A.O. Smith cyclone BFC - 80 Installation And Service Manual Download Page 68

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Instruction manual BFC

13.2 Troubleshooting table for general errors

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

General errors

Symptom

Cause

Solution

Remark

Gas smell

Gas leak

Warning

Close the main gas valve immediately.

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

Warning

Contact your installation engineer 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 power to the isolator.
3. Check whether the ON/OFF switch of the electronic controller is

ON (position I).

4. Check whether there is power to the electrical connector block.
5. The measured voltage must be 230 VAC (-15%, +10%).

See the BFC electrical diagram

(17 "Appendices")

If the error persists, consult your installation engineer.

Defective fuse(s)

Replace fuse(s)

To replace the fuses, you must contact your installation engineer.

Summary of Contents for cyclone BFC - 80

Page 1: ...OMPANY 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 Manual In...

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 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 26 3 10 Electrical connect...

Page 6: ...Extra period 61 11 10 Programming an extra period 61 11 11 Settings 62 12 Service program 65 12 1 Introduction 65 12 2 Setting the hysteresis 65 12 3 Displaying the error history 65 12 4 Displaying th...

Page 7: ...Conditions for Installation and use 87 16 4 Exclusions 88 16 5 Scope of the warranty 88 16 6 Claims 88 16 7 Obligations of A O Smith 88 17 Appendices 89 17 1 Introduction 89 17 2 BFC Electrical Diagra...

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

Page 9: ...ad 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 sparks Do not use any electrical equipment or...

Page 10: ...temperature Note To determine the correct maintenance frequency it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side within three...

Page 11: ...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 menu It...

Page 12: ...Introduction 12 Instruction manual BFC 1 gis...

Page 13: ...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 combustion chamber 9 anode 10 tank 11 heat exchang...

Page 14: ...cold water lower down in the tank they start to condense This condensation causes latent heat energy to be released which is transferred to the cooler water thereby increasing the energy performance o...

Page 15: ...he discharge of flue gases and the supply 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...

Page 16: ...ing valve protects the installation against an excessively high water supply pressure 8 bar These components are fitted to the cold water pipe 3 6 Water connections Vented 2 5 2 Vented installation Wi...

Page 17: ...ance 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 applian...

Page 18: ...nteed 16 Warranty certificate 3 3 4 Working clearances For access to the appliance it is recommended that the following clearances are observed see figure AA around the appliance s control column and...

Page 19: ...ecifications 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 specific...

Page 20: ...tion 20 Instruction manual BFC 3 is 3 4 1 Dimensions of the appliance Plan and elevation of appliance legend see the table 45 18 45 3 5 4 F E 2 6 11 Hy Hx C Ny D 2 5 P M 6 1 4 R S N A G 7 K W H 3 IMD...

Page 21: ...ng 290 290 R Height of drain valve connection 225 225 S Height of T P valve connection 1425 1425 W Height of condensation drain 240 240 1 Cold water supply connection external R11 2 R11 2 2 Hot water...

Page 22: ...e mbar 7 0 6 0 Gas consumption m3 h 8 3 10 1 LP gas Gas category G31 37mbar propane Orifice diameter mm 4 70 5 10 Nominal load gross calorific value kW 84 8 103 3 Nominal output kW 81 9 99 8 Supply pr...

Page 23: ...e 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: ...the hot 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 6 3 Circulation pipe See C in the ins...

Page 25: ...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 26: ...ol 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 Para...

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

Page 28: ...e illustrates how to use the table Practical example of concentric flue gas discharge Example The figure shows a BFC 100 installation The appliance must be fitted with 12m of concentric pipe C13 C33 a...

Page 29: ...d there may be up to three 90 bends Both requirements are fulfilled Specifications Caution For type C13 and C33 installations A O Smith prescribes the use of a roof or wall mounted terminal exclusivel...

Page 30: ...gas discharge 130mm Air supply 200mm 1 No other wall flue terminal is permitted Use this item number to order the wall conduit set from supplier manufacturer or wholesaler Subject Description Roof fl...

Page 31: ...ischarge The following practical example illustrates how to use the table Practical example of parallel flue gas discharge Example The figure shows a BFC 100 installation This has to be fitted with a...

Page 32: ...ply is 8 The bend in the transition piece can be ignored According to the table 2 4 metres per bend must be added This brings the total pipe length to 2 4 x 8 35 19 2 35 54 2m This is less than the ma...

Page 33: ...pecifications 3 10 2 Preparation Caution 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 o...

Page 34: ...wer 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 terminals 22 throu...

Page 35: ...nections Fit the cap on the electrical connector block Fit the plastic covers onto the appliance 3 10 7 Connecting an extra error signal Alarm OUT Alarm OUT is a potential free terminal that is switch...

Page 36: ...e test nipples Loosen both sealing screws by a few turns Do not completely loosen them they can be difficult to re tighten 2 Connect a pressure gauge to the burner pressure nipple 2 3 Open the gas sup...

Page 37: ...l speed 9 Use the pressure gauge to read the supply pressure at 1nipple 1 3 4 3 Gas data Note Consult the mains gas supply company if the supply pressure is not correct 10 Use the pressure gauge to re...

Page 38: ...ivate the OFF mode of the electronic controller 7 If the MENU is not displayed press Use and to place the cursor beside OFF Confirm with 8 Wait until the fan has stopped and switch the electronic cont...

Page 39: ...factory the appliance will have be adapted using a special conversion kit Caution You must check the supply pressure and burner pressure once the conversion is complete Orifice assembly 1 Isolate the...

Page 40: ...into each injector 6 7 Refit the 3 part gas coupling 2 8 Check the burner pressure and supply pressure 3 11 Checking the supply pressure and burner pressure 9 Replace the cover 10 Remove the sticker...

Page 41: ...nual 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 a...

Page 42: ...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 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: ...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 45: ...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 46: ...Draining 46 Instruction manual BFC 6 gis...

Page 47: ...thout icons 7 3 Meaning of icons The table explains 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...

Page 48: ...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 49: ...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 50: ...operating 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...

Page 51: ...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 52: ...Status of the appliance 52 Instruction manual BFC 8 gis...

Page 53: ...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 3 Setting the water temperature 9 3 The applian...

Page 54: ...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 55: ...iance 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 Caution Failure...

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

Page 57: ...decrease the value Confirm with After confirming the appliance enters ONmode Note If the preset temperature is higher than the current water temperature then the appliance might not immediately start...

Page 58: ...ways be followed by a switch off time on the same day of the week A maximum of three periods may be programmed per day You can program a maximum of 21 periods Call up the menu for the week program as...

Page 59: ...ar circulation of hot water in the hot water pipes You can skip this step if you there is no pump in your hot water circuit Confirm with The cursor moves to SAVE 2 Confirm with The display shown in th...

Page 60: ...wn sequentially in the display Assume that the switch on off times for the appliance are programmed as in the figure To delete a period proceed as follows 1 WEEK PROGRAM PROGRAM OVERVIEW Confirm with...

Page 61: ...11 10 Programming an extra period 1 Call up the menu for entering an extra period via 2 EXTRA PERIOD Confirm with The display show the settings for the extra period Setting the switch on time 1 Use a...

Page 62: ...the extra period will NOT be automatically switched on 11 11 Settings Using the SETTINGS option you can adjust certain settings and read certain appliance data Adjustable settings Language of the menu...

Page 63: ...nce takes no account of daylight saving 11 11 3 Displaying appliance specifications Note This category is solely intended for the installation engineer and or service and maintenance engineer The tabl...

Page 64: ...Main menu 64 Instruction manual BFC 11 gis The relevant display appears REGULATION INTERVAL 40_80 C...

Page 65: ...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 66: ...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 67: ...o digits Lines two 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 v...

Page 68: ...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 69: ...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 70: ...nsor 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 necessary parts you must...

Page 71: ...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 72: ...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 73: ...es 2 4 5 Pressure switch 5 Check heat exchanger condensation drainage and or chimney flue for blockages 6 Clear any blockage that may be present 7 Reset appliance controller Defective controller 1 Che...

Page 74: ...engineer Loose DAPS hoses 1 Check the hoses between the DAPS and the burner fan 2 a Replace any broken hoses b Properly connect any loose hoses 3 Reset appliance controller Heat exchanger and or chim...

Page 75: ...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 76: ...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 77: ...till 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...

Page 78: ...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 79: ...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 80: ...eplace 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 a...

Page 81: ...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 82: ...Maintenance frequency 82 Instruction manual BFC 14 is...

Page 83: ...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 84: ...ed value 11 3 Setting the water temperature 11 Remove the plastic cover on the top of the appliance 12 Check the supply and burner pressure 3 11 Checking the supply pressure and burner pressure and ad...

Page 85: ...the appliance and also improves the heating process Take the rate of scale formation into account when deciding on maintenance frequency Scale formation depends on the local water composition the wate...

Page 86: ...on the burner s 3 Fit the burner s 15 4 3 Clean the orifice s 1 Detach the orifice s 2 Remove all contamination present in the orifice s 3 Fit the orifice s 15 4 4 Cleaning the heat exchanger 1 Detach...

Page 87: ...heater 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 article 1 and 2 will apply solely under the follo...

Page 88: ...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 89: ...Instruction manual BFC 89 is 17 Appendices 17 1 Introduction This appendix contains Electrical diagram 17 2 BFC Electrical Diagram Week program card...

Page 90: ...Appendices 90 Instruction manual BFC 17 is 17 2 BFC Electrical Diagram 1 brown 2 blue 3 green 4 black 5 white 6 grey beige 7 red 8 green...

Page 91: ...Display N Fan O Temperature sensor T2 bottom of tank P Dummy Q Temperature sensor T1 top of tank R Selection resistor S Pressure switch T Potentiostat U Frequency controller V RS 485 interface W Elec...

Page 92: ...Appendices 92 Instruction manual BFC 17 is...

Page 93: ...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 94: ...Instruction manual BFC 94...

Page 95: ...ontrolled pump 35 controls 57 conversion to a different gas category 39 D dimensions 21 display 47 displaying error history 65 document contents 11 draining 43 E electrical connection 32 electrical co...

Page 96: ...scale 85 scrolling 47 service check 10 81 service engineer 10 service required 51 setting backlight time 66 setting date 63 setting display contrast 66 setting display scroll speed 66 setting service...

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