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A.O. Smith 28 30 50 60 Installation & Service Manual

A. o. smith corporation service manual water products 28 30 50 60
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Release R.1.3 UK
28
30
50
60
Installation
User and
Service Manual
WATER PRODUCTS
COMPANY
A DIVISION OF A. O. SMITH CORPORATION
XTRA HIGH EFFICIENCY

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Summary of Contents for A.O. Smith 28 30 50 60

  • Page 1 Release R.1.3 UK Installation User and Service Manual WATER PRODUCTS COMPANY A DIVISION OF A. O. SMITH CORPORATION XTRA HIGH EFFICIENCY...
  • Page 2 www.aosmithinternational.com your installer...
  • Page 3 Any brand names mentioned in this manual are registered trademarks of their respective owners. Liability A.O. Smith Water Products Company accepts no liability for claims from third parties arising from improper use other than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven Chamber of Commerce.
  • Page 4 Instruction Manual BFC...

  • Page 5: Table Of Contents

    Table of contents Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 About the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10...
  • Page 6 3.10 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6 3.10.7 3.10.8 3.11 Checking the supply pressure and burner pressure - - - - - - - - - - - - 33 3.12 Conversion to a different gas category - - - - - - - - - - - - - - - - - - - 35...
  • Page 7 Week programme - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 Extra period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60 8.6.1 8.6.2 Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61...
  • Page 8 13.7 Limitation of liability A.O. Smith - - - - - - - - - - - - - - - - - - - - - - 90 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 91...

  • Page 9: Introduction

    Introduction About the appliance This manual describes how to install, service and use the BFC appliance. The BFC appliance is a condensing room-sealed water heater with a fan in the air intake. A concentric chimney connector is fitted standard to the appliance. Alternatively, the appliance can be connected using a parallel system.

  • Page 10: Target Groups

    Introduction Furthermore, the installation must comply with the manufacturer’s instructions. Target groups The three target groups for this manual are: • • • Symbols on each page indicate the target groups for whom the information is intended. See Table 1.1 Target group symbols Symbol Maintenance A service should be carried out at least once a year, both on the water side and...

  • Page 11: Overview Of This Document

    Overview of this Table 1.2 document Table 1.2 Contents of document Chapter Target groups 2 Functioning of the appliance 3 Installation 4 Filling and draining 5 The control panel 6 Status of the appliance 7 Starting up and shutting down 8 Main menu 9 Service program 10 Troubleshooting...
  • Page 12 Introduction Instruction Manual BFC...

  • Page 13: Functioning Of The Appliance

    Functioning of the appliance Introduction Topics covered in this chapter: • • • • Functional Figure 2.1 shows a cut-away view of the appliance. description of the appliance Legend a plastic top cover b hot water outlet c electrical connection block d ThermoControl e pressure switch f control panel...

  • Page 14: The Appliance's Heating Cycle

    Functioning of the appliance In this appliance the cold water enters the bottom of the tank via the cold water inlet n. The tap water, heated by the combustion chamber h and heat exchanger k, leaves the tank through the hot water outlet b. Once the appliance is completely filled with water, it remains constantly under water supply pressure.

  • Page 15: Water Temperature Protection

    2.4.1 Water temperature protection With temperature sensor T1 g and temperature sensor T2 m, the ThermoControl monitors three temperatures which are important for safety. Table 2.1 Table 2.1 Temperature protection Protection Description Against frost The frost protection cuts in. The water is heated to 20°C. <...

  • Page 16: Ionisation Rod

    T&P valve A T&P valve is only mandatory in an ‘unvented’ installation. However, A.O. Smith also recommends the use of a T&P valve in ‘vented’ installations. A T&P valve monitors the pressure in the tank, and the water temperature at the top of the tank.

  • Page 17: Installation

    Installation Introduction This chapter describes the installation activities to be carried out before the appliance may be started up, namely: • • • • • • • • • • Packaging To avoid damaging the appliance, remove the packaging carefully. We recommend unpacking the appliance at or near its intended location.

  • Page 18: Humidity And Ambient Temperature

    Installation 3.3.1 Humidity and ambient temperature The boiler room must be frost-free, or be protected against frost. shows the environmental conditions that must be adhered to, for correct functioning of the electronics present in the appliance to be guaranteed. Table 3.1 Humidity and ambient temperature specifications Humidity and Humidity Ambient temperature...
  • Page 19 Figure 3.1 Working clearances Release R.1.3 UK If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered from A.O. Smith, the installer / supplier. Remark 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.
  • Page 20 Installation Technical The appliance is supplied without accessories. Check the dimensions and other specifications specifications for the accessories to be used, based on Table Figure 3.2 Plan and elevation of the appliance 3.6. Figure 3.2 IMD-0073 Instruction Manual BFC...

  • Page 21: Technical Specifications

    Table 3.4 Dimensions Dime Description nsion Total height (mm) Diameter of the appliance (mm) Diameter of air supply/flue gas discharge (mm) Height of the gas connection (mm) Height of cold water supply connection (mm) Height of hot water outlet connection (mm) Height of cleaning and inspection opening (mm) 200 Height of drain valve (mm) Height of T&P valve (mm)
  • Page 22 Installation Table 3.5 General and electrical data DESCRIPTION Unit Electrical power consumption Supply voltage Mains frequency BFC 28 BFC 30 BFC 50 230 (-15% +10%) 50 (±1 Hz) Instruction Manual BFC BFC 60...

  • Page 23: Installation Diagram

    Table 3.6 Gas data Gas category data 2H3+ Data for natural gas 2H: G20-20 mbar Orifice diameter Nominal load (upper value) Nominal capacity Supply pressure Burner pressure Gas consumption Data for LP gas 3+ General Orifice diameter Restrictor diameter G30-30 mbar (butane) Nominal load (upper value) Supply pressure Burner pressure...
  • Page 24 Installation Legend a pressure-reducing valve (mandatory) b expansion vessel (mandatory) c T&P valve (mandatory) d stop valve (recommended) e non-return valve (mandatory) f circulation pump (optional) g drain valve h gas valve (mandatory) i stop valve (mandatory) j temperature gauge (optional) k condensation drainage (mandatory) l hot water draw-off points...

  • Page 25: Water Connections, Unvented

    Water connections, Unvented 3.6.1 Cold water side See a in 1. Fit an approved stop valve i on the cold water side as required by 2. The maximum working pressure of the appliance is 8 bar. Because the 3. Fit a non-return valve e and an expansion vessel b. 4.

  • Page 26: Water Connections, Vented

    Installation Water connections, Vented 3.7.1 Cold water side See a in 1. Fit an approved stop valve i on the cold water side between the water 3.7.2 Hot water side See b in 1. Fit the T&P valve c. 2. Optional: fit a temperature gauge j to be able to check the temperature of 3.

  • Page 27: Air Supply And Flue Gas Discharge

    Concentric roof flue terminal. Note A.O. Smith prescribes the use of a roof or wall-mounted terminal, exclusively of a type approved for the appliance. See paragraph ’3.9.1 Concentric wall flue terminal’ Use of an incorrect roof or wall-mounted terminal can cause the installation to malfunction.

  • Page 28: Concentric Wall Flue Terminal

    The M2000 MDV SE model is a special version of the Mugro 3000 series. No other wall flue terminal may be used, as the BFC-appliance is approved exclusively for this model of wall flue terminal. You can order the wall flue terminal from A.O. Smith or your trade supplier, by specifying model: M2000 MDV SE.

  • Page 29: Concentric Roof Flue Terminal

    BFC- appliance is approved exclusively for this model of roof flue terminal. You can order the roof flue terminal from A.O. Smith or your trade supplier, by specifying model: M2000 DDV SEC HR.

  • Page 30: Electrical Connection

    Installation 3.10 Electrical connection 3.10.1 Introduction Topics covered in this paragraph: • • Optionally, it is possible to connect an isolating transformer, a continuous pump, a program-controlled pump, a For these options, see: • • • • • 3.10.2 Preparation Figure 3.6 associated connections.

  • Page 31: Mains Voltage

    Figure 3.6 Connection block (connections 1 through 24 explained in Table In preparation you should first remove the two plastic covers and the protective cap of the electrical section. The plastic covers are attached to the appliance by 4 screws and Velcro fastenings. The covers are also joined to each other with Velcro fastenings.

  • Page 32: Isolating Transformer

    Fit the cap on the electrical connection block. Fit the plastic covers onto the appliance. and X ) to terminals 5 and 6 as indicated in Contact A.O. Smith for details of the correct isolating transformer. ) of the power cables to Table 3.10.

  • Page 33: Connecting Extra Error Signal ("Alarm Out")

    This can be used to signal errors, for example by turning on a lamp. A 230 V circuit can be directly powered. For other voltages, a specific relay prescribed by A.O. Smith is required. 1. Connect the phase cables (X 2.
  • Page 34 Installation 9. Turn the ThermoControl ON by setting the 0/I switch to position I. Figure 3.7 ThermoControl INTERNAL CHECK Figure 3.8 Internal check 10. Activate the “ON mode” by going through the following steps: MENU »OFF ^ ON È WEEK PROGRAM Figure 3.9 Main menu 11.

  • Page 35: Conversion To A Different Gas Category

    17. Activate the “OFF mode” of the ThermoControl: MENU » ^ ON È WEEK PROGRAM 18. Wait until the fan has stopped. and turn the ThermoControl off. Figure 3.11 Main menu 19. Shut off the gas supply. 20. Disconnect the two pressure gauges and re-tighten the sealing screws in the 21.
  • Page 36 Installation 8. Remove the burner as complete assembly. Legend a connector b gas coupling c air supply hose d pressure switch hose e distribution plate f orifice Figure 3.12 Orifice assembly 9. Place and fit the burner with parts from the conversion kit. 10.
  • Page 37 Legend g burner pressure regulator h burner pressure control cap i burner pressure control adjusting screw j connector k flat sealing plate l supply pressure test nipple M burner pressure test nipple Figure 3.13 Conversion of gas control 12. If the flat sealing plate or burner pressure regulator need to be replaced: 13.
  • Page 38 Installation Instruction Manual BFC...

  • Page 39: Filling And Draining

    Filling and draining Introduction Topics covered in this chapter: • • The components referred to in these paragraphs are illustrated in Filling the appliance 4.2.1 Filling unvented installations To fill the appliance, proceed as follows. 1. Open the stop valve i in the hot water pipe and, if present, the stop valves 2.
  • Page 40 Filling and draining Legend a pressure-reducing valve (mandatory) b expansion vessel (mandatory) c T&P valve (mandatory) d stop valve (recommended) e non-return valve (mandatory) f circulation pump (optional) g drain valve h gas valve (mandatory) i stop valve (mandatory) j temperature gauge (optional) k condensation drainage (mandatory) l hot water draw-off points...

  • Page 41: Draining The Appliance

    Draining the appliance 4.3.1 Draining unvented installations Some service activities require the appliance to be drained. The procedure is as follows: 1. Activate the MENU 2. Use H and L to place the cursor beside »OFF 3. Confirm ^ ON 4.
  • Page 42 Filling and draining Instruction Manual BFC...

  • Page 43: The Control Panel

    The control panel Introduction Topics covered in this chapter: • • • • • Operating Figure 5.1 driven. It comprises: • • • • • The push buttons are divided into three groups: • • • Figure 5.1 ThermoControl In this manual, the display of the ThermoControl is shown as in with and without icons.

  • Page 44: Explanation Of The Icons

    Figure 5.4 Navigation buttons PC connection. The PC connection is exclusively intended for technicians from A.O. Smith who can read the status and history of the appliance. These details can be important for troubleshooting and/or responding to complaints.

  • Page 45: Status Of The Appliance

    Status of the appliance Introduction Topics covered in this chapter: • • • Operating modes When running, the appliance has four basic operating modes, namely: 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED Figure 6.1 Frost protection 13:45 Thursday 67ÉC Tset 75ÉC Figure 6.2 ON EXTRA 12:30 Thursday...

  • Page 46: Error Conditions

    Status of the appliance PROG 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC Figure 6.4 week program active, current time within programmed period PROG 12:00 Monday 76ÉC MO 11:15 PERIOD ACTIVATED Figure 6.5 week program active, current time outside programmed period In all modes, the temperature may at any moment drop below the desired temperature.

  • Page 47: Service Condition

    Service condition Figure 6.7 appear, then the appliance is in need of a service and maintenance inspection. In that case, contact your service and maintenance engineer. WARNING MAX. BURNINGHOURS: SERVICE REQUIRED Figure 6.7 Service required Release R.1.3 UK shows the message SERVICE REQUIRED Remark The message...
  • Page 48 Status of the appliance Instruction Manual BFC...

  • Page 49: Starting Up And Shutting Down

    Starting up and shutting down Introduction Topics covered in this chapter: • • Starting up Start-up the appliance as follows: 1. Fill the appliance. See chapter 2. Open the gas valve (see 3. Switch on the power to the appliance using the mains switch between the 4.

  • Page 50: Shut The Appliance Down For A Brief Period ("Off Mode")

    Starting up and shutting down • 7.3.1 Shut the appliance down for a brief period (“OFF mode”) To shut the appliance down for a brief period, you must activate the frost protection. With the frost protection you can prevent water freezing in the appliance. Activate the frost protection as follows: 13:45 Thursday 6ÉC...

  • Page 51: The Appliance's Heating Cycle

    The appliance’s The appliance’s heating cycle is activated as soon as the measured water heating cycle temperature (T depends on the currently selected appliance operating mode. For example, if the appliance is in the “OFF mode” (frost protection), then this value is 5°C. If the appliance is in the “ON mode”, then this threshold value is selectable, for example, 65°C.
  • Page 52 Starting up and shutting down 5. After a number of seconds pre-glow, the gas control is opened and ignition Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC IGNITION Figure 7.12 Ignition 6. After ignition, the flame is detected and the appliance will be running. This Ê...

  • Page 53: Main Menu

    Main menu Introduction MENU are: »OFF ^ ON • È WEEK PROGRAM EXTRA PERIOD SETTINGS Figure 8.1 Main menu • • • • Topics covered in this chapter: • • • • Notational convention for SETTINGS menu-related SETTINGS menu of instructions employs the following convention: •...

  • Page 54: Switching Into "On Mode

    Main menu This means: 1. B: Activate the main menu with B. 4. Confirm with E: After pressing E, the sub-menu This notation is also used for more than 2 sub-menus. Switching into “ON You can switch the appliance into “ON mode” from any operational mode, as mode”...

  • Page 55: Week Programme

    Week programme 8.5.1 Introduction Using the week program, you can set the water temperature for the days and times you wish. If the appliance is running under a week program, then this is indicated on the PROG display by the text 07:55 Monday 64ÉC the time of day, the day of the week and the temperature.
  • Page 56 Main menu The display now shows the menu for the week program, see DAY TIME Tset the default setting, the program switches on and off every day at 00:00 and ON »SU 00:00 65ÉC P 23:59 hours respectively, the water temperature is 65ºc and the pump is OFF SU 23:59 switched on (...

  • Page 57: Adding Times To A Week Program

    SU 08:15 7. Use H and L to select the minutes. In the example this is SU 12»15 Tset 65ÉC PUMP ON SAVE Figure 8.12 Setting switch-off minutes in week program Setting the water temperature SU 08:15 8. Use H and L to select the water temperature. In the example this is 75ÉC. SU 12:45 Tset»65ÉC PUMP ON...

  • Page 58: Deleting Times From A Week Program

    Main menu DAY TIME Tset »SU 08:15 75ÉC P 2. Scroll L to OFF SU 12:45 00:00 65ÉC P The sub-menu for adding a period will appear. See OFF SA 23:59 INSERT DELETE START OPERATION Figure 8.18 Week programme »SU 08:15 12:45 Tset 65ÉC...
  • Page 59 2. Scroll with L to WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È 3. Scroll with L to Figure 8.23 week program options 4. The display will change as shown in DAY TIME Tset ON !SU 08:15 75ÉC P OFF SU 12:45 18:00 75ÉC P OFF SU...

  • Page 60: Extra Period

    Main menu Extra period 8.6.1 Introduction Use an extra period when you either want to have the appliance switch on and off for a certain period, either without modifying the active week program, or without taking the appliance out of OFF mode (frost protection active). If the appliance is running under an ‘extra period’, then this is indicated in the EXTRA display with the text...

  • Page 61: Settings

    SU 08:15 Setting the water temperature SU 12:45 Tset»65ÉC 7. Use H and L to select the water temperature. In the example this is 75. PUMP ON SAVE Figure 8.34 Setting water temperature for extra period Setting program-controlled pump 8. If required, a pump can be controlled during the period. Use H and L to SU 08:15 SU 12:45 Tset 75ÉC...

  • Page 62: Setting Day And Time

    Main menu 3. Scroll with L to the desired language. LANGUAGE ENGLISH ^ NEDERLANDS The language is set. ȻDEUTSCH FRANCAIS ITALIANO Figure 8.39 Language selection 8.7.3 Setting day and time Bring up the menu for entering the day and time via: MENU 1.
  • Page 63 Table 8.2 Table 8.2 Appliance specifications Appliance BFC 28 BFC 30 BFC 50 BFC 60 Bring up the menu to display the appliance specifications via: 1. B: MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS Figure 8.46 Main menu 2. Scroll with L to SETTINGS LANGUAGE ^ DAY/TIME...
  • Page 64 Main menu Instruction Manual BFC...

  • Page 65: Service Program

    Service program Introduction The service program is used by the installer or service and maintenance SERVICE MENU engineer for: »HYSTERESE • ^ HISTORIE OF ERRORS È APPLIANCE HISTORY • SELECT APPLIANCE • PUMP RELAY • SERVICE INTERVAL • CONTRAST DISPLAY •...

  • Page 66: Displaying The Appliance History

    Service program Figure 9.3 HISTORIE OF ERRORS(B) HISTORIE OF ERRORS S04 SENSOR ERROR F06 IONIZATION È CO2 50 HZ ERROR Figure 9.3 Blocking errors Figure 9.4 HISTORIE OF ERRORS(L) HISTORIE OF ERRORS F02: FAN F07: FLAME ERROR È ... Figure 9.4 Lock out errors Displaying the The appliance history sub-menu is used to display the burning hours, the appliance history...

  • Page 67: Setting The Display Contrast

    The service interval is based on the number of burning hours. This can be set to 500, 1000 and 1500 hours. The standard setting for number of hours is Once the preset number of hours is reached, a message to this effect will appear.
  • Page 68 Service program Instruction Manual BFC...

  • Page 69: Troubleshooting

    Troubleshooting 10.1 Introduction A distinction is made between: • • S02: SENSOR ERROR TOP TANK SENSOR 1 NOT CONNECTED Figure 10.1 Possible error S02: SENSOR ERROR TOP TANK CHECK TOP TANK SENSOR Figure 10.2 Action Release R.1.3 UK General errors General errors are not reported on the display.

  • Page 83: Maintenance Frequency

    Maintenance frequency 11.1 Introduction A service should be carried out at least 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. 11.2 Determining service To aid servicing, the ThermoControl has a service interval which defines the interval...
  • Page 84 Maintenance frequency Instruction Manual BFC...

  • Page 85: Maintenance

    Maintenance 12.1 Introduction At each service, the appliance undergoes maintenance both on the water side and on the gas side. The maintenance should be carried out in the following order. 12.2 Preparation for To test whether all components are still working properly, you should complete maintenance the following steps: 1.
  • Page 86 Maintenance INTERNAL CHECK Figure 12.3 Internal check 7. Activate the “ON mode” by going through the following steps: MENU »OFF ^ ON È WEEK PROGRAM Figure 12.4 Main menu 8. If there is no heat demand, increase T »START OPERATION ^ CHANGE SETPOINT 9.

  • Page 87: Water-Side Maintenance

    Use a new rubber gasket for this. Cleaning the burner. Cleaning the orifice. Finalising maintenance. A.O. Smith recommends the use of Borcoil, as the composition of this material is known to us. Borcoil can be ordered from A.O. Smith. Water-side maintenance Figure 12.6.

  • Page 88: Cleaning The Orifice

    Maintenance 12.4.3 Cleaning the orifice 1. Detach the orifice. 2. Remove all contamination present in the orifice. 3. Fit the orifice. 12.4.4 Cleaning heat exchanger 1. Detach the burner. 2. Clean the combustion chamber of the heat exchanger using a vacuum 3.

  • Page 89: Warranty (Certificate)

    If within one year of the original installation date of a water heater supplied by A.O. Smith, following verification, and at the sole option of A.O. Smith, a part or component, (with exclusion of the tank) proves to be defective or does not function correctly due to manufacturing and/or material defects, A.O.

  • Page 90: Scope Of The Warranty

    A.O. Smith warranty expressly set out in this Certificate. A.O. Smith is not liable for damage to persons or property caused by (parts or components, or the glass-lined steel tank of) a (replacement) water heater that it has supplied under the terms of this warranty, nor on any other grounds.

  • Page 91: A Appendices

    Appendices Introduction This appendix contains: • • Release R.1.3 UK Electrical diagram BFC. Week program card.

  • Page 92: Electrical Diagram Bfc

    Appendices Electrical diagram = brown = brown & = blue = yellow/green = black = white (flat ca- = grey/beige TERMINAL STRIP CONNECTIONS: Earth Neutral Phase input of controller Phase input of isolating transformer (primary side) Phase output of isolating transformer (secondary side) Phase input of program-controlled pump Phase input of continuous pump COMPONENTS:...

  • Page 95: Index

    Index Alarm OUT connection - - - - - - - - - - - - - 33 ambient temperature - - - - - - - - - - - - - - 18 appliance display selection - - - - - - - - - - - - - - 66 displaying history - - - - - - - - - - - - - - 66 displaying specifications - - - - - - - - - - 62 functional description - - - - - - - - - - - - 13...
  • Page 96 Index maintenance anode - - - - - - - - - - - - - - - - - - - 87 burner - - - - - - - - - - - - - - - - - - - 87 carrying out - - - - - - - - - - - - - - - - - 85 condensation discharge - - - - - - - - - - - 87 descaling - - - - - - - - - - - - - - - - - - 87...

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