A.O. Smith BFC-120 Installation, User And Service Manual Download Page 8

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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.

Document identification

Article number

Language

Version

0311753

2.0

Summary of Contents for BFC-120

Page 1: ...0311753 Innovation has a name Installation User and Service Manual Condensing High Efficiency Gas Solar Water Heater SGS 28 30 50 60 80 100 120 SGS 3017 Changes Reserved...

Page 2: ...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 your installer...

Page 3: ...manual use other than in accordance with the General Conditions registered at the Chamber of Commerce For more information refer to the General Conditions These are available on request free of charg...

Page 4: ...boilers of rated inputs between 70 kW net and 1 8 MW net 2nd and 3rd family gases BS 6700 Design installation testing and maintenance of services supplying water for domestic use within buildings and...

Page 5: ...70 5500 AB Veldhoven The Netherlands Telephone 0870 AOSMITH free 0870 267 64 84 General 31 40 294 25 00 Fax 31 40 294 25 39 E mail info aosmith nl Website www aosmith co uk In the event of problems w...

Page 6: ...6...

Page 7: ...ibes the correct installation and maintenance procedures Target group The information in this manual applies to three target groups users installation engineers service and maintenance engineers The U...

Page 8: ...ed 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 o...

Page 9: ...User part 13 1 Introduction 15 2 Safety 17 3 Interface 19 3 1 Operator interface 19 3 2 Explanation of icons 19 3 3 Control switch 20 3 4 Buttons 20 3 5 PC connection 21 3 6 Status of the water heater...

Page 10: ...am 30 4 3 7 Adding times to a week program 33 4 3 8 Deleting times from a week program 34 4 3 9 Extra period 35 4 3 10 Settings 37 Installation Maintenance and Service part 41 5 Introduction 43 5 1 Ab...

Page 11: ...Preparation 66 7 8 2 Mains power 66 7 8 3 Optional electrical connections 67 7 8 4 Electrical connection of the solar heating system 68 7 9 Commissioning 70 7 9 1 Filling 70 7 9 2 Procedure for check...

Page 12: ...93 10 3 Gas side maintenance 93 10 3 1 Clean the burner 93 10 3 2 Clean the heat exchanger 93 10 4 Solar collector maintenance 94 10 5 Finalization 94 11 Troubleshooting 95 11 1 Errors and warnings 95...

Page 13: ...User part 0311753_SGS_28 120_II_UKUK_V2 0 2017 05 03 13...

Page 14: ...14...

Page 15: ...rough 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 Fig SGS water heat...

Page 16: ...16 User part...

Page 17: ...er Some propellants bleaching agents and degreasing agents etc disperse of explosive vapors and or cause accelerated corrosion If the water heater is used in a room where such substances are stored or...

Page 18: ...18 User part...

Page 19: ...main menu see section 4 3 The service program This chapter is specifically intended for the service and maintenance engineer and installation engineer In this manual the display of the operator inter...

Page 20: ...he water heater and the mains power supply 3 4 Buttons The use of these buttons is explained with the help of the figure showing the main menu see section 4 3 The buttons are Buttons for UP and DOWN E...

Page 21: ...3 6 1 2 ON In this mode the water heater continually responds to the hot water demand The figure shows the display with the following information line one the text ON line two the time the day and T1...

Page 22: ...ne three the next scheduled switch on time line four displays the text PERIOD ACTIVATED In all modes the temperature may at any moment drop below the desired temperature The water heater then enters a...

Page 23: ...warning This message appears when the anode protection is no longer active If the message appears you must contact your service and maintenance engineer Note The water heater continues to function wh...

Page 24: ...24 User part...

Page 25: ...iance is now in ON mode If there is a heat demand the appliance will run through the heating cycle see section 4 1 1 If the heating cycle is not run there is no heat demand if this is the case Tset wi...

Page 26: ...d are dimmed The icon is activated After a number of seconds pre glow the gas control valve is opened and ignition takes place The icon is activated The message IGNITION appears After ignition the fla...

Page 27: ...ater heater will heat the water to 20 C Tset before dropping back to mode OFF Caution The anode protection remains active when the OFF mode is selected Note These values of 5 C and 20 C cannot be adju...

Page 28: ...spond to demand only during pre programmed periods see section 4 3 4 Outside those periods only frost protection is active EXTRA PERIOD Select this option to overrule OFF mode or PROG mode i e Week pr...

Page 29: ...crease the value Confirm with ENTER After confirming the appliance enters ON mode Note If the preset temperature is higher than the current water temperature then the appliance might not immediately s...

Page 30: ...ing the appliance s standard week program see section 4 3 6 Adding times to a week program see section 4 3 7 Deleting times from a week program see section 4 3 8 4 3 5 Starting and stopping the week p...

Page 31: ...the mode of the program controlled pump 4 3 6 1 Week program setting the switch on time Bring the cursor to SU Confirm with ENTER The day indicated by blinks Use and to set the desired day In the exam...

Page 32: ...setting the program controlled pump 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 sk...

Page 33: ...program an extra period in which the switch on time is set to 18 00 and the corresponding switch off time to 22 00 The water temperature will be set to 75 C and the pump will run continuously Proceed...

Page 34: ...AM OVERVIEW Confirm with ENTER Scroll with to PROGRAM OVERVIEW Confirm with ENTER The display shows the menu for the week program Scroll with to DELETE Confirm with ENTER To warn you that you are now...

Page 35: ...the active week program or without taking the water heater out of OFF mode frost protection active If the water heater is running under an extra period then this is indicated in the display with the t...

Page 36: ...its of the switch off period Setting the switch off time Use and to set the hours In the example this is 012 Confirm with ENTER The cursor moves to the minute digits which will blink Use and to set th...

Page 37: ...and time Displayable water heater specifications this category is only relevant to the installation engineer and or service and maintenance engineer Regulation interval water temperature Ignition spee...

Page 38: ...de Sunday Scroll with and to the desired day Confirm with ENTER The day has been set The display shows the submenu for adjusting the time The cursor moves to the hour digits which will blink Scroll wi...

Page 39: ...ctrical data see section 12 1 Call up the menu to display the water heater specifications as follows SETTINGS Confirm with ENTER Scroll with to SPECIFICATIONS Confirm with ENTER The display shows the...

Page 40: ...40 User part...

Page 41: ...Installation Maintenance and Service part 0311753_SGS_28 120_II_UKUK_V2 0 2017 05 03 41...

Page 42: ...42 User part...

Page 43: ...s the bottom of the tank through the cold water inlet 14 Once the water heater and the storage reservoir are completely filled with water they are both constantly under mains water pressure When hot w...

Page 44: ...24 23 22 3 58 19 29 10 8 14 16 18 20 30 21 17 18 20 17 21 30 59 16 Fig Water heater SGS 80 100 120 1 2 5 7 4 6 28 9 11 13 12 15 24 23 22 3 58 19 29 10 8 14 16 18 20 30 21 17 1 Cover 2 Hot water outle...

Page 45: ...eating the water but only if the temperature of the heating fluid S1 is greater than the temperature measured at the appliance sensor S2 by a given adjustable amount When T1 Tset Tsolar limit heating...

Page 46: ...Note T1 can rise above Tset However this is only possible if Tsolar limit is increased via the service menu n 46 Installation Maintenance and Service part...

Page 47: ...nd the flue gas discharge components Make sure that the venting system does not exceed the maximum number of 45 and 90 bends and the maximum pipe length Caution Make sure that the diameter and length...

Page 48: ...ter The water heater has some safety instructions on its cover The text Read the installation instructions before installing the appliance The text Read the user instructions before putting the applia...

Page 49: ...nk that are related to safety Safety Description Anti frost S2 S3 5 C The frost protection cuts in The water is heated to 20 C Against overheating of water S2 S3 85 C The high limit safeguard serves t...

Page 50: ...m flowing backwards from the tank into the cold water supply system The pressure reducing valve protects the water heater against excess mains water pressure refer to the general and electric specific...

Page 51: ...ystem enters error mode The error is also visible on the display of the water heater 6 3 4 Safety of the solar heating system 6 3 4 1 Expansion vessel The solar heating system must be equipped with an...

Page 52: ...be recycled When you discard devices at the end of their service life you must obey local legislation related to waste disposal Never discard your old device together with regular waste Put the device...

Page 53: ...lly to prevent damage to the water heater 7 2 Conditions The water heater is suitable for room sealed and for open combustion For room sealed combustion the air inlet does not depend on the installati...

Page 54: ...4 Working clearances For access to the water heater it is recommended that the following clearances are observed see figure AA around the water heater s control column and cleaning openings 100 cm BB...

Page 55: ...the storage tank space for anode replacement 100 cm Note When installing the storage tank be aware that any leakage can cause damage to the immediate environment or floors below the level of the boil...

Page 56: ...t exchanger 3 T P valve 12 Temperature gauge recommended 37 Combined Q T sensor optional G Heat exchanger return 4 Stop valve recommended H Overflow protection 5 Non return valve mandatory 13 Condensa...

Page 57: ...bar Because the pressure in the water pipe at times can exceed 8 bar you must fit an approved pressure reducing valve 1 Fit a non return valve 5 and an expansion vessel 16 Fit an expansion valve 15 an...

Page 58: ...emperature of the tap water Fit a stop valve 4 in the hot water outlet pipe for servicing If a circulation pipe is required continue by installing the circulation pipe see section 7 4 1 3 7 4 2 3 Circ...

Page 59: ...t the lead to the solar heating system controller and sensor S2 see electrical diagram and connections table see section 7 8 4 1 Connect the communication cable between the solar heating system contro...

Page 60: ...ocal regulations The water heater is intended to be connected to a separately approved and marketed venting system This manual does not discus installation type B23 When you need a B23 system contact...

Page 61: ...130 mm Diameter air inlet 150 mm 200 mm Description parts A O Smith Part number A O Smith Part number Wall terminal set A wall terminal 1 a 500 mm concentric pipe and a 90 bend 0302504 0311465 Wall t...

Page 62: ...stated in the table must be fulfilled Even if you use less than the stated maximum number of bends the maximum pipe length still may not be exceeded Even if you use less than the stated maximum pipe l...

Page 63: ...l venting systems Description Unit SGS 26 60 1 SGS 80 120 2 Default Diameter flue discharge air inlet mm 2x100 2x130 Maximum length air inlet m 55 65 Maximum length flue gas outlet m 55 65 Lequivalent...

Page 64: ...length exceeds the maximum length as stated in the table 7 7 3 C43 C53 C63 systems The length of the air inlet and flue gas outlet is the same for C43 C53 and C63 systems as for C13 and C33 systems R...

Page 65: ...Material flue gas outlet Thick walled aluminum Thick walled aluminum Material air inlet Diameter flue gas outlet 100 0 6 0 6 mm 130 0 6 0 6 mm Diameter air inlet Refer to C13 C33 parallel systems for...

Page 66: ...rimary Secondary pump ON OFF link N L A N L1 A N L2 A X1 X2 A N L3 A X3 X4 X5 X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 to 20 21 22 23 24 7 8 2 Mains power Note The water heater is supplied without a...

Page 67: ...ntroller is 100W Connect neutral N live L and earth A to terminals 13 14 and 15 as indicated in the table see section 7 8 1 Fit the cable in the strain relief If you have no more connections to make F...

Page 68: ...Preparation Remove the cover snap on type from the terminal block for the collector This has the following terminals 7 8 4 2 Connecting the mains power Note Just as with the water heater controller t...

Page 69: ...relief Continue see section 7 8 4 7 7 8 4 6 Connecting top tank sensor Using the blade connectors connect the sensor S3 lead to the sensor Connect the other end to terminals 1 and 3 of J14 Fit the ca...

Page 70: ...A Cold water flows into the water heater Fill the water heater until a full water jet flows from the nearest draw off point The water heater is completely full Open all draw off points to bleed the e...

Page 71: ...ier of the appliance For any other system you should follow the procedure for that system Warning To avoid contaminating the glycol you should flush the solar heating system through with water before...

Page 72: ...ose in an environment friendly manner and according to local regulations 7 9 2 Procedure for checking the supply pressure To check the supply pressure proceed as follows Isolate the appliance from the...

Page 73: ...nite You must wait about 1 minute after the display shows the text RUNNING before reading the dynamic pressures the fan needs this time to get up to full speed so that you can get a reliable reading U...

Page 74: ...supply Connect a pressure gauge to the test nipple Switch on the power to the appliance using the isolator on the appliance Switch the controller ON by setting the 0 I switch to position I The display...

Page 75: ...the appliance until it is cold or by raising the value for Tset in the SERVICE menu Use for this Full load measurement From the service menu select SERVICE OPERATION FULL LOAD Confirm with ENTER The a...

Page 76: ...start the appliance up Switch off the appliance Turn off the gas supply to the appliance Put the covers back on the appliance Contact the appliance s supplier Partial load measurement From the service...

Page 77: ...e of the flue gas outlet pipe Shut off the gas supply Replace the covers 7 9 5 Switching pressure measurement To measure the switching pressure proceed as follows Isolate the appliance from the power...

Page 78: ...rain the water heater 7 10 1 Turn off the water heater Refer to the procedure in the user part to Turn off the water heater see section 4 2 and isolate the water heater from the mains power supply 7 1...

Page 79: ...y measures are required when working with the diluted glycol solution specified by the manufacturer For more information about the fluid please contact the manufacturer Activate the MENU with Position...

Page 80: ...Remove the hose Note Dispose of the drained glycol in an environment friendly manner and according to local regulations 14 n 80 Installation Maintenance and Service part...

Page 81: ...ou can order the conversion kit you need from the supplier of your water heater The conversion kit contains all the parts needed to do the conversion and a description of how to do the conversion The...

Page 82: ...82 Installation Maintenance and Service part...

Page 83: ...the service interval Service mode Setting legionella prevention Solar heating system configuration Setting the central heating configuration These sub menus are briefly described in the following para...

Page 84: ...igure shows an example of Lock out errors In this case the text ERROR HISTORY is followed by L Note For an overview of all errors and the possible causes please refer to the relevant chapter see secti...

Page 85: ...PERATION to display the SERVICE OPERATION menu and can be used to switch between PARTIAL LOAD and FULL LOAD If there is a heat demand the water heater will first run through a startup cycle then conti...

Page 86: ...By default this period is set to Monday from 02 00 to 03 00 hours 9 2 7 1 Switching legionella prevention on and off To switch legionella prevention on or off select ANTI LEGIONELLA Select NO to switc...

Page 87: ...Call up this menu as follows SETTINGS SOLAR TEST SOLAR PUMP The following display appears When START is selected the pump will start to run for two minutes Once the 2 minutes have elapsed the pump st...

Page 88: ...as follows SETTINGS SOLAR Q T SENSOR 9 2 8 6 Displaying contribution This option enables you to read out how much energy the solar heating system supplies For this data to be displayed the installatio...

Page 89: ...ral heating configuration Use this menu to specify whether a central heating system is connected to the installation Note This function is not yet available SETTINGS HEATING n 0311753_SGS_28 120_II_UK...

Page 90: ...90 Installation Maintenance and Service part...

Page 91: ...pare parts look at the data plate for the full serial number the water heater model and the used gas category Use this information when you order the spare parts Do the following maintenance activitie...

Page 92: ...from the discharge points of all valves and remove any scale deposits that may be present Drain the water heater see draining see section 7 10 2 10 2 Water side maintenance To do water side maintenanc...

Page 93: ...Gas side maintenance Do gas side maintenance when the water heater does not operate correctly the air pressure differential is not correct and or the CO2 value is not correct To do gas side maintenan...

Page 94: ...heck the switching pressure of the pressure switch see section 7 9 5 Erase the message SERVICE REQUIRED The displayed message can be reset in either of two ways Temporary reset To postpone the message...

Page 95: ...resets automatically to resume operation The code is displayed continuously and the back light of the display blinks Errors are reported on the display as follows Line one an error code and a brief d...

Page 96: ...on Tighten the threaded 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 an...

Page 97: ...r service and maintenance engineer if the error persists Code and description Cause Measure S01 blocking error Open circuit from temperature sensor T2 at the bottom of the tank Sensor is not correctly...

Page 98: ...r sensor S13 blocking error Short circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Short circuit in sensor circuit Replace the cable and or sensor S14 blocking error Short circuit...

Page 99: ...between the pressure switch and the controller If necessary replace the wiring Pressure switch not closing Check the speed of the fan see section 12 1 Check that the hoses on the pressure switch and t...

Page 100: ...ct roof or wall flue terminal has been installed see section 7 7 If necessary install the correct roof or wall flue terminal Check that the roof or wall flue terminal discharges into a permitted area...

Page 101: ...rror message from the controller EEPROM read error 50 Hz error Internal communication error Internal error message from the controller Gas valve relay error Safety relay error Ignition relay error RAM...

Page 102: ...nty will void Anode protection is not working The cables between the potentiostat and anodes are loose or have been connected incorrectly The earth connection of the anodes is loose The water heater i...

Page 103: ...nutes pumping the fluid in the solar system round If Tcol Tcollector max after this has elapsed the pump will stop running for 30 minutes After 30 minutes the pump will start running again and the con...

Page 104: ...104 Installation Maintenance and Service part...

Page 105: ...2 12 2 12 2 12 2 12 Hysteresis downwards default value C 5 4 4 4 Solar differential adjustment range C 0 8 0 8 0 8 0 8 Solar differential default value C 7 2 2 2 Solar limit adjustment range C 65 80...

Page 106: ...T P overflow pressure kPa bar 700 7 T P overflow temperature C 97 Description Unit SGS 28 SGS 30 SGS 50 SGS 60 Load profile XXL XXL XXL XXL Energy Efficiency Class Energy Label A A A A Energy Efficie...

Page 107: ...5 5 Solar limit adjustment range C 65 80 65 80 65 80 Solar limit default value C 65 65 65 Number of electrical anodes 2 2 2 Observed pressure differential across the pressure switch Pa 260 260 260 Pr...

Page 108: ...Load profile 3XL 3XL 3XL Energy Efficiency Class Energy Label Energy Efficiency 93 93 92 Daily Electricity Consumption kWh 0 281 0 290 0 301 Daily Fuel Consumption kWh GCV 49 811 49 922 50 060 Mixed W...

Page 109: ...of hot water outlet mm 1485 2015 2015 2015 Ny y position of hot water outlet mm 205 205 205 205 P Height of cleaning opening mm 265 270 270 270 R Height of drain valve connection mm 180 170 170 170 S...

Page 110: ...Fig Dimensions SGS 28 30 50 60 110 Installation Maintenance and Service part...

Page 111: ...hot water outlet mm 2060 2060 2060 Ny y position of hot water outlet mm 205 205 205 P Height of cleaning opening mm 290 290 290 R Height of drain valve connection mm 225 225 225 S Height of T P valve...

Page 112: ...Fig Dimensions SGS 80 100 120 112 Installation Maintenance and Service part...

Page 113: ...temperature nominal load C 44 54 63 68 Gas category 3P G31 Diameter of the venturi restrictor mm 6 00 6 00 6 00 6 00 Nominal Load gross kW 31 5 32 6 51 1 62 0 Nominal output kW 31 0 32 7 50 3 60 4 Su...

Page 114: ...41 9 172 9 211 1 Flue gas temperature nominal load C 52 55 60 Gas category 3P G31 Diameter of the venturi restrictor mm 6 60 6 60 6 60 Nominal Load gross kW 84 8 103 3 126 1 Nominal output kW 84 2 100...

Page 115: ...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 OFF OFF 7 ON C ON OFF OFF 8 ON C ON OFF OFF 9 ON C ON OFF OFF 10 ON C ON OFF OFF 11 ON C ON OFF OFF 12 ON C ON OFF OFF 1...

Page 116: ...18 ON C ON OFF OFF 19 ON C ON OFF OFF 20 ON C ON OFF OFF 21 ON C ON OFF OFF Example Period Day Time Tset Pump 1 ON MO 14 30 70 C ON OFF OFF MO 16 15 116 Installation Maintenance and Service part...

Page 117: ...6 12 11 16 15 14 13 19 18 17 20 24 21 22 23 J33 A R J38 J37 X X J34 J35 J39 J36 4 4 M X X 4 X 2 1 3 2 1 1 2 3 1 2 3 4 2 1 1 5 6 2 3 7 8 4 5 1 5 1 1 6 2 1 4 1 2 5 6 3 6 1 2 4 3 1 7 1 1 2 9 7 5 3 1 11 1...

Page 118: ...sformer A Earth K Double pole isolator JP3 Temperature sensor T2 connection N Neutral L Controller O I switch L Live input of controller M Display JP4 Dummy connection L1 Live input of isolating trans...

Page 119: ...sensor S2 tank J16 Connection of BUS link communication EE Combined Q T sensor incl temperature sensor S4 solar collector return Terminal strip connections J18 Connection of PWM signal solar heating s...

Page 120: ...RVAL PROGRAM OVERVIEW SERVICE OPERATION EXTRA PERIOD FULL LOAD PARTIAL LOAD SETTINGS LANGUAGE ANTI LEGIONELLA DAY TIME SOLAR CONFIGURATION SPECIFICATIONS DRAIN BACK REGULATION INTERVAL TEST SOLAR PUMP...

Page 121: ...12 8 Declaration of conformity 0311753_SGS_28 120_II_UKUK_V2 0 2017 05 03 121...

Page 122: ...rnment and local authority installation and building codes rules and regulations in force at the time of installation The water heater remains installed at the original site of installation The water...

Page 123: ...shall not be borne by A O Smith Article 7 Claims A claim on grounds of the specified warranty must be submitted to the dealer from whom the water heater was purchased or to another authorised dealer f...

Page 124: ...124 Installation Maintenance and Service part...

Page 125: ...Index A About this manual 7 Appendices 105 C Copyright 3 I Installation 53 P Preface 3 T Trademark 3 Troubleshooting 95 0311753_SGS_28 120_II_UKUK_V2 0 2017 05 03 125...

Page 126: ...126 Installation Maintenance and Service part...

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