- DL manuals
- A.O. Smith
- Water Heater
- cyclone BFC - 80
- Installation And Service Manual
A.O. Smith cyclone BFC - 80 Installation And Service Manual
XTRA HIGH EFFICIENCY
XTRA HIGH EFFICIENCY
80
100
80
100
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 - 80
Page 1
Xtra high efficiency xtra high efficiency 80 100 80 100 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 se...
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 - - - - - - - - - - - - - - - - - - - - - - 53 9.1 introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 9.2 starting and running- - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 9.3 the appliance's ...
Page 7
Instruction manual bfc 7 16.3 conditions for installation and use - - - - - - - - - - - - - - - - - - - - 87 16.4 exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 16.5 scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - 88 16.6 claims - - - - - - - ...
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 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 prior to the moment of installing, will apply to the installation. 1.4 t...
Page 11
Instruction manual bfc 11 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 this chapter de...
Page 12
Introduction 12 instruction manual bfc 1 gis.
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 the appliance is equipped with a gas/air premix burner (17). The air is drawn in through the fan (18). The gas is supplied via the gas control (16) on the intake side of the fan. The gas/air mixture is then blown into the burner. The...
Page 15
Instruction manual bfc 15 gis • the pressure switch ; • the flame probe . 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 senso...
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 working clearances 3.4 technical specifications 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 accesso...
Page 20
Installation 20 instruction manual bfc 3 is 3.4.1 dimensions of the appliance plan and elevation of appliance (legend: see the table) 45º 18º 45º 3 5 4 f e 2 6 11º hy hx c ny d 2 5 p m 6 1 4 r s n a g 7 k w h 3 imd-0220 r4.
Page 21
Instruction manual bfc 21 is dimensions (all measurements in mm unless otherwise indicated) 3.4.2 general and electrical specifications general and electrical specifications dimen sion description bfc 80 bfc 100 a total height 2060 2060 c position on pallet 530 530 d appliance diameter 850 850 e dep...
Page 22
Installation 22 instruction manual bfc 3 is 3.4.3 gas data gas data description ii 2h3p unit bfc 80 bfc 100 natural gas gas category g20-20 mbar orifice diameter mm 6.30 6.80 nominal load (gross calorific value) kw 86.6 105.5 nominal output kw 81.9 99.8 supply pressure mbar 20 20 burner pressure mba...
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, vented 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 "inst...
Page 25
Instruction manual bfc 25 is 3.7 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") . 3.7.1 cold water side see (a) in the installation diagram (3.5 "installation diag...
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") . Caution make sure that the diameter and length of the gas supply pipe are large...
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 15 metres, and there may be up to three 90° bends. Both requirements are fulfilled. Specifications caution for type c13 and c33 installations,a.O. Smith prescribes...
Page 30
Installation 30 instruction manual bfc 3 is concentric wall flue terminal specifications c13 concentric roof flue terminal specifications c33 subject description wall flue terminal set: • 1x wall flue terminal (incl. Wall flange & clamping ring) • 1x pipe 500mm • 1x bend 90° item no. 0302 326 1 cons...
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. Table of pipe lengths you must use the longest pi...
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 35 metres. This 35 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 a program-controlled pump ; • ...
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 a program-controlled pump 1. Connect phase (l), neutral (n) and earth ( ...
Page 36
Installation 36 instruction manual bfc 3 is gas control 3.11.1 preparation to check the supply pressure and burner pressure, proceed as follows: 1. Isolate (10.3 "electrically isolating the appliance") the water heater from the power supply. 2. Undo the screws of the plastic covers. 3. Carefully rem...
Page 37
Instruction manual bfc 37 is the display will now show internal check for about 10 seconds and go to the main menu. 7. Activate the "on mode" by going through the following steps: - press the blue arrow once ( ) to position the cursor in front of on and press . The display shown here will appear. - ...
Page 38
Installation 38 instruction manual bfc 3 is 3.11.3 adjusting the pressure 1. Remove the cap (4) from the burner pressure regulator (3). 2. Correct the burner pressure by turning the adjusting screw (5), depending on the correction required: - adjustment screw anticlockwise: burner pressure decreases...
Page 39: Conversion to A
Instruction manual bfc 39 is 4 conversion to a different gas category caution 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 set...
Page 40
Conversion to a different gas category 40 instruction manual bfc 4 is 5. Detach the 3-part gas coupling (2) adjacent to the burner. 6. Select and fit the correct orifice from the conversion kit, based on the gas table (3.4.3 "gas data") . The injector diameter is stamped into each injector (6). 7. R...
Page 41: Filling
Instruction manual bfc 41 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 42
Filling 42 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 43: Draining
Instruction manual bfc 43 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 44
Draining 44 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. Caution failure to wait until the fan stops purging can cause damage to...
Page 45
Instruction manual bfc 45 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 46
Draining 46 instruction manual bfc 6 gis.
Page 47: The Control Panel
Instruction manual bfc 47 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 thermocontrol (electronic controller).The figure shows the electronic...
Page 48
The control panel 48 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 49: Status of The
Instruction manual bfc 49 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 50
Status of the appliance 50 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 51
Instruction manual bfc 51 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 52
Status of the appliance 52 instruction manual bfc 8 gis.
Page 53: Starting and Running
Instruction manual bfc 53 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 54
Starting and running 54 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 55: Shutting Down
Instruction manual bfc 55 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 56
Shutting down 56 instruction manual bfc 10 gis.
Page 57: Main Menu
Instruction manual bfc 57 gis 11 main menu 11.1 notational convention for menu-related instructions the menu ( ) of the electronic controller is divided into submenus. For example, settings is one of the functions reached from the main menu. The settings menu is divided into submenus in turn. For ex...
Page 58
Main menu 58 instruction manual bfc 11 gis the appliance's default week program switches the appliance on every day at 00:00 and off at 23:59. The default water temperature setting is 65°c. If you want, you can change every setting in the appliance's standard week program. If the water temperature b...
Page 59
Instruction manual bfc 59 gis confirm with . The cursor moves to the minute digits, which flash. Note because the switch-off time can never be earlier than the switch-on time, the switch-off time setting is automatically adjusted with the switch-on time. 4. Use and to set the minutes. In the example...
Page 60
Main menu 60 instruction manual bfc 11 gis the display shows the menu for the week program. The cursor points to the active period. 2. Scroll 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...
Page 61
Instruction manual bfc 61 gis confirm with . 5. The lines showing switch-on/off times are replaced by the text delete block?. See the figure. Confirm with . (or use to cancel) the switching period has been deleted. You will return now to the week program menu. The cursor points to the first programm...
Page 62
Main menu 62 instruction manual bfc 11 gis 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 45. Confirm with . The cursor moves to the water ...
Page 63
Instruction manual bfc 63 gis 11.11.2 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 /time confirm with . The display shows the sub-menu for...
Page 64
Main menu 64 instruction manual bfc 11 gis the relevant display appears. Regulation interval 40 _ 80Éc.
Page 65: Service Program
Instruction manual bfc 65 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 66
Service program 66 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 67: Troubleshooting
Instruction manual bfc 67 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 68
Is instruction manual bfc 68 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 69
Is instruction manual bfc 69 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 70
Is instruction manual bfc 70 13.3 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 electrical diagram (17 "appendices") damaged c...
Page 71
Is instruction manual bfc 71 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 72
Is instruction manual bfc 72 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 73
Is instruction manual bfc 73 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 74
Is instruction manual bfc 74 fan speed too low 1. Check the fan speed 2. If the fan speed is too low, check the settings 3. If the settings are correct, then replace the fan. 4. Modify the settings if incorrect 5. Reset appliance controller differential air pressure switch not closing during pre-pur...
Page 75
Is instruction manual bfc 75 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 76
Is instruction manual bfc 76 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 77
Is instruction manual bfc 77 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 78
Is instruction manual bfc 78 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 79
Is instruction manual bfc 79 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 80
Is instruction manual bfc 80 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 81: Maintenance
Instruction manual bfc 81 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 82
Maintenance frequency 82 instruction manual bfc 14 is.
Page 83: Performing
Instruction manual bfc 83 s 15 performing maintenance 15.1 introduction caution 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 the ...
Page 84
Performing maintenance 84 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 85
Instruction manual bfc 85 s 17. Check the drain pipes from the discharge points of all valves and remove any lime buildup that may be present. 18. Drain the appliance (see draining ). 15.3 water-side maintenance 15.3.1 introduction the following steps must be carried out on the water side: 1. Checki...
Page 86
Performing maintenance 86 instruction manual bfc 15 s 6. Close the cleaning opening. To avoid damage to the tank, tighten the bolts that fasten the lid with a torque no greater than 50 nm. Use suitable tools for this. 15.3.4 cleaning condensation water discharge regular cleaning of the condensation ...
Page 87: Warranty (Certificate)
Instruction manual bfc 87 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 88
Warranty (certificate) 88 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 89: Appendices
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
Instruction manual bfc 91 is terminal block connections: earth n neutral l phase input of controller l 1 phase output of isolating transformer (secondary side) l 2 phase input of isolating transformer (primary side) l 3 phase input of program-controlled pump l 4 live input of frequency controller l ...
Page 92
Appendices 92 instruction manual bfc 17 is.
Page 93
Instruction manual bfc 93 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 94
Instruction manual bfc 94.
Page 95: Index
Instruction manual bfc 95 index a ambient temperature 18 appliance displaying history 66 displaying selection 66 general working principle 13 heating cycle 14 protection 14 types 9, 17 b burner pressure 35 c claims 88 connect 24, 25 air supply 26 alarm out 35 circulation piping 24, 25 cold water sid...
Page 96
0308 454 4.2 uk index instruction manual bfc mode error 50 extra 49 heat demand 53 ignition 53 off 49 on 49 post-purge 53 pre-glow 53 pre-purge 53 pressure switch 53 prog 50 running 53 service required 51 n navigation buttons 47 o off 49 on 49 on mode 57 on/off switch 47 operating modes extra 49 gen...