A.O. Smith BFC Cyclone 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

0311704

Summary of Contents for BFC Cyclone

Page 1: ...0311704 R2 4 BFC Cyclone High Efficient Condensing Water Heater BFC 28 30 50 60 80 100 120 Installation User and Service Manual 4222 EN...

Page 2: ...7 B8 Armstong Mall Southwood Business Park Farnborough Hampshire GU14 ONR UK T 0870 267 6484 sales aosmith co uk www aosmith co uk A O Smith Europe De Run 5305 PO Box 70 5500 AB Veldhoven The Netherla...

Page 3: ...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 charge We believe that...

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 wi...

Page 6: ...6...

Page 7: ...bes 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 Us...

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: ...ification 8 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 20 3 6 Status of the...

Page 10: ...to a week program 34 4 3 8 Deleting times from a week program 35 4 3 9 Extra period 36 4 3 10 Settings 38 Installation Maintenance and Service part 41 5 Introduction 43 5 1 About the water heater 43...

Page 11: ...edure for checking the gas control valve pressure 70 7 8 4 CO2 adjustment 71 7 8 5 Switching pressure measurement 73 7 8 6 Turn on the water heater 74 7 9 Decommisioning 74 7 9 1 Turn off the water he...

Page 12: ...exchanger 87 10 4 Finalization 88 11 Troubleshooting 89 11 1 Errors and warnings 89 11 1 1 General errors 90 11 1 2 Displayed errors 91 11 1 3 Warnings 96 12 Appendices 97 12 1 Technical details 97 1...

Page 13: ...User part 0311704_BFC_28 120_III_ENEN_V2 4 2022 10 17 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 BFC water heat...

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

Page 17: ...r 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: ...nu see section 4 3 The service program see section 9 2 This chapter is specifically intended for the service and maintenance engineer and installation engineer In this manual the display of the operat...

Page 20: ...tion 4 3 The buttons are Buttons for UP and DOWN Enter ENTER Reset button RESET The arrows and indicate that you can scroll up and or down Use and to scroll The cursor points to the option to be activ...

Page 21: ...y with the following information line one the text ON line two the time the day and T1 see section 4 1 1 line three the programmed water temperature Tset line four is empty when the water heater is id...

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: ...vice interval has been incorrectly selected contact the service and maintenance engineer for instructions on how to rectify this Information on the frequency of maintenance is provided elsewhere in th...

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

Page 25: ...The appliance 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...

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: ...llows Press to select the main menu Using and place the cursor beside OFF Confirm with ENTER The frost protection cuts in when the water temperature drops below 5 C The text FROST will then appear on...

Page 28: ...ition 0 using the control switch on the operator interface Isolate the water heater from the power supply by setting the isolator between the water heater and the mains power supply to position 0 Note...

Page 29: ...e language and the time see section 4 3 10 You can also use this option to display the regulation interval temperature and the ignition and working speeds of the fan Note If you fail to make any selec...

Page 30: ...ent excessively frequent switching on and off there is a heating margin The standard setting for this margin is 5 C The appliance starts heating up if the water temperature is 5 C below the SETPOINT W...

Page 31: ...with ENTER A week program can be shut down simply by activating a different operating mode for example the ON mode 4 3 6 Changing the appliance s standard week program Note First fill in the desired...

Page 32: ...cursor to SU Confirm with ENTER The day indicated by blinks Use and to set the desired day In the example this is SU Sunday Confirm with ENTER The cursor moves to the hour digits which will blink Use...

Page 33: ...ram 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 skip this step if y...

Page 34: ...example we will 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 cont...

Page 35: ...rm 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 working in the de...

Page 36: ...thout modifying 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 di...

Page 37: ...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 the minutes In the...

Page 38: ...ent day of week and time Displayable water heater specifications this category is only relevant to the installation engineer and or service and maintenance engineer Regulation interval water temperatu...

Page 39: ...e cursor moves to the hour digits which will blink Scroll with and to the current hour for example 15 Confirm with ENTER The cursor moves to the minute digits which will blink Scroll with and to the n...

Page 40: ...INGS Confirm with ENTER Scroll with to SPECIFICATIONS Confirm with ENTER The display shows the sub menu for displaying water heater specifications Scroll with to the section to be displayed for exampl...

Page 41: ...Installation Maintenance and Service part 0311704_BFC_28 120_III_ENEN_V2 4 2022 10 17 41...

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

Page 43: ...e venturi 30 on the intake side of the fan The 1 1 gas to air ratio always guarantees the most efficient gas air mixture In this water heater the cold water enters the bottom of the tank through the c...

Page 44: ...ntroller 5 Pressure switch 6 Control panel 7 Temperature sensor T1 8 Combustion chamber 9 Anode 10 Tank 11 Heat exchanger 12 Inspection and cleaning opening 13 Temperature sensor T2 14 Cold water inle...

Page 45: ...as is mixed with the air in the venturi 30 This mixture is ignited by the hot surface igniter 20 and the water becomes heated As soon as the water temperature approaches Tset the fan rpm drops to the...

Page 46: ...46 Installation Maintenance and Service part...

Page 47: ...d 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 o...

Page 48: ...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 appliance...

Page 49: ...rner As a safety measure the gas control valve has two valves Both valves shut off the gas supply 6 3 1 3 Fan The fan 18 provides an optimum air supply when there is a heat demand As a safety feature...

Page 50: ...installation With a vented installation excess pressure is taken up by the open cold water head tank The level of the cold water head tank determines the maximum working pressure in the tank refer to...

Page 51: ...you must obey local legislation related to waste disposal Never discard your old device together with regular waste Put the device into a municipal waste collection depot for electrical and electroni...

Page 52: ...52 Installation Maintenance and Service part...

Page 53: ...ly 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 installatio...

Page 54: ...igure AA around the water heater s control column and cleaning openings 100 cm BB all sides of the water heater 50 cm Top of the water heater 100 cm Fig Working clearances BFC 28 60 Fig Working cleara...

Page 55: ...5 Non return valve mandatory 6 Circulation pump optional 9 Drain valve 10 Manual gas valve mandatory 11 Service stop valve 12 Temperature gauge optional 13 Condensate drain 14 Draw off points 15 Expa...

Page 56: ...pansion vessel 16 Fit an expansion valve 15 and connect the overflow side to an open waste water pipe 7 4 1 2 Hot water side See B in the installation diagram see section 7 3 Note Insulating long hot...

Page 57: ...mperature 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 Circu...

Page 58: ...horizontal air inlet and flue gas outlet in same pressure zone C33 Closed Concentric and or parallel venting system with vertical air inlet and flue gas outlet in same pressure zone C43 Closed Water...

Page 59: ...Fig Venting systems 0311704_BFC_28 120_III_ENEN_V2 4 2022 10 17 59...

Page 60: ...m 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...

Page 61: ...to the table for the correct pipe dimensions of the C13 and C33 concentric systems Description Unit BFC 28 60 BFC 80 120 Diameter flue discharge air inlet mm mm 100 150 130 200 Maximum length m 40 15...

Page 62: ...6 mm 130 0 6 0 6 mm Diameter air inlet Description parts A O Smith Part number A O Smith Part number Wall terminal 1 0302505 0302313 Roof terminal 2 0311463 0306390 Adapter box concentric to parallel...

Page 63: ...e default diameter of 130 mm is insufficient diameter 150 mm should be used Any diameter enlargement must be carried out on both air inlet and flue gas outlet Caution Always make sure the installation...

Page 64: ...pipe dimensions of the C43 C53 and C63 concentric systems Description BFC 28 60 BFC 80 120 Manufacture venting material Muelink Grol Muelink Grol Construction Concentric Concentric Material flue gas...

Page 65: ...Fig Terminal block A Screws B Cover C Terminal block 7 7 1 Preparation In preparation you must first remove the two covers and the cover of the electrical section Undo the screws of the covers Careful...

Page 66: ...power consumed by the appliance goes via the isolating transformer Refer to the fitting instructions provided with the isolating transformer Contact the supplier for details of the correct isolating...

Page 67: ...e sure that the drain valve 9 is closed Open the nearest hot water draw off point 14 Open the stop valve 4 of the cold water supply pipe A Cold water flows into the water heater Fill the water heater...

Page 68: ...checking the supply pressure To check the supply pressure proceed as follows Isolate the appliance from the power supply see section 4 2 2 Carefully remove the covers from the appliance The electrica...

Page 69: ...or about 10 seconds and will then go to the main menu Select SERVICE OPERATION FULL LOAD from the service menu Confirm with ENTER The display shown here will appear The appliance is now in Full load m...

Page 70: ...few turns Do not completely loosen it as it can be difficult to retighten Open the gas supply Connect a pressure gauge to the test nipple Switch on the power to the appliance using the isolator on the...

Page 71: ...ltage to the appliance Start the appliance see section 4 1 Go to the SERVICE OPERATION menu Generate a heat demand by draining the appliance until it is cold or by raising the value for Tset in the SE...

Page 72: ...e measure value is within the range given in the table of CO2 values If you have increased Tset set it back to the original value using Continue with the CO2 measurement under partial load If the meas...

Page 73: ...ockwise means more less lower CO2 level and turning to the right clockwise means more gas higher CO2 level Note After conversion you must check that the gas control valve is gastight Remove the CO2 me...

Page 74: ...ut off the gas supply Disconnect the pressure gauge Put the two black caps back on the pressure switch Replace the covers 7 8 6 Turn on the water heater Refer to the procedure in the user part to Turn...

Page 75: ...ursor in front of OFF Confirm OFF with ENTER Wait until the fan has stopped The icon is then dimmed Caution Failure to wait until the fan stops can cause damage to the water heater Switch the water he...

Page 76: ...76 Installation Maintenance and Service part...

Page 77: ...u 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 f...

Page 78: ...78 Installation Maintenance and Service part...

Page 79: ...the selected water heater Switching the pump on or off Setting the service interval Service mode Setting legionella prevention Setting the central heating configuration These sub menus are briefly de...

Page 80: ...an ellipsis is displayed The display first shows the Blocking errors When ENTER is pressed the Lock out errors are then displayed The figure shows an example of Blocking errors In this case the text E...

Page 81: ...ogram periods is currently active During this period the pump relay setting is OFF If the pump relay is set ON in the service menu the pump will nonetheless remain OFF The pump will only switch ON onc...

Page 82: ...r adjustment the set point must be set back to the original value using if you exit the SERVICE OPERATION menu or if no buttons are pressed for a period of 15 minutes the water heater will revert to t...

Page 83: ...od currently displayed The following display appears This display indicates that legionella prevention is switched on 9 2 8 2 Changing legionella prevention start time If you wish to change the start...

Page 84: ...84 Installation Maintenance and Service part...

Page 85: ...receive the correct spare 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...

Page 86: ...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 9 2 10 2 Water side maintenance To do water side maintenanc...

Page 87: ...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 maintenanc...

Page 88: ...UIRED The displayed message can be reset in either of two ways Temporary reset To postpone the message press RESET once The message will reappear on the display 7 days later Full reset To fully reset...

Page 89: ...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 de...

Page 90: ...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 91: ...i Remove any contamination from the venturi inlet Leakage between venturi and flexible venturi connector Make sure that the flexible venturi connector is not damaged If necessary replace the flexible...

Page 92: ...the cable and or sensor S12 blocking error Short circuit in sensor 1 of temperature sensor T1 at top of tank 1 Short circuit in sensor circuit Replace the cable and or sensor S13 blocking error Short...

Page 93: ...etween 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 th...

Page 94: ...ect roof or wall flue terminal has been installed see section 7 6 If necessary install the correct roof or wall flue terminal Check that the roof or wall flue terminal discharges into a permitted area...

Page 95: ...1 hour If the error does not disappear replace the water heater controller C04 blocking error Appliance selection error Incorrect water heater selection Incorrect selection resistor Check whether the...

Page 96: ...the warranty 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...

Page 97: ...65 Hysteresis upwards adjustment range C 0 5 0 5 0 5 0 5 Hysteresis upwards default value C 5 5 5 5 Hysteresis downwards adjustment range C 0 10 0 10 0 10 0 10 Hysteresis downwards default value C 5 5...

Page 98: ...Unit BFC 28 BFC 30 BFC 50 BFC 60 Load profile XXL XXL XXL XXL Energy Efficiency Class Energy Label A A A A Energy Efficiency 91 91 91 90 Daily Electricity Consumption kWh 0 207 0 210 0 211 0 212 Daily...

Page 99: ...rds adjustment range C 0 5 0 5 0 5 Hysteresis upwards default value C 5 5 5 Hysteresis downwards adjustment range C 0 10 0 10 0 10 Hysteresis downwards default value C 5 5 5 Number of electrical anode...

Page 100: ...P overflow temperature C 97 Description Unit BFC 80 BFC 100 BFC 120 Load profile 3XL 3XL 3XL Energy Efficiency Class Energy Label Energy Efficiency 93 93 92 Daily Electricity Consumption kWh 0 237 0 3...

Page 101: ...mm 1390 1925 1925 1925 Ny y position of hot water outlet mm 205 205 205 205 P Height of cleaning opening mm 170 175 175 175 R Height of drain valve connection mm 85 75 75 75 S Height of T P valve con...

Page 102: ...Fig Dimensions BFC 28 30 50 60 102 Installation Maintenance and Service part...

Page 103: ...of 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 val...

Page 104: ...Fig Dimensions BFC 80 100 120 104 Installation Maintenance and Service part...

Page 105: ...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 106: ...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 107: ...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 108: ...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 15 108 Installation Maintenance and Service part...

Page 109: ...3 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 13 15 10 4 2 8 6 16...

Page 110: ...nal connection A Earth J Isolating transformer JP3 Temperature sensor T2 connection N Neutral K Double pole isolator L Live input of controller L Controller O I switch JP4 Dummy connection L1 Phase in...

Page 111: ...TRA PERIOD SERVICE INTERVAL SETTINGS LANGUAGE SERVICE OPERATION START OPERATION SELECT APPLIANCE PROGRAM OVERVIEW PUMP RELAY HISTORY OF ERRORS CHANGE SETPOINT APPLIANCE HISTORY WEEK PROGRAMMA HYSTERES...

Page 112: ...12 7 Declaration of conformity 112 Installation Maintenance and Service part...

Page 113: ......

Page 114: ......

Page 115: ...O Smith installation instructions for the specific model and the relevant government and local authority installation and building codes rules and regulations in force at the time of installation The...

Page 116: ...ehouse of the parts or components or water heater to be replaced transport labour installation and other costs associated with the replacement shall not be borne by A O Smith Article 6 Claims A claim...

Page 117: ...Index A About this manual 7 Appendices 97 C Copyright 3 I Installation 53 P Preface 3 T Trademark 3 Troubleshooting 89 0311704_BFC_28 120_III_ENEN_V2 4 2022 10 17 115...

Page 118: ...116 Installation Maintenance and Service part...

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