- DL manuals
- A.O. Smith
- Water Heater
- GWV-120
- Installation And Service Manual
A.O. Smith GWV-120 Installation And Service Manual
Summary of GWV-120
Page 1
V 120 150 200 water products company a division of a. O. Smith corporation water products company a division of a. O. Smith corporation installation user and service manual installation user and service manual.
Page 2: Your Installer
Www.Aosmithinternational.Com your installer.
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Instruction manual gwv 3 gis read this manual carefully warning read this manual carefully before starting up the water heater. Failure to read this manual and to follow the instructions in this manual may lead to accidents, personal injury, and damage to the appliance. Copyright © 2007 a.O. Smith w...
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4 instruction manual gwv gis.
Page 5: Table of Contents
Instruction manual gwv 5 table of contents 1 introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.1 about the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.2 what to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9 1.3 regulations - - -...
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Table of contents 6 instruction manual gwv 8.2 operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 8.3 error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 8.4 service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 8.5 warni...
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Instruction manual gwv 7 15 performing maintenance - - - - - - - - - - - - - - - - - - - - 89 15.1 introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89 15.2 preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 89 15.3 water-side maintenance - - - - - - -...
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Table of contents 8 instruction manual gwv.
Page 9: Introduction
Instruction manual gwv 9 gis 1 introduction 1.1 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 ca...
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Introduction 10 instruction manual gwv 1 gis furthermore, the installation must comply with the manufacturer's instructions. Note later amendments and/or additions to all regulations, requirements and guidelines published on or prior to the moment of installing, will apply to the installation. 1.4 t...
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Instruction manual gwv 11 gis 1.7 overview of this document the table provides an overview of the contents of this document. Contents of this document chapter target groups description working principle of the appliance this chapter describes how the appliance functions. Installation this chapter de...
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Introduction 12 instruction manual gwv 1 gis.
Page 13: Working Principle of
Instruction manual gwv 13 gis 2 working principle of the appliance 2.1 introduction topics covered in this chapter: • general working principle of the appliance ; • the appliance's heating cycle ; • protection for the appliance ; • safety of the installation . 2.2 general working principle of the ap...
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Working principle of the appliance 14 instruction manual gwv 2 gis cut-away view of the appliance im d -05 00 r1 8 7 6 5 4 3 2 20 19 1 13 11 12 10 9 31 30 29 33 28 27 32 22 21 17 18 16 15 14 24 25 26 23.
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Instruction manual gwv 15 gis 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. The water is heated by the heat exchanger (20) in the combustion chamber (19). The heated wat...
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Working principle of the appliance 16 instruction manual gwv 2 gis 2.4 protection for the appliance 2.4.1 introduction the electronic controller monitors the water temperature and ensures safe combustion. This is achieved by: • the water temperature protection • the gas control • the fan • the press...
Page 17
Instruction manual gwv 17 gis 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. Note the trip point of the pressure switch is not adjustable. Pressure switch trip points 2.4.6 fla...
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Working principle of the appliance 18 instruction manual gwv 2 gis 2.5 safety of the instal- lation as well as the standard safeties in the appliance (2.4 "protection for the appliance") , it must also be protected by an inlet combination and a pressure- reducing valve. A p-valve is also used. 2.5.1...
Page 19: Installation
Instruction manual gwv 19 is 3 installation warning installation work should 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 service. The appliance may only be installed in a ro...
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Installation 20 instruction manual gwv 3 is 3.3 environmental conditions caution an open appliance may not be used in rooms where chemical substances are stored or used due to the risk of explosion and corrosion of the appliance. Some propellants, bleaching agents and degreasing agents etc. Disperse...
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Instruction manual gwv 21 is 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 note if the water spe...
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Installation 22 instruction manual gwv 3 is 3.4 technical specifica- tions check the dimensions (3.4.1 "dimensions of the appliance") , the gas data (3.4.3 "gas data") and other specifications (3.4.2 "general and electrical specifications") of the appliance. 3.4.1 dimensions of the appliance plan an...
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Instruction manual gwv 23 is dimensions (all measurements in mm unless otherwise indicated) 3.4.2 general and electrical specifications chimney data 1) stated lengths and bends apply for both flue gas removal and air supply tap capacity size description gwv 120 gwv 150 gwv 200 a overall height 835 8...
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Installation 24 instruction manual gwv 3 is contact ratings operating pressure 3.4.3 gas data gas data unit gwv 120 gwv 150 gwv 200 electrical power consumption w 200 210 350 supply voltage vac 230 (+10 -15%) - 50hz unit gwv 120 gwv 150 gwv 200 operating pressure bar 8 8 8 description ii 2h3p unit g...
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Instruction manual gwv 25 is 3.5 installation diagram this figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described. Installation diagram unvented vented a 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 d 10 9 9 12 b c imd-0486 r2 4 ...
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Installation 26 instruction manual gwv 3 is 3.6 water connections, vented warning the installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "regulations") . 3.6.1 cold water side see (a) in the installation diagram (3.5 "inst...
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Instruction manual gwv 27 is distance x distance x • 0 • 2 • 4 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. Remove the cap of the adjuster unit. 5. Turn the adjuster unit so ...
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Installation 28 instruction manual gwv 3 is 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. 3.7 water connections, unvented warning the installation should be carried out by an authorised installation engineer, in compliance wi...
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Instruction manual gwv 29 is 3.8 gas connection warning the installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "regulations") . Caution make sure that the diameter and length of the gas supply pipe are large enough to supp...
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Installation 30 instruction manual gwv 3 is c13: appliance with wall conduit c33: appliance with roof conduit note make sure that the chimney discharges into an area where this is permitted for this category of appliance. B a imd-0503 r0 a c b imd-0509 r0
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Instruction manual gwv 31 is 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 (3.9.2 "requirements for flue gas discharge materials") to the concentric wall conduit or roof conduit using a trans...
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Installation 32 instruction manual gwv 3 is specifications for transition piece and concentric wall flue terminal (c13) specifications for transition piece and concentric roof conduit (c33) subject description wall flue terminal set: • 1x wall flue terminal (incl. Transition piece) • 1x wall plate •...
Page 33
Instruction manual gwv 33 is specification of condensation outlet for uninsulated lengths greater than 8 metres and no more than 20 metres 3.10 electrical connection warning the installation should be carried out by an authorised installation engineer, in compliance with general and local regulation...
Page 34
Installation 34 instruction manual gwv 3 is 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 cap (b) from the electrical section. The connector block ...
Page 35
Instruction manual gwv 35 is electrical connector block 3.10.3 connecting the mains voltage the appliance is supplied without a power cable and isolator. Note to provide the appliance with voltage, the appliance must be permanently connected to the mains voltage. A double-pole isolator with a contac...
Page 36
Installation 36 instruction manual gwv 3 is 4. If you do not need to make any more connections: - fit the protector plate onto the electrical connector block. 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 ...
Page 37
Instruction manual gwv 37 is gas control 3.11.1 preparation to check the supply pressure and burner pressure, proceed as follows: 1. Isolate (10.3 "isolating the appliance from the mains") the appliance from the power supply. 2. Undo the screws of the front cover. 3.11.2 procedure for checking press...
Page 38
Installation 38 instruction manual gwv 3 is the display will now show internal check for about 10 seconds and go to the main menu. 7. Activate the "on mode" by going through the following steps: - press the blue arrow once ( ) to position the cursor in front of on and press . The display shown here ...
Page 39
Instruction manual gwv 39 is 3. Cover the opening of the adjusting screw and check the burner pressure against the value given in the gas table (3.4.3 "gas data") . 4. If the pressure is not set correctly, repeat the preceding steps until the correct pressure is attained. 5. Fit the cap (4) back on ...
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Installation 40 instruction manual gwv 3 is.
Page 41: Conversion to A
Instruction manual gwv 41 is 4 conversion to a different gas category caution the conversion may only by carried out by an authorised installation engineer. If the appliance must operate on a family of gases (lp gas or natural gas) or other gas category than that for which the appliance has been set...
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Conversion to a different gas category 42 instruction manual gwv 4 is.
Page 43: Filling
Instruction manual gwv 43 gis 5 filling 5.1 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 a 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 d 10 9 9 12 b c imd-0486 r...
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Filling 44 instruction manual gwv 5 gis 5.2 filling unvented installations to fill the appliance, 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-...
Page 45
Instruction manual gwv 45 gis 9. The appliance is now under water supply pressure. There should be no water coming out of the expansion valve (15) or out of the p-valve (23). If there is, the cause might be: - the water supply pressure is greater than the specified 8 bar. Rectify this by fitting a p...
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Filling 46 instruction manual gwv 5 gis.
Page 47: Draining
Instruction manual gwv 47 gis 6 draining 6.1 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 a 1 5 15 16 4 4 14 14 14 6 5 4 23 3 11 11 11 d 10 9 9 12 b c imd-0486 ...
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Draining 48 instruction manual gwv 6 gis 6.2 draining unvented installations some service activities require the appliance 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 symb...
Page 49
Instruction manual gwv 49 gis 5. Switch the appliance off (position 0) using the on/off switch on the control panel. 6. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0. 7. Shut off the gas supply (10). 8. Close the...
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Draining 50 instruction manual gwv 6 gis 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..
Page 51: The Control Panel
Instruction manual gwv 51 gis 7 the control panel 7.1 introduction topics covered in this chapter: • operation ; • meaning of icons ; • electronic controller on/off switch ; • navigation buttons ; • pc connection . 7.2 operation the entire appliance is controlled and monitored by the thermocontrol (...
Page 52
The control panel 52 instruction manual gwv 7 gis the ^ and È indicate that you can scroll up and/or down. Use the and buttons to scroll. 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, ...
Page 53: Status of The
Instruction manual gwv 53 gis 8 status of the appliance 8.1 introduction topics covered in this chapter, in sequence: • operating modes • error conditions • service condition • warning 8.2 operating modes when running, the appliance has four basic operating modes, namely: • off • on • prog • extra 8...
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Status of the appliance 54 instruction manual gwv 8 gis 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") for all basic operating modes. Note setting and...
Page 55: Starting and Running
Instruction manual gwv 55 gis 9 starting and running 9.1 introduction topics covered in this chapter, in sequence: • starting and running . • the appliance's heating cycle . 9.2 starting and running start the appliance as follows: 1. Fill the appliance (5 "filling") . 2. Open (3.5 "installation diag...
Page 56
Starting and running 56 instruction manual gwv 9 gis 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. -...
Page 57
Instruction manual gwv 57 gis 10. When the water is up to temperature, the heat demand drops off and the post-purge starts. This lasts about 25 seconds. - the , and icons are removed. - the icon is activated. - the message post purge appears. 11. Following the post-purge, the fan stops and the press...
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Starting and running 58 instruction manual gwv 9 gis.
Page 59: Shutting Down
Instruction manual gwv 59 gis 10 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 dow...
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Shutting down 60 instruction manual gwv 10 gis.
Page 61: Main Menu
Instruction manual gwv 61 gis 11 main menu 11.1 introduction the menu is reached by pressing the button of the electronic controller. The main menu comprises: • off 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. In this...
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Main menu 62 instruction manual gwv 11 gis • confirm with .After confirming, the appliance enters "on mode". 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 o...
Page 63
Instruction manual gwv 63 gis 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). Example as an example, we will set the...
Page 64
Main menu 64 instruction manual gwv 11 gis 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 n...
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Instruction manual gwv 65 gis 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. To delete a period, proceed as follows: the display shows the menu for the week ...
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Main menu 66 instruction manual gwv 11 gis 11.11 programming an extra period 1. Call up the menu for entering an extra period via: 2. : extra period confirm with . The display show the settings for the extra period. 11.11.1 setting the switch-on time 1. Use and to set the day. In the example, this i...
Page 67
Instruction manual gwv 67 gis 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 install...
Page 68
Main menu 68 instruction manual gwv 11 gis confirm the minute setting with 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. ...
Page 69: Service Program
Instruction manual gwv 69 is 12 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 ; ...
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Service program 70 instruction manual gwv 12 is 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. 12.6 switching the pump on or...
Page 71
Instruction manual gwv 71 is the appliance switches from partial load to full load if the temperature difference between the water in the storage tank (t 3 ) and the set point (t set ) minus the negative hysteresis is greater than this stage difference. Conversely, the apparatus switches from full l...
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Service program 72 instruction manual gwv 12 is.
Page 73: Troubleshooting
Instruction manual gwv 73 gis 13 troubleshooting 13.1 introduction a distinction is made between: • 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. - water leakage - explosive ignition. The man...
Page 74
Is instruction manual gwv 74 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 comment gas smell gas leak warning close the main gas valve immediately. Warning do not...
Page 75
Is instruction manual gwv 75 features cause measures to take comment explosive ignition incorrect supply pressure and/or burner pressure set the correct supply pressure and/or burner pressure. (3.11 "checking the supply pressure and burner pressure") if ignition is not improved, consult your install...
Page 76
Is instruction manual gwv 76 13.3 troubleshooting table for displayed errors displayed errors code + description cause measures to take comment s01 (blocking error) open circuit for temperature sensor t 1 , inlet to heat exchanger sensor is not (correctly) connected connect the sensor lead to jp3 se...
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Is instruction manual gwv 77 code + description cause measures to take comment s11 (blocking error) short-circuit for temperature sensor t 1 , inlet to heat exchanger short circuit in sensor circuit replace sensor t 1 to replace the necessary parts, you must contact your installation engineer s12 (b...
Page 78
Is instruction manual gwv 78 code + description cause measures to take comment f01 (blocking error) defect in power supply circuit live and neutral connected wrong way round connect live and neutral correctly (3.10 "electrical connection") ; the appliance is phase-sensitive see the gwv electrical di...
Page 79
Is instruction manual gwv 79 code + description cause measures to take comment f03 (lock out error) the pressure switch fails to work correctly damaged wiring/open circuit 1. Check the wiring between the pressure switch and the controller 2. If necessary, replace the wiring if the error cannot be re...
Page 80
Is instruction manual gwv 80 code + description cause measures to take comment f04 (lock out error) three unsuccessful ignition attempts. No gas 1. Open the main gas valve and/or the manual gas valve supplying the water heater 2. Check the supply pressure to the gas control 3. If necessary, repair t...
Page 81
Is instruction manual gwv 81 code + description cause measures to take comment f06 (blocking error) short circuit between flame probe and earth damaged cable in contact with metal surface. Check the wiring of the flame probe. Replace the wiring if necessary.. If the error persists, contact your inst...
Page 82
Is instruction manual gwv 82 code + description cause measures to take comment f10 (lock out error) restriction on the number of ignition attempts based on pressure switch state changes. Pressure switch not closing 1. Check the running speed of the fan 2. Check that the hoses are fitted correctly to...
Page 83
Is instruction manual gwv 83 code + description cause measures to take comment c02 (lock out error) error message from the appliance controller. Incorrect reference voltage from the ad converter. 1. Reset electronic controller. 2. Check that the frequency of the power supply is compliant (3.4.2 "gen...
Page 84
Is instruction manual gwv 84 note: (1) temperature sensor t 2 is a '2 in 1' sensor; t 2 contains 2 ntcs for maximum thermostat and safety thermostat protection. (2) the dummy flue gas sensor consists of dummy flue gas sensor 1 and dummy flue gas sensor 2. Code + description cause measures to take co...
Page 85
Is instruction manual gwv 85 13.4 warnings warning maintenance may only be performed by a qualified service and maintenance engineer. Note: (1) as a result of this warning, the appliance will switch to partial load and remain active in that mode until the warning is cleared with reset and enter (2) ...
Page 86
Troubleshooting 86 instruction manual gwv 13 gis.
Page 87: Maintenance
Instruction manual gwv 87 is 14 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 temper...
Page 88
Maintenance frequency 88 instruction manual gwv 14 is.
Page 89: Performing
Instruction manual gwv 89 s 15 performing maintenance 15.1 introduction caution maintenance may only be performed by a qualified service and 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 ...
Page 90
Performing maintenance 90 instruction manual gwv 15 s 6. Switch the electronic controller on by setting the on/off switch to position i. The display will now show internal check for about 10 seconds and go to the main menu. 7. Activate the 'on mode' by going through the following steps: - press the ...
Page 91
Instruction manual gwv 91 s 15.3 water-side mainte- nance 15.3.1 introduction the following steps must be carried out on the water side: 1. Checking the anodes 2. Descaling and cleaning the storage tank 15.3.2 checking the anodes timely replacement of the anodes extends the service life of the appli...
Page 92
Performing maintenance 92 instruction manual gwv 15 s 15.4 gas-side mainte- nance 15.4.1 introduction the following steps must be carried out on the gas side: 1. Clean the burner(s) 2. Clean the injector(s) 3. Cleaning the aluminium strips 15.4.2 clean the burner(s) 1. Dismantle first the yellow fle...
Page 93: Warranty (Certificate)
Instruction manual gwv 93 gis 16 warranty (certificate) to register your warranty, you should complete and return the enclosed warranty card after which a warranty certificate will be sent to you. This certificate gives the owner of a appliance supplied by a.O. Smith water products company b.V. Of v...
Page 94
Warranty (certificate) 94 instruction manual gwv 16 gis 16.4 exclusions the warranty set out in articles 1 and 2 will not apply in the event of: a. Damage to the appliance caused by an external factor; b. Misuse, neglect (including frost damage), modification, incorrect and/or unauthorised use of th...
Page 95: Appendices
Instruction manual gwv 95 is 17 appendices 17.1 introduction this appendix contains: • electrical diagram (17.2 "electrical diagram") • week program card.
Page 96
Appendices 96 instruction manual gwv 17 is 17.2 electrical diagram electrical diagram 1 = brown, 2 = blue, 3 = yellow/green, 4 = black, 5 = white, 6 = orange, 7 = red q a x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 3 3 3 x j35 jp12 j37 jp6 ...
Page 97
Instruction manual gwv 97 is terminal block connections: earth n neutral l phase input of controller l 1 phase input of system pump l 2 phase input of program-controlled pump components: a controller b flame probe c hot surface igniter d gas control 1 e gas control 2 f display g fan h external on mo...
Page 98
Appendices 98 instruction manual gwv 17 is.
Page 99
Instruction manual gwv 99 17.3 week program card you can cut the week program card out and keep it near the appliance. Example period day time tset pump 1. On ....°c on / off off 2. On ....°c on / off off 3. On ....°c on / off off 4. On ....°c on / off off 5. On ....°c on / off off 6. On ....°c on /...
Page 100
Instruction manual gwv 100
Page 101: Index
Instruction manual gwv 101 index a ambient temperature 20 appliance displaying history 69 displaying selection 70 c 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...
Page 102
0307 971 4.0 uk index instruction manual gwv.