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SGE Condensing Gas-Solar Water Heater SGE - 40/60 Installation, User and Service Manual 0311 166 / 07-2013 Innovation has a name. 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. Errata The amendments below apply to: the preparation of the electrical connection of the solar heating control (3.12.1 "Preparation"); finishing maintenance (15.6 "Finalizing maintenance"); the electrical diagram of the solar heating control (17.4 "Electrical diagram solar heating system"). These instructions supersede the previous instructions of the solar heating control. 3.12.1 Preparation Remove the cover (snap-on type) from the terminal block of the solar heating control. This has the following terminals: Power n.a. n.a. not applicable Pump (solar) not applicable not applicable L N - - - - - - L3 N L4 - - - - - - - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 e l b a c i l p p a t o n 1 S r o s n e S e l b a c i l p p a t o n 1 S r o s n e S e l b a c i l p p a t o n 2 S r o s n e S e l b a c i l p p a t o n 2 S r o s n e S e l b a c i l p p a t o n e l b a c i l p p a t o n e l b a c i l p p a t o n e l b a c i l p p a t o n V 5 r e w o P 4 S r o s n e S l a n g i s w o l F e l b a c i l p p a t o n e l b a c i l p p a t o n k n i l - S U B k n i l - S U B 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. Check the switching pressure of the pressure switch. (3.12.4 "Switching pressure measurement") 5. Erase the message SERVICE REQUIRED. The displayed message can be reset in either of two ways. 1. Temporary reset: To postpone the message, press RESET once. The message will reappear on the display 7 days later. 2.Full reset: To fully reset the message, press and hold both RESET and ENTER at the same time for 5 sec. On completion of the full reset of the message, the message below will appear on the display. This message will NOT be shown after a temporary rest of the message. E1 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 E2 TERMINAL BLOCK CONNECTIONS Earth N Neutral L Live input of the controller L3 Live input for the solar heating system modulating pump L4 Modulating output of the solar heating system modulating pump COMPONENTS AA Controller BB Solar heating system pump (modulating) CC Temperature 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 temperature sensor S2 (2-4) J16 Connection of BUS-link communication F2 Fuse (T 3.15A - 250 V) E3 gis Read this manual carefully Warning Read this manual carefully before starting the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater. Copyright © 2013 A.O.Smith Water Products Company All rights reserved. Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by whatsoever means, without the prior written approval of A.O.Smith Water Products Company. A.O.Smith Water Products Company reserves the right to modify specifications stated in this manual. Trademarks Any brand names mentioned in this manual are registered trademarks of their respective owners. Liability A.O.Smith Water Products Company accepts no liability for claims from third parties arising from unauthorised use, use other than 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 inaccuracies. Should you detect any errors or inaccuracies in the manual, we would be grateful if you would inform us. This helps us to further improve our documentation. More information If you have any comments or queries concerning specific aspects related to the water heater, then please do not hesitate to contact: A.O.Smith Water Products Company PO Box 70 5500 AB Veldhoven The Netherlands Telephone: 0870-AOSMITH 0870-2676484 General: +31 40 294 25 00 Fax: +31 40 294 25 39 E-mail: info@aosmith.nl Website: www.aosmith.co.uk In the event of problems with your gas, electricity or water supply connections, please contact the supplier/installation engineer of your installation. Instruction manual SGE 3 gis 4 Instruction manual SGE gis Contents 1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.1 About the water heater - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9 1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11 1.6 Notation conventions- - - - - - - - - - - - - - - - - - - - - - - - - - - 11 1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 12 2 Working principle of the water heater - - - - - - - - - - - - - 13 2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 2.2 General working principle of the water heater - - - - - - - - - - - - - - - 13 2.3 Water heater operating cycle - - - - - - - - - - - - - - - - - - - - - - - 14 2.4 Protection for the water heater - - - - - - - - - - - - - - - - - - - - - - 15 2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 16 2.6 Protection for the solar heating system - - - - - - - - - - - - - - - - - - 17 2.7 Safety of the solar heating system - - - - - - - - - - - - - - - - - - - - 18 3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 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 pressure, gas control valve pressure, CO2 value and switching pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40 4 Conversion to a different gas category - - - - - - - - - - - - 47 4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 5.1 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 50 5.2 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 50 5.3 Filling solar heating system- - - - - - - - - - - - - - - - - - - - - - - - 51 6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 6.1 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 54 6.2 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 54 6.3 Draining solar heating system - - - - - - - - - - - - - - - - - - - - - - 55 Instruction manual SGE 5 Contents 7 The control panel - - - - - - - - - - - - - - - - - - - - - - - - 57 7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 7.2 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 7.3 Explanation of icons- - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 7.4 ON/OFF switch on controller - - - - - - - - - - - - - - - - - - - - - - - 57 7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 8 Status of the water heater - - - - - - - - - - - - - - - - - - - 59 8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60 8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60 8.5 Anode warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 8.6 Q/T Sensor warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 8.7 Collector temperature warning- - - - - - - - - - - - - - - - - - - - - - - 61 9 Starting the water heater - - - - - - - - - - - - - - - - - - - - 63 9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63 9.2 Starting the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 63 9.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 63 10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 65 10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65 10.2 Decommissioning the water heater for a short period- - - - - - - - - - - - 65 10.3 Isolating the water heater from the mains - - - - - - - - - - - - - - - - - 65 10.4 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 from a week program- - - - - - - - - - - - - - - - - - - - 71 11.10 Extra period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72 11.11 Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73 12 Service program - - - - - - - - - - - - - - - - - - - - - - - - 75 12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75 12.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - 75 12.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 75 12.4 Displaying the water heater history - - - - - - - - - - - - - - - - - - - - 76 12.5 Display the selected water heater - - - - - - - - - - - - - - - - - - - - - 76 12.6 Switching the pump on or off - - - - - - - - - - - - - - - - - - - - - - - 76 12.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 76 12.8 Service mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76 12.9 Setting legionella prevention- - - - - - - - - - - - - - - - - - - - - - - - 77 12.10 Solar heating system configuration - - - - - - - - - - - - - - - - - - - - 78 12.11 Setting the central heating configuration - - - - - - - - - - - - - - - - - - 79 6 Instruction manual SGE 13 Errors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - 82 13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - 85 13.4 Warnings on the display - - - - - - - - - - - - - - - - - - - - - - - - - 94 14 Service interval- - - - - - - - - - - - - - - - - - - - - - - - - 97 14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97 14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - 97 15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 99 15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 15.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 99 15.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 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 17.2 Menu structure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106 17.3 Electrical diagram for the appliance- - - - - - - - - - - - - - - - - - - - 108 17.4 Electrical diagram, solar heating system - - - - - - - - - - - - - - - - - 110 17.5 Declaration of conformity - - - - - - - - - - - - - - - - - - - - - - - - - 112 17.6 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Instruction manual SGE 7 Contents 8 Instruction manual SGE gis 1 Introduction 1.1 About the water heater 0063 1.2 What to do if you smell gas This manual describes how to install, service and use the SGE water heater. The SGE water heater is a condensing boiler with a fan in the air intake. The water is heated partly by means of an external heat exchanger that can be connected to e.g. a solar energy source. The SGE can be installed as either an open or room-sealed water heater. A concentric chimney connector is fitted standard to the water heater, but a parallel system can also be connected. The possible installation types are B23, C13, C33, C43, C53 and C63. The information in this manual applies to the: SGE 40 and SGE 60. The water heater has been manufactured and equipped in accordance with the European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89). The water heaters are therefore compliant with the European Directive for Gas water heaters, and and are entitled to bear the CE mark. Warning Read this manual carefully before starting the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater. 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 building! After leaving the building, alert the gas distribution company or your installation engineer. 1.3 Regulations Gas Safety (installations and Use) Regulations 1998 (as amended). It is law that all gas appliances are installed by competent persons, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest and that of safety, to ensure that this law is complied with. The installation of the water heater MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, IEE Regulations and the Water Supply (water fittings) Regulations. The installation should also be in accordance with any relevant requirements of the HSE, local gas region and local authority and the relevant recommendations of the following documents: Instruction manual SGE 9 1 gis Introduction British and European Standards • BS 6891: Installation of low pressure gas pipework of up to 35 mm (R1¼) in domestic premises (2nd family gas) - Specification. Note: for lager installations see IGE/UP/2 below. • BS 6798: Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net. • BS 6644: Specification for installation of gas-fired hot water boilers of rated inputs between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family gases). • BS 6700: Design, installation, testing and maintenance of services supplying water for domestic use within buildings and their cartilages - Specifications • BS EN 806-2: Specification for installations inside buildings conveying water for human consumption. Part 2: Design. • BS 5546: Specification for installation of hot water supplies for domestic purposes, using gas-fired appliances 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) Publications • IGE/UP/1: Soundness testing and purging of industrial and commercial gas installations. • IGE/UP/1A: Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations. • IGE/UP/2: Gas installation pipework, boosters and compressors on industrial and commercial premises. • IGE/UP/10: Installation of flued gas appliances in industrial and commercial premises. CIBSE Publications • Guide G: Public Health Engineering. 1.4 Target groups The three target groups for this manual are: • (end) users; • installation engineers; • service and maintenance engineers. Symbols on each page indicate the target groups for whom the information is intended. See the table. 10 Instruction manual SGE gis Target group symbols Symbol Target Group (End) user Installation engineer Service and maintenance engineer Caution This water heater is not intended for use by persons with reduced physical, sensory or mental capacities, or who lack the necessary experience or knowledge, unless the person responsible for their safety is supervising them or has explained to them how the water heater should be used. Caution This water heater is not intended to be used by children. Always supervise children, and ensure that they do not play with the water heater. 1.5 Maintenance A service should be carried out at least once a year, both on the water side and on the gas side. Among other things, the service interval depends on the water quality, the average burning time per day and the set water temperature. Note To determine the 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 responsible for regular maintenance. They will need to establish clear agreements on this. Note If the water heater is not regularly serviced, the warranty will become void. 1.6 Notation conventions The following notation is used in this manual: Note Important information. Caution Ignoring this information can lead to the water heater being damaged. Warning Failure to carefully read this information may lead to danger of personal injury, and serious damage to the water heater. Instruction manual SGE 11 1 gis 1.7 Overview of this document Introduction Chapter Target groups Description Working principle of the water heater This chapter describes the working principle of the water heater. Installation This chapter describes the installation activities to be carried out before final commissioning. Conversion to a different gas category This chapter describes the activities required to convert the water heater to a different gas category. Filling This chapter describes how to fill the water heater. Draining This chapter describes how to drain the water heater. The control panel This chapter describes the general control of the water heater using the display. Status of the water heater This chapter describes the status (mode or condition) that the water heater may have, and possible actions to take. Starting the water heater This chapter describes how to start the water heater. The general operating cycle of the water heater is also described. Shutting down This chapter describes how to decommission the water heater for a brief or long period of time. Main 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 additional information about the water heater. Errors This chapter is mainly intended for the installation engineer and the service and maintenance engineer. It describes water heater errors. These errors are reported on the display. A troubleshooting table of possible causes and solutions is provided. End users may also refer to this chapter for additional information about the water heater. Service interval This chapter describes how to determine the optimum service interval (frequency of regular maintenance). Both the end user and the service and maintenance engineer are responsible for regular maintenance. They need to reach clear agreement on this. Note If the water heater is not regularly serviced, the warranty will become void. Performing maintenance This chapter sets out the maintenance tasks to be carried out. Warranty (certificate) This chapter states the warranty terms and conditions. 12 Instruction manual SGE gis 2 Working principle of the water heater 2.1 Introduction This chapter covers the following topics: • General working principle of the water heater; • Water heater operating cycle; • Protection for the water heater; • Safety of the installation; • Protection for the solar heating system; • Safety of the solar heating system. 2.2 General working principle of the water heater The water heater is fitted with a modulating premix burner system with 1:1 gas to-air ratio regulation. The air required for combustion is delivered by the fan (18). The gas is supplied via the gas control valve (16) and the venturi (30) on the intake side of the fan. The 1:1 gas-to-air ratio always guarantees the most efficient gas/air mixture. In this water heater, the cold water enters the bottom of the tank through the cold water inlet (14). The water is heated by means of a heat exchanger (55) connected to a solar heating 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 combustion chamber, then upwards via the heat exchanger, and downwards again alongside the water in the tank. The flue gases gradually become cooler in the process. Because the cooled flue gases flow alongside the cold water lower down in the tank, they start to condense. This condensation causes latent heat energy to be transferred to the cooler water, thereby increasing the performance of the unit. The condensate yielded by this process is discharged via the condens trap (23). The insulation layer (24) prevents heat loss. The inside of the tank is enamelled to protect against corrosion. The anodes (9) provide extra protection against corrosion. The water heater has an inspection and cleaning opening (12) for maintenance. Instruction manual SGE 13 2 gis Legend Unused numbers are not applicable 1. cover Working principle of the water heater Cut-away view of the water heater 2. hot water outlet 3. electrical connector block 4. controller 5. pressure switch 6. control panel 7. temperature sensor T1 8. combustion chamber 9. anode 10. tank 11. heat exchanger 12. inspection and cleaning opening 13. temperature sensor T2 14. cold water inlet 15. drain valve 16. gas control valve 17. burner 18. fan 19. air supply hose 20. hot surface igniter 21. flame probe 22. chimney pipe 23. condens trap 24. insulation layer 29. base 55. heat exchanger (e.g. solar heating system) 56. temperature sensor S2 58. flue gas test nipple 59. pressure-reducing valve 2.3 Water heater operating cycle The water temperature (T 1) at the top of the water heater is used to control when the gas burner is started and stopped. The temperature changes in the water heater are used for switching the solar heating system on and off (using T1 and S2). T1 is the curve shown in the figure. In addition, temperatures S1 and S2 are used by the solar heating system controller. Temperature S1 is measured in the solar collector and S2 between the inlet and outlet of the heat exchanger (55). The other settings that govern the control behaviour are: • Tset Tset is the the required water temperature that has been set on the appliance (11.4.1 "Setting the water temperature via the SET POINT MENU"). As soon as 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 Tset. 14 Instruction manual SGE gis • Hysteresis The moment that T1 falls below (Tset - Tsolar diff - hysteresis), the controller registers such a heat demand that the gas burner and the solar heating system jointly heat the water. The solar heating system is only employed when the temperature measured by S1 is a certain (adjustable) value grater than that of S2. • Tsolar diff When Tnet exceeds (Tset - Tsolar diff), the gas burner is shut off and the water is heated by the solar heating system alone. When T1 rises above Tset (provided that Tset = Tsolar limit), the solar heating system is switched off. The value of Tsolar diff is adjustable (12.10.4 "Setting the solar difference"). • Tsolar limit Preset (12.10.3 "Setting the solar limit") water temperature at which heating via the solar heating system is stopped. Graphical representation of operating cycle Legend A = Gas burner on B = Gas burner off T1: • = No heat demand, so water is not heated • = Water heated via solar heating system • = Water heated via solar heating system and gas burner t = time T = Temperature 45 o C = Minimum tap water temperature 2.4 Protection for the water heater Tsolar limit Tset Solar diff. Hys. Tmin = 45 C Note T1can rise above Tset. However, this is only possible if Tsolar limit is increased via the service menu. 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 2.4.2 Water heater water temperature protection The controller (4) controls and monitors the safety of the water heater by means of sensors T1 and T2. S2 is also used for protection of the water heater. However, this is primarily intended for control of the solar heating system (2.6 "Protection for the solar heating system"). The table explains the functioning of these temperature sensors. Instruction manual SGE 15 2 gis Working principle of the water heater Temperature protection protection Description Against frost: - T1 < 5°C - T2 < 5°C The frost protection cuts in. The water is heated to 20°C. Against overheating of water: - T1 > 88°C - T2 > 88°C - S2 > 88°C The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the water heater. If the high-limit safeguard is activated, the heating is stopped. This causes the water in the tank to cool down. Once the water has cooled sufficiently (T1 < 81°C), the controller resets the water heater. For extra safety: - T1 > 93°C - T2 > 93°C - S2 > 93°C A lockout error of the water heater controller takes place. The controller must be manually reset before the water heater can resume operation (8.3 "Error conditions"). The reset may only be performed once T 1 <81°C. 2.4.3 Gas control valve The controller opens the gas control valve so that gas can be supplied to the burner. As a safety measure, the gas control valve has two valves. Both valves shut off the gas supply. 2.4.4 Fan The fan (18) provides an optimum air supply when there is a heat demand. As a safety feature, the fan ensures that any gases present in the combustion chamber are removed, both before and after combustion. We refer to this as pre- and post-purge. The fan speed is continuously monitored by the controller (4). The controller takes control if the fan rpm varies too much from the value set. 2.4.5 Pressure switch The pressure switch only guarantees the supply of air during pre-purging of the water heater. If the pressure difference during pre-purging is sufficient, the pressure switch closes. The table (3.4.2 "General and electrical specifications") shows the trip point for each water heater. Note The trip point of the pressure switch is not adjustable. 2.4.6 Flame probe To ensure that no gas can flow when there is no combustion, the water heater is fitted with a flame probe (21). The controller uses this probe to detect the presence of a flame, by means of ionisation 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 the water mains pressure is too high (3.4.2 "General and electrical specifications"), a pressure-reducing valve must be used. Both components must be fitted in the cold water inlet (3.7 "Vented water connections"). The use of an expansion vessel, expansion valve and/or pressure reducing valve depends on the type of installation: unvented or vented. 16 Instruction manual SGE gis 2.5.1 Unvented installation With an unvented installation, an expansion valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being caused to the enamel coating (in the water heater) or to the tank. A non-return valve prevents excessive pressure build-up in the water supply system. This valve also prevents water from flowing backwards from the tank into the cold water supply system. The pressure-reducing valve protects the water heater against excess mains water pressure (3.4.2 "General and electrical specifications"). These components are installed in the cold water inlet (3.7 "Vented water connections"). 2.5.2 Vented installation With a vented installation, excess pressure is taken up by the open cold water head tank. The level of the cold water head tank determines the maximum working pressure (3.4.2 "General and electrical specifications") in the tank. The water heater must also be fitted with a vent pipe from the hot water pipe, which opens into the cold water head tank. Ideally, the vent pipe should discharge into a separate discharge channel/drain or otherwise to the open cold water head tank. The water heater should also be fitted with a stop valve (3.6.2 "Hot water side") on the hot water side. 2.5.3 T&P valve A T&P valve is only mandatory in unvented installations. However, 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 supply pressure, cold water will automatically flow into the tank. The valve remains open until the unsafe situation has been rectified. The water heater is fitted standard with a connection for a T&P valve (3.6.2 "Hot water side"). 2.6 Protection for the solar heating system 2.6.1 Drain-back tank The solar heating system may optionally be equipped with a drain-back tank. The tank fills itself with the heating fluid when there is no heat demand. This avoids overheating of the solar heating system. The high insulation factor of the tank also protects the system against freezing of the fluid. The use of the drain back tank also serves to extend the useful life of the fluid. The existence of a drain-back tank is set (12.10.1 "Setting the drain-back tank") during the installation. Refer to the solar heating system manual for more details. 2.6.2 Fluid temperature The heat exchanger of the solar heating system is filled with glycol. If the temperature of the heating fluid is too high, a signal is sent to the controller of the solar collector and the pump of the solar collector is switched off. This signal is passed to the controller by temperature sensor S1. Instruction manual SGE 17 2 gis 2.7 Safety of the solar heating system Working principle of the water heater Temperature protection for solar heating system Protection Description Maximum temperature: - S1 > 130°C The pump of the solar heating system switches off when the temperature of the heating fluid at S1 exceeds the maximum value. The solar heating system enters error mode. The error is also visible on the display of the SGE water heater 2.7.1 Expansion vessel The solar heating system must be equipped with an expansion vessel. An expansion vessel serves to limit pressure variations in the system. The expansion vessel in the solar heating system can withstand a maximum pressure of 600 kPa (6 bar). The supply pressure to the expansion vessel depends on the static head of the system. The system is protected from overpressure by an expansion valve (2.7.1 "Expansion vessel") as well as the expansion vessel. 2.7.2 Expansion valve The solar heating system is equipped with 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 filled automatically, the system will have to be filled (5 "Filling") again when the expansion valve has been activated. A system with a drain-back tank is not pressurized and does not have an expansion valve. 18 Instruction manual SGE is 3 Installation Warning The installation must be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire brigade. The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations"). 3.1 Introduction This chapter describes the installation activities to be carried out before final commissioning (9 "Starting the water heater"), namely: • Packaging; • Ambient conditions; • Technical specifications; • Installation diagram; • Unvented water connections; • Vented water connections; • Gas connection; • Air supply and chimney flue discharge; • Solar heating system; • Electrically connecting the water heater; • Electrical connection of the solar heating system; • Check the supply pressure, gas control valve pressure, CO2 value and switching pressure. For possible conversion to a different gas category, see conversion (4 "Conversion 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 combustion. If installed as a room-sealed water heater, it is independent of the installation site for the necessary external air supply. In this event, there are no additional ventilation requirements. If the water heater is to be installed as an open system, it must meet the locally-applicable directives and ventilation regulations for open water heaters. The possible installation types are B23, C13, C33, C43, C53 and C63. Caution The water heater may not be used in rooms where chemical substances are stored or used due to the risk of explosion, and corrosion of the water heater. Some propellants, bleaching agents and degreasing agents etc. disperse vapours that are explosive and/or cause accelerated corrosion. If the water heater is used in a room in which such substances are present, the warranty will be void. Instruction manual SGE 19 3 is Installation 3.3.1 Air humidity and ambient temperature The boiler room must be frost-free, or be protected against frost. The table shows the ambient 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 Air humidity and ambient temperature Air humidity max. 93% RH at +25°C Ambient temperature functionality: 0 < T < 60°C 3.3.2 Water heater maximum floor load Allow for the water heater's weight and the maximum floor load; refer to the table (3.4.2 "General and electrical specifications"). 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 overview of the specifications. Water specifications Water composition Hardness (alkaline earth ions) > 1.00 mmol/l: • German hardness> 5.6° dH • French hardness > 10.0° fH • English hardness > 7.0° eH • CaCO3 > 100 mg/l Conductivity > 125 µS/cm Acidity (pH value) 7.0 < pH value < 9.5 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 the water heater's control column and cleaning openings: 100 cm. • BB: all sides of the water heater: 50 cm. • Top of the water heater: 100 cm 20 Instruction manual SGE is Working clearances BB AA A AIMD-0767 R0 3.4 Technical specifications Legend See the table. The water heater is supplied without accessories. Check the dimensions (3.4 "Technical specifications"), 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 F Hx Hy C 3 44º E Ny 4 2 5 6 45º 45º D G 3 2 5 12 A N 14 H K 13 P M 11 1 4 S 6 Z R 9 10 7 U X V Y T W IMD-0772 R0 Instruction manual SGE 21 3 is Installation Size Description Unit SGE 40 SGE 60 A Overall height mm 2055 2055 C Position on pallet mm 490 490 D Appliance diameter mm 705 705 E Depth mm 925 925 F Width mm 850 850 G Diameter of flue gas discharge mm 100 / 150 100 / 150 H Height of chimney flue mm 1995 1995 Hx x position flue gas outlet mm 260 260 Hy x position flue gas outlet mm 370 370 K Height of gas/burner connection mm 1960 1960 M Height of cold water supply mm 185 185 N Height of hot water outlet mm 2055 2055 Ny y position of hot water outlet mm 205 205 P Height of cleaning opening mm 365 365 R Height of drain valve connection mm 180 180 S Height of T&P valve connection mm 1555 1555 T Height of coil inlet 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 connection (external) - R 3/4 R 3/4 4 Drain valve connection (internal) - 3/4" 3/4" 5 T&P valve connection (female) - 1" - 11.5 NPT 1" - 11.5 NPT 6 Cleaning/inspection opening mm 95 x 70 95 x 70 7 Condensation drainage connection (female) - Ø 40 Ø 40 9 Coil inlet connection (female) - Rp 1 Rp 1 10 Coil outlet connection (female) - Rp 1 Rp 1 11 Electric element connection (female) - Rp 11/2 Rp 11/2 12 Heat exchanger supply connector (female) - Rp 1 Rp 1 13 Heat exchanger outlet connector (female) - Rp 1 Rp 1 14 Recirculation connection (female) - Rp 1 Rp 1 22 Instruction manual SGE is 3.4.2 General and electrical specifications General and electrical specifications Description Unit SGE 40 SGE 60 Contents litres 370 370 Empty weight kg 245 245 Maximum floor load kg 615 615 Maximum operating pressure (vented) kPa (bar) 800 (8) 800 (8) Maximum operating pressure, unvented kPa (bar) 550 (5,5) 550 (5,5) Control thermostat adjustment range °C 40…80 40…80 Control thermostat and default value °C 65 65 Adjustment range for hysteresis downwards °C 2…12 2…12 Default value for hysteresis downwards °C 5 5 Adjustment range for solar differential °C 0…8 0…8 Solar differential default value °C 3 5 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 solar controller W max. 700 max. 700 Supply voltage (-15% +10% VAC) volts 230 230 Mains frequency (+ 1Hz) Hz 50 50 IP class - IP 20 IP 20 Description Unit Value Maximum mains pressure of cold water supply (vented) kPa (bar) 800 (8) Maximum mains pressure of cold water supply (unvented) kPa (bar) 500 (5,5) Maximum mains pressure of the protected cold supply setup kPa (bar) 500 (5) T&P overflow pressure kPa (bar) 700 (7) T&P overflow temperature °C 97 Instruction manual SGE 23 3 is Installation 3.4.3 Gas data Gas data II2H3P description Unit SGE 40 SGE 60 Gas category 2H: G20 - 20 mbar Venturi injector diameter mm - - Nominal load (gross) kW 44,4 63,3 Nominal output 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 mbar and 15°C. 24 Instruction manual SGE is 3.5 Installation diagram The figure shows the Installation diagram. This diagram is referred to in the sections describing the actual connection procedure. Installation diagram Legend Vented and unvented Unused numbers are not applicable 1. pressure reducing valve (mandatory) 3. T&P valve (mandatory) 4. stop valve (recommended in UNVENTED 14 12 T 11 26 42 S1 B pipe C and mandatory in pipe 14 A) D 14 10 5. non-return valve (mandatory) 6. circulation pump (optional) 3 9. drain valve (mandatory) 10. manual gas valve 5 6 4 4 (mandatory) C 20. pressure valve (mandatory) 13 26. air bleed (mandatory) F 11. service stop valve S2 (recommended) G 12. temperature gauge 9 (recommended) 38 37 Q TS4 16 16 5 1 4 A 15 13. condensation drain (mandatory) 14. draw-off points 15. expansion valve (mandatory) 16. expansion vessel (mandatory) 17. 3-way aeration valve VENTED A 4 19 18 H 17 E 14 14 11 D 12 B 26 S1 T 42 14 (recommended) 10 18. cold water head tank 19. float switch 23. pressure valve (mandatory) 37. combined Q/T sensor 6 5 4 4 C (optional) 38. solar heating system pump station (modulating - mandatory) A. cold water supply B. hot water supply 9 C. circulation pipe 4 D. gas supply E. overflow pipe F. supply heat exchanger G. heat exchanger return H. overflow protection S1. collector sensor (mandatory) S2. tank sensor (mandatory) S4. heat exchanger discharge sensor (optional) F G 3 13 S2 37 Q T 38 S4 16 IMD-0783 R0 Instruction manual SGE 25 3 is 3.6 Unvented water connections Installation Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this. Warning The installation should be carried out by a competent person, in compliance with general and locally applicable regulations (1.3 "Regulations"). 3.6.1 Cold water side See (A) in the installation diagram (3.5 "Installation diagram"). 1. Fit an approved stop valve (4) on the cold water side as required by the applicable regulations (1.3 "Regulations"). 2. The maximum working pressure of the water heater is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve (1). 3. Fit a non-return valve (5) and an expansion vessel (16). 4. Fit an expansion valve (15) and connect the overflow 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 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 resistance of the circulation system. 2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation. 3. Fit two stop valves for servicing (4). 4. Connect the circulation pipe according to the installation diagram (3.5 "Installation diagram"). 3.6.4 Condensation drain 1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge. Caution If the condensation drain is not fitted to the waste water discharge using an open connection, this can cause faults. 26 Instruction manual SGE is 3.7 Vented water connections Warning The installation should be carried out by a competent person, in compliance with general and locally applicable regulations (1.3 "Regulations"). 3.7.1 Cold water side See (A) in the installation diagram (3.5 "Installation diagram"). 1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the water heater, as required by applicable regulations. 3.7.2 Hot water side See (B) in the installation diagram (3.5 "Installation diagram"). Note Insulating long hot water pipes prevents unnecessary energy loss. 1. Fit the T&P 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 servicing. 4. If 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 resistance of the circulation system. 2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation. 3. Fit two stop valves for servicing (4). 4. Connect the circulation pipe according to the installation diagram (3.5 "Installation diagram"). 3.7.4 Condensation drain 1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge. Caution If the condensation drain is not fitted to the waste water discharge using an open connection, this can cause faults. Instruction manual SGE 27 3 is Installation 3.8 Gas connection Warning The installation should be carried out by a competent person, in compliance with general and locally applicable regulations (1.3 "Regulations"). Caution Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the water heater. See (D) in the installation diagram (3.5 "Installation diagram"). 1. Fit a manual gas valve (10) in the gas supply pipe. 2. Blow the gas pipe clean before use. 3. Close the manual gas valve. 4. Fit the gas supply pipe to the gas control valve. Warning After fitting, check for leaks. 3.9 Solar heating system Note Please refer to the installation diagram (3.5 "Installation diagram"), electrical diagram (17.4 "Electrical diagram, solar heating system") and terminal 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 - connections table (3.11.2 "Preparation"). 4. Connect the communication cable between the solar heating system controller and the water heater, see: - electrical diagram (17.4 "Electrical diagram, solar heating system") and - connections table (3.11.2 "Preparation"). Warning The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this. 28 Instruction manual SGE is 3.10 Air supply and chimney flue discharge 3.10.1 Introduction This section covers the following topics: • Requirements for flue gas discharge materials • Concentric connections • Parallel connections 3.10.2 Requirements for flue gas discharge materials Warning The installation should be carried out by a competent person, in compliance with general and locally 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 more information by contacting A.O. Smith. The figure and table give information about these types of installation. For an explanation of the possibilities, please contact the manufacturer. Instruction manual SGE 29 3 is C43 Installation Installation types B23 C33 C13 C53 IMD-0789 R0 30 Instruction manual SGE is Explanation of types of installation Installation type Description B23 Air for combustion is drawn from the boiler room. C13 Concentric and/or parallel wall flue terminal. C33 Concentric and / or parallel roof flue terminal C43 Water heaters on common air supply and flue gas discharge (concentric and/or parallel) in multi-storey building. C53 Air supply and flue gas discharge terminal types mixed. C63 Water heaters supplied without flue gas discharge materials and/or terminal. These water heaters must be installed in compliance with local regulations. Note Make sure that the chimney flue discharges into an area approved for this type of installation. 3.10.3 Concentric connections The table shows the requirements for concentric systems. Warning Install flue gas discharge pipe runs with a run-off of 5 mm per metre towards the water heater. Flue gas discharge requirements for concentric systems (C13, C33) Appliance Diameter Maximum length Maximum number of 90o bends SGE 40 100/150 mm 40 m 7 SGE 60 100/150 mm 40 m 7 Caution Both conditions stated in the table must be fulfilled. Even if you use less than the stated maximum number of bends, the maximum pipe length still may not be exceeded. Even if you use less than the stated maximum pipe length, the maximum number of bends still may not be exceeded. The following example illustrates 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. Instruction manual SGE 31 3 is Installation Water heater with concentric flue gas discharge material IMD-0791 R0 According to the table, the maximum permitted length is 40 metres, and 4 x 90 degree bends are permitted. Both requirements are fulfilled. Specifications Caution For type C13 and C33 installations,A.O.Smith prescribes the use of a roof or wall flue terminal, exclusively of a type approved for the water heater. Use of an incorrect roof or wall-mounted flue terminal can cause the installation to malfunction. Concentric wall flue terminal specifications C13 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 with lip ring seal Air supply Thin-walled galvanised sheet steel Pipe diameters Flue gas discharge Ø 100 mm Air supply Ø 150 mm (1) No other wall flue terminal is permitted. Use this item number to order the wall conduit set from supplier, manufacturer or wholesaler. 32 Instruction manual SGE is Concentric roof flue terminal specifications C33 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 with lip ring seal Air supply Thin-walled galvanised sheet steel Pipe diameters Flue gas discharge Ø 100 mm Air supply Ø 150 mm (1) No other roof flue terminal may be used. Use this item number to order the roof flue terminal set from the supplier, manufacturer or wholesalor. 3.10.4 Parallel connections The table states the maximum pipe lengths for parallel systems. The maximum pipe length depends on the chosen diameter. Warning Install flue gas discharge pipe runs with a run-off of 5 mm per metre towards the water heater. Chimney flue requirements for parallel systems Appliance Diameter1 Maximum total length Lequivalent 90o bend Lequivalent 45o bend SGE 40 100 55 m 4.6 m 1.2 m SGE 60 100 55 m 4.6 m 1.2 m SGE 40 130 100 m 2.4 m 1.4 m SGE 60 130 100 m 2.4 m 1.4 m 1) Parallel systems with diameter of 100 mm. If the maximum total length when using a diameter of 130 mm is insufficient, a diameter of 150 mm must be used. Any diameter enlargement must be carried out on both air supply and flue gas outlet. You must use the longest pipe when calculating the pipe length. For example, if the chimney pipe is 4 metres and the air supply pipe is 3 metres, use 4 metres as the length for the calculation. Next, add the Lequivalent for every 90° and 45° bend to this 4 metres, in both the air supply and flue gas outlet. The following practical example illustrates how to use the table. Practical example of parallel flue gas discharge Example The figure shows a SGE 60 installation. This has to be fitted with a 4 m parallel pipe 100 mm in diameter, plus four 90-degree bends. The configuration must be checked for compliance with the requirements stated in the table. Instruction manual SGE 33 3 is Installation Appliance with parallel flue gas discharge material 3.11 Electrically connecting the water heater The longest pipe must be used to check the maximum length. In this case, the chimney pipe is the longest. This is 4 metres. This 4 metres is the sum of pipe sections 1 and 2. The length of the transition piece can be ignored. The total number of bends used in the chimney flue and air supply , is 4. The bend in the transition piece can be ignored. According to the table, 4.6 metres must be added for each bend. This brings the total pipe length to: (4.6 x 4) + 4 = 18.4 + 4 = 22.4 m. This is less than the maximum length of 55 metres stated in the table. The installation therefore meets the requirements. 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 storage tank and the water heater) and an extra alarm signal to the water heater. For these options, see: • Isolating transformer • Connecting a program-controlled pump • Connecting an extra ON mode switch • Connect additional error signal Connecting the solar heating system is also described: • Connecting communication cable to solar heating system Note The optional components are not included in the electrical power consumption rating stated in the table (3.4.2 "General and electrical specifications"). 34 Instruction manual SGE is 3.11.2 Preparation Caution The water heater is phase-sensitive. It is absolutely essential to connect the mains live (L) to the live of the water heater, and the mains neutral (N) to the neutral of the water heater. Caution There must be no potential difference between neutral (N) and earth ( ). If this is the case, then an isolating transformer (3.11.4 "Isolating transformer") must be used in the supply circuit. For more information or to order this 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 Legend A. screws B. cover C. terminal 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. Loosen the 2 screws (A) and remove the cover (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. Instruction manual SGE 35 3 is Installation Terminal block Mains voltage Isolating transformer Alarm Out Program controlled pump External ON/OFF Bus-link primary secondary N L N L1 N L2 X1 X2 N L3 X3 X4 X5 X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 to 20 21 22 23 24 3.11.3 Connecting the mains power The water heater is supplied without a power cable and isolator. Note In order to receive electrical power, the water heater has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the water heater. The power cable must have cores of at least 3 x 1.0 mm 2 . Warning Leave the water heater electrically isolated until you are ready to commission it. 1. Connect neutral (N), live (L) and earth ( ) of the power cable to terminals 1 thru 3 of the terminal block as shown in the table (3.11.2 "Preparation"). 2. Fit the power cable in the strain relief. 3. Connect the power cable to the isolator. 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 supplier for details of the correct isolating transformer.) 2. Connect the neutral (N), live (L) and earth ( ) of the power cables to terminals 4 through 9 of the connection block according to the table (3.11.2 "Preparation"). 3. Fit the cables in the strain relief. 4. If you have no more connections to make: - Fit the cover on the terminal block. - Fit the covers onto the water heater. 5. Connect the power cable to the isolator. 36 Instruction manual SGE is 3.11.5 Connecting a program-controlled pump Note The maximum power capacity for a pump regulated by the controller is 100W. 1. Connect neutral (N), live (L) and earth ( ) to terminals 13, 14 and 15 as indicated in the table (3.11.2 "Preparation"). 2. Fit the cable in the strain relief. 3. If you have no more connections to make: - Fit the cover on the terminal block. - Fit the covers onto the water heater. 3.11.6 Connecting an extra ON mode switch External ON/OFF is an option for connecting an external ON/OFF switch. In the OFF position, the programmed operating mode is active. In the ON position, the programmed operating mode is overruled, and "ON mode" is active. 1. Connect leads (X3 and X4) to terminals 21 and 22 according to the table (3.11.2 "Preparation"). 2. Fit the cable in the strain relief. 3. If you have no more connections to make: - Fit the 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 according to the table (3.11.2 "Preparation"). If required, connect earth ( ) to terminal 12. 2. Fit the cable in the strain relief. 3. If you have no more connections to make: - Fit the cover on the terminal block. - Fit the covers onto the water heater. 3.11.8 Connecting communication cable to solar heating system You must connect a communication cable between the controllers of the water heater and the solar heating system. 1. Connect the cables (X5 and X6) to terminals 23 and 24 as shown in the table (3.11.2 "Preparation"). 2. Fit the cable in the strain relief. 3. If you have no more connections to make: - Fit the cover on the terminal block. - Fit the covers onto the water heater. Instruction manual SGE 37 3 is 3.12 Electrical connection of the solar heating system Installation This section covers the following topics: • Preparation • Connecting the mains power • Connecting pump station - modulating pump • Connecting solar collector • Connecting tank sensor • Connecting communication cable Optionally you can connect an extra head pump and Q/T sensor: • Connecting extra head pump • Connecting Q/T sensor 3.12.1 Preparation See Eratta. has the following terminals: Power n.a. Pump ON/OFF Modulating pump n.a. L N - - - L1 N M1 M2 M3 - - - - - - - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 . a . n . a . n . a . n . a . n V 5 r e w o P 4 S r o s n e S l a n g i s w o l F . a . n 1 S r o s n e S . a . n 1 S r o s m e S . a . n 2 S r o s n e S . a . n 2 S r o s n e S 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 J3 J12 J13 J14 3.12.2 Connecting the mains power Note Just as with the water heater controller, the solar heating system controller must have a permanent electrical connection to the mains power supply. There must be a double-pole isolator installed in the permanent connection. This is the same double-pole isolator as installed between the mains power supply and the 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 station contains a modulating pump (4-wire connection). You must connect this pump to the controller of the solar heating system. 1. Connect earth, live and neutral to terminals 10 through 12 . 2. Connect the fourth lead to terminal 13. 3. Fit the cables in the strain relief. 4. Continue (3.12.4 "Connecting solar collector"). 38 Instruction manual SGE is 3.12.4 Connecting solar collector Note This sensor must be mounted in the solar collector;refer to the solar collector installation manual. Connect the sensor (S1) to the water heater as follows: 1. Connect the sensor to terminal 2 and 4 of J13. 2. Fit the cables in the strain relief. 3. Continue (3.12.5 "Connecting tank sensor"). 3.12.5 Connecting tank sensor Note This sensor is already mounted in the tank prior to delivery. The sensor is mounted between the inlet and outlet of the heat exchanger. However, you must still connect the lead to the solar heating system controller. 1. Connect the lead for sensor S2 with the blade connectors to the sensor. 2. Connect the other end to terminals 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 cable to the terminal block of the appliance. See - connecting communication cable to the appliance (3.12.6 "Connecting communication cable"). - electrical diagram for the appliance (17.3 "Electrical diagram for the appliance") - electrical diagram for the solar heating system (17.4 "Electrical diagram, solar heating system") 4. Connect the optional head pump (3.12.7 "Connecting extra head pump") or Q/T sensor (3.12.8 "Connecting Q/T sensor"). 5. If you do not need to make any more connections: - Fit the cover over the controller. Instruction manual SGE 39 3 is Installation 3.12.7 Connecting extra head pump Note This pump is essential if a greater head is required. When the system has such a high resistance (>66 kPa) that the pump in the pump station is insufficient, you can connect a second (ON/OFF) pump to the solar heating system controller. 1. Connect earth ( ), live and neutral to terminals 7 through 9. 2. Fit the cable in the strain relief. 3. If you need to connect an extra head pump, continue (3.12.8 "Connecting Q/T sensor"); otherwise: - Fit the covers over the controller. 3.12.8 Connecting Q/T sensor Note You can optionally add a Q/T sensor to the installation. This enables you to calculate the energy contribution of the system. For more information or to order the Q/T sensor, please contact your supplier. 1. Connect the 5V to J12-1. 2. Connect sensor S4 to J12-2. 3. Connect earth to J12-3. 4. Connect the "flow signal" to J12-4. 5. Fit the cable in the strain relief. 6. If 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 conversion, you must always check the supply pressure, the gas control valve pressure, the CO2 value and the switching pressure. Note A CO2 meter and a pressure gauge must be available for checking the supply pressure, gas control valve pressure, CO2 value and switching pressure. 3.13.1 Procedure for checking the supply pressure To check the supply 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. There is a test nipple before the gas control valve (for natural gas appliances) or before the pressure-reducing valve (for LPG appliances) so that the supply pressure can be measured. 40 Instruction manual SGE is This test nipple has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it as it can be difficult to retighten. IMD-1095a R0 IMD-1096a R0 5. Open the gas supply and vent the gas supply line via the test nipple. 6. Connect a pressure gauge to the test nipple as soon as gas starts to flow from it. 7. Switch on the power to the appliance using the isolator on the appliance. 8. Switch the controller ON by setting 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. INTERNAL CHECK SERVICE MENU SERVICE INTERVAL »SERVICE OPERATION È ANTI LEGIONELLA 9. Select SERVICE OPERATION, FULL LOAD from the service menu. 10. Confirm with . The display shown here will appear. SERVICE OPERATION »FULL LOAD PARTIAL LOAD 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 pressures (the fan needs this time to get up to full speed, so that you can get a reliable reading). Instruction manual SGE 41 3 is Installation 12. Use the pressure gauge to read the supply pressure and compare it against the value from the gas table (3.4.3 "Gas data"). Note Consult the mains gas supply company if the supply pressure is not correct. You cannot yet start using the appliance. You must now take the appliance out of service (10.3 "Isolating the water heater from the mains"). Note After conversion, you must check that the gas control valve is gastight. 13. Shut off the gas supply. 14. Disconnect the pressure gauge and retighten the sealing screw in the test nipple. 15. If there is nothing else you need to check or adjust, you can put the covers back on the appliance. 3.13.2 Procedure for checking the gas control valve pressure The procedure for checking the gas control valve pressure is only applicable to appliances that have a pressure-reducing 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 that can be used for measuring the gas control valve pressure. This test nipple has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it as it can be difficult to retighten. 5. Open the gas supply. 6. Connect a pressure gauge to the test nipple. 7. Switch on the power to the appliance using the isolator on the appliance. 8. Switch the controller ON by setting 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. INTERNAL CHECK SERVICE MENU SERVICE INTERVAL »SERVICE OPERATION È ANTI LEGIONELLA 9. Select SERVICE OPERATION, FULL LOAD from the service menu. 42 Instruction manual SGE is 10. Confirm with . The display shown here will appear. SERVICE OPERATION FULL LOAD »PARTIAL LOAD The appliance is now in "PARTIAL LOAD" mode and will ignite. 11. You must wait about 1 minute after the display shows the text RUNNING before reading the dynamic pressures (the fan needs this time to get up to full speed, so that a reliable reading can be obtained). 12. Use the pressure gauge to read the pressure and compare it against the value from the gas table (3.4.3 "Gas data"). 13. If necessary, adjust the gas control valve pressure using the reducing valve's adjuster screw (2) until the value is within the range listed in the table Gas control valve pressure adjustment IMD-1096b R0 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 (58) of the flue gas outlet pipe. 5. Open the gas supply and vent the gas supply line. 6. Use the main switch to apply mains voltage to the appliance. 7. Start (9 "Starting the water heater") the appliance. 8. Go to the :SERVICE OPERATION menu. 9. Generate a heat demand by draining the appliance until it is cold or by raising the value for Tset in the SERVICE menu. Use for this. Instruction manual SGE 43 3 is Installation Full-load measurement 10. From the service menu, select: - SERVICE OPERATION | FULL LOAD - Confirm with . The appliance is now in "FULL LOAD mode" and will ignite. SERVICE Ê Ê FULL LOAD 65ÉC Tset 70ÉC RUNNING 11. The appliance is now running at FULL LOAD. Read the value from the CO2 meter and wait until this measured value has remained stable for some time. This may take several minutes. 12. Then compare the measured CO2 value against the value from the table (3.4.3 "Gas data"). Caution The CO2 value at full load must be within ±1.0 vol% 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) IMD-1095b R0 Note Turning to the left (anticlockwise) means more gas (higher CO2 level) and turning to the right (clockwise) means less gas (lower CO2 level). Note After conversion, you must check that the gas control valve is gastight. 14. If you have increased Tset, set it back to the original value using . 15. Continue with the CO2 measurement under partial load. 44 Instruction manual SGE is Partial load measurement 16. From the service menu, select: - SERVICE OPERATION | PARTIAL LOAD - Confirm with . The appliance is now in "PARTIAL LOAD" mode and will ignite. SERVICE Ê Ê PARTIAL LOAD 65ÉC Tset 70ÉC RUNNING 17. The appliance is now running at PARTIAL LOAD. Read the value from the CO2 meter and wait until this measured value has remained stable for some time. This may take several minutes. 18. Compare the CO2 value measured against the value measured under full load. Caution The CO2 value at partial load must be within ±0.3 vol% of the CO2 value measured or adjusted 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) IMD-1095c R0 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 After conversion, you must check that the gas control valve is gastight. 20. Remove the CO2 measurement probe from the measurement nipple of the flue gas outlet pipe. 21. Put the cap back on the measurement nipple of the flue gas outlet pipe. 22. Shut off the gas supply. 23. Replace the covers. Instruction manual SGE 45 3 is Installation 3.13.4 Switching pressure measurement To measure the switching 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. Remove the black caps from the measurement point of the pressure switch. 5. Connect the + of the pressure gauge to the H of the measurement point of the pressure switch. 6. Connect the - of the pressure gauge to the L of the measurement point 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: ON Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC PRESSURE SWITCH 11. Check whether the measured value matches the value from the table (3.4.3 "Gas data"). Note If the message PRESSURE SWITCH does not appear, there is a fault. This must be resolved first by a qualified service engineer. 12. Shut off the gas supply. 13. Disconnect the pressure gauge. 14. Put the two black caps back on the pressure switch. 15. Replace the covers. 46 Instruction manual SGE is 4 Conversion to a different gas category 4.1 Introduction Caution The conversion may only by carried out by a competent person. If the appliance has to operate on a different family of gases (liquid petroleum gas or natural gas) or gas category other than that for which the appliance has been configured at the factory, then the appliance will have be adapted using a special 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 or LPG to LPG, if applicable. Caution After the conversion, you must check that the appliance is gastight and check the supply pressure, gas control valve pressure, the CO2 value and the switching pressure. Instruction manual SGE 47 4 is Conversion to a different gas category 48 Instruction manual SGE gis 5 Filling Installation diagram Legend Vented and unvented Unused numbers are not applicable 1. pressure reducing valve (mandatory) 3. T&P valve (mandatory) 4. stop valve (recommended in UNVENTED 14 12 T 11 26 42 S1 pipe C and mandatory in pipe 14 A) D 14 10 5. non-return valve (mandatory) 6. circulation pump (optional) 9. drain valve (mandatory) 10. manual gas valve 6 5 4 4 (mandatory) C 20. pressure valve (mandatory) 26. air bleed (mandatory) 11. service stop valve (recommended) 12. temperature gauge 9 (recommended) B F G 3 13 S2 38 37 Q TS4 16 16 5 1 4 A 15 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) VENTED A 4 19 18 H 17 E 14 14 14 4 C 11 6 D 5 10 4 12 B T 26 42 3 S1 38 16 38. solar heating system pump 13 F station (modulating - 37 mandatory) S2 S4 G Q T A. cold water supply B. hot water supply 9 C. circulation pipe 4 D. gas supply E. overflow pipe F. supply heat exchanger G. heat exchanger return H. overflow protection S1. collector sensor (mandatory) S2. tank sensor (mandatory) S4. heat exchanger discharge sensor (optional) IMD-0783 R0 Instruction manual SGE 49 5 gis 5.1 Filling unvented installations 5.2 Filling vented installations Filling Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this. Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this. To fill the water heater, proceed as follows: 1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6). 2. Close the drain valve (9). 3. Open the nearest hot water draw-off point (14). 4. Open the valve of the inlet combination (2) so that cold water flows into the water heater. 5. Completely fill the water heater. When a full water jet flows from 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 this by fitting a pressure reducing valve (1). - The expansion valve in the protected cold supply set-up is defective or incorrectly fitted. - The T&P valve is defective, or incorrectly installed. To fill the water heater, proceed as follows: 1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6). 2. Close the drain valve (9). 3. Open the nearest hot water draw-off point (14). 4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the water heater. 5. Completely fill the water heater. When a full water jet flows from 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 be no water coming out of the T&P valve (3). If this does happen, the T&P valve might be defective or incorrectly fitted. 50 Instruction manual SGE gis 5.3 Filling solar heating system Note No special safety measures are required when working with the diluted glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer. Warning Before filling the solar heating system to replenish the heating fluid, make certain that: • The appliance is switched off (10.2 "Decommissioning the water heater for a short period"). • The solar heating system is switched off. Refer to the documentation of the solar heating system. • The appliance has cooled down sufficiently to prevent personal injury (burns). Note The filling procedure described in this manual is intended for the pump system supplied by the supplier of the appliance. For any other system, you should follow the procedure for that system. Warning To avoid contaminating the glycol, you should flush the solar heating system through with water before filling. 5.3.1 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 system with glycol. Instruction manual SGE 51 5 gis Filling 5.3.2 Filling met glycol 1. Insert the hose of the glycol pump into the jerry can containing the glycol. 2. Connect the pump to the jerry can. 3. Connect the hose of the glycol pump to the inlet combination of the pump station. 4. Open the valve of the inlet combination. 5. Plug the glycol pump into a mains socket. 6. Start the glycol pump using the ON/OFF switch on the glycol pump. 7. Stop the glycol pump as soon as the pressure gauge on the pump station begins to rise. 8. Completely bleed the system of air at the air bleed point (26, see installation diagram). 9. Close the air bleed when no further air comes out. 10. User the service menu (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 installation does have a drain-back system, then it should not be pressurised. For the installation, filling and drainage of a drain-back system, please refer to the installation manual and users manual of the solar collectors. 12. Switch off the glycol pump. 13. Close the valve of the inlet combination and disconnect the glycol pump (including the hoses). Note Dispose of the residual glycol in the filler hose in an environment-friendly manner, and according to local regulations. 52 Instruction manual SGE gis 6 Draining Installation diagram Legend Vented and unvented Unused numbers are not applicable 1. pressure reducing valve (mandatory) 3. T&P valve (mandatory) 4. stop valve (recommended in UNVENTED 14 12 T 11 26 42 S1 pipe C and mandatory in pipe 14 A) D 14 10 5. non-return valve (mandatory) 6. circulation pump (optional) 9. drain valve (mandatory) 10. manual gas valve 6 5 4 4 (mandatory) C 20. pressure valve (mandatory) 26. air bleed (mandatory) 11. service stop valve (recommended) 12. temperature gauge 9 (recommended) B F G 3 13 S2 38 37 Q TS4 16 16 5 1 4 A 15 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) VENTED A 4 19 18 H 17 E 14 14 14 4 C 11 6 D 5 10 4 12 B T 26 42 3 S1 38 16 38. solar heating system pump 13 F station (modulating - 37 mandatory) S2 S4 G Q T A. cold water supply B. hot water supply 9 C. circulation pipe 4 D. gas supply E. overflow pipe F. supply heat exchanger G. heat exchanger return H. overflow protection S1. collector sensor (mandatory) S2. tank sensor (mandatory) S4. heat exchanger discharge sensor (optional) IMD-0783 R0 Instruction manual SGE 53 6 gis 6.1 Draining unvented installations 6.2 Draining vented installations Draining Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems. Please contact the pump unit supplier for this. Some service activities require the water heater to be drained. The procedure is as follows: 1. Activate the MENU with . MENU »OFF ^ ON È WEEK PROGRAM 2. Position the cursor in front of OFF. 3. Confirm OFF with . 4. Wait until the fan has stopped. The icon is then dimmed. Caution Failure to wait until the fan stops can cause damage to the water heater. 5. Switch the water heater OFF (position 0) using the ON/OFF switch on the control panel. 6. Isolate the water heater from the power supply by setting the isolator 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). 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 front of OFF. 3. Confirm OFF with . 4. Wait until the fan has stopped. The icon is then dimmed. Caution Failure to wait until the fan stops can cause damage to the water heater. 5. Switch the water heater OFF (position 0) using the ON/OFF switch on the control panel. 6. Isolate the water heater from the power supply by setting the isolator 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 stop valve (4) between the cold water head tank and the cold water inlet (A). 10. Open the drain valve (9). 11. Bleed the water heater (or installation) so that it drains completely. 54 Instruction manual SGE gis 6.3 Draining solar heating system Note No special safety measures are required when working with the diluted glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer. 1. Activate the MENU with . MENU »OFF ^ ON È WEEK PROGRAM 2. Position the cursor in front of OFF. 3. Confirm OFF with . 4. Wait until the fan has stopped. The icon is then dimmed. Caution Failure to wait until the fan stops can cause damage to the water heater. Warning The fluid in the pipes and the pipes themselves 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 is full. 11. Insert the hose in a new jerry can. 12. Repeat steps 6 and 7 until no further glycol comes out of the system. 13. Close the air bleed point and the valve of the drain point. 14. Remove the hose. Note Dispose of the drained glycol in an environment-friendly manner, and according to local regulations. Instruction manual SGE 55 6 gis Draining 56 Instruction manual SGE gis 7 The control panel 7.1 Introduction This chapter covers the following topics: • Control; • Explanation of icons; • ON/OFF switch on controller; • Navigation buttons; • PC connection. 7.2 Control The control panel is completely menu-driven, and comprises: • a 4-line display with 20 characters per line; • 6 buttons for controlling the water heater (below the display); • 6 graphical symbols (above the display); • a connector for a service PC; • an ON/OFF switch. The buttons are divided into three groups: • Navigation buttons: - Buttons for UP , and DOWN ; - Enter: ; - Reset button: • The main menu (11 "Main menu"): ; • the service program (12 "Service program"): . This chapter is specifically intended for the service and maintenance engineer and installation engineer. In this manual, the display of the controller is shown as in the figure, both with and without icons. »START OPERATION ^ CHANGE SETPOINT È Tset=70ÉC 7.3 Explanation of icons The table explains the meanings of the icons. Icons and their meaning Name Explanation Heat demand Heat demand detected Purge Pre- and post-purge using fan Pressure switch Pressure switch is closed Glow (Pre)glow Gas control valve Gas control valve open/ignition Flame detection Water heater operational Solar heating system Solar energy is heating the water 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. INTERNAL CHECK After switching on, the text INTERNAL CHECK appears on the display for about 10 seconds. The main menu (11 "Main menu") then appears. If no selection is made in the main menu, the water heater automatically switches to the OFF mode (8.2 "Operating modes"). Note To electrically isolate the water heater, you must use the isolator between the water heater and the mains power supply. Instruction manual SGE 57 7 gis 7.5 Navigation buttons The control panel The use of these buttons is explained with the help of the figure showing the main menu (11 "Main menu"). The navigation buttons are: • Buttons for UP , and DOWN ; • Enter: ; • Reset button: . The arrows ^ and È indicate that you can scroll up and/or down. Use the buttons and to scroll. MENU OFF ^»ON È WEEK PROGRAM EXTRA PERIOD SETTINGS The cursor » points to the option to be activated. In the display as shown in the figure, you can scroll through the main menu. The main menu comprises: OFF, 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 connection is exclusively intended to enable technicians from A.O.Smith to read the status and history of the water heater. These details can be important for troubleshooting and/or resolving complaints. 58 Instruction manual SGE gis 8 Status of the water heater 8.1 Introduction This chapter covers the following topics: • Operating modes; • Error conditions; • Service condition; • Anode warning; • Q/T Sensor warning; • Collector temperature warning 8.2 Operating modes When running, the water heater has four basic operating modes, namely: • OFF • ON • EXTRA • PROG 8.2.1 OFF In this mode, the frost protection is activated. The figure shows the display with the following information: • line one: the text OFF; • line two: the time, the day and T1. (9.3 "The appliance's heating cycle") • lines three and four: the text FROST PROTECTION ACTIVATED. OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED 8.2.2 ON In this mode, the water heater continually responds to the hot water demand. The figure shows the display with the following information: • line 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. ON 13:45 Thursday 67ÉC Tset 75ÉC 8.2.3 EXTRA In this mode, one extra period is programmed and activated. In this mode, the OFF orPROG mode is temporarily overruled to fulfil a single period of demand. When the period has passed, the water heater automatically returns to the previous operating mode. The figure shows the display with the following information: • line one: the text EXTRA; • line two: the time, the day and T1; (9.3 "The appliance's heating cycle") • line three: the switch-on time and the related water temperature setting; • line four: the text PERIOD ACTIVATED. EXTRA 12:30 Thursday 76ÉC TH 12:45 Tset 75ÉC PERIOD ACTIVATED Instruction manual SGE 59 8 gis 8.2.4 PROG Status of the water heater • line one: error code comprising a letter and two In this mode a preset week program is active, and the water heater responds continually to demand within the time periods set in the week program. There are two distinct situations possible in this mode: PROG 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC 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; (9.3 "The appliance's heating cycle") - line three: the next scheduled switch-off time and the water temperature Tset of the active period - line four: is empty, or depending on the operating cycle (9.3 "The appliance's heating cycle") , displays a text such as HEAT DEMAND. PROG 12:00 Monday 76ÉC MO 11:15 PERIOD ACTIVATED 2. The current time falls outside a set time period of the week program. The figure shows the display with the following information: - line one: the text PROG; - line two: the time, the day and T1; (9.3 "The appliance's heating cycle") - line three: the next scheduled switch-on time; - line four: displays the text PERIOD ACTIVATED. In all modes, the temperature may at any moment drop below the desired temperature. The water heater then enters an operating cycle. This operating cycle is identical (9.3 "The appliance's heating cycle") for all basic operating modes. Note Setting and if necessary programming of the basic operating modes are described in the main menu (11 "Main menu") chapter. 8.3 Error conditions The figure shows an example of an error condition. If the water heater enters this condition, the display will show the following information: 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. S04: SENSOR ERROR CHECK SENSOR OR DUMMY Caution The displayed action to resolve the error may only be performed by a service and maintenance engineer. There are various types of errors: • 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 error has been removed, after which the water heater resumes operation by itself. The display does not show what type of error has been detected. A comprehensive overview of the errors is provided elsewhere in the manual (13 "Errors"). If, as end-user, you find the water heater in an error condition, you may attempt to re-start the water heater by pressing the button once. However, if the error returns or occurs several times in a short time, you must contact your service and maintenance engineer. 8.4 Service condition The figure shows the message !!! WARNING !!! MAX. BURNING HOURS: SERVICE REQUIRED SERVICE REQUIRED. If this message appears, the water heater needs a service and maintenance inspection. In this case, contact your service and maintenance engineer. Note The message SERVICE REQUIRED is based on the number of expired burning hours and the preset service interval. If the service interval has been incorrectly selected, contact the service and maintenance engineer for instructions on how to rectify this. Information on the frequency of maintenance is provided elsewhere in the manual (14 "Service interval"). 60 Instruction manual SGE gis 8.5 Anode warning This message appears when the anode protection is no longer active. If the message appears, you must contact your service and maintenance engineer. !!! WARNING !!! POWER ANODE MALFUNCTION Note The water heater continues to function when this message appears. 8.6 Q/T Sensor warning This message appears if the Q/T sensor has 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. !!! WARNING !!! Q/T SENSOR NOT CORRECTLY CONNECTED 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 maintenance engineer. !!! WARNING !!! TEMPERATURE COLLECTOR TOO HIGH Instruction manual SGE 61 8 gis Status of the water heater 62 Instruction manual SGE gis 9 Starting the water heater 9.1 Introduction This chapter covers the following topics: • Starting the appliance. • The appliance's heating cycle. Note The first time the water heater is started, you must enter (12.10 "Solar heating system configuration") the settings of the solar heating system. 9.2 Starting the appliance Start the water heater as follows: 1. Fill the water heater (5 "Filling"). 2. Open (3.5 "Installation diagram") the manual gas valve. 3. Switch on the power to the water heater using the isolator between the water heater and the power supply. 4. Switch the controller ON by setting the ON/OFF switch to positionI. The display will now show INTERNAL CHECK for about 10 seconds and will then go to the main menu. INTERNAL CHECK MENU »OFF ^ ON È WEEK PROGRAM 5. Press once on the blue arrow ( ) to position the cursor beside ON, then press . The display shown in the figure will appear. »START OPERATION ^CHANGE SETPOINT È Tset=65ÉC 6. Confirm the selection START OPERATION with . The appliance is now in "ON mode". If there is a heat demand, the appliance will run through the heating cycle (9.3 "The appliance's heating cycle"). If the heating cycle is not run, 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) falls below the threshold value (Tset). This threshold value depends on the currently selected appliance operating mode. For example, if the appliance is in "OFF" mode (frost protection), then this value is 5°C. If the appliance is in "ON mode", this threshold value is adjustable, for example to 65°C. The heating cycle runs successively through the following states: 1. HEAT DEMAND; 2. PRE-PURGE; 3. PRESSURE SWITCH; 4. PRE-GLOW; 5. IGNITION; 6. RUNNING; 7. POST-PURGE. The entire cycle is explained in the following example, which assumes the water heater is in operating mode ON. Note The same operating cycle applies to the other operating modes. Instruction manual SGE 63 9 gis Starting the water heater When the water heater starts, it will run through the following steps: 1. The water temperature drops below the set temperature of (for example) 65°C. The controller detects a heat demand and starts the operating cycle. - The icon is activated. - The message HEAT DEMAND appears. ON Ê 13:45 Thursday 63ÉC Tset 65ÉC HEAT DEMAND 2. Once demand is registered, the fan is started to vent any gases that may be present. This phase is called pre-purge and lasts about 15 seconds. - The icon is activated. - The message PRE PURGE appears. ON Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC PRE PURGE 3. During the pre-purge, the pressure switch closes. - The icon is activated. - The message PRESSURE SWITCH appears. ON Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC PRESSURE SWITCH 4. This is then followed by the (pre-)glow of the hot surface igniter. - The icons and are dimmed - The icon is activated. ON Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC GLOW PLUG 5. After a number of seconds pre-glow, the gas control valve is opened and ignition takes place. - The icon is activated. - The message IGNITION appears. ON Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC IGNITION 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. ON Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC RUNNING 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 activated. - The message POST PURGE appears. ON Ê Ê 13:45:00 Thursday 65ÉC Tset 65ÉC POST PURGE 8. Following the post-purge, the fan stops and the pressure switch opens: - The icons and are dimmed. - The message POST PURGE vanishes. ON 14:05 Thursday 65ÉC With any subsequent heat demand, the heating cycle will resume from step 1. 64 Instruction manual SGE gis 10 Shutting down 10.1 Introduction This chapter describes: • Decommissioning the water heater for a short period. • Isolating the water heater from the mains; • Decommissioning the water heater for a long period. 10.2 Decommissioning the water heater for a short period To decommission the water heater for a short period, you must activate the frost protection. The frost protection will prevent water from freezing in the water heater. Activate the frost protection as follows: 1. Press button to select the main menu. 2. Using and , place the cursor beside OFF. Confirm with . OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED The frost protection cuts in when the water temperature drops below 5°C. The text FROST will then appear on line one of the display. The water heater will heat the water to 20°C (Tset) before dropping back to mode OFF. Note These values of 5°C and 20°C cannot be adjusted. Caution The anode protection remains active when the OFF mode is selected. Note If the water heater is not used for longer than two months and the water is not drained, air bubbles may form in the water heater. This can lead to air in the water pipes. 10.3 Isolating 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 . MENU »OFF ^ ON È WEEK PROGRAM 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 (position 0) using the ON/OFF switch on the control panel. 6. Isolate the water heater from the power supply by setting the isolator between the water heater and the mains power supply to position 0. Note Setting the main switch between the water heater and the electricity mains to 0 will switch off the power supply to the potentiostat; there is then no longer any anode protection. 10.4 Decommissioning the water heater for a long period Drain the water heater if you are decommissioning it for a long period. Proceed as follows: 1. Isolate the water heater from the power supply (10.3 "Isolating the water heater from the mains"). 2. Shut off the gas supply. 3. Close the stop valve in the hot water pipe. 4. Close the supply valve of the protected cold supply set-up. 5. Open the drain valve 6. Bleed the water heater (or installation) so that it drains completely. Instruction manual SGE 65 10 gis Shutting down 66 Instruction manual SGE gis 11 Main menu 11.1 Introduction The MENU is reached by pressing the button on the controller. MENU »OFF ^ ON È WEEK PROGRAM EXTRA PERIOD SETTINGS The main menu comprises: • OFF Select this option if you wish to shut the water heater down (10 "Shutting down") for a brief period, but do not wish to drain it. In this mode, the frost protection is active. This prevents water from freezing in the water heater. • ON In this mode, the water heater continually responds to the hot water demand (11.3 "Switching to "ON mode""). • WEEK PROGRAM Select this option to allow the water heater to respond to demand only during pre-programmed periods (11.5 "Week program"). Outside those periods, only frost protection is active. • EXTRA PERIOD Select this option to overrule OFF mode or PROG mode (i.e. Week program) so that a single temporary period (11.10 "Extra period") of heat demand will be fulfilled. • SETTINGS Select this option to set (11.11 "Settings") the language and the time. You can also use this option to display the regulation interval (temperature), and the ignition and working speeds of the fan. Note If you fail to make any selection with the main menu open, then after 30 seconds, the 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, LANGUAGE is a sub-menu of SETTINGS. So, for example, to select menu LANGUAGE, this manual employs the following convention: • : SETTINGS | LANGUAGE Confirm with . This means: 1. : Activate the main menu with . 2. SETTINGS: Using button and/or go to SETTINGS and confirm with . 3. LANGUAGE: Using button and/or go to LANGUAGE 4. Confirm with . After pressing , you will have activated sub-menu LANGUAGE. 11.3 Switching to "ON mode" You can switch the water heater to ON mode from any operational mode, as follows: 1. : ON | START OPERATION Confirm with . Note Also refer to the chapter on starting the water heater (9 "Starting the water heater"). 11.4 Setting the water temperature 11.4.1 Setting the water temperature via the SET POINT MENU Set the water temperature via: 1. : ON | CHANGE SETPOINT Confirm with . START OPERATION ^»CHANGE SETPOINT È Tset=65ÉC Instruction manual SGE 67 11 gis 2. Use: • to increase the value; • to decrease the value. Main menu 11.6 Starting and stopping the week program The week program can be started up from any other • Confirm with .After confirming, the water heater enters "ONmode". SETPOINT » 65ÉC 11.4.2 Setting water temperature during ON mode The water temperature can also be directly adjusted when the water heater is in "ONmode". Simply use: • to increase the value; • to decrease the value. • Confirm with . ON 13:45 Thursday 65ÉC Tset»65ÉC 11.5 Week program Using the week program, you can set the water temperature for the days and times you want. If the appliance is running under a week program, then this is indicated on the display by the text PROG on the first line (see the figure). The second line shows the time of day, the day of the week and the temperature. The third line shows the next switching time of the week program and the programmed temperature. The fourth line shows the text PROGRAM ACTIVATED. PROG 07:55 Monday 64?C MO 08:00 Tset 75?C PROGRAM ACTIVATED The appliance's default week program switches the appliance on every day at 00:00 and off at 23:59. The default water temperature setting is 65oC. If you want, you can change every setting in the appliance's standard week program. If the water temperature becomes too low while the week program is running, the appliance will run through the heating cycle (9.3 "The appliance's heating cycle") and return to the week program. 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 operating mode, as follows: 1. : WEEK PROGRAM | START OPERATION Confirm with . A week program can be shut down simply by activating a different operating mode, for example the "ON mode". 11.7 Changing the appliance's standard week program Note First fill-in the desired week program on the supplied week program card. A week program is made up of a number of programmable periods in which you can have the appliance switch on and off. A period consists of: • switch-on time: day of the week, hours and minutes: • switch-off time: hours and minutes; • the water temperature setting; • on/off setting for a program-controlled pump. Note The switch-off time must always be followed by a switch-off time on the same day of the week. A maximum of three periods may be programmed per day. You can program a maximum of 21 periods. Call up the menu for the week program as follows: • : WEEK PROGRAM | PROGRAM OVERVIEW. Confirm with . WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È 68 Instruction manual SGE gis The display shows the menu for the week program, see the figure below. With the default setting, the program switches on and off every day at 00:00 and 23:59 respectively, the water temperature is 65ºC and the pump is switched on (P). DAY TIME Tset ON »SU 00:00 65?C P OFF SU 23:59:00 ON MO 00:00 65?C P OFF MO 23:59 ON TU 00:00 65?C P OFF TU 23:59 ON WE 00:00 65?C P OFF WE 23:59 ON TH 00:00 65?C P OFF TH 23:59 ON FR 00:00 65?C P OFF FR 23:59 ON SA 00:00 65?C P OFF SA 23:59 INSERT DELETE START OPERATION Example As an example, we will set the switch-on time for Sunday to 08:15 hours, and the matching switch-off time to 12:45 hours. The water temperature will be set to 75ºC and the pump will run continuously. The following settings are entered one by one using the menus: the switch-on time, the switch-off time, the desired water temperature, and the mode of the program-controlled pump. 11.7.1 Week program: setting the switch on time 1. Bring the cursor to SU Confirm with . ON »SU 00:00 OFF SU 23:59 Tset 65ÉC PUMP ON SAVE The day indicated by » blinks. 2. Use and to set the desired day. In the example this is SU (Sunday). Confirm with . ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON SAVE The cursor moves to the hour digits, which will blink. 3. Use and to set the hours. In the example, this is 08. Confirm with . The cursor moves to the minute digits, which will blink. ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON SAVE 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. ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON SAVE 11.7.2 Week program: setting the switch off time 1. Use and to set the hours. In the example, this is 12. Confirm with . The cursor moves to the minute digits, which will blink. ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON SAVE 2. Use and to set the minutes. In the example, this is 45. Confirm with . The cursor moves to the desired water temperature. ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON SAVE Instruction manual SGE 69 gis 11.7.3 Week program: 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 ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON SAVE 11.7.4 Week program: 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 circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit. Confirm with . The cursor moves to SAVE. ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »SAVE 2. Confirm with . The display shown in the figure will appear. DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59 3. If you wish, you can use to scroll to another day, and change more switch-on (11.7.1 "Week program: setting the switch-on time") and switch off (11.7.2 "Week program: setting the switch-off time") times . 4. After changing all desired switch-on and switch off times, you can start running the week program: Scroll with to START OPERATION. Confirm 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 . WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È The display shows the menu for the week program. The cursor points to the active period. DAY TIME Tset ON »SU 08:15:00 75?C P OFF SU 12:45:00 ON MO 00:00 65?C P .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION 2. Scroll to INSERT. Confirm with . The submenu for adding a period will appear. ON »SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON SAVE Example As an example, we will program an extra period in which the switch-on time is set to 18:00 and the corresponding switch-off time to 22:00. The water temperature will be set to 75oC and the pump will run continuously. DAY TIME Tset ON »SU 18:00 75?C P OFF SU 22:00 ON MO 00:00 65?C P OFF MO 23:59 .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION Instruction manual SGE 70 gis 3. Proceed as follows: a. Set the switch-on time (11.7.1 "Week program: setting the switch-on time"). b. Set the switch-off time (11.7.2 "Week program: setting the switch-off time"). c. Set the water temperature (11.7.3 "Week program: setting the water temperature"). d. Set the program-controlled pump (11.7.4 "Week program: setting the program-controlled pump"). 5. To activate the week program with the new period added, scroll down with to START OPERATION and confirm with . 11.9 Deleting times from a week program All switch-on/off times are shown sequentially in the display. Assume that the switch-on/off times for the water heater are programmed as in the figure. DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P OFF SU 22:00 .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION To delete a period, proceed as follows: 1. : WEEK PROGRAM | PROGRAM OVERVIEW. Confirm with . MENU OFF ^»ON È WEEK PROGRAM 2. Scroll with to PROGRAM OVERVIEW. Confirm with . WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È 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. DAY TIME Tset ON !SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P OFF SU 22:00 .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION 4. Scroll with to the day to be deleted. For example, SU (Sunday) in the second period. See the figure. Confirm with . DAY TIME Tset ON !SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P OFF MO 23:59 .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION 5. The lines showing switch-on/off times are replaced by the text DELETE BLOCK?. See the figure. Confirm with . (or use to cancel) DAY TIME Tset ON ! DELETE OFF BLOCK? ON MO 00:00 65ÉC P Instruction manual SGE 71 gis The switching period has been deleted. You will return now to the week program menu. The cursor points to the first programmed period. DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P OFF MO 23:59 .................... .................... OFF SA 23:59 INSERT DELETE START OPERATION 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 water heater switch on and off for a certain period, either without modifying the active week program, or without taking the water heater out of OFF mode (frost protection active). If the water heater is running under an "extra period", then this is indicated in the display with the text EXTRA. EXTRA 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC PERIOD ACTIVATED During the extra period (11.10.1 "Programming an extra period"), if the water temperature becomes too low, the water heater will run through the operating cycle (9.3 "The appliance's heating cycle"), then return to the extra period. The same settings can be made for an extra period as for a week program (11.7 "Changing the appliance's standard week program"). 11.10.1 Programming an extra period 1. Call up the menu for entering an extra period via: 2. : EXTRA PERIOD Confirm with . MENU ON ^ WEEK PROGRAM È»EXTRA PERIOD The display show the settings for the extra period. Setting the switch-on time 1. Use and to set the day. In the example this is SU. Confirm with . The cursor moves to the hour digits, which will blink. ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON START 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. ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON START Note Because the switch-off time can never be earlier than the switch-on time, the switch-off time setting is automatically adjusted with the switch-on time. 3. Use and to set the minutes. In the example, this is 15. Confirm with . The cursor moves to the hour digits of the switch off period. ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON START 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 will blink. ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON START Instruction manual SGE 72 gis 2. Use and to set the minutes. In the example, this is 45. Confirm with . The cursor moves to the water temperature. See the figure ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON START 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 ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON START 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 circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit. Confirm with . The cursor moves to START. ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »START 2. Confirm with . The extra period has been programmed. Note Once the extra period has completed running, the controller returns to the mode ON, OFF or WEEK PROGRAM. The following week, the extra period will NOT be automatically switched back on. 11.11 Settings 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. 11.11.1 Setting menu language To set menu language: MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS 1. Call up the menu for selecting the language as follows: 2. : SETTINGS. Confirm with . The display shows the menu for settings. SETTINGS »LANGUAGE ^ DAY/TIME È SPECIFICATIONS 3. The cursor is positioned beside LANGUAGE Confirm with . The display shows the language selection menu. LANGUAGE ENGLISH ^ NEDERLANDS È»DEUTSCH FRANCAIS ITALIANO CZECH ESPANOL 4. Scroll with to the desired language. Confirm with . The language is set. Instruction manual SGE 73 gis 11.11.2 Setting day and time To enter the time and day: MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS 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/TIME Confirm with . SETTINGS LANGUAGE ^»DAY/TIME È SPECIFICATIONS The display shows the sub-menu for adjusting the day. DAY »Sunday ^ Monday È Tuesday Wednesday Thursday Friday Saturday 4. The cursor is positioned beside Sunday. Scroll with and to the desired day. Confirm with . The day has been set. The display shows the sub menu for adjusting the time. TIME »00:00 5. The cursor moves to the hour digits, which will blink. Scroll with and to the current hour, for example 15. Confirm with . TIME 15»00 6. The cursor moves to the minute digits, which will blink. Scroll with and to the next minute, for example 45. Confirm the minute setting with TIME 15»45 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 . MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS 2. Scroll with to SPECIFICATIONS Confirm with . SETTINGS LANGUAGE ^ DAY/TIME È»SPECIFICATIONS The display shows the sub-menu for displaying water heater specifications. SPECIFICATIONS »REGULATION INTERVAL ^ IGNITION SPEED È WORKING SPEED 3. Scroll with to the section to be displayed, for example REGULATION INTERVAL. The corresponding display appears. REGULATION INTERVAL 40_80ÉC Instruction manual SGE 74 is 12 Service program 12.1 Introduction The service program is used by the installation engineer or service and maintenance engineer for: • Displaying the water heater history • Displaying the error history • Displaying the water heater history • Display the selected water heater • Switching the pump on or off • Setting the service interval • Service mode • Setting legionella prevention • Solar heating system configuration • Setting the central heating configuration SERVICE MENU »HYSTERESIS ^ ERROR HISTORY È APPLIANCE HISTORY SELECT APPLIANCE PUMP RELAY SERVICE INTERVAL SERVICE OPERATION ANTI LEGIONELLA SETTINGS SOLAR SETTINGS HEATING These sub-menus are briefly described in the following paragraphs. If you are not generally familiar with the use of the displays and menus, first read the relevant chapter (7 "The control panel"). Note The notation convention for the service menu is identical to that of the main menu (11.2 "Notation convention for menu-related instructions"). The difference is, you use to bring up the service program, instead of which brings up the main menu. 12.2 Setting the hysteresis Call up the menu to set the hysteresis as follows: : HYSTERESIS DOWN HYSTERESIS DOWN »3ÉC 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 error messages. If there are fewer than 15 error messages, an ellipsis (...) is displayed. The display first shows the "Blocking errors". When is pressed, the "Lock out errors" are then displayed. The figure shows an example of "Blocking errors". In this case, the text ERROR HISTORY is followed by (B). ERROR HISTORY(B) S04 SENSOR ERROR F06 IONIZATION È CO2 50 HZ ERROR The figure shows an example of "Lock out errors". In this case, the text ERROR HISTORY is followed by (L). ERROR HISTORY(L) F02 FAN F07 FLAME ERROR È ... Note For an overview of all errors and the possible causes, please refer to the relevant chapter (13 "Errors"). Instruction manual SGE 75 is 12.4 Displaying the water heater history The water heater history sub-menu is used to display the burning hours, the number of ignitions, the number of flame errors and the number of ignition errors. Call up the menu for displaying the water heater history as follows: • : APPLIANCE HISTORY The figure shows an example. APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021 IGNIT ERROR 000013 12.5 Display the selected water heater Call up the menu for displaying the water heater selection as follows: • : SELECT APPLIANCE The water heater number can be found on the rating plate. The water heater selection has been correctly preset in the factory. SELECT APPLIANCE »5934 ^ 8576 È 3379 6527 .... 12.6 Switching the pump on or off If a program-controlled pump is installed (3.11.5 "Connecting a program-controlled pump") , it can be switched ON or OFF as follows: • : PUMP RELAY The standard setting for the pump relay is OFF. PUMP RELAY »ON OFF If the mode WEEK PROGRAM or EXTRA PERIOD is active, then the setting for mode WEEK PROGRAM or EXTRA PERIOD has priority over the ON/OFF selection for the pump relay in the service menu. Example One of the week program periods is currently active. During this period, the pump relay setting is OFF. If the pump relay is set ON in the service menu, the pump will nonetheless remain OFF. The pump will only switch ON once the week program period has ended. 12.7 Setting the service interval The service interval is a feature 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 condition") will appear. Set the service interval as follows: • : SERVICE INTERVAL SERVICE INTERVAL 6 9 Months »12 12.8 Service mode The Installation engineer uses the SERVICE OPERATION menu to adjust the water heater CO2 setting duringFULL LOAD and PARTIAL LOAD operation. Use :SERVICE OPERATION to display the SERVICE OPERATION menu. SERVICE OPERATION »FULL LOAD PARTIAL LOAD and can be used to switch between PARTIAL LOAD and FULL LOAD. If there is a heat demand, the water heater will first run through a startup cycle, then continue to operate in FULL LOAD or PARTIAL LOAD mode. If there is no heat demand, the installation engineer must create one. This can be done by draining the water heater until it is cold or by temporarily raising the set point using . After adjustment, the set point must be set back to the original value using . if you exit the SERVICE OPERATION menu or if no buttons are pressed for a period of 15 minutes, the water heater will revert to the original operating mode. Instruction manual SGE 76 is Temporarily raising the setpoint during FULL LOAD or PARTIAL LOAD 1. :>:SERVICE OPERATION. SERVICE OPERATION »FULL LOAD PARTIAL LOAD 2. Select FULL LOAD or PARTIAL LOAD. The example below describes the situation for FULL LOAD, which is identical to that for PARTIAL LOAD. 3. Confirm with . SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 65ÉC RUNNING 4. To create a heat demand, you can temporarily raise the set point using to e.g. 70oC. SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 70ÉC RUNNING 5. Confirm with . 6. After adjusting for the CO2 value (3.13.3 "CO2 adjustment"), you must use to restore the set point to its original value. 7. Press twice to return to the MENU menu via the SERVICE OPERATION menu. MENU »OFF ^ ON È WEEK PROGRAM EXTRA PERIOD SETTINGS 12.9 Setting legionella prevention To prevent infection with legionella bacteria, the water heater heats the water to 65 °C once per week, for 1 hour. This period is adjustable. By default, this period is set to Monday from 02:00 to 03:00 hours. 12.9.1 Switching legionella prevention on and off To switch legionella prevention on or off, select: • : ANTI LEGIONELLA ANTI LEGIONELLA »YES NO • Select NO to switch legionella prevention off. • Select YES to switch legionella prevention on. The following screen appears: ON MO 02:00 LEG OFF MO 03:00 Tset 65ÉC »START Change • Select START to activate the period currently displayed. The following display appears. This display indicates that legionella prevention is switched on. LEG Ê Ê Ê 02:45 Monday 60ÉC MO 03:00 Tset 65ÉC RUNNING 12.9.2 Changing legionella prevention start time If you wish to change the start time, select: : ANTI LEGIONELLA | YES | Change The following display appears. ON ÈMO 02:00 LEG OFF MO 03:00 Tset 65ÉC START • Now set the day and time the same way as described for setting an extra period in the week menu (11.10.1 "Programming an extra period"). In this case however, the pump will be automatically started. • Select START to start. Instruction manual SGE 77