A.O. Smith BFM - 100 Installation & Service Manual Download Page 1

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Summary of Contents for BFM - 100

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Page 3: ...ther than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven 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 inaccurac...

Page 4: ...4 Instruction manual BFM gis ...

Page 5: ...ns 19 3 5 Installation diagram 23 3 6 Water connections Vented 24 3 7 Water connections Unvented 25 3 8 Gas connection 26 3 9 Air supply and flue 27 3 10 Electrical connection 34 3 11 Checking the supply pressure and burner pressure 36 4 Conversion to a different gas category 39 4 1 Conversion 39 4 2 Orifice replacement 40 4 3 Replacement of burner pressure regulator or blank plate BFM30 50 80 100...

Page 6: ...ng period 55 11 Troubleshooting 57 11 1 Introduction 57 11 2 Troubleshooting general errors 58 11 3 Troubleshooting insufficient hot water 59 11 4 Troubleshooting No hot water 60 12 Performing maintenance 63 12 1 Introduction 63 12 2 Preparation for maintenance 63 12 3 Water side maintenance 64 12 4 Gas side maintenance 66 12 5 Finalising maintenance 66 13 Warranty certificate 67 13 1 General warr...

Page 7: ... you smell gas Warning If there is a gas smell No naked flames No smoking Avoid causing sparks Do not use any electrical equipment or switch i e no telephones plugs or bells Open windows and doors Shut off the mains gas supply valve Warn occupants and leave the building After leaving the building alert the gas distribution company or your installation engineer 1 3 Regulations As the end user insta...

Page 8: ...ck the best maintenance frequency can be determined Note Regular maintenance extends the service life of the appliance Note Both the end user and the service and maintenance engineer are responsible for regular maintenance They will need to establish clear agreements on this Note If the appliance is not regularly maintained the warranty will become void 1 5 Forms of notation The following notation...

Page 9: ...appliance This chapter describes the status mode or condition that the appliance may have and possible actions to take Starting and running This chapter describes how to start the appliance running The general heating cycle of the appliance is also described Shutting down This chapter describes how to shut the appliance down for a brief or long period of time Troubleshooting This chapter is mainly...

Page 10: ...Introduction 10 Instruction manual BFM 1 gis ...

Page 11: ...1 Introduction Topics covered in this chapter General working principle of the appliance The appliance s heating cycle Protection for the appliance Safety of the installation 2 2 General working principle of the appliance The figure shows a cut away view of the appliance ...

Page 12: ...n 21 flame probe 22 chimney pipe 24 insulation layer 36 bar burners burner tray 38 safety thermostat sensor 39 high limit thermostat sensor 40 burner control 41 control thermostat 42 high limit thermostat 43 safety thermostat 44 frost thermostat 45 control thermostat sensor 46 frost thermostat sensor 47 air supply 49 air restrictor 50 combustion chamber with air distribution plate 51 pilot burner ...

Page 13: ...ance via the top box 46 The top box of the BFM 100 and 120 is non standard see box An air distribution plate 50 mounted below the burner tray radiation shield also serves as a radiation shield Any condensation that forms is drained towards the siphon via the air distribution plate The PU insulation layer 24 prevents heat loss The inside of the tank is enamelled to protect against corrosion The ano...

Page 14: ...es of this probe for flame detection The burner control closes the gas valve the instant it determines that there is a gas flow but no flame is present Protection Description Frost thermostat When the frost thermostat sensor 46 measures a temperature of 20 C or less the heating cycle 2 3 The appliance s heating cycle will start High limit thermostat When the high limit thermostat sensor 39 measure...

Page 15: ...allation With a vented installation excess pressure is taken up by the open cold water head tank The height of the head tank determines the working pressure in the water heater which may not exceed 8 bar The installation must also be fitted with a vent pipe from the hot water pipe that opens into the cold water tank Ideally the vent pipe should discharge into a separate tundish drain or otherwise ...

Page 16: ...Working principle of the appliance 16 Instruction manual BFM 2 gis ...

Page 17: ...a different gas category see conversion 4 Conversion to a different gas category 3 2 Packaging To avoid damaging the appliance remove the packaging carefully We recommend unpacking the appliance at or near its intended location Caution The appliance may only be manoeuvred in an upright position Take care that the appliance is not damaged after unpacking 3 3 Ambient conditions The appliance has a s...

Page 18: ...iance 50cm Above the appliance room to replace the anodes 100cm if using fixed anodes or 50cm if using flexible anodes If the available clearance is less than 100cm flexible magnesium anodes may be ordered Note When installing the appliance be aware that any leakage from the tank and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this i...

Page 19: ...cifica tions The appliance is supplied without accessories Check the dimensions 3 4 1 Dimensions of the appliance gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan to use IMD 0241 R1 A A AA A A BB ...

Page 20: ...ensions of the appliance Plan and elevation of the appliance Replacement of burner pressure regulator or blank plate BFM30 50 80 100 2 BFM 100 120 IMD 0057 R5 37º 10º 45º 37º 10º 45º A B N S 1 6 6 2 5 3 4 D K R M P P 6 4 6 F E G L 6 4 6 F E G L C C Hy 1 2 ...

Page 21: ... 550 550 540 540 540 S Height of T P valve connection 1600 1600 1600 1600 1600 1 Cold water supply connection external R11 2 R11 2 R11 2 R11 2 R11 2 2 Hot water outlet connection internal Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 3 Gas control connection internal Rp3 4 Rp3 4 Rp3 4 Rp3 4 Rp1 4 Drain valve connection internal Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 5 T P valve connection internal 1 11 5 NPT 1 1...

Page 22: ...meter of pilot flame orifice mm 0 25 0 25 0 25 0 25 1 Blank plate 2 Burner pressure regulator 1 or 2 1 1 1 1 Nominal load upper value kW 31 4 49 9 81 3 110 5 Nominal output kW 26 4 41 4 67 5 90 8 Supply pressure mbar 30 30 30 30 Burner pressure mbar Gas consumption kg h 2 3 3 6 5 9 8 0 G31 37mbar propane Orifice diameter mm 1 45 1 40 1 50 1 95 2 30 Diameter of pilot flame orifice mm 0 25 0 25 0 25...

Page 23: ...6 circulation pump optional 7 top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supp...

Page 24: ...rculation pipe Ø 22 mm a stop valve 11 and a top to bottom circulation pump 7 2 Fit a non return valve 5 3 Fit a stop valve 11 3 6 3 Hot water side See B in the installation diagram 3 5 Installation diagram Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the T P valve 3 2 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fit a stop ...

Page 25: ...Regulations 2 The maximum working pressure of the appliance is 8 bar Because the pressure in the water pipe at times can exceed 8 bar you must fit an approved pressure reducing valve 1 3 Fit a non return valve 5 and an expansion vessel 16 4 Fit an expansion valve 15 and connect the overflow side to an open wastewater pipe 3 7 2 Recirculation pipe You can install a top to bottom circulation pump to...

Page 26: ...ice purposes 4 4 Connect the circulation pipe to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve 3 8 Gas connection Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Caution Make sure that the diameter and length of the gas supply pipe are large enough to suppl...

Page 27: ...pes C13 and C33 The instruction manual describes these types For a more detailed explanation please contact your supplier or the manufacturer Note We prescribe the use of a concentric roof or wall flue terminal exclusively of a type approved for the appliance You must fulfil the following requirements The maximum permissible length of chimney pipe A B C is 7 metres The maximum permissible number o...

Page 28: ...m 1x Bend 90 Art No BFM 30 BFM 50 BFM 80 0302 515 1 0302 504 1 0302 326 1 Construction Concentric Manufacturer Muelink Grol Type M2000 MDV SE WL Pipe material Construction Concentric Chimney flue Thick walled aluminium with lip ring seal Air supply Thin walled galvanised sheet steel Pipe diameters Chimney flue BFM 30 BFM 50 BFM 80 Ø 80 mm Ø 100 mm Ø 130 mm Air supply BFM 30 BFM 50 BFM 80 Ø 125 mm ...

Page 29: ...Instruction manual BFM 29 is 3 9 5 Concentric roof flue terminal BFM 30 50 80 Roof flue terminal A B C IMD 0061 R2 ...

Page 30: ... flue terminal set 1x Roof flue terminal incl clamping ring 1x pipe 1000 mm 1x mounting flange Art No BFM 30 BFM 50 BFM 80 0302 5181 0302 5071 0302 3271 Construction Concentric Manufacturer Muelink Grol Type M2000 DDV SE HR VR Pipe material Construction Concentric Chimney flue Thick walled aluminium with lip ring seal Air supply Thin walled galvanised sheet steel Pipe diameters Chimney flue BFM 30...

Page 31: ...imum run off of 5 mm per running metre of pipe towards the appliance The transition piece to convert the air supply and chimney flue from parallel to concentric must be installed immediately before the wall or roof flue terminal The intake duct of the air supply must be approximately the same as the chimney flue Make sure that the chimney flue discharges into an area approved for this type of appl...

Page 32: ... 1x Transition piece 2x Pipe 500 mm 2x Bend 90 Art No 0306 774 1 Construction Concentric Manufacturer Muelink Grol Type M2000 MDV SCC Pipe material Construction Parallel Chimney flue Thick walled aluminium with lip ring seal Air supply Thick walled aluminium with lip ring seal Pipe diameters Chimney flue Ø 130 mm Air supply Ø 130 mm 1 No other wall flue terminal is permitted Order the wall flue te...

Page 33: ...Instruction manual BFM 33 is 3 9 10 Concentric roof flue terminal BFM 100 120 Roof flue terminal IMD 0239 R1 A C B ...

Page 34: ...hows the appropriate connections Connector block Subject Description Roof flue terminal set 1x Wall flue terminal incl clamping ring 1x Pipe 1000 mm 1x Mounting flange Art No 0306 773 1 Construction Concentric Manufacturer Muelink Grol Type M2000 DDV SE Pipe material Construction Parallel Chimney flue Thick walled aluminium with lip ring seal Air supply Thick walled aluminium with lip ring seal Pi...

Page 35: ...wer the appliance has to be connected to the mains power by means of a permanent electrical connection A double pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance The power cable must have cores of at least 3 x 1 0 mm2 Warning Leave the appliance isolated until you are ready to start it up 1 Feed the power cable through the metric s...

Page 36: ...ck the gas pressures is by using two pressure gauges This procedure assumes that these two gauges are available If the appliance is to be run on a different gas category than the factory preset gas category see type plate then you must first convert 4 Conversion to a different gas category the appliance Gas control for BFM 30 through 100 Legend 1 burner pressure regulator 2 burner pressure regulat...

Page 37: ...pple 6 5 Connect a pressure gauge to the manifold test nipple 6 when gas starts to flow from this nipple 6 Switch on the power to the appliance using the isolator on the appliance 7 Set the control thermostat to the maximum temperature and start the appliance running by setting the ON OFF switch to position I 8 The heating cycle will start and after a short time the burner tray will ignite 9 After...

Page 38: ...the burner pressure by turning adjustment screw 3 PG using the Allen key supplied with the appliance Adjustment screw anticlockwise burner pressure decreases Adjustment screw clockwise burner pressure increases Warning Adjustment screw Ps adjusts the starting pressure This need not and must never be adjusted from the factory preset 18 Check the burner pressure against the value given in the gas ta...

Page 39: ...ory is different from the one that is currently fitted If so replace 4 2 Orifice replacement it Note The current gas category is stated on the type plate 4 Referring to the gas table 3 4 3 Gas data determine whether the main orifice for the intended gas category is different from the one that is currently fitted If so replace 4 2 Orifice replacement it 5 Referring to the gas table 3 4 3 Gas data d...

Page 40: ...nd or main orifices Lay the burner tray on its side and approach it from the underside 7 If the gas table 3 4 3 Gas data indicates that the pilot flame orifice needs to be replaced a Remove the spark electrode 1 from its retaining clip This way you will gain space to remove the pilot flame orifice b Turn the flame probe 2 and remove it from its bracket to gain space c Remove the bracket of the pil...

Page 41: ... gas supply 14 Re fit the protective cover Note Refer to the electrical diagram 14 Electrical diagram for correct connection of the electrical components 4 3 Replacement of burner pressure regulator or blank plate BFM30 50 80 100 Referring to the gas table determine whether the gas control needs to be fitted with a blank plate or burner pressure regulator If necessary replace them as follows 1 Car...

Page 42: ...Conversion to a different gas category 42 Instruction manual BFM 4 is ...

Page 43: ... 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe H overflow pipe IMD 0467 R0 UNVENTED VENTED B A 4 18 19 E H C 14...

Page 44: ...cause might be The water supply pressure is greater than the specified 8 bar Rectify this by fitting a pressure reducing valve 1 The expansion valve in the protected cold supply setup is defective or incorrectly fitted 5 2 Filling vented instal lations To fill the appliance proceed as follows 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6...

Page 45: ...e 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe H overflow pipe IMD 0467 R0 UNVENTED VENTED B A 4 18 19 E H C 1...

Page 46: ...F switch on the control panel to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the supply valve of the cold water supply A 6 Open the drain valve 9 7 Bleed the appliance or installation so that it drains completely...

Page 47: ...l panel to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the stop valve 4 between the cold water head tank and the cold water inlet 6 Open the drain valve 9 7 Bleed the appliance or installation so that it drains c...

Page 48: ...Draining 48 Instruction manual BFM 6 gis ...

Page 49: ... the appliance in ON mode or OFF mode In OFF mode the appliance is still electrically live This ensures that the frost protection is active Note To electrically isolate the appliance you must use the isolator between the appliance and the mains power supply 7 5 Control thermostat Use the rotary knob of the control thermostat to set the desired water temperature between 40 C and 70 C The range is c...

Page 50: ...rner control When this happens the reset button lamp will be lit Once the cause of the error has been rectified you can reset the appliance using the reset button Note Never use the reset button until you have rectified the error Many errors 11 Troubleshooting can be identified according to the appliance status 8 Status of the appliance ...

Page 51: ...vided into three groups Lock out errors of the burner control In this event the red error light will be lit in the reset button on the control panel The burner control is in lockout Once the cause has been rectified the reset button must be pressed to restart the appliance Cycling of appliance In this case the appliance continuously attempts to start but there is an error that prevents the heating...

Page 52: ...Status of the appliance 52 Instruction manual BFM 8 gis ...

Page 53: ...0 C The heating cycle runs successively through the following states 1 HEAT DEMAND 2 WAIT 3 PRE GLOW 4 IGNITION 5 RUNNING 6 WAIT The entire cycle is explained in the example below Note The cycle has the same steps when frost protection is activated 1 The control thermostat sensor measures the temperature The water temperature falls below the set temperature of for example 60 C causing the control ...

Page 54: ...Starting and running 54 Instruction manual BFM 9 gis ...

Page 55: ...the frost protection you can prevent water freezing in the appliance Frost protection is activated by setting the ON OFF switch on the control panel to position 0 10 3 Isolating the appliance from the mains The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Shut down the appliance by setting the ON OFF switch to position 0 2 Isolate the ...

Page 56: ...Shutting down 56 Instruction manual BFM 10 gis ...

Page 57: ...ton must be pressed to restart the appliance Cycling of appliance In this case the appliance continuously attempts to start but there is an error that prevents the heating cycle 9 3 The appliance s heating cycle from completing successfully Once the cause has been rectified the appliance will restart automatically Blocking errors You can recognize this condition when the appliance does not start r...

Page 58: ...tion engineer Leakage from another nearby water appliance or pipe segment Trace the leak Leakage from the appliance s tank Consult the supplier and or manufacturer Condensation Before drawing too much tap water wait until the water in the boiler has reached the set temperature Explosive ignition Poor flame profile Incorrect supply pressure and or burner pressure Set the correct supply pressure and...

Page 59: ...perature setting Tset is too low Set the control thermostat 7 5 Control thermostat to a higher value Hot water supply is used up 1 Reduce hot water consumption and give the appliance time to heat up 2 If this error persists check whether the high limit thermostat is switching If this is the case check that the circulation and or top to bottom circulation pump are working If this error persists che...

Page 60: ...y flue or air supply Trace the blockage Remove the blockage 2 Defective pressure switch Check the wiring of the pressure switch Check that the pressure switch is working Once the error is rectified the appliance will automatically start up if there is a heat demand If the error cannot be resolved or is persistent contact your installation engineer Failure in the thermostat circuit 1 Check whether ...

Page 61: ...Failed start attempt No gas 1 Check that the gas valve is open 2 Check whether the gas control is opening clicking of the gas control 3 Check the leads of the gas control If the error cannot be resolved or is persistent contact your installation engineer No ignition 1 Check whether the spark igniter is sparking in the pilot flame cap 2 Check the leads of the glow igniter 3 Check whether the spark ...

Page 62: ...is Instruction manual BFM 62 ...

Page 63: ...control panel to position 0 2 Set the control thermostat to the highest value note the original setting and set the ON OFF switch back again to position I 3 If there is no heat demand draw off some water to create a heat demand 4 Check whether the heating cycle 9 3 The appliance s heating cycle runs correctly 5 Set the control thermostat back to the original setting and set the ON OFF switch back ...

Page 64: ... If necessary replace them 12 Place a new sealing ring on the rim of the tank and re fit the lid 13 Re fit the top box 14 Feed the fan cable through the strain relief and connect the leads to the fan See addendum A BFM electrical diagram 15 Re fit the cover on the top box 12 3 3 Descaling and cleaning the tank Scale and lime buildup prevent effective conduction of the heat to the water Periodic cl...

Page 65: ...tion 6 If the scale cannot be removed by hand descale the appliance with a descaling agent Contact the supplier manufacturer for advice on what descaling agent to use 7 Close the cleaning opening To avoid damage to the tank tighten the bolts that fasten the lid with a torque no greater than 50 Nm Use suitable tools for this For the best possible watertight seal of the cleaning opening the bolts in...

Page 66: ... 3 Clean the orifice s 1 Detach the orifice s 2 Remove all contamination present in the orifice s 3 Fit the orifice s 12 4 4 Checking the flue baffles Warning The flue baffles can be hot 1 Remove the flue baffles from the appliance 2 Check the flue baffles for the presence of corrosion removing this if necessary 3 Check the flue baffles for wear and replace the flue baffles if necessary 12 5 Final...

Page 67: ...r heater the warranty shall be reduced to one year from the original installation date 13 3 Conditions for Instal lation and 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 A O Smith installation instructions for the specific model and the relevant government and local authority installation and ...

Page 68: ...e water heater other than by an approved service engineer 13 5 Scope of the warranty The obligations of A O Smith pursuant to the specified warranty do not extend beyond free delivery from the Veldhoven warehouse of the replacement sections parts or water heater respectively Shipping labour installation and any other costs associated with the replacement will not be accepted by A O Smith 13 6 Clai...

Page 69: ...Instruction manual BFM 69 is 14 Electrical diagram 14 1 Introduction This chapter shows the electrical diagram s and accompanying legend ...

Page 70: ...14 is 14 2 BFM Electrical Diagram 1 brown 2 blue 3 yellow green 4 black 5 white 6 red 7 white orange 8 white purple 9 black green 10 black red 11 black white 230VAC L N FAN PVC NO 50 Hz N L S S S S 1 2 3 4 NC PVC 11 10 9 8 7 6 2 4 1 5 3 0305485 R2 ...

Page 71: ...former C DPS Differential air pressure switch D Filter E Reset button F Frost thermostat G Control thermostat H ON OFF switch K Safety thermostat L High limit thermostat M Burner control N Terminal block P Earth strip R Relay OPTIONAL COMPONENTS S Clock T Potentiostat ...

Page 72: ...Electrical diagram 72 Instruction manual BFM 14 is ...

Page 73: ...9 gas connection 26 general specifications 3 H heating cycle 13 humidity 17 I icons 49 explanation 49 ignition 13 installation engineer 8 9 isolator 35 L liability 3 M mains power 35 maintenance anode 64 burner 66 finalising 66 gas side 66 orifice 66 perform 63 preparation 63 water side 64 O operating modes 51 P packaging 17 protection 13 R reset button 50 roof flue terminal 29 33 running 53 S sca...

Page 74: ...0306 723 4 0 UK Index Instruction manual BFM ...

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