A.O. Smith 28 30 50 60 Installation & Service Manual Download Page 1

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WATER PRODUCTS

COMPANY

A DIVISION OF A. O. SMITH CORPORATION

XTRA HIGH EFFICIENCY

XTR

A HI

EFF

ICIE

N CY

XTR

A HI

EFF

ICIE

N CY

Installation

User and

Service Manual

28
30
50
60

Release R.1.

Summary of Contents for 28 30 50 60

Page 1: ...WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION XTRA HIGH EFFICIENCY XTRA HIGH EFFICIE N CY XTRA HIGH EFFICIE N CY Installation User and Service Manual 28 30 50 60 Release R 1 3 UK...

Page 2: ...your installer www aosmithinternational com...

Page 3: ...accordance with the General Conditions registered at the Eindhoven Chamber of Commerce Refer further to the General Conditions These are available on request and without charge Although considerable...

Page 4: ...4 Instruction Manual BFC...

Page 5: ...nvented installation 16 2 5 2 Vented installation 16 2 5 3 T P valve 16 3 Installation 17 3 1 Introduction 17 3 2 Packaging 17 3 3 Environmental conditions 17 3 3 1 Humidity and ambient temperature 18...

Page 6: ...ions 41 5 The control panel 43 5 1 Introduction 43 5 2 Operating 43 5 3 Explanation of the icons 44 5 4 ON OFF switch of ThermoControl 44 5 5 Navigation buttons 44 5 6 PC connection 44 6 Status of the...

Page 7: ...ting the pump on off 66 9 7 Setting the service interval 66 9 8 Setting the display contrast 67 9 9 Setting the backlight time 67 9 10 Setting the display scroll speed 67 10 Troubleshooting 69 10 1 In...

Page 8: ...warranty 89 13 3 Installation and conditions of use 89 13 4 Exclusions 89 13 5 Scope of the warranty 90 13 6 Claims 90 13 7 Limitation of liability A O Smith 90 A Appendices 91 A 1 Introduction 91 A 2...

Page 9: ...ons may lead to personal injury and damage to the appliance 1 2 What to do if you smell gas Warning Whenever there is a smell of gas No naked flames No smoking Avoid causing sparks Do not use any elec...

Page 10: ...g other things on the water quality the average burning time per day and the set water temperature n Remark To determine the correct maintenance frequency it is recommended to arrange for the service...

Page 11: ...his is the actual menu for the user however the installer and service and maintenance engineers will also need to use this menu 9 Service program is Describes the service menu It is mainly intended fo...

Page 12: ...Introduction 12 Instruction Manual BFC 1 gis...

Page 13: ...liance Legend a plastic top cover b hot water outlet c electrical connection block d ThermoControl e pressure switch f control panel g temperature sensor T1 h combustion chamber i anode j tank k heat...

Page 14: ...increases the performance of the unit The water of condensation yielded by this process is discharged via the siphon w The PU insulation layer x prevents heat loss The inside of the tank is enamelled...

Page 15: ...ressure switch The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre purge and normal running of the appliance The standard position of the pressure swi...

Page 16: ...m The pressure reducing valve protects the installation against an excessively high water supply pressure 8 bar These components are fitted to the cold water pipe See paragraph 3 6 1 Cold water side 2...

Page 17: ...Water connections Unvented Water connections Vented Gas connection Air supply and flue gas discharge Electrical connection Checking the supply pressure and burner pressure Conversion to a different ga...

Page 18: ...ion cannot be guaranteed See also chapter 13 Warranty Certificate 3 3 4 Working clearances For access to the appliance it is recommended that the following clearances are observed see Figure 3 2 AA ar...

Page 19: ...the tank and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this is the case then the appliance should be installed above a wastewater dr...

Page 20: ...3 4 Technical specifications The appliance is supplied without accessories Check the dimensions and other specifications for the accessories to be used based on Figure 3 2 and Table 3 6 Figure 3 2 Pl...

Page 21: ...of air supply connection mm 1205 1730 1730 1730 1 Cold water supply connection R 1 external 2 Hot water outlet connection R 1 external 3 Gas control connection Rp internal 4 Drain valve connection ex...

Page 22: ...ion 22 Instruction Manual BFC 3 is Electrical power consumption W 175 Supply voltage VAC 230 15 10 Mains frequency Hz 50 1 Hz Table 3 5 General and electrical data DESCRIPTION Unit BFC 28 BFC 30 BFC 5...

Page 23: ...mbar 8 5 8 5 8 5 11 5 Gas consumption 1 m3 h 3 1 3 3 5 0 6 0 Data for LP gas 3 General Orifice diameter mm 2 50 2 60 3 40 3 80 Restrictor diameter mm n a n a n a n a G30 30 mbar butane Nominal load u...

Page 24: ...temperature gauge optional k condensation drainage mandatory l hot water draw off points m pressure relief valve mandatory n water cistern o float valve p 3 way venting valve recommended q overflow pi...

Page 25: ...rature gauge j to be able to check the temperature of the tap water 2 Fit the T P valve c 3 Fit a stop valve i in the hot water outlet pipe for use when servicing 3 6 3 Circulation pipe See c in Figur...

Page 26: ...points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fit a circulation pump f of the correct capacity for the length and resistance of the circulation system 2...

Page 27: ...tact A O Smith cNote A O Smith prescribes the use of a roof or wall mounted terminal exclusively of a type approved for the appliance See paragraph 3 9 1 Concentric wall flue terminal and 3 9 2 Concen...

Page 28: ...M2000 MDV SE 1 Pipe material flue gas discharge Thick walled aluminium with lip ring seal Pipe material air intake Thin walled galvanised sheet steel Pipe diameter Concentric BFC 28 80 125 mm BFC 30 5...

Page 29: ...r Muelink Grol Model M2000 DDV SEC HR 1 1 The model M2000 DDV SEC HR is a special version of the Mugro 3000 series No other roof flue terminal may be used as the BFC appliance is approved exclusively...

Page 30: ...ror signal Alarm OUT n Remark The optional components are not included in the rating for electrical power consumption see tables in paragraph 3 4 3 10 2 Preparation cNote The appliance is phase sensit...

Page 31: ...tion of electrical components 3 10 3 Mains voltage The appliance is supplied without a power cord and main switch n Remark In order to receive electrical power the appliance has to be connected to the...

Page 32: ...power is connected to the appliance 1 Connect phase L neutral N and earth A to terminals 7 8 and 9 as indicated in Table 3 10 2 Fit the cable in the pull relief 3 If you do not need to make any more c...

Page 33: ...structions cNote Before starting up for the first time and following conversion you must always check the supply pressure and burner pressure If necessary adjust these to be certain of optimum perform...

Page 34: ...ly pressure is not correct n Remark If the burner pressure is not correct and the appliance is fitted with a flat sealing plate you will not be able to adjust the pressure In this case consult your in...

Page 35: ...rsion to a different gas category cNote The conversion may only by carried out by an authorised installer If the appliance must operate on a family of gas LP gas or natural gas other than the category...

Page 36: ...e metal of the gas air distribution plate 5 10 Select and fit the correct orifice from the conversion kit based on Table 3 6 The injector diameter is stamped into each injector 6 11 Check whether ther...

Page 37: ...t the flat sealing plate or burner pressure regulator supplied with the conversion kit Refit the connector to the gas control 13 Refit the connector 1 of the glow igniter and ionisation rod to the con...

Page 38: ...Installation 38 Instruction Manual BFC 3 is...

Page 39: ...e There should be no water coming out of the overflow valve m nor the T P valvec If this does happen the cause might be The water supply pressure is greater than the specified 8 bar Rectify this by fi...

Page 40: ...y j temperature gauge optional k condensation drainage mandatory l hot water draw off points m pressure relief valve mandatory n water cistern o float valve p 3 way venting valve recommended q overflo...

Page 41: ...e drain valve g 11 Bleed the appliance or installation so that it drains completely empty 4 3 2 Draining vented installations Some service activities require the appliance to be drained The procedure...

Page 42: ...Filling and draining 42 Instruction Manual BFC 4 gis...

Page 43: ...ow the display 6 graphical symbols above the display a connector for a service PC an ON OFF switch The push buttons are divided into three groups Navigation buttons Buttons UP H and DOWN L Enter E Res...

Page 44: ...dicate that you can scroll up and or down Use buttons H and L to scroll The cursor points to the option to be activated In the display as shown in Figure 5 4 you can scroll through the main menu The m...

Page 45: ...r depending on the heating cycle a text such as HEAT DEMAND See 7 4 The appliance s heating cycle EXTRA In this mode one extra period is programmed and activated In this mode the OFF or PROG position...

Page 46: ...ppliance enters this condition the display will show the following information line one error code comprising a letter and two digits followed by the error description lines two through four alternate...

Page 47: ...t case contact your service and maintenance engineer n Remark The message SERVICE REQUIRED is based on the number of burning hours and the preset service interval Should the service interval have been...

Page 48: ...Status of the appliance 48 Instruction Manual BFC 6 gis...

Page 49: ...Press once on the DOWN button L to position the cursor beside ON then press E The display shown in figure Figure 7 4 will appear Confirm with E the option START OPERATION The appliance will now enter...

Page 50: ...orrect way The correct procedure is as follows 1 Activate the MENU with B 2 Use H and L to position the cursor beside OFF See Figure 7 6 3 Confirm OFF with E 4 Wait until the fan has stopped The S ico...

Page 51: ...h 8 steps 1 The water temperature drops below the set temperature of for example 65 C The ThermoControl detects a heat demand and starts the heating cycle The W icon is activated The message HEAT DEMA...

Page 52: ...The message RUNNING appears 7 Once the water is up to temperature the heat demand drops off and the post purge starts This lasts about 25 seconds The W G and V icons are dimmed The S icon is activate...

Page 53: ...OFF ON WEEK PROGRAM EXTRA PERIOD SETTINGS Figure 8 1 Main menu OFF Select this option if you wish to shut the appliance down for a brief period but do not wish to drain it In this mode the frost prot...

Page 54: ...the value Confirm with E After confirming the appliance enters ON mode n Remark If the temperature setting is higher than the current water temperature it is possible that the appliance does not imme...

Page 55: ...andard week program 8 5 4 Adding times to a week program 8 5 5 Deleting times from a week program 8 5 2 Starting up and shutting down the week program The week program can be started up from any other...

Page 56: ...ample this is 08 Confirm with E The cursor moves to the minute digits which will blink See Figure 8 10 n Remark Because the switch off time can never be earlier than the switch on time the switch off...

Page 57: ...roll to another day and change more switch on and switch off times Simply repeat steps 3 through 10 12 After changing all desired switch on and switch off times you can start running the week program...

Page 58: ...ew period added scroll down with L to START OPERATION and confirm with E 8 5 5 Deleting times from a week program All switch on off times are shown sequentially in the display Assume that the switch o...

Page 59: ...to cancel deletion The switching period has been deleted You will return now to the week program menu The cursor is beside the first programmed period See Figure 8 27 7 Scroll with L to START OPERATIO...

Page 60: ...will blink See Figure 8 30 3 Use H and L to set the switch on hour to the desired value In the example this is 08 Confirm with E The cursor moves to the minute digits which will blink See Figure 8 31...

Page 61: ...ain settings and display certain appliance specifications See Table 8 1 8 7 2 Setting menu language Bring up the menu for selecting the language via 1 B SETTINGS Confirm with E The display shows the m...

Page 62: ...ith H and L to the current hour for example 15 Confirm with E 5 The cursor moves to the minute digits which will blink Scroll with H and L to the next minute in time for example 45 Confirm the minute...

Page 63: ...AL The relevant display specification appears see Figure 8 49 Table 8 2 Appliance specifications Appliance Ignition speed of fan Running speed of fan Regulation interval BFC 28 4500 rpm 4980 rpm 40 80...

Page 64: ...Main menu 64 Instruction Manual BFC 8 gis...

Page 65: ...pliance might not immediately start the heating cycle see chapter 7 4 The appliance s heating cycle To prevent excessively frequent switching on and off a there is a heating margin We refer to this ma...

Page 66: ...S PUMP RELAY The standard setting for the pump relay is OFF Figure 9 7 shows the related display If the mode WEEK PROGRAM or EXTRA PERIOD is active then the setting for mode WEEK PROGRAM or EXTRA PER...

Page 67: ...e is from 0 through 100 Figure 9 9 shows the related display 9 9 Setting the backlight time Adjust the backlight time the time that the display backlight stays lit after the last button is pressed via...

Page 68: ...Service program 68 Instruction Manual BFC 9 is...

Page 69: ...ng every 2 seconds See Figure 10 1 and Figure 10 2 The displayed errors are divided into two groups There are various types of errors LOCK OUT ERRORS When the cause is no longer present these errors r...

Page 70: ...shooting table for general errors Table 10 1 General errors Sheet 1 of 3 Symptom Cause Solution Remark Gas smell Gas leak Warning Immediately close the main gas valve Warning Do not operate any switch...

Page 71: ...t be 230 VAC 15 10 See appendix A 2 Electrical diagram BFC If the error cannot be rectified contact your installer Defective fuse s Replace fuse s To replace the fuses you must contact your installer...

Page 72: ...lectric power present 1 Check whether the mains switch is ON 2 Check that there is power to the mains switch 3 Check whether the ON OFF switch of the ThermoControl is ON position I 4 Check whether the...

Page 73: ...ng error Open circuit from sensor 2 of temperature sensor T 1 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5 See appendix A 2 Electrical diagram BFC Damaged...

Page 74: ...perature sensor T 1 at the top of the tank Short circuit in the sensor circuit Replace sensor T 1 To replace the necessary parts you must contact your installer S14 blocking error Short circuit from d...

Page 75: ...contact your installer Floating neutral Install an isolating transformer See 3 10 4 Isolating Transformer Contact your installer to have an isolating transformer installed F02 lock out error Fan fails...

Page 76: ...supply hose between fan and burner are correctly fitted Refit these if necessary 3 Check the hoses on the pressure switch and the air supply hose between fan and burner for cracks If necessary replac...

Page 77: ...k that the gas valve s open and shut correctly 3 If necessary replace the gas control Defect in the glow igniter circuit 1 Check that the glow igniter is correctly connected JP2 2 Check the wiring of...

Page 78: ...rod is broken cracked 1 Check whether the ceramic part of the ionisation rod is still intact in the vicinity of the air distribution plate of the burner 2 If this is not the case the ionisation rod mu...

Page 79: ...ing appliance specifications 2 Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted Refit these if necessary 3 Check for cracks in the hoses...

Page 80: ...ay only be performed by a qualified service and maintenance engineer F11 lock out error Flame detection with closed gas valve Defective gas valves See F07 Table 10 2 Displayed errors Sheet 8 of 10 Cod...

Page 81: ...ller 3 If the frequency is correct but the error persists replace the ThermoControl To replace the necessary parts you must contact your installer Internal error message from the water heater controll...

Page 82: ...he tank is 85 C None This is a temporary message that may appear from time to time but will disappear automatically E03 blocking error Error in temperature sensor T 1 at the top of the tank The temper...

Page 83: ...00 or 1500 burning hours The standard setting is 500 burning hours Example In the first three months the appliance has burnt 300 hours During maintenance it is evident that one service per year will b...

Page 84: ...Maintenance frequency 84 Instruction Manual BFC 11 gs...

Page 85: ...y by ordering with this information can you be sure to receive the correct spare parts These details can be found on the rating plate 12 2 Preparation for maintenance To test whether all components ar...

Page 86: ...and adjust these where necessary See paragraph 3 11 Checking the supply pressure and burner pressure 13 Check that all components of the flue gas system are properly attached 14 Check the pressure di...

Page 87: ...of the appliance and also improves the heating process Take the rate of scale formation into account when deciding on maintenance frequency 1 Remove the cover plate 1 on the outer jacket See Figure 1...

Page 88: ...lean the end of the heat exchanger using tap water 5 Fit the burner 6 Fit the flue gas discharge n Remark Check the pressure differential again after cleaning If the pressure differential is too low f...

Page 89: ...nd conditions of use The warranty set out in article 1 and 2 will apply solely under the following conditions a the water heater is installed under strict adherence to the installation instructions of...

Page 90: ...acement parts or components or water heater Shipping labour installation and any other costs associated with the replacement will not be accepted by A O Smith 13 6 Claims A claim on grounds of the spe...

Page 91: ...Release R 1 3 UK 91 A Appendices A 1 Introduction This appendix contains The Electrical diagram BFC A Week program card is...

Page 92: ...OFF switch control N Display Flat cable O Fan P Temperature sensor T2 bottom of tank Q Dummy R Temperature sensor T1 top of tank S Selection resistor T Pressure switch CONTROLLER CONNECTIONS J1 Conne...

Page 93: ...FF 13 ON C ON OFF OFF OFF 3 ON C ON OFF 14 ON C ON OFF OFF OFF 4 ON C ON OFF 15 ON C ON OFF OFF OFF 5 ON C ON OFF 16 ON C ON OFF OFF OFF 6 ON C ON OFF 17 ON C ON OFF OFF OFF 7 ON C ON OFF 18 ON C ON O...

Page 94: ...Release R 1 3 UK 94...

Page 95: ...ide 25 continuous pump connection 32 conversion to different gas 35 D data general 21 descaling 87 dimensions 21 display 43 displaying error history 65 document contents 11 draining 41 E electrical co...

Page 96: ...scale 87 scrolling 44 service check 10 83 service engineer 10 service required 47 setting backlight time 67 setting display contrast 67 setting display scroll speed 67 setting service interval 66 sett...

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