A.O. Smith SGE Installation And Operation Manual Download

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Installation
User and
Service Manual

Summary of Contents for SGE

Page 1: ...40 60 Installation User and Service Manual Installation User and Service Manual...

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

Page 3: ...er 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...

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

Page 5: ...nmental conditions 19 3 4 Technical specifications 22 3 5 Installation diagram 26 3 6 Water connections Unvented 27 3 7 Water connections Vented 28 3 8 Gas connection 29 3 9 Air supply and flue 29 3 1...

Page 6: ...gram 66 11 6 Starting and stopping the week program 66 11 7 Changing the appliance s standard week program 66 11 8 Adding times to a week program 68 11 9 Deleting times from a week program 69 11 10 Ex...

Page 7: ...ce 96 16 Warranty certificate 97 16 1 General warranty 97 16 2 Tank warranty 97 16 3 Collector warranty 97 16 4 Conditions for Installation and use 97 16 5 Exclusions 98 16 6 Scope of the warranty 98...

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

Page 9: ...to follow the printed instructions may lead to personal injury and damage to the appliance 1 2 What to do if you smell gas Warning If there is a gas smell No naked flames No smoking Avoid causing spa...

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...

Page 11: ...ibes 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 chap...

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

Page 13: ...is fed to the burner via the gas control 16 The modulated supply of gas and air ensures that the optimum gas air mixture is always achieved The special construction of the burner causes the mixture to...

Page 14: ...T MENU As soon as Tnet falls below Tset the water heating via the solar heating system is started however only if the temperature of the heating fluid S1 is a certain adjustable value higher than the...

Page 15: ...re water temperature at which heating via the solar heating system is stopped Graphical representation of heating cycle Note Tnet can rise above Tset However this is only possible if Tsolar limit is i...

Page 16: ...varies too much from the set value 2 4 5 Pressure switch The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre purge and normal running of the appliance...

Page 17: ...ermines the working pressure in the water heater which may not exceed 8 bar The installation must also be fitted with a vent pipe from the hot water pipe that opens into the cold water tank Ideally th...

Page 18: ...a maximum pressure of 6 bar The supply pressure to the expansion vessel depends on the static head of the system Besides the expansion vessel the system is protected from overpressure by an expansion...

Page 19: ...amaging 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...

Page 20: ...3 3 3 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 over...

Page 21: ...If the available clearance is less than 100 cm flexible magnesium anodes may be ordered Note When installing the appliance be aware that any leakage from the tank and or connections can cause damage t...

Page 22: ...ed without accessories Check the dimensions 3 4 1 Dimensions of the appliance gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan t...

Page 23: ...alve connection 1485 T Height of coil inlet 630 U Height of coil outlet 305 V Height of recirculation connection 1035 W Height of condensation drain 765 X Height of heat exchanger supply 1465 Y Height...

Page 24: ...ion W 275 Power consumption of solar heating system controller W 700 Supply voltage 15 10 VAC volts 230 Mains frequency Hz 1Hz 50 IP class 30 Description II2H3 Unit SGE 40 SGE 60 Gas category 2H G20 2...

Page 25: ...per value kW 61 8 Nominal output kW 59 7 Supply pressure mbar 37 Burner pressure mbar Gas consumption kg h 4 5 Based on 1013 25 mbar and 15 C If using a blank plate instead of a burner pressure regula...

Page 26: ...n 26 Instruction manual SGE 3 is 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 Installati...

Page 27: ...s 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...

Page 28: ...valve 3 2 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fit a stop valve 4 in the hot water outlet pipe for use when servicing 4 If a circulation pipe is requ...

Page 29: ...ing 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 Concentric connections Parallel co...

Page 30: ...Installation 30 Instruction manual SGE 3 is Types of appliances...

Page 31: ...imum pipe length may not be exceeded Even if the total pipe length is less than the stated maximum the maximum number of bends may not be exceeded Type of appliance Description B23 Air for combustion...

Page 32: ...r compliance with the requirements stated in the table Appliance with concentric flue gas discharge material According to the table the maximum length allowed is 15 metres and there may be up to three...

Page 33: ...permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler Subject Description Roof flue terminal set 1x Wall flue terminal incl clamping ring 1x Pipe 1000...

Page 34: ...eter and eight 90 degree bends The configuration must be checked for compliance with the requirements stated in the table Appliance with parallel flue gas discharge material The longest pipe must be u...

Page 35: ...eturn valve may be used solely in closed pressure systems In systems with a drain back tank it is prohibited to fit a non return valve in the solar heating system 3 11 Electrical connection Warning Th...

Page 36: ...ater Products Company The figure shows a view of the electrical connector block and the table shows the appropriate connections Connector block In preparation you must first remove the two plastic cov...

Page 37: ...to the appliance 3 11 4 Isolating transformer An isolating transformer should be used if there is a case of floating neutral 1 Refer to fitting instructions provided with the isolating transformer Con...

Page 38: ...rors for example with a lamp A 230 V circuit can be directly powered Other voltages require a relay prescribed by the manufacturer 1 Connect the phase cables X1 and X2 to terminals 13 and 14 according...

Page 39: ...station modulating pump 3 12 3 Connecting pump station modulating pump The pump station contains a modulating pump 4 wire connection You must connect this pump to the controller of the solar heating...

Page 40: ...heating system electrical diagrams 17 3 Electrical diagram for the appliance 4 Connect the optional head pump 3 12 7 Connecting extra head pump or QT sensor 3 12 8 Connecting Q T sensor 5 If you have...

Page 41: ...ressure 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 T...

Page 42: ...ipple 2 Sealing screws are located inside the test nipples Loosen both sealing screws by a few turns Do not completely loosen them they can be difficult to re tighten 2 Connect a pressure gauge to the...

Page 43: ...appliance is indeed fitted with a burner pressure regulator the pressure can be adjusted as described in the procedure 3 13 3 Adjusting the pressure 3 13 3 Adjusting the pressure 1 Remove the cap 4 f...

Page 44: ...est nipples 3 Replace the cover 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...

Page 45: ...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...

Page 46: ...hree part gas coupling 2 adjacent to the burner Detach the air supply hose 3 Detach the pressure switch hose 4 7 Remove the burner as complete assembly 8 Place and fit the burner with parts from the c...

Page 47: ...r pressure regulator need to be replaced Unscrew the connector 9 from the gas control If necessary remove the blank plate or burner pressure regulator 7 If necessary fit the blank plate or burner pres...

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

Page 49: ...Instruction manual SGE 49 gis 5 Filling Installation diagram...

Page 50: ...he 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...

Page 51: ...ld flush the solar heating system through with water before filling Flushing with water 1 Connect a water supply to the filling point of the pump station 2 Connect a drain hose to the drain point 3 Op...

Page 52: ...p including the hoses Note Dispose of the residual glycol in the filler hose in an environment friendly manner and according to local regulations Caution The very first time the appliance is started t...

Page 53: ...Instruction manual SGE 53 gis 6 Draining Installation diagram...

Page 54: ...mentioned 1 pressure reducing valve mandatory if the mains water pressure exceeds 8 bar 3 T P valve mandatory 4 stop valve recommended in pipe C and mandatory in pipe A 5 non return valve mandatory 6...

Page 55: ...pliance 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 stop valve 4 between the water tank and the cold water inlet A...

Page 56: ...ould follow the procedure for that system 1 Switch off the solar heating system 2 Connect a hose to the lowest drain point in the solar heating system 3 Insert the hose into the glycol jerry can 4 Ope...

Page 57: ...er 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 sw...

Page 58: ...main 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 Pre...

Page 59: ...is programmed and activated In this mode the OFF orPROG mode is temporarily overruled to fulfil a single period of demand Once the period has passed the appliance automatically returns to the previous...

Page 60: ...ar 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 overv...

Page 61: ...heating system 5 Press once on the blue arrow to position the cursor beside ON then press 6 Confirm the selection START OPERATION with The appliance is now in ON mode If there is a heat demand the app...

Page 62: ...dimmed The icon is activated 5 After a number of seconds pre glow the gas control is opened and ignition takes place The icon is activated The message IGNITION appears 6 After ignition the flame is d...

Page 63: ...lectrically isolating the appliance The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 2 Position the cursor in fron...

Page 64: ...Shutting down 64 Instruction manual SGE 10 gis...

Page 65: ...s the 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 e...

Page 66: ...e week program This following are discussed 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...

Page 67: ...itch 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 d...

Page 68: ...l to INSERT Confirm with The sub menu for adding a period will appear Example As an example we will program an extra period in which the switch on time is set to 18 00 hours and the corresponding swit...

Page 69: ...st programmed period 6 Scroll with to START OPERATION Confirm with The week program is active 11 10 Extra period Use an extra period when you either want to have the appliance switch on and off for a...

Page 70: ...od Setting the switch off time 1 Use and to set the hours In the example this is 012 Confirm with The cursor moves to the minute digits which flash 2 Use and to set the minutes In the example this is...

Page 71: ...2 2 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 with and to DAY...

Page 72: ...the appliance specifications as follows 1 SETTINGS Confirm with 2 Scroll with to SPECIFICATIONS Confirm with The display shows the sub menu for displaying appliance specifications 3 Scroll with to th...

Page 73: ...display an overview of Blocking errors and Lock out errors In both cases the electronic controller reserves 15 lines for the last 15 error messages If there are fewer than 15 error messages an ellipsi...

Page 74: ...ce 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...

Page 75: ...mp of the solar heating system is switched on when the difference 9 3 The appliance s heating cycle between the temperature at the top of the solar collector sensor S1 and that in the appliance sensor...

Page 76: ...les you to read out how much energy the solar heating system supplies For this data to be displayed the installation must be equipped with a QT sensor 12 9 6 Setting the QT sensor yes no 3 values are...

Page 77: ...recommended 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 ERROR...

Page 78: ...r or local gas company immediately Display is off Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 Check if the isolator is ON 2 Check that there is po...

Page 79: ...fice s 15 4 3 Clean the orifice s Hot water supply insufficient or absent Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 Check if the isolator is ON...

Page 80: ...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 L...

Page 81: ...ead to JP5 See the SGE electrical diagram 17 Appendices Damaged cable or defective sensor Replace sensor T1 To replace the necessary parts you must contact your installation engineer S04 blocking erro...

Page 82: ...it Replace sensor T1 To replace the necessary parts you must contact your installation engineer S13 blocking error Short circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Short cir...

Page 83: ...nstallation engineer Floating neutral Install an isolating transformer 3 11 4 Isolating transformer Contact your installation engineer to have an isolating transformer installed F02 lock out error Fan...

Page 84: ...ctly 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 that the flue gas ou...

Page 85: ...er 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 igni...

Page 86: ...ill present after the gas valves have closed 3 If this is the case the gas control must be replaced If the error cannot be resolved or is persistent contact your installation engineer To replace the n...

Page 87: ...ion for maintenance If there is insufficient pressure differential clean the heat exchanger If the pressure differential is acceptable check that the pressure switch is closing using a multimeter If t...

Page 88: ...rror Ignition relay error RAM error EEPROM error EEPROM contents do not match the software version Processor software error C03 blocking error Reset error Too many resets in too short a period Wait fo...

Page 89: ...Replace the sensor if the error persists To replace the necessary parts you must contact your installation engineer E04 lock out error Error in dummy sensor 2 The two dummy sensors in the tank detect...

Page 90: ...laced contact your installation engineer Collector temperature excessive Temperature S1 is higher than Tcollector max The pump in the solar circuit switches off until S1 70 C 1 You can let the message...

Page 91: ...can be set to 500 1000 or 1500 burning hours The standard setting is 500 burning hours Example In the first three months the appliance has burnt 300 hours During maintenance it is evident that one se...

Page 92: ...Maintenance frequency 92 Instruction manual SGE 14 is...

Page 93: ...mportant 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...

Page 94: ...n it to the desired value 11 4 Setting the water temperature 11 Remove the plastic cover on the top of the appliance 12 Check the supply and burner pressure 3 13 Checking the supply pressure and burne...

Page 95: ...tion 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...

Page 96: ...the burner s 3 Fit the burner s 15 4 3 Clean the orifice s 1 Detach the orifice s 2 Remove all contamination present in the orifice s 3 Fit the orifice s 15 4 4 Cleaning the heat exchanger 1 Detach t...

Page 97: ...at 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 16 3 Collector warranty For warranty and i...

Page 98: ...omposition 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 16 6 Scop...

Page 99: ...ction This appendix contains Menu structure 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 Ele...

Page 100: ...CHANGE SETPOINT APPLIANCE HISTORY WEEK PROGRAM SELECT APPLIANCE START OPERATION PUMP RELAY PROGRAM OVERVIEW EXTRA PERIOD SERVICE INTERVAL ANTI LEGIONELLA SETTINGS LANGUAGE SOLAR CONFIGURATION DAY TIM...

Page 101: ...Instruction manual SGE 101 is...

Page 102: ...Appendices 102 Instruction manual SGE 17 is 17 3 Electrical diagram for the appliance Electrical diagram 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 7 red 8 dark green 9 yellow...

Page 103: ...Controller 0 I switch N Display O Fan P Temperature sensor T2 bottom of tank Q Dummy R Temperature sensor T1 top of tank S Selection resistor T Pressure switch U Solar heating system controller BUS l...

Page 104: ...Appendices 104 Instruction manual SGE 17 is 17 4 Electrical diagram solar heating system Electrical diagram 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 7 red 8 dark green 9 yellow...

Page 105: ...d Q T sensor incl temperature sensor S4 solar collector return GG Controller BUS link F2 Fuse 1 2 L1 Power 3 N 4 n a 5 n a 6 n a 7 8 L1 Solar heating system pump ON OFF 9 N 10 Solar heating system pum...

Page 106: ...Appendices 106 Instruction manual SGE 17 is...

Page 107: ...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...

Page 108: ...Instruction manual SGE 108...

Page 109: ...5 D display 57 displaying error history 73 draining 53 E electrical connection 35 electrical connector block 36 environmental conditions 19 error 60 extra period 59 operating mode 59 settings 70 F fan...

Page 110: ...ing 58 service check 10 91 service engineer 10 service required 60 setting date 71 setting service interval 74 softlite 16 specifications 22 supply pressure 41 symbol installation engineer 10 service...

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A.O. Smith SGE, Installation And Operation Manual

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