A.O. Smith 28 30 50 60 User Manual

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Release R.1.3 UK

28 30 50 60

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Installation

User and

Service Manual

WATER PRODUCTS

COMPANY

A DIVISION OF A. O. SMITH CORPORATION

XTRA HIGH EFFICIENCY

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www.aosmithinternational.com

your installer

Page 3

Copyright

Trademarks

Liability

Warning

Read this manual carefully before first using 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.

Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by whatsoever means, without the prior written approval of A.O. Smith Water Products Company.

A.O. Smith Water Products Company reserves the right to modify specifications stated in this manual.

Any brand names mentioned in this manual are registered trademarks of their respective owners.

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.

Refer further to the General Conditions. These are available on request, and without charge.

Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components, the manual may nonetheless contain errors and inaccuracies.

Should you detect any errors or inaccuracies in the manual, we would be grateful to receive notification. This helps us to further improve our documentation.

More information

If you have any comments or queries concerning any aspect related to the appliance, then please do not hesitate to contact A.O. Smith Water Products Company.

A.O. Smith Postbus 70 5500 AB Veldhoven The Netherlands

Freephone: 008008 AOSMITH

008008 2 67 64 84 General: +31 40 294 25 00 Sales: +31 40 294 25 37 Help desk: +31 40 294 25 38 Fax: +31 40 294 25 39

E-mail: info@aosmith.nl Internet: www.aosmithinternational.com

In the event of problems with connecting to the gas, electricity or water supply, please contact your installation’s supplier/installer.

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4 Instruction Manual BFC

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1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.1 About the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9

1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.6 Forms of notation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 11

2 Functioning of the appliance - - - - - - - - - - - - - - - - - - 13

2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

2.2 Functional description of the appliance - - - - - - - - - - - - - - - - - - 13

2.3 The appliance’s heating cycle - - - - - - - - - - - - - - - - - - - - - - 14

2.4 Protection for the appliance - - - - - - - - - - - - - - - - - - - - - - - 14

2.4.1 Water temperature protection - - - - - - - - - - - - - - - - - 15

2.4.2 Gas control - - - - - - - - - - - - - - - - - - - - - - - - - - 15

2.4.3 Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

2.4.4 Pressure switch - - - - - - - - - - - - - - - - - - - - - - - - 15

2.4.5 Ionisation rod - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.5.1 Unvented installation - - - - - - - - - - - - - - - - - - - - - 16

2.5.2 Vented installation- - - - - - - - - - - - - - - - - - - - - - - 16

2.5.3 T&P valve - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.3 Environmental conditions- - - - - - - - - - - - - - - - - - - - - - - - - 17

3.3.1 Humidity and ambient temperature- - - - - - - - - - - - - - - 18

3.3.2 Maximum floor loading - - - - - - - - - - - - - - - - - - - - 18

3.3.3 Water composition - - - - - - - - - - - - - - - - - - - - - - 18

3.3.4 Working clearances - - - - - - - - - - - - - - - - - - - - - - 18

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 20

3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

3.6 Water connections, Unvented - - - - - - - - - - - - - - - - - - - - - - 25

3.6.1 Cold water side - - - - - - - - - - - - - - - - - - - - - - - - 25

3.6.2 Hot water side- - - - - - - - - - - - - - - - - - - - - - - - - 25

3.6.3 Circulation pipe - - - - - - - - - - - - - - - - - - - - - - - - 25

3.6.4 Condensation drainage - - - - - - - - - - - - - - - - - - - - 25

3.7 Water connections, Vented- - - - - - - - - - - - - - - - - - - - - - - - 26

3.7.1 Cold water side - - - - - - - - - - - - - - - - - - - - - - - - 26

3.7.2 Hot water side- - - - - - - - - - - - - - - - - - - - - - - - - 26

3.7.3 Circulation pipe - - - - - - - - - - - - - - - - - - - - - - - - 26

3.7.4 Condensation drainage - - - - - - - - - - - - - - - - - - - - 26

3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

3.9 Air supply and flue gas discharge- - - - - - - - - - - - - - - - - - - - - 27

3.9.1 Concentric wall flue terminal - - - - - - - - - - - - - - - - - - 28

3.9.2 Concentric roof flue terminal - - - - - - - - - - - - - - - - - - 29

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3.10 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.10.2 Preparation- - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.10.3 Mains voltage - - - - - - - - - - - - - - - - - - - - - - - - - 31

3.10.4 Isolating Transformer - - - - - - - - - - - - - - - - - - - - - - 32

3.10.5 Continuous pump- - - - - - - - - - - - - - - - - - - - - - - - 32

3.10.6 program-controlled pump - - - - - - - - - - - - - - - - - - - - 32

3.10.7 Extra ON mode switch (“Tank ON”) - - - - - - - - - - - - - - - 32

3.10.8 Connecting extra error signal (“Alarm OUT”) - - - - - - - - - - 33

3.11 Checking the supply pressure and burner pressure - - - - - - - - - - - - 33

3.12 Conversion to a different gas category - - - - - - - - - - - - - - - - - - - 35

4 Filling and draining - - - - - - - - - - - - - - - - - - - - - - - 39

4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

4.2 Filling the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

4.2.1 Filling unvented installations - - - - - - - - - - - - - - - - - - 39

4.2.2 Filling vented installations- - - - - - - - - - - - - - - - - - - - 39

4.3 Draining the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - 41

4.3.1 Draining unvented installations - - - - - - - - - - - - - - - - - 41

4.3.2 Draining vented installations - - - - - - - - - - - - - - - - - - 41

5 The control panel - - - - - - - - - - - - - - - - - - - - - - - - 43

5.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

5.2 Operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

5.3 Explanation of the icons - - - - - - - - - - - - - - - - - - - - - - - - - - 44

5.4 ON/OFF switch of ThermoControl - - - - - - - - - - - - - - - - - - - - - 44

5.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

5.6 PC connection. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

6 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 45

6.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

6.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

6.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

6.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

7 Starting up and shutting down - - - - - - - - - - - - - - - - - 49

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.2 Starting up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.3 Shutting down- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.3.1 Shut the appliance down for a brief period (“OFF mode”) - - - - 50

7.3.2 Disconnect the appliance from the mains - - - - - - - - - - - - 50

7.3.3 Shut the appliance down for a longer period - - - - - - - - - - - 50

7.4 The appliance’s heating cycle - - - - - - - - - - - - - - - - - - - - - - - 51

8 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

8.2 Notational convention for menu-related instructions - - - - - - - - - - - - 53

8.3 Switching into “ON mode” - - - - - - - - - - - - - - - - - - - - - - - - - 54

8.4 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - - 54

8.4.1 Setting the water temperature via SETPOINT MENU - - - - - - 54

8.4.2 Setting water temperature during ON mode - - - - - - - - - - - 54

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8.5 Week programme - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

8.5.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 55

8.5.2 Starting up and shutting down the week program - - - - - - - - 55

8.5.3 Changing the appliance’s standard week program - - - - - - - 55

8.5.4 Adding times to a week program - - - - - - - - - - - - - - - - 57

8.5.5 Deleting times from a week program - - - - - - - - - - - - - - 58

8.6 Extra period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

8.6.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 60

8.6.2 Programming an extra period - - - - - - - - - - - - - - - - - 60

8.7 Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 61

8.7.2 Setting menu language - - - - - - - - - - - - - - - - - - - - 61

8.7.3 Setting day and time- - - - - - - - - - - - - - - - - - - - - - 62

8.7.4 Displaying appliance specifications - - - - - - - - - - - - - - 62

9 Service program - - - - - - - - - - - - - - - - - - - - - - - - 65

9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

9.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - 65

9.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 65

9.4 Displaying the appliance history - - - - - - - - - - - - - - - - - - - - - 66

9.5 Display the selected appliance - - - - - - - - - - - - - - - - - - - - - - 66

9.6 Setting the pump on/off - - - - - - - - - - - - - - - - - - - - - - - - - 66

9.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 66

9.8 Setting the display contrast- - - - - - - - - - - - - - - - - - - - - - - - 67

9.9 Setting the backlight time- - - - - - - - - - - - - - - - - - - - - - - - - 67

9.10 Setting the display scroll speed- - - - - - - - - - - - - - - - - - - - - - 67

10 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 69

10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

10.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - 70

10.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - 72

11 Maintenance frequency - - - - - - - - - - - - - - - - - - - - 83

11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83

11.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - 83

12 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 85

12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

12.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 85

12.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 87

12.3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 87

12.3.2 Checking the anodes - - - - - - - - - - - - - - - - - - - - - 87

12.3.3 Descaling and cleaning the tank - - - - - - - - - - - - - - - - 87

12.3.4 Cleaning condensation water discharge - - - - - - - - - - - - 87

12.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 87

12.4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 87

12.4.2 Cleaning the burner - - - - - - - - - - - - - - - - - - - - - - 87

12.4.3 Cleaning the orifice - - - - - - - - - - - - - - - - - - - - - - 88

12.4.4 Cleaning heat exchanger - - - - - - - - - - - - - - - - - - - 88

12.5 Finalising maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - 88

13 Warranty (Certificate)- - - - - - - - - - - - - - - - - - - - - - 89

13.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

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13.2 Tank warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

13.3 Installation and conditions of use - - - - - - - - - - - - - - - - - - - - - 89

13.4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

13.5 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - 90

13.6 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90

13.7 Limitation of liability A.O. Smith - - - - - - - - - - - - - - - - - - - - - - 90

A Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 91

A.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91 A.2 Electrical diagram BFC - - - - - - - - - - - - - - - - - - - - - - - - - - 92

IX Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

8 Instruction Manual BFC

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About the appliance

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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 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. Installation types possible with this appliance are C13, C33, C43, C53 and C63. The information in this manual is applicable to types: BFC 28, BFC 30, BFC 50 and BFC 60.

The manner of construction and features of the appliance are in conformance with the European standard for gas-fired storage water heaters for the production of domestic hot water (ES 89). The appliances are therefore compliant with the European Directive for Gas Appliances, and have the right to bear the CE mark.

Warning

0063

Read this manual carefully before starting up the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the appliance.

1.2 What to do if you smell gas

1.3 Regulations As the (end) user, installer or service and maintenance engineer, you must

Warning

Whenever there is a smell of gas:

No naked flames! No smoking!

Avoid causing sparks! Do not use any electrical equipment or switch, i.e. no telephones, plugs or bells!

Shut off the mains gas supply!

Open windows and doors!

Warn occupants and leave the building!

After leaving the building, alert the gas distribution company or installer.

ensure that the entire installation complies, as a minimum, with the official local:

• building regulations;

• energy supplier’s directives for existing gas installations;

• directives and technical guidelines for natural gas installations;

• safety requirements for low-voltage installations;

• regulations governing the supply of drinking water;

• regulations governing ventilation in buildings;

• regulations governing the supply of air for combustion;

• regulations governing the discharge of products of combustion;

• requirements for installations that consume gas;

• regulations governing indoor waste water disposal;

• regulations imposed by fire service, power companies and municipality;

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Introduction

Furthermore, the installation must comply with the manufacturer’s instructions.

n Remark

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 Target groups The three target groups for this manual are:

• (end) users;

•installers;

• service and maintenance engineers.

Symbols on each page indicate the target groups for whom the information is intended. See Table 1.1.

Tabl e 1 .1 Target group symbols

Symbol Target group

(End) user

installer

Service and maintenance engineer

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1.5 Maintenance 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.

n Remark

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, three months after installation. Based on this check, the best maintenance frequency can be determined.

n Remark

Regular maintenance extends the service life of the appliance.

1.6 Forms of notation The following notation is used in this manual:

n Remark

Important information

cNote

Ignoring this information can lead to the appliance being damaged.

Warning

Failure to carefully read this information may lead to danger of personal injury, and serious damage to the appliance.

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Overview of this document

1.7 Overview of this document

Tab le 1. 2 Contents of document

Chapter Target groups Description

2 Functioning of the appliance

3 Installation

4 Filling and draining

Ta bl e 1. 2 provides an overview of the contents of this document.

This chapter describes how the appliance functions.

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This chapter describes the installation activity to be completed

before you actually start up the appliance.

This chapter describes how to fill and drain the appliance.

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5 The control panel

6 Status of the appliance

7 Starting up and shutting down

8 Main menu

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This chapter describes the general control of the appliance using the display.

This chapter describes the status (mode or condition) that the appliance may have, and possible actions to take.

This chapter describes how to start up the appliance, and how to shut it down for a brief or long period of time. The general heating cycle of the appliance is also described.

Describes the main menu of the display. This is the actual menu for the user, however the installer and service and maintenance engineers will also need to use this menu.

9 Service program

10 Troubleshooting

11 Maintenance frequency

12 Maintenance

13 Warranty (Certificate)

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Describes the service menu. It is mainly intended for the installer and service and maintenance engineers. End users may also refer to this chapter for additional information about the appliance.

This chapter is mainly intended for the installer and the service and maintenance engineer. It describes appliance errors. These errors are indicated on the display. A troubleshooting table of possible causes and solutions is provided. End users may also refer to this chapter for additional information about the appliance.

This chapter describes how to determine the optimum frequency at which to carry out maintenance. Both the end user and the service and maintenance engineer are responsible for regular maintenance. They need to reach clear agreement on this.

n Remark

If the appliance is not regularly maintained, the warranty will become void.

This chapter sets out the maintenance tasks to be carried out during a service.

This chapter states the warranty terms and conditions.

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Introduction

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2 Functioning of the

appliance

2.1 Introduction Topics covered in this chapter:

• Functional description of the appliance;

• The appliance’s heating cycle;

• Protection for the appliance;

• Safety of the installation.

Introduction

2.2 Functional 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

g temperature sensor T

h combustion chamber

i anode

j tank

k heat exchanger

l inspection and cleaning

opening

m temperature sensor T

n cold water inlet

o drain valve

p gas control

q burner

r fan

s air supply hose

t glow igniter

u ionisation rod

v chimney pipe

w siphon

x PU insulation layer

Figure 2.1 shows a cut-away view of the appliance.

IMD-0070

Figure 2.1 Cut-away view of the appliance

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Functioning of the appliance

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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. As hot water is drawn from the appliance, cold water is immediately added.

The air required for combustion is forcibly delivered to the burner q by the fan r. The gas is fed to the burner q via the gas control p. Thanks to the modulated supply of gas and air, the optimum gas/air mixture is always achieved. The special construction of the burner causes the mixture to form a vortex (the cyclone effect), before it becomes ignited. Because of this vorticity, ignition at the glow igniter t is improved, and the combustion efficiency is also optimised. Through the special design of the heat exchanger k, the flue gases are first led downwards via the combustion chamber, then upwards again via the heat exchanger, then once more downwards beside the water in the tank. In this process, the flue gases gradually become cooler. Because the cooled flue gases flow alongside the cold water below in the tank, they start to condense. This condensation causes latent heat energy to be released, which is transferred to the cooler water, and thereby increases the performance of the unit. The water of condensation yielded by this process is discharged via the siphon w.

The PU insulation layer x prevents heat loss. The inside of the tank is enamelled to protect against corrosion. The magnesium anodes i provide extra protection against corrosion.

For use during maintenance, the appliance has a inspection and cleaning opening l.

2.3 The appliance’s heating cycle

2.4 Protection for the appliance

The entire appliance is controlled (and monitored) by theThermoControl d. The temperature sensor T1 g (in the top of the tank j) and the temperature sensor T2 m (in the bottom of the tank) measure the water temperature. These temperatures are sent to the ThermoControl. Based on these two observations, the ThermoControl calculates a net water temperature: T lies between the temperatures measured at the top and bottom of the tank. As soon as T registers a ‘heat demand’. The gas control p is opened, and the gas is mixed with air. This mixture is ignited by the glow igniter t and the water becomes heated. As soon as T ThermoControl stops the heating cycle.

Both when registering and ending the heat demand, the ThermoControl assumes a certain margin. We refer to this margin as the hysteresis (see paragraph ’9.2 Setting the hysteresis’).

The ThermoControl monitors the water temperature and ensures safe combustion. This is achieved by:

• the Water temperature protection;

• the Gas control;

• the Fan;

• the Pressure switch;

• the Ionisation rod.

falls below the set water temperature (T

net

rises above T

net

, the heat demand ends, and the

set

. The value of T

net

), the ThermoControl

set

net

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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.

Ta bl e 2 .1 explains the functioning of the temperature sensors.

Tab le 2. 1 Temperature protection

Protection Description

Protection for the appliance

Against frost

< 5°C or T2 < 5°C)

For maximum water temperature (T

> 85°C or T2 > 85°C)

For extra safety (T

> 93°C or T2 > 93°C)

2.4.2 Gas control

2.4.3 Fan

The frost protection cuts in. The water is heated to 20°C.

The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the appliance. Should the high-limit safeguard be activated, the heating is halted. This causes the water in the tank to cool down. Once the water has cooled sufficiently (T1 < 78 °C), the ThermoControl resets the appliance.

A lockout error of the water heater controller takes place. The controller must be manually reset before the appliance can resume operation (see paragraph

’6.3 Error conditions’). The reset may only be performed once T

The ThermoControl opens the gas control so that gas can be supplied to the burner. As a safety measure, the gas control has two valves. Both valves shut off the gas supply.

Smooth ignition is achieved by opening the gas control with a delay (‘softlite’).

The fan provides an optimum air supply when there is a heat demand. A safety aspect is that the fan ensures that any gases present in the combustion chamber get removed, both before and after combustion. We refer to this as pre- and post-purge.

The fan speed is continuously monitored by the ThermoControl. The ThermoControl takes control if the speed of rotation varies too much from the value set.

< 78°C.

2.4.4 Pressure switch

The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre-purge and normal running of the appliance. The standard position of the pressure switch is open. When sufficient pressure differential is reached, the pressure switch closes. However, in the event of a fault, the pressure switch will be tripped open, and the heating cycle will be interrupted.

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Functioning of the appliance

gis

Table 2.2 shows the trip point per appliance.

Tabl e 2 .2 Pressure switch trip points

AppliancePressure differential [Pa]

Closing Opening

2.4.5 Ionisation rod

2.5 Safety of the installation

2.5.1 Unvented installation

BFC 28 >

BFC 30 >

BFC 50 >

BFC 60 >

635 < 605

855 < 825

885 < 855

1085 < 1055

n Remark

The trip point of the pressure switch is not adjustable.

To ensure that no gas will flow when there is no combustion, an ionisation rod has been fitted. The ThermoControl uses this rod for flame detection, by means of ionisation detection. The ThermoControl cuts in, the instant it detects that there is a gas flow but no flame.

In addition to the appliance’s standard safety monitoring, the appliance must also be protected by an expansion vessel, pressure overflow valve, non-return valve and a T&P valve.

Use of an expansion vessel, a pressure relief valve and/or a pressure reducing valve depends on the type of installation: unvented or vented.

With an unvented installation, a pressure relief valve and expansion vessel prevent excessive pressure in the tank. This prevents damage being caused to the enamelled coating (in the appliance) or to the tank. A non-return valve prevents excessive pressure in the water supply system. This valve also prevents water from flowing backwards from the tank into the cold water supply system. The pressure reducing valve protects the installation against an excessively high water supply pressure (> 8 bar). These components are fitted to the cold water pipe. See paragraph ’3.6.1 Cold water side’.

2.5.2 Vented installation

With a vented installation, excess pressure is taken up by the open water reservoir. The level of the water reservoir determines the maximum working pressure in the tank, which may not exceed 8 bar. The installation must also be fitted with an overflow from the hot water pipe, which discharges into the water reservoir. See paragraph ’3.6.2 Hot water side’.

2.5.3 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. If the pressure in the tank becomes excessive (>10 bar) or the water temperature is too high (>97°C), the valve will open. The hot water will immediately flow out of the tank. Because the appliance is under water supply pressure, cold water will automatically flow into the tank. The valve remains open until the unsafe situation has been averted. A connecting point for a T&P valve is standard on the appliance. See paragraph ’3.6.2 Hot water side’.

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Page 17

Introduction

3 Installation

Warning

The installation should be carried out by an approved installer 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 room which complies with the requirements stated in national and local ventilation regulations.

Refer also to paragraph ’1.3 Regulations’.

3.1 Introduction This chapter describes the installation activities to be carried out before the

appliance may be started up, namely:

• Packaging;

• Environmental conditions;

• Technical specifications;

• Water connections, Unvented;

• Water connections, Vented;

• Gas connection;

• Air supply and flue gas discharge;

• Electrical connection;

• Checking the supply pressure and burner pressure;

• Conversion to a different gas category.

n Remark

Starting up the appliance is described in chapter ’7 Starting up and shutting

down’.

3.2 Packaging To avoid damaging the appliance, remove the packaging carefully. We

recommend unpacking the appliance at or near its intended location.

cNote

The appliance may only be manoeuvred in an upright position. Take care that the appliance is not damaged after unpacking.

3.3 Environmental

conditions

The BFC appliance is a room-sealed appliance. Installation types possible with this appliance are C13, C33, C43, C53 and C63. This makes it possible to install the appliance in either a closed or an open boiler room.

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Installation

3.3.1 Humidity and ambient temperature

The boiler room must be frost-free, or be protected against frost. Table 3.1 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 ambient temperature

Humidity max. 93% RH at +25°C

Ambient temperature Functional: 0 ≤ t ≤ 60°C

3.3.2 Maximum floor loading

In connection with the appliance’s weight, take account of the maximum floor loading, see Tab le 3 .2 .

Table 3 . 2 Weight specifications related to maximum floor loading

Weight of the appliance filled with water

BFC 28 392 kg

BFC 30, BFC 50, BFC 60 593 kg

3.3.3 Water composition

The appliance is intended for heating drinking water. The drinking water must comply with the regulations governing drinking water for human consumption.

Table 3.3 shows these requirements.

Table 3 . 3 Water specifications

Water composition

Hardness (alkaline earth ions)

Conductivity > 125 µS/cm

Acidity (pH value) 7.0 < pH value < 9.5

n Remark

If the water specifications deviate from those stated in Ta bl e 3 .3 , then the tank protection cannot be guaranteed. See also chapter ’13 Warranty (Certificate)’.

3.3.4 Working clearances

For access to the appliance it is recommended that the following clearances are observed (see Figure 3.2):

• AA: around the appliance’s control column and cleaning openings: 100 cm.

• BB: around the appliance itself: 50 cm.

• Above the appliance (room to replace the anodes):

- 100 cm if using fixed anodes, or

- 50 cm if using flexible anodes.

> 1.00 mmol/l:

• German hardness >5.6° dH

• French hardness > 10.0° fH

• British hardness > 7.0° eH

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Environmental conditions

If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered from A.O. Smith, the installer / supplier.

n 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. If this is the case, then the appliance should be installed above a wastewater drain or in a suitable metal leak tray. The leak tray must have an appropriate wastewater drain and must be at least 5cm deep with a length and width at least 5cm greater than the diameter of the appliance.

Figure 3.1 Working clearances

IMD-0073

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Installation

3.4 Technical specifications

The appliance is supplied without accessories. Check the dimensions and other specifications for the accessories to be used, based on Figure 3.2 and

Table 3.6.

IMD-0073

Figure 3.2 Plan and elevation of the appliance

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Tab l e 3.4 Dimensions

Technical specifications

Dime nsion

A Total height (mm) 1370 1900 1900 1900

D Diameter of the appliance (mm) 705 705 705 705

G Diameter of air supply/flue gas discharge (mm) 80/125 100/150 100/150 100/150

K Height of the gas connection (mm) 1270 1810 1810 1810

M Height of cold water supply connection (mm) 160 160 160 160

N Height of hot water outlet connection (mm) 1405 1920 1920 1920

P Height of cleaning and inspection opening (mm) 200 200 200 200

R Height of drain valve (mm) 75 75 75 75

S Height of T&P valve (mm) 890 1415 1415 1415

W Height of condensation drainage (mm) 110 110 110 110

X Height of air supply connection (mm) 1205 1730 1730 1730

1 Cold water supply connection R 1½ (external)

2 Hot water outlet connection R 1½ (external)

3 Gas control connection Rp ¾ (internal)

4 Drain valve connection (external) ¾”

Description BFC 28 BFC 30 BFC 50 BFC 60

5 T&P valve connection (internal) ¾” NPT 1 - 11.5 NPT

6 Dimensions cleaning and inspection opening

7 Condensation drainage connection (internal) Ø 40 mm Rp 1 Rp 1 Rp 1

Tab le 3. 5 General and electrical data

DESCRIPTION Unit BFC 28 BFC 30 BFC 50 BFC 60

Capacity litres 217 368 368 368

Maximum working pressure bar 8 8 8 8

Empty weight kg 175 225 225 225

Heating time ∆T = 45

Number of anodes - 4 4 4 4

Number of bar burners/orifices - n.a. n.a. n.a. n.a.

Number of flue tubes/flue baffles - 1/? 1/? 1/? 1/?

Fan rotational speed at ignition r. p.m. 4500 4500 4500 4500

Working speed of fan rpm 4980 5400 6000 6660

Diameter of air restrictor mm 23.0 23.0 28.0 29.0

(mm)

C minutes 23 35 24 20

95 x 70

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Installation

Tabl e 3 .5 General and electrical data

DESCRIPTION Unit BFC 28 BFC 30 BFC 50 BFC 60

Electrical power consumption W 175

Supply voltage VAC 230 (-15% +10%)

Mains frequency Hz 50 (±1 Hz)

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Tab l e 3.6 Gas data

Installation diagram

Gas category dataII

Data for natural gas 2H: G20-20 mbar

Orifice diameter mm 4.90 5.10 7.00 7.10

Nominal load (upper value) kW 32.1 34.5 52.6 63.2

Nominal capacity kW 30.3 32.8 48.6 59.6

Supply pressure mbar 20 20 20 20

Burner pressure mbar 8.5 8.5 8.5 11.5

Gas consumption

Data for LP gas 3+

General

Orifice diameter mm 2.50 2.60 3.40 3.80

Restrictor diameter mm n.a. n.a. n.a. n.a.

G30-30 mbar (butane)

Nominal load (upper value) kW 30.7 32.8 50.6 59.4

Supply pressure mbar 37 37 37 37

Burner pressure

Gas consumption

(1)

(2)

(1)

Unit BFC 28 BFC 30 BFC 50 BFC 60

2H3+

m3/h 3.1 3.3 5.0 6.0

mbar 37 37 37 37

kg/h 2.2 2.4 3.7 4.3

G31-37 mbar (butane)

Nominal load (upper value) kW 29.0 30.9 50.3 59.1

Supply pressure mbar 37 37 37 37

Burner pressure

Gas consumption

(1) Based on 1013.25 mbar and 15oC. (2) If using a flat sealing plate instead of a burner pressure regulator, it is assumed that the burner pressure is equal to the supply pressure.

In practice however, the burner pressure will be lower.

3.5 Installation diagram

(2)

(1)

Figure 3.3 shows the water and gas connection diagrams for unvented and

vented installations. The following paragraphs, describing the connections in detail, make reference to these diagrams

mbar 37 37 37 37

kg/h 2.1 2.2 3.6 4.2

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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

m pressure relief valve

(mandatory)

n water cistern

o float valve

p 3-way venting valve

(recommended)

q overflow pipe

a cold water supply

b hot water outlet

c circulation pipe

d gas supply

e flue gas discharge and air

supply

UNVENTED

VENTED

E N

E R

f e

IMD-0139

efd

IMD-0138

Figure 3.3 Installation diagrams

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3.6 Water connections,

Unvented

3.6.1 Cold water side

3.6.2 Hot water side

Water connections, Unvented

See a in Figure 3.3.

1. Fit an approved stop valve i on the cold water side as required by regulations. Refer also to paragraph ’1.3 Regulations’.

2. The maximum working pressure of the appliance is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve a.

3. Fit a non-return valve e and an expansion vessel b.

4. Fit a pressure relief valve m and connect the overflow side to an open wastewater pipe.

See b in Figure 3.3.

n Remark

Insulating long hot water pipes prevents unnecessary energy loss.

1. Optional: fit a temperature gauge j to be able to check the temperature of the tap water.

2. Fit the T&P valve c.

3. Fit a stop valve i in the hot water outlet pipe, for use when servicing.

3.6.3 Circulation pipe

See c in Figure 3.3.

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort and reduces water wastage.

1. Fit a circulation pump f of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valvee behind the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves d for service purposes.

4. Connect the circulation pipe to the cold water supply pipe.

3.6.4 Condensation drainage

1. Fit a sloping wastewater pipe to the siphon k for condensation drainage and connect this to the wastewater discharge in the boiler room.

cNote

All piping behind the siphon must be condensation-resistant.

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3.7 Water connections, Vented

3.7.1 Cold water side

3.7.2 Hot water side

Installation

See a in Figure 3.3.

1. Fit an approved stop valve i on the cold water side between the water cistern n and the appliance, as required by regulations. Refer also to paragraph ’1.3 Regulations’.

See b in Figure 3.3.

n Remark

Insulating long hot water pipes prevents unnecessary energy loss.

1. Fit the T&P valve c.

2. Optional: fit a temperature gauge j to be able to check the temperature of the tap water.

3. Fit a stop valve i in the hot water outlet pipe, for use when servicing.

4. If a circulation pipe is to be fitted, then refer to paragraph 3.7.3.

3.8 Gas connection

3.7.3 Circulation pipe

See c in Figure 3.3.

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort and reduces water wastage.

1. Fit a circulation pump f of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valvee behind the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves d for service purposes.

4. Connect the circulation pipe to the cold water supply pipe.

3.7.4 Condensation drainage

See paragraph ’3.6.4 Condensation drainage’.

Warning

Gas installation may only be carried out by an authorised installer in compliance with the general regulations imposed by the gas company. Refer also to paragraph ’1.3 Regulations’.

cNote

Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the appliance.

See d in Figure 3.3.

1. Fit a gas valve h in the gas supply pipe.

2. Blow the gas pipe through before use, to be sure it is clean.

3. Close the gas valve.

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3.9 Air supply and flue gas discharge

Air supply and flue gas discharge

4. Fit the gas supply pipe to the gas control.

Warning

Check for leaks after fitting.

Warning

The installation should be carried out by an authorised installer, in compliance with the general and local regulations imposed by gas, water supply and power supply companies and the fire service. Refer also to paragraph ’1.3 Regulations’.

Depending on the approved installation types, there are several alternatives for connecting the air supply and flue gas discharge. The BFC appliances are approved for installation types C13, C33, C43, C53 and C63.

The most common installation types are:

• C13: Concentric wall flue terminal and

• C33: Concentric roof flue terminal.

This manual describes these installation types. If an explanation of other types of installation is required, please contact A.O. Smith.

cNote

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’ and ’3.9.2 Concentric roof flue terminal’.

Use of an incorrect roof or wall-mounted terminal can cause the installation to malfunction.

n Remark

Make sure that the chimney discharges into an area where this is permitted for this category of appliance.

Ta bl e 3 .7 shows the maximum length of the chimney configurations. The

following requirements must also be fulfilled:

• the maximum chimney length is 15 metres.

• The maximum permitted number of 45° or 90° bends is four.

Tabl e 3.7 Chimney configurations for concentric wall and roof termination.

Dimension

(1)

A 0-15 m 0-15 m 0-15 m 0-15 m

B 0-15 m 0-15 m 0-15 m 0-15 m

BFC 28 BFC 30 BFC 50 BFC 60

a + B max. 15 m max. 15 m max. 15 m max. 15 m

1. See ’Figure 3.4 Wall flue terminal’ and ’Figure 3.5 Roof flue terminal’.

cNote

If you make use of horizontal piping, then this must slope towards the appliance with a minimum of 5 mm per metre running length!

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3.9.1 Concentric wall flue terminal

Table 3.8 shows the wall flue terminal prescribed by A.O. Smith (installation

type C13).

IMD-0075

Figure 3.4 Wall flue terminal

Table 3 . 8 Concentric wall flue terminal specifications

Specification Description

Manufacturer Muelink & Grol

Model M2000 MDV SE

Pipe material, flue gas discharge Thick-walled aluminium with lip ring seal

Pipe material, air intake Thin-walled galvanised sheet steel

Pipe diameter Concentric

• BFC 28: Ø 80/125 mm.

• BFC 30, 50 and 60: Ø 100/150 mm.

1. 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.

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3.9.2 Concentric roof flue terminal

A.O. Smith Water Products Company prescribes the roof flue terminal (installation type C33) as specified in Ta b le 3 .9 .

Tabl e 3.9 Concentric roof flue terminal specifications

Specification Description

Manufacturer Muelink & Grol

Model M2000 DDV SEC HR

Air supply and flue gas discharge

(1)

Pipe material, flue gas discharge

Pipe material, air intake Thin-walled galvanised sheet steel

Pipe diameter Concentric

1. The model M2000 DDV SEC HR is a special version of the Mugro 3000 series. No other roof flue terminal may be used, as the 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.

Thick-walled lip ring seal

• BFC 28: 80/125 mm.

• BFC 30, 50 and 60: Ø 100/150 mm.

IMD-0004

Figure 3.5 Roof flue terminal

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3.10 Electrical connection

Installation

Warning

The installation should be carried out by an approved installer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. Refer also to paragraph ’1.3 Regulations’.

3.10.1 Introduction

Topics covered in this paragraph:

• 3.10.2 Preparation;

• 3.10.3 Mains voltage;

Optionally, it is possible to connect an isolating transformer, a continuous pump, a program-controlled pump, a “Tank ON” and an “Alarm OFF” to the appliance. For these options, see:

• 3.10.4 Isolating Transformer;

• 3.10.5 Continuous pump;

• 3.10.6 program-controlled pump;

• 3.10.7 Extra ON mode switch (“Tank ON”);

• 3.10.8 Connecting extra error signal (“Alarm OUT”).

n Remark

The optional components are not included in the rating for electrical power consumption (see tables in paragraph 3.4).

3.10.2 Preparation

cNote

The appliance is phase-sensitive. It is absolutely essential to connect the phase (L) from the mains to the phase of the appliance, and the neutral (N) of the mains to the neutral of the appliance. There should also be no potential difference present between neutral (N) and earth ( applied in the supply circuit. See ’3.10.4 Isolating Transformer’.

Figure 3.6 shows a view of the electrical connection block. Ta b le 3 .1 0 shows the

associated connections.

Table 3 . 1 0 Electrical connection block

Unu

Tank on Continuous

sed

X1X

1-4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

pump

LNNL

Regulated

pump

A). If this is the case, then an isolating transformer must be

Alarm Off Isolating transformer Mains power

primary secondary

X1X

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Electrical connection

Figure 3.6 Connection block (connections 1 through 24 explained in

Ta bl e 3 .1 0)

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.

1. Unscrew the screws of the plastic covers.

2. Carefully remove the black plastic covers from the appliance. The electrical section is now visible.

3. Undo the 2 screws 1 from the electrical section and remove the protective cap 2 from the electrical section. The connection block 3 is now visible.

IMD-0077

n Remark

Refer to ’A.2 Electrical diagram BFC’ for the connection of electrical components.

3.10.3 Mains voltage

The appliance is supplied without a power cord and main switch.

n Remark

In order to receive electrical power, the appliance has to be connected to the mains voltage by means of a permanent electrical connection. A twoterminal main switch with a contact gap of at least 3 mm must be fitted between this fixed connection and the appliance. The power cord must have cores of at least 3 x 1.0 mm2.

1. Connect phase (L), neutral (N) and earth ( 22 through 24 of the connector block as indicated in Table 3.10.

2. Fit the power cord in the pull relief.

3. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

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A) of the power cord to terminals

Page 32

Installation

4. Connect the power cord to the main switch.

Warning

Leave the appliance disconnected until you are ready to start it up.

5. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

3.10.4 Isolating Transformer

An isolating transformer should be used if there is a case of “floating neutral”.

1. Refer to fitting instructions provided with the isolating transformer

2. Connect phase (L), neutral (N) and earth ( terminals 16 through 21 of the connector block as indicated in Table 3.10.

3. Fit the cables in the pull relief.

4. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

5. Connect the power cord to the main switch.

(1)

A) of the power cables to

3.10.5 Continuous pump

The continuous pump will start up as soon as mains power is connected to the appliance.

1. Connect phase (L), neutral (N) and earth ( indicated in Ta bl e 3 .1 0 .

2. Fit the cable in the pull relief.

3. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

3.10.6 program-controlled pump

Switching on of the program-controlled pump is determined by settings of the ThermoControl.

1. Connect phase (L), neutral (N) and earth ( indicated in Ta bl e 3 .1 0 .

2. Fit the cable in the pull relief.

3. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

3.10.7 Extra ON mode switch (“Tank ON”)

Tank ON is a facility for connecting an external ON/OFF switch. In the OFF position, the programmed operating mode is active. In the ON position, the programmed operating mode is overruled, and the “ON mode” is active.

1. Connect cables (X

2. Fit the cable in the pull relief.

and X2) to terminals 5 and 6 as indicated in Ta b le 3 .1 0.

A) to terminals 7, 8 and 9 as

A to terminals 10, 11 and 12 as

1. Contact A.O. Smith for details of the correct isolating transformer.

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3.10.8 Connecting extra error signal (“Alarm OUT”)

3.11 Checking the supply pressure and burner pressure

Checking the supply pressure and burner pressure

3. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

Alarm OUT is a potential free terminal that is switched when an error is detected. 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

in Table 3.10. If required, connect earth (A) to terminal 15.

2. Fit the cable in the pull relief.

3. If you do not need to make any more connections:

- Fit the cap on the electrical connection block.

- Fit the plastic covers onto the appliance.

and X2) to terminals 13 and 14 as indicated

cNote

Before you start up the appliance and/or begin to check the supply pressure and burner pressure, you must first fill the appliance. Please refer to paragraph ’4.2 Filling the appliance’ for filling instructions.

cNote

Before starting-up for the first time, and following conversion, you must always check the supply pressure and burner pressure. If necessary, adjust these to be certain of optimum performance of the appliance.

cNote

The easiest way to check the gas pressures is by using two pressure gauges. This procedure assumes that these two gauges are available.

To check the supply pressure and burner pressure, proceed as follows:

1. Disconnect the appliance from the mains. See paragraph ’7.3.2 Disconnect

the appliance from the mains’.

2. Undo the screws of the plastic covers.

3. Carefully remove the black plastic covers from the appliance. The electrical section is now visible.

4. There are 2 test nipples on the gas control (Figure 3.13) for measuring the supply pressure @ and the burner pressure # respectively. Sealing screws are located inside the test nipples. Loosen both sealing screws by a few turns. Do not loosen them completely; this makes them difficult to tighten again.

5. Connect a pressure gauge to the lower pressure test nipple #.

6. Open the gas supply and vent the gas supply line via the upper nipple @.

7. Connect a pressure gauge to the upper test nipple as soon as gas starts to flow from this nipple.

8. Switch on the power to the appliance using the mains switch on the appliance.

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Figure 3.7 ThermoControl

INTERNAL CHECK

Figure 3.8 Internal check

MENU »OFF ^ ON È WEEK PROGRAM

Figure 3.9 Main menu

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

Figure 3.10 Starting up

Installation

9. Turn the ThermoControl ON by setting the 0/I switch to position I.

The display will now show will then go to the main menu.

10. Activate the “ON mode” by going through the following steps:

- Press once on the blue arrow (L) to bring the pointer ( press E. The display as shown in Figure 3.10 appears.

- Confirm with E the option

The appliance is now in “ON mode” and will ignite.

11. Once the display shows the text before reading the dynamic pressures (the fan needs this time to run up to full rotational speed).

12. Use the pressure gauge to read the supply pressure at the test nipple #. Depending on the gas, refer to Ta b le 3 .6 .

n Remark

Consult the mains gas supply company if the supply pressure is not correct.

INTERNAL CHECK for about 10 seconds, and

») to ON and

START OPERATION.

RUNNING you must wait about 1 minute

n Remark

If the burner pressure is not correct and the appliance is fitted with a flat sealing plate, you will not be able to adjust the pressure. In this case, consult your installer or supplier. If the appliance is fitted with a burner pressure regulator, then the pressure can be adjusted by following steps 13 through 17.

13. Remove the cap 8 from the burner pressure regulator 7.

14. Adjust the burner pressure by turning the adjusting screw 9, depending on the correction required:

- Adjusting screw anticlockwise: burner pressure decreases.

- Adjusting screw clockwise: burner pressure increases.

15. Cover the opening of the adjusting screw and check the burner pressure against the target value from Ta bl e 3. 6.

16. If the pressure reading is not correct, repeat steps 14 and 15 until the correct pressure is attained.

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MENU »OFF ^ ON È WEEK PROGRAM

Figure 3.11 Main menu

Conversion to a different gas category

17. Activate the “OFF mode” of the ThermoControl:

- If the

- Use H and L to position the cursor (») beside OFF

- Confirm with E.

18. Wait until the fan has stopped. and turn the ThermoControl off.

MENU is not displayed:

press B.

cNote

Failure to wait until the fan stops can cause damage to the appliance.

19. Shut off the gas supply.

20. Disconnect the two pressure gauges and re-tighten the sealing screws in the test nipples.

21. Replace the plastic covers.

n Remark

Before starting-up the appliance, take time to fill in the warranty card supplied with the appliance. This enables us to guarantee the quality of our systems, and to further enhance our warranty procedure.

3.12 Conversion to a different gas category

Please return this card as soon as possible. Your customer will then receive a warranty certificate with our warranty conditions.

cNote

The conversion may only by carried out by an authorised installer.

If the appliance must operate on a family of gas (LP gas or natural gas) other than the category of gas for which the appliance has been set up at the factory, the appliance will have be adapted using a special conversion kit.

cNote

After conversion, check the supply pressure and the burner pressure.

1. Disconnect the appliance from the mains. See paragraph ’7.3.2 Disconnect

the appliance from the mains’.

2. Shut off the gas supply.

3. Undo the screws of the plastic covers.

4. Carefully remove the black plastic covers from the appliance.

5. Loosen the 2 screws of the electrical section, and remove the protective cap from the electrical section Figure 3.6).

6. Detach the connector 1 that connects the cabling of the glow igniter and the ionisation rod to the controller.

7. Detach the three-part gas coupling 2 adjacent to the burner.

- Detach the air supply hose 3.

- Detach the detach the pressure switch hose 4.

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Legend

a connector b gas coupling c air supply hose d pressure switch hose e distribution plate f orifice

Installation

8. Remove the burner as complete assembly.

Figure 3.12 Orifice assembly

9. Place and fit the burner with parts from the conversion kit.

n Remark

The burner for LP gases can be recognised by the letter ‘P’ which is stamped into the metal of the gas/air distribution plate 5.

10.Select and fit the correct orifice from the conversion kit, based on Table 3.6. The injector diameter is stamped into each injector 6

11. Check whether there is a burner pressure regulator 7 fitted to the gas control, or simply a flat sealing plate!.

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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

Conversion to a different gas category

Figure 3.13 Conversion of gas control

n Remark

12.If the flat sealing plate or burner pressure regulator need to be replaced:

13.Refit the connector 1 of the glow igniter and ionisation rod to the controller.

14.Re-fit the three-part gas coupling b.

cNote

15.Check the burner and supply pressure (see paragraph 3.11).

In the event the supply pressure for a gas category is the same as the burner pressure (see the gas tables in paragraph 3.4) then the gas control must be fitted with a flat sealing plate with cork gasket. A burner pressure that deviates in comparison to the supply pressure requires the use of a burner pressure regulator with rubber gasket. Each conversion kit contains all the necessary components.

- Unscrew the connector j from the gas control.

- If necessary, remove the flat sealing plate ! or burner pressure regulator 7.

- If necessary, fit the flat sealing plate or burner pressure regulator supplied with the conversion kit.

- Refit the connector to the gas control.

IMD-0079

16.Replace the plastic cover.

17.Remove the sticker showing the new gas category from the conversion kit, and attach it below the appliance’s rating plate. This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied.

18.Start the appliance (see paragraph 7.2).

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Installation

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4 Filling and draining

4.1 Introduction Topics covered in this chapter:

• Filling the appliance.

• Draining the appliance.

The components referred to in these paragraphs are illustrated in Figure 4.1.

4.2 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 d for the circulation pump.

2. Shut drain valve g.

3. Open the nearest hot water draw-off point l.

4. Open the supply valve i on the cold water side a so that cold water flows into the appliance.

5. Completely fill the appliance (when cold water flows at normal pressure from the nearest hot water draw-off point, the appliance is full).

6. Bleed the entire installation of air, for example by opening all hot water drawoff points.

7. The appliance is now under water supply pressure. There should be no water coming out of the overflow valve m nor the T&P valvec. If this does happen, the cause might be:

- The water supply pressure is greater than the specified 8 bar.

Rectify this by fitting a pressure-reducing valve a.

- The overflow valve in the protected cold supply setup is defective or

incorrectly fitted.

Introduction

4.2.2 Filling vented 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 d for the circulation pump.

2. Shut drain valve g.

3. Open the nearest hot water draw-off point l.

4. Open the supply valve i on the cold water side a so that cold water flows into the appliance.

5. Completely fill the appliance (when cold water flows at normal pressure from the nearest hot water draw-off point, the appliance is full).

6. Bleed the entire installation of air, for example by opening all hot water drawoff points.

7. The appliance is now under water supply pressure. There should be no water coming out of the T&P valve c. If this does happen, the T&P valve might be defective or incorrectly fitted.

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Filling and draining

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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

m pressure relief valve

(mandatory)

n water cistern

o float valve

p 3-way venting valve

(recommended)

q overflow pipe

a cold water supply

b hot water outlet

c circulation pipe

d gas supply

e flue gas discharge and air

supply

UNVENTED

VENTED

E N

E R

f e

IMD-0139

efd

IMD-0138

Figure 4.1 Installation diagrams

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4.3 Draining the appliance

MENU »OFF ^ ON È WEEK PROGRAM

Figure 4.2 Main menu

Figure 4.3 ThermoControl

4.3.1 Draining unvented installations

Some service activities require the appliance to be drained. The procedure is as follows:

1. Activate the MENU with B.

2. Use H and L to place the cursor beside

3. Confirm

4. Wait until the fan has stopped. The

OFF with E.

cNote

Failure to wait until the fan stops can cause damage to the appliance.

5. Turn the appliance OFF (position 0) using the ON/OFF switch on the control panel. See Figure 4.3.

6. Disconnect the appliance by putting the mains switch between the appliance and the mains power supply to position 0.

7. Shut off the gas supply h.

8. Close the stop valve i in the hot water pipe.

9. Close the supply valve of the cold water supply a.

10. Open the drain valve g.

11. Bleed the appliance (or installation) so that it drains completely empty.

Draining the appliance

OFF. See Figure 4.2.

S icon is then dimmed.

4.3.2 Draining vented installations

Some service activities require the appliance to be drained. The procedure is as follows:

1. Activate the

2. Use H and L to place the cursor beside

3. Confirm

4. Wait until the fan has stopped. The

MENU with B.

OFF with E.

cNote

Failure to wait until the fan stops can cause damage to the appliance.

5. Turn the appliance OFF (position 0) using the ON/OFF switch on the control panel. See Figure 4.3.

6. Disconnect the appliance by putting the mains switch between the appliance and the mains power supply to position 0.

7. Shut off the gas supply h.

8. Close the stop valve i in the hot water pipe.

9. Close the stop valve between the water cistern and the cold water inlet.

10. Open the drain valve g.

11. Bleed the appliance (or installation) so that it drains completely empty.

OFF. See Figure 4.2.

S icon is then dimmed.

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5 The control panel

5.1 Introduction Topics covered in this chapter:

• 5.2 Operating;

• 5.3 Explanation of the icons;

• 5.4 ON/OFF switch of ThermoControl;

• 5.5 Navigation buttons;

• 5.6 PC connection..

5.2 Operating Figure 5.1 shows the ThermoControl. The control panel is completely menu-

driven. It comprises:

• a 4-line display with 20 characters per line;

• 6 push buttons for operating the appliance (below the display);

• 6 graphical symbols (above the display);

• a connector for a service PC;

• an ON/OFF switch.

The push buttons are divided into three groups:

• Navigation buttons:

- Buttons UP H, and DOWN L;

- Enter: E;

- Reset button: R

• The main menu: B (see chapter ’8 Main menu’);

• the service program: S (see chapter ’9 Service program’, this chapter is specifically intended for the service and maintenance engineer and installer).

MENU »OFF ^ ON » WEEK PROGRAM

Figure 5.1 ThermoControl

^»START OPERATION È CHANGE SETPOINT

Tset=70ÉC

Figure 5.2 The display

Release R.1.3 UK 43

In this manual, the display of the ThermoControl is shown as in Figure 5.2, both with and without icons.

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The control panel

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5.3 Explanation of the icons

5.4 ON/OFF switch of ThermoControl

INTERNAL CHECK

Table 5.1 gives an explanation of the icons.

Tabl e 5 .1 Icons and their meaning

Icon Name Explanation

W S D

O G V

The ON/OFF switch of the ThermoControl switches the appliance ON and OFF. Note that in the OFF position the appliance remains electrically live, in order for the continuous pump to stay running.

After switching on, the text 10 seconds. The main menu then appears (see chapter ’8 Main menu’). If no selection is made in the main menu, the appliance automatically switches to OFF mode. See paragraph ’6.2 Operating modes’.

Heat demand Heat demand detected

Purge Pre- and post-purge using fan

Pressure switch Pressure switch is closed

Glow (Pre)glow

Gas control Gas control open / ignition

Flame detection Appliance running

INTERNAL CHECK appears on the display for about

n Remark

Figure 5.3 Internal check

5.5 Navigation buttons The use of these buttons is explained with the help of Figure 5.4. This figure

MENU OFF ^»ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

Figure 5.4 Navigation buttons

To electrically disconnect the appliance, you must use the main switch between the appliance and the mains power supply.

shows the main menu. See also chapter’8 Main menu’.

The navigation buttons are:

• Buttons UP H and DOWN L;

• Enter: E;

• Reset button: R

The arrows and L to scroll.

The cursor » points to the option to be activated. In the display as shown in

Figure 5.4 you can scroll through the main menu.

The main menu consists of:

SETTINGS. The options EXTRA PERIOD and SETTINGS only become visible

after scrolling downwards.

The selected option is confirmed using E.

With the R button, you go back one page in a menu, and all options selected in the current menu are lost.

^ and È indicate that you can scroll up and/or down. Use buttons H

OFF, ON, WEEK PROGRAM, EXTRA PERIOD and

n Remark

The R button is also used to reset the appliance following an error.

5.6 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.

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Introduction

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6 Status of the

appliance

6.1 Introduction Topics covered in this chapter:

• 6.2 Operating modes;

• 6.3 Error conditions;

• 6.4 Service condition.

6.2 Operating modes When running, the appliance has four basic operating modes, namely:

OFF

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

Figure 6.1 Frost protection

ON 13:45 Thursday 67ÉC Tset 75ÉC

Figure 6.2 ON

EXTRA 12:30 Thursday 76ÉC TH 12:45 Tset 75ÉC PERIOD ACTIVATED

Figure 6.3 Extra period

In this mode, the frost protection is activated. Figure 6.1 shows the display with the following information:

- line one: the text OFF;

- line two: the time, the day and alternately T

2.3;

- lines three and four: the text FROST PROTECTION ACTIVATED.

In this mode the appliance continuously fulfils the demand for hot water.

Figure 6.2 shows the display with the following information:

- line one: the text ON;

- line two: the time, the day and alternately T

2.3;

- line three: the programmed water temperature T

- line four: is empty when the appliance is idle, or depending on the heating cycle, a text such as

heating cycle’.

EXTRA

In this mode, one extra period is programmed and activated. In this mode,

OFF or PROG position is temporarily overruled to fulfil a single period of

the heat demand. Once the period has passed, the appliance automatically returns to the previous operating mode. Figure 6.3 shows the display with the following information:

- line one: the text EXTRA;

- line two: the time, the day and alternately T

2.3;

- line three: the switch-on time, and the related water temperature setting;

- line four: the text PERIOD ACTIVATED.

PROG

In this mode a preset week program is active, and the appliance responds continually to heat demand within the time periods set in the week program. There are two distinct situations possible in this mode:

HEAT DEMAND. See ’7.4 The appliance’s

and T

. See paragraph

net

. See paragraph

net

;

set

. See paragraph

net

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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

1) The current time falls within a set time period of the week program.

Figure 6.4 shows the display in this situation:

- line one: the text PROG;

- line two: the time, the day and alternately T

2.3;

- line three: the next scheduled switch-off time and the water temperature T

- line four: is empty, or depending on the heating cycle, a text such as

HEAT DEMAND. See paragraph ’7.4 The appliance’s heating cycle’

2) The current time falls outside a set time period of the week program.

Figure 6.5 shows the display in this situation:

- line one: the text

- line two: the time, the day and alternately T

2.3;

- line three: the next scheduled switch-on time;

- line four: the text

In all modes, the temperature may at any moment drop below the desired temperature. The appliance then enters a heating cycle. This heating cycle is the same for all basic operating modes. See paragraph ’7.4 The appliance’s

heating cycle’.

of the active period;

set

PROG;

PERIOD ACTIVATED.

and T

. See paragraph

net

. See paragraph

net

n Remark

Setting and programming of the basic operating modes are described in chapter ’8 Main menu’.

6.3 Error conditions

S04: SENSOR ERROR

CHECK

SENSOR OR DUMMY

Figure 6.6 Example of an error message

Figure 6.6 shows an example of an error condition. If the appliance enters this

condition, the display will show the following information:

• line one: error code comprising a letter and two digits, followed by the error description;

• lines two through four: alternately, a brief explanation of the error, and a brief action to resolve the error.

cNote

The displayed action to resolve the error may only be performed by a service- and maintenance engineer.

There are various types of errors:

• LOCK OUT ERRORS When the cause is no longer present, these errors require a reset with the R button, before the appliance can resume running.

• BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed, after which the appliance resumes by itself.

The display does not show what type of error has been detected. For a detailed overview of error conditions, please refer to chapter ’10 Troubleshooting’.

If, as end-user, you find the appliance in an error condition, you may attempt to re-start the appliance by pressing the R button once.

However, should the error return or become persistent, you should contact your service and maintenance engineer.

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6.4 Service condition

!!! WARNING !!!

Service condition

Figure 6.7 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.

MAX. BURNINGHOURS:

SERVICE REQUIRED

Figure 6.7 Service required

n Remark

The message SERVICE REQUIRED is based on the number of burning hours and the preset service interval. Should the service interval have been incorrectly selected, contact the service and maintenance engineer for instructions on how to adjust this. See chapter ’11 Maintenance frequency’.

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7 Starting up and

shutting down

7.1 Introduction Topics covered in this chapter:

• Starting up.

• Shutting down.

7.2 Starting up Start-up the appliance as follows:

1. Fill the appliance. See chapter ’4 Filling and draining’

2. Open the gas valve (see ’Figure 4.1 Installation diagrams’).

3. Switch on the power to the appliance using the mains switch between the appliance and the power supply.

4. Turn the ThermoControl ON by setting ON/OFF switch to position I.

Introduction

Figure 7.1 ThermoControl

INTERNAL CHECK

Figure 7.2 Internal check

OFF ^ ON È WEEK PROGRAM

Figure 7.3 Main menu

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

Figure 7.4 Starting up

The display will now show INTERNAL CHECK for about 10 seconds, then go to the main menu.

5. Activate the “ON mode” by going through the following steps:

- Press once on the DOWN button (L) to position the cursor (») beside ON, then press E. The display shown in figure Figure 7.4 will appear.

- Confirm with E the option START OPERATION.

The appliance will now enter “ON mode”. If there is a heat demand, the appliance will run through a heating cycle. See paragraph ’7.4 The

appliance’s heating cycle’.

If the heating cycle is not run, then there is no current heat demand; should this happen, then T described in paragraph ’8.4 Setting the water temperature’

will probably need to be set. This is

set

7.3 Shutting down You can:

• Shut the appliance down for a brief period (“OFF mode”).

• Disconnect the appliance from the mains.

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OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

Figure 7.5 Frost protection

Starting up and shutting down

gis

• Shut the appliance down for a longer period.

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:

1. Press button B to select the main menu.

2. Using H and L position the cursor (») beside OFF.

Confirm with E.

The frost protection cuts in if the water temperature drops below 5°C. The text FROST will then appear on line one of the display The appliance will heat the water to 20°C (T

n Remark

These values of 5°C and 20°C cannot be adjusted.

7.3.2 Disconnect the appliance from the mains

The appliance should only be disconnected from mains power in the correct way. The correct procedure is as follows:

) before dropping back to OFF mode.

set

MENU »OFF ^ ON È WEEK PROGRAM

Figure 7.6 Main menu

Figure 7.7 ThermoControl

1. Activate the MENU with B.

2. Use H and L to position the cursor beside OFF. See Figure 7.6.

3. Confirm OFF with E.

4. Wait until the fan has stopped. The

S icon is then dimmed.

cNote

Failure to wait until the fan stops can cause damage to the appliance.

5. Turn the appliance OFF (position 0) using the ON/OFF switch on the control panel. See Figure 7.7.

6. Disconnect the appliance by putting the mains switch between the appliance and the mains power supply to position 0.

7.3.3 Shut the appliance down for a longer period

Drain the appliance, if you are shutting it down for a longer period of time. Proceed as follows:

1. Disconnect the appliance from the mains as described in paragraph 7.3.2.

2. Shut off the gas supply.

3. Close the stop valve in the hot water pipe.

4. Open the drain valve.

5. Bleed the appliance (or installation) so that it drains completely empty.

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The appliance’s heating cycle

7.4 The appliance’s heating cycle

Ê 13:45 Thursday 63ÉC Tset 65ÉC HEAT DEMAND

The appliance’s heating cycle is activated as soon as the measured water 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.

The heating cycle runs in turn through the following states:

1. HEAT DEMAND;

2. PRE-PURGE;

3. PRESSURE SWITCH;

4. PRE-GLOW;

5. IGNITION;

6. RUNNING;

7. POST-PURGE.

The complete cycle is explained in the example set out below assuming the appliance is operating in mode ON.

) falls below the threshold value (T

net

). This threshold value

set

n Remark

The same heating cycle applies to the other operating modes.

Once the appliance starts, it will run through 8 steps:

1. The water temperature drops below the set temperature of (for example) 65°C. The ThermoControl detects a heat demand and starts the heating cycle.

-The

- The message HEAT DEMAND appears.

W icon is activated.

Figure 7.8 Frost protection cuts in

ON 13:45 Thursday 63ÉC Tset 65ÉC PRE PURGE

Figure 7.9 Pre-purge

Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC PRESSURE SWITCH

Figure 7.10 Pressure switch

ON Ê 13:45 Thursday 63ÉC Tset 65ÉC GLOW PLUG

Figure 7.11 Pre-glow

Ê Ê

2. Following the heat demand, the fan is powered up and the pre-purge begins. This lasts about 15 seconds. During this phase, any residual gases are removed.

-The

- The message PRE PURGE appears.

3. During the pre-purge, the pressure switch closes.

-The

- The message PRESSURE SWITCH appears.

4. After some time, the pre-purge ceases and the ThermoControl reduces the speed of the fan to the rotational speed for ignition. This is followed by the pre-glow of the glow igniter.

-The S and D icons are dimmed.

-The

S icon is activated.

D icon is activated.

O icon is activated.

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ON Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC IGNITION

Figure 7.12 Ignition

ON Ê Ê Ê 13:45 Thursday 63ÉC Tset 65ÉC RUNNING

Figure 7.13 Running

ON Ê Ê 13:45 Thursday 65ÉC Tset 65ÉC POST PURGE

Figure 7.14 Post-purge

ON 14:05 Thursday 65ÉC

5. After a number of seconds pre-glow, the gas control is opened and ignition takes place.

-The

- The message IGNITION appears.

6. After ignition, the flame is detected and the appliance will be running. This means that actual heating has started. The rotation speed of the fan then

increases to the normal running speed, and the pressure switch will close:

-The

- The message RUNNING appears.

7. Once the water is up to temperature, the heat demand drops off, and the post-purge starts. This lasts about 25 seconds.

-The W, G and V icons are dimmed.

-The

- The message POST PURGE appears.

8. Following the post-purge, the fan stops and the pressure switch opens:

-The D and S icons are dimmed.

- The message POST PURGE disappears.

At the first subsequent heat demand, the heating cycle will resume from step 1.

G icon is activated.

O icon is dimmed. V and D icons are activated.

S icon is activated.

Figure 7.15 Running

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8 Main menu

8.1 Introduction

MENU »OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

Figure 8.1 Main menu

Introduction

The MENU is reached by pressing button B of theThermoControl. The options are:

OFF

•

Select this option if you wish to shut the appliance down for a brief period, but do not wish to drain it. In this mode, the frost protection is active. This prevents water from freezing in the appliance. See paragraph ’7.3 Shutting

down’.

•

In this mode, the appliance continually responds to the hot water demand. See paragraph ’8.3 Switching into “ON mode”’.

WEEK PROGRAM

•

Select this option to allow the appliance to respond to heat demand only during pre-programmed periods. Outside those periods, only frost protection is active. See paragraph ’8.5 Week programme’.

EXTRA PERIOD

•

Select this option to override the OFF mode or PROG mode so that a single temporary period of heat demand will be fulfilled. See paragraph ’8.6 Extra

period’.

SETTINGS

•

Select this option in order to set the language and the time. You can also use this option to display the regulation interval (temperature), and the ignition and running speeds of the fan. See paragraph ’8.7 Settings’.

n Remark

If you fail to make any selection with the main menu open, then after 30 seconds, the appliance will automatically return to the mode it was previously in.

Topics covered in this chapter:

• Setting the water temperature

• Week programme

• Extra period

• Settings

8.2 Notational convention for menu-related instructions

Release R.1.3 UK 53

The MENU (B) of the ThermoControl is divided into sub-menus. For example,

SETTINGS is one of the functions reached from the main menu. The menu SETTINGS is itself divided into sub-menus. For example, LANGUAGE is a sub-

menu of SETTINGS. So, for example, to select menu LANGUAGE, this manual employs the following convention:

• B: SETTINGS | LANGUAGE

Confirm with E.

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This means:

Activate the main menu with B.

1. B:

SETTINGS: Using button H and/or L go to SETTINGS and press E.

LANGUAGE: Using button H and/or L go to LANGUAGE.

4. Confirm with E: After pressing E, the sub-menu LANGUAGE is

activated.

This notation is also used for more than 2 sub-menus.

8.3 Switching into “ON mode”

8.4 Setting the water temperature

8.4.1 Setting the water temperature via SETPOINT MENU

START OPERATION ^»CHANGE SETPOINT È Tset=65ÉC

Figure 8.2 Setting SETPOINT

SETPOINT

» 65ÉC

Figure 8.3 Adjusting water temperature

You can switch the appliance into “ON mode” from any operational mode, as follows:

• B: ON | START OPERATION

Confirm with E.

n Remark

Starting up and shutting down the entire appliance is described in chapter 7.

The water temperature can be set to any value between 40°C and 80°C.

Set the water temperature via:

ON | CHANGE SETPOINT

1. B:

Confirm with E.

2. Use:

- H to increase the value;

- L to decrease the value.

- Confirm with E. After confirming, the appliance enters “ON

mode”.

n Remark

If the temperature setting is higher than the current water temperature, it is possible that the appliance does not immediately start heating. To prevent excessively frequent switching on and off, there is a heating margin. This margin is set standard to 2°C. The appliance starts heating when the water temperature is 2°C colder than the SETPOINT and continues heating until the water is 2°C hotter than the SETPOINT. We refer to this margin as the hysteresis. The service and maintenance engineer can adjust this value (see paragraph 9.2).

8.4.2 Setting water temperature during ON mode

ON 13:45 Thursday 65ÉC Tset=65ÉC

Figure 8.4 ON mode: the appliance is on

54 Instruction Manual BFC

The water temperature can also be directly adjusted when the appliance is in “ON mode”. Simply use:

• H to increase the value;

• L to decrease the value.

• t6Confirm with E.

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8.5 Week programme

8.5.1 Introduction

PROG 07:55 Monday 64ÉC MO 08:00 Tset 75ÉC PROGRAM ACTIVATED

Figure 8.5 week program active

Week programme

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 display by the text the time of day, the day of the week and the temperature. The third line shows the next switching time of the week program and the programmed temperature. The fourth line shows the text

The appliance’s default week program switches the appliance on every day at 00:00 hours and off at 23:59 hours. The water temperature setting is standard 65°C.

If you wish, you can change every setting in the standard week program of the appliance.

If, while the week program is running, the water temperature becomes too low, then the appliance will run through the heating cycle (see ’7.4 The appliance’s

heating cycle’), then return to the week program.

The following topics are covered in this paragraph:

• 8.5.2 Starting up and shutting down the week program

• 8.5.3 Changing the appliance’s standard week program

• 8.5.4 Adding times to a week program

• 8.5.5 Deleting times from a week program

PROG on the first line (see Figure 8.5). The second line shows

PROGRAM ACTIVATED.

8.5.2 Starting up and shutting down the week program

The week program can be started up from any other operating mode, as follows:

• B:

WEEK PROGRAM | START OPERATION

Confirm with E.

A week program can be shut down simply by activating a different operating mode, for example “ON mode”.

8.5.3 Changing the appliance’s standard week program

n Remark

First fill-in the desired week program on the program card supplied. See appendix ’A.3 Week program card’.

A week program is made up of a number of programmable periods in which you can have the appliance switch on and off. A period consists of:

• switch-on time: day of the week, and time in hours and minutes;

• switch-off time: in hours and minutes;

• the water temperature setting;

• on/off setting for a program-controlled pump.

n Remark

The switch-off time must always 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 per week.

WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È

Figure 8.6 Week programme

Bring up the menu for the week program via:

WEEK PROGRAM | PROGRAM OVERVIEW.

1. B:

Confirm with E.

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DAY TIME Tset ON »SU 00:00 65ÉC P OFF SU 23:59 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59 ON WE 00:00 65ÉC P OFF WE 23:59 ON TH 00:00 65ÉC P OFF TH 23:59 ON FR 00:00 65ÉC P OFF FR 23:59 ON SA 00:00 65ÉC P OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.7 Standard week program

ON »SU 00:00 OFF SU 23:59 Tset 65ÉC PUMP ON SAVE

Figure 8.8 Week programme

ON SU»08:00 OFF SU 08:00 Tset 65ÉC PUMP ON SAVE

Figure 8.9 Setting switch-on hours in week program

ON SU 08»15 OFF SU 08:15 Tset 65ÉC PUMP ON SAVE

Figure 8.10 Setting switch-on minutes in week program

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON SAVE

Figure 8.11 Setting switch-off hours in week program

The display now shows the menu for the week program, see Figure 8.7. With the default setting, the program switches on and off every day at 00:00 and 23:59 hours respectively, the water temperature is 65ºc and the pump is switched on (

Example

As an example, we will set the switch-on time for Sunday to 08:15 hours, and the matching switch-off time to 12:45 hours. The water temperature will be set to 75ºC and the pump will run continuously. The following settings are entered one by one via the menu: the switch-on time, the switch-off time, the desired water temperature, and the state of the programcontrolled pump.

Setting the switch-on time

2. Bring the cursor to

Figure 8.8 will appear. The day indicated by the » will blink.

3. Use H and L to select the day desired. In the example, this is

Confirm with E.

The cursor moves to the hour digits, which will blink. See Figure 8.9.

4. Use H and L to select the hour. In the example this is

Confirm with E.

The cursor moves to the minute digits, which will blink. See Figure 8.10.

P).

SU and press E. The sub-menu shown in

SU (Sunday).

08.

n Remark

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.

5. Use H and L to select the minutes. In the example this is

Confirm with E.

The cursor moves to the switch-off hour digits, which will blink. See

Figure 8.11.

Setting switch-off time

6. Use H and L to select the hour. In the example this is

Confirm with E.

15.

12.

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Week programme

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON SAVE

Figure 8.12 Setting switch-off minutes in week program

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON SAVE

Figure 8.13 Setting water temperature in week program

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON SAVE

Figure 8.14 Setting the pump in week program

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »SAVE

Figure 8.15 Save week program

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59

The cursor moves to the minute digits, which will blink. See Figure 8.12.

7. Use H and L to select the minutes. In the example this is

45.

Confirm with E.

The cursor moves to the water temperature. See Figure 8.13.

Setting the water temperature

8. Use H and L to select the water temperature. In the example this is 75ÉC.

Confirm with E.

The cursor moves to

PUMP ON . See Figure 8.14.

Setting program-controlled pump

9. If required, a pump can be controlled during the period. Use H and L to

PUMP ON . The pump ensures a regular circulation of hot water in

select the hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with E.

The cursor moves to SAVE. See Figure 8.15.

10. Confirm with E.

The display shown in Figure 8.16 appears.

11. If you wish, use L to scroll to another day, and change more switch-on and

switch-off times. Simply repeat steps 3 through 10.

12. After changing all desired switch-on and switch off times, you can start running the week program:

- Scroll with L to

START OPERATION.

Confirm with E.

Figure 8.16 Add week program

8.5.4 Adding times to a week program

WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È

Figure 8.17 Inserting a week program

The menu to INSERT switch-on and switch-off times into a week program is reached via:

WEEK PROGRAM | PROGRAM OVERVIEW.

1. B:

Confirm with E.

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DAY TIME Tset »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.18 Week programme

ON »SU 08:15 OFF SU 12:45 Tset 65ÉC PUMP ON SAVE

Figure 8.19 Adding a period

DAY TIME Tset ON »SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.20 Period added

The display shows the menu for the week program, see Figure 8.18. The cursor points to the active period.

2. Scroll L to

Confirm with E.

The sub-menu for adding a period will appear. See Figure 8.19.

Example

As an example, we will program an extra period in which the switch-on time is set to 18:00 hours, and the matching switch-off time to 22:00 hours. The water temperature will be set to 75ºC and the pump will run continuously.

3. Repeat steps 3 through 10 of paragraph 8.5.3. After the option display as shown in Figure 8.20 appears; i.e. with the cursor beside the period we have just added.

4. To activate the week program with the new period added, scroll down with L to

INSERT.

SAVE the

START OPERATION and confirm with E.

8.5.5 Deleting times from a week program

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.21 A program

MENU OFF ^»ON È WEEK PROGRAM

Figure 8.22 Week programme

All switch-on/off times are shown sequentially in the display. Assume that the switch-on/off times for the appliance are programmed as in Figure 8.21.

To delete a period, proceed as follows:

WEEK PROGRAM.

1. B:

Confirm with E.

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Week programme

WEEK PROGRAM START OPERATION ^»PROGRAM OVERVIEW È

Figure 8.23 week program options

DAY TIME Tset ON !SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.24 A program

DAY TIME Tset ON !SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.25 Select

DAY TIME Tset ON ! DELETE OFF BLOCK? ON MO 00:00 65ÉC P

Figure 8.26 Confirm deletion of block from week program

DAY TIME Tset ON SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59 INSERT DELETE START OPERATION

Figure 8.27 Period deleted

2. Scroll with L to PROGRAM OVERVIEW.

Confirm with E.

The display will show the week program sub-menu, see Figure 8.21.

3. Scroll with L to

DELETE.

Confirm with E.

4. The display will change as shown in Figure 8.24. To warn you that you are now working in the delete sub-menu, the cursor is replaced with an exclamation mark (

!) and the period settings will blink (illustrated in the

figure by underlining).

5. Scroll with L to the day to be deleted. For example, the second period of SU (Sunday). See Figure 8.25.

Confirm with E.

6. The lines showing switch-on/off times are replaced by the text

DELETE BLOCK?. See Figure 8.26.

Confirm with E (or use R to cancel deletion)

The switching period has been deleted. You will return now to the week program menu. The cursor is beside the first programmed period. See

Figure 8.27.

7. Scroll with L to

START OPERATION.

Confirm with E.

The week program is active.

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8.6 Extra period

8.6.1 Introduction

EXTRA 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC PERIOD ACTIVATED

Figure 8.28 Extra period active

8.6.2 Programming an extra period

MENU ON ^ WEEK PROGRAM È»EXTRA PERIOD

Figure 8.29 Extra period

ON SU»08:00 OFF SU 08:00 Tset 65ÉC PUMP ON START

Figure 8.30 Setting switch-on hour for extra period

ON SU 08»15 OFF SU 08:15 Tset 65ÉC PUMP ON START

Figure 8.31 Setting the switchon minutes for extra period

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON START

Figure 8.32 Setting switch-off hour for extra period

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON START

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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 display with the text EXTRA. See Figure 8.28.

If the water temperature becomes too low during the extra period (see

’8.6.2 Programming an extra period’), the appliance will run through the heating

cycle (see ’7.4 The appliance’s heating cycle’), then fall back into the extra period.

The same settings can be made for an extra period as for a week program period. See paragraph ’8.5.3 Changing the appliance’s standard week

program’.

Bring up the menu for entering an extra period via:

EXTRA PERIOD

1. B:

Confirm with E.

The display show the settings for the extra period. See Figure 8.30.

Setting the switch-on time

2. Use H and L to select the day desired. In the example this is SU.

Confirm with E.

The cursor moves to the hour digits, which will blink. See Figure 8.30.

3. Use H and L to set the switch-on hour to the desired value. In the example

08.

this is

Confirm with E.

The cursor moves to the minute digits, which will blink. See Figure 8.31.

n Remark

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 H and L to select the minutes. In the example this is

Confirm with E.

The cursor moves to the hour digits of the switch-off period. See Figure 8.32.

Setting switch-off time

5. Use H and L to select the hour. In the example this is 12.

Confirm with E.

The cursor moves to the minute digits, which will blink. See Figure 8.33.

6. Use H and L to select the minutes. In the example this is

Confirm with E.

15.

45.

Figure 8.33 Setting the switchoff minutes for extra period

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Settings

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON SAVE

Figure 8.34 Setting water temperature for extra period

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON START

Figure 8.35 Pump setting for extra period

ON ZO 08:15 OFF ZO 12:45 Tset 75ÉC PUMP ON »START

Figure 8.36 Saving extra period

8.7 Settings

The cursor moves to the water temperature. See Figure 8.34.

Setting the water temperature

7. Use H and L to select the water temperature. In the example this is 75.

Confirm with E.

The cursor moves to

PUMP ON. See Figure 8.35.

Setting program-controlled pump

8. If required, a pump can be controlled during the period. Use H and L to

PUMP ON. The pump ensures a regular circulation of hot water in the

select hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with E.

The cursor moves to

START. See Figure 8.36.

9. Confirm with E.

The extra period has been programmed.

n Remark

Once the extra period has completed running, the controller returns to the mode ON, OFF or WEEK PROGRAM. The following week, the extra period will NOT be automatically switched on.

MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Figure 8.37 Settings

SETTINGS »LANGUAGE ^ DAY/TIME È SPECIFICATIONS

8.7.1 Introduction

Using the option SETTINGS you can adjust certain settings, and display certain appliance specifications. See Table 8.1.

Tab le 8.1 Adjustable settings and displayable appliance specifications

Adjustable settings ! Menu language

Displayable appliance specifications

This category is only relevant to the installer and/or service and maintenance engineer.

8.7.2 Setting menu language

Bring up the menu for selecting the language via:

SETTINGS.

1. B:

Confirm with E.

The display shows the menu for settings. See Figure 8.38.

2. The cursor is positioned beside LANGUAGE

Confirm with E.

The display shows the language selection menu. See Figure 8.39.

! Current day of week, and time

! Regulation interval (water

temperature).

! Ignition speed of fan.

! Running speed of fan.

Figure 8.38 Language

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LANGUAGE ENGLISH ^ NEDERLANDS È»DEUTSCH

FRANCAIS ITALIANO

Figure 8.39 Language selection

8.7.3 Setting day and time

MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Figure 8.40 Settings

SETTINGS LANGUAGE ^»DAY/TIME È SPECIFICATIONS

Figure 8.41 Day and time

DAY »Sunday Monday Tuesday

Wednesday Thursday Friday Saterday

Figure 8.42 Setting the day

TIME

»00:00

3. Scroll with L to the desired language.

Confirm with E.

The language is set.

Bring up the menu for entering the day and time via:

SETTINGS.

1. B:

Confirm with E.

The display shows the menu for settings. See Figure 8.38.

2. Scroll with H and L to DAY/TIME

Confirm with E.

The display shows the sub-menu for selecting the day of the week. See

Figure 8.42.

3. The cursor is positioned beside Sunday.

Scroll with H and L to the desired day.

Confirm with E.

The day of the week has been set. The display shows the sub-menu for adjusting the time. See Figure 8.43.

4. The cursor moves to the hour digits, which will blink.

Scroll with H and L to the current hour, for example 15.

Confirm with E.

Figure 8.43 Setting the hour

TIME

Figure 8.44 Setting the minutes

TIME

Figure 8.45 Setting the minutes

15»00

15»45

5. The cursor moves to the minute digits, which will blink.

Scroll with H and L to the next minute in time, for example 45.

Confirm the minute setting with E.

The current time has been set.

n Remark

The appliance takes no account of daylight saving.

8.7.4 Displaying appliance specifications

n Remark

This category is only relevant to the installer and/or service and maintenance engineer.

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Settings

Ta bl e 8 .2 shows the standard appliance specifications.

Tab le 8.2 Appliance specifications

MENU WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Figure 8.46 Main menu

SETTINGS LANGUAGE ^ DAY/TIME È»SPECIFICATIONS

Figure 8.47 Settings

SPECIFICATIONS

»REGULATION INTERVAL ^ IGNITION SPEED È WORKING SPEED

Appliance Ignition speed

of fan

Running speed of fan

Regulation interval

BFC 28 4500 rpm 4980 rpm 40-80 °C

BFC 30 4500 rpm 5400 rpm 40-80 °C

BFC 50 4500 rpm 6000 rpm 40-80 °C

BFC 60 4500 rpm 6660 rpm 40-80 °C

Bring up the menu to display the appliance specifications via:

1. B: SETTINGS.

Confirm with E.

2. Scroll with L to SPECIFICATIONS

Confirm with E.

The display shows the sub-menu for displaying appliance specifications. See Figure 8.48.

3. Scroll with L to the section to be displayed, for example

REGULATION INTERVAL.

The relevant display specification appears, see Figure 8.49.

Figure 8.48 Appliance specifications

REGULATION INTERVAL

40_80ÉC

Figure 8.49 Regulation interval

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9 Service program

9.1 Introduction

SERVICE MENU »HYSTERESE ^ HISTORIE OF ERRORS È APPLIANCE HISTORY

SELECT APPLIANCE PUMP RELAY SERVICE INTERVAL CONTRAST DISPLAY TIME BACKLIGHT SCROLLSPEED

Figure 9.1 Service program

Introduction

The service program is used by the installer or service and maintenance engineer for:

• Setting the hysteresis;

• Displaying the error history;

• Displaying the appliance history;

• Display the selected appliance;

• Setting the pump on/off;

• Setting the service interval;

• Setting the display contrast;

• Setting the backlight time;

• Setting the display scroll speed.

These sub-menus are briefly described in the following paragraphs. If you are not familiar in general with how to use the displays and menus, first read chapter

’5 The control panel’.

9.2 Setting the hysteresis

HYSTERESE UP »3ÉC

Figure 9.2 Heating cycle upper limit

9.3 Displaying the error history

n Remark

The notation convention for the service menu is identical to that described in paragraph ’8.2 Notational convention for menu-related instructions’. The difference is, you use S to bring up the service program, instead of B which brings up the main menu.

If the preset temperature (SETPOINT) is higher than the current water temperature, then the appliance might not immediately start the heating cycle (see chapter ’7.4 The appliance’s heating cycle’). To prevent excessively frequent switching on and off, a there is a heating margin. 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 reaches 2°C above the SETPOINT.

Set the hysteresis via:

• S:

Set the hysteresis via

• S:

Display the error history via:

• S:

The controller will display an overview of ‘Blocking errors’ and ‘Lock out errors’. In both cases, note that the ThermoControl reserves 15 lines for the last 15 error messages. If there are less than 15 error messages, then an ellipsis (...) is displayed. The display first shows the ‘Blocking errors’. When E is pressed, the ‘Lock out Errors’ are then displayed.

HYSTERESE UP

Figure 9.2 shows an example.

HYSTERESE DOWN

HISTORIE OF ERRORS

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Service program

HISTORIE OF ERRORS(B) S04 SENSOR ERROR F06 IONIZATION È CO2 50 HZ ERROR

Figure 9.3 Blocking errors

HISTORIE OF ERRORS(L) F02: FAN F07: FLAME ERROR È ...

Figure 9.4 Lock out errors

9.4 Displaying the appliance history

APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021

IGNIT ERROR 000013

Figure 9.5 service program

9.5 Display the selected appliance

SELECT APPLIANCE »ADM 40 - 135 ^ ADMR 40 - 135 È BFC 28

BFC 30 BFC 50 BFC 60 BFC 80 BFC 100

Figure 9.3 shows an example of ‘Blocking errors’. In this case, the text

HISTORIE OF ERRORS is followed by (B).

Figure 9.4 shows an example of the ‘Lock out errors’. In this case, the text

HISTORIE OF ERRORS is followed by (L).

n Remark

For an overview of all errors and the possible causes, please refer to chapter

’10 Troubleshooting’.

The appliance history sub-menu is used to display the burning hours, the number of ignitions, the number of flame errors, and the number of ignition errors.

Bring up the menu for displaying the appliance history via:

• S:

Bring up the menu for displaying the appliance selection via:

• S:

APPLIANCE HISTORY

Figure 9.5 shows an example.

SELECT APPLIANCE

The appliance selection has been correctly preset in the factory.

Figure 9.6 shows the relevant display.

Figure 9.6 Select appliance

9.6 Setting the pump on/off

PUMP RELAY »ON OFF

Figure 9.7 Pump relay

9.7 Setting the service interval

If a program-controlled pump is installed (Installation, see paragraph 3.10.6) then this can be turned ON or OFF via:

• S:

If the mode mode WEEK PROGRAM or EXTRA PERIOD has priority over the ON/OFF selection for the pump relay in the service menu.

Example

One of the week program periods is currently active. The pump relay setting is OFF within this period. If the pump relay is set ON in the service menu, the pump will nonetheless remain OFF. The pump will only switch ON once the week program period has ended.

To aid servicing, the ThermoControl has a service interval which defines the frequency of maintenance by the service and maintenance engineer based on the number of burning hours. Refer also to paragraph 11.2 .

PUMP RELAY

The standard setting for the pump relay is OFF.

Figure 9.7 shows the related display.

WEEK PROGRAM or EXTRA PERIOD is active, then the setting for

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SERVICE INTERVAL » 500 ^ 1000 BURNING HOURS È 1500

Figure 9.8 Service interval

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 500. Once the preset number of hours is reached, a message to this effect will appear. See paragraph ’6.4 Service condition’.

Adjust the service interval via:

• S:

Refer also to paragraph ’11.2 Determining service interval’.

SERVICE INTERVAL

Figure 9.8 shows the related display.

9.8 Setting the display

contrast

CONTRAST DISPLAY

» 95 %

Figure 9.9 Display contrast

9.9 Setting the backlight

time

TIME BACKLIGHT

» 255 sec

Figure 9.10 Backlight time

9.10 Setting the display

scroll speed

SCROLLSPEED

» 10

Adjust the display contrast via:

• S:

Adjust the backlight time (the time that the display backlight stays lit after the last button is pressed) via:

• S: TIME BACKLIGHT

Adjust the display scroll speed via:

• S: SCROLLSPEED

CONTRAST DISPLAY

The standard setting is 100%. The range is from 0 through 100%.

Figure 9.9 shows the related display.

The standard value is 255 sec. The range is from 0 through 255 seconds.

Figure 9.10 shows the related display.

The standard setting is 10. The range is from 0 through 100. Setting the value too high or low will make scrolling difficult.

Figure 9.11 shows the related display.

Figure 9.11 Scroll speed

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10 Troubleshooting

10.1 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

Table 10.1 gives a troubleshooting overview for general errors.

• Displayed errors

S02: SENSOR ERROR

TOP TANK SENSOR 1

NOT CONNECTED

Figure 10.1 Possible error

Errors are reported on the display, as follows:

- Line 1: An error code and its short description. The code is made up of a letter and two digits.

- Lines 2, 3 and 4: a long description, and a recommended action, alternating every 2 seconds. See Figure 10.1 and Figure 10.2.

S02: SENSOR ERROR

TOP TANK

CHECK TOP TANK

SENSOR

Figure 10.2 Action

The displayed errors are divided into two groups:

There are various types of errors:

- LOCK OUT ERRORS When the cause is no longer present, these errors require a reset with the R button, before the appliance can resume running.

- BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed, after which the appliance resumes by itself.

Table 10.2 gives a troubleshooting overview for the errors that appear on the

display.

n Remark

Footnotes referred to from within any table are shown at the bottom of the last page of that table.

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Immediately contact your installer or local gas company.

n Remark

Warning

Immediately close the main gas valve.

Warning

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

10.2 Troubleshooting table for general errors

Symptom Cause Solution Remark

Table 10.1 General errors (Sheet 1 of 3)

Gas smell Gas leak

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

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If the error cannot be rectified, contact your installer.

See appendix ’A.2 Electrical diagram BFC’.

(position I).

block.

Check that the condensation water discharge is working properly.

Rectify if necessary.

1. Check whether the mains switch is ON.

2. Check that there is power to the mains switch.

3. Check whether the ON/OFF switch of the ThermoControl is ON

4. Check whether there is power to the electrical connection

5. The voltage measured must be 230 VAC (-15%, +10%).

No electric power

present

Warning

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

Symptom Cause Solution Remark

Table 10.1 General errors (Sheet 2 of 3)

Display is off Appliance is turned off. Start-up the appliance. See ’7.2 Starting up’

Tighten the threaded connection. If the leak persists, consult your installer.

Defective fuse(s) Replace fuse(s) To replace the fuses you must contact your installer.

Water leakage Leakage from one of

the water connections

(threaded).

Trace the leak.

Condensation water

leakage

Leakage from another

nearby water

appliance or pipe

Consult the supplier and/or manufacturer.

segment.

Leakage from the

appliance’s tank.

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If ignition is not improved, consult your installer.

Set the correct supply pressure and/or burner pressure, see

’3.11 Checking the supply pressure and burner pressure’.

If the error cannot be rectified, contact your installer.

See appendix ’A.2 Electrical diagram BFC’.

(position I).

block.

1. Check whether the mains switch is ON.

2. Check that there is power to the mains switch.

3. Check whether the ON/OFF switch of the ThermoControl is ON

4. Check whether there is power to the electrical connection

If there continues to be insufficient or no hot water, consult your

installer.

Reduce hot water consumption and give the appliance time to heat

up.

5. The voltage measured must be 230 VAC (-15%, +10%).

Put the controller in ON mode, see ’8.3 Switching into “ON mode”’.

) to a higher value, see ’8.4 Setting the water

set

Set temperature (T

temperature’.

) is

set

Hot water supply is

used up.

Appliance is turned off. Start-up the appliance. See ’7.2 Starting up’

No electric power

pressure and/or burner

pressure.

Contaminated burner Clean the burner. See ’12.4.2 Cleaning the burner’

Contaminated orifice. Clean the orifice. See ’12.4.3 Cleaning the orifice’

Warning

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

Symptom Cause Solution Remark

Table 10.1 General errors (Sheet 3 of 3)

Explosive ignition Incorrect supply

Insufficient or no hot

present.

water.

The controller is in

Temperature (T

OFF mode.

set too low.

10.3 Troubleshooting table for displayed errors

Release R.1.3 UK 72

Page 73

Replace the sensor. To replace the necessary parts, you must contact your installer.

Connect the sensor lead to JP3. See appendix ’A.2 Electrical diagram BFC’.

Damaged wiring or

Sensor is not

(correctly) connected.

defective sensor.

Connect the sensor lead to JP5. See appendix ’A.2 Electrical diagram BFC’.

Sensor is not

(correctly) connected.

to JP4. See appendix ’A.2 Electrical diagram BFC’.

(2)

. To replace the necessary parts, you must contact your installer.

Replace sensor T

Damaged wiring or

defective sensor.

(1)

. To replace the necessary parts, you must contact your installer.

Replace sensor T

Connect the sensor lead to JP5. See appendix ’A.2 Electrical diagram BFC’.

Damaged wiring or

Sensor is not

(correctly) connected.

defective sensor.

(1)

Connect the dummy sensor lead

Dummy is not

(correctly) connected.

to JP4. See appendix ’A.2 Electrical diagram BFC’.

(3)

Connect the dummy sensor lead

Defective dummy. Replace the dummy sensor. To replace the necessary parts, you must contact your installer.

Dummy is not

(correctly) connected.

Defective dummy. Replace the dummy sensor. To replace the necessary parts, you must contact your installer.

. To replace the necessary parts, you must contact your installer.

Replace sensor T

Short circuit in the

sensor circuit.

at the

Warning

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

Code + Description Possible cause Solution Remark

S01 (blocking error)

Open circuit from

Table 10.2 Displayed errors (Sheet 1 of 10)

temperature sensor T

at bottom of tank.

S02 (blocking error)

Open circuit from

sensor 1 of

temperature sensor T

at the top of the tank

S03 (blocking error)

Open circuit from

sensor 2 of

temperature sensor T

S04 (blocking error)

Open circuit from

dummy 1.

S05 (blocking error)

Open circuit from

dummy 2.

S11 (blocking error)

Short circuit from the

at the top of the tank

temp. sensor T

bottom of the tank.

Release R.1.3 UK 73

Page 74

. To replace the necessary parts, you must contact your installer.

Replace sensor T

Short circuit in the

sensor circuit

. To replace the dummy sensor you must contact your installer.

(2)

. To replace the necessary parts, you must contact your installer.

Replace the dummy sensor

Short circuit in dummy

circuit

Replace sensor T

Short circuit in the

sensor circuit

. To replace the dummy sensor you must contact your installer.

(2)

Replace the dummy sensor

Short circuit in dummy

circuit

Warning

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

Table 10.2 Displayed errors (Sheet 2 of 10)

S12 (blocking error)

Short circuit from

Code + Description Possible cause Solution Remark

sensor 1 of

S13 (blocking error)

Short circuit from

sensor 2 of

temperature sensor T

S14 (blocking error)

Short circuit from

dummy 1

S15 (blocking error)

Short in circuit of

temperature sensor T

at the top of the tank

dummy 2.

Release R.1.3 UK 74

Page 75

To have the wiring replaced and a new fan fitted, you must contact

If errors become persistent, contact your installer.

See appendix ’A.2 Electrical diagram BFC’.

your installer.

circuit.

1. Disconnect the lead at the ionisation rod.

2. Ignite the appliance 3 times, with an interrupted ionisation

Connect the phase and the neutral correctly. The appliance is

phase-sensitive. See ’3.10 Electrical connection’.

Condensation on the

Phase and neutral

swapped in error.

Warning

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

Code + Description Possible cause Solution Remark

F01 (blocking error)

Defect in power supply

Table 10.2 Displayed errors (Sheet 3 of 10)

circuit.

3. Reconnect the ionisation lead to the ionisation rod.

ionisation rod.

4. Ignite the appliance again

condensation to evaporate.

5. The repeated ignition attempts will have caused the

Floating neutral. Install an isolating transformer. See ’3.10.4 Isolating Transformer’. Contact your installer to have an isolating transformer installed.

replaced.

2. If any wires are damaged, the wiring harness must be

3. Reset the water heater controller.

1. Check whether the fan is contaminated.

2. Check that the rotor can rotate freely.

3. Reset the water heater controller.

1. Check the supply voltage. This must be 230 VAC (+10% -15%).

2. Reset the water heater controller.

Damaged wiring. 1. Check the wiring between the fan and the controller.

F02 (lock out error)

Fan fails to run at

correct speed.

Contaminated or

blocked fan.

Because of a voltage

drop in the mains

power, the fan will not

run at the correct

speed.

Release R.1.3 UK 75

Page 76

If the error cannot be resolved or is persistent, contact your

installer.

To replace the necessary parts, you must contact your installer.

appliance specifications’.

hose between fan and burner are correctly fitted. Refit these if

necessary.

hose between fan and burner for cracks. If necessary, replace

the hoses.

controller.

1. Check the wiring between the pressure switch and the

2. If necessary, replace the wiring.

Damaged wiring /

Open circuit

Warning

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

Table 10.2 Displayed errors (Sheet 4 of 10)

F03 (lock out error)

The pressure switch

Code + Description Possible cause Solution Remark

fails to work correctly.

2. Check that the hoses on the pressure switch and the air supply

1. Check the running speed of the fan. See ’8.7.4 Displaying

Pressure switch not

closing.

3. Check the hoses on the pressure switch and the air supply

Ta bl e 3 .7 .

4. Check whether the flue gas discharge is compliant with

blockage that may be present.

Remove any blockage that may be present.

See Ta bl e 1 2. 1. If there is insufficient pressure differential,

clean the heat exchanger. If the pressure differential is

acceptable, check that the pressure switch is closing, using a

multimeter.

5. Check for blockage in the flue gas discharge. Remove any

6. Check for blockage in the condensation water discharge.

7. Measure the pressure differential across the pressure switch.

Release R.1.3 UK 76

Page 77

To repair the gas supply, contact your installer.

control.

2. Check supply pressure to the gas control.

how to bleed air from the gas line, and measure the supply

pressure and burner pressure.

To replace the necessary parts, you must contact your installer.

3. If necessary, repair the gas supply.

2. Check that the gas valve(s) open and shut correctly.

If the error persists, contact your installer.

To replace the necessary parts, you must contact your installer.

between 2 and 5 Ω.

3. If necessary, replace the gas control.

1. Check that the glow igniter is correctly connected (JP2).

2. Check the wiring of the glow igniter.

3. Measure the resistance across the glow igniter. This must lie

µA.

4. Check that the glow igniter lights up during ignition.

5. If necessary, replace the glow igniter.

1. Check that the ionisation rod is correctly connected (JP2).

2. Check the wiring of the ionisation rod.

3. Measure the ionisation current. This must be a minimum of 1.5

4. If necessary, replace the wiring.

(+10% -15%).

No gas. 1. Open the main gas valve and/or the gas valve before the gas

Warning

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

Table 10.2 Displayed errors (Sheet 5 of 10)

F04 (lock out error)

Three unsuccessful

Code + Description Possible cause Solution Remark

ignition attempts.

Air in the gas pipes. Bleed the air out of the gas pipe. See ’3.11 Checking the supply pressure and burner pressure’ for

No burner pressure. 1. Check the burner pressure at the gas control.

Defect in the glow

igniter circuit.

Defect in the ionisation

circuit.

Supply voltage too low Check the supply voltage to the appliance. This must be 230 VAC

Release R.1.3 UK 77

Page 78

If the error cannot be resolved or is persistent, contact your

installer.

If the error persists, contact your installer.

To replace the necessary parts, you must contact your installer.

If the error cannot be resolved or is persistent, contact your

installer.

To replace the necessary parts, you must contact your installer.

If the error cannot be resolved or is persistent, contact your

installer.

To replace the necessary parts, you must contact your installer.

2. If necessary, install the correct roof or wall terminal.

Recirculating flue

have been signalled.

area.

3. Check that the roof or wall terminal discharges into a permitted

gases.

Check the wiring of the ionisation rod. If necessary, replace the

wiring.

Damaged cable in

contact with metal

F06 (lock out error)

Short circuit between

’3.9 Air supply and flue gas discharge’.

1. Check that the correct roof or wall terminal has been fitted. See

Incorrect roof or wall

terminal.

Warning

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

Code + Description Possible cause Solution Remark

F05 (lock out error)

Table 10.2 Displayed errors (Sheet 6 of 10)

Too many flame errors

intact, in the vicinity of the air distribution plate of the burner.

1. Check whether the ceramic part of the ionisation rod is still

2. If this is not the case, the ionisation rod must be replaced.

surface.

Ceramic part of the

ionisation rod is

broken/cracked.

ionisation rod and

earth

gas valves have closed.

Defective gas valves. 1. Check whether there is still burner pressure present, after the

F07 (lock out error)

A flame has been

have closed.

2. Check whether a flame is still present, after the gas valves

3. If this is the case, then the gas control must be replaced.

detected after the gas

valve was closed.

1. Reset ThermoControl.

Flame detection

before gas valve

F08 (lock out error)

2. If the error appears again, replace ThermoControl.

opened.

Error message from

safety relay.

Release R.1.3 UK 78

Page 79

If the error cannot be resolved or is persistent, contact your

installer.

If the error cannot be resolved or is persistent, contact your

installer.

To replace the necessary parts, you must contact your installer.

1. Check that the circulation pump (if present) is working.

2. Check the position of the temperature sensor T

3. Reset the water heater controller.

C. If this is the

Error “F09” remains active in the event that the water

temperature during a reset was higher than 78

n Remark

case, first draw water off by opening the nearest hot water tap,

appliance specifications’.

hose between fan and burner are correctly fitted. Refit these if

necessary.

air supply hose between fan and burner. If necessary, replace

the hoses.

so that cold water can flow in.

2. Check that the hoses on the pressure switch and the air supply

1. Check the running speed of the fan. See ’8.7.4 Displaying

3. Check for cracks in the hoses on the pressure switch and the

Ta bl e 3 .8 .

4. Check whether the flue gas discharge is compliant with

blockage that may be present.

Remove any blockage that may be present.

Ta bl e 1 2. 1. If there is insufficient pressure differential, clean the

heat exchanger. If the pressure differential is acceptable, check

that the pressure switch is closing, using a multimeter.

5. Check for blockage in the flue gas discharge. Remove any

6. Check for blockage in the condensation water discharge.

7. Measure the pressure differential across the pressure switch.

Temperature at the top

of the tank exceeds

93°C.

Warning

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

Table 10.2 Displayed errors (Sheet 7 of 10)

F09 (lock out error)

Water temperature

Code + Description Possible cause Solution Remark

protection.

Pressure switch not

closing.

F10 (lock out error)

Restriction on number

of ignition attempts

based on pressure

switch state changes.

Release R.1.3 UK 79

Page 80

Defective gas valves. See F07.

Warning

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

Table 10.2 Displayed errors (Sheet 8 of 10)

F11 (lock out error)

Flame detection with

Code + Description Possible cause Solution Remark

closed gas valve.

Release R.1.3 UK 80

Page 81

To replace the necessary parts, you must contact your installer.

table 3.8. If this is not the case, contact your installer.

ThermoControl.

1. Reset the ThermoControl.

2. Check that the frequency of the mains power complies with

3. If the frequency is correct but the error persists, replace the

Incorrect reference

voltage from the AD

converter.

Warning

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

Table 10.2 Displayed errors (Sheet 9 of 10)

C02 (lock out error)

Error message from

Code + Description Possible cause Solution Remark

the water heater

controller.

EEPROM read error.

50 Hz error.

Internal error message

from the water heater

controller.

Internal

communication error

Gas valve relay error.

Safety relay error.

Internal error message

from the water heater

controller.

Ignition relay error.

RAM error.

EEPROM error.

EEPROM contents do

not match the software

version.

Processor software

error.

Release R.1.3 UK 81

Page 82

If the error does not disappear, you must contact your installer.

To replace the necessary parts, you must contact your installer.

To obtain a selection resistor, you must contact your installer.

To replace the necessary parts, you must contact your installer.

To replace the dummy sensor you must contact your installer.

resistor.

’9.5 Display the selected appliance’.

3. If incorrect appliance selected, select the correct one.

None. This is a temporary message that may appear from time to

The temperature of the

E01 (blocking error)

time, but will disappear automatically.

water at the top of the

tank is > 85°C.

The temperature

protection at the top of

the tank has been

activated.

Wait for the error to disappear (maximum 1 hour). If the error does

not disappear, the water heater controller must be replaced.

1. Check whether the correct appliance has been selected. See

2. If the correct appliance is selected, fit the correct selection

Too many resets in too

short a period.

Incorrect appliance

selection /

Incorrect selection

resistor.

Warning

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

Table 10.2 Displayed errors (Sheet 10 of 10)

C03 (blocking error)

Reset error.

C04 (blocking error)

Appliance selection

Code + Description Possible cause Solution Remark

error.

1. Check sensor position and wiring.

The temperature

E03 (blocking error)

the error persists.

2. Reset the ThermoControl if necessary. Replace the sensor if

differential between

the two temperature

at the top of

Error in temperature

sensor T

sensors in the tank is >

the tank.

10°C over a period of

60 seconds or longer.

if the error persists.

1. Check wiring from dummy 1 and dummy 2.

2. Reset ThermoControl if necessary. Replace the dummy sensor

10°C

The two dummy

sensors detect a

differential of >

(2)

E04 (blocking error)

Error in the dummy

sensor

contains 2 NTCs for the high-limit thermostat and safety thermostat protection.

over a period of 60

seconds or longer.

is a ‘2 in 1’ sensor, T

2. The dummy sensor consists of dummy sensor 1 and dummy sensor 2

3. The dummy sensor consists of dummy sensor 1 and dummy sensor 2

1. Temperature sensor T

Release R.1.3 UK 82

Page 83

Introduction

11 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.

n Remark

Regular maintenance extends the service life of the appliance.

n Remark

11.2 Determining service interval

!!! WARNING !!!

MAX. BURNINGHOURS:

SERVICE REQUIRED

Figure 11.1 Service required

To aid servicing, the ThermoControl has a service interval which defines the frequency of maintenance by the service and maintenance engineer based on the number of burning hours.

The service interval 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 service per year will be sufficient. So after one year, some 1200 burning hours will have elapsed. The first value below 1200 hours that can be selected is 1000 burning hours.

In this case, the service and maintenance engineer sets the interval to 1000.

Example

In the first three months, the appliance has burnt 300 hours. During maintenance, it is evident (perhaps due to the water quality) that service will be required at least once every 6 months. So after six months, some 600 burning hours will have elapsed. The first value below 600 hours that can be selected is 500 burning hours.

In this case, the service and maintenance engineer sets the interval to 500.

Once the set number of burning hours has elapsed, the message SERVICE REQUIRED will appear on the display. See Figure 11.1. Once the message appears. contact should be made with the service and maintenance engineer.

Release R.1.3 UK 83

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Maintenance frequency

84 Instruction Manual BFC

Page 85

12 Maintenance

12.1 Introduction

Introduction

cNote

Maintenance may only by carried out by an approved service and maintenance engineer.

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.

1. Preparation for maintenance;

2. Water-side maintenance;

3. Gas-side maintenance;

4. Finalising maintenance.

12.2 Preparation for maintenance

MENU »OFF ^ ON È WEEK PROGRAM

Figure 12.1 Main menu

n Remark

Before ordering spare parts, take a moment to write down the appliance type and model, and the full serial number of the appliance. Only by ordering with this information can you be sure to receive the correct spare parts. These details can be found on the rating plate.

To test whether all components are still working properly, you should complete the following steps:

1. Activate the MENU with B.

2. Use H and L to position the cursor beside OFF. See Figure 12.1.

3. Confirm OFF with E.

4. Wait until the fan has stopped. The

S icon is then dimmed.

cNote

Failure to wait until the fan stops can cause damage to the appliance.

5. Turn the appliance OFF (position 0) using the ON/OFF switch on the control panel. See Figure 12.2.

6. Turn the ThermoControl ON by putting the ON/OFF switch to position I.

Figure 12.2 ThermoControl

Release R.1.3 UK 85

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Maintenance

INTERNAL CHECK

Figure 12.3 Internal check

MENU »OFF ^ ON È WEEK PROGRAM

Figure 12.4 Main menu

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

Figure 12.5 Starting up

The display will now show INTERNAL CHECK for about 10 seconds, and will then go to the main menu.

7. Activate the “ON mode” by going through the following steps:

- Press once on the DOWN button (L) to position the cursor beside ON,

then press E. The display shown in Figure 12.5 appears.

- Confirm with E the option START OPERATION.

8. If there is no heat demand, increase T

water temperature’ (take note of the original setting) and draw off some

water to create a heat demand.

9. Check whether the heating cycle runs correctly. See paragraph ’7.4 The

appliance’s heating cycle’.

10. If you adjusted T

’8.4 Setting the water temperature’.

11. Remove the plastic cover on the top side of the appliance.

12. Check the supply and burner pressures and adjust these, where necessary. See paragraph ’3.11 Checking the supply pressure and burner pressure’.

13. Check that all components of the flue gas system are properly attached.

14. Check the pressure differential across the orifice plate of the pressure switch. See Table 12.1. If the pressure differential is too low, then the heat exchanger should be cleaned. See paragraph ’12.5 Finalising

maintenance’.

Table 12.1 Pressure switch differential

, return the setting to the original value. See paragraph

set

. See paragraph ’8.4 Setting the

set

Appliance Observed pressure differential across the pressure switch

(Pa)

BFC 28 >

BFC 30 >

BFC 50 >

BFC 60 >

15. Test the operation of the overflow valve of the 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 wastewater pipes of the overflow valves and remove any lime buildup that may be present.

18. Drain the appliance. See paragraph ’4.3 Draining the appliance’.

635

885

1085

86 Instruction Manual BFC

Page 87

12.3 Water-side maintenance

12.3.1 Introduction

12.3.2 Checking the anodes

12.3.3 Descaling and cleaning the tank

1. Remove the cover plate 1 on the outer jacket. See Figure 12.6.

IMD-0080

Figure 12.6 Cleaning opening

Water-side maintenance

The following steps should be carried out on the water side:

1. Checking the anodes.

2. Descaling and cleaning the tank.

3. Cleaning condensation water discharge.

Timely replacement of the anodes extends the service life of the appliance. The appliance’s anodes must be replaced as soon as they are 60% or more used up (take this into consideration when determining the maintenance frequency).

1. Loosen the anodes using suitable tools.

2. Check the anodes, and if necessary, replace them.

Scale and lime buildup prevent effective conduction of the heat to the water. Periodic descaling prevents buildup of these deposits. This increases the service life of the appliance, and also improves the heating process. Take the rate of scale formation into account when deciding on maintenance frequency.

2. Undo the bolts.

3. Remove the cover and the gasket.

4. Inspect the tank and remove any contamination.

(1)

5. Remove the scale using Borcoil

6. Close the cleaning opening. Use a new rubber gasket for this.

12.3.4 Cleaning condensation water discharge

12.4 Gas-side maintenance

12.4.1 Introduction

12.4.2 Cleaning the burner

It is essential to clean the condensation water discharge and siphon, to prevent blockages.

The following steps should be carried out on the gas side:

1. Cleaning the burner.

2. Cleaning the orifice.

3. Finalising maintenance.

1. Detach the burner.

2. Remove all contamination present on the burner.

3. Fit the burner.

1. 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.

Release R.1.3 UK 87

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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 cleaner and a soft brush.

3. Detach the flue gas discharge.

4. Clean the end of the heat exchanger using tap water.

5. Fit the burner.

6. Fit the flue gas discharge.

n Remark

Check the pressure differential again after cleaning. If the pressure differential is too low following cleaning, please contact the supplier of the appliance.

12.5 Finalising maintenance

To finalise the maintenance carry out the following steps:

1. Fill the appliance. See paragraph ’4.2 Filling the appliance’.

2. Re-start the appliance. See ’7.2 Starting up’.

3. Remove the

pressing R once, followed by E once.

SERVICE REQUIRED message. Do this by:

88 Instruction Manual BFC

Page 89

General warranty

gis

13 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 water heater supplied by A.O. Smith Water Products Company B.V. of Veldhoven, The Netherlands (hereinafter “A.O. Smith”) the right to the warranty set out below, defining commitments of A.O. Smith to the owner.

13.1 General warranty 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. Smith shall replace or repair this part or component.

13.2 Tank warranty If within 3 years of the original installation date of a water heater supplied by

A.O. Smith, following inspection, and at the sole option of A.O. Smith, the glasslined steel tank proves to be leaking due to rust or corrosion occurring on the water side, A.O. Smith shall provide an entirely new water heater of equivalent size and quality. The warranty period given on the replacement water heater shall be equal to the remaining warranty period of the original water heater that was supplied. Notwithstanding that stated earlier in this article, in the event that unfiltered or softened water is used, or allowed to stand in the water heater, the warranty shall be reduced to one year from the original installation date.

13.3 Installation and

conditions of use

The warranty set out in article 1 and 2 will apply solely under the following conditions:

a. the water heater is installed under strict adherence to the installation

instructions of A.O. Smith applying to the specific model, and the relevant local authority installation and building codes, rules and regulations in force;

b. the water heater remains installed at the original site of installation;

c. the appliance is exclusively used with drinking water, which at all times can

freely circulate (a separately installed heat exchanger is mandatory for heating salt water or corrosive water);

d. the tank is safeguarded against harmful scaling and lime buildup by means

of periodic maintenance;

e. the water temperatures in the heater do not exceed the maximum setting of

the thermostats, which form a part of the water heater;

f. the water pressure and/or heat load do not exceed the maximum values

stated on the water heater rating plate;

g. the water heater is installed in a non-corrosive atmosphere or environment;

h. the water heater is connected to a cold water supply arrangement, which is:

approved by the relevant authority; with sufficient capacity for this purpose; supplying a pressure no greater than the working pressure stated on the water heater; and where applicable, fitted with a temperature and pressure relief valve compliant with the installation instructions of A.O. Smith pertaining to the specific model of water heater, and under adherence to the relevant local authority installation and building codes, rules and regulations in force;

i. the anodes are replaced and renewed no later than when 60% used up.

13.4 Exclusions The warranty set out in article 1 and 2 will not apply, in the event of:

a. damage to the water heater caused by an external factor;

Release R.1.3 UK 89

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Warranty (Certificate)

gis

b. misuse, neglect (including frost damage), modification, incorrect and/or

unauthorised use of the water heater and any attempt to repair leaks;

c. contaminants or other substances having been allowed to enter the tank;

d. the conductivity of the water being less than 125 µS/cm and/or the hardness

(alkaline-earth ions) of the water being less than 1.00 mmol/lit (seeTa bl e 3 .3 );

e. unfiltered, recirculated water flowing through or being stored in the water

heater;

f. any attempts at repair to a defective water heater other than by an approved

service engineer.

13.5 Scope of the warranty

13.6 Claims A claim on grounds of the specified warranty must be submitted to the dealer

13.7 Limitation of liability A.O. Smith

The obligations of A.O. Smith pursuant to the specified warranty do not extend beyond free delivery from the Veldhoven warehouse of the replacement parts or components or water heater. Shipping, labour, installation and any other costs associated with the replacement will not be accepted by A.O. Smith.

from whom the water heater was purchased, or to another authorised dealer for the products of A.O. Smith Water Products Company. Inspection of the water heater as referred to in articles 1 and 2 shall take place in one of the laboratories of A.O. Smith.

A.O. Smith grants no other warranty or guarantee over its water heaters nor the (parts or components of) water heaters supplied for replacement, other than the 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.

90 Instruction Manual BFC

Page 91

A Appendices

A.1 Introduction This appendix contains:

•The Electrical diagram BFC.

•A Week program card.

Release R.1.3 UK 91

Page 92

A.2 Electrical diagram

BFC

Appendices

= brown

= blue

= yellow/green

= black

(

= white (flat ca-

= grey/beige

TERMINAL STRIP CONNECTIONS:

A Earth

N Neutral L1Phase input of controller L2Phase input of isolating transformer (primary side) L3Phase output of isolating transformer (secondary side) L4Phase input of program-controlled pump L5Phase input of continuous pump

COMPONENTS:

A Controller B Ionisation rod C Glow igniter D Gas control E Burner earth connection F Extra ON mode switch G Continuous pump H Program-controlled pump J Extra error signal K Isolating transformer L Double-pole mains switch M ON/OFF switch control N Display/Flat cable

OFan P Temperature sensor (T2 - bottom of tank) Q Dummy R Temperature sensor (T1 - top of tank) S Selection resistor T Pressure switch

CONTROLLER CONNECTIONS:

J1 Connector for display to controller J2 Connector for power supply to controller J19 Connector for extra error signal J20 Connector for gas control J21 Connector for program-controlled pump J24 Connector for fan JP2 Connector for ionisation rod and glow igniter JP3 Connector for temperature sensor T2 JP4 Connector for dummy JP5 Connector for temperature sensor T1 JP6 Connector for selection resistor and pressure switch JP8 Connector for extra ON mode switch

F1 Fuse F2 Fuse

Figure A.1 Electrical diagram BFC

92 Instruction Manual BFC

Page 93

.... °C ON / OFF

A.3 Week program card

.... °C ON / OFF 12.

.... °C ON / OFF 13.

.... °C ON / OFF 14.

.... °C ON / OFF 15.

.... °C ON / OFF 16.

.... °C ON / OFF 17.

.... °C ON / OFF 18.

.... °C ON / OFF 19.

.... °C ON / OFF 20.

.... °C ON / OFF 21.

.... °C ON / OFF

OFF OFF

Period DAY TIME Ts et Pump Period DAY TIME Ts et Pump

10.

You can fill-in the week program card, cut it out and keep it near the appliance.

!- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

OFF

OFF OFF

11.

Example

Period DAY TIME Ts et Pump

70 °C ON / OFF

ON Monday 14:30

OFF Monday 16:15

Release R.1.3 UK 93

Page 94

Release R.1.3 UK 94

Page 95

gis

IX Index

Alarm OUT connection - - - - - - - - - - - - - 33 ambient temperature - - - - - - - - - - - - - - 18 appliance

display selection - - - - - - - - - - - - - - 66 displaying history - - - - - - - - - - - - - - 66 displaying specifications - - - - - - - - - - 62 functional description - - - - - - - - - - - - 13 heating cycle - - - - - - - - - - - - - - - - 14 installation types - - - - - - - - - - - - - - 9 protection- - - - - - - - - - - - - - - - - - 14

burner pressure- - - - - - - - - - - - - - - - - 33

extra period - - - - - - - - - - - - - - - - - - - 45

programming - - - - - - - - - - - - - - - -60

fan - - - - - - - - - - - - - - - - - - - - - - - 15 filling - - - - - - - - - - - - - - - - - - - - - - 39 floor loading- - - - - - - - - - - - - - - - - - - 18 forms of notation - - - - - - - - - - - - - - - - 10 frost protection - - - - - - - - - - - - - - - - - 45 functional description - - - - - - - - - - - - - - 13

gas

conversion - - - - - - - - - - - - - - - - - 35

gas connection - - - - - - - - - - - - - - - - - 26 gas control - - - - - - - - - - - - - - - - - - - 15

Index

check

supply pressure, burner pressure - - - - - - 33

chimney length - - - - - - - - - - - - - - - - - 27 claims - - - - - - - - - - - - - - - - - - - - - 90 condensation drainage

connect- - - - - - - - - - - - - - - - - - - 25

condition

ERROR - - - - - - - - - - - - - - - - - - 46 SERVICE REQUIRED - - - - - - - - - - - 47

connect

Alarm OUT - - - - - - - - - - - - - - - - - 33 circulation pipe - - - - - - - - - - - - - 25 cold water side - - - - - - - - - - - - -25 condensation drainage - - - - - - - - - - - 25 continuous pump - - - - - - - - - - - - - - 32 electrical - - - - - - - - - - - - - - - - - - 30 gas - - - - - - - - - - - - - - - - - - - - - 26 hot water side- - - - - - - - - - - - - - - - 25 isolating transformer - - - - - - - - - - - - 32 program-controlled pump - - - - - - - - - - 32 Tank ON - - - - - - - - - - - - - - - - - - 32

connecting circulation pipe - - - - - - - - -25 connecting cold water side - - - - - - - - -25 connecting hot water side - - - - - - - - - - - - 25 continuous pump connection - - - - - - - - - - 32 conversion to different gas - - - - - - - - - - - 35

data

general - - - - - - - - - - - - - - - - - - - 21

descaling - - - - - - - - - - - - - - - - - - - - 87 dimensions - - - - - - - - - - - - - - - - - - - 21 display - - - - - - - - - - - - - - - - - - - - - 43 displaying error history - - - - - - - - - - - - - 65 document contents - - - - - - - - - - - - - - - 11 draining- - - - - - - - - - - - - - - - - - - - - 41

, 26 , 26

heat demand - - - - - - - - - - - - - - - - - - 51 heating cycle - - - - - - - - - - - - - - - -14, 51 humidity - - - - - - - - - - - - - - - - - - - - 18 hysteresis setting - - - - - - - - - - - - - - - - 65

icon

(pre)glow - - - - - - - - - - - - - - - - - - 44 flame detection - - - - - - - - - - - - - - -44 gas control - - - - - - - - - - - - - - - - - 44 heat demand - - - - - - - - - - - - - - - - 44

icons - - - - - - - - - - - - - - - - - - - - - -44 ignition - - - - - - - - - - - - - - - - - - - - -51 installation diagram - - - - - - - - - - - - - - - 23 installation types

air supply - - - - - - - - - - - - - - - - - - 27 flue gas discharge- - - - - - - - - - - - - - 27

installer - - - - - - - - - - - - - - - - - - - - - 10 ionisation rod - - - - - - - - - - - - - - - - - - 16 isolating transformer connection - - - - - - - - -32

language setting - - - - - - - - - - - - - - - - 61 liability - - - - - - - - - - - - - - - - - - - - - 3 lime- - - - - - - - - - - - - - - - - - - - - - - 87

mains power - - - - - - - - - - - - - - - - - - 31 mains switch - - - - - - - - - - - - - - - - - - 31 Maintenance

heat exchanger - - - - - - - - - - - - - - - 88

electrical connection - - - - - - - - - - - - - - 30 electrical connection block - - - - - - - - - - - 30 electrical diagram - - - - - - - - - - - - - - - - 92 environmental conditions - - - - - - - - - - - - 17 error - - - - - - - - - - - - - - - - - - - - - - 46 extra - - - - - - - - - - - - - - - - - - - - - - 45

Release R.1.3 UK 95

Page 96

Index

gis

maintenance

anode - - - - - - - - - - - - - - - - - - - 87 burner - - - - - - - - - - - - - - - - - - - 87 carrying out - - - - - - - - - - - - - - - - - 85 condensation discharge - - - - - - - - - - - 87 descaling - - - - - - - - - - - - - - - - - - 87 finalising - - - - - - - - - - - - - - - - - - 88 gas-side - - - - - - - - - - - - - - - - - - 87 lime buildup- - - - - - - - - - - - - - - - - 87 orifice- - - - - - - - - - - - - - - - - - - - 88 preparation - - - - - - - - - - - - - - - - - 85 water-side - - - - - - - - - - - - - - - - - 87

mode - - - - - - - - - - - - - - - - - - - - - - 45

EXTRA - - - - - - - - - - - - - - - - - - - 45 OFF - - - - - - - - - - - - - - - - - - - - 45 PROG - - - - - - - - - - - - - - - - - - - 45

navigation buttons - - - - - - - - - - - - - - - 44

off - - - - - - - - - - - - - - - - - - - - - - - 45 on - - - - - - - - - - - - - - - - - - - - - - - 45 ON mode - - - - - - - - - - - - - - - - - - - - 54 on/off switch - - - - - - - - - - - - - - - - - - 44 operating - - - - - - - - - - - - - - - - - - - - 43 operating mode

EXTRA - - - - - - - - - - - - - - - - - - - 45 OFF - - - - - - - - - - - - - - - - - - - - 45 ON - - - - - - - - - - - - - - - - - - - - - 45 PROG - - - - - - - - - - - - - - - - - - - 45

operating modes - - - - - - - - - - - - - - - - 45

packaging - - - - - - - - - - - - - - - - - - - 17 PC connection - - - - - - - - - - - - - - - - - 44 post-purge - - - - - - - - - - - - - - - - - - - 51 power cord - - - - - - - - - - - - - - - - - - - 31 pre-glow - - - - - - - - - - - - - - - - - - - - 51 pre-purge - - - - - - - - - - - - - - - - - - - - 51 pressure switch - - - - - - - - - - - - - - - 15 prog - - - - - - - - - - - - - - - - - - - - - - 45 program-controlled pump connection - - - - - - 32 protection- - - - - - - - - - - - - - - - - - - - 14 pump - - - - - - - - - - - - - - - - - - - - - - 66 push buttons - - - - - - - - - - - - - - - - - - 43

roof flue terminal - - - - - - - - - - - - - - - - 29 running - - - - - - - - - - - - - - - - - - - - - 51

safety- - - - - - - - - - - - - - - - - - - - - - 16 scale - - - - - - - - - - - - - - - - - - - - - - 87

, 51

scrolling- - - - - - - - - - - - - - - - - - - - - 44 service check - - - - - - - - - - - - - - - -10 service engineer - - - - - - - - - - - - - - - - 10 service required - - - - - - - - - - - - - - - - - 47 setting backlight time - - - - - - - - - - - - - - 67 setting display contrast - - - - - - - - - - - - - 67 setting display scroll speed - - - - - - - - - - - 67 setting service interval- - - - - - - - - - - - - - 66 setting the day - - - - - - - - - - - - - - - - - 62 shutting down

brief period - - - - - - - - - - - - - - - - -50 disconnecting - - - - - - - - - - - - - - - - 50

longer period - - - - - - - - - - - - - - - - 50 softlite - - - - - - - - - - - - - - - - - - - - -15 specifications - - - - - - - - - - - - - - - - - - 20

starting up - - - - - - - - - - - - - - - - - - -49 state

HEAT DEMAND - - - - - - - - - - - - - - 51

IGNITION - - - - - - - - - - - - - - - - - - 51

POST-PURGE - - - - - - - - - - - - - - - 51

PRE-GLOW- - - - - - - - - - - - - - - - - 51

PRE-PURGE - - - - - - - - - - - - - - - - 51

PRESSURE SWITCH - - - - - - - - - - - - 51

RUNNING - - - - - - - - - - - - - - - - - 51 supply pressure - - - - - - - - - - - - - - - - - 33

symbol

installer - - - - - - - - - - - - - - - - - - - 10

service engineer - - - - - - - - - - - - - - 10

user - - - - - - - - - - - - - - - - - - - - 10

Tank ON connections - - - - - - - - - - - - - - 32 target groups - - - - - - - - - - - - - - - - - - 10 temperature sensor

T1 - - - - - - - - - - - - - - - - - - - - - 14

T2 - - - - - - - - - - - - - - - - - - - - - 14 ThermoControl - - - - - - - - - - - - - - - - - 43

on/off switch - - - - - - - - - - - - - - - -44

operating - - - - - - - - - - - - - - - -43 Tnet - - - - - - - - - - - - - - - - - - - - - - 14

trademarks - - - - - - - - - - - - - - - - - - - 3

user - - - - - - - - - - - - - - - - - - - - - - 10

wall flue terminal - - - - - - - - - - - - - - - - 28 warranty - - - - - - - - - - - - - - - - - - - - 89

exclusions - - - - - - - - - - - - - - - - - 89

general - - - - - - - - - - - - - - - - - - - 89

installation and conditions of use - - - - - - 89

scope - - - - - - - - - - - - - - - - - - - - 90

tank- - - - - - - - - - - - - - - - - - - - - 89 water

composition - - - - - - - - - - - - - - - - - 18

setting the temperature - - - - - - - - - - -54 week program- - - - - - - - - - - - - - - - - - 45

, 83

, 53

0306 059

Instruction Manual BFC

A.O. Smith 28 30 50 60 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Copyright

Trademarks

Liability

More information

Table of contents

About the appliance

1 Introduction

1.2 What to do if you smell gas

1.3 Regulations As the (end) user, installer or service and maintenance engineer, you must

1.4 Target groups The three target groups for this manual are:

1.5 Maintenance A service should be carried out at least once a year, both on the water side and

1.6 Forms of notation The following notation is used in this manual:

1.7 Overview of this document

Introduction

2.2 Functional description of the appliance

2.3 The appliance’s heating cycle

2.4 Protection for the appliance

2.4.1 Water temperature protection

2.4.2 Gas control

2.4.3 Fan

2.4.4 Pressure switch

2.4.5 Ionisation rod

2.5.1 Unvented installation

2.5.2 Vented installation

2.5.3 T&P valve

Introduction

3 Installation

• Packaging;

• Environmental conditions;

3.3.1 Humidity and ambient temperature

3.3.2 Maximum floor loading

3.3.3 Water composition

3.3.4 Working clearances

3.4 Technical specifications

Tab l e 3.6 Gas data

3.5 Installation diagram

3.6.1 Cold water side

3.6.2 Hot water side

Water connections, Unvented

3.6.3 Circulation pipe

3.6.4 Condensation drainage

3.7 Water connections, Vented

3.7.1 Cold water side

3.7.2 Hot water side

3.8 Gas connection

3.7.3 Circulation pipe

3.7.4 Condensation drainage

3.9 Air supply and flue gas discharge

3.9.1 Concentric wall flue terminal

3.9.2 Concentric roof flue terminal

3.10 Electrical connection

3.10.1 Introduction

3.10.2 Preparation

3.10.3 Mains voltage

3.10.4 Isolating Transformer

3.10.5 Continuous pump

3.10.6 program-controlled pump

3.10.7 Extra ON mode switch (“Tank ON”)

3.10.8 Connecting extra error signal (“Alarm OUT”)

3.11 Checking the supply pressure and burner pressure

3.12 Conversion to a different gas category

15.Check the burner and supply pressure (see paragraph 3.11).

4 Filling and draining

4.2 Filling the appliance

4.2.1 Filling unvented installations

Introduction

4.2.2 Filling vented installations

4.3 Draining the appliance

4.3.1 Draining unvented installations

4.3.2 Draining vented installations

Introduction

5 The control panel

• 5.2 Operating;

5.3 Explanation of the icons

5.4 ON/OFF switch of ThermoControl

Figure 5.4 Navigation buttons