ICW - INSTANO High efficient condensing instantaneous water heater 0312229 2716 - Reserved Changes. ICW - 25/35/60 Installation, User, Service and Maintenance Manual UK 62403636 - R00 20-06-2016_UK Innovation has a name.
INDEX 1 - GENERAL SAFETY RECOMMENDATIONS...................................................................................................4 1.1 - National laws and regulations................................................................................................................................... 5 2 - GENERAL INFORMATION..............................................................................................................................6 2.1 - Presentation...............................
INDEX 8.1.4 - Verify flue and air lines in good condition and sealed tight;....................................................................... 44 8.1.5 - Check system water pressure/system piping/expansion tank;.................................................................. 44 8.1.6 - Check control settings................................................................................................................................ 44 8.1.7 - Check wiring and connections.............................
1 - GENERAL SAFETY RECOMMENDATIONS If you smell gas 1. - Close the manual gas valve. 2. - Ventilate the room. 3. - Do not switch on any electric device, telephone included. 4. - From another room, call a professionally qualified technician immediately or the gas supply company. Call the Fire department if the former is not available. appliance by a person responsible for their safety.
1 - GENERAL SAFETY RECOMMENDATIONS 1.1 - National laws and regulations Institute of Gas Engineers and Managers (IGEM) Publications 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.
2 - GENERAL INFORMATION 2.1 - Presentation Congratulations! You have purchased one of the best products on the market. Each individual part is proudly designed, produced, tested and assembled within the A.O. Smith establishment, thus guaranteeing the best quality control. This product has been developed thanks to the A.O. Smith who pay the highest respect to the environment with class 5 classification as being the last polluting as envisioned by EN297 (and EN 483) Technical Standards. 2.
2 - GENERAL INFORMATION 2.3 - Manufacturer 2.5 - Maintenance A.O. Smith Water Products Company PO Box 70 5500 AB Veldhoven The Netherlands Telephone: (free) 0870-AOSMITH 0870-2676484 General: +31 40 294 25 00 Fax: +31 40 294 25 39 E-mail: info@aosmith.nl Website: www.aosmithinternational.
3 - MAIN COMPONENTS 16 19 20 16 21 45 020003.01.
3 - MAIN COMPONENTS 33 35 37 36 38 40 39 41 43 020003.01.058 32 - ---------33 - Front cover fixing tabs 34 - ---------35 - Ignition electrodes 36 - Burner sight glass 37 - Flue condensate collection collar drain pipe (connected to siphon) 38 - Burner 39 - Air/gas mixer 40 - Condensate drain siphon 41 - Safety valve drain pipe 42 - ---------43 - Condensate collection funnel 44 - ---------45 - High limit flue gas temperature fuse 46 - D.H.W.
3 - MAIN COMPONENTS 19 16 16 45 21 15 22 23 11 24 46 25 8 26 27 14 28 020008.01.
3 - MAIN COMPONENTS 47 33 35 36 37 38 39 40 7 28 41 41 43 020008.01.020 32 - ---------33 - Front door fixing tabs 34 - ---------35 - Ignition electrodes 36 - Gas burner sight glass 37 - Flue condensate collection collar drain pipe (connected to siphon) 38 - Burner 39 - Air/gas mixer 40 - Condensate drain siphon 41 - Safety valve drain pipe 42 - ---------43 - Condensate collection funnel 44 - ---------45 - High limit flue gas temperature fuse 46 - D.H.W.
4 - OPERATION Key to figure 4-1: 1 = Water heater 2 = Combustion air intake 3 = Exhaust flue 1006) 4 = Exhaust flue temperature sensor (Par. 5 = High limit flue gas temperature fuse 6 = Sealed chamber 7 = Water collection tub 1001) 9 = Heat exchanger outlet temperature sensor 2 (Par. 1005) 8 = Heat exchanger outlet temperature sensor 1 (Par. 10 = Burner 11 = Heat exchanger 12 = Fan 1007) 13 = Cold water temperature sensor (Par.
4 - OPERATION 4.1 - Operation and intended use of the appliance This product is a condensing gas appliance, intended for the production of domestic hot water for civil use. Consider the water pressure drops as illustrated in figure 4-2. The temperature of the domestic hot water can be adjusted by following the procedure in section 7.4. This appliance is not suitable for installation outdoors. It must not be exposed to temperature below zero or temperature above 50°C.
4 - OPERATION 4.2 - Examples of installation In figures 4-3, 4-4 and 4-5 you can see some examples of correct installation while in figure 4-6 you can see one example of wrong installation. Figure 4-3 - Example of basic installation Figure 4-4 - Example of installation with secondary return performed by an external pump (see section 5.
5 - INSTALLATION 5.1 - Opening the packaging The appliance is supplied in a carton box. 5.2 - Dimensions and minimum clearances It is necessary to leave free spaces around the appliance as illustrated in figure 5-1 both for installation and maintenance. 5.3 - Choosing suitable installation location Figure 5-1 - Minimum distances for maintenance CAUTION !!! The appliance must be installed exclusively on a solid, vertical wall, which can support the weight.
5 - INSTALLATION must supply and install a device that will shut-off the appliance before the system material’s maximum operating temperature and pressure are met. In figures 5-2 and 5-3 the service and maintenance valves are not shown. Hydraulic and gas connections should be fitted with isolation valves to accomodate service and maintenance works. 5.6 - Gas CAUTION !!! It is prohibited to operate the appliance with the incorrect gas type.
5 - INSTALLATION means of appropriate siphon with disjunction capable of preventing the pressurisation of the system and to prevent the return of bad odours from the sewer (detail “5” in figure 5-5). because the condensate is acid some local codes 5.8 - Safety pressure relief valve The appliance is protected against overpressures by a safety valve rated to 10 bar (see figures 3-1 and 3-4 detail “28”). The safety valve drain is conveyed on the same pipe “9” as per figure 5-5.
5 - INSTALLATION 5.11 - Electrical connections For connection to mains electricity, a bi-polar switch CAUTION !!! The appliance is only electrically safe when it has been correctly connected to an efficient earth circuit, performed as envisioned by the current Safety Standards. Respect the polarity between neutral and phase during must be envisioned in the vicinity of the appliance with a contacts opening distance of at least 3mm, as envisioned by the current regulations. connection of the appliance.
5 - INSTALLATION 5.11.1 - Power supply cable connection Proceed as follows to connect the power supply cable (refer to figure 5-6): 1.- use a three-polar cable with double isolation, with minimum section of 1,5 mm² 2.- remove the casing from the appliance following instructions in section 8.2; 3.- rotate the panel “A” towards the front of the appliance; 4.- operate on the flaps “C” and open the lid “B” as indicated by the arrow; 5.
5 - INSTALLATION 5.12 - Flue systems CAUTION !!! The relevant national and local regulations must be strictly adhered to when installing the exhaust flue and combustion air pipes. CAUTION !!! The exhaust flue gases from the appliance can reach 90°C in certain conditions. Therefore, the plastic flue components must be capable of withstanding high temperatures and they must be approved for these specific appliance. CAUTION!!! This appliance is the “condensing” type.
5 - INSTALLATION During operation, especially in winter, a plume will be visible The flow of air can also be obtained from an adjacent room as the water vapour in the exhaust gases come into contact as long as: with the outside air.
5 - INSTALLATION 5.12.2 - “Split 80/80PP” System (polypropylene) (Type C13; C33) ICW 25 and 35 A B The appliance is supplied as per standard with fittings for the connection of the flue/air intake. To connect it to a “80/80PP Split” system, the relevant kit must be installed as in figure 5-8. Fitting “A” can rotate freely by 360°, guaranteeing optimum installation versatility.
5 - INSTALLATION A B 5.12.3 - “Split 80/80PP” System (polypropylene) (Type C13; C33) ICW 60 The appliance is supplied as per standard without fittings for the connection of the flue/air intake. To connect it to a “80/80PP Split” system, the relevant kit must be requested and must be installed as in figure 5-9. Fitting “A” can rotate freely by 360°, guaranteeing optimum installation versatility.
5 - INSTALLATION Subject Description Split adaptor (at appliance) Ø 60/100mm to 2x Ø 80mm Art. No. ICW 25, ICW 35 0312 273 (1) Split adaptor (at appliance) Ø 80/125mm to 2x Ø 80mm Art. No. ICW 60 0312 209 (1) Adaptor (to roof or wall terminal) Art. No. 2x Ø 80mm to Ø 80/125mm ICW 25, ICW 35, ICW 60 0307 177 (1) Roof Flue terminal Art. No. ICW 25, ICW 35, ICW 60 0310 753 * Wall flue terminal Art. No.
5 - INSTALLATION 5.12.4 - “60/100PP vertical coaxial” System (polypropylene) (Type C13; C33) ICW 25 and 35 C The appliance is supplied as per standard with fittings for the connection of the flue/air intake vertical 60/100 system. D CAUTION !!! The coaxial exhaust and intake pipes must be appropriately sustained via rigid brackets positioned no more than 1 metre from each other. The brackets must be fixed to rigid walls that can support the weight of the pipe itself.
5 - INSTALLATION Subject Wall flue terminal Pipe material Pipe diameters Description Art. No. ICW 25, ICW 35 Manufacturer Muelink & Grol Type Coax line Plus Construction Concentric Flue gas discharge PP polypropylene with lipped sealing ring Air supply Thin-walled galvanized sheet steel Flue gas discharge ICW 25, ICW 35 Air supply 0312 247 (1) Ø 60 mm Ø 100 mm (1) = No other wall flue terminal is permitted.
5 - INSTALLATION 5.12.5 - “80/125PP vertical coaxial” System (polypropylene) (Type C13; C33) ICW 60 C The appliance is supplied as per standard with fittings for the connection of the flue/air intake vertical 80/125 system. A CAUTION !!! The coaxial exhaust and intake pipes must be appropriately sustained via rigid brackets positioned no more than 1 metre from each other. The brackets must be fixed to rigid walls that can support the weight of the pipe itself. B 020008.01.
5 - INSTALLATION Figure 5-19 - Examples of coaxial pipe installations 28
6 - OPERATING 6.1 - Operating Before starting the appliance up, it is necessary to carry out the following. 6.1.1 - User instructions Instruct the user regarding correct use of the appliance and the plant in general. In particular: 6.2 - General recommendations regarding the supply of gas Give the installation and user manual and all documentation contained in the packaging to the user.
6 - OPERATING 6.3 - Type of gas for which the appliance is regulated. C D There is a label on the front of the appliance certifying the gas supply type and pressure for which it is adjusted. The appliance may have the following 2 types of wording: H E 2H-G20-20mbar NATURAL GAS means that the appliance is adjusted to operate with H type F gas of the second family (natural gas) at a supply pressure of 20 mbar.
6 - OPERATING 17. - replace the gas orifice “R” (see figure 6-5) with an appropriate one according to that stated in figure 6-8 under “Gas orifice diameter”; 18. - remount the gas valve (see figure 6-4, detail “P”), making sure to reposition the spring “M”. 19. - remount the gas supply pipe by the two fittings (see B figure 6-3, details “H” and “L”); OFF ON 20. - remount the air manifold (see figure 6-3, detail “C”); 21. - open the gas supply manual valve; 22. - check for any gas leaks on all joints.
6 - OPERATING A 6.5 - Ignition 1.- Open the gas manual valve; 2.- Turn the electrical power; 3. - Adjust the temperature desired for the domestic hot water and keys. The icon service using the , present on the display will inform regarding the operating state of the domestic hot water service: icon: domestic hot water inactive (no-one is a) fixed tapping domestic hot water). 020003.01.023 icon: domestic hot water is being tapped. b) flashing 4.
6 - OPERATING A 6.7 - Measurement and adjustment of CO2 levels B C D E 020002.01.015 Figure 6-10 - Combustion analysis port on ICW 25 and 35 B D 020008.01.023 Figure 6-11 - Combustion analysis port on ICW 60 The appliance in normal operating condition and for altitudes within 1000 m, must have a CO2 (carbon dioxide) level in the exhaust flue gases within the parameters as detailed in section 9. A value which is different to those detailed can cause malfunctions and is strictly prohibited.
6 - OPERATING 6.8 - Self-learning and calibration of the minimum and maximum capacity output This water heater have a self-learning procedure to reach the best water temperature tuning. In order to do this, the water heater automatically calibrate the maximum and minimum capacity based on the typical tappings. Because at the first installation it is not known what’s the typical tappings, for an immediate satisfactory temperature tuning it is suggested to help the water heater in its selflearning.
7 - USE Figure 7-1 - Control panel Key for figure 7-1 A - On/off switch B - Reset Key C - Burner status (the burner is on when this icon is present) D - State of the domestic water service: Icon off = domestic water off Icon on = domestic water active but not operating Icon flashing = domestic water active and operating F - Indicator of the various parameters inside the various menus G - Icon for entry into the “Installer” menu H - Domestic hot water temperature or indicator of the values assumed
7 - USE 7.5 - Pump control features and timers 7.3 - “User menu” Entry into the “User menu” is highlighted by the visual display To safeguard the lifespan of the appliance, improve the comfort “F”, in figure 7-1, which indicates parameters that can assume generated and increase energy saving, timers have been introduced during operation. to . To enter the “User menu”: values from These timers are: 1.
7 - USE 7.7 - “User menu” Parameters To access the “User menu” follow that reported in section 7.3. The following parameters can be queried in this menu: Parameter 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1040 1041 1042 1043 1051 1052 1053 1055 1056 1057 1058 1059 1060 1061 1062 Parameter Description M.U.
7 - USE 7.8 - “Installer menu” & parameters CAUTION !!! The modification of these parameters could cause the appliance, and therefore the plant, to malfunction. For this reason only a technician that has the awareness and in-depth knowledge of the appliance can modify them. The appliance command and control board makes this parameter menu available to the technician for the analysis of operation and adaptation of the appliance to the plant. Proceed as follows to enter the “Installer menu”: 1.
7 - USE 2024 Climatic adjustment: supply temperature corresponding to the external spring-like temperature (N/A) (N/A) (N/A) 40 (N/A) 2027 Temperature reduction by room thermostat opening (N/A) (N/A) (N/A) 10 (N/A) 2040 Climatic adjustment: central heating boost temperature (N/A) (N/A) (N/A) 0 (N/A) 2041 Climatic adjustment: central heating boost time (N/A) (N/A) (N/A) 20 (N/A) 2042 Protection against frequent switch-on in central heating mode: time (N/A) (N/A) (N/A) 180 (N/A)
7 - USE 7.9.1 - Diagnostics “Loc” block fault codes and potential solution Block Block Description Checks Solutions Loc 0 Internal memory error E2prom at command board Replace the command and control board. Loc 1 1 No flame detection after Control: Supply gas pressure (see section 6.6), three successive ignition sparks on the ignition electrodes (see section 8.6); attempts. 230Vac electric power supply to the gas valve; electric resistance of the two gas valve coils of 0.88 Kohm and 6.
7 - USE Loc 16 Exhaust flue maximum temperature. ATTENTION !!! If the block is repeated more than once a day, turn off the appliance and contact a qualified service center. NOT GROPE TO RESTORE. Check that the pump is operating correctly; If the pump does not operate, it must be replaced. Measure that appliance performance; it must correspond to that declared in the technical features.
7 - USE 7.9.2 - Diagnostics “E” error fault codes and potential solutions Error Error Description Checks Solutions Err 100 Software error inside the command board Replace the command and control board. Err 101 Software error inside the command board Replace the command and control board. Err 102 Software error inside the command board Replace the command and control board. Err 103 Software error inside the command board Replace the command and control board.
7 - USE Err 122 Domestic hot water outlet sensor (1002) circuit open Check that the electric resistance of the sensor matches the graphics in section 8.14. Check the electric cables for connection between the sensor and the command board. If the electric resistance does not match, replace it. The electric circuit must be repaired if it is damaged. Without either of the two previous cases, replace the command and control board.
8 - MAINTENANCE 8.1 - Care and maintenance This section must be brought to the attention of the user by the installer so that the user can make the necessary arrangements with a qualified service agency for the periodic care and maintenance of the heater. The installer must also inform the user that the lack of proper care and maintenance of this heater and any fuel burning equipment may result in an hazardous condition. Installer should discuss contents of section 7 (User’s section) with the user.
8 - MAINTENANCE 8.2 - Casing removal Proceed as follows to remove the casing (refer to figure CAUTION !!! If gas flow occurs, close the manual gas 8-1): shutoff valve and troubleshoot the system to determine why there is gas flow when the gas valve should be deenergized. 1.- loosen the screws “H”; Do not operate the boiler until the problem is resolved or a 2.
8 - MAINTENANCE 8.3 - Burner and fan removal Proceed as follows to remove the burner fan unit (refer to figure 8-2 when not differently specified): 1.- access the internal components following section 8.2; 2.- remove the air manifold (detail “C” in figure 6-3) rotating it towards the outside of the appliance and then pulling it towards the right (see figure 6-3); 3.- unscrew nut “C” from the valve “D”; 4.
8 - MAINTENANCE E B H L F G C D A 020003.01.062 Figure 8-2 - Removing the burner fan unit GASKET 020009.01.032 HEAT EXCHANGER DOOR CAUTION!!! Gasket is intended for sealing combustion. If damaged DO NOT reuse it, the heat exchanger door must be replaced. Consult factory to replace heat exchanger door.
8 - MAINTENANCE 8.5 - Condensate siphon cleaning procedure 020003.01.063 For correct cleaning of the collection siphon and the conveying of the condensate produced by combustion, operate as follows (refer to the figures 8-3, 8-4 and 8-5): 1.- with the appliance on, open a domestic hot water tap or taps fully to force the burner to its maximum power and the level of the liquid present inside the siphon tank “D” lowers (see figure 8-4); 2.- switch off the appliance and disconnect the electrical supply; A 3.
8 - MAINTENANCE 8.6 - Ignition and ionisation flame electrodes position For good working order of the appliance, it is indispensable that the electrodes are positioned correctly (refer to figure 8-6): - the distance between the ignition electrodes “A” and “B”, must be between 2,0 and 2,5 mm; - the distance between the ignition electrodes from the burner surface must be between 5 and 5,5 mm; - the distance of the ionisation electrode “C” from the surface of the burner must be between 5,5 and 6,5 mm.
8 - MAINTENANCE 8.8 - Domestic water flow meter replacement procedure Proceed as follows, making reference to figure 8-8: 1.- empty the domestic hot water circuit, following the procedure in section 8.10; 2.- disconnect the electric power supply upstream from the appliance; 3.- access the components inside the appliance, following section 8.2; 4.- disconnect the cables from the flow meter (detail “B” in figure 8-8); 5.
8 - MAINTENANCE 8.10 - Procedure for draining the water heater 8.13 - Checking the ionisation current In any operating status, also during verifications of minimum and maximum power stated in section 8.12, the ionisation To empty the appliance proceed as follows (see figure 5-5): 1.- close the isolation valves “10” and “3”; 2.- connect a drain pipe to drain valves “4”; 3.- open the drain valves “4”; 4.
8 - MAINTENANCE 8.15 - ICW 25, 35 and 60 electrical connections CAUTION !!! To consult the wiring diagram correctly, references K are given followed by a number (see example above) to identify the correct followon of the cables in the next page. 1001 - Heat exchanger output sensor 1002 - D.H.W.
8 - MAINTENANCE GS - Spark generator IG - Main electrical switch J1 - 8 pin Molex connector J12- 6 pin Molex connector J2 - 6 pin Molex connector J26- 4 pin Molex connector J3 - 10 pin Molex connector J4 - 6 pin Stelvio connector J5 - 4 pin Molex connector J6 - 14 pin Molex connector J7- 10 pin Molex connector J9- 4 pin Molex connector SDC- Connection board TF- High limit flue gas temperature fuse TU - Domestic hot water flow meter VG1- Gas Valve 53
8 - MAINTENANCE 8.
8 - MAINTENANCE 55
9 - TECHNICAL DATA TECHNICAL DATA UM Type (Type of exhaust flue/combustion air intake) ICW 25 ICW 35 ICW 60 B23; C13; C33; C43; C53; C63; C83 Category CE type certificate (PIN) II2H3P II2H3P II2H3P 0476CQ1097 0476CQ1097 0476CQ1097 Max. heat input NET (GROS) kW 25,5 (28,3) 32,0 (35,5) 57,8 (64,2) Min. heat input NET (GROS) kW 3,2 (3,6) 6,0 (6,7) 12,0 (13,3) Max. useful heat output kW 27,0 33,5 60,9 NET Efficiency at max.
10 - COMMAND MENU DIAGRAM Key for figure 10-1 Symbol Description Press and release the RESET key Hold the reset key down for a time in seconds, indicated by the number (2) Hold the reset key down for a time in seconds, indicated by the number (5) Hold down the RESET and key simultaneously for a time in seconds, indicated by the number Press and release the key Press and release the key Installer menu access (see section 7.8) Installer menu parameters (see section 7.
11 - ENGINEERS TEST MODE CAUTION !!! The modification of these parameters could cause the appliance, and therefore the plant, to malfunction. For this reason only a technician that has the awareness and in-depth knowledge of the appliance can modify them. To access this menu, move the switch in the board as stated in figure 6-6 detail “B”.
12 - CE DECLARATION OF CONFORMITY Declaration of Conformity Distributor: A.O. Smith Water Products Company b.v.
13 - WARRANTY To register your warranty, you should complete and return the enclosed warranty card. Exclusions The warranty set out in Articles 1 and 2 will not apply in the event of: • damage to the water heater caused by an external factor; If, after verification and at the sole discretion of A.O.
14 - PRODUCT FICHE INFORMATION SYMBOL UNIT VALUE Trademark - - A.O.
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.
