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A.O. Smith BFM - 120 Installation Manual

1. ae SES Dee 7 i B 2770 Ki 3 m09 Y R i ey Ee 5 97 4 On 16 gt i LI 514 is a n 15 VENTED H aa ae do OT ea el m a ees SO 17 13 es AE kZ 12 oo amp N pY 11 De 3 4 4 y7 14 5 4 c 4 6 5 4 s gt T 4 97 od 10 i 5 Filling 5 1 Filling unvented To fill the appliance proceed as follows Mk installations 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6 2 Close the drain valve 9 3 Open the nearest hot water draw off point 14 4 Open the stop valve 4 on the cold water side A so that cold water flows into the appliance 5 Completely fill the appliance When a full water jet flows from the nearest draw off point the appliance is full 6 Bleed the entire installation of air for example by opening all draw off points 7 The appliance is now under water supply pressure There should be no water coming out of the expansion valve 15 nor the T amp P valve 3 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 1 The expansion valve in the protected cold supply setup is defective or incorrectly fitted 5 2 Filling vented instal To fil
2. 39 Orifice replacement 40 Replacement of burner pressure regulator or blank plate BEM30 50 80 100 41 Filling aa 43 Filling unvented installations 44 Filling vented installations 44 Draining eee eee eee 45 Draining unvented installations 46 Draining vented installations 47 The control panel 49 Introduction 49 Control panel 49 Explanation of icons 49 ON OFF switch eee 49 Control thermostat 49 Burner control reset button 50 5 10 11 12 13 14 8 1 8 2 8 3 9 1 9 2 9 3 10 1 10 2 10 3 10 4 11 1 11 2 11 3 11 4 12 1 12 2 12 3 12 4 12 5 13 1 13 2 13 3 13 4 13 5 13 6 13 7 14 1 14 2 Table of contents Status of the appliance 54 Introduction 5 bae Sa an BnR Aa ba Ea 54 Operating modes
3. 51 Error conditions 54 Starting and running 53 Introduction 53 Starting the appliance 53 The appliance s heating cycle 53 Shutting down 55 Introduction a52 S28 AR DR He BA ees 55 Shutting down the appliance for a brief period OFF mode 55 Isolating the appliance from the mains 55 Shutting the appliance down for along period 55 Troubleshooting 57 Introduction 552555 57 Troubleshooting general errors 58 Troubleshooting insufficient hot water 59 Troubleshooting No hot water 60 Performing maintenance 63 Introduction 2 2 52 eee eee ee eee 63 Preparation for maintenance 63 Water side maintenance 64 Gas side maintenance 66 Finalising maintenance 66
4. Installation User and Service Manual I SS IVE WATER PRODUCTS COMPANY A DIVISION OF A 0 SMITH CORPORATION www aosmithinternational com your installer Mk Read this manual carefully Trademarks Liability More information Instruction manual BFM yy Warning Read this manual carefully before starting up the water heater Failure to read this manual and to follow the instructions in this manual may lead to accidents personal injury and damage to the appliance Copyright 2007 A O Smith Water Products Company 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 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 free of charge Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant co
5. Instruction manual BFM 61 va EX Instruction manual BFM 62 12 Performing maintenance 121 Introduction Caution Maintenance may only by carried out by an approved service and maintenance engineer At each service the appliance undergoes maintenance on both the water side and the gas side The maintenance must be carried out in the following order 1 Water side maintenance 2 Water side maintenance 3 Gas side maintenance 4 Finalising maintenance Note Before ordering spare parts it is important to write down the appliance type and model and the full serial number of the appliance These details can be found on the rating plate Only by ordering with this information can you be sure to receive the correct spare parts 12 2 Preparation for To test whether all components are still working properly complete the following maintenance steps 1 Set the ON OFF switch on the control panel to position 0 2 Setthe control thermostat to the highest value note the original setting and set the ON OFF switch back again to position I 3 If there is no heat demand draw off some water to create a heat demand 4 Check whether the heating cycle 9 3 The appliance s heating cycle runs correctly 5 Set the control thermostat back to the original setting and set the ON OFF switch back again to position I 6 Check the supply and burner pressure 3 11 Checking the supply pressure and burner pressure and adjus
6. user 8 wall flue terminal 28 31 warranty 67 exclusions 68 general 67 installation and conditions of use 67 scope 68 water composition 18 13 Index 0306 723 4 0 UK Instruction manual BFM
7. 14 cold water inlet 12 15 drain valve 16 gas control 18 fan 21 flame probe 22 chimney pipe 24 insulation layer 36 bar burners burner tray 38 safety thermostat sensor 39 high limit thermostat sensor 40 burner control 41 control thermostat IMD 0240 R2 42 high limit thermostat 43 safety thermostat 44 frost thermostat 45 control thermostat sensor 46 frost thermostat sensor 47 air supply 49 air restrictor 50 combustion chamber with air distribution plate 51 pilot burner 52 spark igniter Instruction manual BFM Mk 2 3 The appliance s heating cycle 24 Protection for the appliance Instruction manual BFM 2 4 1 In this appliance the cold water enters the bottom of the tank through the cold water inlet 14 The heat of combustion is conducted to the water by the combustion chamber 50 and heat exchanger 11 The heated tap water leaves the tank through the hot water outlet 2 Once the appliance is completely filled with water it will constantly be under mains water pressure When hot water is drawn from the appliance it is immediately replenished with cold water The air required for combustion is forced into the combustion chamber by the fan The gas required for combustion flows via the gas control 16 in the manifold The gas control for the BFM 120 is non standard see box Orifices are mounted in the manifold The gas is injected into the burner bars
8. 7 5 Control thermostat These errors disappear automatically once the cause of the error has been removed after which the appliance resumes operation by itself The cause of the error is not shown on the control panel For a comprehensive overview of errors refer to troubleshooting 11 Troubleshooting As an end user if you find the appliance in an error condition you can attempt to start the appliance running by pressing the rest button once However if the error returns or occurs several times in a short time you must contact your service and maintenance engineer 51 52 Status of the appliance Mk Instruction manual BFM Mk 9 Starting and running 91 Introduction Topics covered in this chapter e Starting the appliance e The appliance s heating cycle 9 2 Starting the appliance Start the appliance as follows 1 Fill the appliance 5 Filling 2 Open 3 5 Installation diagram the manual gas valve 3 Switch on the power to the appliance using the isolator between the appliance and the power supply 4 Put the appliance in ON mode by setting the ON OFF switch on the control panel to position I 5 Using the control thermostat 7 5 Control thermostat set the desired water temperature If there is a heat demand the appliance will run through the heating cycle 9 3 The appliance s heating cycle 9 3 The appliance s heating cycle The appliance s heating cycle is
9. If necessary replace them as follows 1 Carry out steps 7 through 9 of orifice replacement 4 2 Orifice replacement Remove the burner pressure regulator or blank plate from the appliance Fit the burner pressure regulator or blank plate from the conversion set 4 Carry out steps 10 through 14 of orifice replacement 4 2 Orifice replacement Note Once you have completed the replacement of the components you must check the supply pressure and burner pressure to match the intended gas category 3 11 Checking the supply pressure and burner pressure 41 42 Conversion to a different gas category ba pas Instruction manual BFM Mk 5 Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply hot water supply circulation pipe gas supply overflow pipe overflow pipe ND a amp T MO Instruction manual BFM Filling Installation diagram UNVENTED
10. Warranty certificate 67 General warranty 67 Tank warranty 67 Conditions for Installation and use 67 Exclusions 68 Scope of the warranty 68 Claims 5 222 2 22 68 Obligations of A O Smith 68 Electrical diagram 69 Introduction 2 555 222 69 BFM Electrical Diagram 70 Instruction manual BFM Mk 1 11 About the appliance CE 0063 1 2 What to do if you smell gas 1 3 Regulations Instruction manual BFM Introduction This manual describes how to install service and use the BFM appliance The BFM appliance is a gas fired sealed boiler with afan in the air supply The parallel or concentric chimney connections are appliance dependent Possible installation types are C13 or C33 The information in this manual applies to the BFM 30 BFM 50 BFM 80 BFM 100 and BFM 120 The appliance has been manufactured and eguipped in accordance with the European standard for gas fired storage water heaters for the production of domestic hot water EN 89 The appliances
11. period To shut the appliance down for a longer period you must drain the appliance 6 Draining Instruction manual BFM 10 Shutting down Mk Instruction manual BFM Mx 11 111 Introduction Instruction manual BFM Troubleshooting This chapter deals with the following problems with the appliance Gas smell Water leakage Explosive ignition Poor flame profile No hot water Insufficient hot water When the appliance is in an error condition the heat demand is temporarily ignored and you cannot draw hot water The frost protection is also out of action The error conditions are divided into three groups Lock out errors of the burner control In this event the red error light will be lit on the control panel The burner control is in lockout Once the cause has been rectified the reset button must be pressed to restart the appliance Cycling of appliance In this case the appliance continuously attempts to start but there is an error that prevents the heating cycle 9 3 The appliance s heating cycle from completing successfully Once the cause has been rectified the appliance will restart automatically Blocking errors You can recognize this condition when the appliance does not start running despite the fact that the water is colder than the temperature set with the control thermostat 7 5 Control thermostat These errors disappear automatically once the cause of the error has b
12. x F 0 IMN NNAN DI 3 9 4 C13 concentric wall flue terminal specifications BFM 30 50 80 C13 Concentric wall flue terminal specifications Subject Description Wall flue terminal set BFM 30 0302 515 1 e 1x Wall flue terminal incl wall flange BFM 50 0302 504 1 amp clamping ring BFM 80 0302 326 1 e 1x Pipe 500 mm Construction Concentric 1x Bend 90 Manufacturer Muelink amp Grol Type M2000 MDV SE WL Pipe material Construction Concentric Chimney flue Thick walled aluminium with lip ring seal Air supply Thin walled galvanised sheet steel Pipe diameters Chimney flue BFM 30 80 mm BFM 50 100 mm BFM 80 130 mm Air supply BFM 30 125mm BFM 50 150 mm BFM 80 200 mm 1 No other wall flue terminal is permitted Order the wall flue terminal set from manufacturer or trade supplier stating the article number 28 Instruction manual BFM TJA Instruction manual BFM 3 9 5 Concentric roof flue terminal BFM 30 50 80 Roof flue terminal td EA i g T IMD 0061 R2 29 3 Installation 3 9 6 C33 concentric roof flue terminal specifications BFM 30 50 80 C33 concentric roof flue terminal specifications Subject Description Roof flue terminal set 1x Roof flue terminal in
13. 15 10 Remark See the BFM electrical diagram 14 Electrical diagram If the error cannot be rectified contact your installation engineer No attempt to start heating cycle blocking error Pressure switch not closing 1 Blockage in the chimney flue or air supply Trace the blockage Remove the blockage Defective pressure switch Check the wiring of the pressure switch Check that the pressure switch is working Once the error is rectified the appliance will automatically start up if there is a heat demand If the error cannot be resolved or is persistent contact your installation engineer Failure in the thermostat circuit Check whether the control thermostat is switched closed Check leads and sensors of the control and high limit thermostats Repetitive starting of the heating cycle cycling of the appliance Too much resistance in the chimney flue the pressure switch opens during heating Instruction manual BFM Check whether the chimney flue configuration 3 9 Air supply and flue has been installed in accordance with instructions If the error cannot be resolved or is persistent contact your installation engineer 60 TJA Symptom Cause Solution Remark Burner control reset There are three possible causes for this error In order to determine the cause you must see the appliance s heating cycle 9 3 The appliance s heating button burner control
14. 2 Fita non return valve 5 3 Fita stop valve 11 Hot water side See B in the installation diagram 3 5 Installation diagram g Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fitthe T amp P valve 3 2 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fita stop valve 4 in the hot water outlet pipe for use when servicing 4 Ifa circulation pipe is required continue further by installing the circulation pipe 3 6 5 Circulation pipe Drain valve 1 Fitthe standard drain valve 9 supplied with the appliance 2 If applicable fit a circulation pipe 3 6 5 Circulation pipe If not fit the blind threaded plug and gasket C supplied with the drain valve as shown in the figure IMD 0122 R1 Instruction manual BFM TJA 3 7 Water connectio Unvented Instruction manual BFM 3 6 5 ns 3 7 1 3 7 2 3 7 3 3 7 4 Circulation pipe See C in the installation diagram 3 5 Installation diagram 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 6 of the correct capacity for the length and resistance of the circulation system 2 Fita non return valve 5 behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connec
15. 774 1 Construction Concentric Manufacturer Muelink amp Grol Type M2000 MDV SCC Pipe material Construction Parallel Chimney flue Thick walled aluminium with lip ring seal Air supply Thick walled aluminium with lip ring seal Pipe diameters Chimney flue 130 mm Air supply 130 mm 1 No other wall flue terminal is permitted Order the wall flue terminal set from manufacturer or trade supplier Stating the article number 32 Instruction manual BFM Concentric roof flue terminal BFM 100 120 if 3 9 10 Roof flue terminal FT za g NI IMD 0239 R1 Instruction manual BFM 3 Installation 3 9 11 C33 concentric roof flue terminal specifications BFM 100 120 C33 concentric roof flue terminal specifications Subject Description Roof flue terminal set Art No 0306 773 1x Wall flue terminal incl clamping Construction ring 1x Pipe 1000 mm 1x Mounting flange Type M2000 DDV SE Concentric Manufacturer Muelink amp Grol Pipe material Construction Parallel Chimney flue Thick walled aluminium with lip ring seal Air supply Thick walled aluminium with lip ring seal Pipe diameters Chimney f
16. A B C is 7 metres The maximum permissible number of 45 or 90 bends is 2 If you are using a horizontal pipe you must mount it with a minimum run off of 5 mm per running metre of pipe towards the appliance The transition piece to convert the air supply and chimney flue from parallel to concentric must be installed immediately before the wall or roof flue terminal The intake duct of the air supply must be approximately the same as the chimney flue Make sure that the chimney flue discharges into an area approved for this type of appliance See the figures Wall flue terminal 3 9 8 Concentric wall flue terminal BFM100 120 and Roof flue terminal 3 9 10 Concentric roof flue terminal BFM 100 120 for examples of installation 3 9 8 Concentric wall flue terminal BFM100 120 Wall flue terminal Instruction manual BFM f l Nita L A A P5 IMD 0226 R1 31 3 Installation 3 9 9 C13 concentric wall flue terminal specifications BFM 100 120 C13 Concentric wall flue terminal specifications Subject Description Wall flue terminal set 1x Wall flue terminal incl wall flange amp clamping ring 1x Clamping ring 1x Transition piece 2x Pipe 500 mm 2x Bend 90 Art No 0306
17. G30 30 mbar butane Orifice diameter Diameter of pilot flame orifice 1 Blank plate 2 Burner pressure regulator Nominal load upper value Nominal output Supply pressure Burner pressure T Gas consumption G31 37mbar propane Orifice diameter Diameter of pilot flame orifice 1 Blank plate 2 Burner pressure regulator Nominal load upper value Nominal output Supply pressure Burner pressure t 7 2 22 0 Gas consumption kg h 2 2 3 4 5 5 7 9 8 9 Based on 1013 25 mbar and 15 C t If using a blank 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 22 Instruction manual BFM y ee 3 5 Installation diagram 3 5 1 Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water sup
18. O Instruction manual BFM IMD 0235 R2 1 Remove the cover plate 1 on the outer jacket see the figure 2 Carefully remove the insulation layer 2 and set it to one side This will be needed again later Undo the bolts Remove the lid the gasket and the O ring Inspect the tank and remove the loose scale deposits and contamination If the scale cannot be removed by hand descale the appliance with a descaling agent Contact the supplier manufacturer for advice on what descaling agent to use IMD 0282 R1 Close the cleaning opening To avoid damage to the tank tighten the bolts that fasten the lid with a torque no greater than 50 Nm Use suitable tools for this For the best possible watertight seal of the cleaning opening the bolts in the lid should be torqued down in the sequence shown in the figure 65 12 124 Gas side mainte nance 12 4 1 12 4 2 12 4 3 12 4 4 12 5 Finalising mainte nance 66 Performing maintenance Introduction The following steps must be carried out on the gas side 1 Clean the burner s 2 Clean the orifice s 3 Checking the flue baffles Clean the burner s 1 Detach the burner s 2 Remove all contamination present on the burner s 3 Fit the burner s Clean the orifice s 1 Detach the orifice s 2 Remove all contamination present in the orifice s 3 Fit the orifice s Checking the flue baffles W Warning The flu
19. To electrically isolate the appliance you must use the isolator between the appliance and the mains power supply 7 5 Control thermostat Use the rotary knob of the control thermostat to set the desired water temperature between 40 C and 70 C The range is continuous and is labelled 1 through 4 The table shows the temperatures corresponding to the numbers on the knob Temperature settings Position Temperature 40 C 50 C 60 C 70 C 49 f The control panel 7 6 Burner control reset button An error in the appliance can cause a lockout of the burner control When this happens the reset button lamp will be lit Once the cause of the error has been rectified you can reset the appliance using the reset button Note Never use the reset button until you have rectified the error Many errors 11 Troubleshooting can be identified according to the appliance status 8 Status of the appliance 50 Mx Instruction manual BFM Mk 8 Status of the appliance 8 1 Introduction Topics covered in this chapter e Operating modes e Error conditions 8 2 Operating modes When running the appliance has three basic operating modes namely e ELECTRICALLY ISOLATED In this mode the appliance is off and no components are live The isolator switch between the appliance and the mains power supply is off On the control panel the ON OFF switch is at position 0 the gr
20. activated as soon as the measured water temperature Twater falls below the threshold value Tt This threshold value depends on the currently selected appliance operating mode For example if the appliance is in OFF mode frost protection then this value is 20 C If the appliance is in ON mode for example then this threshold value can be selected e g position 3 60 C The heating cycle runs successively through the following states HEAT DEMAND WAIT PRE GLOW IGNITION RUNNING WAIT Oak O N Instruction manual BFM The entire cycle is explained in the example below Note The cycle has the same steps when frost protection is activated 1 The control thermostat sensor measures the temperature The water temperature falls below the set temperature of for example 60 C causing the control thermostat to close The burner control now detects a demand and starts the heating cycle Following demand the wait period starts This wait ensures that the ignition is safe The wait period lasts approximately 15 seconds Once the wait period has elapsed there is audible clicking of the relay in the burner control the PRE GLOW starts After about 12 seconds pre glowing the gas control opens and ignition takes place After ignition the flame is detected and the appliance will be running This means that actual heating has started When the water reaches the set temperature the demand ce
21. are therefore compliant with the European Directive for Gas Appliances and and are entitled to bear the CE mark o Warning 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 W Warning If there is a gas smell No naked flames No smoking Avoid causing sparks Do not use any electrical equipment or switch i e no telephones plugs or bells Open windows and doors Shut off the mains gas supply valve Warn occupants and leave the building After leaving the building alert the gas distribution company or your installation engineer As the end user installation engineer or service and maintenance engineer you must ensure that the entire installation complies as a minimum with the official local e building regulations e energy supplier s directives for existing gas installations e directives and technical guidelines for natural gas installations e safety requirements for low voltage installations e regulations governing the supply of drinking water e regulations governing ventilation in buildings regulations governing the supply of air for combustion e regulations governing the discharge of products of combustion e requirements for installations that consume gas e regulations governing indoor waste water disposal regulations imposed by fire brigade power companies an
22. cause the error to appear again cycle lock out error 1 Reset the appliance by pressing the reset button 1x 2 Cause a occurs between step 4 and step 5 of the heating cycle 3 Cause b occurs in step 5 or 6 4 Cause c occurs in step 7 a Continuous failure 1 Check whether the thermostat is defective If the error cannot be resolved or is persistent contact your aa a 2 Check whether the sensor of the thermostat is defective installation engineer 3 Check the leads of the thermostat b Failed start attempt No gas If the error cannot be resolved or is persistent contact your installation engineer 1 Check that the gas valve is open 2 Check whether the gas control is opening clicking of the gas control 3 Check the leads of the gas control No ignition 1 Check whether the spark igniter is sparking in the pilot flame cap 2 Check the leads of the glow igniter 3 Check whether the spark igniter is correctly mounted in the bracket No flame detection 1 Check whether the flame probe is defective Check that the flame probe leads are properly connected c Failure in the safety circuit during heating the safety thermostat has switched Check whether the control thermostat is working If the error cannot be resolved or is persistent contact your installation engineer 2 1 2 Check whether the high limit thermostat is working 3 Check that the circulation pump if present is working
23. difference is reached the pressure switch closes However in the event of a fault the pressure switch is tripped open and the heating cycle is interrupted The table shows the trip point per appliance Note The trip point of the pressure switch is not adjustable Pressure switch trip points Appliance Closing pressure Opening pressure difference difference BFM 2 200 Pa lt 170 Pa 30 BFM gt 270 Pa lt 240 Pa 50 BFM gt 255 Pa lt 225 Pa 80 BFM 2 610 Pa 580 Pa 100 BFM 2 220 Pa lt 190 Pa 120 Flame probe To ensure that no gas can flow when there is no combustion the water heater is fitted with aflame probe 21 The burner control uses the ionisation detecting properties of this probe for flame detection The burner control closes the gas valve the instant it determines that there is a gas flow but no flame is present Instruction manual BFM Mk 2 5 Safety of the ins lation Instruction manual BFM tal 2 5 1 2 5 2 2 5 3 In addition to the appliance s standard built in safety monitoring the appliance must also be protected by an expansion vessel expansion valve pressure reducing valve non return valve and a T amp P valve The use of an expansion vessel expansion valve and or pressure reducing valve depends on the type of installation unvented or vented Unvented installation With an unvented installation an expansion valve valve and expansion vessel p
24. from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the stop valve 4 between the cold water head tank and the cold water inlet 6 Open the drain valve 9 7 Bleed the appliance or installation so that it drains completely Instruction manual BFM 47 rainin Mk Instruction manual BFM Mk T The control panel 7 1 Introduction Topics covered in this chapter e Control panel e Explanation of icons e ON OFF switch Control thermostat e Burner control reset button 7 2 Control panel The figure shows the control panel The control panel WATER PROOUCTS COMPANY IMD 0462 RO The control panel comprises an ON OFF switch with status lamp e areset button with status lamp e acontrol thermostat with rotary knob two status lamps Instruction manual BFM 7 3 Explanation of icons The table explains the meanings of the icons Icons and their meaning Name Explanation ON OFF Switch ON mode OFF mode Reset button with Resets burner error status control Temperature control For setting water temperature Tset 7 4 ON OFF switch The ON OFF switch sets the appliance in ON mode or OFF mode In OFF mode the appliance is still electrically live This ensures that the frost protection is active Note
25. frost thermostat both independently measure the water temperature Twater The appliance s heating cycle is activated as soon as T water falls below the threshold value Tset The value of T et depends on the selected mode of the appliance 8 2 Operating modes When the appliance is in OFF mode frost protection this value is determined by the frost thermostat threshold value 20 C When the appliance is in ON mode the threshold value can be set via the control thermostat 40 C 70 C The instant Twater falls below Tse the appropriate thermostat control or frost will close and the burner control will identify a heat demand The gas control will open and the gas will mix with air This mixture is ignited by the spark igniter and the water becomes heated As soon as Twater rises above Tg the thermostats will open once more The heat demand is suspended and the burner control stops the heating cycle The thermostats have a certain margin both when opening and when closing We refer to this margin as hysteresis The hysteresis cannot be adjusted Introduction The burner control monitors the water temperature by means of thermostats and ensures that the combustion is safe This takes place using 13 Protection 2 4 2 Team emut TS e the Water temperature protection the Flame probe the Pressure switch Water temperature protection By means of the frost high limit and safety thermostats
26. pipe for servicing Drain valve 1 Fit the standard drain valve 9 supplied with the appliance 2 If applicable fit a circulation pipe 3 6 5 Circulation pipe If not fit the blind threaded plug and gasket C supplied with the drain valve as shown in the figure 25 3 8 26 Gas connection 3 7 5 Installation ye pee IMD 0122 R1 Circulation pipe See C in the installation diagram 3 5 Installation diagram 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 6 of the correct capacity for the length and resistance of the circulation system 2 Fita non return valve 5 behind the circulation pump to guarantee the direction of circulation 3 Fit two stop valves for service purposes 4 4 Connect the circulation pipe to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve yy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Caution Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the appliance See D in the installation diagram 3 5 Installation diagram 1 Fit a manual gas valve 10 in the gas supply pipe 2 Blow the gas pipe clean before use 3 Close the
27. to shut the appliance down for a brief or long period of time This chapter is mainly intended for the installation engineer and the service and maintenance engineer It describes appliance errors A table is included stating potential symptoms causes and solutions End users may also refer to this chapter for additional information about the appliance Performing maintenance This chapter sets out the maintenance tasks to be carried out during a service Warranty certificate Instruction manual BFM This chapter states the warranty terms and conditions Introduction Mk Instruction manual BFM Mk 21 Introduction 2 2 General working principle of the appliance Instruction manual BFM Working principle of the appliance Topics covered in this chapter e General working principle of the appliance e The appliance s heating cycle e Protection for the appliance Safety of the installation The figure shows a cut away view of the appliance 11 2 Working principle of the appliance Cut away view of the appliance Legend Only applicable numbers are mentioned 2 hot water outlet 5 pressure switch 8 combustion chamber 9 anode 10 tank 11 heat exchanger 12 inspection and cleaning opening
28. Clean the orifice s 12 4 3 Clean the orifice s Inadequate air supply Instruction manual BFM Improve the air supply by providing better ventilation in the boiler room If ignition is not improved consult your installation engineer 58 11 3 Troubleshooting insufficient hot water Wy Warning Maintenance may only be performed by a qualified service and maintenance engineer Insufficient hot water Symptom Cause Solution TJA Remark Insufficient hot water Water temperature setting Tet is too low Set the control thermostat 7 5 Control thermostat to a higher value Hot water supply is used up Instruction manual BFM 1 Reduce hot water consumption and give the appliance time to heat up If this error persists check whether the high limit thermostat is switching If this is the case check that the circulation and or top to bottom circulation pump are working If this error persists check whether the high limit thermostat is switching 59 11 4 Troubleshooting No hot water No hot water Symptom No attempt to start heating cycle No supply voltage present Solution 1 2 3 4 5 Check if the isolator is ON Check whether there is power to the isolator Check whether there is power to the electrical connector block Check whether there is power to the burner control Check fuse in the burner control The measured voltage must be 230 VAC
29. MPONENTS S T Clock Potentiostat 71 72 14 Electrical diagram ba pes Instruction manual BFM Mk Index ambient temperature 17 burner pressure 36 claims 68 connect air supply 27 circulation piping 25 26 cold water side 24 25 electrical 34 35 gas 26 hot water side 25 shut pipe 24 25 connecting air supply 27 connecting circulation pipe 25 26 connecting cold water side 24 25 connecting flue gas discharge 27 connecting hot water side 25 control thermostat 49 conversion to a different gas category 39 document contents 9 draining 45 electrical connection 34 environmental conditions 17 filling 43 flame probe 15 forms of notation 8 gas category conversion to different 39 gas connection 26 general specifications 3 heating cycle 13 humidity 17 icons 49 explanation 49 ignition 13 installation engineer 8 9 isolator 35 liability 3 Instruction manual BFM mains power 35 maintenance anode 64 burner 66 finalising 66 gas side 66 orifice 66 perform 63 preparation 63 water side 64 operating modes 51 packaging 17 protection 13 reset button 50 roof flue terminal 29 33 running 53 scale 64 service check 8 service engineer 8 shunt pump 24 25 specifications 19 starting up 53 supply pressure 36 symbol installation engineer 8 service engineer 8 user 8 target groups 8 to shut down electrically isolating 55 longer period 55 short period 55 trademarks 3
30. ases The gas control closes and the burner tray is extinguished A new wait period of about 10 seconds starts At the end of this wait the appliance enters the idle state and waits until the water temperature once more falls below the set temperature With any subsequent heat demand the heating cycle will resume from step 1 53 54 Starting and running Mk Instruction manual BFM AEX 10 Shutting down 10 1 Introduction Topics covered in this chapter Shutting down the appliance for a brief period OFF mode e Isolating the appliance from the mains e Shutting the appliance down for a long period 10 2 Shutting down the appliance for a brief period OFF mode To shut the appliance down for a brief period you must activate frost protection using the appliance s heating cycle 2 3 The appliance s heating cycle By using the frost protection you can prevent water freezing in the appliance Frost protection is activated by setting the ON OFF switch on the control panel to position 0 10 3 Isolating the appliance from the mains The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Shut down the appliance by setting the ON OFF switch to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 10 4 Shutting the appliance down for a long
31. at pressure from these orifices 36 The burner bars together form the burner tray The injection of gas into the burner bars also draws in the primary air from the combustion chamber which is required for combustion The narrow opening in the orifice causes the gas flow to accelerate This in turn causes a partial vacuum It is this partial vacuum that draws in the air the Venturi effect Ignition of the gas air mixture takes place in two stages First the pilot flame is ignited by a spark igniter This pilot flame then ensures that the complete ignition takes place The flue gases released by this combustion are led through the heat exchanger The heat exchanger is composed of flue tubes that contain flue baffles These retard the flow of the flue gases thereby increasing the thermal efficiency of the appliance The flue gases are exhausted from the appliance via the top box 46 The top box of the BFM 100 and 120 is non standard see box An air distribution plate 50 mounted below the burner tray radiation shield also serves as a radiation shield Any condensation that forms is drained towards the siphon via the air distribution plate The PU insulation layer 24 prevents heat loss The inside of the tank is enamelled to protect against corrosion The anodes 9 offer extra protection The entire appliance is controlled by the burner control 40 and the control thermostat 41 or frost thermostat 44 The control thermostat and
32. cl clamping ring e 1x pipe 1000 mm BFM 30 BFM 50 BFM 80 0302 518 0302 5071 0302 3271 Construction Concentric 1x mounting flange Manufacturer Muelink amp Grol Type M2000 DDV SE HR VR Construction Concentric Pipe material Chimney flue Thick walled aluminium with lip ring seal Air supply Thin walled galvanised sheet steel Chimney flue BFM 30 80 mm BFM 50 100 mm BFM 130 mm 80 Air supply BFM 30 125mm BFM 50 150 mm BFM 200 mm 80 1 No other roof flue terminal is permitted Order the roof flue terminal set from manufacturer or trade supplier stating the article number Pipe diameters 3 9 7 Installing chimney flue components for BFM 100 120 The air supply duct 1 and chimney flue 2 for the BFM 100 and 120 emerge separately from the top box They must be connected to the concentric wall flue terminal or roof flue terminal by means of a transition piece Parallel connection BFM 100 120 Legend 1 Air supply 2 chimney flue IMD 0252 R1 30 Instruction manual BFM TJA A O Smith prescribes the use of a concentric roof or wall flue terminal exclusively of a type approved for the appliance Use of an incorrect roof or wall flue terminal can cause the installation to malfunction You must also fulfil the following requirements The maximum permissible length of chimney pipe
33. d municipality 1 4 1 5 1 6 Maintenance Forms of notation Target groups ei AK Furthermore the installation must comply with the manufacturer s instructions Note Later amendments and or additions to all regulations reguirements and guidelines published on or prior to the moment of installing will apply to the installation A service should be carried out at least once a year both on the water side and on the gas side Maintenance freguency depends among other things on the water guality the average burning time per day and the set water temperature Note To determine the correct maintenance freguency it is recommended to arrange forthe service and maintenance engineer to check the appliance on both the water and gas side within three months following installation Based on this check the best maintenance freguency can be determined Note Regular maintenance extends the service life of the appliance Note Both the end user and the service and maintenance engineer are responsible for regular maintenance They will need to establish clear agreements on this Note If the appliance is not regularly maintained the warranty will become void The following notation is used in this manual Note Important information Caution Ignoring this information can lead to the appliance being damaged yy Warning Failure to carefully read this information may lead to personal injury and serious damage to th
34. d with those for the current gas category and adjust 3 11 Checking the supply pressure and burner pressure these if necessary 39 4 4 2 Orifice replacement Strain relief spark electrode lead flame probe lead burner control gas control connector s gas control gas coupling AON OORA WN burner tray 40 Conversion to a different gas category a pe Gas control assembly removed on amp IMD 0254 R1 Remove the protective cover from the control column undo the 4 screws and remove the protective cover by lifting it The electrical section will now be exposed Remove the strain relief 1 and disconnect the leads of the spark electrode 2 red and the flame probe 3 black from the burner control 4 Unscrew the connector s 5 of the gas control 6 Remove the gas coupling 7 of the gas control Remove the ten screws that fasten the burner tray 8 Withdraw the burner tray from the appliance Note When exchanging the pilot flame orifice and or main orifices Lay the burner tray on its side and approach it from the underside 7 If the gas table 3 4 3 Gas data indicates that the pilot flame orifice needs to be replaced a Remove the spark electrode 1 from its retaining clip This way you will gain space to remove the pilot flame orifice b Turn the flame probe 2 and remove it from its bracket to gain space Remove th
35. e anodes using suitable tools 55 00 A0 OB ON 0 Check the anodes and if necessary replace them 1 Now also check the flue baffles 12 4 4 Checking the flue baffles If necessary replace them 12 Place a new sealing ring on the rim of the tank and re fit the lid 13 Re fit the top box 14 Feed the fan cable through the strain relief and connect the leads to the fan See addendum A BFM electrical diagram 15 Re fit the cover on the top box Descaling and cleaning the tank Scale and lime buildup prevent effective conduction of the heat to the water Periodic cleaning and 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 Scale formation depends on the local water composition the water consumption and the water temperature setting A water temperature setting of maximum 60 C is recommended for prevention of excessive scale buildup To ensure the perfectly watertight sealing of a cleaning opening the gasket 6 O ring 7 sealing rings 4 bolts 3 and possibly the lid 5 should be replaced with new components after opening see the figure A special set is obtainable from the supplier manufacturer To simplify the task of descaling and cleaning the tank the appliance is equipped with two cleaning openings Instruction manual BFM OY ON Be
36. e appliance The three target groups for this manual are e end users e installation engineers service and maintenance engineers Symbols on each page indicate the target groups for whom the information is intended See the table Target group symbols Target group End user Installation engineer Service and maintenance engineer Instruction manual BFM Mk 1 7 Overview of this document Chapter Working principle of the appliance The table provides an overview of the contents of this document Contents of this document Target groups Description This chapter describes how the appliance functions Installation This chapter describes the installation activity to be completed before you actually start up the appliance Filling Draining This chapter describes how to fill the appliance This chapter describes how to drain the appliance The control panel This chapter describes the general operation of the appliance and explains how to use the control panel Status of the appliance This chapter describes the status mode or condition that the appliance may have and possible actions to take Starting and running This chapter describes how to start the appliance running The general heating cycle of the appliance is also described Shutting down Troubleshooting This chapter describes how
37. e baffles can be hot 1 Remove the flue baffles from the appliance 2 Check the flue baffles for the presence of corrosion removing this if necessary 3 Check the flue baffles for wear and replace the flue baffles if necessary To finalise the maintenance carry out the following steps 1 Fill the appliance 5 Filling 2 Start the appliance 9 Starting and running Instruction manual BFM Mx 13 13 1 General warranty 13 2 Tank warranty 13 3 Conditions for Instal lation and use Instruction manual BFM Warranty certificate To register your warranty you should complete and return the enclosed warranty card after which a warranty certificate will be sent to you This certificate gives the owner of a appliance supplied by A O Smith Water Products Company B V of Veldhoven The Netherlands hereinafter A O Smith the right to the warranty set out below defining the commitments of A O Smith to the owner If within one year of the original installation date of a water heater supplied by A O Smith following verification and at the sole discretion of A O Smith a section or part with exclusion of the tank proves to be defective or fails to function correctly due to manufacturing and or material defects then A O Smith shall repair or replace this section or part If within 3 years of the original installation date of a water heater supplied by A O Smith following inspection and at the sole discre
38. e bracket of the pilot flame orifice 3 d Replace the current pilot flame orifice 4 with a pilot flame orifice of the correct diameter from the conversion set e Check the pilot flame orifice The orifice diameter is stamped on the orifice itself f Re fit the bracket the flame probe and the spark electrode Instruction manual BFM TJA 4 3 Replacement of burner pressure regulator or blank plate BFM30 50 80 100 Instruction manual BFM 8 Ifthe gas table 3 4 3 Gas data indicates that the main burner orifices need to be replaced a Remove the main orifices 5 b Fitthe main orifices from the conversion set Check the required orifice diameter against the value given in the gas table 3 4 3 Gas data The orifice diameter is stamped on the orifice itself 9 If necessary replace the blank plate or burner pressure regulator 10 Re fit the burner tray and fasten it using the screws 11 Fit the gas coupling to the gas control and firmly tighten the connector s of the gas control 12 Reconnect the leads of the spark electrode and flame probe to the burner control and fasten them in the strain relief 13 Connect the gas supply 14 Re fit the protective cover Note Refer to the electrical diagram 14 Electrical diagram for correct connection of the electrical components Referring to the gas table determine whether the gas control needs to be fitted with a blank plate or burner pressure regulator
39. ecreases Adjustment screw clockwise burner pressure increases 15 BFM 120 16 Remove the cap 2 from the burner pressure regulator 17 Depending on the correction reguired correct the burner pressure by turning adjustment screw 3 PG using the Allen key supplied with the appliance Adjustment screw anticlockwise burner pressure decreases Adjustment screw clockwise burner pressure increases yy Warning Adjustment screw Ps adjusts the starting pressure This need not and must never be adjusted from the factory preset 18 Check the burner pressure against the value given in the gas table 3 4 3 Gas data 19 If the pressure reading is not correct repeat the burner pressure adjustment until the correct pressure is obtained 20 Shut down the appliance by setting the 0 1 switch to position 0 21 Shut off the gas supply 22 Disconnect the two pressure gauges and re tighten the sealing screws in the test nipples Note 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 further enhance our warranty procedure Please return this card as soon as possible Your customer will then receive a warranty certificate with our warranty conditions Instruction manual BFM y 4 1 Instruction manual BFM Conversion Conversion to a different gas category Caution The conversion may only by carried o
40. ed 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 yS cm and or the hardness alkaline earth ions of the water being less than 1 00 mmol litre 3 3 3 Water composition 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 A O Smith pursuant to the specified warranty do not extend beyond free delivery from the Veldhoven warehouse of the replacement sections parts or water heater respectively Shipping labour installation and any other costs associated with the replacement will not be accepted by A O Smith 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 A O Smith Water Products Company products 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 Water Products Company A O Smith grants no other warranty or guarantee over its water heaters nor the sections or parts of water heaters supplied for replacement other than the warranty expressly set out in this Certificate Under the terms of the supplied warranty A O Smith is not liable for damage to persons or property ca
41. een removed after which the appliance resumes operation by itself Possible error conditions are explained in the following troubleshooting tables Note Footnotes referred to in the tables can be found on the last page of each table 57 11 2 Troubleshooting general errors Wy Warning Maintenance may only be performed by a qualified service and maintenance engineer General errors Symptom Solution y Remark Gas smell Warning Close the main gas valve immediately Warning Do not operate any switches Warning No naked flames Warning Ventilate the boiler room yy Warning Contact your installation engineer or local gas company immediately Water leakage Leakage from a water connection threaded Tighten the threaded connection Leakage from another nearby water appliance or pipe segment Trace the leak Leakage from the appliance s tank Consult the supplier and or manufacturer Condensation Before drawing too much tap water wait until the water in the boiler has reached the set temperature If the leak persists consult your installation engineer Explosive ignition Poor flame profile Incorrect supply pressure and or burner pressure Set the correct supply pressure and or burner pressure 3 11 Checking the supply pressure and burner pressure Contaminated burner Clean the burner s 12 4 2 Clean the burner s Contaminated orifice
42. een light is dimmed OFF In this mode the frost protection is activated The isolator is at position On the control panel the ON OFF switch is at position 0 the green light is lit ON In this mode the appliance continuously responds to the heat demand On the control panel the ON OFF switch is at position the water temperature can be set using the rotary knob of the control thermostat 7 5 Control thermostat the green light is lit 8 3 Error conditions When the appliance is in an error condition the heat demand is temporarily ignored and you cannot draw hot water The frost protection is also out of action The error conditions are divided into three groups e Lock out errors of the burner control In this event the red error light will be lit in the reset button on the control panel The burner control is in lockout Once the cause has been rectified the reset button must be pressed to restart the appliance e Cycling of appliance In this case the appliance continuously attempts to start but there is an error that prevents the heating cycle from completing successfully Instruction manual BFM Once the cause has been rectified the appliance will restart automatically e Blocking errors You can recognize this condition when the appliance makes no attempt to start the heating cycle despite the fact that the water is colder than the temperature set with the control thermostat
43. f the specifications Water specifications Water composition Hardness gt 1 00 mmol l alkaline earth ions German hardness gt 5 6 dH e French hardness gt 10 0 fH e English hardness gt 7 0 eH Conductivity gt 125 HS cm Acidity pH value 7 0 lt pH value 9 5 Note If the water specifications deviate from those stated in the table then the tank protection cannot be guaranteed 13 Warranty certificate Working clearances For access to the appliance it is recommended that the following clearances are observed see figure e AA around the appliance s control column and cleaning openings 100cm e BB all sides of the appliance 50cm e Above the appliance room to replace the anodes 100cm if using fixed anodes or 50cm if using flexible anodes If the available clearance is less than 100cm flexible magnesium anodes may be ordered g Note When installing the appliance be aware that any leakage from the tank and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this is the case 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 Instruction manual BFM TJA 3 4 Technical specifica tions Instruction man
44. l the appliance proceed as follows lations 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6 2 Close the drain valve 9 3 Open the nearest hot water draw off point 14 4 Open the stop valve 4 on the cold water side A so that cold water flows into the appliance 5 Completely fill the appliance When a full water jet flows from the nearest draw off point the appliance is full 6 Bleed the entire installation of air for example by opening all draw off points 7 The appliance is now under water supply pressure There should be no water coming out of the T amp P valve 3 If this does happen the T amp P valve might be defective or incorrectly fitted 44 Instruction manual BFM Mk 6 Legend Only applicable numbers are mentioned 1 pressure reducing valve mandatory T amp P valve mandatory stop valve recommended non return valve mandatory circulation pump optional top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply hot water supply circulation pipe gas supply overflow pipe overflow pipe NO AR T MO Instruc
45. ling the appliance Caution Before starting up for the first time or after conversion you must always check the supply pressure and burner pressure Note The easiest way to check the gas pressures is by using two pressure gauges This procedure assumes that these two gauges are available If the appliance is to be run on a different gas category than the factory preset gas category see type plate then you must first convert 4 Conversion to a different gas category the appliance Gas control for BFM 30 through 100 IMD 0256 R1 Instruction manual BFM TJA Legend 1 burner pressure regulator 3 burner pressure regulator adjustment screw 6 supply pressure test nipple gas control 8 manifold test nipple Gas control for BFM 120 N IMD 0257 R1 1 Isolate the appliance from the power supply 10 3 Isolating the appliance from the mains 2 There are two test nipples on the gas control Test nipple 6 is used to check the supply pressure The other test nipple on the gas control is not used The manifold test nipple 8 is used to measure the burner pressure Sealing screws are located inside the test nipples Loosen both sealing screws by a few turns Do not completely loosen them they can be difficult to re tighten 3 Connect a pressure gauge to the manifold test nipple 8 4 Open the gas supply and bleed the air from the mains gas
46. lue 130 mm Air supply 130mm 1 No other roof flue terminal is permitted Order the roof flue terminal set from manufacturer or trade supplier stating the article number 3 10 Electrical y Warning connection The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations This paragraph describes the electrical connections The figure shows a view of the electrical connector block and the table shows the appropriate connections Connector block Legend A screws B protective cap C connector block IMD 0243 R1 34 Instruction manual BFM TJA In preparation you should first remove the two plastic covers and the protective cap of the electrical section 1 Undo the screws of the plastic covers 2 Carefully remove the covers from the appliance The electrical section is now visible 3 Loosen the 2 screws A of the electrical section and remove the protective cover B from the electrical section The connector block C is now visible g Note Refer to the table for connections 1 through 10 Consult the electrical diagram 14 Electrical diagram for the electrical component connections Electrical connector block Mains power Alarm Off N L1 L S1 1 2 5 7 3 10 1 Connecting the mains power The appliance is su
47. manual gas valve 4 Fit the gas supply pipe to the gas control yy Warning After fitting check for leaks Instruction manual BFM TJA 3 9 Air supply and flue Instruction manual BFM 3 9 1 3 9 2 Introduction yy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations The BFM 30 50 and 80 differ from the BFM 100 and 120 in how the air supply and chimney flue are connected Installing chimney flue components for BFM 30 50 80 The BFM appliances are approved for installation types C13 and C33 The instruction manual describes these types For a more detailed explanation please contact your supplier or the manufacturer Note We prescribe the use of a concentric roof or wall flue terminal exclusively of a type approved for the appliance You must fulfil the following requirements The maximum permissible length of chimney pipe A B C is 7 metres The maximum permissible number of 45 or 90 bends is 2 e Ifyou are using a horizontal pipe you must mount it with a minimum run off of 5 mm per running metre of pipe towards the appliance e Make sure that the chimney discharges into an area approved for this type of appliance 27 3 Installation Wa 3 9 3 Concentric wall flue terminal BFM 30 50 80 Wall flue terminal lt aga ha Te a
48. mponents the manual may nonetheless contain errors and inaccuracies Should you detect any errors or inaccuracies in the manual we would be grateful if you would inform us This helps us to further improve our documentation 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 PO Box 70 5500 AB Veldhoven Netherlands Telephone free 0870 AOSMITH 0870 267 64 84 General 31 40 294 25 00 Fax 31 40 294 25 39 E mail info aosmith nl Website www aosmithinternational com In the event of problems with connecting to the gas electricity or water supply please contact your installation s supplier installation engineer Mk Instruction manual BFM Mk Instruction manual BFM 1 1 1 2 1 3 1 4 1 5 1 6 1 7 2 1 2 2 2 3 2 4 2 5 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 4 1 4 2 4 3 5 1 5 2 6 1 6 2 7 1 7 2 7 3 74 7 5 7 6 Table of contents Introduction 7 About the appliance 7 What to do if you smell gas 7 Regulations 7 Maintenance 8 Forms of notation ii 8 Target gro
49. nt gas category To avoid damaging the appliance remove the packaging carefully We recommend unpacking the appliance at or near its intended location Caution The appliance may only be manoeuvred in an upright position Take care that the appliance is not damaged after unpacking The appliance has a sealed combustion chamber and obtains its air supply independently of the boiler room There are therefore no additional ventilation requirements Possible installation types are C13 and C33 Air humidity and ambient temperature The boiler room must be frost free or be protected against frost The table shows the environmental conditions that must be adhered to for correct functioning of the electronics present in the appliance to be guaranteed Air humidity and ambient temperature specifications Air humidity and ambient temperature Air humidity max 93 RV at 25 C Ambient temperature Functional 0 lt T lt 60 C 17 3 3 2 3 3 3 3 3 4 Installation ye pee Maximum floor load Allow for the appliance s weight with respect to the maximum floor load refer to the table Weight of the appliance filled with water BFM 30 BFM 50 BFM 80 BFM 100 BFM 120 539 kg 543 kg 548 kg 573 kg 573 kg Water composition The appliance is intended for heating drinking water The drinking water must comply with the regulations governing drinking water for human consumption The table gives an overview o
50. 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 protected cold 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 by a likewise approved temperature and pressure relief valve fitted in accordance with installation instructions of A O Smith applying to the specific model of water heater and further in compliance with the government and local authority installation and building codes rules and regulations 67 13 4 13 5 13 6 13 7 68 13 Exclusions Scope of the warranty Claims Obligations of A O Smith Warranty certificate Ah Ga hd i The appliance is at all times fitted with cathodic protection If sacrificial anodes are used for this these must be replaced and renewed when and as soon as they are 60 or more consumed When electric anodes are used it is important to ensure that they continue to work properly The warranty set out in articles 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 unauthoris
51. ply hot water supply circulation pipe gas supply overflow pipe overflow pipe ND OB W Imppp Instruction manual BFM Installation This figure shows the installation diagram This diagram is used in the sections in which the actual connection process is described Installation diagram UNVENTED 14 14 14 t t t Ha i B 0 a gt 3 mon R E ep Ta 2 7 5 ay 16 4 D e 10 it VENTED H Get i 17 T k i o pami Ta m We 3 K4 7 14 5 4 JL Ch 4 gs 4 9 Del IMD 0467 RO 23 3 3 6 Water connections 24 Vented 3 6 1 3 6 2 3 6 3 3 6 4 Installation ye pe yy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Cold water side See A in the installation diagram 3 5 Installation diagram 1 Fitan approved stop valve 4 on the cold water side between the cold water head tank 18 and the appliance as required by regulations 1 3 Regulations Recirculation pipe You can install a top to bottom circulation pump to prevent water stacking in the boiler 1 Optional depending on the draw off pattern fit a recirculation pipe 22 mm a stop valve 11 and a top to bottom circulation pump 7
52. pplied without a power cable and isolator Note In order to receive electrical power the appliance has to be connected to the mains power by means of a permanent electrical connection A double pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance The power cable must have cores of at least 3 x 1 0 mm yy Warning Leave the appliance isolated until you are ready to start it up 1 Feed the power cable through the metric strain relief to the top side of the control column 2 Connect the earth live L4 and neutral N of the power cable to terminals 1 through 3 in the connector block as stated in the table 3 Turn the strain relief tight to clamp the lead If you do not need to make any more connections fit the protective cover onto the control column 5 Connect the power cable to the isolator yy Warning gt Leave the appliance electrically isolated until you are ready to start it up Instruction manual BFM 35 3 3 11 Checking the supply pressure and burner pressure Legend 1 2 3 36 Oo NO On burner pressure regulator burner pressure regulator cap burner pressure regulator adjustment screw gas control connector blank plate supply pressure test nipple gas control manifold test nipple Installation ye pee Note Before starting the appliance and or checking the supply pressure and burner pressure you must fill 5 Fil
53. revent the buildup of 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 buildup 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 3 6 Water connections Vented Vented installation With a vented installation excess pressure is taken up by the open cold water head tank The height of the head tank determines the working pressure in the water heater which may not exceed 8 bar The installation must also be fitted with a vent pipe from the hot water pipe that opens into the cold water tank Ideally the vent pipe should discharge into a separate tundish drain or otherwise to the open cold water head tank The water heater should also be fitted on the hot water side with a stop valve 3 7 3 Hot water side T amp P valve A T amp P valve is only mandatory in an unvented installation However A O Smith also recommends the use of a T amp P valve in vented installations A T amp P Temperature and Pressure Relief 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 gt 10 bar or the water
54. supply via test nipple 6 5 Connect a pressure gauge to the manifold test nipple 6 when gas starts to flow from this nipple 6 Switch on the power to the appliance using the isolator on the appliance 7 Set the control thermostat to the maximum temperature and start the appliance running by setting the ON OFF switch to position I 8 The heating cycle will start and after a short time the burner tray will ignite 9 After the burner tray has ignited wait approximately 1 minute before reading the dynamic pressures 10 Use the pressure gauge to read the supply pressure at test nipple 6 Refer to the gas data table 3 4 3 Gas data Note Consult the mains gas supply company if the supply pressure is not correct Instruction manual BFM 37 Installation ye pee 11 Use the pressure gauge to read the burner pressure at nipple 8 Refer to the gas data table 3 4 3 Gas data Note If the burner pressure is incorrect and the appliance is fitted with a blank plate or high low control then you cannot adjust the pressure In this case consult your installation engineer or supplier If the appliance is indeed fitted with a burner pressure regulator then you can adjust the pressure 12 BFM 30 50 80 100 13 Remove the cap 2 from the burner pressure regulator 14 Depending on the correction required correct the burner pressure by turning adjustment screw 3 Adjustment screw anticlockwise burner pressure d
55. t the circulation pipe to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve yy Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Cold water side See A in the installation diagram 3 5 Installation diagram 1 Fit an approved stop valve 4 on the cold water side as required by applicable regulations 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 1 3 Fit a non return valve 5 and an expansion vessel 16 4 Fit an expansion valve 15 and connect the overflow side to an open wastewater pipe Recirculation pipe You can install a top to bottom circulation pump to prevent water stacking in the boiler 1 Optional depending on the draw off pattern fit a recirculation pipe O 22 mm a stop valve 11 and a top to bottom circulation pump 7 2 Fit anon return valve 5 3 Fit a stop valve 11 Hot water side See B in the installation diagram 3 5 Installation diagram g Note Insulating long hot water pipes will prevent unnecessary energy loss 1 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 2 Fitthe T amp P valve 3 3 Fita stop valve 11 in the hot water outlet
56. t them if necessary 7 Check that all components of the chimney flue system are properly attached 8 Test the operation of the overflow valve of the protected cold supply set up The water should spurt out 9 Test the overflow operation of the T amp P valve The water should spurt out 10 Test the overflow operation of the T amp P valve The water should spurt out with a strong jet 11 Check the drainpipes from the discharge points of all valves and remove any scale deposits that may be present 12 Drain the appliance 6 Draining Instruction manual BFM 63 12 12 3 Water side mainte nance 64 12 3 1 12 3 2 12 3 3 Performing maintenance Introduction The following steps must 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 appliance s anodes must be replaced as soon as they are 60 used or more take this into consideration when determining the maintenance frequency 1 Remove the chimney flue components from the top box Remove the cover from the top box Disconnect the fan leads and withdraw the cable through the strain relief Undo the screws in the top box Remove the top box from the appliance Undo the screws of the lid in the top side of the appliance Remove the lid from the appliance Remove the sealing ring from the appliance Loosen th
57. temperature is too high gt 97 C the valve will open The hot water can now 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 rectified The appliance is fitted standard with a connecting point for a T amp P valve 3 7 3 Hot water side 15 16 Working principle of the appliance Mk Instruction manual BFM JX 3 3 1 Introduction 3 2 Packaging 3 3 Ambient conditions Instruction manual BFM 3 3 1 Installation yy Warning Installation work should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas water and power supply companies and the fire service The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations 1 3 Regulations This chapter describes the installation activities to be carried out before the appliance may be started up 9 Starting and running in particular e Packaging Ambient conditions e Technical specifications Water connections Vented Water connections Vented e Gas connection e Air supply and flue Electrical connection e Checking the supply pressure and burner pressure For a possible conversion to a different gas category see conversion 4 Conversion to a differe
58. the burner control monitors three temperatures that are important for safety The table explains the working principle of the thermostats with sensors Temperature protection Description Frost thermostat When the frost thermostat sensor 46 measures a temperature of 20 C or less the heating cycle 2 3 The appliance s heating cycle will start High limit thermostat When the high limit thermostat sensor 39 measures a temperature higher than 84 C the high limit thermostat will open The heat demand is terminated and the burner control halts the heating cycle until the high limit thermostats close once more At that moment the burner control will reset the appliance and the heating cycle will restart The high limit safeguard serves to prevent overheating and or excessive formation of scale in the appliance Safety thermostat 14 2 4 3 2 4 4 When the safety thermostat sensor 38 measures a temperature higher than 93 C the safety thermostat will open The heat demand is terminated and the burner control will immediately halt the heating cycle The burner control will go into a lockout error state This must be manually reset before the appliance can resume operation 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 default state of the pressure switch is open When sufficient pressure
59. tion manual BFM Draining Installation diagram UNVENTED ae SES Dee 7 i B 2770 Ki 3 m09 Y R i ey Ee 5 97 4 On 16 gt i LI 514 is a n 15 VENTED H aa ae EO ea el m a ees SO 17 13 es AE kZ 12 oo amp N pY 11 De 3 4 4 y7 14 5 4 c 4 6 5 4 s gt T 4 97 od 10 i 6 Draining Ga 61 Draining unvented installations Some service activities require the appliance to be drained The procedure is as follows 1 Shut down the appliance by setting the ON OFF switch on the control panel to position 0 IMD 0462 RO 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 Shut off the gas supply 10 Close the stop valve 11 in the hot water pipe Close the supply valve of the cold water supply A Open the drain valve 9 NO Gr oR o Bleed the appliance or installation so that it drains completely 46 Instruction manual BFM ENGANS 6 2 Draining vented installations Some service activities require the appliance to be drained The procedure is as follows 1 Shut down the appliance by setting the ON OFF switch on the control panel to position 0 IMD 0462 RO 2 Isolate the water heater
60. tion of A O Smith the glass lined steel tank proves to be leaking due to rust or corrosion occurring on the water side then A O Smith shall offerto replace the defective water heater with an entirely new water heater of eguivalent size and guality The warranty period given on the replacement water heater shall be egual 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 A O Smith installation instructions for the specific model and the relevant government and local authority installation and building codes rules and regulations in force at the time of installation 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
61. ual BFM Working clearances IMD 0241 R1 The appliance is supplied without accessories Check the dimensions 3 4 1 Dimensions of the appliance gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan to use 19 3 Installation We 341 Dimensions of the appliance Plan and elevation of the appliance z z ATA uan q IMD 0057 R5 Replacement of burner pressure regulator or blank plate BFM30 50 80 100 2 BFM 100 120 20 Instruction manual BFM Dimensions all measurements in mm unless otherwise indicated Description BFM100 BFM120 Total height 2020 2020 Height of top of appliance 1820 1820 Position on pallet 580 580 Appliance diameter 710 710 Depth 1000 1000 Width 755 755 Diameter of chimney flue 130 130 y position air supply 235 235 lt Height of gas connection 600 760 Diameter of Air supply 130 130 Height of cold water supply 590 590 Height of hot water outlet 1655 1655 Height of cleaning opening 760 760 Height of drain valve connection 540 540 Height of T amp P val
62. ups 8 Overview of this document 9 Working principle of the appliance 11 Introduction 11 General working principle of the appliance 11 The appliance s heating cycle 13 Protection for the appliance 13 Safety of the installation 15 Installation 17 Introduction 17 Packaging 17 Ambient conditions 17 Technical specifications 19 Installation diagram 23 Water connections Vented 24 Water connections Unvented 25 Gas connection eee 26 Air supply and flue 27 Electrical connection 34 Checking the supply pressure and burner pressure 36 Conversion to a different gas category 39 Conversion
63. used by sections or parts or the glass lined steel tank of a replacement water heater that it has supplied Instruction manual BFM Dg 14 14 1 Introduction Instruction manual BFM Electrical diagram This chapter shows the electrical diagram s and accompanying legend 69 14 14 2 BFM Electrical Electrical diagram va IK Diagram 230VAC PVC PVC 50 Hz FAN NO NC NL N L S S S S Kai 1 i ro Ta ie eal EEE i i ji FI 0305485 R2 1 brown 2 blue 3 yellow green 4 black 5 white 6 red 7 white orange 8 white purple 9 black green 10 black red 11 black white 70 Instruction manual BFM og Instruction manual BFM COMPONENTS A Mantle B Isolating transformer C DPS Differential air pressure switch D Filter E Reset button F Frost thermostat G Control thermostat H ON OFF switch K Safety thermostat L High limit thermostat M Burner control N Terminal block P Earth strip R Relay OPTIONAL CO
64. ut by an authorised installation engineer If the appliance must operate on a family of gases LP gas or natural gas or other gas category than that for which the appliance has been set at the factory the appliance will have be adapted using a special conversion kit Caution You must check the supply pressure and burner pressure once the conversion is complete Isolate 10 3 Isolating the appliance from the mains the water heater from the power supply 2 Shut off the gas supply 3 Referring to the gas table 3 4 3 Gas data determine whether the pilot a 4 flame orifice for the intended gas category is different from the one that is currently fitted If so replace 4 2 Orifice replacement it Note The current gas category is stated on the type plate Referring to the gas table 3 4 3 Gas data determine whether the main orifice for the intended gas category is different from the one that is currently fitted If so replace 4 2 Orifice replacement it Referring to the gas table 3 4 3 Gas data determine whether the use of a blank plate or burner pressure regulator is required for the intended gas category If this is different than for the current gas category exchange 4 3 Replacement of burner pressure regulator or blank plate BFM30 50 80 100 it Referring to the gas table 3 4 3 Gas data determine whether the supply pressure and burner pressure for the intended gas category correspon
65. ve connection 1600 1600 Cold water supply connection external R1 TA R1 TA Hot water outlet connection internal Rp1 173 Rp1 To Gas control connection internal Rp4 Rp1 Drain valve connection internal Rp1 1 Rp1 To aj A oj N gt MW D Vi Zl Zl mya T amp P valve connection internal Rp1 1 3 Rp1 1 Cleaning inspection opening 3 4 2 General and electrical specifications General and electrical specifications DESCRIPTION Unit Volume litres Maximum operating pressure bar Empty weight kg Heating up time AT 45 C minutes Diameter of air restrictor mm Number of anodes Number of bar burners orifices Number of flue tubes flue baffles Electrical power consumption W Supply voltage volts 15 10 VAC Mains frequency Hz 1Hz IP class Instruction manual BFM 21 3 Installation i 3 4 3 Gas data Gas data Description Gas category 30 through 100 Il 434 120 lloy3p Natural gas G20 20 mbar Orifice diameter 2 60 2 50 2 70 3 20 3 30 Diameter of pilot flame orifice 0 56 0 41 0 56 0 41 0 56 0 41 0 56 0 41 0 56 0 41 1 Blank plate 2 2 2 2 2 2 Burner pressure regulator Nominal load upper value Nominal output Supply pressure Burner pressure G Gas consumption LP gas data

A.O. Smith BFM - 120 Installation Manual

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