A.O. Smith SGE - 40 Troubleshooting guide

0311 166 / 07-2013 Innovation has a name.
Installation, User and Service
Manual
Condensing Gas-Solar
Water Heater
SGE - 40/60
SGE

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.

E1
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
not applicable
Sensor S1
not applicable
Sensor S1
not applicable
Sensor S2
not applicable
Sensor S2
not applicable
not applicable
not applicable
not applicable
Power 5V
Sensor S4
Flow signal
not applicable
not applicable
BUS-link
BUS-link
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 CO2value (3.12.3 "CO2adjustment").
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.

E2
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

E3
TERMINAL BLOCK CONNECTIONS
Earth
N Neutral
L Live input of the controller
L3Live input for the solar heating system modulating pump
L4Modulating 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)

Instruction manual SGE 3
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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: [phone]
Fax: [phone]
E-mail: [e-mail]
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.

4Instruction manual SGE
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Instruction manual SGE 5
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, CO2value 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
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Contents
6Instruction manual SGE
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

Instruction manual SGE 7
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