A.O. Smith Cyclone BFC-28 Installation, User And Service Manual Download Page 1

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0310 878

Innovation has a name.

Installation, User and Service
Manual

High Efficient Condensing
Water Heater

BFC - 28/30/50/60/80/100/120

BFC

Summary of Contents for Cyclone BFC-28

Page 1: ...0310 878 Innovation has a name Installation User and Service Manual High Efficient Condensing Water Heater BFC 28 30 50 60 80 100 120 BFC...

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: ...CO2 adjustment 4 Check the switching pressure of the pressure switch 3 12 4 Switching pressure measurement 5 Erase the message SERVICE REQUIRED The displayed message can be reset in either of two way...

Page 4: ...E2...

Page 5: ...that stated in this manual and use other than in accordance with the General Conditions registered at the Chamber of Commerce Refer further to the General Conditions These are available on request fr...

Page 6: ...4 Instruction manual BFC gis...

Page 7: ...ns 17 3 4 Technical specifications 19 3 5 Installation diagram 25 3 6 Unvented water connections 26 3 7 Vented water connections 27 3 8 Gas connection 27 3 9 Air supply and chimney flue discharge 28 3...

Page 8: ...he water temperature 61 11 5 Week program 62 11 6 Starting and stopping the week program 62 11 7 Changing the appliance s standard week program 62 11 8 Adding times to a week program 64 11 9 Deleting...

Page 9: ...zing maintenance 90 16 Warranty certificate 91 16 1 General warranty 91 16 2 Tank warranty 91 16 3 Conditions for Installation and use 91 16 4 Exclusions 92 16 5 Scope of the warranty 92 16 6 Claims 9...

Page 10: ...Contents 8 Instruction manual BFC...

Page 11: ...and to follow the printed instructions may lead to personal injury and damage to the water heater 1 2 What to do if you smell gas Warning If you smell gas No naked flames No smoking Avoid causing spa...

Page 12: ...s of rated input not exceeding 70 kW BS 5440 Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net 1st 2nd and 3rd family gases Part 1 Specification for installation of gas...

Page 13: ...e correct service interval it is recommended to arrange for the service and maintenance engineer to check the water heater on both the water and gas side within three months following installation Bas...

Page 14: ...ter heater for a brief or long period of time Main menu This chapter describes the main menu of the display This is the actual menu for the user However the installation engineer and service and maint...

Page 15: ...tank through the hot water outlet 2 Once the water heater is completely filled with water it will constantly be under mains water pressure As hot water is drawn from the water heater cold water is imm...

Page 16: ...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 inlet 15 drain valve 16 gas cont...

Page 17: ...d T2 13 the controller monitors three temperatures that are important for safety The table explains the functioning of the temperature sensors Temperature protection 2 4 3 Gas control valve The contro...

Page 18: ...used to the enamel coating in the water heater or to the tank A non return valve prevents excessive pressure build up in the water supply system This valve also prevents water from flowing backwards f...

Page 19: ...maging the water heater remove the packaging carefully We recommend unpacking the water heater at or near its intended location Caution The water heater may only be manoeuvred in an upright position T...

Page 20: ...governing drinking water for human consumption The table gives an overview of the specifications Water specifications Note If the water specifications deviate from those stated in the table then the...

Page 21: ...in a suitable metal leak tray The leak tray must have an appropriate waste water drain and must be at least 5 cm deep with a length and width at least 5 cm greater than the diameter of the water heat...

Page 22: ...20 Instruction manual BFC 3 4 1 Dimensions of the water heater Top and front view of the appliance Legend See the table BFC 28 30 50 60 BFC 80 100 120...

Page 23: ...25 225 225 N Height of hot water outlet mm 1390 1910 1910 1910 2060 2060 2060 Ny y position of hot water outlet mm 205 205 205 205 205 205 205 P Height of cleaning opening mm 170 175 175 175 290 290 2...

Page 24: ...Adjustment range for hysteresis upwards o C 0 5 0 5 0 5 0 5 0 5 0 5 0 5 Default value for hysteresis upwards o C 5 5 5 5 5 5 5 Adjustment range for hysteresis downwards o C 0 10 0 10 0 10 0 10 0 10 0...

Page 25: ...ns pressure of cold water supply vented kPa bar 800 8 Maximum mains pressure of cold water supply unvented kPa bar 550 5 5 Maximum mains pressure of the protected cold supply setup kPa bar 500 5 T P o...

Page 26: ...0 9 0 1 0 8 9 1 0 8 9 1 0 8 9 1 0 Gas consumption m3 h 3 1 3 2 5 0 6 0 8 3 10 1 12 3 Gas category 3P G31 37 50 mbar Diameter of the venturi restrictor mm 6 00 6 00 6 00 6 00 6 60 6 60 6 60 Nominal lo...

Page 27: ...d 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 condensation drain 14 draw off points 15 e...

Page 28: ...cessary energy loss 1 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 2 Fit the T P valve 3 3 Fit a stop valve 11 in the hot water outlet pipe for servicing 3 6 3...

Page 29: ...ram 3 5 Installation diagram If an immediate flow of hot water is required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fit a circulation pu...

Page 30: ...r flue gas discharge materials Warning The installation should be carried out by a competent person in compliance with general and locally applicable regulations 1 3 Regulations Depending on the appro...

Page 31: ...Instruction manual BFC 29 is Installation types IMD 0789 R0 C43 C13 C53 B23 C33...

Page 32: ...es how to use the table Practical example of concentric flue gas discharge Example The figure shows a BFC 30 installation The water heater must be fitted with 25 m of concentric pipe C13 C33 and four...

Page 33: ...ric wall flue terminal specifications C13 IMD 0791 R0 Subject Description Wall flue terminal set 1x wall flue terminal incl wall flange clamping ring 1x pipe 500 mm 1x 90o bend Art No BFC 28 30 50 60...

Page 34: ...423 1 BFC 80 100 120 0306 855 1 Manufacturer Muelink Grol Type M2000 DDV HR C Pipe material Construction Concentric Flue gas discharge Thick walled aluminium with lipped sealing ring Air supply Thin w...

Page 35: ...metres must be added for each bend This brings the total pipe length to 4 6 x 8 10 36 8 10 46 8 m This is less than the maximum length of 55 metres stated in the table The installation therefore fulf...

Page 36: ...r this isolating transformer please contact A O Smith Water Products Company The figure shows a view of the terminal block and the table explains the relevant connections Connector block In preparatio...

Page 37: ...have no more connections to make Fit the cover on the terminal block Fit the covers onto the water heater 3 10 4 Isolating transformer An isolating transformer should be used if there is a case of fl...

Page 38: ...additional error signal The appliance has a terminal that is switched when an error is detected This can be used to signal errors for example with a bulb A 230V circuit can be powered directly Other...

Page 39: ...s or before the pressure reducing valve for LPG appliances so that the supply pressure can be measured This test nipple has a sealing screw Loosen the sealing screw by a few turns Do not completely lo...

Page 40: ...ompany if the supply pressure is not correct You cannot yet start using the appliance You must now take the appliance out of service 10 3 Isolating the water heater from the mains Note After conversio...

Page 41: ...d will then go to the main menu 9 Select SERVICE OPERATION FULL LOAD from the service menu 10 Confirm with The display shown here will appear The appliance is now in PARTIAL LOAD mode and will ignite...

Page 42: ...ple of the water heater 5 Open the gas supply and vent the gas supply line 6 Use the main switch to apply mains voltage to the appliance 7 Start 9 Starting the water heater the appliance 8 Go to the S...

Page 43: ...her CO2 level and turning to the right clockwise means less gas lower CO2 level Note After conversion you must check that the gas control valve is gastight 14 If you have increased Tset set it back to...

Page 44: ...is measured value has remained stable for some time This may take several minutes 21 Compare the CO2 value measured against the value measured under full load Caution The CO2 value at partial load mus...

Page 45: ...11 4 Switching pressure measurement To measure the switching pressure proceed as follows 1 Isolate 10 3 Isolating the water heater from the mains the appliance from the power supply 2 Carefully remov...

Page 46: ...w 11 Check whether the measured value matches the value from the table 3 4 3 Gas data Note If the message PRESSURE SWITCH does not appear there is a fault This must be resolved first by a qualified se...

Page 47: ...ial conversion kit You can order the conversion kit you need from the supplier of your appliance The conversion kit contains all the parts needed to do the conversion A description of how to do the co...

Page 48: ...Conversion to a different gas category 46 Instruction manual BFC 4 is...

Page 49: ...10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drain 14 draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration...

Page 50: ...g a pressure reducing valve 1 The expansion valve in the protected cold supply set up is defective or incorrectly fitted 5 2 Filling vented installations To fill the water heater proceed as follows 1...

Page 51: ...e 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drain 14 draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeratio...

Page 52: ...lve 4 in the cold water inlet A 10 Open the drain valve 9 6 2 Draining vented installations Some service activities require the water heater to be drained The procedure is as follows 1 Activate the ME...

Page 53: ...Icons and their meaning 7 4 ON OFF switch on controller The ON OFF switch of the controller turns the water heater ON and OFF Note that in the OFF position the water heater remains electrically live...

Page 54: ...own further to see the options EXTRA PERIOD and SETTINGS The selected option is confirmed using Pressing the button takes you back one page in a menu and discards all options selected in the current m...

Page 55: ...he time the day and T1 9 3 The appliance s heating cycle line three the programmed water temperature Tset line four is empty when the water heater is idle or depending on the operating cycle 9 3 The a...

Page 56: ...e comprising a letter and two digits followed by the error description lines two to four alternately a brief explanation of the error and a brief action to resolve the error Caution The displayed acti...

Page 57: ...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 when this...

Page 58: ...Status of the water heater 56 Instruction manual BFC 8 gis...

Page 59: ...run through the heating cycle 9 3 The appliance s heating cycle If the heating cycle is not run there is no heat demand if this is the case Tset will probably need to be set 11 4 Setting the water tem...

Page 60: ...ed and ignition takes place The icon is activated The message IGNITION appears 6 After ignition the flame is detected and the appliance will be running This means that actual heating has started The i...

Page 61: ...ng the water heater from the mains The water heater may only be isolated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 2 Position the cursor in front...

Page 62: ...Shutting down 60 Instruction manual BFC 10 gis...

Page 63: ...the main menu open then after 30 seconds the water heater will automatically return to the mode it was previously in 11 2 Notation convention for menu related instructions The MENU of the controller i...

Page 64: ...r temperature setting is 65o C If you want you can change every setting in the appliance s standard week program If the water temperature becomes too low while the week program is running the applianc...

Page 65: ...the minute digits which will blink Note Because the switch off time can never be earlier than the switch on time the switch off time setting is automatically adjusted with the switch on time 4 Use and...

Page 66: ...Confirm with 11 8 Adding times to a week program Call up the menu to INSERT switch on and switch off times into a week program as follows 1 WEEK PROGRAM PROGRAM OVERVIEW Confirm with The display show...

Page 67: ...you are now working in the delete sub menu the cursor is replaced with an exclamation mark and the period settings will blink 4 Scroll with to the day to be deleted For example SU Sunday in the second...

Page 68: ...rsor moves to the hour digits which will blink 2 Use and to set the switch on hour to the desired value In the example this is 08 Confirm with The cursor moves to the minute digits which will blink No...

Page 69: ...and maintenance engineer Regulation interval water temperature Ignition speed of fan Working speed of fan 11 11 1 Setting menu language To set menu language 1 Call up the menu for selecting the langu...

Page 70: ...er specifications Note This category is solely intended for the installation engineer and or service and maintenance engineer The corrected data is shown in the table of general and electrical data 3...

Page 71: ...e starts when the water temperature drops to 5 C below the SETPOINT and ends when the water reaches 5 C above the SETPOINT Set the hysteresis as follows HYSTERESIS UP The figure shows an example Set t...

Page 72: ...maintenance 14 2 Determining service interval The service interval is determined by the number of months that the appliance has been running This can be set to 6 9 and 12 months The default service in...

Page 73: ...o switch legionella prevention on or off select ANTI LEGIONELLA Select NO to switch legionella prevention off Select YES to switch legionella prevention on The following screen appears Select START to...

Page 74: ...Service program 72 Instruction manual BFC 12 is...

Page 75: ...commended action See the figures The first shows a possible error the second shows the appropriate checking action There are various types of errors all falling into one of two groups LOCK OUT ERRORS...

Page 76: ...tion engineer or local gas company The display is off The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check th...

Page 77: ...ng the burner Insufficient or no hot water The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check that there is...

Page 78: ...u must contact your installation engineer S03 blocking error Open circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5...

Page 79: ...installation engineer 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 To replace the nec...

Page 80: ...tion engineer to have an isolating transformer installed F02 lock out error Fan fails to run at correct speed Defective motor and or rotor 1 Check the motor and rotor 2 Replace the fan if the motor or...

Page 81: ...correctly fitted Refit them if necessary 3 Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner If necessary replace the hoses 4 Check whether the chi...

Page 82: ...Measure the resistance across the hot surface igniter This must lie between 2 and 10 Ohm at room temperature 4 Check that the hot surface igniter lights up during ignition 5 If necessary replace the h...

Page 83: ...or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F08 lock out error Error message from safety relay Flame detection befor...

Page 84: ...or EEPROM contents do not match the software version Processor software error C03 blocking error Reset error Too many resets in too short a period Wait for the error to disappear maximum 1 hour If the...

Page 85: ...ecessary Replace the sensor if the error persists To replace the necessary parts you must contact your installation engineer E04 lock out error Defect in the dummy sensor 2 The two temperature sensors...

Page 86: ...ineer Anode protection 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 is not fille...

Page 87: ...tenance engineer to check the water heater on both the water and gas side three months after installation Based on this check the best service interval can be determined 14 2 Determining service inter...

Page 88: ...Service interval 86 Instruction manual BFC 14 is...

Page 89: ...own the installation type water heater model and the full serial number of the water heater These details can be found on the rating plate Only by ordering with this information can you be sure to rec...

Page 90: ...and switching pressure and adjust them where necessary 13 Check that all components of the chimney flue system are properly attached 14 Check the pressure differential across the pressure switch 3 11...

Page 91: ...the figure 2 Undo the bolts 3 Remove the cover and the gasket 4 Inspect the tank and remove the loose scale deposits and contamination 5 If the scale cannot be removed by hand descale the water heate...

Page 92: ...flue Note Check the pressure differential again after cleaning If the pressure differential is too low following cleaning please contact the supplier of the water heater 15 5 Finalizing maintenance Se...

Page 93: ...the warranty shall be reduced to one year from the original installation date 16 3 Conditions for Installation and use The warranty set out in articles 1 and 2 will apply solely under the following c...

Page 94: ...ve water heater other than by an approved service engineer 16 5 Scope of the warranty The obligations of A O Smith by virtue of the warranty provided do not extend beyond delivery free of charge from...

Page 95: ...7 Appendices 17 1 Introduction This appendix contains Menu structure 17 2 Menu structure Electrical diagram 17 3 Electrical diagram Declaration of conformity 17 4 Declaration of conformity Week progra...

Page 96: ...REGULATION INTERVAL FULL LOAD PARTIAL LOAD EXTRA PERIOD SERVICE INTERVAL SETTINGS LANGUAGE SERVICE OPERATION START OPERATION SELECT APPLIANCE PROGRAM OVERVIEW PUMP RELAY HISTORY OF ERRORS CHANGE SETPO...

Page 97: ...Instruction manual BFC 95 is...

Page 98: ...6 6 X X 6 6 X X 6 JP3 JP11 X 6 6 X F3 X 3 X 2 F1 1 X J2 Q P O S 6 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...

Page 99: ...witch M Display N Fan O Temperature sensor T2 bottom of tank P Dummy Q Temperature sensor T1 top of tank R Selection resistor S Push button T Electrical anodes U Signalling for electrical anodes V Pot...

Page 100: ...Appendices 98 Instruction manual BFC 17 is 17 4 Declaration of conformity Declaration of conformity...

Page 101: ...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 Period DAY TIME Tset Pump 1 ON MO 14 30 70 C ON OFF OFF MO 16 1...

Page 102: ...Instruction manual BFC 100...

Page 103: ...etection 51 gas control valve 51 heat demand 51 installation diagram 25 installation engineer 10 J join air supply 28 circulation pipe 26 27 cold water side 26 27 electrical 33 flue gas discharge 28 g...

Page 104: ...OFF switch 51 trademarks 3 U user 10 W warranty 91 exclusions 92 General information 91 installation and conditions of use 91 scope 92 water composition 18 setting the temperature 61 water heater disp...

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A.O. Smith Cyclone BFC-28, Installation, User And Service Manual

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