instruction manual SGE 17 is 17 5 Declaration of conformity Declaration of conformity ...

Page 116: ...ON 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...

Page 117: ...Instruction manual SGE 114 ...

Page 118: ...ter side 26 L language setting 73 liability 3 M maintenance condensation water discharge 101 descaling 100 gas side 101 heat exchanger 102 preparation 99 scale 100 mode ERROR 60 SERVICE REQUIRED 60 N navigation buttons 58 notation conventions 11 O ON mode 67 ON OFF switch 57 operating cycle 14 P packaging 19 PC connection 58 protection 15 protection for the solar heating system 17 pump 76 S safety...

Page 119: ... user 10 T target groups 10 terminal block 35 ThermoControl ON OFF switch 57 trademarks 3 U user 10 W warranty 103 exclusions 104 General information 103 installation and conditions of use 103 scope 104 water composition 20 water heater displaying history 76 displaying the selection 76 types 9 19 ...

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A.O. Smith SGE - 40, Installation, User And Service Manual

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