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Summary of Contents for A.O. Smith Innovo 12-160
- Page 1 Water Heaters Innovo Condensing High-Efficiency Water Heater IR - 12-160/12-200/20-160/20-200/24-245/ IR - 24-285/32-245/32-285/32-380 Installation, Service, Maintenance and User Manual Innovation has a name.
- Page 2 A.O. Smith UK, Unit B8 Amstrong Mall, Southwood Business Park, Farnborough, Hampshire GU14 0NR Water www.aosmith.co.uk Heaters “A.O. Smith Water Heaters” is a trading name of Advance Services (Sales) Ltd. Reg.
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Page 3: Preface
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 in this manual. Trademarks Brand names in this manual are registered trademarks of their respective owners. -
Page 4: Regulations
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. -
Page 5: Contact Information
Contact information If you have any comments or questions, please contact: A.O. Smith Water Products Company Adress: PO Box 70 5500 AB Veldhoven The Netherlands Telephone: 0870 - AOSMITH (free) 0870 - 267 64 84 General: +31 40 294 25 00... -
Page 7: About This Manual
About this manual Scope This manual gives information about safe and correct use of the water heater and how installation, maintenance and service activities have to be done correctly. You must obey the instructions in this manual. Caution Read this manual carefully before you start the water heater. It can cause personal injury and damage to the water heater when you do not read the manual and/or do not obey the instructions. -
Page 8: Document Identification
This manual contains the following text styles/symbols for situations that may endanger users/engineers, cause damage to equipment or need special attention: Note A note gives more information on a topic. Caution Obey the caution instructions to prevent damage of the water heater. Warning Obey the warning instructions to prevent danger of personal injury, and serious damage to the water heater. -
Page 9: Table Of Contents
Table of Contents Preface..................3 Copyright................3 Trademarks............... 3 Warranty................3 Liability................3 Compliance............... 3 Regulations............... 4 Contact information............5 About this manual............... 7 Scope................7 Target group..............7 Notation conventions............7 Document identification............8 User part..............13 Introduction................15 Safety..................17 Interface................... 19 Operator interface............ - Page 10 4.2.1 Switch to ON mode............25 4.2.2 Set the water temperature..........25 Turn off the water heater...........25 4.3.1 Turn off for a short period..........25 4.3.2 Isolate from the mains............26 4.3.3 Turn off for a long period........... 26 Installation, Maintenance and Service part....27 Introduction................
- Page 11 8.7.2 C13/C33 parallel systems..........46 8.7.3 C43/C53/C63 systems............48 Electrical connections............49 8.8.1 Preparation..............49 8.8.2 Mains power..............50 8.8.3 Optional electrical connections..........50 8.8.4 Finalization..............51 Commissioning..............51 8.9.1 Filling................52 8.9.2 Air pressure differential............. 52 8.9.3 Gas supply pressure............53 8.9.4 value................54 8.9.5 Turn on the water heater........... 56 8.10 Decommisioning...............
- Page 12 12.1.2 Displayed errors............... 73 12.1.3 Warnings.................80 Appendices................81 13.1 Technical details...............81 13.2 Dimensions..............82 13.3 Gas details..............84 13.3.1 Energy labeling..............85 13.4 Electrical wiring diagram............86 13.5 Declaration of conformity...........87 13.6 Warranty.................88 Index..................91...
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Page 13: User Part
User part 0312266_INNOVO_UKUK_V3.0, 2017-02-10... -
Page 15: Introduction
Introduction The Innovo water heater stores and heats water for sanitary purposes. Cold water enters the bottom of the tank through the water inlet (1). The heated water leaves the tank at the top through the hot water outlet (2). To operate the water heater, the operator interface (3) and control switch (4) are used. - Page 16 User part...
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Page 17: Safety
Safety A.O. Smith cannot be held responsible for damages or injuries leading back to: • Failure to follow the instructions provided in this manual. • Carelessness during use or maintenance of the water heater. Every user has to study the user part of this manual and has to follow the instructions in this part of the manual strictly. - Page 18 User part...
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Page 19: Interface
Interface Operator interface The operator interface consists of: • a control switch (see section 3.1.1) on the left side of the water heater • 5 push buttons (see section 3.1.2) to navigate through the menu • a LCD-display (see section 3.1.3) that shows settings, functions, values and errors. The operator interface is parameter driven and enables the user to change parameters and to verify the status and history of the water heater. -
Page 20: Buttons
3.1.2 Buttons The 5 buttons on the operator panel give access to the menu of the water heater. Button Function Scroll up / Raise Scroll down / Lower [ENTER] Enter / Confirm [RESET] Reset / Cancel [MENU] Go to menu 3.1.3 LCD display The LCD display shows 7 different symbols around the outer edge of the display and 3... -
Page 21: Status Of The Water Heater
The user menu parameters are: Parameter Description Unit/Value Adjustable Range Default Turn the water heater on or off. OFF - water heater off (OFF mode) ON - water heater on (ON mode) Setpoint ON mode ºC 40…max setpoint Hysteresis ºC 2…15 Turn setpoint EXT mode (005) ENA - Enable... -
Page 22: Error Conditions
Fig. Actual water Fig. Setpoint Fig. Standby temperature 3.2.1.3 External ON mode In the external ON mode, the water heater will respond to a heat demand when the relay switch is closed. Use parameter 004 to switch on the setpoint (parameter 005) of the external ON mode. -
Page 23: Anode Warning
3.2.4 Anode warning An anode protects the tank against corrosion. When the anode protection is not active, the display shows Ano. Contact your service and maintenance engineer. Fig. Anode warning display Note If you ignore the anode warning, the tank protection cannot be guaranteed. The warranty will be void. - Page 24 User part...
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Page 25: Use
Set a parameter value To set a parameter value: Press [MENU] to access the user menu. Press [ ] or [ ] to scroll to the concerning parameter, refer to Parameters (see section 3.1.3). Press [ENTER] to select. Use [ ] or [ ] to change the parameter value. Press [ENTER] to confirm. -
Page 26: Isolate From The Mains
4.3.2 Isolate from the mains To isolate the water heater from the mains: Set parameter 001 to OFF, refer to Set a parameter value (see section 4.1). Wait 1 minute to make sure that the water heater stopped operating. Set the control switch to 0. Disconnect the water heater from the mains by turning the isolator. -
Page 27: Installation, Maintenance And Service Part
Installation, Maintenance and Service part 0312266_INNOVO_UKUK_V3.0, 2017-02-10... - Page 28 User part...
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Page 29: Introduction
Introduction About the water heater The Innovo water heater is intended for heating water for sanitary purposes. The Innovo is a condensing gas–fired storage water heater with a fan in the air intake. The flue gasses transfer their heat to the water through an efficient heat exchanger. The water heater has a concentric venting connector and can function as an open or as a room- sealed water heater. - Page 30 When the temperature is too low, the water heater starts a operating cycle: The controller detects a "heat demand". The icon "Heat demand present" is shown on the display of the water heater. The fan starts pre-purging. The air proving switch closes when the air pressure differential is sufficient. The hot surface igniter starts pre-ignition.
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Page 31: Safety
Safety Safety instructions For safety instructions about the use of the water heater, refer to Safety (see section 2) in the User part of this manual. Warning Installation, maintenance and service must be carried out by a qualified engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire brigade. -
Page 32: Instructions On The Water Heater
Caution The anode protection remains active when the water heater is in OFF mode and the control switch is set to 0. Note Any leakage from the tank and/or connections can cause damage to the immediate environment or floors below the level of the boiler room. Install the water heater above a waste water drain or in a suitable metal leak tray. -
Page 33: Safety Devices
Safety devices Fig. Safety devices 1. Temperature sensor 2. Gas control valve 3. Air proving switch 4. Flame probe Safety devices of the water heater: Temperature The water heater controls the water temperature sensor (1) using a temperature sensor: • T <... -
Page 34: Environmental Aspects
Environmental aspects 6.4.1 Recycling The packaging material is environmentally friendly, recyclable and relatively easy to discard. 6.4.2 Disposal Old end-of-life appliances contain materials that need to be recycled. When you discard devices at the end of their service life, you must obey local legislation related to waste disposal. -
Page 35: Water Heater
Water heater Structure of the water heater The water heater has the following main components: Controller (8) The controller monitors and manages all internal processes of the water heater for a safe operation. Operator interface (1) To control the water heater and to verify the status, the operator interface has 5 buttons and a 3-character display. - Page 36 Installation, Maintenance and Service part...
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Page 37: Installation
For more safety instructions, refer to Safety instructions (see section 6.1). Packaging A.O. Smith recommends to unpack the water heater at or near its intended location. Remove the packaging material carefully to prevent damage to the water heater. Conditions The water heater is suitable for room-sealed and for open combustion: •... -
Page 38: Water Composition
8.2.3 Water composition The water must comply with the regulations for drinking water for human consumption. Water composition Hardness > 1.00 mmol/l: (alkaline earth ions) • German hardness > 5.6° dH • French hardness > 10.0° fH • English hardness > 7.0° eH •... -
Page 39: Installation Diagram
Fig. Adjustable leg water heater Installation diagram Note This manual only discusses unvented installations. Fig. Installation diagram 1. Pressure relief valve (mandatory if the mains water pressure is too high) 3. T&P valve 4. Stop valve (recommended) 5. Non-return valve 6. -
Page 40: Water Connections
Note Use this installation diagram when you: • install the water connections (see section 8.4) • install the condensate drain (see section 8.5) • install the gas connection (see section 8.6) • fill the water heater (see section 8.9.1) • drain the water heater (see section 8.10.2) Water connections 8.4.1... -
Page 41: Condensate Drain
Condensate drain Caution When the condensate drain is not connected to the waste water discharge by an open connection, this can cause faults. Caution Do not change the condensate drain or cause any blockage in the condensate drain. Install the condensate drain: Install a drain pipe to the condense drain (13) for condensate drainage. -
Page 42: Venting System
This manual does not discus installation type B23. When you need a B23 system, contact A.O. Smith for more information. Caution Always make sure that the flue gas outlet discharges into an area approved for the correct type of installation. - Page 43 Fig. Venting systems 0312266_INNOVO_UKUK_V3.0, 2017-02-10...
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Page 44: C13/C33 Concentric Systems
+0,3 -0,6 -0,7 Diameter air inlet +0,5 +0,5 (Dn 125) (Dn 125) Description parts A.O. Smith Part A.O. Smith Part number number Wall terminal set 0310759 0302515 A wall terminal (1), a 500 mm concentric pipe and a 90° bend... - Page 45 Fig. Example concentric venting system Caution During installation, obey the instructions delivered with the sets of air supply components and the flue gas discharge components. Make sure that the venting system does not exceed the maximum number of 45º and 90º bends and the maximum pipe length. Caution Use a run-off of 50 mm per meter towards the water heater.
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Page 46: C13/C33 Parallel Systems
Diameter flue gas outlet +0,6 +0,3 -0,6 -0,7 Diameter air inlet Description parts A.O. Smith Part A.O. Smith Part number number Wall terminal set 0310730 A wall terminal (1), an adapter, a 500 mm parallel pipe and a 90° bend... - Page 47 Fig. Example parallel venting system Refer to the table for the correct pipe dimensions of the C13 or a C33 parallel venting systems. Description Unit IR-12-160 to IR 24-245 to IR 20-200 IR 32-380 Diameter flue discharge/ mm/mm 80/80 80/80 air inlet Maximum length air inlet Maximum length flue gas...
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Page 48: C43/C53/C63 Systems
The flue gas terminal must comply to the EN 1856-1 requirements. The maximum allowable recirculation rate is 10% under wind conditions. Contact A.O. Smith for more information and/or part numbers of the C43, C53 and C63 venting systems. Concentric systems Refer to the table for the correct pipe dimensions of the C43, C53 and C63 concentric systems. -
Page 49: Electrical Connections
Use the "adapter box concentric to parallel - water heater side" (part number 0312209) for C63 parallel systems. Electrical connections Warning Leave the water heater electrically isolated until you are ready to commission it. 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. -
Page 50: Mains Power
Connect an additional error signal to the water heater. 8.8.3.1 Isolating transformer For more information about an isolating transformer, or to order an isolating transformer, please contact A.O. Smith. 8.8.3.2 External ON mode switch Install an external ON mode switch: Pull the cables through the tulles. -
Page 51: Finalization
8.8.3.3 Additional error signal Note The water heater has a relay contact that can be used when an error occurs. The relay contact is potential–free (maximal 5 A). Install an additional error signal: Pull the power cable through the tulles. Connect the cables to X1 and X2. -
Page 52: Filling
8.9.1 Filling Refer to the installation diagram (see section 8.3) when you fill the water heater: Open the stop valve (11) in the hot water supply pipe. If applicable, open the stop valves (4) of the circulation pipe (C). Make sure that the drain valve (9) is closed. Open the nearest hot water draw-off point (14). -
Page 53: Gas Supply Pressure
Fig. Air pressure differential 8.9.3 Gas supply pressure Check the gas supply pressure: Loosen the sealing screw (4) of the test nipple by a few turns. Note Do not completely loosen the sealing screw, it can be difficult to retighten it. Open the gas supply to vent the gas pipes through the test nipple. -
Page 54: Co 2 Value
Fig. Gas supply pressure 1. Adjuster screw 2. Gas control valve 3. Gas supply pipe 4. Sealing screw 8.9.4 value Check the CO value: Open the gas supply. Remove the cap (1) from the test nipple (2) of the flue gas outlet pipe. Place the measurement probe of the CO meter in the test nipple of the flue gas outlet pipe. - Page 55 If necessary, create a heat demand: Use a hot water draw-off point to tap water, or Raise the setpoint of the water temperature, refer to Set the water temperature (see section 4.2.2). Wait until the measured value on the CO meter remains stable for some time.
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Page 56: Turn On The Water Heater
8.9.5 Turn on the water heater Refer to the procedure in the user part to Turn on the water heater (see section 4.2). 8.10 Decommisioning To decommission the water heater: Turn off the water heater (see section 8.10.1) Drain the water heater (see section 8.10.2) 8.10.1 Turn off the water heater Refer to the procedure in the user part to Turn off the water heater (see section 4.3) and... -
Page 57: Conversion Of Gas Type
Conversion of gas type Caution Conversion of the water heater may only be carried out by a qualified person. Use a special conversion kit to converse the water heater when: • The water heater has to operate on a different family of gases (liquid petroleum gas or natural gas). - Page 58 Installation, Maintenance and Service part...
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Page 59: Settings
Settings 10.1 Operator interface The operator interface is parameter driven and enables the user to change parameters and to verify the status and history of the water heater. When you press [MENU] once, parameters 001 to 120 can be accessed. All other parameters can be accessed when you press [MENU] for 10 seconds. - Page 60 Parameter Description Unit/Value Adjustable Range Default Status burner Initialization 0 - Initialization Reset 1 - Reset Stand-by 2 - Stand-by Pre-purge (1) 3 - Pre-purge (part 1) Pre-Purge (2) 4 - Pre-Purge Pre-Ignition (part 2) Ignition 5 - Pre Ignition Flame check 6 - Ignition Burn...
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Page 61: Hysteresis
Parameter Description Unit/Value Adjustable Range Default Interval between last blocking Minutes 00n...59n = 0 till 59 minutes error and read-out. Hours 01h...23h = 1 till 23 hours Days 01d...06d = 1 till 6 days Weeks 01...63 = 1 till 63 weeks Number of flame failures 0…990 Number of successful ignitions... -
Page 62: Test Cycle
10.5 Test cycle The test cycle can be used to activate the test modes. These test modes can, for example, be used to set the CO2 value at full and at partial load or to check the air pressure differential. Use parameter 201 to activate the test cycle. -
Page 63: Maintenance
On the operator interface, the maintenance interval can be set as a reminder. The display shows Src when the pre-set interval has elapsed. To determine the correct interval, A.O. Smith recommends to do a system check on both the water and the gas side, three months after installation. -
Page 64: Preparation
Make sure the gas supply pressure is correct, refer to Gas supply pressure (see section 8.9.3). Make sure the CO value is correct, refer to CO value (see section 8.9.4). 11.2 Preparation Isolate the water heater from the mains (see section 4.3.2) before you start maintenance tasks. -
Page 65: Gas-Side Maintenance
Make sure that there is no grit or other blockages in the drain pipe (3). Make sure that the slope of the drain pipe is correct; 5 mm/m. Install the condense trap onto the condensate drain. Fig. Condensate drain 1. Condensate drain 2. - Page 66 Remove the burner: Loosen the four nuts (5) to disconnect the burner assembly (6) from the combustion chamber (7). Take the burner assembly out of the combustion chamber. Caution Be carefull, the burner can be hot Caution Always replace the seal after removal of the burner Note Mind the ground cable! Fig.
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Page 67: Clean The Combustion Chamber
Fig. Disassemble the burner assembly 8. Non return valve 9. Bolts 10. Hot surface igniter 11. Flame rod 12. Adapter 13. Gasket 14. Burner 15. Burner flange Use compressed air to remove all contamination from the outside to the inside of the burner (7). -
Page 68: Finalization
Note If necessary, replace the cleaning opening cover with gasket and bolts. You can order a clean out service kit at your supplier. Look at the data plate for the correct ordering information. Refer to the figures in Clean the burner (see section 11.4.1) to assemble the burner: Place the burner in the burner flange. - Page 69 After that: Fill the water heater (see section 8.9.1). Make sure the air pressure differential is correct, refer to Air pressure differential (see section 8.9.2). Make sure the gas supply pressure is correct, refer to Gas supply pressure (see section 8.9.3). Make sure the CO2 value is correct, refer to CO value (see section 8.9.4).
- Page 70 Installation, Maintenance and Service part...
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Page 71: Troubleshooting
Troubleshooting 12.1 Errors and warnings The water heater can have three different kinds of errors and warnings: • General errors (see section 12.1.1), which are not displayed • Displayed errors (see section 12.1.2), which are divided in two different groups: Lock out errors: when the cause is removed, you can reset the error to resume operation. - Page 72 Indication Cause Measure Water leakage There is a leakage from a threaded Tighten the threaded connection. water connection. There is a condensate leakage Make sure that the condensation water discharge is working properly. If necessary, correct the water discharge. There is a leakage from another nearby Trace the leakage.
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Page 73: Displayed Errors
Indication Cause Measure value (at full load) The unit is not set for the correct gas • Make sure that the gas type corresponds type with the information on the rating plate is not correct • Make sure if the venturi restrictor has the correct diameter, refer to Gas details (see section 13.3). - Page 74 Code and description Cause Measure Content EEPROM not correct. Reset the controller. C05 (blocking error) Control error If the error reappears, contact your supplier. E01 (blocking error) The temperature in the tank is above • Tap off water, so the temperature drops Temperature error 90ºC.
- Page 75 Code and description Cause Measure Damaged wiring/closed circuit. • Make sure that the wiring, between the F03 (lock out error) Air proving switch error air proving switch and the control, is connected and not damaged. Switch is closed when fan •...
- Page 76 Code and description Cause Measure Hoses are damaged. • Make sure that the hoses, between the F03 (lock out error) Air proving switch error air proving switch and fan and the air proving switch and gas control valve are Switch is not closed when not damaged and reset the controller.
- Page 77 Code and description Cause Measure No gas. • Make sure that the main gas supply valve F04 (lock out error) Ignition error is open. If necessary, open the valve. • Make sure that the manual gas supply Three unsuccessful valve, before the gas control valve, is ignition attempts.
- Page 78 Code and description Cause Measure Recirculating flue gases due too • Make sure the flue terminal is installed F05 (lock out error) Flame error incorrect roof or wall flue terminal. correctly, refer to Venting system (see section 8.7). If necessary, connect the Too many flame failures correct flue terminal.
- Page 79 Code and description Cause Measure Sensor is not (correctly) connected. • Make sure that the connector is S02 (blocking error) Sensor error connected to J3. • Make sure that the wire is connected to Open circuit from sensor 1 the sensor. of the temperature sensor Damaged wiring and/or defective Replace the wiring and/or sensor.
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Page 80: Warnings
12.1.3 Warnings Note For the coding of the connections, refer to the Electrical wiring diagram (see section 13.4). Indication Cause Remark The water heater exceeded the pre-set The water heater operates, but displays this Src Service is required service interval. warning. -
Page 81: Appendices
Appendices 13.1 Technical details Description Unit IR-12-160 IR-12-200 IR-24-245 IR-24-285 IR-32-380 IR-20-160 IR-20-200 IR-32-245 IR-32-285 General Capacity Empty Weight Maximum floor load Maximum operating pressure kPa (bar) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5) - installation Maximum operating pressure kPa (bar) 800 (8) 800 (8) -
Page 82: Dimensions
13.2 Dimensions Size Description Unit IR-12-160 IR-12-200 IR-24-245 IR-24-285 IR-32-380 IR-20-160 IR-20-200 IR-32-245 IR-32-285 Dimensions water heater Height 1270 1545 1545 1745 1745 Width Depth Flue gas outlet/Air inlet mm/mm 80/125 80/125 80/125 80/125 80/125 Dimensions connections Cold water supply Rp 3/4 Rp 3/4 Rp 1... - Page 83 0312266_INNOVO_UKUK_V3.0, 2017-02-10...
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Page 84: Gas Details
13.3 Gas details Description Unit IR-12-160 IR-20-160 IR-24-245 IR-32-245 IR-12-200 IR-20-200 IR-24-285 IR-32-285 IR-32-380 Gas category 2H (G20) Diameter of the venturi 3.95 3.95 3.95 3.95 restrictor Nominal Load (gross) 12.1 20.0 24.4 32.2 Nominal output 11.7 19.1 23.5 30.7 (12-160) (24-245) (32-245) -
Page 85: Energy Labeling
13.3.1 Energy labeling Description Unit IR-12-160 IR-12-200 IR-20-160 IR-20-200 Declared load profile Load profile Energy efficiency class ( Energy label) Energy efficiency Daily electricity consumption 0.175 0.181 0.172 0.182 Daily fuel consumption kWh GCV 20.526 19.924 20.661 20.853 Mixed water 40 °C (V40) 1111 Additional load profile Load profile... -
Page 86: Electrical Wiring Diagram
13.4 Electrical wiring diagram Cable colors: Terminal block connections: C. Hot surface igniter M. Earth connection mounting plate D. Gas control valve 1. Brown A. Earth P. Earth connection E. External ON mode switch 2. Blue N. Neutral burner flange F. -
Page 87: Declaration Of Conformity
13.5 Declaration of conformity 0312266_INNOVO_UKUK_V3.0, 2017-02-10... -
Page 88: Warranty
Article 2: Tank warranty If, after inspection and at the sole discretion of A.O. Smith, the glass-lined steel tank of a water heater supplied by A.O. Smith proves within 3 years of the original installation date to be leaking due to rust or corrosion occurring on the water side, then A.O. - Page 89 (assemblies or parts of) water heaters supplied for replacement, other than the warranty expressly set out in these Articles. Under the terms of the supplied warranty, A.O. Smith is not liable for damage to persons or property caused by (assemblies or parts, or the glass-lined steel tank of) a (replacement) water heater that it has supplied.
- Page 90 Installation, Maintenance and Service part...
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Page 91: Index
Index Installation........37 LCD display........20 About this manual....... 7 Anode warning........23 Preface..........3 Appendices........81 Tank..........35 Buttons..........20 Trademark......... 3 Troubleshooting........ 71 Condensate drain......35, 41 Control switch........19 Water inlet........29 Controller......... 35 Water outlet........29 Copyright........... 3 Working clearances......38 Error conditions.........22 External ON mode switch....50 Fan.......... - Page 92 Installation, Maintenance and Service part...
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