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Installation Installation User and User and Service Manual Service Manual WATER PRODUCTS WATER PRODUCTS COMPANY COMPANY A DIVISION OF A. O. SMITH CORPORATION A DIVISION OF A. O. SMITH CORPORATION...
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www.aosmithinternational.com your installer...
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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 improper use other than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven Chamber of Commerce.
Introduction About the appliance This manual describes how to install, service and use the GWV appliance. This appliance is a closed, gas-fired water heater with a fan in the air supply. The appliance is always supplied together with a storage tank. The possible categories for this appliance are C13, C33, and B23.
Introduction Furthermore, the installation must comply with the manufacturer's instructions. guidelines published on or prior to the moment of installing, will apply to the installation. Target groups The three target groups for this manual are: • • • Symbols on each page indicate the target groups for whom the information is intended.
Overview of this The table provides an overview of the contents of this document. document Contents of this document Chapter Target groups Working principle of the appliance Installation Filling Draining The control panel Status of the appliance Starting and running Shutting down Main menu Service program...
Working principle of the appliance Introduction Topics covered in this chapter: • • • • General working The figure shows a cut-away view of the appliance. principle of the appliance Instruction manual GWV General working principle of the appliance; The appliance's heating cycle;...
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Working principle of the appliance Cut-away view of the appliance Instruction manual GWV...
Legend Hot water outlet Insulation layer Electrical connector block Aluminium strips ThermoControl (electronic controller) Flue gas discharge Jacket cover plate Air supply Gas controls In this appliance, the cold water enters the bottom of the storage tank through the cold water inlet (24). The system pump (22) ensures that the water flows into the appliance.
Working principle of the appliance Protection for the appliance 2.4.1 Introduction The electronic controller monitors the water temperature and ensures safe combustion. This is achieved by: • • • • • • 2.4.2 Water temperature protection The electronic controller monitors the water temperature with temperature sensors T Temperature protection Safety...
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Pressure measurements are made at the air distribution plate (high pressure) and in a Venturi in the burners (low pressure). The table shows the trip point per appliance. Pressure switch trip points Appliance GWV 120 GWV 150 GWV 200 2.4.6 Flame probe To ensure that no gas can flow when there is no combustion, the water heater has a flame probe (14).
Working principle of the appliance Safety of the instal- lation As well as the standard safeties in the appliance appliance"), it must also be protected by an inlet combination and a pressure- reducing valve. A P-valve is also used. 2.5.1 Unvented installation With unvented installation, an expansion valve and expansion vessel prevent excessive pressure in appliance.
Installation in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations Introduction This chapter describes the installation activities to be carried out before you...
Installation Environmental conditions are stored or used due to the risk of explosion and corrosion of the appliance. Some propellants, bleaching agents and degreasing agents etc. disperse vapours that are explosive and/or cause accelerated corrosion. If the appliance is used in a room in which such substances are present, the warranty will be void.
(alkaline earth ions) Conductivity Acidity (pH value) tank protection cannot be guaranteed If the water hardness is greater than 4° dH, please contact A.O. Smith. 3.3.4 Working clearances For access to the appliance and the storage tank it is recommended that the following clearances are observed: •...
Installation Technical specifica- Check the dimensions data tions specifications") 3.4.1 Dimensions of the appliance Plan and elevation of the appliance (3.4.1 "Dimensions of the (3.4.3 "Gas data") and other specifications of the appliance. appliance"), the gas (3.4.2 "General and electrical IMD-0483 R0 Instruction manual GWV...
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Dimensions (all measurements in mm unless otherwise indicated) Size Description Overall height Height of pump connection + heat exchanger outlet Length of appliance Length including flow switch Width of appliance Air supply diameter Diameter of flue gas discharge Centre-to-centre distance between air supply/flue gas outlet Air supply distance Air supply/flue gas discharge distance...
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Installation Contact ratings Electrical power consumption Supply voltage Operating pressure Operating pressure 3.4.3 Gas data Gas data Description II 2H3P Gas category 2H: G20 - 20 mbar Orifice diameter (1) = Blank plate (2) = Burner pressure regulator Nominal load (upper value) Nominal output Supply pressure Burner pressure...
Installation diagram This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described. Installation diagram Unvented Vented Instruction manual GWV IMD-0486 R2 IMD-0487 R2...
Installation Legend Only applicable numbers are mentioned. pressure-reducing valve (mandatory if the mains water pressure exceeds 8 bar) inlet combination (mandatory) expansion valve stop valve (recommended) non-return valve (mandatory) circulation pump (optional) drain valve manual gas valve (mandatory) service stop valve temperature gauge (recommended) Water connections, Vented...
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Distance X Pipe diameter Distance X • • • You set the revs using the pump's adjuster unit. Proceed as follows: 1. Unscrew the pump's cap. 2. The pump's adjuster unit can be seen. 3. Take the adjuster unit out. 4.
Installation 6. Put the cap back on the adjuster unit. 7. Insert the adjuster unit back in the pump. 8. Fit the cap back on the pump. Water connections, Unvented in compliance with general and local regulations 3.7.1 Cold water side See (A) in the installation diagram 1.
Gas connection in compliance with general and local regulations enough to supply sufficient capacity to the appliance. See (D) in the installation diagram 1. Fit a manual gas valve (10) in the gas supply pipe. 2. Blow the gas pipe clean before use. 3.
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Installation C13: appliance with wall conduit C33: appliance with roof conduit for this category of appliance. Note Make sure that the chimney discharges into an area where this is permitted IMD-0503 R0 IMD-0509 R0 Instruction manual GWV...
3.9.3 Parallel connections The air supply duct and flue gas outlet duct for the GWV 120, 150 and 200 exit the appliance separately. They must be connected flue gas discharge materials") using a transition piece. The following requirements must also be fulfilled: •...
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Installation Specifications for transition piece and concentric wall flue terminal (C13) Subject Wall flue terminal set: • 1x wall flue terminal (incl. transition piece) • 1x wall plate • 1x clamping ring • 2x pipe, 500mm • 3x bend, 90° Pipe material Pipe diameters No other wall flue terminal is permitted.
Specification of condensation outlet for uninsulated lengths greater than 8 metres and no more than 20 metres Subject Condensation outlet set • 1x clamping ring • 1x trap • 2x pipe Ø 32x500 mm • 2x bend, Ø 32 90 Pipe material Pipe diameters 3.10 Electrical...
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Installation Connector block Legend screws protector plate connector block As part of the preparations, you should first remove the protective plate from the electrical section. 1. Loosen the 2 screws (A) of the electrical section, and remove the protective the electrical component connections. cap (B) from the electrical section.
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Electrical connector block Terminal Name Function Earth connection External on/off switch Earth connection Alarm signal Earth connection Program-controlled pump System pump Mains voltage (230VAC-50Hz) 3.10.3 Connecting the mains voltage The appliance is supplied without a power cable and isolator. connected to the mains voltage. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance.
Installation 4. If you do not need to make any more connections: 3.10.5 Connecting an external on/off switch There is an option for connecting an external ON/OFF switch. In the OFF position, the programmed operating state is active. In the ON position, the programmed operating mode is overruled, and the "ON mode"...
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Gas control Legend Only applicable numbers are mentioned. supply pressure test nipple burner pressure test nipple burner pressure regulator burner pressure control cap burner pressure control adjusting screw 3.11.1 Preparation To check the supply pressure and burner pressure, proceed as follows: 1.
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Installation MENU ^ ON È WEEK PROGRAM 7. Activate the "ON mode" by going through the following steps: »START OPERATION ^ CHANGE SETPOINT È 8. When the display shows the text RUNNING 2, you must wait about 1 9. Use the pressure gauge to read the supply pressure at the test nipple 10.
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3. Cover the opening of the adjusting screw and check the burner pressure 4. If the pressure is not set correctly, repeat the preceding steps until the 5. Fit the cap (4) back on the burner pressure regulator. 6. Activate the "OFF mode" of the electronic controller: MENU ^ ON È...
The conversion instructions are not part of this manual. Contact A.O. Smith if conversion is needed. Instruction manual GWV Caution The conversion may only by carried out by an authorised installation...
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Conversion to a different gas category Instruction manual GWV...
Filling Installation diagram This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described. Installation diagram Unvented Instruction manual GWV IMD-0486 R2...
Filling Vented Legend Only applicable numbers are mentioned. pressure-reducing valve (mandatory if the mains water pressure exceeds 8 bar) inlet combination (mandatory) expansion valve stop valve (recommended) non-return valve (mandatory) circulation pump (optional) drain valve manual gas valve (mandatory) service stop valve temperature gauge (recommended) Filling unvented To fill the appliance, proceed as follows:...
9. The appliance is now under water supply pressure. There should be no Filling vented instal- To fill the appliance, proceed as follows: lations 1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves 2.
Draining Installation diagram This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described. Installation diagram Unvented Instruction manual GWV IMD-0486 R2...
5. Switch the appliance OFF (position 0) using the ON/OFF switch on the 6. Isolate the water heater from the power supply by putting the isolator 7. Shut off the gas supply (10). 8. Close the stop valve (11) in the hot water pipe. 9.
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Draining 9. Close the stop valve (4) between the water tank and the cold water inlet (A). 10. Open the drain valve (9). 11. Bleed the appliance (or installation) so that it drains completely. Instruction manual GWV...
The control panel Introduction Topics covered in this chapter: • Operation; • Meaning of icons; • Electronic controller ON/OFF switch; • Navigation buttons; • connection. Operation The entire appliance is controlled and monitored by the ThermoControl (the electronic control).The figure shows the electronic controller.
PC connection The PC connection is solely intended to enable technicians from A.O. Smith to display the status and history of the appliance. These details can be important for troubleshooting and/or responding to complaints.
Status of the appliance Introduction Topics covered in this chapter, in sequence: • Operating modes • Error conditions • Service condition • Warning Operating modes When running, the appliance has four basic operating modes, namely: • • • PROG • EXTRA 8.2.1 In this mode, the frost protection is activated.
Status of the appliance In all modes, the temperature may at any moment drop below the desired temperature. The appliance then enters a heating cycle. This heating cycle is identical (2.3 "The appliance's heating cycle") basic operating modes. Note Setting and programming the basic operating modes is described in the chapter on the Main menu (11 "Main...
Starting and running Introduction Topics covered in this chapter, in sequence: • Starting and running. • The appliance's heating cycle. Starting and running Start the appliance as follows: 1. Fill the appliance "Filling"). 2. Open (3.5 "Installation diagram") the manual gas valve.
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Starting and running Once the appliance starts, it will run through the following steps: 1. The water temperature drops below the set temperature of (for example) 65°C. The electronic controller detects a demand and starts the heating cycle. The icon is activated.
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10. When the water is up to temperature, the heat demand drops off and the post-purge starts. This lasts about 25 seconds. icons are removed. icon is activated. The message POST PURGE appears. Ê Ê 13:45 Thursday 65ÉC Tset 65ÉC POST PURGE 11.
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Starting and running Instruction manual GWV...
Shutting down 10.1 Introduction This chapter describes: • Shutting the installation down for a brief period ("OFF mode"); • Isolating the appliance from the mains; • Shutting the appliance and storage tank down for a long period. 10.2 Shutting the installation down for a brief period ("OFF mode") To shut the installation down for a brief period, you must activate the frost protection.
Main menu 11.1 Introduction The MENU is reached by pressing the electronic controller. MENU »OFF ^ ON È WEEK PROGRAM EXTRA PERIOD SETTINGS The main menu comprises: • Select this option if you wish to shut the appliance down (10 "Shutting down") for a brief period, but do not wish to drain it.
Main menu • Confirm with .After confirming, the appliance enters "ON mode". SET POINT » 65ÉC Note If the temperature setting is higher than the current water temperature, it is possible that the appliance will not immediately start heating. To prevent excessively frequent switching on and off, there is a heating margin.
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The display shows the menu for the week program (see 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 65ÉC P...
Main menu 11.7.4 Week program: setting the program- controlled pump 1. If required, a pump can be controlled during the period. Use 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.
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 appliance are programmed as in the figure. DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 18:00 75ÉC P OFF SU...
Main menu 11.11 Programming an extra period 1. Call up the menu for entering an extra period via: : EXTRA PERIOD Confirm with MENU ^ WEEK PROGRAM ȻEXTRA PERIOD The display show the settings for the extra period. 11.11.1 Setting the switch-on time 1.
11.12 Settings Using the SETTINGS option, you can adjust certain settings and read certain appliance data: • Adjustable settings Language of the menu. Current day of week and time. • Displayable appliance specifications, this category is only relevant to the installation engineer and/or service and maintenance engineer Control range (water temperature).
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Main menu Confirm the minute setting with TIME 15»45 The time has been set. Note The appliance takes no account of summer time. 11.12.3 Displaying appliance specifications Note This category is only relevant to the installation engineer and/or service and maintenance engineer. The table shows the correct settings.
Service program 12.1 Introduction The service program is used by the installation engineer or service and maintenance engineer for: • Setting the hysteresis; • Displaying the error history; • Displaying the appliance history; • Displaying the appliance selection; • Switching the pump on or off;...
Service program APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021 IGNIT ERROR 000013 12.5 Displaying the appliance selection To display the appliance selection, use: • : SELECT APPLIANCE The appliance number can be found on the rating plate. The appliance selection has been correctly preset in the factory.
The appliance switches from partial load to full load if the temperature difference between the water in the storage tank (T ) and the set point (T negative hysteresis is greater than this stage difference. Conversely, the apparatus switches from full load to partial load if this temperature difference is smaller than the stage difference.
Troubleshooting 13.1 Introduction A distinction is made between: • • S02: SENSOR ERROR S02: SENSOR ERROR • Instruction manual GWV General errors General errors are not reported on the display. General errors are: Gas smell Display does not light up Insufficient or no hot water.
13.2 Troubleshooting table for general errors Warning Maintenance may only be performed by a qualified service and maintenance engineer. General errors Features Cause Measures to take Gas smell Gas leak Display is off Appliance is turned off Start the appliance up No supply voltage 1.
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Features Cause Measures to take Explosive ignition Incorrect supply Set the correct supply pressure and/or burner pressure and/or burner pressure. pressure pressure") Contaminated burner Clean the burner(s) Contaminated orifice Clean the orifice(s) Hot water supply Appliance is turned off Start the appliance up insufficient or absent No supply voltage 1.
13.3 Troubleshooting table for displayed errors Displayed errors Code + description Cause Measures to take S01 (blocking error) Sensor is not (correctly) Connect the sensor lead to JP3 connected Open circuit for Damaged cable or Replace sensor T temperature sensor T defective sensor inlet to heat exchanger S02 (blocking error)
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Code + description Cause Measures to take S11 (blocking error) Short circuit in sensor Replace sensor T circuit Short-circuit for temperature sensor T inlet to heat exchanger S12 (blocking error) Short circuit in sensor Replace sensor T circuit Circuit for sensor 1 of temperature sensor T is shorted.
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Code + description Cause Measures to take F01 (blocking error) Live and neutral Connect live and neutral correctly connected wrong way the appliance is phase-sensitive round Defect in power supply circuit Condensation on the 1. Disconnect the lead at the flame probe flame probe 2.
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Code + description Cause Measures to take F03 (lock out error) Damaged wiring/Open 1. Check the wiring between the pressure switch and the circuit The pressure switch 2. If necessary, replace the wiring fails to work correctly Pressure switch not 1.
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Code + description Cause Measures to take F04 (lock out error) No gas 1. Open the main gas valve and/or the manual gas valve supplying Three unsuccessful 2. Check the supply pressure to the gas control ignition attempts. 3. If necessary, repair the gas supply Air in the gas pipes Bleed the air out of the gas pipe No burner pressure...
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Code + description Cause Measures to take F06 (blocking error) Damaged cable in Check the wiring of the flame probe. Replace the wiring if contact with metal necessary.. surface. Short circuit between flame probe and earth Ceramic part of the 1.
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Code + description Cause Measures to take F10 (lock out error) Pressure switch not 1. Check the running speed of the fan closing 2. Check that the hoses are fitted correctly to the pressure switch Restriction on the number of ignition attempts based on 3.
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Code + description Cause Measures to take C02 (lock out error) Incorrect reference 1. Reset electronic controller. voltage from the AD 2. Check that the frequency of the power supply is converter. Error message from the appliance controller. 3. If the frequency is correct but the error persists, replace the Internal error message •...
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Code + description Cause Measures to take E03 (lock-out error) The two temperature 1. Check sensor position and wiring. sensors in the tank 2. If necessary, reset the electronic controller. Replace the sensor detect a differential of > Error in temperature C over a period of sensor T , outlet of...
13.4 Warnings Warning Maintenance may only be performed by a qualified service and maintenance engineer. Features Cause The display shows the text: Fan is running at the wrong speed during !!! WARNING !!! full load. WORKING SPEED 2 NOT CORRECT (see note 1) The display shows the text: Defective pump...
Maintenance frequency 14.1 Introduction A service should be carried out at least once a year, both on the water side and on the gas side. Maintenance frequency depends, among other things, on the water quality, the average burning time per day and the set water temperature. To determine the correct maintenance frequency, it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side, three months after installation.
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Maintenance frequency Instruction manual GWV...
Performing maintenance 15.1 Introduction maintenance engineer. At each service, the appliance undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order. model, and the full serial number of the appliance. These details can be found on the rating plate.
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Performing maintenance 6. Switch the electronic controller ON by setting the On/Off switch to position I. MENU ^ ON È WEEK PROGRAM 7. Activate the 'ON mode' by going through the following steps: 8. If there is no heat demand, increase Tset 9.
15.3 Water-side mainte- nance 15.3.1 Introduction The following steps must be carried out on the water side: 15.3.2 Checking the anodes Timely replacement of the anodes extends the service life of the appliance. The appliance's anodes must be replaced as soon as they are 60% used or more (take this into consideration when determining the maintenance frequency).
Performing maintenance 15.4 Gas-side mainte- nance 15.4.1 Introduction The following steps must be carried out on the gas side: 15.4.2 Clean the burner(s) 1. Dismantle first the yellow flexible gas hose, the manifold and then the 2. Remove all contamination present on the burner(s). 3.
If within one year of the original installation date of an appliance supplied by A.O. Smith following verification, and at the sole option of A.O. Smith, a section or part proves to be defective or fails to function correctly due to manufacturing and/or material defects, then A.O.
Smith warranty expressly set out in this Certificate. A.O. Smith is not liable for damage to persons or property caused by (parts or components, or the glass-lined steel storage tank of) a (replacement) appliance that it has supplied under the terms of this warranty, nor on any other grounds.
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TERMINAL BLOCK CONNECTIONS: CONTROLLER CONNECTIONS: JP12 Connection for flow-through switch Instruction manual GWV Earth Neutral Phase input of controller Phase input of system pump Phase input of program-controlled pump COMPONENTS: Controller Flame probe Hot surface igniter Gas control 1 Gas control 2 Display External ON mode switch Alarm signal...
17.3 Week program card You can cut the week program card out and keep it near the appliance. Period TIME Example Period TIME 14:30 16:15 Instruction manual GWV Tset Pump Period ...°C ON / OFF ...°C ON / OFF ...°C ON / OFF ...°C ON / OFF...
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Index ambient temperature 20 appliance displaying history 69 displaying selection 70 connect air supply 29 cold water side 26, 28 electrical 33 hot water side 28 connecting cold water side 26, 28 connecting flue gas discharge 29 connecting hot water side 28 controls 61 conversion to a different gas category 41 display 51...
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Index Instruction manual GWV 0307 971 4.0 UK...