Installation User and Service Manual Installation User and Service
Contents
1. 43 Introduction 43 Control panel 43 Explanation of the icons 44 V 0 l svvitch 44 Control thermostat 44 Week timer circuit 44 Flue gas backflow safeguard reset button 45 Status of the appliance 47 Introduction 47 Operating states 47 Power Anode Status 47 Error states 48 Starting up and shutting down 49 Introduction 49 Starting up 49 Shutting down 50 7 3 1 Shutting the appliance down for brief periods OFF mode 50 7 3 2 Disconnecting the appliance from the mains 50 7 3 3 Shutting the appliance down for a longer period 50 The appliance s heating cycle 50 Troubleshooting 53 Inthoduction lt s Sem om etin rp ches sezon 53 Troubleshooting table for general errors 54 Troubleshooting table no hot water 56 Troubleshooting tabl2. 9194 ejem joy Aue Ajddns o sje a2upudde au J 49 2M joy OU lqe Bunooysalgnosl g g yeoulbue soueuayuiew pue eones p lJilenb e Aq mo pales aq juo p noys S9UEURUIEiN BuluEAA A 18 0 Z q Aedold ale sdund junys Jo pue UOHE NDIO ay 18 Oe os J 1noyul Buryno si 80 JOIJEJSUI INO aye pue A BA yuu yBly ay seyjeym yoayo AyeinBas sinooo 10118 SIULI Z 586 y HO nus suleul ay woy soueldde ay joauuoosip Jajem au dn 1894 o aun ybnoua dn aq ued sne Jayjo ou pue palos JOU sey ay esueljdde au mojjy uonduinsuoo joy jo ay sonpay pasn Ajddns Jajem JOH 18 OLJUOD Ce xo oo 951 Bunjes yde Besed sas Sum s JayBiy e o jeysouay O4JUOD ay jes JOY juelsynsu SEU uonn os sneo uio jdu s JOY lu l9ijinsul 8 lqeL ABJEM JOY JUSIOIYNSU 678 4 1 ay nsuog S SDE ajgissod ale 9194 ejem joy Aue Ajddns o sje aoueldde au J JOY ualoiynsui lqe Bupoousaigno1l rg X et yeoulbue pue eones panijenb e Aq mo pales aq juo p noys 59u eu lu jN En BuluEAA A 89 0 Z q sdUeUS UIEW pue ales paljenb e Aq jno panes aq juo pinous 52ueu lu e lj
3. A 9 9 1 Introduction 9 2 Preparing for maintenance 9 3 Water side maintenance 9 3 1 9 3 2 Release R 2 0 Uk Introduction Maintenance W Caution 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 Preparing for maintenance N Water side maintenance m Gas side maintenance Finalising maintenance ul Note Before ordering spare parts take a moment to write down the appliance type and model and the full serial number of the appliance Only 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 Check the supply pressure and burner pressure and adjust these where necessary See paragraph 3 12 Checking the supply pressure and burner pressure Also check that this is running properly during the warm up cycle See paragraph 7 4 The appliance s heating cycle 2 Check that all components of the flue gas system are properly attached 3 Test the operation of the overflow valve of the cold water supply arrangement The water should spurt out 4 Test the overflow operation of the T amp P valve The water should s
4. 28 Flue gas discharge 28 3 9 1 Introduction 29 3 9 2 Fitting the draught diverter 29 3 9 3 Flue gas thermostat assembly 30 5 3 10 3 11 3 12 4 1 4 2 4 3 5 1 5 2 5 3 5 4 5 5 5 6 5 7 6 1 6 2 6 3 6 4 7 1 7 2 7 3 7 4 8 1 8 2 8 3 8 4 9 1 9 2 Electrical connection 31 3 10 1 Introduction z m Scar oz Tez es se um ee 31 3 10 2 Mains power 32 3 10 3 Week timer circuit 32 Conversion to a different gas category 32 3 11 1 Introduction 33 3 11 2 Conversion to a different gas category 33 Checking the supply pressure and burner pressure 35 Filling and draining 39 Introduction gt 302 E mi a N 39 Filling the appliance 40 4 2 1 Filling unvented installations 40 4 2 2 Filling vented installations 40 Draining the appliance 40 4 3 1 Draining unvented installations 40 4 3 2 Draining vented installations 41 Controls
5. 16 Safety of the installation 16 2 5 1 Unvented installation sealed 16 2 5 2 Vented installation open 17 2 5 3 T amp P valve 17 Installation 19 Introduction 19 Packaging 21 Environmental conditions 21 3 3 1 Working clearances 21 3 3 2 Humidity and ambient temperature 21 3 3 3 Maximum floor loading 22 3 3 4 Water composition 22 Technical specifications 22 Installation diagrams 24 Water connections Unvented 26 3 6 1 Cold water side 26 3 6 2 Shunt pipe 26 3 6 3 Hot water side 26 3 6 4 Drain valve 26 3 6 5 Circulation pipe 27 Water connections Vented 27 3 7 1 Cold water side 27 3 7 2 Shunt pipe 27 3 7 3 Hot water side 27 3 7 4 Circulation pipe 27 Gas connection
6. 23 3 Installation Table 3 5 Specifications for gas categories appliance category 1l243 Continued ED Description Unit BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 G31 propane Nominal load Upper Value kW 41 4 52 8 78 4 98 3 125 5 Supply pressure mbar 37 37 37 37 37 Burner pressure mbar Gas consumption kg h 3 0 3 8 5 6 7 0 9 0 1 If using a flat sealing plate instead or 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 2 Based on 1013 25 mbar and 15 C Table 3 6 General data Description Unit BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 Capacity litres 309 298 335 278 253 Number of bar burners orifices 3 4 7 7 9 Number of flue tubes flue baffles 5 7 9 12 16 Empty weight kg 198 212 241 247 273 Number of anodes 2 2 3 3 4 Maximum working pressure bar 8 8 8 8 8 Table 3 7 Electrical data DESCRIPTION Unit All models Electrical power consumption W 30 Supply voltage ACS VAC 230 15 10 Net frequency Hz 50 1 Hz 3 5 Installation diagrams 24 Figure 3 2 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 Instruction Manual BCT EX Leg
7. General errors cannot be displayed on the control panel but these errors usually do not cause the hot water supply to fail neither fully nor partially If the hot water supply should fail this is termed an error state See paragraph 6 4 Error states If the hot water supplied is insufficient this is usually caused by an incorrect setting or some temporary problem The following pages provide troubleshooting tables for each type of error 53 195 ay sey Jajesy ay Ul au HUN yem ejem de yonu 00 joy yo Buimelp 210429 uonesu puo2 1 Ie sui ino insuo u q zou sey Yee au 11 Aueduuoo 566 jesoj JO Ja eysul 12 1400 son 6 JeJnj9ejnueu Jo pue 40 5 ay 11 19402 NUE s s9ueijdde ay wou abeyea7 NE l ay SOLI Aqueau adid JO agueldde Jajem Jayjoue beyes Uono uuoo au uay IL s souel dde ay WOO ay 1 S UIEH payeu ON M Saus Aue ejesado jou oq 1 SAA 586 urew ay esojo jejerpawuu 1 uonnlos uono uuoo5 e wo ebeyes7 YES seo sneo AN 0 Z se l z Beye 1 PAA 1 1 9415 seo woj dwfs Z 40 Bed S1
8. S Height of the T amp P plug centre mm 1490 1490 1700 1535 1600 1 Cold water supply connection external R1 2 Hot water outlet connection internal Rp 1 3 Gas control connection internal Rp 4 Tank drain valve connection internal Rp 1 5 T amp P valve connection internal 1 11 5 NPT 6 Dimensions of the cleaning opening and inspection 100 opening mm Table 3 5 Specifications for gas categories appliance category Iloy34 Description Unit BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 Data for natural gas gas category 2H Diameter of orifices mm 3 20 3 20 2 95 3 20 3 30 Burner pressure regulator Yes Yes Yes Yes Yes G20 Nominal load Upper Value kW 42 1 53 4 83 2 102 6 128 8 Supply pressure mbar 20 20 20 20 20 Burner pressure mbar 8 6 7 8 8 5 9 2 7 8 Gas consumption m h 4 0 5 1 7 9 9 8 12 3 Heating up time dT 44 C min 30 23 16 11 8 Data for LP gas gas category 3 Diameter of orifices mm 1 70 1 60 1 50 1 70 1 75 G30 30 mbar butane Nominal load Upper Value kW 42 2 53 4 80 8 100 1 127 5 Supply pressure mbar 30 30 30 30 30 Burner pressure mbar Gas consumption kg h 3 1 3 9 5 9 7 3 9 3 2 If using a flat sealing plate instead or 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 Based on 1013 25 mbar and 15 C Release R 2 0 Uk
9. Table 5 2 Temperature settings Position Temperature 1 40 C 2 50 C 3 60 C 4 70 C Optionally you can use the week timer to program when the appliance must supply the heat demand Set the 1 0 ll switch to the Il position to activate the week timer circuit The timer O week disk is divided into seven segments Monday to Sunday Each day is divided into 12 tabs O 2 hours per tab To set a two hour period during which the appliance must respond to a heat demand press the tab for that period outwards The current time can be read from the hands 12 hour clock nstruction Manual BCT AE Legend timer week disk marker arrow hands manual switch D 2 3 o e tabs Figure 5 2 Week timer 5 7 Flue gas backflow safeguard reset button Release R 2 0 Uk Flue gas backflow safeguard reset button Set the day and time as follows to set roughly turn the week disk in the direction of the arrow until the current weekday is aligned with the marker arrow for fine setting turn the minute hand clockwise until the current time is set For the timer program to work the manual switch must always be in the central position A malfunction in the flue gas discharge e g a blockage in the chimney can lead to the flue gas thermostat locking out This state can be recognised by the fact that the push button for the flue gas thermostat has been activated see Figure 5 3 Onc
10. chimney is not drawing sufficiently for example due to a blockage in the chimney the flue gases will reflux and flow back past the flue gas thermostat sensor The sensor then detects an excessive temperature and the flue gas thermostat will open The circuit of the main valve of the gas control is interrupted and the valve closes which forces the heating cycle to stop The flue gas discharge thermostat will be locked out and the appliance will require a manual reset before it can be re started In addition to the standard safety monitoring of the appliance the appliance must also be protected by an expansion vessel pressure overflow valve non return valve and a T amp 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 Unvented installation sealed 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 check 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 gt 8 bar These components are fitted to the cold water pipe See paragraph 3 6 1 Cold water side Ins
11. 4 Take care The flue baffles may be hot 9 5 Finalising maintenance Release R 2 0 Uk Finalising maintenance Cleaning the injectors 1 Detach the injectors 2 Remove any contamination present in the injectors 3 Re attach the injectors Checking the flue baffles Complete steps 1 to 7 from paragraph 9 3 2 Checking the anodes Remove the flue baffles from the appliance Check the flue baffles for rust and remove any rust which is present Check the flue baffles for wear and replace any worn flue baffles Fit a new sealing ring around the edge of the tank and replace the cover Er Na Reconnect the flue gas thermostat connector to the connector on the unit To finalise the maintenance carry out the follovving steps 1 Fill the appliance See paragraph 4 2 Filling the appliance 2 Re start the appliance See 7 2 Starting up 61 62 Maintenance Instruction Manual BCT 10 10 1 General warranty 10 2 Tank warranty 10 3 Installation and conditions of use Release R 2 0 Uk 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 the supplier the right to the warranty set out below defining commitments of the supplier to the owner If within one year of the original installation date of a water heater supplied by th
12. Starting up and shutting down Topics covered in this chapter Starting up Shutting down IMD 0195 Figure 7 1 Gas control 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 Connection diagrams 3 Switch on the power to the appliance using the main switch between the appliance and the power supply 49 7 3 7 4 The appliance s 50 Shutting down heating cycle 7 3 1 7 3 2 7 3 3 s m n ES 4 Begin the ignition procedure by pressing and holding the white button 6 on the gas control while repeatedly pressing the piezo igniter until the pilot flame ignites See Figure 7 1 The pilot flame can be viewed through the inspection window above the burner tray Warning If the pilot flame goes out during the ignition procedure or warm up cycle you must wait 5 minutes before repeating the ignition procedure 5 Keep the white button pressed in for about 30 seconds before carefully releasing it The pilot flame should now stay lit 6 Set the appliance to the ON mode by switching the 1 0 ll switch on the control panel to the position 7 Setthe desired water temperature using the control thermostat See paragraph 5 5 Control thermostat If there is a heat demand the heating cycle will run its course See paragraph 7 The appliance s heating cycle You can Shutting the appli
13. control panel The panel consists of an 1 0 1l switch a control thermostat vvith rotary knob a vveek timer optional a Power Anode indicator LED optional Figure 5 1 The control panel Release R 2 0 Uk si d de 43 5 5 3 Explanation of the icons 5 4 1 0 ll switch 5 5 Control thermostat 5 6 Week timer circuit 44 con AED Table 5 1 explains the icons on the control panel Table 5 1 Control panel icons Name Explanation o o 5 1 0 11 switch Sets appliance mode to ON Week Program or OFF Temperature control Sets water temperature Tse Week timer Sets the weekly water heating program a Power Anode indicator Shows Power Anode status O lamp Using the 1 0 ll switch set the appliance to the ON mode OU position OFF mode 0 position or the weekly program mode IT position See paragraph 6 2 Operating states The appliance remains live even when in the OFF mode This keeps the weekly water heating program and or Power Anode active gl Note To electrically disconnect the appliance you must use the main svvitch between the appliance and the mains power supply Use the rotary knob on the control thermostat to set the desired water temperature to between 40 C and 70 C The rotary knob is continuous over a scale of 1 to 4 Table 5 2 shows the approximate temperature at each position
14. sensor that are supplied must be fitted in the draught diverter Fitting the draught diverter The draught diverter 6 is fastened using two fastening screws The assembly procedure is as follows gt 0 5m IMD 0148 l Figure 3 4 Fitting the draught diverter 1 Place the draught diverter on the appliance and mark the drill holes Remove the draught diverter from the appliance ul Note The position of the holes already made for the flue gas backflovv safeguard sensor must be taken into account The holes should be roughly in line with the flue gas thermostat bracket 2 Now drill two holes into the top of the appliance 3 2 mm drill bit 3 Using the fastening screws fix the draft diverter to the appliance 4 Fit a vertical chimney pipe of at least 0 5 metres length to the opening of the draft diverter before fitting the rest of the chimney materials according to current regulations See paragraph 1 3 Regulations gl Note Use flue gas discharge materials that comply vvith the regulations See paragraph 1 3 Regulations gl Note Make sure that the chimney discharges into an area vvhere this is permitted for this category of appliance 29 3 Installation WE 3 9 3 Flue gas thermostat assembly The flue gas thermostat sensor is already mounted in the draught diverter The bracket with thermostat needs to be mounted on the top of the unit and the cable from the thermostat needs to be connected with the c
15. the tank through the hot water outlet Once the appliance is completely filled with water it remains constantly under water supply pressure As hot water from the appliance is consumed it is continuously replenished with cold water Instruction Manual BCT AE 2 3 Heating cycle of the appliance 2 4 Protection for the appliance Release R 2 0 Uk 2 4 1 2 4 2 Heating cycle of the appliance The appliance is fitted with a igniter electrode which ignites the pilot burner The gas that fuels the combustion flows via the gas control into the manifold in which Injectors are located Via these injectors the gas enters the bar burners Together the bar burners constitute the burner tray As the gas is injected into the bar burners the primary air required for combustion is also drawn in Additional air is drawn through the openings in the burner tray When the gas air mixture starts to flow it is ignited by the pilot burner The flue gases arising from combustion here are drawn upwards through the flue tubes O Flue baffles are located in the flue tubes These slow down the flue gas exhaust improving the heat transfer efficiency The flue gases leave the appliance via the draught diverter A radiation shield condensation tray is fitted under the burner tray This prevents overheating of the floor surface under the appliance and serves as a collection tray for condensation water The PU insulatio
16. 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 the supplier 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 appliance is at all times fitted with cathodic protection If sacrificial anodes are used for this then these must be replaced and renewed when and as soon as they are 60 or more consumed When electric anodes are in use it is important to ensure that these continue to work properly 63 10 4 10 5 10 6 10 7 64 10
17. 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 gl Note To determine the correct maintenance frequency it is recommended to arrange for the service 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 gd Note Regular maintenance extends the service life of the appliance Both the end user and the service engineer are responsible for regular maintenance They will need to establish clear agreements on this gl Note If the appliance is not regularly maintained the warranty will become void Instruction Manual BCT MIX Gre 1 6 Forms of notation The following notation is used in this manual gl Note mportant information W Caution Ignoring this information can lead to the appliance being damaged Py Warning Failure to carefully read this information may lead to danger of personal injury and serious damage to the appliance 1 7 Overview of this Table 1 2 provides an overview of the contents of this document document Table 1 2 Content of document Chapter Target groups Description 2 Functioning of the appliance Ah ba gt This chapter describes how the appliance functions 3 Installation v x This chapter describes the installation acti
18. 01139 6 Lg IALL 10119 819496 103 lqe Bunooysalgnosl 28 yeoulbue pue eones p llilenb e Aq mo pales aq juo p noys S9UEURUIEiN BuluEAA A AN 0 Z q se l z 1 Ie sui jnsuo9 aq JOUULD 10119 AU 11 Jejjeisui INOA Insuo3 paaodu zou SI uoniubi J Je sonusjod Alddns samod ay 19949 v 0 iddns samod ON P UHE apouy punoj ase Aue Ji aeoejdas pue sye sq 40 S QE UE YOOUD r saiqeo apew AH dold aJe suono uuoo Ile Jeu s o YO9YD suo ul yesi LUE BeIp 199 V xIpuedde ses pajoauuoo si Spouy v 18 Z jo SI ay jeu YOOUD SI soueljdde ay U lUA Ul WOO v Buneinu A Jayeq Aq Ajddns se v y ull JOe U0D Buniguijous pouv Ajddns ue ajenbapeuj s1ojoalul ay Bulup l r 6 ses Joel v ue O Joyelul pajeuluejuos Sang au Bulue o 26 88S aunq ay ue o J UINQ pajeulejuoo SInssald pue aunssald Ajddns ay Bunoayo 2 6 aas 59 Jo pue aunssaud Ajddns 15 uo2 ay J9s uonnios alnssaJd Jong Jo pue asnssald Ajddns j99 109U Seng Ho s due pal s due JOJeoIpu Ieuondo po
19. AED Instruction Manual BCT AED 1 1 1 About the appliance 0063 1 2 What to do if you smell gas 1 3 Regulations Release R 2 0 Uk Introduction This manual describes how to install service and use an BCT appliance An BCT appliance is a gas fired open water heater without a fan The BCT appliance is fitted with a flue gas backflow safeguard and falls into the appliance category B11BS This information is located on the appliance s identification plate The information in this manual is applicable to types BCT 80 140 80 180 95 260 70 360 65 400 The construction and fittings of each appliance conform to the European standard for gas fired storage water heaters for sanitary use EN 89 The appliances are therefore compliant with the European Directive on Gas Appliances and thereby authorised to bear the CE mark Warning Read this manual carefully before commissioning the water heater Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the appliance W 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 As the end user installer or service and maintenanc
20. Connecting block connections 1 to 14 explained in Table 3 8 IMD 0150 31 3 Installation WE In preparation first remove the protective cover from the control column Undo the 4 screws and remove the protective cover from the electrical section The connecting block is now visible y Note Consult A BCT electrical diagram for electrical component connections 3 10 2 Mains power The appliance is supplied without a power cord and main switch ul Note n order to receive electrical povver the appliance has to be connected to the mains voltage by means of a permanent electrical connection A tvvo terminal main svvitch vvith a contact gap of at least 3 mm must be fitted betvveen this fixed connection and the appliance The povver cord must have cores of at least 3 x 1 0 mm 1 Feed the power cord through the metric pull relief on the top of the control column 2 Connect earth phase L4 and neutral N on the power cord to points 1 to 3 of the connecting block as set out in Table 3 8 3 Tighten the pull relief so that the cable is clamped If you do not need to make any more connections then fit the protective cap on the control column 5 Connect the power cord to the main switch Py Warning Leave the appliance disconnected until you are ready to start it up 3 10 3 Week timer circuit 1 Cut out the week timer image from the control panel Fit the week timer in the hole 3 Connect the
21. ED Instruction Manual BCT IX Index A ambient temperature 21 appliance categories 9 general operation 14 protection 15 warm up cycle 15 B burner pressure 35 C calcium deposition 60 checking pre pressure burner pressure 35 claims 64 condensation drainage connecting 27 connecting condensation drainage 27 electrical 022 ese los l lt 31 gas 28 the circulation pipe 27 the cold water side 26 27 the hot water side 26 connecting the circulation pipe 27 connecting the cold water side 26 27 connecting the hot water side 26 content of document 11 control thermostat 44 convert to another gas 32 D data electrical m 2 24 descaling 60 dimensions 22 droit et it oe Bo ee eee eer 40 E electrical connecting block 31 electrical connection 31 environmental conditions 21 F filling 40 floor load
22. Exclusions Scope of the warranty Claims Limitation of liability the supplier Warranty Certificate AN WE 26 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 b misuse neglect including frost damage modification incorrect and or unauthorised use of the water heater and any attempt to repair leaks contaminants or other substances having been allowed to enter the tank d the conductivity of the water being less than 125 uS cm and or the hardness alkaline earth ions of the water being less than 1 00 mmol lit see Table 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 The obligations of the supplier 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 the supplier A claim on grounds of the specified warranty must be submitted to the dealer from whom the water heater was purchased or to another authorised dealer for the products of the supplier Inspection of the water heater as referred to in articles 1 and 2 shall take place in one of the laboratories of the supplier The suppl
23. Installation User and Service Manual DANCE ED m ae C your installer DANCE EDN aD uD Copyright Trademarks Liability More information Release R 2 0 Uk Py 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 Copyright 2006 All rights reserved 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 the supplier The supplier reserves the right to modify specifications stated in this manual Any brand names mentioned in this manual are registered trademarks of their respective owners The supplier 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 furthe
24. ance down for brief periods OFF mode Disconnecting the appliance from the mains Shutting the appliance down for a longer period Shutting the appliance down for brief periods OFF mode To shut down the appliance for a brief period you can set the appliance in OFF mode Activate frost protection by switching the 1 0 Il switch on the control panel to the 0 position The pilot flame will remain on Disconnecting the appliance from the mains When servicing the appliance must be electrically disconnected The correct procedure is as follows 1 Putthe appliance in OFF mode by setting the 1 0 ll switch to the 0 position 2 Switch off the power to the appliance by setting the main switch between the appliance and the mains power supply to position 0 3 The pilot flame will remain on but you can extinguish it if required by pressing the red button on the gas control See Figure 7 1 Y Caution These operating states of OFF mode and Disconnected are advisable only if there is no risk of frost If frost can be expected you will need to drain the appliance see paragraph 7 3 3 Shutting the appliance down for a longer period Shutting the appliance down for a longer period Drain the appliance if you are shutting it down for a longer period of time Proceed as described in paragraph 4 3 Draining the appliance The appliance s heating cycle is activated as soon as the measured water temperature Twater
25. and resistance of the circulation system 2 Fita non return valve behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for servicing 4 Connect the circulation pipe to the T piece on the drain valve See Figure 3 3 Cold water side See O in Figure 3 2 Fit an approved stop valve on the cold water side between the water cistern and the appliance as required by regulations See also paragraph 1 3 Regulations Shunt pipe You can connect a shunt pump to prevent stacking of the water in the water heater 1 Optional fit a shunt pipe depending on the tap design 22 mm a stop valve and a shunt pump 2 Fita non return valve O 3 Fita stop valve O Hot water side See in Figure 3 2 y Note Insulating long hot water pipes prevents unnecessary energy loss Fit the T amp P valve 2 Optional fit a temperature gauge 6 to be able to check the temperature of the tap water 3 Fita stop valve in the hot water outlet pipe for use when servicing 4 Refer to paragraph 3 7 4 if a circulation pipe is to be fitted Circulation pipe See in Figure 3 2 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 O of the correct capacity for the length and resistance of the circulation system 2 Fita non return valve behi
26. circulation pump optional drain valve gas valve mandatory stop valve mandatory temperature gauge recommended shunt pump optional draught diverter hot water draw off points pressure relief valve mandatory water cistern e float valve e 3 way venting valve recommended overflow pipe cold water supply hot water outlet circulation pipe gas supply flue gas discharge 000008 Release R 2 0 Uk Topics covered in this chapter Filling the appliance Draining the appliance Introduction Filling and draining The components referred to in these sections are illustrated in Figure 4 1 IMD 0146 Figure 4 1 Connection diagrams IMD 0147 39 4 2 4 3 40 4 Filling the appliance Draining the appliance 4 2 1 4 2 2 4 3 1 m AE Filling unvented installations To fill the appliance proceed as follows 1 Open the stop valve on the hot water pipe and if present the stop valves for the circulation pump 2 Close the drain valve 3 Open the nearest hot water draw off point 4 Open the stop valve on the cold water side 6 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
27. ck the burner pressure and supply pressure see paragraph 3 12 Instruction Manual BCT ED 3 12 Checking the supply pressure and burner pressure Release R 2 0 Uk Checking the supply pressure and burner pressure 14 Remove the sticker showing the new gas category from the conversion kit 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 15 Start up the appliance see paragraph 7 2 y Note Before you start up the appliance and or begin to check the supply pressure and burner pressure you must fill the appliance For the filling procedure please refer to paragraph 4 2 Filling the appliance W Caution 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 ul Note The easiest way to check the gas pressures is by using two pressure gauges This procedure assumes that these two gauges are available 1 Switch off the power to the appliance and extinguish the pilot flame See paragraph 7 3 2 Disconnecting the appliance from the mains 2 The supply pressure is checked using a test nipple O on the gas control Figure 3 8 The manifold test nipple is used for measuring the burner pressure Sealing screws are located inside the test nipples Loosen both seal
28. dge of the tank and replace the cover 12 Reconnect the flue gas thermostat connector to the connector on the unit y Note This unit is also appropriate for the use of Povver Anodes These are available as an accessory and can be ordered separately Please check your Povver Anode instructions for correct use or consult your installer Descaling and cleaning the tank Scale and chalk deposits prevent effective conduction of the heat to the vvater Periodic descaling prevents build up of these deposits This increases the service life of the appliance and also improves the heating process Take the rate at which scale is formed into account when determining the maintenance frequency Remove the cover plate in the outer jacket See Figure 9 1 Undo the bolts Remove the cover and the rubber O ring Inspect the tank and remove any contamination Remove the chalk deposits using Borcoil oak WN gt Close the cleaning opening Use a new rubber O ring for this Introduction On the gas side the following steps should be carried out 1 Cleaning the burners 2 Cleaning the injectors 3 Checking the flue baffles Cleaning the burners 1 Detach the burners 2 Carefully remove any contaimation present on the burners 3 Re attach the burners 1 The supplier recommends the use of Borcoil because the composition of this product is known Borcoil can be ordered from the supplier Instruction Manual BCT 9 4 3 9 4
29. divided into three groups Gas control lock out errors In this case the gas control s safety valve is closed as a result of which the pilot flame is extinguished Once this error has been rectified the pilot flame must be re lit See paragraph 77 2 Starting up Blocking errors In this case the gas control s main valve is closed Despite a possible heat demand combustion is stopped although the pilot flame remains ignited These errors disappear automatically once the cause of the error disappears after which the appliance re starts itself Lock out error due to the flue gas backflow safeguard This error state has much the same characteristics as a Blocking error The difference here is that the lock out push button for the flue gas thermostat in the draught diverter is activated See paragraph 5 7 Flue gas backflow safeguard reset button After removing the cause the push button must be pressed to allow the appliance to automatically re start The cause of the error cannot be seen on the control panel Please refer to chapter 8 Troubleshooting for a detailed overview of error states If you find the appliance in a fault state as an end user you can attempt to re start the appliance see paragraph 7 2 Starting up However should the error return or become persistent you should contact your service engineer Instruction Manual BCT 7 1 Introduction 7 2 Starting up Release R 2 0 Uk Introduction
30. e insufficient hot water 57 Maintenance 59 Introduetion Sse v4 a ee ara rire ai eo ear 59 Preparing for maintenance 59 Instruction Manual BCT AE 9 3 Water side maintenance 59 9 3 1 Introduction 59 9 3 2 Checking the anodes 59 9 3 3 Descaling and cleaning the tank 60 9 4 Gas side maintenance 60 9 4 1 Introduction 60 9 4 2 Cleaning the burners 60 9 4 3 Cleaning the injectors 61 9 4 4 Checking the flue baffles 61 9 5 Finalising maintenance 61 10 Warranty Certificate 63 10 1 General warranty 63 10 2 Tank warranty 63 10 3 Installation and conditions of use 63 10 4 Exclusions 64 10 5 Scope of the warranty 64 10 6 Claims 64 10 7 Limitation of liability the supplier 64 A BCT electrical diagram 65 IX Index 67 Release R 2 0 Uk 7
31. e engineer you must be certain that the complete installation as a minimum complies 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 removal 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 1 4 Target groups 1 5 10 Maintenance mera AEX Furthermore the installation must comply with the manufacturer s regulations gl Note Later amendments and or additions to all regulations requirements and guidelines published on or prior to the moment of installing will apply to the installation The three target groups for this manual are end users e installers service engineers Symbols on each page indicate the target groups for whom the information is intended See Table 1 1 Table 1 1 Symbols for each target group Symbol Target groups A End user y Installer x Service and maintenance engineer A service should be carried out at least once a year both on the
32. e supplier following verification and at the sole option of the supplier 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 the supplier shall replace or repair this part or component If within 3 years of the original installation date of a water heater supplied by the supplier following inspection and at the sole option of the supplier the glass lined steel tank proves to be leaking due to rust or corrosion occurring on the water side the supplier 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 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 the supplier 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 The appliance is exclusively used with drinking
33. e the cause is removed and if the sensor has cooled down sufficiently press this button to release the interlock if you do not allow the sensor to cool down sufficiently the flue gas thermostat will again immediately lock out The appliance will then automatically start up again if there is a current heat demand If the appliance does not re start when it should refer to chapter 8 Troubleshooting for an extensive overview of error conditions IMD 0151 Figure 5 3 Flue gas backflow safeguard reset button 45 AED Instruction Manual BCT 6 6 1 Introduction 6 2 Operating states 6 3 Power Anode Status Release R 2 0 Uk Introduction Status of the appliance Topics covered in this chapter 6 2 Operating states 6 3 Power Anode Status 6 4 Error states During operation the appliance has four basic operating states namely DISCONNECTED In this state the appliance is off and all components are electrically dead The main switch switch between the appliance and the power supply is set to off On the control panel the 1 0 Il switch is set to the position ul Note If no week timer is installed the II state is the same as the 0 state OFF The main switch is set to position On the control panel the UO switch is set to the 0 position ON In this state the appliance continuously fulfils the demand for heat On the control panel The 1 0 ll switch is set to the I posi
34. end O pressure reducing valve mandatory expansion vessel mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional drain valve gas valve mandatory stop valve mandatory temperature gauge recommended shunt pump optional draught diverter hot water draw off points pressure relief valve mandatory water cistern e float valve e 3 way venting valve recommended overflow pipe cold water supply hot water outlet circulation pipe gas supply flue gas discharge 000086 e Figure 3 2 Installation diagrams Release R 2 0 Uk Installation diagrams UNVENTED 13 El Pe B XA ve Y 5 X4 1 9 parle TT ras VENTED Te 16 A S n Z 4 N e o Y 3 A La L mi a lie 8 per ES IMD 0147 25 3 3 6 Water connections Unvented 26 3 6 1 3 6 2 3 6 3 3 6 4 Installation ve py Cold water side See in Figure 3 2 1 Fit an approved stop valve on the cold water side as required by regulations See also 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 p
35. falls below the threshold value Tset Tset can be adjusted using the control thermostat for example position 3 60 C The heating cycle runs in turn through the following states 1 HEAT DEMAND 2 IGNITION 3 RUNNING Instruction Manual BCT AE Release R 2 0 Uk The appliance s heating cycle The complete cycle is explained in the example set out below 1 The control thermostat sensor measures the water temperature T water If Twater drops below the set temperature Teet there is a heat demand and the control thermostat will close This will cause the gas control to open 2 Once the gas control is open the pilot burner will ignite the gas flow 3 The appliance is now running This means that actual heating has started When the water is up to temperature the heat demand cuts out The gas control closes and the burner tray is extinguished the pilot flame stays lit 4 The appliance is now said to be in a state of rest and waiting until T water once again falls below Tset With any subsequent heat demand the heating cycle will resume from step 1 51 52 Starting up and shutting down AES Instruction Manual BCT AEJK 8 8 1 Introduction Release R 2 0 Uk Troubleshooting This chapter covers the following errors General errors Gas smell Water leakage Explosive ignition Poor flame profile Power Anode optional No hot water Insufficient hot water
36. full 6 Bleed the entire installation of air by opening all hot water draw off points for example 7 The appliance is now under water supply pressure There should be no water coming out of the overflow valve nor the T amp P valve If this does happen the cause might be The water supply pressure pressure is greater than the stipulated 8 bar Rectify this by fitting a pressure reducing valve O The overflow valve in the cold water supply arrangement is defective or incorrectly fitted Filling vented installations To fill the appliance proceed as follows 1 Open the stop valve on the hot water pipe and if present the stop valves for the circulation pump 2 Close the drain valve 3 Open the nearest hot water draw off point 4 Open the stop valve on the cold water side 6 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 by opening all hot water draw off points for example 7 The appliance is now under water supply pressure There should be no water coming out of the T amp P valve If this does happen the T amp P valve might be defective or incorrectly fitted Draining unvented installations For some procedures may require the appliance to be drained Proceed as follows 1 Shut the appliance down by setting t
37. he 1 0 ll switch to the position 2 Switch off the power to the appliance by setting the main switch between the appliance and the mains power supply to its 0 position Close the gas supply Close the stop valve in the hot water outlet Close the stop valve in the cold water supply pipe 6 oa kw Open the drain valve Instruction Manual BCT AE Release R 2 0 Uk 4 3 2 T Draining the appliance Bleed the appliance or installation so that it drains completely empty Draining vented installations For some procedures may require the appliance to be drained Proceed as follows 1 2 N mo o Shut the appliance down by setting the I 0 II switch to the position Switch off the power to the appliance by setting the main switch between the appliance and the mains power supply to its 0 position Close the gas supply Close the stop valve in the hot water outlet Close the stop valve in the cold water supply pipe 6 Open the drain valve Bleed the appliance or installation so that it drains completely empty 41 Filling and draining AES Instruction Manual BCT Introduction 5 Controls 5 1 Introduction Topics covered in this chapter 5 2 Control panel 5 3 Explanation of the icons 5 4 1 0 Il switch 5 5 Control thermostat 5 6 Week timer circuit 5 7 Flue gas backflow safeguard reset button 5 2 Control panel Figure 5 1 illustrates the
38. ier 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 The supplier 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 Instruction Manual BCT H E r ba o 230V AC 50Hz kel lli LON 1 4 y I OO KL ssp o brown Lo 4 2 blue 3 yellow green black 5 white flat cable TERMINAL BLOCK CONNECTIONS COMPONENTS Earth A On off switch N Neutral Control thermostat L Phase High limit thermostat LT Phase input to controller Safety thermostat L2 Phase input to thermal non return safety device Gas control Eye terminal for earthing to the Jacket mTm cou OPTIONAL COMPONENTS G Main power switch H Potentiostat for power anodes J Thermal Reflux Safeguard TRS K Week timer circuit Figure A 1 BCT electrical diagram Release R 2 0 Uk 65 66 A BCT electrical diagram
39. implify assembly of the burner 5 Remove the burners one by one from their brackets at the front To do this you first move them away from you and then downwards The orifices are then accessible 6 Remove the orifices Release R 2 0 Uk 33 Legend See Figure 3 7 for 6 to o 8600000 burner pressure regulator flat sealing plate supply pressure test nipple burner pressure test nipple gas control burner pressure control cap burner pressure control adjusting screw Installation ve py 7 Select and fit the correct orifices from the conversion kit by referring to Table 3 9 The orifice diameter is shown on the orifice by means of stamped figures IMD 0137 Figure 3 8 Converting the gas control 34 8 Refit the burners back in their original position 9 Re fit the locking strips gl Note If the radiation shield condensation tray was loosened re tighten it 10 Check whether there is a burner pressure regulator attached to the top of the gas control or simply a flat sealing plate 11 Check with the help of the burner pressure in Table 3 5 whether a burner pressure regulator is required for the new gas category 12 If the flat sealing plate must be replaced with a burner pressure regulator or vice versa Remove the existing flat sealing plate or burner pressure regulator O Fit the new burner pressure regulator or flat sealing plate supplied with the conversion kit 13 Che
40. ineer 10 shunt pump 26 27 specifications 22 stacking 26 27 state DISCONNECTED 47 HEAT REQUIREMENT 50 IGNITE rgere rer eee 50 INOPERATION 50 OFF 47 ON 47 supply cable 32 67 IX symbol installer service engineer user target groups trademarks 0307 635 Index W warm up cycle 15 50 warranty exclusions 64 general 63 installation and conditions of use 63 scope 64 tank 63 vvater composition 22 stacking 26 27 nstruction Manual BCT
41. ing screws by a few turns Do no completely undo them as it may be awkward retightening them 3 There are two test nipples on the gas control 4 Open the gas supply and vent the gas supply line via supply pressure test nipple 5 Connect a pressure gauge to the supply pressure test nipple as soon as gas starts to flow from this nipple 6 Switch on the power to the appliance using the main switch on the appliance 7 Begin the ignition procedure by pressing and holding the white button on the gas control while repeatedly pressing the piezo igniter until the pilot flame ignites The pilot flame can be seen through the inspection window above the burner tray 8 Keep the white button pressed in for about 30 seconds before carefully releasing it The pilot flame must now keep burning 9 Set the control thermostat to the highest position take note of the original setting and set the 1 0 II svvitch back to position 1 10 If there is no heat demand then draw off some hot water to initiate a heat demand 11 The heating cycle will start and the burner tray will ignite after a short time Py Warning If the pilot flame goes out during the ignition procedure or heating cycle you must wait 5 minutes before repeating the ignition procedure 12 After the burner tray has ignited wait for approximately 1 minute before you start reading the dynamic pressures 35 Installation ve py 13 Use the pressure gauge to read the sup
42. ld be carried out by an authorised installation engineer in compliance with the official 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 See also paragraph 1 3 Regulations 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 Flue gas discharge Electrical connection Conversion to a different gas category Checking the supply pressure and burner pressure Note Starting up the appliance is described in chapter 7 Starting up and shutting down Figure 3 1 shows a plan and elevation drawing of the appliance 19 Installation O a 2 i 5 LEA lt m 6_ A I 4 uu 1 m3 K Li x 5 i 1 Figure 3 1 Plan and elevation of the appliance 20 1 IMD 0145 Instruction Manual BCT ED 3 2 Packaging 3 3 Environmental conditions Release R 2 0 Uk 3 3 1 3 3 2 Packaging To avoid damaging the appliance remove the packaging carefully We recomme
43. le 2 1 explains how the high limit and safety thermostats respond to the sensors Protection High limit thermostat Description If the high limit thermostat sensor detects a temperature greater than 84 C the high limit thermostat opens and the gas control s main valve circuit is broken closing the valve The heating cycle stops until the high limit thermostat closes again At this point the gas control opens again and the heating cycle is repeated The high limit protection also prevents excessive scale forming in the appliance Safety thermostat If the safety thermostat sensor detects a temperature greater than 93 C the safety thermostat opens The gas control s safety valve circuit is broken and the safety and main valve both close Combustion immediately ceases and the pilot flame also goes out In order to re start the appliance the pilot flame must be re lit 2 5 Safety of the installation 2 4 4 2 5 1 Flue gas backflow safeguard The flue gases are drawn outside via the draught diverter and the flue gas discharge To prevent the flue gases from flowing back into the installation room the discharge ducting is monitored by a feature called the Thermal Reflux Safeguard T R S For this purpose a flue gas thermostat sensor complete with flue gas thermostat is fitted in the draught diverter Under normal circumstances this sensor measures the ambient temperature However if the
44. le metal leak tray The leak tray must have an appropriate wastewater drain and must be at least 5 cm deep with a length and width at least 5 cm greater than the diameter of the appliance Humidity and ambient temperature The boiler room must be frost free or be protected against frost Table 3 1 shows the environmental specifications which must be observed to guarantee correct functioning of the appliance Table 3 1 Humidity and ambient temperature specifications Humidity and ambient temperature Humidity max 93 RH at 25 C Ambient temperature Functional O lt t lt 60 C 21 3 Installation yi Because of the weight of the appliance when filled see Table 3 2 verify that the maximum floor loading for the boiler room is not exceeded 3 3 3 Maximum floor loading Table 3 2 Weight specifications with regard to maximum floor loading Weight of the appliance filled with water BCT 80 140 BCT 80 180 BCT 95 260 BCT 70 360 BCT 65 400 507 kg 510 kg 576 kg 525 kg 526 kg 3 3 4 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 gt 1 00 mmol l alkaline earth ions German hardness gt 5 6 dH French hardness gt 10 0 fH e British hardness gt 7 0 eH Conductivit
45. n layer prevents heat loss The inside of the tank is enamelled to protect against corrosion The anodes provide additional protection The Hydro Cannon also protects the bottom of the tank from scaling The entire appliance is regulated by a control thermostat The control thermostat monitors the water temperature Tater The appliance s heating cycle is activated as soon as Tater falls below the specified threshold value Tset The value for Tse can be adjusted using the control thermostat 440 C 70 C As soon as Twater drops below Tse there is a demand for heat and the control thermostat closes causing the main valve on the gas control to open The gas mixes with the air it draws along This mixture is ignited by the pilot burner and the water becomes heated As soon as Twater exceeds Tse the heat demand ceases the thermostat opens again and the heating cycle stops The control thermostat has a certain margin both when closing and opening referred to as the hysteresis The hysteresis cannot be adjusted The appliance is protected by means of the following the Gas Control the Thermocouple the Water Temperature Safeguard the Flue Gas Backflow Safeguard Gas control The gas control has 2 valves for safety purposes 1 The main valve which controls the gas supply to the burner tray and which is switched via the I 0 Il switch circuit and the control high limit and flue gas thermostats This circuit is p
46. nd the circulation pump to guarantee the direction of circulation 27 3 Installation 3 4 3 8 Gas connection ks Fit two stop valves for servicing Connect the circulation pipe to the cold water supply pipe Py Warning Gas installation may only be carried out by an authorised installation engineer in compliance with the general regulations imposed by the gas company See also paragraph 1 3 Regulations Y Caution Make sure that the diameter and length of the gas supply pipe is are large enough to supply sufficient capacity to the appliance See in Figure 3 2 1 Fit a gas valve in the gas supply pipe 2 Blow the gas pipe through before use to be sure it is clean 3 4 Fit the gas supply pipe to the gas control Close the gas valve Py Warning 3 9 Flue gas discharge Check for leaks after fitting Py Warning 28 The installation should be carried out by an authorised installation engineer in compliance with the general and local regulations imposed by gas water supply and power supply companies and the fire service See also paragraph 1 3 Regulations Instruction Manual BCT ED 3 9 1 3 9 2 Legend draught diverter O fastening screws 8 chimney pipe Release R 2 0 Uk Flue gas discharge Introduction When connecting the appliance to the chimney the draught diverter O supplied with the appliance must be used The standard flue gas thermostat and
47. nd unpacking the appliance at or near its intended location Y Caution The appliance may only be manoeuvered in an upright position Take care that the appliance is not damaged after unpacking Y Caution The appliance may not be used in rooms where chemical substances are stored or used due to the risk of explosion and corrosion to the appliance Some propellants bleaching agents degreasing agents etc disperse vapours which are explosive and or which cause accelerated corrosion If the appliance is used in a room in which such substances are present the warranty will be void BCT appliances are open appliances and may only be placed in an open boiler room They fall under category B11BS Working clearances For access to the appliance it is recommended that the following clearances are observed see Figure 3 1 AA around the appliance s control column and cleaning openings 100 cm BB around the appliance itself 50 cm s Above the appliance room to replace the anodes 100 cm if using fixed anodes or 50 cm if using flexible anodes If the available clearance is less than 100 cm flexible magnesium anodes may be ordered from the supplier Note y 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 the appliance should be installed above a wastewater drain or in a suitab
48. onnector on the unit Py Warning If the flue gas thermostat is not or is incorrectly fitted connected the flue gas discharge will not be protected An incorrectly fitted chimney can causes flue gases to backflow into the boiler room w Note Figure 3 5 shows an example For each type of unit the position of the sensor can slightly differ IMD 0187 Figure 3 5 Flue gas backflow safeguard Fit the flue gas thermostat as follows 1 Remove the flue gas thermostat assembly from the packet 2 Fit the bracket with the thermostat to the top of the appliance 30 Instruction Manual BCT EDI 3 10 Electrical connection 3 10 1 Electrical connection 3 Plug the connector from the flue gas thermostat to the connector on the appliance Py Warning The installation should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas water and power supply companies and the fire service See also paragraph 1 3 Regulations Introduction This paragraph covers each of the following 3 10 2 Mains power 3 10 3 Week timer circuit Figure 3 6 shows a front view of the electrical connecting block Table 3 8 shows the associated connections Table 3 8 Electrical connecting block BCT Mains voltage Flue gas backflow safeguard Week timer circuit Release R 2 0 Uk Figure 3 6
49. owered by the supply voltage 2 The safety valve which controls the gas supply to the pilot burner and which is switched via the thermocouple circuit and the safety thermostat This circuit is powered by the millivolt potential from the thermocouple that is located in the pilot flame Whenever the safety valve closes the main valve also closes Thermocouple 1 To prevent gas flowing when there is no combustion a thermocouple is fitted As a result of the presence of the permanent pilot flame the thermo couple maintains a millivoltage potential which keeps the gas control s safety valve open 2 If the pilot flame goes out this voltage disappears and the gas control s safety valve closes interrupting the gas supply to the burner tray 1 The gas flow is accelerated through the narrow opening in the injector This creates a vacuum which also draws in air through the Venturi effect 15 Table 2 1 Temperature protection 2 4 3 Functioning of the appliance A Ga Ka Water temperature protection To ensure a safe water temperature is not exceeded the high limit thermostat sensor is installed at the top of the appliance In the event of stratification stacking of the water temperature the temperature at the top of the appliance can be considerably higher than the set temperature for the hot water In the event that both the control and maximum thermostats should fail there is also a safety thermostat Tab
50. ply pressure at the test nipple Refer to Table 3 9 gd Note Consult the mains gas supply company if the supply pressure is not correct 14 Use the pressure gauge to read the burner pressure at the burner pressure test nipple Refer to Table 3 9 Table 3 9 Conversion data for appliance category IIZH3 DESCRIPTION Unit BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 Data for natural gas gas category 2H Diameter of orifices mm 3 20 3 20 2 95 3 20 3 30 G20 Supply pressure mbar 20 20 20 20 20 Burner pressure mbar 8 6 7 8 8 5 9 2 7 8 Data for LP gas gas category 3 Diameter of orifices mm 1 70 1 60 1 50 1 70 1 75 G30 butane Supply pressure mbar 30 30 30 30 30 Burner pressurel mbar G31 propane Supply pressure mbar 37 37 37 37 37 Burner pressurel mbar 1 Ifa flat sealing plate or high low regulator is in use the burner pressure is expected to be the same as the supply pressure In practice however the burner pressure will be lower 6 17 18 19 Note 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 n this case consult your installation engineer or supplier If the appliance is fitted with a burner pressure regulator then the pressure can be adjusted by following steps 15 to 20 Remove the cap f
51. purt out 5 Check the wastewater pipes of the overflow valves and remove any scale deposits that may be present 6 Drain the appliance See paragraph 4 3 Draining the appliance Introduction The following steps should be carried out on the water side 1 Checking the anodes 2 Descaling and cleaning the tank Checking the anodes Timely replacement of the anodes extends the service life of the appliance The anodes that are present must be replaced as soon as they are 60 or more used up take this into consideration when determining the maintenance frequency 59 9 Take care A The draught diverter and the cover may be hot 9 3 3 IMD 0128 Figure 9 1 Cleaning opening 9 4 Gas side maintenance 9 4 1 Take care The burners may be hot 9 4 2 60 Maintenance Remove the flue gas thermostat connector from the connector on the unit Disconnect the draught diverter from the flue gas discharge Undo the screws on the draught diverter Remove the draught diverter from the appliance Undo the screws on the cover on the top of the appliance Remove the cover from the appliance Remove the sealing ring from the tank Undo the anodes using the appropriate tool Check the anodes and if necessary replace them 2 O ON OOP ON a 0 Now also check the flue baffles Replace them if necessary See paragraph 9 4 4 Checking the flue baffles 11 Fit a new sealing ring around the e
52. r improve our documentation If you have any comments or queries concerning any aspect related to the appliance then please do not hesitate to contact the supplier In the event of problems with connecting to the gas electricity or water supply please contact your installation s supplier installer Instruction Manual BCT AED Release R 2 0 Uk 1 1 1 2 1 3 14 1 5 1 6 1 7 2 1 2 2 2 3 24 2 5 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 Table of contents Introduction 9 About the appliance 9 What to do if you smell gas 9 Regulations 9 Target groups 10 Maintenance 10 Forms of notation 11 Overview of this document 11 Functioning of the appliance 13 Introduction 13 Functional description of the appliance 14 Heating cycle of the appliance 15 Protection for the appliance 15 2 4 1 Gas control 15 2 4 2 Thermocouple 15 2 4 3 Water temperature protection 16 2 4 4 Flue gas backflow safeguard
53. ressure reducing valve 6 3 Fit a non return valve and an expansion vessel 4 Fit a pressure relief valve and connect the overflow side to an open water vvastevvater pipe Shunt pipe You can connect a shunt pump to prevent stacking of the vvater in the vvater heater 1 Optional fit a shunt pipe depending on the tap design 22 mm a stop valve and a shunt pump 2 Fit a non return valve 3 Fit a stop valve Hot vvater side See 6 in Figure 3 2 y Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the T amp P valve 1 Optional fit a temperature gauge 6 to be able to check the temperature of the tap water 2 Fit a stop valve O in the hot water outlet pipe for use when servicing Drain valve 1 Fit the standard drain valve supplied 2 Refer to paragraph 3 6 5 if a circulation pipe is to be fitted Otherwise fit the sealing nut and gasket supplied with the drain valve See Figure 3 3 Instruction Manual BCT 3 6 5 IMD 0122 Figure 3 3 Drain valve 3 7 Water connections Vented Release R 2 0 Uk 3 7 1 3 7 2 3 7 3 3 7 4 Water connections Vented Circulation pipe See in Figure 3 2 and 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 Fita circulation pump O of the correct capacity for the length
54. rom the burner pressure regulator O Adjust the burner pressure by turning the adjusting screw depending on the correction required To reduce burner pressure turn the adjusting screw anti clockwise To increase burner pressure turn the adjusting screw clockwise Cover the opening of the adjusting screw and check the burner pressure against the target value from Table 3 9 If the pressure reading is not correct repeat steps 16 and 17 until the correct pressure is attained Re fit the cap on the burner pressure regulator Instruction Manual BCT ED Release R 2 0 Uk Checking the supply pressure and burner pressure 20 Shut down the appliance by setting the 1 0 ll switch to the 0 position 21 Shut off the gas supply 22 Disconnect the two pressure gauges and re tighten the sealing screws in the test nipples ul Note Before starting up the appliance take time to fill in the warranty card supplied vvith the appliance This enables us to guarantee the quality of our systems and to further enhance our vvarranty procedure Please return this card as soon as possible Your customer vvill then receive a vvarranty certificate vvith our vvarranty conditions 37 38 Installation ED Instruction Manual BCT 4 4 1 Introduction Legend O pressure reducing valve mandatory expansion vessel mandatory T amp P valve mandatory O stop valve recommended check valve mandatory O
55. s a Se ee See 22 forms of notation 11 G gas converting 32 gas connection 28 general operation 14 Release R 2 0 Uk Index heat requirement 50 humidity 21 icons 44 ignite 50 in operation 50 installer en eg zz Sop som E arie 10 li d e pali 3 main switch m aa R e o m s 32 mains voltage 32 maintenance anode 59 b rner s ges igus Ske ees 60 carryout 59 complete 61 descaling 60 injector 61 on the gas side 60 on the water side 59 preparation 59 scaling 60 operating states 47 packaging 21 pre pressure 35 protection 15 putting into operation 49 putting out of operation disconnecting from the mains 50 lengthy period 50 short period 50 safety 16 scaling 60 service 10 service eng
56. tion The water temperature can be set by turning the rotary knob on the control thermostat see paragraph 5 5 Control thermostat WEEK PROGRAM optional In this position the appliance only meets the heat demand during the periods set by the timer Outside these periods only frost protection is active On the control panel The 1 0 ll switch is set to the II position The water temperature can be set by turning the rotary knob on the control thermostat see paragraph 5 5 Control thermostat The period during which the heat demand must be fulfilled can be programmed using the week timer see paragraph 5 6 Week timer circuit If the appliance is fitted with a Power Anode there is an extra indicator lamp on the operating panel Depending on the status of the appliance this lamp will be lit either Green or Red or it will be Off Green This state indicates that the Power Anode is working correctly Red This state indicates an error and the Power Anode is not working 47 6 4 48 Error states Status of the appliance ER Ga Ka Off This state indicates that the Power Anode is not working gl Note If there is an error with the Power Anode Red or if the Power Anode is not working Off this will have no effect on the hot water supply However no tank protection will take place If the appliance has an error heat demand will be temporarily ignored There are various types of errors
57. troduction Release R 2 0 Uk Introduction Functioning of the appliance This chapter successively covers the following topics e Functional description of the appliance Heating cycle of the appliance Protection for the appliance Safety of the installation 13 2 2 2 Functional description of the appliance Legend 060 000000000 SG S 8 8 8 8 8 8 8 8 8 8 8 8 8 e e 14 flue gas discharge draught diverter anodes flue tubes flue baffles PU insulation layer tank cleaning opening drain valve combustion chamber radiation shield condensation tray gas control flue gas thermostat sensor flue gas thermostat hot water outlet safety thermostat sensor high limit thermostat sensor control panel control thermostat high limit thermostat safety thermostat control thermostat sensor thermo couple pilot burner igniter electrode cold water inlet piezo igniter bar burners burner tray Functioning of the appliance EA ia Es Figure 2 1 shows a cut away view of the appliance HYDRO CANNON Figure 2 1 Cut away view of the appliance In this appliance the cold water enters the bottom of the tank via the cold water inlet The heat of combustion is transferred to the water through the combustion chamber and flue tubes O The heated tap water leaves
58. truction Manual BCT AE Release R 2 0 Uk 2 5 2 2 5 3 Safety of the installation Vented installation open 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 that empties into the water reservoir See paragraph 3 6 3 Hot water side T amp P valve A valve is only required in unvented installations However the supplier also recommends the use of a T amp P valve in vented installations A T amp 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 too high gt 10 bar or the water temperature is too high gt 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 The appliance is standard equipped with a connecting point for a T amp P valve See paragraphs 3 6 3 Hot water side Unvented and 3 7 3 Hot water side Vented 17 Functioning of the appliance AED Instruction Manual BCT Kaka 3 1 Introduction Release R 2 0 Uk Introduction Installation Py Warning The installation shou
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60. vity to be completed before you actually start up the appliance Instructions are also provided for the installation and or service engineer on converting the appliance to other types of gas s lt ka gt This chapter describes how to fill and drain the appliance 4 Filling and draining A s lt This chapter describes the appliance s control panel and how a Ka to use it 5 Controls K 6 Status of the appliance K gt This chapter describes each status state that the appliance may be in and how to respond if necessary EN 7 Starting up and shutting down Ah This chapter describes how to start up the appliance and how Ka to shut it down for a brief or long period of time The general heating cycle of the appliance is also described engineer It describes appliance errors These errors are indicated on the display A table of possible causes and solutions is provided End users may also refer to this additional information about the appliance 8 Troubleshooting A gt This chapter is mainly intended for the installer and the service 9 Maintenance This chapter sets out the maintenance tasks to be carried out Ka during a service 10 Warranty Certificate Al Ga Ka This chapter states the warranty terms and conditions Release R 2 0 Uk 11 Introduction AES Instruction Manual BCT 2 2 1 In
61. week timer by connecting the wires with core bush to 10 N 12 L and 14 L 4 Connect the cable with sliding bush to position B4 of the 1 0 ll switch If you do not need to make any more connections then fit the protective cap on the control column 3 11 Conversion to a different gas Y Caution category The conversion may only by carried out by an authorised installation engineer 32 Instruction Manual BCT vi Conversion to a different gas category ep 3 11 1 Introduction 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 Converting the BCT appliances is described in 3 11 2 Conversion to a different gas category Legend O cover plate locking strip orifice with stamped figures IMD 0196 Figure 3 7 Replacing the orifices 3 11 2 Conversion to a different gas category 1 Disconnect the appliance from the mains See paragraph 7 3 2 Disconnecting the appliance from the mains 2 Shut off the gas supply Take care 3 Unscrew the cover plate O from the burner support The burner may be hot Use a suitable tool to remove the locking strips Note the locking strips ot have especially sharp edges Withdraw the locking strips straight upwards gl Note The radiation shield condensation tray can be temporarily loosened to s
62. y gt 125 uS cm Acidity pH value 7 0 lt pH value lt 9 5 y Note If the water specifications deviate from those stated in Table 3 3 then the tank protection cannot be guaranteed See also chapter 10 Warranty Certificate 3 4 Technical The appliance is supplied without accessories Check the dimensions and other specifications specifications for any accessories to be used against Figure 3 1 and tables Table 3 4 through Table 3 7 Table 3 4 Dimensions BCT Dimension amp Description BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 A Height including draught diverter mm 1910 1890 2155 1950 2145 B Height excluding draught diverter mm 1700 1700 1900 1735 1810 D Diameter of the appliance mm 710 710 710 710 710 F Width including control column mm 800 800 800 800 800 G Flue gas outlet diameter mm 130 150 180 200 250 K Height of the gas connection mm 145 145 145 145 145 M Height of the cold water supply mm 505 505 505 515 590 N Height of the hot water outlet mm 1545 1545 1750 1580 1655 22 Instruction Manual BCT Technical specifications ED Table 3 4 Dimensions BCT Continued Dimension amp Description BCT BCT BCT BCT BCT 80 140 80 180 95 260 70 360 65 400 P Height of the cleaning opening centre mm 670 670 670 680 765 R Height of the drain valve centre mm 440 440 455 465 540
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