A.O. Smith Cyclone BFC - 30 Installation And Service Manual Download Page 1

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XTRA HIGH EFFICIENCY

WATER PRODUCTS

COMPANY

WATER PRODUCTS

COMPANY

A DIVISION OF A. O. SMITH CORPORATION

WATER PRODUCTS

COMPANY

A DIVISION OF A. O. SMITH CORPORATION

Installation
User and
Service Manual

Summary of Contents for Cyclone BFC - 30

Page 1: ...CTS COMPANY WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION A DIVISION OF A O SMITH CORPORATION WATER PRODUCTS COMPANY A DIVISION OF A O SMITH CORPORATION Installation User and Service Manu...

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

Page 3: ...her 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...

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

Page 5: ...7 3 4 Technical specifications 20 3 5 Installation diagram 23 3 6 Water connections Unvented 24 3 7 Water connections Vented 25 3 8 Gas connection 26 3 9 Air supply and flue 26 3 10 Electrical connect...

Page 6: ...63 11 10 Extra period 63 11 11 Programming an extra period 64 11 12 Settings 65 12 Service program 67 12 1 Introduction 67 12 2 Setting the hysteresis 67 12 3 Displaying the error history 67 12 4 Disp...

Page 7: ...anty 89 16 3 Conditions for Installation and use 89 16 4 Exclusions 90 16 5 Scope of the warranty 90 16 6 Claims 90 16 7 Obligations of A O Smith 90 17 Appendices 91 17 1 Introduction 91 17 2 Electric...

Page 8: ...Table of contents 8 Instruction manual BFC...

Page 9: ...to follow the printed instructions may lead to personal injury and damage to the appliance 1 2 What to do if you smell gas Warning If there is a gas smell No naked flames No smoking Avoid causing spar...

Page 10: ...once a year both on the water side and on the gas side Maintenance frequency depends among other things on the water quality the average burning time per day and the set water temperature Note To det...

Page 11: ...llowing notation is used in this manual Note Important information Attention Ignoring this information can lead to the appliance being damaged Warning Failure to carefully read this information may le...

Page 12: ...display This is the actual menu for the user however the installation engineer and service and maintenance engineers will also need to use this menu Service program This chapter describes the service...

Page 13: ...the appliance Legend Only applicable numbers are mentioned 1 cover 2 hot water outlet 3 electrical connector block 4 electronic controller 5 pressure switch 6 control panel 7 temperature sensor T1 8...

Page 14: ...ferred to the cooler water thereby increasing the energy performance of the unit The condensate yielded by this process is discharged via the siphon 23 The insulation layer 24 prevents heat from escap...

Page 15: ...y of incoming air during the pre purge and normal running of the appliance The default state of the pressure switch is open When sufficient pressure difference is reached the pressure switch closes Ho...

Page 16: ...cing valve protects the installation against an excessively high water supply pressure 8 bar These components are fitted to the cold water pipe 3 7 Water connections Vented 2 5 2 Vented installation W...

Page 17: ...ce remove the packaging carefully We recommend unpacking the appliance at or near its intended location Attention The appliance may only be manoeuvred in an upright position Take care that the applian...

Page 18: ...table gives an overview of the specifications Water specifications Note If the water specifications deviate from those stated in the table then the tank protection cannot be guaranteed 16 Warranty cer...

Page 19: ...can cause damage to the immediate environment or floors below the level of the boiler room If this is the case the appliance should be installed above a wastewater drain or in a suitable metal leak t...

Page 20: ...ions 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 3 4 1 Dimensions of the appliance...

Page 21: ...lve connection 900 1410 1410 1410 W Height of condensation drain 125 145 145 145 1 Cold water supply connection ext R11 2 R11 2 R11 2 R11 2 2 Hot water outlet ext R11 2 R11 2 R11 2 R11 2 3 Gas valve c...

Page 22: ...1 Blank plate 2 Burner pressure regulator 1 or 2 1 1 1 1 Gas category G30 30 mbar butane Nominal load gross calorific value kW 30 7 32 8 50 6 59 4 Nominal output kW 29 8 31 8 48 1 57 4 Supply pressur...

Page 23: ...ve 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drainage 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17...

Page 24: ...ting long hot water pipes will prevent unnecessary 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 th...

Page 25: ...water outlet pipe for use when servicing 4 If a circulation pipe is required continue further by installing the circulation pipe 3 6 3 Circulation pipe 3 7 3 Circulation pipe See C in the installatio...

Page 26: ...rol Warning After fitting check for leaks 3 9 Air supply and flue 3 9 1 Introduction This section covers the following subjects Requirements for flue gas discharge materials Concentric connections Par...

Page 27: ...Instruction manual BFC 27 is Types of appliances IMD 0468 R0 C43 C13 C53 B23 C33...

Page 28: ...the table Practical example of concentric flue gas discharge Example The figure shows a BFC 30 installation The appliance must be fitted with 25 m of concentric pipe C13 C33 and four 90 degree bends...

Page 29: ...ere may be up to seven 90 degree bends Both requirements are fulfilled Specifications Attention For type C13 and C33 installations A O Smith prescribes the use of a roof or wall mounted terminal exclu...

Page 30: ...ly BFC 28 BFC 30 50 60 125 mm 150 mm 1 No other wall flue terminal is permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler Specification Description Ro...

Page 31: ...le illustrates how to use the table Practical example of parallel flue gas outlet Example The diagram shows a BFC 30 This has to be fitted with a 25m parallel pipe 100mm in diameter plus eight 90 degr...

Page 32: ...he bend in the transition piece can be ignored According to the table 4 6 metres must be added for each bend This brings the total pipe length to 4 6 x 8 25 36 8 25 61 8m This is less than the maximum...

Page 33: ...ons 3 10 2 Preparation Attention The appliance is phase sensitive It is absolutely essential to connect the mains phase L to the phase of the appliance and the mains neutral N to the neutral of the ap...

Page 34: ...liance 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 Connect phase L neutral N and earth of the power cable to termi...

Page 35: ...ank ON is a facility for connecting an external ON OFF switch In the OFF position the programmed operating state is active In the ON position the programmed operating mode is overruled and the ON mode...

Page 36: ...ure gauges This procedure assumes that these two gauges are available Gas control 3 11 1 Preparation To check the supply pressure and burner pressure proceed as follows 1 Isolate 10 3 Electrically iso...

Page 37: ...witch on the power to the appliance using the isolator on the appliance 6 Switch the electronic controller ON by setting the 0 I switch to position I The display will now show INTERNAL CHECK for about...

Page 38: ...sure increases 3 Cover the opening of the adjusting screw and check the burner pressure against the value given in the gas table 3 4 3 Gas data 4 If the pressure is not set correctly repeat the preced...

Page 39: ...LP gas or natural gas or other gas category than that for which the appliance has been set at the factory the appliance will have be adapted using a special conversion kit Attention You must check th...

Page 40: ...hree part gas coupling 2 adjacent to the burner Detach the air supply hose 3 Detach the pressure switch hose 4 7 Remove the burner as complete assembly 8 Place and fit the burner with parts from the c...

Page 41: ...r pressure regulator need to be replaced Unscrew the connector 9 from the gas control If necessary remove the blank plate or burner pressure regulator 7 If necessary fit the blank plate or burner pres...

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

Page 43: ...anual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drainage 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way...

Page 44: ...s happen the 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...

Page 45: ...manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drainage 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way...

Page 46: ...appliance and the mains power supply to position 0 7 Shut off the gas supply 10 8 Close the stop valve 11 in the hot water pipe 9 Close the supply valve 4 in the cold water supply A 10 Open the drain...

Page 47: ...iance and the mains power supply to position 0 7 Shut off the gas supply 10 8 Close the stop valve 11 in the hot water pipe 9 Close the stop valve 4 between the water tank and the cold water inlet A 1...

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

Page 49: ...lains the meanings of the icons Icons and their meaning 7 4 Electronic controller ON OFF switch The ON OFF switch of the electronic controller is used to switch the appliance ON and OFF Note that in t...

Page 50: ...NGS You have to scroll down 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 s...

Page 51: ...lternately 9 3 The appliance s heating cycle T1 and Tnet line three the programmed water temperature Tset line four blank when the appliance is idle or depending on the heating cycle 9 3 The appliance...

Page 52: ...perating modes Note Setting and if necessary programming of the basic operating modes are described in the main menu 11 Main menu chapter 8 3 Error conditions The figure shows an example of an error c...

Page 53: ...e and maintenance engineer Note The message SERVICE REQUIREDis based on the number of expired burning hours and the preset service interval Should the service interval have been incorrectly selected c...

Page 54: ...Status of the appliance 54 Instruction manual BFC 8 gis...

Page 55: ...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 temperature 9 3 The applian...

Page 56: ...pened 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 Th...

Page 57: ...ance should 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 of OFF 3 Confirm OFF with Attention Failure...

Page 58: ...Shutting down 58 Instruction manual BFC 10 gis...

Page 59: ...nds the appliance will automatically return to the mode it was previously in 11 2 Notational convention for menu related instructions The MENU of the electronic controller is divided into submenus For...

Page 60: ...is 65 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 appliance will run through the...

Page 61: ...itch on time the switch off time setting is automatically adjusted with the switch on time 4 Use and to set the minutes In the example this is 15 Confirm with The cursor moves to the switch off hour d...

Page 62: ...l to INSERT Confirm with The sub menu for adding a period will appear Example As an example we will program an extra period in which the switch on time is set to 18 00 hours and the corresponding swit...

Page 63: ...st programmed period 6 Scroll with to START OPERATION Confirm with The week program is active 11 10 Extra period Use an extra period when you either want to have the appliance switch on and off for a...

Page 64: ...od Setting the switch off time 1 Use and to set the hours In the example this is 012 Confirm with The cursor moves to the minute digits which flash 2 Use and to set the minutes In the example this is...

Page 65: ...2 2 Setting day and time To enter the time and day 1 Call up the menu for entering the day and time as follows 2 SETTINGS Confirm with The display shows the menu for settings 3 Scroll with and to DAY...

Page 66: ...roll with to SPECIFICATIONS Confirm with The display shows the sub menu for displaying appliance specifications 3 Scroll with to the section to be displayed for example REGULATION INTERVAL The relevan...

Page 67: ...gin We refer to this margin as the hysteresis The standard setting for this margin is 2 C The heating cycle starts if the water temperature drops to 2 C below the SETPOINT and ends when the water reac...

Page 68: ...ting the service interval To aid servicing the electronic controller includes a service interval which is used to set the frequency of maintenance interval 14 2 Determining service interval by the ser...

Page 69: ...o three and four a long description alternating with a recommended action See the figures The first shows a possible error the second shows the appropriate checking action There are various types of e...

Page 70: ...r or local gas company immediately Display is off Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 Check if the isolator is ON 2 Check that there is po...

Page 71: ...fice s 15 4 3 Clean the orifice s Hot water supply insufficient or absent Appliance is turned off Start the appliance up 9 Starting and running No supply voltage present 1 Check if the isolator is ON...

Page 72: ...top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP5 See the BFC electrical diagram 17 Appendices Damaged cable or defective sensor Replace sensor T1 To replace the nece...

Page 73: ...in sensor circuit Replace the dummy sensor 2 To replace the necessary parts you must contact your installation engineer F01 blocking error Defect in power supply circuit Live and neutral connected wro...

Page 74: ...pply voltage the fan is not running at the correct speed 1 Check the supply voltage this must be 230 VAC 15 10 2 Reset appliance controller The F02 entries below are applicable solely to appliances th...

Page 75: ...nnect loose or detached hoses 2 Reset appliance controller Heat exchanger and or chimney flue is blocked 3 Measure the pressure differential across the air pressure switch 4 Check the values 2 4 5 Pre...

Page 76: ...ctly 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 that the flue gas ou...

Page 77: ...er 3 Measure the resistance across the hot surface igniter This must lie between 2 and 5 ohms 4 Check that the hot surface igniter lights up during ignition 5 If necessary replace the hot surface igni...

Page 78: ...ill present after the gas valves have closed 3 If this is the case the gas control must be replaced If the error cannot be resolved or is persistent contact your installation engineer To replace the n...

Page 79: ...heck for blockage in the flue gas discharge Remove any blockage that may be present 6 Check for blockage in the condensation water discharge Remove any blockage that may be present 7 Measure the press...

Page 80: ...rror Ignition relay error RAM error EEPROM error 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 fo...

Page 81: ...Replace the sensor if the error persists To replace the necessary parts you must contact your installation engineer E04 lock out error Error in dummy sensor 2 The two dummy sensors in the tank detect...

Page 82: ...is Instruction manual BFC 82...

Page 83: ...can be set to 500 1000 or 1500 burning hours The standard setting is 500 burning hours Example In the first three months the appliance has burnt 300 hours During maintenance it is evident that one se...

Page 84: ...Maintenance frequency 84 Instruction manual BFC 14 is...

Page 85: ...wn the appliance type and model and the full serial number of the appliance These details can be found on the rating plate Only by ordering with this information can you be sure to receive the correct...

Page 86: ...he appliance s heating cycle 10 If you have adjusted Tset return it to the desired value 11 4 Setting the water temperature 11 Remove the plastic cover on the top of the appliance 12 Check the supply...

Page 87: ...the anodes and if necessary replace them 15 3 3 Descaling and cleaning the tank Scale and lime buildup prevent effective conduction of the heat to the water Periodic cleaning and descaling prevents bu...

Page 88: ...heat exchanger 4 Finalizing maintenance 15 4 2 Clean the burner s 1 Detach the burner s 2 Remove all contamination present on the burner s 3 Fit the burner s 15 4 3 Clean the orifice s 1 Detach the or...

Page 89: ...heater the warranty shall be reduced to one year from the original installation date 16 3 Conditions for Instal lation and use The warranty set out in article 1 and 2 will apply solely under the foll...

Page 90: ...water heater other than by an approved service engineer 16 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...

Page 91: ...Instruction manual BFC 91 is 17 Appendices 17 1 Introduction This appendix contains Electrical diagram Week program card...

Page 92: ...Appendices 92 Instruction manual BFC 17 is 17 2 Electrical diagram Electrical diagram 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 0307 579 R1...

Page 93: ...ection K Isolating transformer L Double pole isolator M Controller 0 I switch N Display O Fan P Temperature sensor T2 bottom of tank Q Dummy R Temperature sensor T1 top of tank S Selection resistor T...

Page 94: ...Appendices 94 Instruction manual BFC 17 is...

Page 95: ...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 15...

Page 96: ...Instruction manual BFC 96...

Page 97: ...35 connecting the program controlled pump 35 controls 59 conversion to a different gas category 39 D dimensions 21 display 49 displaying error history 67 document contents 12 draining 45 E electrical...

Page 98: ...scale 87 scrolling 49 service check 10 83 service engineer 10 service required 53 setting backlight time 68 setting date 65 setting display contrast 68 setting display scroll speed 68 setting service...

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