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- A.O. Smith
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- Cyclone BFC - 30
- Installation And Service Manual
A.O. Smith Cyclone BFC - 30 Installation And Service Manual
XTRA HIGH EFFICIENCY
XTRA HIGH EFFICIENCY
28
30
50
60
28
30
50
60
WATER PRODUCTS
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 Manual
Installation
User and
Service Manual
Installation
User and
Service Manual
Summary of Cyclone BFC - 30
Page 1
Xtra high efficiency xtra high efficiency 28 30 50 60 28 30 50 60 water products 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 manual installation u...
Page 2: Your Installer
Www.Aosmithinternational.Com your installer.
Page 3
Instruction manual bfc 3 gis read this manual carefully warning read this manual carefully before starting up the water heater. Failure to read this manual and to follow the instructions in this manual may lead to accidents, personal injury, and damage to the appliance. Copyright © 2008 a.O. Smith w...
Page 4
4 instruction manual bfc gis.
Page 5: Table of Contents
Instruction manual bfc 5 table of contents 1 introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.1 about the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 1.2 what to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9 1.3 regulations - - -...
Page 6
Table of contents 6 instruction manual bfc 9 starting and running - - - - - - - - - - - - - - - - - - - - - - 55 9.1 introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 9.2 starting and running- - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 9.3 the appliance's ...
Page 7
Instruction manual bfc 7 16.2 tank warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89 16.3 conditions for installation and use - - - - - - - - - - - - - - - - - - - - 89 16.4 exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 16.5 scope of the warranty...
Page 8
Table of contents 8 instruction manual bfc.
Page 9: Introduction
Instruction manual bfc 9 gis 1 introduction 1.1 about the appliance this manual describes how to install, service and use the bfc appliance. The bfc appliance is a condensing water heater with a fan in the air intake. The bfc can be installed as either an open or room-sealed appliance. A concentric ...
Page 10
Introduction 10 instruction manual bfc 1 gis • regulations imposed by fire brigade, power companies and municipality. Furthermore, the installation must comply with the manufacturer's instructions. Note later amendments and/or additions to all regulations, requirements and guidelines published on or...
Page 11
Instruction manual bfc 11 gis 1.6 forms of notation the following 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 lead to personal injury and serious damag...
Page 12
Introduction 12 instruction manual bfc 1 gis 1.7 overview of this document the table provides an overview of the contents of this document. Contents of this document chapter target groups description working principle of the appliance this chapter describes how the appliance functions. Installation ...
Page 13: Working Principle of
Instruction manual bfc 13 gis 2 working principle of the appliance 2.1 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 ap...
Page 14
Working principle of the appliance 14 instruction manual bfc 2 gis in this appliance the cold water enters the bottom of the tank via the cold water inlet (14). Once heated by the combustion chamber (8) and heat exchanger (11), the hot tapwater leaves the tank through the hot water outlet (2). Once ...
Page 15
Instruction manual bfc 15 gis 2.4.2 water temperature protection the electronic controller uses temperatures sensors t1 (7) and t2 (13) to monitor three temperatures that are important for safety. The table explains the functioning of the temperature sensors. Temperature protection 2.4.3 gas valve t...
Page 16
Working principle of the appliance 16 instruction manual bfc 2 gis 2.4.6 flame probe to ensure that no gas can flow when there is no combustion, the water heater is fitted with a flame probe (21). The electronic controller uses this probe to detect the presence of a flame, by means of ionisation det...
Page 17: Installation
Instruction manual bfc 17 is 3 installation warning installation work should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. The appliance may only be installed in a ro...
Page 18
Installation 18 instruction manual bfc 3 is 3.3.1 air humidity and ambient temperature the boiler room must be frost-free, or be protected against frost. The table shows the environmental conditions that must be adhered to for correct functioning of the electronics present in the appliance to be gua...
Page 19
Instruction manual bfc 19 is if the available clearance is less than 100 cm, 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 ...
Page 20
Installation 20 instruction manual bfc 3 is 3.4 technical specifica- 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 accessori...
Page 21
Instruction manual bfc 21 is dimensions (all sizes in mm, unless otherwise stated) 3.4.2 general and electrical specifications general and electrical specifications dimen sion description bfc 28 bfc 30 bfc 50 bfc 60 a total height 1390 1910 1910 1910 d diameter of the appliance 705 705 705 705 g flu...
Page 22
Installation 22 instruction manual bfc 3 is 3.4.3 gas data gas data description ii 2h3+ unit bfc 28 bfc 30 bfc 50 bfc 60 gas category 2h: g20 - 20 mbar injector orifice diameter mm 4.90 5.10 7.00 7.10 (1) = blank plate (2) = burner pressure regulator 1 or 2 2 2 2 2 nominal load (gross calorific valu...
Page 23
Instruction manual bfc 23 is 3.5 installation diagram installation diagram legend only applicable numbers are mentioned. 1. Pressure reducing valve (mandatory) 3. T&p valve (mandatory) 4. Stop valve (recommended in pipe c and mandatory in pipe a) 5. Non-return valve (mandatory) 6. Circulation pump (...
Page 24
Installation 24 instruction manual bfc 3 is 3.6 water connections, unvented warning the installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "regulations") . 3.6.1 cold water side see (a) in the installation diagram (3.5 "in...
Page 25
Instruction manual bfc 25 is 3.7 water connections, vented warning the installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "regulations") . 3.7.1 cold water side see (a) in the installation diagram (3.5 "installation diagra...
Page 26
Installation 26 instruction manual bfc 3 is 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") . Attention make sure that the diameter and length of the gas supply pipe are lar...
Page 27
Instruction manual bfc 27 is types of appliances imd-0468 r0 c43 c13 c53 b23 c33.
Page 28
Installation 28 instruction manual bfc 3 is explanation of type of appliance note make sure that the chimney discharges into an area where this is permitted for this category of appliance. 3.9.3 concentric connections the table shows the requirements for concentric systems. Warning install flue gas ...
Page 29
Instruction manual bfc 29 is appliance with concentric flue gas discharge material according to the table, the maximum length allowed is 40 metres, and there may be up to seven 90 degree bends. Both requirements are fulfilled. Specifications attention for type c13 and c33 installations,a.O. Smith pr...
Page 30
Installation 30 instruction manual bfc 3 is concentric wall flue terminal specifications c13 concentric roof flue terminal specifications c33 specification description wall flue terminal set: • 1x wall flue terminal (incl. Wall flange & clamping ring) • 1x pipe 500mm • 1x bend 90° art. No. Bfc 28 bf...
Page 31
Instruction manual bfc 31 is 3.9.4 parallel connections the table states the maximum pipe lengths for parallel systems. The maximum pipe length depends on the chosen diameter. Warning install flue component pipe runs with a run-off of 5 mm per metre. Flue gas outlet requirements for parallel systems...
Page 32
Installation 32 instruction manual bfc 3 is appliance with parallel flue gas discharge material the longest pipe must be used to check the maximum length. In this case, the chimney pipe is the longest. This is 25 metres. This 25 metres is the sum of pipe sections 1, 2, 3, 4 and 5. The length of the ...
Page 33
Instruction manual bfc 33 is optionally, it is possible to connect an isolating transformer, a continuous pump, a program-controlled pump, an extra on mode switch and an extra alarm signal to the appliance. For these options, see: • isolating transformer ; • connecting continuous pump ; • connecting...
Page 34
Installation 34 instruction manual bfc 3 is in preparation, you must first remove the two plastic covers and the protective cap of the electrical section. 1. Undo the screws of the plastic covers. 2. Carefully remove the covers from the appliance. The electrical section is now visible. 3. Loosen the...
Page 35
Instruction manual bfc 35 is 4. If you have no more connections to make: - fit the cap on the electrical terminal block. - fit the plastic covers onto the appliance. 5. Connect the power cable to the isolator. 3.10.5 connecting continuous pump 1. Connect phase (l), neutral (n) and earth ( ) to termi...
Page 36
Installation 36 instruction manual bfc 3 is 3.11 checking the supply pressure and burner pressure note before starting the appliance and/or checking the supply pressure and burner pressure, you must fill (5 "filling") the appliance. Attention before starting up for the first time or after conversion...
Page 37
Instruction manual bfc 37 is 3.11.2 procedure to check pressures 1. There are two test nipples on the gas control: - a supply pressure nipple (1) - a burner pressure nipple (2) sealing screws are located inside the test nipples. Loosen both sealing screws by a few turns. Do not completely loosen the...
Page 38
Installation 38 instruction manual bfc 3 is 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 read the burner pressure at nipple (2) (3.4.3 "gas data...
Page 39: Conversion to A
Instruction manual bfc 39 is 4 conversion to a different gas category attention the conversion may only by carried out by an authorised installation engineer. If the appliance must operate on a family of gases (lp gas or natural gas) or other gas category than that for which the appliance has been s...
Page 40
Conversion to a different gas category 40 instruction manual bfc 4 is 1. Isolate the water heater from the power supply (10.3 "electrically isolating the appliance") . 2. Shut off the gas supply. 3. Undo the screws of the plastic covers. 4. Carefully remove the covers from the top of the appliance. ...
Page 41
Instruction manual bfc 41 is 10. Check whether there is a burner pressure regulator (7) attached to the top of the gas control, or simply a blank plate (8). Note in the event of the supply pressure for a gas category being the same as the burner pressure (3.4.3 "gas data") , the gas control must be ...
Page 42
Conversion to a different gas category 42 instruction manual bfc 4 is.
Page 43: Filling
Instruction manual bfc 43 gis 5 filling installation diagram legend only applicable numbers are mentioned. 1. Pressure reducing valve (mandatory) 3. T&p valve (mandatory) 4. Stop valve (recommended in pipe c and mandatory in pipe a) 5. Non-return valve (mandatory) 6. Circulation pump (optional) 9. D...
Page 44
Filling 44 instruction manual bfc 5 gis 5.1 filling the appliance 5.1.1 filling unvented installations 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). 2. Close the drain valve (9). 3. Open...
Page 45: Draining
Instruction manual bfc 45 gis 6 draining installation diagram legend only applicable numbers are mentioned. 1. Pressure reducing valve (mandatory) 3. T&p valve (mandatory) 4. Stop valve (recommended in pipe c and mandatory in pipe a) 5. Non-return valve (mandatory) 6. Circulation pump (optional) 9. ...
Page 46
Draining 46 instruction manual bfc 6 gis 6.1 draining unvented installations 1. Activate the menu with . 2. Position the cursor in front of off. 3. Confirm off with . 4. Wait until the fan has stopped. The symbol is then dimmed. Attention failure to wait until the fan stops purging can cause damage ...
Page 47
Instruction manual bfc 47 gis 6. Isolate the water heater from the power supply by putting the isolator between the 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 stop valve (4) between the water t...
Page 48
Draining 48 instruction manual bfc 6 gis.
Page 49: The Control Panel
Instruction manual bfc 49 gis 7 the control panel 7.1 introduction topics covered in this chapter: • controls ; • meaning of icons ; • electronic controller on/off switch ; • navigation buttons ; • pc connection . 7.2 controls the figure shows the electronic controller. The control panel is complete...
Page 50
The control panel 50 instruction manual bfc 7 gis • buttons for up , and down ; • enter: ; • reset button: . The ^ arrows and È indicate that you can scroll up and/or down. Use the buttons and to scroll. The cursor » points to the option to be activated. In the display as shown in the figure, you ca...
Page 51: Status of The
Instruction manual bfc 51 gis 8 status of the appliance 8.1 introduction topics covered in this chapter: • operating modes ; • error conditions ; • service condition . 8.2 operating modes when running, the appliance has four basic operating modes, namely: • off • on • extra • prog 8.2.1 off in this ...
Page 52
Status of the appliance 52 instruction manual bfc 8 gis 8.2.4 prog in this mode a preset week program is active, and the appliance responds continually to demand within the time periods set in the week program. There are two distinct situations possible in this mode: 1. The current time falls within...
Page 53
Instruction manual bfc 53 gis 8.4 service condition the figure shows the message service required .Should this message appear, then the appliance is in need of a service and maintenance inspection. In that case, contact your service and maintenance engineer. Note the message service requiredis based...
Page 54
Status of the appliance 54 instruction manual bfc 8 gis.
Page 55: Starting and Running
Instruction manual bfc 55 gis 9 starting and running 9.1 introduction topics covered in this chapter, in sequence: • starting and running . • the appliance's heating cycle . 9.2 starting and running start the appliance as follows: 1. Fill the appliance (5 "filling") . 2. Open (3.5 "installation diag...
Page 56
Starting and running 56 instruction manual bfc 9 gis once the appliance starts, it will run through the following steps: 1. The water temperature drops below the set temperature of (for example) 65°c. The electronic controller detects a demand and starts the heating cycle. - the icon is activated. -...
Page 57: Shutting Down
Instruction manual bfc 57 gis 10 shutting down 10.1 introduction this chapter describes: • shut the appliance down for a brief period ("off mode") ; • electrically isolating the appliance ; • shutting the appliance down for a long period . 10.2 shut the appliance down for a brief period ("off mode")...
Page 58
Shutting down 58 instruction manual bfc 10 gis.
Page 59: Main Menu
Instruction manual bfc 59 gis 11 main menu 11.1 introduction the menu is reached by pressing the button on the electronic controller. The main menu comprises: • off select this option if you wish to turn off (10 "shutting down") the appliance for a brief period, but do not wish to drain it. In this ...
Page 60
Main menu 60 instruction manual bfc 11 gis • 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 the heating cycle. To prevent excessively frequent switching on and ...
Page 61
Instruction manual bfc 61 gis the display shows the menu for the week program, see the figure below. With the default setting, the program switches on and off every day at 00:00 and 23:59 hours respectively, the water temperature is 65°c and the pump is switched on (p). Example as an example, we wil...
Page 62
Main menu 62 instruction manual bfc 11 gis 11.7.4 week program: setting the program- controlled pump 1. If required, a pump can be controlled during the period. Use and to set pump on . The pump ensures a regular circulation of hot water in the hot water pipes. You can skip this step if you there is...
Page 64
Main menu 64 instruction manual bfc 11 gis if the water temperature becomes too low during the extra period (11.11 "programming an extra period") , the appliance will run through the heating cycle (9.3 "the appliance's heating cycle") and fall back into the extra period. The same settings can be mad...
Page 65
Instruction manual bfc 65 gis 11.12 settings using the settings option, you can adjust certain settings and read certain appliance data: • adjustable settings - language of the menu. - current day of week and time. • displayable appliance specifications, this category is only relevant to the install...
Page 66
Main menu 66 instruction manual bfc 11 gis confirm the minute setting with the time has been set. Note the appliance takes no account of daylight saving. 11.12.3 displaying appliance specifications note this category is solely intended for the installation engineer and/or service and maintenance eng...
Page 67: Service Program
Instruction manual bfc 67 is 12 service program 12.1 introduction the service program is used by the installation engineer or service and maintenance engineer for: • setting the hysteresis ; • displaying the error history ; • displaying the appliance history ; • display the selected appliance ; • sw...
Page 68
Service program 68 instruction manual bfc 12 is 12.4 displaying the appliance history the appliance history submenu is used to display the burning hours, the number of ignitions, the number of flame errors and the number of ignition errors. Call up the menu for displaying the appliance history as fo...
Page 69: Troubleshooting
Instruction manual bfc 69 gis 13 troubleshooting 13.1 introduction a distinction is made between: • general errors general errors are not reported on the display. General errors are: - gas smell - display does not light up - insufficient or no hot water. - water leakage - explosive ignition. The man...
Page 70
Is instruction manual bfc 70 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 a...
Page 71
Is instruction manual bfc 71 water leakage leakage from a water connection (threaded) tighten the threaded connection if the leak persists, consult your installation engineer condensate leakage check that the condensation water discharge is working properly. Rectify if necessary leakage from another...
Page 72
Is instruction manual bfc 72 13.3 troubleshooting table for displayed errors displayed errors code + description cause solution remark s01 (blocking error) open circuit from temperature sensor t2 at bottom of the tank sensor is not (correctly) connected connect the sensor lead to jp3 see the bfc ele...
Page 73
Is instruction manual bfc 73 s12 (blocking error) short circuit in sensor 1 of temperature sensor t 1 at the top of the tank (1) short circuit in sensor circuit replace sensor t 1 to replace the necessary parts, you must contact your installation engineer s13 (blocking error) short circuit in sensor...
Page 74
Is instruction manual bfc 74 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 rotor is defective. 3. Reset appliance controller see the bfc electrical diagram (17 "appendices") to have the wiring rep...
Page 75
Is instruction manual bfc 75 air pressure switch fails to close during pre- purge. Air pressure switch leads 1. Check the wiring between the air pressure switch and the controller. Rectify any defect: - if any wires are damaged, replace the wiring harness - properly connect loose or detached hoses 2...
Page 76
Is instruction manual bfc 76 f03 (lock out error) the pressure switch fails to work correctly damaged wiring/open circuit 1. Check the wiring between the pressure switch and the controller 2. If necessary, replace the wiring if the error cannot be resolved or is persistent, contact your installation...
Page 77
Is instruction manual bfc 77 f04 (lock out error) three unsuccessful ignition attempts. No gas 1. Open the main gas valve and/or the manual gas valve supplying the water heater 2. Check the supply pressure to the gas control 3. If necessary, repair the gas supply to repair the gas supply, contact yo...
Page 78
Is instruction manual bfc 78 f06 (lock out error) short circuit between flame probe and earth damaged cable in contact with metal surface. Check the wiring of the flame probe. If necessary, replace the wiring. If the error persists, contact your installation engineer. To replace the necessary parts,...
Page 79
Is instruction manual bfc 79 f10 (lock out error) restriction on the number of ignition attempts based on pressure switch state changes. Pressure switch not closing 1. Check the running speed of the fan (12.5 "display the selected appliance") 2. Check that the hoses on the pressure switch and the ai...
Page 80
Is instruction manual bfc 80 c02 (lock out error) error message from the appliance controller. Incorrect reference voltage from the ad converter. 1. Reset electronic controller. 2. Check that the frequency of the power supply is compliant (3.4.2 "general and electrical specifications") . If this is ...
Page 81
Is instruction manual bfc 81 e01 (blocking error) the temperature protection at the top of the tank has been activated. The temperature of the water at the top of the tank is > 85 o c. None. This is a temporary message that may appear from time to time, but will disappear automatically. E03 (lock-ou...
Page 82
Is instruction manual bfc 82.
Page 83: Maintenance
Instruction manual bfc 83 is 14 maintenance frequency 14.1 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 temper...
Page 84
Maintenance frequency 84 instruction manual bfc 14 is.
Page 85: Performing
Instruction manual bfc 85 s 15 performing maintenance 15.1 introduction attention maintenance may only be performed by a qualified service and maintenance engineer. At each service, the appliance undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in th...
Page 86
Performing maintenance 86 instruction manual bfc 15 s 6. Switch the electronic controller on by setting the on/off switch to position i. The display will now show internal check for about 10 seconds, and will then go to the main menu. 7. Activate "on mode" by going through the following steps: - pre...
Page 87
Instruction manual bfc 87 s 15. Test the operation of the overflow valve of the protected cold supply setup. The water should spurt out. 16. Test the overflow operation of the t&p valve. The water should spurt out. 17. Check the drain pipes from the discharge points of all valves and remove any lime...
Page 88
Performing maintenance 88 instruction manual bfc 15 s 4. Inspect the tank and remove the loose scale deposits and contamination. 5. If the scale cannot be removed by hand, then the appliance will need to be descaled using a descaling agent. Contact the supplier for advice on the preferred descaling ...
Page 89: Warranty (Certificate)
Instruction manual bfc 89 gis 16 warranty (certificate) to register your warranty, you should complete and return the enclosed warranty card after which a warranty certificate will be sent to you. This certificate gives the owner of a appliance supplied by a.O. Smith water products company b.V. Of v...
Page 90
Warranty (certificate) 90 instruction manual bfc 16 gis i. The appliance is at all times fitted with cathodic protection. If sacrificial anodes are used for this, these must be replaced and renewed when, and as soon as, they are 60% or more consumed. When electric anodes are used, it is important to...
Page 91: Appendices
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
Instruction manual bfc 93 is terminal block connections: earth n neutral l 1 phase input of controller l 2 phase input of isolating transformer (primary side) l 3 phase output of isolating transformer (secondary side) l 4 phase input of program-controlled pump l 5 phase input of continuous pump comp...
Page 94
Appendices 94 instruction manual bfc 17 is.
Page 95
Instruction manual bfc 95 17.3 week program card you can cut the week program card out and keep it near the appliance. Example period day time tset pump 1. On ....°c on / off off 2. On ....°c on / off off 3. On ....°c on / off off 4. On ....°c on / off off 5. On ....°c on / off off 6. On ....°c on /...
Page 96
Instruction manual bfc 96.
Page 97: Index
Instruction manual bfc 97 index a ambient temperature 18 appliance displaying history 68 displaying selection 68 displaying specifications 66 general working principle 13 heating cycle 14 protection 14 types 9, 17 b burner pressure 36 c claims 90 connect 24, 25 air supply 26 alarm out 35 circulation...
Page 98
0306 059 4.1 uk index instruction manual bfc mode error 52 extra 51 heat demand 55 ignition 55 off 51 on 51 post-purge 55 pre-glow 55 pre-purge 55 pressure switch 55 prog 52 running 55 service required 53 n navigation buttons 49 o off 51 on 51 on mode 59 on/off switch 49 operating modes extra 51 gen...