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30
50
60
XTR
A
H
IGH
EF
F
IC
I
EN
C
Y
Installation
User and
Service Manual
WATER PRODUCTS
COMPANY
A DIVISION OF A. O. SMITH CORPORATION
XTRA HIGH EFFICIENCY
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your installer
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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
Copyright 2003 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.
Trademarks
Liability
Any brand names mentioned in this manual are registered trademarks of their
respective owners.
A.O. Smith Water Products Company accepts no liability for claims from third
parties arising from improper use other than that stated in this manual and in
accordance with the General Conditions registered at the Eindhoven Chamber
of Commerce.
Refer further to the General Conditions. These are available on request, and
without charge.
Although considerable care has been taken to ensure a correct and suitably
comprehensive description of all relevant components, the manual may
nonetheless contain errors and inaccuracies.
Should you detect any errors or inaccuracies in the manual, we would be
grateful to receive notification. This helps us to further improve our
documentation.
More information
If you have any comments or queries concerning any aspect related to the
appliance, then please do not hesitate to contact A.O. Smith Water Products
Company.
A.O. Smith
Postbus 70
5500 AB Veldhoven
The Netherlands
Freephone:
008008 AOSMITH
008008 2 67 64 84
+31 40 294 25 00
+31 40 294 25 37
+31 40 294 25 38
+31 40 294 25 39
General:
Sales:
Help desk:
Fax:
E-mail:
Internet:
In the event of problems with connecting to the gas, electricity or water supply,
please contact your installation’s supplier/installer.
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Table of contents
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About the appliance
gis
1 Introduction
1.1 About the appliance
This manual describes how to install, service and use the BFC appliance. The
BFC appliance is a condensing room-sealed water heater with a fan in the air
intake. A concentric chimney connector is fitted standard to the appliance.
Alternatively, the appliance can be connected using a parallel system.
Installation types possible with this appliance are C13, C33, C43, C53 and C63.
The information in this manual is applicable to types: BFC 28, BFC 30, BFC 50
and BFC 60.
The manner of construction and features of the appliance are in conformance
with the European standard for gas-fired storage water heaters for the
production of domestic hot water (ES 89). The appliances are therefore
compliant with the European Directive for Gas Appliances, and have the right to
bear the CE mark.
Warning
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.
0063
1.2 What to do if you
smell gas
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.
1.3 Regulations
As the (end) user, installer or service and maintenance engineer, you must
ensure that the entire installation complies, as a minimum, with the official local:
•
•
•
•
•
•
•
•
•
•
•
building regulations;
energy supplier’s directives for existing gas installations;
directives and technical guidelines for natural gas installations;
safety requirements for low-voltage installations;
regulations governing the supply of drinking water;
regulations governing ventilation in buildings;
regulations governing the supply of air for combustion;
regulations governing the discharge of products of combustion;
requirements for installations that consume gas;
regulations governing indoor waste water disposal;
regulations imposed by fire service, power companies and municipality;
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Introduction
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Furthermore, the installation must comply with the manufacturer’s instructions.
n Remark
Later amendments and/or additions to all regulations, requirements and
guidelines published on or prior to the moment of installing, will apply to the
installation.
1.4 Target groups
The three target groups for this manual are:
•
•
•
(end) users;
installers;
service and maintenance engineers.
Symbols on each page indicate the target groups for whom the information is
Table 1.1 Target group symbols
Symbol
g
i
s
Target group
(End) user
installer
Service and maintenance engineer
1.5 Maintenance
A service should be carried out at least once a year, both on the water side and
on the gas side. Maintenance frequency depends, among other things, on the
water quality, the average burning time per day and the set water temperature.
n Remark
To determine the correct maintenance frequency, it is recommended to
arrange for the service and maintenance engineer to check the appliance on
both the water and gas side, three months after installation. Based on this
check, the best maintenance frequency can be determined.
n Remark
Regular maintenance extends the service life of the appliance.
1.6 Forms of notation
The following notation is used in this manual:
n Remark
Important information
cNote
Ignoring this information can lead to the appliance being damaged.
Warning
Failure to carefully read this information may lead to danger of personal
injury, and serious damage to the appliance.
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Overview of this document
gis
1.7 Overview of this
document
Table 1.2 provides an overview of the contents of this document.
Table 1.2 Contents of document
Chapter
Target groups
Description
This chapter describes how the appliance functions.
This chapter describes the installation activity to be completed
before you actually start up the appliance.
This chapter describes how to fill and drain the appliance.
This chapter describes the general control of the appliance
using the display.
This chapter describes the status (mode or condition) that the
appliance may have, and possible actions to take.
This chapter describes how to start up the appliance, and how
to shut it down for a brief or long period of time. The general
heating cycle of the appliance is also described.
Describes the main menu of the display. This is the actual
menu for the user, however the installer and service and
maintenance engineers will also need to use this menu.
Describes the service menu. It is mainly intended for the
installer and service and maintenance engineers. End users
may also refer to this chapter for additional information about
the appliance.
This chapter is mainly intended for the installer and the service
and maintenance engineer. It describes appliance errors.
These errors are indicated on the display. A troubleshooting
table of possible causes and solutions is provided. End users
may also refer to this chapter for additional information about
the appliance.
This chapter describes how to determine the optimum
frequency at which to carry out maintenance. Both the end
user and the service and maintenance engineer are
responsible for regular maintenance. They need to reach clear
agreement on this.
n Remark
If the appliance is not regularly maintained, the warranty
will become void.
This chapter sets out the maintenance tasks to be carried out
during a service.
This chapter states the warranty terms and conditions.
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Introduction
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Introduction
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2 Functioning of the
appliance
2.1 Introduction
Topics covered in this chapter:
•
•
•
•
2.2 Functional
Figure 2.1 shows a cut-away view of the appliance.
description of the
appliance
Legend
a
b
p
q
a plastic top cover
b hot water outlet
c electrical connection block
d ThermoControl
c
r
s
d
e
f
e pressure switch
f control panel
g temperature sensor T
h combustion chamber
i anode
1
g
t
u
j tank
k heat exchanger
h
i
j
k
l inspection and cleaning
v
opening
m temperature sensor T
n cold water inlet
o drain valve
p gas control
q burner
2
r fan
s air supply hose
t glow igniter
u ionisation rod
v chimney pipe
w siphon
l
m
w
x
n
o
x PU insulation layer
IMD-0070
Figure 2.1 Cut-away view of the appliance
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Functioning of the appliance
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In this appliance the cold water enters the bottom of the tank via the cold water
inlet n. The tap water, heated by the combustion chamber h and heat
exchanger k, leaves the tank through the hot water outlet b. Once the
appliance is completely filled with water, it remains constantly under water
supply pressure. As hot water is drawn from the appliance, cold water is
immediately added.
The air required for combustion is forcibly delivered to the burner q by the
fan r. The gas is fed to the burner q via the gas control p. Thanks to the
modulated supply of gas and air, the optimum gas/air mixture is always
achieved. The special construction of the burner causes the mixture to form a
vortex (the cyclone effect), before it becomes ignited. Because of this vorticity,
ignition at the glow igniter t is improved, and the combustion efficiency is also
optimised. Through the special design of the heat exchanger k, the flue gases
are first led downwards via the combustion chamber, then upwards again via the
heat exchanger, then once more downwards beside the water in the tank. In this
process, the flue gases gradually become cooler. Because the cooled flue
gases flow alongside the cold water below in the tank, they start to condense.
This condensation causes latent heat energy to be released, which is
transferred to the cooler water, and thereby increases the performance of the
unit. The water of condensation yielded by this process is discharged via the
siphon w.
The PU insulation layer x prevents heat loss. The inside of the tank is
enamelled to protect against corrosion. The magnesium anodes i provide
extra protection against corrosion.
For use during maintenance, the appliance has a inspection and cleaning
opening l.
2.3 The appliance’s
heating cycle
The entire appliance is controlled (and monitored) by theThermoControl d. The
temperature sensor T1 g (in the top of the tank j) and the temperature sensor
T2 m (in the bottom of the tank) measure the water temperature. These
temperatures are sent to the ThermoControl. Based on these two observations,
the ThermoControl calculates a net water temperature: T . The value of T
net
net
lies between the temperatures measured at the top and bottom of the tank. As
soon as T falls below the set water temperature (T ), the ThermoControl
net
set
registers a ‘heat demand’. The gas control p is opened, and the gas is mixed
with air. This mixture is ignited by the glow igniter t and the water becomes
heated. As soon as T rises above T , the heat demand ends, and the
net
set
ThermoControl stops the heating cycle.
Both when registering and ending the heat demand, the ThermoControl
assumes a certain margin. We refer to this margin as the hysteresis (see
2.4 Protection for the
appliance
The ThermoControl monitors the water temperature and ensures safe
combustion. This is achieved by:
•
•
•
•
•
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Protection for the appliance
gis
2.4.1 Water temperature protection
With temperature sensor T1 g and temperature sensor T2 m, the
ThermoControl monitors three temperatures which are important for safety.
Table 2.1 explains the functioning of the temperature sensors.
Table 2.1 Temperature protection
Protection
Description
Against frost
The frost protection cuts in. The water is heated to 20°C.
(T < 5°C or T < 5°C)
1
2
For maximum water temperature The high-limit safeguard serves to prevent overheating and/or excessive
(T > 85°C or T > 85°C)
formation of scale in the appliance. Should the high-limit safeguard be
activated, the heating is halted. This causes the water in the tank to cool down.
1
2
Once the water has cooled sufficiently (T < 78 °C), the ThermoControl resets
1
the appliance.
For extra safety
A lockout error of the water heater controller takes place. The controller must
be manually reset before the appliance can resume operation (see paragraph
(T > 93°C or T > 93°C)
1
2
1
2.4.2 Gas control
The ThermoControl opens the gas control so that gas can be supplied to the
burner. As a safety measure, the gas control has two valves. Both valves shut
off the gas supply.
Smooth ignition is achieved by opening the gas control with a delay (‘softlite’).
2.4.3 Fan
The fan provides an optimum air supply when there is a heat demand. A safety
aspect is that the fan ensures that any gases present in the combustion
chamber get removed, both before and after combustion. We refer to this as
pre- and post-purge.
The fan speed is continuously monitored by the ThermoControl. The
ThermoControl takes control if the speed of rotation varies too much from the
value set.
2.4.4 Pressure switch
The pressure switch ensures the discharge of flue gases and the supply of
incoming air during the pre-purge and normal running of the appliance. The
standard position of the pressure switch is open. When sufficient pressure
differential is reached, the pressure switch closes. However, in the event of a
fault, the pressure switch will be tripped open, and the heating cycle will be
interrupted.
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Table 2.2 shows the trip point per appliance.
Table 2.2 Pressure switch trip points
Applianc Pressure differential [Pa]
e
Closing
Opening
< 605
BFC 28
BFC 30
BFC 50
BFC 60
> 635
> 855
> 885
> 1085
< 825
< 855
< 1055
n Remark
The trip point of the pressure switch is not adjustable.
2.4.5 Ionisation rod
To ensure that no gas will flow when there is no combustion, an ionisation rod
has been fitted. The ThermoControl uses this rod for flame detection, by means
of ionisation detection. The ThermoControl cuts in, the instant it detects that
there is a gas flow but no flame.
2.5 Safety of the instal-
lation
In addition to the appliance’s standard safety monitoring, the appliance must
also be protected by an expansion vessel, pressure overflow valve, non-return
valve and a T&P valve.
Use of an expansion vessel, a pressure relief valve and/or a pressure reducing
valve depends on the type of installation: unvented or vented.
2.5.1 Unvented installation
With an unvented installation, a pressure relief valve and expansion vessel
prevent excessive pressure in the tank. This prevents damage being caused to
the enamelled coating (in the appliance) or to the tank. A non-return valve
prevents excessive pressure in the water supply system. This valve also
prevents water from flowing backwards from the tank into the cold water supply
system. The pressure reducing valve protects the installation against an
excessively high water supply pressure (> 8 bar). These components are fitted
2.5.2 Vented installation
With a vented installation, excess pressure is taken up by the open water
reservoir. The level of the water reservoir determines the maximum working
pressure in the tank, which may not exceed 8 bar. The installation must also be
fitted with an overflow from the hot water pipe, which discharges into the water
2.5.3 T&P valve
A T&P valve is only mandatory in an ‘unvented’ installation. However,
A.O. Smith also recommends the use of a T&P valve in ‘vented’ installations.
A T&P valve monitors the pressure in the tank, and the water temperature at the
top of the tank. If the pressure in the tank becomes excessive (>10 bar) or the
water temperature is too high (>97°C), the valve will open. The hot water will
immediately flow out of the tank. Because the appliance is under water supply
pressure, cold water will automatically flow into the tank. The valve remains
open until the unsafe situation has been averted. A connecting point for a T&P
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Introduction
is
3 Installation
Warning
The installation should be carried out by an approved installer in compliance
with the general and local regulations imposed by the gas, water and power
supply companies and the fire service.
The appliance may only be installed in a room which complies with the
requirements stated in national and local ventilation regulations.
3.1 Introduction
This chapter describes the installation activities to be carried out before the
appliance may be started up, namely:
•
•
•
•
•
•
•
•
•
•
n Remark
Starting up the appliance is described in chapter ’7 Starting up and shutting
3.2 Packaging
To avoid damaging the appliance, remove the packaging carefully. We
recommend unpacking the appliance at or near its intended location.
cNote
The appliance may only be manoeuvred in an upright position. Take care
that the appliance is not damaged after unpacking.
3.3 Environmental
conditions
The BFC appliance is a room-sealed appliance. Installation types possible with
this appliance are C13, C33, C43, C53 and C63. This makes it possible to install
the appliance in either a closed or an open boiler room.
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3.3.1 Humidity and ambient temperature
The boiler room must be frost-free, or be protected against frost. Table 3.1
shows the environmental conditions that must be adhered to, for correct
functioning of the electronics present in the appliance to be guaranteed.
Table 3.1 Humidity and ambient temperature specifications
Humidity and ambient temperature
Humidity
max. 93% RH at +25°C
Ambient temperature
Functional: 0 ≤ t ≤ 60°C
3.3.2 Maximum floor loading
In connection with the appliance’s weight, take account of the maximum floor
loading, see Table 3.2.
Table 3.2 Weight specifications related to maximum floor loading
Weight of the appliance filled with water
BFC 28
392 kg
593 kg
BFC 30, BFC 50, BFC 60
3.3.3 Water composition
The appliance is intended for heating drinking water. The drinking water must
comply with the regulations governing drinking water for human consumption.
Table 3.3 Water specifications
Water composition
Hardness
> 1.00 mmol/l:
(alkaline earth ions)
•
•
•
German hardness >5.6° dH
French hardness > 10.0° fH
British hardness > 7.0° eH
Conductivity
> 125 µS/cm
Acidity (pH value)
7.0 < pH value < 9.5
n Remark
tank protection cannot be guaranteed.
3.3.4 Working clearances
For access to the appliance it is recommended that the following clearances
are observed (see Figure 3.2):
•
•
•
AA: around the appliance’s control column and cleaning openings: 100 cm.
BB: around the appliance itself: 50 cm.
Above the appliance (room to replace the anodes):
-
-
100 cm if using fixed anodes, or
50 cm if using flexible anodes.
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Environmental conditions
is
If the available clearance is less than 100 cm, flexible magnesium anodes
may be ordered from A.O. Smith, the installer / supplier.
n Remark
When installing the appliance, be aware that any leakage from the tank and/
or connections can cause damage to the immediate environment or floors
below the level of the boiler room. If this is the case, then the appliance
should be installed above a wastewater drain or in a suitable metal leak tray.
The leak tray must have an appropriate wastewater drain and must be at
least 5cm deep with a length and width at least 5cm greater than the
diameter of the appliance.
IMD-0073a
Figure 3.1 Working clearances
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3.4 Technical
The appliance is supplied without accessories. Check the dimensions and other
specifications for the accessories to be used, based on Figure 3.2 and
specifications
IMD-0073
Figure 3.2 Plan and elevation of the appliance
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Technical specifications
is
Table 3.4 Dimensions
Dime Description
nsion
BFC 28
BFC 30
BFC 50
BFC 60
A
D
G
K
M
N
P
R
S
W
X
1
Total height (mm)
1370
705
1900
705
1900
705
1900
705
Diameter of the appliance (mm)
Diameter of air supply/flue gas discharge (mm) 80/125
100/150
1810
160
100/150
1810
160
100/150
1810
160
Height of the gas connection (mm)
1270
160
Height of cold water supply connection (mm)
Height of hot water outlet connection (mm)
1405
1920
200
1920
200
1920
200
Height of cleaning and inspection opening (mm) 200
Height of drain valve (mm)
75
75
75
75
Height of T&P valve (mm)
890
110
1205
1415
110
1415
110
1415
110
Height of condensation drainage (mm)
Height of air supply connection (mm)
Cold water supply connection
Hot water outlet connection
1730
1730
1730
R 1½ (external)
R 1½ (external)
Rp ¾ (internal)
¾”
2
3
Gas control connection
4
Drain valve connection (external)
T&P valve connection (internal)
5
¾” NPT
1 - 11.5 NPT
95 x 70
6
Dimensions cleaning and inspection opening
(mm)
7
Condensation drainage connection (internal)
Ø 40 mm
Rp 1
Rp 1
Rp 1
Table 3.5 General and electrical data
DESCRIPTION
Capacity
Unit
BFC 28
BFC 30
368
8
BFC 50
368
8
BFC 60
368
8
litres
217
8
Maximum working pressure
Empty weight
bar
kg
175
23
225
35
225
24
225
20
o
Heating time ∆T = 45 C
minutes
Number of anodes
-
4
4
4
4
Number of bar burners/orifices
Number of flue tubes/flue baffles
Fan rotational speed at ignition
Working speed of fan
-
n.a.
1/?
4500
4980
23.0
n.a.
1/?
n.a.
1/?
n.a.
1/?
-
r. p.m.
rpm
mm
4500
5400
23.0
4500
6000
28.0
4500
6660
29.0
Diameter of air restrictor
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Table 3.5 General and electrical data
DESCRIPTION
Unit
BFC 28
BFC 30
BFC 50
175
BFC 60
Electrical power consumption
Supply voltage
W
VAC
Hz
230 (-15% +10%)
50 (±1 Hz)
Mains frequency
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Installation diagram
is
Table 3.6 Gas data
Unit
BFC 28
BFC 30
BFC 50
BFC 60
2H3+
Data for natural gas 2H: G20-20 mbar
Orifice diameter
mm
kW
4.90
32.1
30.3
20
5.10
34.5
32.8
20
7.00
52.6
48.6
20
7.10
63.2
59.6
20
Nominal load (upper value)
Nominal capacity
kW
Supply pressure
mbar
mbar
Burner pressure
8.5
8.5
8.5
11.5
6.0
3
Data for LP gas 3+
General
m /h
3.1
3.3
5.0
mm
mm
2.50
n.a.
2.60
n.a.
3.40
n.a.
3.80
n.a.
Restrictor diameter
kW
30.7
37
32.8
37
50.6
37
59.4
37
mbar
mbar
kg/h
37
37
37
37
G31-37 mbar (butane)
Nominal load (upper value)
Supply pressure
2.2
2.4
3.7
4.3
kW
29.0
37
30.9
37
50.3
37
59.1
37
mbar
mbar
kg/h
Burner pressure(2)
37
37
37
37
2.1
2.2
3.6
4.2
o
(2) If using a flat sealing plate instead of a burner pressure regulator, it is assumed that the burner pressure is equal to the supply pressure.
In practice however, the burner pressure will be lower.
Figure 3.3 shows the water and gas connection diagrams for unvented and
vented installations. The following paragraphs, describing the connections in
detail, make reference to these diagrams
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Legend
a pressure-reducing valve
l
UNVENTED
b
(mandatory)
b
expansion vessel (mandatory)
c T&P valve (mandatory)
d stop valve (recommended)
e non-return valve (mandatory)
f circulation pump (optional)
g drain valve
T
d
h
EN
T
SE
T
ER
RE
h gas valve (mandatory)
i stop valve (mandatory)
j temperature gauge (optional)
d
f
e
k condensation drainage
d
(mandatory)
l hot water draw-off points
m pressure relief valve
(mandatory)
c
n water cistern
o float valve
p 3-way venting valve
(recommended)
a
q overflow pipe
a cold water supply
b hot water outlet
c circulation pipe
d gas supply
k
g
IMD-0139
a
VENTED
p
o
q
e flue gas discharge and air
l
supply
n
b
T
c
d
h
a
d e f d c
k
g
IMD-0138
Figure 3.3 Installation diagrams
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Water connections, Unvented
is
3.6 Water connections,
Unvented
3.6.1 Cold water side
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
3. Fit a non-return valve e and an expansion vessel b.
4. Fit a pressure relief valve m and connect the overflow side to an open
wastewater pipe.
3.6.2 Hot water side
n Remark
Insulating long hot water pipes prevents unnecessary energy loss.
the tap water.
3.6.3 Circulation pipe
If an immediate flow of hot water is required at draw-off points, a circulation
pump can be installed. This improves comfort and reduces water wastage.
1. Fit a circulation pump f of the correct capacity for the length and resistance
of the circulation system.
2. Fit a non-return valvee behind the circulation pump to guarantee the
direction of circulation.
3. Fit two stop valves d for service purposes.
4. Connect the circulation pipe to the cold water supply pipe.
3.6.4 Condensation drainage
1. Fit a sloping wastewater pipe to the siphon k for condensation drainage and
connect this to the wastewater discharge in the boiler room.
cNote
All piping behind the siphon must be condensation-resistant.
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3.7 Water connections,
Vented
3.7.1 Cold water side
cistern n and the appliance, as required by regulations. Refer also to
3.7.2 Hot water side
n Remark
Insulating long hot water pipes prevents unnecessary energy loss.
the tap water.
3.7.3 Circulation pipe
If an immediate flow of hot water is required at draw-off points, a circulation
pump can be installed. This improves comfort and reduces water wastage.
1. Fit a circulation pump f of the correct capacity for the length and resistance
of the circulation system.
2. Fit a non-return valvee behind the circulation pump to guarantee the
direction of circulation.
3. Fit two stop valves d for service purposes.
4. Connect the circulation pipe to the cold water supply pipe.
3.7.4 Condensation drainage
3.8 Gas connection
Warning
Gas installation may only be carried out by an authorised installer in
compliance with the general regulations imposed by the gas company.
cNote
Make sure that the diameter and length of the gas supply pipe are large
enough to supply sufficient capacity to the appliance.
1. Fit a gas valve h in the gas supply pipe.
2. Blow the gas pipe through before use, to be sure it is clean.
3. Close the gas valve.
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Air supply and flue gas discharge
is
4. Fit the gas supply pipe to the gas control.
Warning
Check for leaks after fitting.
3.9 Air supply and flue
gas discharge
Warning
The installation should be carried out by an authorised installer, in
compliance with the general and local regulations imposed by gas, water
supply and power supply companies and the fire service. Refer also to
Depending on the approved installation types, there are several alternatives
for connecting the air supply and flue gas discharge. The BFC appliances are
approved for installation types C13, C33, C43, C53 and C63.
The most common installation types are:
•
•
This manual describes these installation types. If an explanation of other types
of installation is required, please contact A.O. Smith.
cNote
A.O. Smith prescribes the use of a roof or wall-mounted terminal,
exclusively of a type approved for the appliance. See paragraph
Use of an incorrect roof or wall-mounted terminal can cause the installation
to malfunction.
n Remark
Make sure that the chimney discharges into an area where this is permitted
for this category of appliance.
following requirements must also be fulfilled:
•
•
the maximum chimney length is 15 metres.
The maximum permitted number of 45° or 90° bends is four.
Table 3.7 Chimney configurations for concentric wall and roof
termination.
Dimension
BFC 28
BFC 30
BFC 50
BFC 60
(1)
A
0-15 m
0-15 m
0-15 m
0-15 m
B
0-15 m
0-15 m
0-15 m
0-15 m
a + B
max. 15 m
max. 15 m
max. 15 m
max. 15 m
1. See ’Figure 3.4 Wall flue terminal’ and ’Figure 3.5 Roof flue terminal’.
cNote
If you make use of horizontal piping, then this must slope towards the
appliance with a minimum of 5 mm per metre running length!
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3.9.1 Concentric wall flue terminal
Table 3.8 shows the wall flue terminal prescribed by A.O. Smith (installation
type C13).
B
A
IMD-0075
Figure 3.4 Wall flue terminal
Table 3.8 Concentric wall flue terminal specifications
Specification
Description
Manufacturer
Muelink & Grol
M2000 MDV SE
(1)
Model
Pipe material, flue gas discharge
Pipe material, air intake
Pipe diameter
Thick-walled aluminium with lip ring seal
Thin-walled galvanised sheet steel
Concentric
•
•
BFC 28: Ø 80/125 mm.
BFC 30, 50 and 60: Ø 100/150 mm.
1. The M2000 MDV SE model is a special version of the Mugro 3000 series. No other wall flue terminal may be used, as the
BFC-appliance is approved exclusively for this model of wall flue terminal. You can order the wall flue terminal from A.O. Smith or your
trade supplier, by specifying model: M2000 MDV SE.
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Air supply and flue gas discharge
is
3.9.2 Concentric roof flue terminal
A.O. Smith Water Products Company prescribes the roof flue terminal
(installation type C33) as specified in Table 3.9.
Table 3.9 Concentric roof flue terminal specifications
Specification
Manufacturer
Model
Description
Muelink & Grol
M2000 DDV SEC HR
(1)
Pipe material, flue gas
discharge
Thick-walled lip ring seal
Pipe material, air intake
Pipe diameter
Thin-walled galvanised sheet steel
Concentric
•
•
BFC 28: 80/125 mm.
BFC 30, 50 and 60: Ø 100/150 mm.
1. The model M2000 DDV SEC HR is a special version of the Mugro 3000 series. No other
roof flue terminal may be used, as the BFC- appliance is approved exclusively for this
model of roof flue terminal. You can order the roof flue terminal from A.O. Smith or your
trade supplier, by specifying model: M2000 DDV SEC HR.
IMD-0004
Figure 3.5 Roof flue terminal
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Warning
is
3.10 Electrical
connection
The installation should be carried out by an approved installer in compliance
with the general and local regulations imposed by the gas, water and power
supply companies and the fire service.
3.10.1 Introduction
Topics covered in this paragraph:
•
•
Optionally, it is possible to connect an isolating transformer, a continuous pump,
a program-controlled pump, a “Tank ON” and an “Alarm OFF” to the appliance.
For these options, see:
•
•
•
•
•
n Remark
The optional components are not included in the rating for electrical power
3.10.2 Preparation
cNote
The appliance is phase-sensitive. It is absolutely essential to connect the
phase (L) from the mains to the phase of the appliance, and the neutral (N)
of the mains to the neutral of the appliance.
There should also be no potential difference present between neutral (N)
and earth (A). If this is the case, then an isolating transformer must be
associated connections.
Table 3.10 Electrical connection block
Unu Tank on Continuous Regulated
Alarm Off
Isolating transformer
Mains power
sed
pump
pump
primary
secondary
X
X
L
8
N
9
N
L
X
X
2
N
L
N
L
N
L
A
A
A
A
A
A
1
2
1
1-4
5
6
7
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
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is
1
2
1
1
3
24
IMD-0077
Figure 3.6 Connection block (connections 1 through 24 explained in
Table 3.10)
In preparation you should first remove the two plastic covers and the
protective cap of the electrical section. The plastic covers are attached to the
appliance by 4 screws and Velcro fastenings. The covers are also joined to
each other with Velcro fastenings.
1. Unscrew the screws of the plastic covers.
2. Carefully remove the black plastic covers from the appliance.
The electrical section is now visible.
3. Undo the 2 screws 1 from the electrical section and remove the protective
cap 2 from the electrical section.
The connection block 3 is now visible.
n Remark
components.
3.10.3 Mains voltage
The appliance is supplied without a power cord and main switch.
n Remark
In order to receive electrical power, the appliance has to be connected to the
mains voltage by means of a permanent electrical connection. A two-
terminal main switch with a contact gap of at least 3 mm must be fitted
between this fixed connection and the appliance. The power cord must have
2
cores of at least 3 x 1.0 mm .
1. Connect phase (L), neutral (N) and earth (A) of the power cord to terminals
22 through 24 of the connector block as indicated in Table 3.10.
2. Fit the power cord in the pull relief.
3. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
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4. Connect the power cord to the main switch.
Warning
Leave the appliance disconnected until you are ready to start it up.
5. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
3.10.4 Isolating Transformer
An isolating transformer should be used if there is a case of “floating neutral”.
(1)
1. Refer to fitting instructions provided with the isolating transformer
.
2. Connect phase (L), neutral (N) and earth (A) of the power cables to
terminals 16 through 21 of the connector block as indicated in Table 3.10.
3. Fit the cables in the pull relief.
4. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
5. Connect the power cord to the main switch.
3.10.5 Continuous pump
The continuous pump will start up as soon as mains power is connected to the
appliance.
1. Connect phase (L), neutral (N) and earth (A) to terminals 7, 8 and 9 as
indicated in Table 3.10.
2. Fit the cable in the pull relief.
3. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
3.10.6 program-controlled pump
Switching on of the program-controlled pump is determined by settings of the
ThermoControl.
1. Connect phase (L), neutral (N) and earth (A to terminals 10, 11 and 12 as
indicated in Table 3.10.
2. Fit the cable in the pull relief.
3. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
3.10.7 Extra ON mode switch (“Tank ON”)
Tank ON is a facility for connecting an external ON/OFF switch. In the OFF
position, the programmed operating mode is active. In the ON position, the
programmed operating mode is overruled, and the “ON mode” is active.
1. Connect cables (X and X ) to terminals 5 and 6 as indicated in Table 3.10.
1
2
2. Fit the cable in the pull relief.
1. Contact A.O. Smith for details of the correct isolating transformer.
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Checking the supply pressure and burner pressure
is
3. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
3.10.8 Connecting extra error signal (“Alarm OUT”)
Alarm OUT is a potential free terminal that is switched when an error is
detected. This can be used to signal errors, for example by turning on a lamp.
A 230 V circuit can be directly powered. For other voltages, a specific relay
prescribed by A.O. Smith is required.
1. Connect the phase cables (X and X ) to terminals 13 and 14 as indicated
1
2
in Table 3.10. If required, connect earth (A) to terminal 15.
2. Fit the cable in the pull relief.
3. If you do not need to make any more connections:
-
-
Fit the cap on the electrical connection block.
Fit the plastic covers onto the appliance.
3.11 Checking the supply
pressure and burner cNote
Before you start up the appliance and/or begin to check the supply
pressure and burner pressure, you must first fill the appliance. Please
pressure
cNote
Before starting-up for the first time, and following conversion, you
must always check the supply pressure and burner pressure. If
necessary, adjust these to be certain of optimum performance of the
appliance.
cNote
The easiest way to check the gas pressures is by using two pressure
gauges. This procedure assumes that these two gauges are available.
To check the supply pressure and burner pressure, proceed as follows:
2. Undo the screws of the plastic covers.
3. Carefully remove the black plastic covers from the appliance.
The electrical section is now visible.
supply pressure @ and the burner pressure # respectively.
Sealing screws are located inside the test nipples. Loosen both sealing
screws by a few turns. Do not loosen them completely; this makes them
difficult to tighten again.
5. Connect a pressure gauge to the lower pressure test nipple #.
6. Open the gas supply and vent the gas supply line via the upper nipple @.
7. Connect a pressure gauge to the upper test nipple as soon as gas starts to
flow from this nipple.
8. Switch on the power to the appliance using the mains switch on the
appliance.
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9. Turn the ThermoControl ON by setting the 0/I switch to position I.
Figure 3.7 ThermoControl
The display will now show INTERNAL CHECKfor about 10 seconds, and
will then go to the main menu.
INTERNAL CHECK
Figure 3.8 Internal check
10. Activate the “ON mode” by going through the following steps:
-
Press once on the blue arrow (L) to bring the pointer (») to ONand
press E. The display as shown in Figure 3.10 appears.
MENU
»OFF
^ ON
-
Confirm with Ethe option START OPERATION.
The appliance is now in “ON mode” and will ignite.
È WEEK PROGRAM
Figure 3.9 Main menu
11. Once the display shows the text RUNNINGyou must wait about 1 minute
before reading the dynamic pressures (the fan needs this time to run up to
full rotational speed).
»START OPERATION
^ CHANGE SETPOINT
12. Use the pressure gauge to read the supply pressure at the test nipple #.
È
Tset=65ÉC
n Remark
Figure 3.10 Starting up
Consult the mains gas supply company if the supply pressure is not correct.
n Remark
If the burner pressure is not correct and the appliance is fitted with a flat
sealing plate, you will not be able to adjust the pressure. In this case, consult
your installer or supplier.
If the appliance is fitted with a burner pressure regulator, then the pressure
can be adjusted by following steps 13 through 17.
13. Remove the cap 8 from the burner pressure regulator 7.
14. Adjust the burner pressure by turning the adjusting screw 9, depending on
the correction required:
-
-
Adjusting screw anticlockwise: burner pressure decreases.
Adjusting screw clockwise: burner pressure increases.
15. Cover the opening of the adjusting screw and check the burner pressure
16. If the pressure reading is not correct, repeat steps 14 and 15 until the correct
pressure is attained.
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Conversion to a different gas category
is
17. Activate the “OFF mode” of the ThermoControl:
-
If the MENUis not displayed:
press B.
MENU
»OFF
^ ON
È WEEK PROGRAM
-
-
Use Hand Lto position the cursor (») beside OFF
Confirm with E.
18. Wait until the fan has stopped. and turn the ThermoControl off.
Figure 3.11 Main menu
cNote
Failure to wait until the fan stops can cause damage to the appliance.
19. Shut off the gas supply.
20. Disconnect the two pressure gauges and re-tighten the sealing screws in the
test nipples.
21. Replace the plastic covers.
n Remark
Before starting-up the appliance, take time to fill in the warranty card
supplied with the appliance. This enables us to guarantee the quality of our
systems, and to further enhance our warranty procedure.
Please return this card as soon as possible. Your customer will then receive
a warranty certificate with our warranty conditions.
3.12 Conversion to a
different gas
cNote
The conversion may only by carried out by an authorised installer.
category
If the appliance must operate on a family of gas (LP gas or natural gas) other
than the category of gas for which the appliance has been set up at the
factory, the appliance will have be adapted using a special conversion kit.
cNote
After conversion, check the supply pressure and the burner pressure.
2. Shut off the gas supply.
3. Undo the screws of the plastic covers.
4. Carefully remove the black plastic covers from the appliance.
5. Loosen the 2 screws of the electrical section, and remove the protective cap
6. Detach the connector 1 that connects the cabling of the glow igniter and the
ionisation rod to the controller.
7. Detach the three-part gas coupling 2 adjacent to the burner.
-
-
Detach the air supply hose 3.
Detach the detach the pressure switch hose 4.
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8. Remove the burner as complete assembly.
Legend
a
a connector
b gas coupling
c air supply hose
d pressure switch hose
e distribution plate
f orifice
e
c
d
b
5
Figure 3.12 Orifice assembly
9. Place and fit the burner with parts from the conversion kit.
n Remark
The burner for LP gases can be recognised by the letter ‘P’ which is stamped
into the metal of the gas/air distribution plate 5.
The injector diameter is stamped into each injector 6
11. Check whether there is a burner pressure regulator 7 fitted to the gas
control, or simply a flat sealing plate!.
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Conversion to a different gas category
is
Legend
g burner pressure regulator
h burner pressure control cap
i burner pressure control
adjusting screw
k
j connector
k flat sealing plate
l supply pressure test nipple
M burner pressure test nipple
l
m
j
h
g
i
IMD-0079
Figure 3.13 Conversion of gas control
n Remark
In the event the supply pressure for a gas category is the same as the burner
fitted with a flat sealing plate with cork gasket. A burner pressure that
deviates in comparison to the supply pressure requires the use of a burner
pressure regulator with rubber gasket. Each conversion kit contains all the
necessary components.
12. If the flat sealing plate or burner pressure regulator need to be replaced:
-
-
Unscrew the connector j from the gas control.
If necessary, remove the flat sealing plate ! or burner pressure
regulator 7.
-
-
If necessary, fit the flat sealing plate or burner pressure regulator
supplied with the conversion kit.
Refit the connector to the gas control.
13. Refit the connector 1 of the glow igniter and ionisation rod to the controller.
14. Re-fit the three-part gas coupling b.
cNote
16. Replace the plastic cover.
17. Remove the sticker showing the new gas category from the conversion kit,
and attach it below the appliance’s rating plate. This clearly indicates that the
appliance may no longer be run on the gas for which it was originally
supplied.
18. Start the appliance (see paragraph 7.2).
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Introduction
gis
4 Filling and draining
4.1 Introduction
Topics covered in this chapter:
•
•
4.2 Filling the appliance
4.2.1 Filling unvented installations
To fill the appliance, proceed as follows.
d for the circulation pump.
into the appliance.
5. Completely fill the appliance (when cold water flows at normal pressure from
the nearest hot water draw-off point, the appliance is full).
6. Bleed the entire installation of air, for example by opening all hot water draw-
off points.
7. The appliance is now under water supply pressure. There should be no
happen, the cause might be:
-
The water supply pressure is greater than the specified 8 bar.
-
The overflow valve in the protected cold supply setup is defective or
incorrectly fitted.
4.2.2 Filling vented installations
To fill the appliance, proceed as follows.
d for the circulation pump.
into the appliance.
5. Completely fill the appliance (when cold water flows at normal pressure from
the nearest hot water draw-off point, the appliance is full).
6. Bleed the entire installation of air, for example by opening all hot water draw-
off points.
7. The appliance is now under water supply pressure. There should be no
might be defective or incorrectly fitted.
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Filling and draining
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Legend
a pressure-reducing valve
UNVENTED
(mandatory)
b
b expansion vessel (mandatory)
c T&P valve (mandatory)
d stop valve (recommended)
e non-return valve (mandatory)
f circulation pump (optional)
g drain valve
T
d
EN
T
SE
T
ER
RE
h gas valve (mandatory)
i stop valve (mandatory)
j temperature gauge (optional)
k condensation drainage
(mandatory)
l hot water draw-off points
m pressure relief valve
(mandatory)
c
n water cistern
o float valve
p 3-way venting valve
(recommended)
a
q overflow pipe
a cold water supply
b hot water outlet
c circulation pipe
d gas supply
k
g
IMD-0139
VENTED
a
o
n
p
q
e flue gas discharge and air
supply
b
T
c
d
a
c
k
IMD-0138
Figure 4.1 Installation diagrams
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Draining the appliance
gis
4.3 Draining the
appliance
4.3.1 Draining unvented installations
Some service activities require the appliance to be drained. The procedure is as
follows:
1. Activate the MENUwith B.
MENU
»OFF
^ ON
2. Use Hand Lto place the cursor beside OFF. See Figure 4.2.
3. Confirm OFF with E.
È WEEK PROGRAM
4. Wait until the fan has stopped. The S icon is then dimmed.
Figure 4.2 Main menu
cNote
Failure to wait until the fan stops can cause damage to the appliance.
5. Turn the appliance OFF (position 0) using the ON/OFF switch on the
control panel. See Figure 4.3.
6. Disconnect the appliance by putting the mains switch between the appliance
and the mains power supply to position 0.
9. Close the supply valve of the cold water supply a.
11. Bleed the appliance (or installation) so that it drains completely empty.
Figure 4.3 ThermoControl
4.3.2 Draining vented installations
Some service activities require the appliance to be drained. The procedure is as
follows:
1. Activate the MENUwith B.
2. Use Hand Lto place the cursor beside OFF. See Figure 4.2.
3. Confirm OFFwith E.
4. Wait until the fan has stopped. The S icon is then dimmed.
cNote
Failure to wait until the fan stops can cause damage to the appliance.
5. Turn the appliance OFF (position 0) using the ON/OFF switch on the
control panel. See Figure 4.3.
6. Disconnect the appliance by putting the mains switch between the appliance
and the mains power supply to position 0.
9. Close the stop valve between the water cistern and the cold water inlet.
11. Bleed the appliance (or installation) so that it drains completely empty.
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Introduction
gis
5 The control panel
5.1 Introduction
Topics covered in this chapter:
•
•
•
•
•
5.2 Operating
Figure 5.1 shows the ThermoControl. The control panel is completely menu-
driven. It comprises:
•
•
•
•
•
a 4-line display with 20 characters per line;
6 push buttons for operating the appliance (below the display);
6 graphical symbols (above the display);
a connector for a service PC;
an ON/OFF switch.
The push buttons are divided into three groups:
•
Navigation buttons:
-
-
-
Buttons UP H, and DOWN L;
Enter: E;
Reset button: R
•
•
specifically intended for the service and maintenance engineer and
installer).
MENU
»OFF
^ ON
» WEEK PROGRAM
Figure 5.1 ThermoControl
with and without icons.
^»START OPERATION
È CHANGE SETPOINT
Tset=70ÉC
Figure 5.2 The display
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The control panel
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5.3 Explanation of the
icons
Table 5.1 gives an explanation of the icons.
Table 5.1 Icons and their meaning
Icon
W
S
D
O
G
V
Name
Explanation
Heat demand
Heat demand detected
Purge
Pre- and post-purge using fan
Pressure switch Pressure switch is closed
Glow
(Pre)glow
Gas control
Gas control open / ignition
Flame detection Appliance running
5.4 ON/OFF switch of
ThermoControl
The ON/OFF switch of the ThermoControl switches the appliance ON and OFF.
Note that in the OFF position the appliance remains electrically live, in order for
the continuous pump to stay running.
After switching on, the text INTERNAL CHECKappears on the display for about
selection is made in the main menu, the appliance automatically switches to
INTERNAL CHECK
n Remark
To electrically disconnect the appliance, you must use the main switch
between the appliance and the mains power supply.
Figure 5.3 Internal check
5.5 Navigation buttons
The use of these buttons is explained with the help of Figure 5.4. This figure
The navigation buttons are:
•
•
•
Buttons UP Hand DOWN L;
Enter: E;
Reset button: R
The arrows ^and Èindicate that you can scroll up and/or down. Use buttons H
and Lto scroll.
The cursor »points to the option to be activated. In the display as shown in
Figure 5.4 you can scroll through the main menu.
MENU
OFF
^»ON
The main menu consists of: OFF, ON, WEEK PROGRAM, EXTRA PERIODand
SETTINGS. The options EXTRA PERIODand SETTINGSonly become visible
after scrolling downwards.
È WEEK PROGRAM
The selected option is confirmed using E.
EXTRA PERIOD
SETTINGS
With the Rbutton, you go back one page in a menu, and all options
selected in the current menu are lost.
Figure 5.4 Navigation buttons
n Remark
The Rbutton is also used to reset the appliance following an error.
5.6 PC connection.
The PC connection is exclusively intended for technicians from A.O. Smith who
can read the status and history of the appliance. These details can be important
for troubleshooting and/or responding to complaints.
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Introduction
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6 Status of the
appliance
6.1 Introduction
Topics covered in this chapter:
•
•
•
6.2 Operating modes
When running, the appliance has four basic operating modes, namely:
OFF
with the following information:
OFF
13:45 Thursday 6ÉC
FROST PROTECTION
ACTIVATED
-
-
line one: the text OFF;
line two: the time, the day and alternately T and T . See paragraph
1
net
2.3;
Figure 6.1 Frost protection
-
lines three and four: the text FROST PROTECTION ACTIVATED.
ON
ON
In this mode the appliance continuously fulfils the demand for hot water.
Figure 6.2 shows the display with the following information:
13:45 Thursday 67ÉC
Tset 75ÉC
-
-
line one: the text ON;
line two: the time, the day and alternately T and T . See paragraph
2.3;
1
net
Figure 6.2 ON
-
-
line three: the programmed water temperature T
;
set
line four: is empty when the appliance is idle, or depending on the
EXTRA
In this mode, one extra period is programmed and activated. In this mode,
the OFFor PROGposition is temporarily overruled to fulfil a single period of
heat demand. Once the period has passed, the appliance automatically
returns to the previous operating mode. Figure 6.3 shows the display with
the following information:
EXTRA
12:30 Thursday 76ÉC
TH 12:45 Tset 75ÉC
PERIOD ACTIVATED
-
-
line one: the text EXTRA;
Figure 6.3 Extra period
line two: the time, the day and alternately T and T . See paragraph
1
net
2.3;
-
-
line three: the switch-on time, and the related water temperature
setting;
line four: the text PERIOD ACTIVATED.
PROG
In this mode a preset week program is active, and the appliance responds
continually to heat demand within the time periods set in the week program.
There are two distinct situations possible in this mode:
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Status of the appliance
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1) The current time falls within a set time period of the week program.
PROG
10:00 Monday
MO 11:15 Tset 75ÉC
Figure 6.4 shows the display in this situation:
76ÉC
-
-
line one: the text PROG;
line two: the time, the day and alternately T and T . See paragraph
1
net
2.3;
Figure 6.4 week program
active, current time within
programmed period
-
-
line three: the next scheduled switch-off time and the water
temperature T of the active period;
set
line four: is empty, or depending on the heating cycle, a text such as
2) The current time falls outside a set time period of the week program.
Figure 6.5 shows the display in this situation:
PROG
12:00 Monday
MO 11:15
76ÉC
-
-
line one: the text PROG;
PERIOD ACTIVATED
line two: the time, the day and alternately T and T . See paragraph
1
net
2.3;
Figure 6.5 week program
active, current time outside
programmed period
-
-
line three: the next scheduled switch-on time;
line four: the text PERIOD ACTIVATED.
In all modes, the temperature may at any moment drop below the desired
temperature. The appliance then enters a heating cycle. This heating cycle is
the same for all basic operating modes. See paragraph ’7.4 The appliance’s
n Remark
Setting and programming of the basic operating modes are described in
6.3 Error conditions
Figure 6.6 shows an example of an error condition. If the appliance enters this
condition, the display will show the following information:
S04: SENSOR ERROR
•
line one: error code comprising a letter and two digits, followed by the error
description;
CHECK
SENSOR OR DUMMY
•
lines two through four: alternately, a brief explanation of the error, and a brief
action to resolve the error.
Figure 6.6 Example of an error
message
cNote
The displayed action to resolve the error may only be performed by a
service- and maintenance engineer.
There are various types of errors:
•
•
LOCK OUT ERRORS
When the cause is no longer present, these errors require a reset with the
Rbutton, before the appliance can resume running.
BLOCKING ERRORS
These errors disappear automatically once the cause of the error has been
removed, after which the appliance resumes by itself.
The display does not show what type of error has been detected. For a detailed
If, as end-user, you find the appliance in an error condition, you may attempt to
re-start the appliance by pressing the Rbutton once.
However, should the error return or become persistent, you should contact your
service and maintenance engineer.
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Service condition
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6.4 Service condition
appear, then the appliance is in need of a service and maintenance inspection.
In that case, contact your service and maintenance engineer.
!!! WARNING !!!
MAX. BURNINGHOURS:
SERVICE REQUIRED
n Remark
The message SERVICE REQUIREDis based on the number of burning
hours and the preset service interval. Should the service interval have been
incorrectly selected, contact the service and maintenance engineer for
Figure 6.7 Service required
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Status of the appliance
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Introduction
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7 Starting up and
shutting down
7.1 Introduction
7.2 Starting up
Topics covered in this chapter:
•
•
Start-up the appliance as follows:
3. Switch on the power to the appliance using the mains switch between the
appliance and the power supply.
4. Turn the ThermoControl ON by setting ON/OFF switch to position I.
Figure 7.1 ThermoControl
The display will now show INTERNAL CHECKfor about 10 seconds, then
go to the main menu.
INTERNAL CHECK
Figure 7.2 Internal check
5. Activate the “ON mode” by going through the following steps:
-
Press once on the DOWN button (L) to position the cursor (») beside
ON, then press E. The display shown in figure Figure 7.4 will
appear.
MENU
»OFF
^ ON
È WEEK PROGRAM
Figure 7.3 Main menu
-
Confirm with Ethe option START OPERATION.
The appliance will now enter “ON mode”. If there is a heat demand, the
appliance will run through a heating cycle. See paragraph ’7.4 The
»
START OPERATION
^ CHANGE SETPOINT
È
If the heating cycle is not run, then there is no current heat demand;
Tset=65ÉC
should this happen, then T will probably need to be set. This is
set
Figure 7.4 Starting up
described in paragraph ’8.4 Setting the water temperature’
7.3 Shutting down
You can:
•
•
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Starting up and shutting down
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•
7.3.1 Shut the appliance down for a brief period (“OFF mode”)
To shut the appliance down for a brief period, you must activate the frost
protection.
With the frost protection you can prevent water freezing in the appliance.
OFF
Activate the frost protection as follows:
1. Press button Bto select the main menu.
2. Using Hand Lposition the cursor (») beside OFF.
Confirm with E.
13:45 Thursday 6ÉC
FROST PROTECTION
ACTIVATED
Figure 7.5 Frost protection
The frost protection cuts in if the water temperature drops below 5°C. The text
FROSTwill then appear on line one of the display The appliance will heat the
water to 20°C (T ) before dropping back to OFFmode.
set
n Remark
These values of 5°C and 20°C cannot be adjusted.
7.3.2 Disconnect the appliance from the mains
The appliance should only be disconnected from mains power in the correct
way. The correct procedure is as follows:
1. Activate the MENUwith B.
MENU
»OFF
^ ON
2. Use Hand Lto position the cursor beside OFF. See Figure 7.6.
3. Confirm OFFwith E.
4. Wait until the fan has stopped. The S icon is then dimmed.
È WEEK PROGRAM
Figure 7.6 Main menu
cNote
Failure to wait until the fan stops can cause damage to the appliance.
5. Turn the appliance OFF (position 0) using the ON/OFF switch on the
control panel. See Figure 7.7.
6. Disconnect the appliance by putting the mains switch between the appliance
and the mains power supply to position 0.
Figure 7.7 ThermoControl
7.3.3 Shut the appliance down for a longer period
Drain the appliance, if you are shutting it down for a longer period of time.
Proceed as follows:
2. Shut off the gas supply.
3. Close the stop valve in the hot water pipe.
4. Open the drain valve.
5. Bleed the appliance (or installation) so that it drains completely empty.
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The appliance’s heating cycle
gis
7.4 The appliance’s
heating cycle
The appliance’s heating cycle is activated as soon as the measured water
temperature (T ) falls below the threshold value (T ). This threshold value
depends on the currently selected appliance operating mode. For example, if
the appliance is in the “OFF mode” (frost protection), then this value is 5°C. If
the appliance is in the “ON mode”, then this threshold value is selectable, for
example, 65°C.
net
set
The heating cycle runs in turn through the following states:
1. HEAT DEMAND;
2. PRE-PURGE;
3. PRESSURE SWITCH;
4. PRE-GLOW;
5. IGNITION;
6. RUNNING;
7. POST-PURGE.
The complete cycle is explained in the example set out below assuming the
appliance is operating in mode ON.
n Remark
The same heating cycle applies to the other operating modes.
Once the appliance starts, it will run through 8 steps:
1. The water temperature drops below the set temperature of (for example)
65°C. The ThermoControl detects a heat demand and starts the heating
cycle.
ON
Ê
13:45 Thursday 63ÉC
Tset 65ÉC
HEAT DEMAND
-
-
The W icon is activated.
The message HEAT DEMANDappears.
Figure 7.8 Frost protection cuts
in
2. Following the heat demand, the fan is powered up and the pre-purge begins.
This lasts about 15 seconds. During this phase, any residual gases are
removed.
ON
Ê Ê
13:45 Thursday 63ÉC
Tset 65ÉC
PRE PURGE
-
-
The S icon is activated.
The message PRE PURGEappears.
Figure 7.9 Pre-purge
3. During the pre-purge, the pressure switch closes.
-
-
The D icon is activated.
ON
Ê Ê Ê
The message PRESSURE SWITCH appears.
13:45 Thursday 63ÉC
Tset 65ÉC
PRESSURE SWITCH
Figure 7.10 Pressure switch
4. After some time, the pre-purge ceases and the ThermoControl reduces the
speed of the fan to the rotational speed for ignition. This is followed by the
pre-glow of the glow igniter.
ON
Ê
Ê
13:45 Thursday 63ÉC
Tset 65ÉC
GLOW PLUG
-
-
The S and D icons are dimmed.
The O icon is activated.
Figure 7.11 Pre-glow
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Starting up and shutting down
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5. After a number of seconds pre-glow, the gas control is opened and ignition
takes place.
ON
Ê
Ê Ê
-
-
The G icon is activated.
13:45 Thursday 63ÉC
Tset 65ÉC
The message IGNITIONappears.
IGNITION
Figure 7.12 Ignition
6. After ignition, the flame is detected and the appliance will be running. This
means that actual heating has started. The rotation speed of the fan then
increases to the normal running speed, and the pressure switch will close:
ON
Ê Ê Ê Ê
13:45 Thursday 63ÉC
Tset 65ÉC
RUNNING
-
-
-
The O icon is dimmed.
The V and D icons are activated.
The message RUNNINGappears.
Figure 7.13 Running
7. Once the water is up to temperature, the heat demand drops off, and the
post-purge starts. This lasts about 25 seconds.
-
-
-
The W, G and V icons are dimmed.
The S icon is activated.
ON
Ê Ê
13:45 Thursday 65ÉC
Tset 65ÉC
POST PURGE
The message POST PURGEappears.
Figure 7.14 Post-purge
8. Following the post-purge, the fan stops and the pressure switch opens:
-
-
The D and S icons are dimmed.
ON
The message POST PURGEdisappears.
14:05 Thursday 65ÉC
At the first subsequent heat demand, the heating cycle will resume from step 1.
Figure 7.15 Running
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Introduction
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8 Main menu
8.1 Introduction
The MENUis reached by pressing button Bof theThermoControl. The options
are:
MENU
»OFF
^ ON
È WEEK PROGRAM
OFF
•
EXTRA PERIOD
SETTINGS
Select this option if you wish to shut the appliance down for a brief period,
but do not wish to drain it. In this mode, the frost protection is active. This
prevents water from freezing in the appliance. See paragraph ’7.3 Shutting
Figure 8.1 Main menu
ON
•
•
In this mode, the appliance continually responds to the hot water demand.
WEEK PROGRAM
Select this option to allow the appliance to respond to heat demand only
during pre-programmed periods. Outside those periods, only frost
EXTRA PERIOD
•
•
Select this option to override the OFFmode or PROGmode so that a single
temporary period of heat demand will be fulfilled. See paragraph ’8.6 Extra
SETTINGS
Select this option in order to set the language and the time. You can also
use this option to display the regulation interval (temperature), and the
n Remark
If you fail to make any selection with the main menu open, then after 30
seconds, the appliance will automatically return to the mode it was
previously in.
Topics covered in this chapter:
•
•
•
•
8.2 Notational
convention for
menu-related
instructions
The MENU(B) of the ThermoControl is divided into sub-menus. For example,
SETTINGSis one of the functions reached from the main menu. The menu
SETTINGSis itself divided into sub-menus. For example, LANGUAGEis a sub-
menu of SETTINGS. So, for example, to select menu LANGUAGE, this manual
employs the following convention:
• B: SETTINGS | LANGUAGE
Confirm with E.
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Main menu
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This means:
1. B: Activate the main menu with B.
2. SETTINGS: Using button Hand/or Lgo to SETTINGSand press E.
3. LANGUAGE: Using button Hand/or Lgo to LANGUAGE.
4. Confirm with E: After pressing E, the sub-menu LANGUAGEis
activated.
This notation is also used for more than 2 sub-menus.
8.3 Switching into “ON
mode”
You can switch the appliance into “ON mode” from any operational mode, as
follows:
• B: ON | START OPERATION
Confirm with E.
n Remark
8.4 Setting the water
temperature
8.4.1 Setting the water temperature via SETPOINT MENU
The water temperature can be set to any value between 40°C and 80°C.
Set the water temperature via:
1. B: ON | CHANGE SETPOINT
START OPERATION
^»CHANGE SETPOINT
Confirm with E.
È
Tset=65ÉC
Figure 8.2 Setting SETPOINT
2. Use:
- Hto increase the value;
- Lto decrease the value.
SETPOINT
» 65ÉC
-
Confirm with E. After confirming, the appliance enters “ON
mode”.
Figure 8.3 Adjusting water
temperature
n Remark
If the temperature setting is higher than the current water temperature, it is
possible that the appliance does not immediately start heating. To prevent
excessively frequent switching on and off, there is a heating margin. This
margin is set standard to 2°C. The appliance starts heating when the water
temperature is 2°C colder than the SETPOINT and continues heating until
the water is 2°C hotter than the SETPOINT.
We refer to this margin as the hysteresis. The service and maintenance
8.4.2 Setting water temperature during ON mode
The water temperature can also be directly adjusted when the appliance is in
“ON mode”. Simply use:
ON
13:45 Thursday 65ÉC
Tset=65ÉC
• Hto increase the value;
• Lto decrease the value.
•
t6Confirm with E.
Figure 8.4 ON mode: the
appliance is on
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Week programme
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8.5 Week programme
8.5.1 Introduction
Using the week program, you can set the water temperature for the days and
times you wish.
If the appliance is running under a week program, then this is indicated on the
the time of day, the day of the week and the temperature. The third line shows
the next switching time of the week program and the programmed temperature.
The fourth line shows the text PROGRAM ACTIVATED.
PROG
07:55 Monday
MO 08:00 Tset 75ÉC
PROGRAM ACTIVATED
64ÉC
Figure 8.5 week program active
The appliance’s default week program switches the appliance on every day at
00:00 hours and off at 23:59 hours. The water temperature setting is standard
65°C.
If you wish, you can change every setting in the standard week program of the
appliance.
If, while the week program is running, the water temperature becomes too low,
then the appliance will run through the heating cycle (see ’7.4 The appliance’s
heating cycle’), then return to the week program.
The following topics are covered in this paragraph:
•
•
•
•
8.5.2 Starting up and shutting down the week program
The week program can be started up from any other operating mode, as follows:
• B: WEEK PROGRAM | START OPERATION
Confirm with E.
A week program can be shut down simply by activating a different operating
mode, for example “ON mode”.
8.5.3 Changing the appliance’s standard week program
n Remark
First fill-in the desired week program on the program card supplied. See
A week program is made up of a number of programmable periods in which you
can have the appliance switch on and off. A period consists of:
•
•
•
•
switch-on time: day of the week, and time in hours and minutes;
switch-off time: in hours and minutes;
the water temperature setting;
on/off setting for a program-controlled pump.
n Remark
The switch-off time must always be followed by a switch-off time on the
same day of the week. A maximum of three periods may be programmed
per day. You can program a maximum of 21 periods per week.
Bring up the menu for the week program via:
1. B: WEEK PROGRAM | PROGRAM OVERVIEW.
Confirm with E.
WEEK PROGRAM
START OPERATION
^»PROGRAM OVERVIEW
È
Figure 8.6 Week programme
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Main menu
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The display now shows the menu for the week program, see Figure 8.7. With
the default setting, the program switches on and off every day at 00:00 and
23:59 hours respectively, the water temperature is 65ºc and the pump is
switched on (P).
DAY TIME Tset
ON »SU 00:00 65ÉC P
OFF SU 23:59
ON MO 00:00 65ÉC P
OFF MO 23:59
ON TU 00:00 65ÉC P
OFF TU 23:59
ON WE 00:00 65ÉC P
OFF WE 23:59
ON TH 00:00 65ÉC P
OFF TH 23:59
Example
As an example, we will set the switch-on time for Sunday to 08:15 hours, and
the matching switch-off time to 12:45 hours. The water temperature will be set
to 75ºC and the pump will run continuously.
The following settings are entered one by one via the menu: the switch-on time,
the switch-off time, the desired water temperature, and the state of the program-
controlled pump.
ON FR 00:00 65ÉC P
OFF FR 23:59
ON SA 00:00 65ÉC P
OFF SA 23:59
INSERT
DELETE
START OPERATION
Figure 8.7 Standard week
program
Setting the switch-on time
ON »SU 00:00
OFF SU 23:59
Tset 65ÉC
2. Bring the cursor to SUand press E. The sub-menu shown in
Figure 8.8 will appear. The day indicated by the »will blink.
PUMP ON
SAVE
3. Use Hand Lto select the day desired. In the example, this is SU(Sunday).
Confirm with E.
Figure 8.8 Week programme
The cursor moves to the hour digits, which will blink. See Figure 8.9.
4. Use Hand Lto select the hour. In the example this is 08.
Confirm with E.
ON SU»08:00
OFF SU 08:00
Tset 65ÉC
PUMP ON
SAVE
Figure 8.9 Setting switch-on
hours in week program
The cursor moves to the minute digits, which will blink. See Figure 8.10.
ON SU 08»15
OFF SU 08:15
Tset 65ÉC
n Remark
Because the switch-off time can never be earlier than the switch-on time, the
switch-off time setting is automatically adjusted with the switch-on time.
PUMP ON
SAVE
Figure 8.10 Setting switch-on
minutes in week program
5. Use Hand Lto select the minutes. In the example this is 15.
Confirm with E.
The cursor moves to the switch-off hour digits, which will blink. See
Figure 8.11.
Setting switch-off time
ON SU 08:15
OFF SU»08:15
Tset 65ÉC
6. Use Hand Lto select the hour. In the example this is 12.
Confirm with E.
PUMP ON
SAVE
Figure 8.11 Setting switch-off
hours in week program
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Week programme
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The cursor moves to the minute digits, which will blink. See Figure 8.12.
7. Use Hand Lto select the minutes. In the example this is 45.
Confirm with E.
ON SU 08:15
OFF SU 12»15
Tset 65ÉC
PUMP ON
SAVE
The cursor moves to the water temperature. See Figure 8.13.
Figure 8.12 Setting switch-off
minutes in week program
Setting the water temperature
ON SU 08:15
OFF SU 12:45
Tset»65ÉC
8. Use Hand Lto select the water temperature. In the example this is 75ÉC.
Confirm with E.
PUMP ON
SAVE
The cursor moves to PUMP ON . See Figure 8.14.
Figure 8.13 Setting water
temperature in week program
Setting program-controlled pump
9. If required, a pump can be controlled during the period. Use Hand Lto
select PUMP ON . The pump ensures a regular circulation of hot water in
the hot water pipes. You can skip this step if you there is no pump in your
hot water circuit.
ON SU 08:15
OFF SU 12:45
Tset 75ÉC
PUMP ON
SAVE
Confirm with E.
Figure 8.14 Setting the pump in
week program
The cursor moves to
SAVE. See Figure 8.15.
ON SU 08:15
OFF SU 12:45
Tset 75ÉC
10. Confirm with E.
PUMP ON
»SAVE
Figure 8.15 Save week
program
The display shown in Figure 8.16 appears.
DAY TIME Tset
ON »SU 08:15 75ÉC P
OFF SU 12:45
11. If you wish, use Lto scroll to another day, and change more switch-on and
ON MO 00:00 65ÉC P
12. After changing all desired switch-on and switch off times, you can start
running the week program:
OFF MO 23:59
ON TU 00:00 65ÉC P
OFF TU 23:59
-
Scroll with Lto START OPERATION.
Confirm with E.
Figure 8.16 Add week program
8.5.4 Adding times to a week program
The menu to INSERTswitch-on and switch-off times into a week program is
reached via:
WEEK PROGRAM
START OPERATION
^»PROGRAM OVERVIEW
È
1. B: WEEK PROGRAM | PROGRAM OVERVIEW.
Confirm with E.
Figure 8.17 Inserting a week
program
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Main menu
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The display shows the menu for the week program, see Figure 8.18. The
cursor points to the active period.
DAY TIME Tset
»SU 08:15 75ÉC P
OFF SU 12:45
2. Scroll Lto INSERT.
ON MO 00:00 65ÉC P
Confirm with E.
....................
....................
OFF SA 23:59
INSERT
The sub-menu for adding a period will appear. See Figure 8.19.
DELETE
START OPERATION
Figure 8.18 Week programme
ON »SU 08:15
OFF SU 12:45
Tset 65ÉC
PUMP ON
SAVE
Figure 8.19 Adding a period
Example
As an example, we will program an extra period in which the switch-on time is
set to 18:00 hours, and the matching switch-off time to 22:00 hours. The water
temperature will be set to 75ºC and the pump will run continuously.
DAY TIME Tset
ON »SU 18:00 75ÉC P
OFF SU 22:00
ON MO 00:00 65ÉC P
SAVEthe
OFF MO 23:59
....................
....................
OFF SA 23:59
INSERT
display as shown in Figure 8.20 appears; i.e. with the cursor beside the
period we have just added.
4. To activate the week program with the new period added, scroll down with
Lto START OPERATIONand confirm with E.
DELETE
START OPERATION
Figure 8.20 Period added
8.5.5 Deleting times from a week program
All switch-on/off times are shown sequentially in the display. Assume that the
DAY TIME Tset
ON »SU 08:15 75ÉC P
OFF SU 12:45
ON SU 18:00 75ÉC P
OFF SU 22:00
....................
....................
OFF SA 23:59
INSERT
DELETE
START OPERATION
Figure 8.21 A program
To delete a period, proceed as follows:
1. B: WEEK PROGRAM.
MENU
OFF
^»ON
È WEEK PROGRAM
Confirm with E.
Figure 8.22 Week programme
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Week programme
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2. Scroll with Lto PROGRAM OVERVIEW.
Confirm with E.
WEEK PROGRAM
START OPERATION
^»PROGRAM OVERVIEW
È
3. Scroll with Lto DELETE.
Figure 8.23 week program
options
Confirm with E.
4. The display will change as shown in Figure 8.24. To warn you that you are
now working in the delete sub-menu, the cursor is replaced with an
exclamation mark (!) and the period settings will blink (illustrated in the
figure by underlining).
DAY TIME Tset
ON !SU 08:15 75ÉC P
OFF SU 12:45
ON SU 18:00 75ÉC P
OFF SU 22:00
....................
....................
OFF SA 23:59
INSERT
DELETE
START OPERATION
Figure 8.24 A program
5. Scroll with Lto the day to be deleted. For example, the second period of SU
DAY TIME Tset
ON !SU 18:00 75ÉC P
OFF SU 22:00
Confirm with E.
ON MO 00:00 65ÉC P
OFF MO 23:59
....................
....................
OFF SA 23:59
INSERT
DELETE
START OPERATION
Figure 8.25 Select
6. The lines showing switch-on/off times are replaced by the text
DAY TIME Tset
DELETE BLOCK?. See Figure 8.26.
ON !
OFF
DELETE
BLOCK?
Confirm with E
(or use Rto cancel deletion)
ON MO 00:00 65ÉC P
Figure 8.26 Confirm deletion of
block from week program
The switching period has been deleted. You will return now to the week
program menu. The cursor is beside the first programmed period. See
Figure 8.27.
DAY TIME Tset
ON SU 08:15 75ÉC P
OFF SU 12:45
7. Scroll with Lto START OPERATION.
Confirm with E.
ON MO 00:00 65ÉC P
OFF MO 23:59
....................
....................
OFF SA 23:59
INSERT
The week program is active.
DELETE
START OPERATION
Figure 8.27 Period deleted
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Main menu
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8.6 Extra period
8.6.1 Introduction
Use an extra period when you either want to have the appliance switch on and
off for a certain period, either without modifying the active week program, or
without taking the appliance out of OFF mode (frost protection active).
If the appliance is running under an ‘extra period’, then this is indicated in the
EXTRA
10:00 Monday
76ÉC
If the water temperature becomes too low during the extra period (see
’8.6.2 Programming an extra period’), the appliance will run through the heating
period.
MO 11:15 Tset 75ÉC
PERIOD ACTIVATED
Figure 8.28 Extra period active
The same settings can be made for an extra period as for a week program
period. See paragraph ’8.5.3 Changing the appliance’s standard week
8.6.2 Programming an extra period
Bring up the menu for entering an extra period via:
1. B:EXTRA PERIOD
MENU
ON
^ WEEK PROGRAM
ȻEXTRA PERIOD
Confirm with E.
The display show the settings for the extra period. See Figure 8.30.
Setting the switch-on time
Figure 8.29 Extra period
2. Use Hand Lto select the day desired. In the example this is SU.
Confirm with E.
ON SU»08:00
OFF SU 08:00
Tset 65ÉC
The cursor moves to the hour digits, which will blink. See Figure 8.30.
PUMP ON
START
3. Use Hand Lto set the switch-on hour to the desired value. In the example
Figure 8.30 Setting switch-on
this is 08.
hour for extra period
Confirm with E.
ON SU 08»15
OFF SU 08:15
Tset 65ÉC
n Remark
Because the switch-off time can never be earlier than the switch-on time, the
switch-off time setting is automatically adjusted with the switch-on time.
PUMP ON
START
Figure 8.31 Setting the switch-
on minutes for extra period
4. Use Hand Lto select the minutes. In the example this is 15.
Confirm with E.
Setting switch-off time
ON SU 08:15
OFF SU»08:15
Tset 65ÉC
5. Use Hand Lto select the hour. In the example this is 12.
Confirm with E.
PUMP ON
START
Figure 8.32 Setting switch-off
hour for extra period
6. Use Hand Lto select the minutes. In the example this is 45.
Confirm with E.
ON SU 08:15
OFF SU 12»15
Tset 65ÉC
PUMP ON
START
Figure 8.33 Setting the switch-
off minutes for extra period
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ON SU 08:15
OFF SU 12:45
Tset»65ÉC
Setting the water temperature
7. Use Hand Lto select the water temperature. In the example this is 75.
Confirm with E.
PUMP ON
SAVE
Figure 8.34 Setting water
temperature for extra period
Setting program-controlled pump
8. If required, a pump can be controlled during the period. Use Hand Lto
select PUMP ON. The pump ensures a regular circulation of hot water in the
hot water pipes. You can skip this step if you there is no pump in your hot
water circuit.
ON SU 08:15
OFF SU 12:45
Tset 75ÉC
PUMP»ON
START
Confirm with E.
Figure 8.35 Pump setting for
extra period
9. Confirm with E.
ON ZO 08:15
OFF ZO 12:45
Tset 75ÉC
The extra period has been programmed.
n Remark
PUMP ON
»START
Once the extra period has completed running, the controller returns to the
mode ON, OFF or WEEK PROGRAM. The following week, the extra period
will NOT be automatically switched on.
Figure 8.36 Saving extra period
8.7 Settings
8.7.1 Introduction
Using the option SETTINGSyou can adjust certain settings, and display certain
Table 8.1 Adjustable settings and displayable appliance specifications
Adjustable settings
ꢀ
ꢀ
Menu language
Current day of week, and time
Displayable appliance
specifications
ꢀ
Regulation interval (water
temperature).
This category is only relevant to
the installer and/or service and
maintenance engineer.
ꢀ
ꢀ
Ignition speed of fan.
Running speed of fan.
8.7.2 Setting menu language
Bring up the menu for selecting the language via:
1. B: SETTINGS.
MENU
WEEK PROGRAM
^ EXTRA PERIOD
ȻSETTINGS
Confirm with E.
The display shows the menu for settings. See Figure 8.38.
Figure 8.37 Settings
2. The cursor is positioned beside LANGUAGE
Confirm with E.
SETTINGS
»LANGUAGE
^ DAY/TIME
È SPECIFICATIONS
The display shows the language selection menu. See Figure 8.39.
Figure 8.38 Language
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Main menu
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3. Scroll with Lto the desired language.
Confirm with E.
LANGUAGE
ENGLISH
^ NEDERLANDS
ȻDEUTSCH
The language is set.
FRANCAIS
ITALIANO
Figure 8.39 Language selection
8.7.3 Setting day and time
Bring up the menu for entering the day and time via:
1. B: SETTINGS.
MENU
WEEK PROGRAM
^ EXTRA PERIOD
ȻSETTINGS
Confirm with E.
The display shows the menu for settings. See Figure 8.38.
Figure 8.40 Settings
2. Scroll with Hand Lto DAY/TIME
Confirm with E.
SETTINGS
LANGUAGE
^»DAY/TIME
È SPECIFICATIONS
The display shows the sub-menu for selecting the day of the week. See
Figure 8.41 Day and time
3. The cursor is positioned beside Sunday.
Scroll with Hand Lto the desired day.
Confirm with E.
DAY
»Sunday
Monday
Tuesday
The day of the week has been set. The display shows the sub-menu for
adjusting the time. See Figure 8.43.
Wednesday
Thursday
Friday
Saterday
Figure 8.42 Setting the day
4. The cursor moves to the hour digits, which will blink.
Scroll with Hand Lto the current hour, for example 15.
Confirm with E.
TIME
»00:00
Figure 8.43 Setting the hour
5. The cursor moves to the minute digits, which will blink.
Scroll with Hand Lto the next minute in time, for example 45.
Confirm the minute setting with E.
TIME
15»00
Figure 8.44 Setting the minutes
The current time has been set.
TIME
15»45
n Remark
The appliance takes no account of daylight saving.
Figure 8.45 Setting the minutes
8.7.4 Displaying appliance specifications
n Remark
This category is only relevant to the installer and/or service and
maintenance engineer.
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Settings
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Table 8.2 shows the standard appliance specifications.
Table 8.2 Appliance specifications
Appliance
Ignition speed
of fan
Running speed
of fan
Regulation
interval
40-80 °C
40-80 °C
40-80 °C
40-80 °C
BFC 28
BFC 30
BFC 50
BFC 60
4500 rpm
4500 rpm
4500 rpm
4500 rpm
4980 rpm
5400 rpm
6000 rpm
6660 rpm
Bring up the menu to display the appliance specifications via:
1. B: SETTINGS.
MENU
Confirm with E.
WEEK PROGRAM
^ EXTRA PERIOD
ȻSETTINGS
Figure 8.46 Main menu
2. Scroll with Lto SPECIFICATIONS
Confirm with E.
SETTINGS
LANGUAGE
^ DAY/TIME
ȻSPECIFICATIONS
The display shows the sub-menu for displaying appliance specifications.
See Figure 8.48.
Figure 8.47 Settings
3. Scroll with Lto the section to be displayed, for example
REGULATION INTERVAL.
SPECIFICATIONS
The relevant display specification appears, see Figure 8.49.
»REGULATION INTERVAL
^ IGNITION SPEED
È WORKING SPEED
Figure 8.48 Appliance
specifications
REGULATION INTERVAL
40_80ÉC
Figure 8.49 Regulation interval
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Introduction
is
9 Service program
9.1 Introduction
The service program is used by the installer or service and maintenance
engineer for:
SERVICE MENU
»HYSTERESE
^ HISTORIE OF ERRORS
È APPLIANCE HISTORY
•
•
•
•
•
•
•
•
•
SELECT APPLIANCE
PUMP RELAY
SERVICE INTERVAL
CONTRAST DISPLAY
TIME BACKLIGHT
SCROLLSPEED
Figure 9.1 Service program
These sub-menus are briefly described in the following paragraphs. If you are
not familiar in general with how to use the displays and menus, first read chapter
n Remark
The notation convention for the service menu is identical to that described
difference is, you use Sto bring up the service program, instead of B
which brings up the main menu.
9.2 Setting the
hysteresis
If the preset temperature (SETPOINT) is higher than the current water
temperature, then the appliance might not immediately start the heating cycle
frequent switching on and off, a there is a heating margin. We refer to this
margin as the hysteresis. The standard setting for this margin is 2°C. The
heating cycle starts if the water temperature drops to 2°C below the SETPOINT
and ends when the water reaches 2°C above the SETPOINT.
Set the hysteresis via:
• S: HYSTERESE UP
Figure 9.2 shows an example.
Set the hysteresis via
HYSTERESE UP
»3ÉC
Figure 9.2 Heating cycle upper
• S: HYSTERESE DOWN
limit
9.3 Displaying the error
history
Display the error history via:
• S: HISTORIE OF ERRORS
The controller will display an overview of ‘Blocking errors’ and ‘Lock out errors’.
In both cases, note that the ThermoControl reserves 15 lines for the last 15 error
messages. If there are less than 15 error messages, then an ellipsis (...) is
displayed. The display first shows the ‘Blocking errors’. When Eis
pressed, the ‘Lock out Errors’ are then displayed.
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Service program
is
Figure 9.3 shows an example of ‘Blocking errors’. In this case, the text
HISTORIE OF ERRORSis followed by (B).
HISTORIE OF ERRORS(B)
S04 SENSOR ERROR
F06 IONIZATION
È CO2 50 HZ ERROR
Figure 9.3 Blocking errors
Figure 9.4 shows an example of the ‘Lock out errors’. In this case, the text
HISTORIE OF ERRORSis followed by (L).
HISTORIE OF ERRORS(L)
F02: FAN
F07: FLAME ERROR
È ...
n Remark
For an overview of all errors and the possible causes, please refer to chapter
Figure 9.4 Lock out errors
9.4 Displaying the
appliance history
The appliance history sub-menu is used to display the burning hours, the
number of ignitions, the number of flame errors, and the number of ignition
errors.
Bring up the menu for displaying the appliance history via:
• S: APPLIANCE HISTORY
APPLIANCE HISTORY
BURNINGHOURS 000410
^IGNITIONS
001000
Figure 9.5 shows an example.
ÈFLAME ERRORS 000021
IGNIT ERROR 000013
Figure 9.5 service program
9.5 Display the selected
appliance
Bring up the menu for displaying the appliance selection via:
• S: SELECT APPLIANCE
The appliance selection has been correctly preset in the factory.
Figure 9.6 shows the relevant display.
SELECT APPLIANCE
»ADM 40 - 135
^ ADMR 40 - 135
È BFC 28
BFC 30
BFC 50
BFC 60
BFC 80
BFC 100
Figure 9.6 Select appliance
9.6 Setting the pump
on/off
then this can be turned ON or OFF via:
• S: PUMP RELAY
PUMP RELAY
»ON
The standard setting for the pump relay is OFF.
Figure 9.7 shows the related display.
OFF
If the mode WEEK PROGRAMor EXTRA PERIODis active, then the setting for
mode WEEK PROGRAMor EXTRA PERIODhas priority over the ON/OFF
selection for the pump relay in the service menu.
Figure 9.7 Pump relay
Example
One of the week program periods is currently active. The pump relay setting is
OFF within this period. If the pump relay is set ON in the service menu, the pump
will nonetheless remain OFF. The pump will only switch ON once the week
program period has ended.
9.7 Setting the service
interval
To aid servicing, the ThermoControl has a service interval which defines the
frequency of maintenance by the service and maintenance engineer based on
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Setting the display contrast
is
The service interval is based on the number of burning hours. This can be set
to 500, 1000 and 1500 hours. The standard setting for number of hours is 500.
Once the preset number of hours is reached, a message to this effect will
Adjust the service interval via:
SERVICE INTERVAL
» 500
• S: SERVICE INTERVAL
^ 1000 BURNING HOURS
È 1500
Figure 9.8 shows the related display.
Figure 9.8 Service interval
9.8 Setting the display
contrast
Adjust the display contrast via:
• S: CONTRAST DISPLAY
CONTRAST DISPLAY
» 95 %
The standard setting is 100%. The range is from 0 through 100%.
Figure 9.9 shows the related display.
Figure 9.9 Display contrast
9.9 Setting the backlight
time
Adjust the backlight time (the time that the display backlight stays lit after the last
button is pressed) via:
• S: TIME BACKLIGHT
The standard value is 255 sec. The range is from 0 through 255 seconds.
Figure 9.10 shows the related display.
TIME BACKLIGHT
» 255 sec
Figure 9.10 Backlight time
9.10 Setting the display
scroll speed
Adjust the display scroll speed via:
• S: SCROLLSPEED
The standard setting is 10. The range is from 0 through 100. Setting the
value too high or low will make scrolling difficult.
SCROLLSPEED
» 10
Figure 9.11 shows the related display.
Figure 9.11 Scroll speed
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10 Troubleshooting
10.1 Introduction
A distinction is made between:
•
General errors
General errors are not reported on the display. General errors are:
-
-
-
-
-
Gas smell
Display does not light up
Insufficient or no hot water.
Water leakage
Explosive ignition
Table 10.1 gives a troubleshooting overview for general errors.
Displayed errors
•
Errors are reported on the display, as follows:
S02: SENSOR ERROR
TOP TANK
-
Line 1: An error code and its short description. The code is made up
of a letter and two digits.
SENSOR 1
NOT CONNECTED
-
Lines 2, 3 and 4: a long description, and a recommended action,
alternating every 2 seconds. See Figure 10.1 and Figure 10.2.
Figure 10.1 Possible error
S02: SENSOR ERROR
TOP TANK
CHECK TOP TANK
SENSOR
Figure 10.2 Action
The displayed errors are divided into two groups:
There are various types of errors:
-
LOCK OUT ERRORS
When the cause is no longer present, these errors require a reset with
the Rbutton, before the appliance can resume running.
-
BLOCKING ERRORS
These errors disappear automatically once the cause of the error has
been removed, after which the appliance resumes by itself.
Table 10.2 gives a troubleshooting overview for the errors that appear on the
display.
n Remark
Footnotes referred to from within any table are shown at the bottom of the
last page of that table.
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Introduction
gs
11 Maintenance
frequency
11.1 Introduction
A service should be carried out at least once a year, both on the water side and
on the gas side. Maintenance frequency depends, among other things, on the
water quality, the average burning time per day and the set water temperature.
n Remark
Regular maintenance extends the service life of the appliance.
n Remark
To determine the correct maintenance frequency, it is recommended to
arrange for the service and maintenance engineer to check the appliance on
both the water and gas side, three months after installation. Based on this
check, the best maintenance frequency can be determined.
11.2 Determining service
interval
To aid servicing, the ThermoControl has a service interval which defines the
frequency of maintenance by the service and maintenance engineer based on
the number of burning hours.
The service interval can be set to: 500, 1000 or 1500 burning hours. The
standard setting is 500 burning hours.
Example
In the first three months, the appliance has burnt 300 hours. During
maintenance, it is evident that one service per year will be sufficient. So after
one year, some 1200 burning hours will have elapsed. The first value below
1200 hours that can be selected is 1000 burning hours.
In this case, the service and maintenance engineer sets the interval to 1000.
Example
In the first three months, the appliance has burnt 300 hours. During
maintenance, it is evident (perhaps due to the water quality) that service will be
required at least once every 6 months. So after six months, some 600 burning
hours will have elapsed. The first value below 600 hours that can be selected is
500 burning hours.
In this case, the service and maintenance engineer sets the interval to 500.
Once the set number of burning hours has elapsed, the message
SERVICE REQUIREDwill appear on the display. See Figure 11.1. Once the
message appears. contact should be made with the service and maintenance
engineer.
!!! WARNING !!!
MAX. BURNINGHOURS:
SERVICE REQUIRED
Figure 11.1 Service required
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Maintenance frequency
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Introduction
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12 Maintenance
12.1 Introduction
cNote
Maintenance may only by carried out by an approved service and
maintenance engineer.
At each service, the appliance undergoes maintenance both on the water side
and on the gas side. The maintenance should be carried out in the following
order.
n Remark
Before ordering spare parts, take a moment to write down the appliance type
and model, and the full serial number of the appliance. Only by ordering with
this information can you be sure to receive the correct spare parts. These
details can be found on the rating plate.
12.2 Preparation for
maintenance
To test whether all components are still working properly, you should complete
the following steps:
1. Activate the MENUwith B.
MENU
»OFF
^ ON
2. Use Hand Lto position the cursor beside OFF. See Figure 12.1.
3. Confirm OFFwith E.
4. Wait until the fan has stopped. The S icon is then dimmed.
È WEEK PROGRAM
Figure 12.1 Main menu
cNote
Failure to wait until the fan stops can cause damage to the appliance.
5. Turn the appliance OFF (position 0) using the ON/OFF switch on the
control panel. See Figure 12.2.
6. Turn the ThermoControl ON by putting the ON/OFF switch to position I.
Figure 12.2 ThermoControl
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Maintenance
s
The display will now show INTERNAL CHECKfor about 10 seconds, and
will then go to the main menu.
INTERNAL CHECK
Figure 12.3 Internal check
7. Activate the “ON mode” by going through the following steps:
-
Press once on the DOWN button (L) to position the cursor beside ON,
then press E. The display shown in Figure 12.5 appears.
MENU
»OFF
^ ON
È WEEK PROGRAM
Figure 12.4 Main menu
-
Confirm with Ethe option START OPERATION.
set
water to create a heat demand.
»START OPERATION
^ CHANGE SETPOINT
È
Tset=65ÉC
10. If you adjusted T , return the setting to the original value. See paragraph
set
Figure 12.5 Starting up
11. Remove the plastic cover on the top side of the appliance.
12. Check the supply and burner pressures and adjust these, where necessary.
13. Check that all components of the flue gas system are properly attached.
14. Check the pressure differential across the orifice plate of the pressure
switch. See Table 12.1. If the pressure differential is too low, then the heat
exchanger should be cleaned. See paragraph ’12.5 Finalising
Table 12.1 Pressure switch differential
Appliance Observed pressure differential across the pressure switch
(Pa)
BFC 28
BFC 30
BFC 50
BFC 60
> 635
> 885
> 885
> 1085
15. Test the operation of the overflow valve of the cold supply setup. The water
should spurt out.
16. Test the overflow operation of the T&P valve. The water should spurt out.
17. Check the wastewater pipes of the overflow valves and remove any lime
buildup that may be present.
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Water-side maintenance
s
12.3 Water-side mainte-
nance
12.3.1 Introduction
The following steps should be carried out on the water side:
12.3.2 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% or more used up
(take this into consideration when determining the maintenance frequency).
1. Loosen the anodes using suitable tools.
2. Check the anodes, and if necessary, replace them.
12.3.3 Descaling and cleaning the tank
Scale and lime buildup prevent effective conduction of the heat to the water.
Periodic descaling prevents buildup of these deposits. This increases the
service life of the appliance, and also improves the heating process. Take the
rate of scale formation into account when deciding on maintenance frequency.
2. Undo the bolts.
3. Remove the cover and the gasket.
4. Inspect the tank and remove any contamination.
1
(1)
5. Remove the scale using Borcoil
.
6. Close the cleaning opening.
Use a new rubber gasket for this.
IMD-0080
Figure 12.6 Cleaning opening
12.3.4 Cleaning condensation water discharge
It is essential to clean the condensation water discharge and siphon, to prevent
blockages.
12.4 Gas-side mainte-
nance
12.4.1 Introduction
The following steps should be carried out on the gas side:
12.4.2 Cleaning the burner
1. Detach the burner.
2. Remove all contamination present on the burner.
3. Fit the burner.
1. A.O. Smith recommends the use of Borcoil, as the composition of this material is known to us.
Borcoil can be ordered from A.O. Smith.
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Maintenance
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12.4.3 Cleaning the orifice
1. Detach the orifice.
2. Remove all contamination present in the orifice.
3. Fit the orifice.
12.4.4 Cleaning heat exchanger
1. Detach the burner.
2. Clean the combustion chamber of the heat exchanger using a vacuum
cleaner and a soft brush.
3. Detach the flue gas discharge.
4. Clean the end of the heat exchanger using tap water.
5. Fit the burner.
6. Fit the flue gas discharge.
n Remark
Check the pressure differential again after cleaning. If the pressure
differential is too low following cleaning, please contact the supplier of the
appliance.
12.5 Finalising mainte-
nance
To finalise the maintenance carry out the following steps:
3. Remove the SERVICE REQUIREDmessage. Do this by:
pressing Ronce, followed by Eonce.
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General warranty
gis
13 Warranty (Certificate)
To register your warranty, you should complete and return the enclosed
warranty card after which a warranty certificate will be sent to you. This
certificate gives the owner of a water heater supplied by A.O. Smith Water
Products Company B.V. of Veldhoven, The Netherlands (hereinafter
“A.O. Smith”) the right to the warranty set out below, defining commitments of
A.O. Smith to the owner.
13.1 General warranty
If within one year of the original installation date of a water heater supplied by
A.O. Smith, following verification, and at the sole option of A.O. Smith, a part or
component, (with exclusion of the tank) proves to be defective or does not
function correctly due to manufacturing and/or material defects, A.O. Smith
shall replace or repair this part or component.
13.2 Tank warranty
If within 3 years of the original installation date of a water heater supplied by
A.O. Smith, following inspection, and at the sole option of A.O. Smith, the glass-
lined steel tank proves to be leaking due to rust or corrosion occurring on the
water side, A.O. Smith shall provide an entirely new water heater of equivalent
size and quality. The warranty period given on the replacement water heater
shall be equal to the remaining warranty period of the original water heater that
was supplied. Notwithstanding that stated earlier in this article, in the event that
unfiltered or softened water is used, or allowed to stand in the water heater, the
warranty shall be reduced to one year from the original installation date.
13.3 Installation and
conditions of use
The warranty set out in article 1 and 2 will apply solely under the following
conditions:
a. the water heater is installed under strict adherence to the installation
instructions of A.O. Smith applying to the specific model, and the relevant
local authority installation and building codes, rules and regulations in force;
b. the water heater remains installed at the original site of installation;
c. the appliance is exclusively used with drinking water, which at all times can
freely circulate (a separately installed heat exchanger is mandatory for
heating salt water or corrosive water);
d. the tank is safeguarded against harmful scaling and lime buildup by means
of periodic maintenance;
e. the water temperatures in the heater do not exceed the maximum setting of
the thermostats, which form a part of the water heater;
f. the water pressure and/or heat load do not exceed the maximum values
stated on the water heater rating plate;
g. the water heater is installed in a non-corrosive atmosphere or environment;
h. the water heater is connected to a cold water supply arrangement, which is:
approved by the relevant authority; with sufficient capacity for this purpose;
supplying a pressure no greater than the working pressure stated on the
water heater; and where applicable, fitted with a temperature and pressure
relief valve compliant with the installation instructions of A.O. Smith
pertaining to the specific model of water heater, and under adherence to the
relevant local authority installation and building codes, rules and regulations
in force;
i. the anodes are replaced and renewed no later than when 60% used up.
13.4 Exclusions
The warranty set out in article 1 and 2 will not apply, in the event of:
a. damage to the water heater caused by an external factor;
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Warranty (Certificate)
gis
b. misuse, neglect (including frost damage), modification, incorrect and/or
unauthorised use of the water heater and any attempt to repair leaks;
c. contaminants or other substances having been allowed to enter the tank;
d. the conductivity of the water being less than 125 µS/cm and/or the hardness
(alkaline-earth ions) of the water being less than 1.00 mmol/lit
e. unfiltered, recirculated water flowing through or being stored in the water
heater;
f. any attempts at repair to a defective water heater other than by an approved
service engineer.
13.5 Scope of the
warranty
The obligations of A.O. Smith pursuant to the specified warranty do not extend
beyond free delivery from the Veldhoven warehouse of the replacement parts or
components or water heater. Shipping, labour, installation and any other costs
associated with the replacement will not be accepted by A.O. Smith.
13.6 Claims
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 A.O. Smith Water Products Company. Inspection of the water
heater as referred to in articles 1 and 2 shall take place in one of the laboratories
of A.O. Smith.
13.7 Limitation of liability
A.O. Smith
A.O. Smith grants no other warranty or guarantee over its water heaters nor the
(parts or components of) water heaters supplied for replacement, other than the
warranty expressly set out in this Certificate.
A.O. Smith is not liable for damage to persons or property caused by (parts or
components, or the glass-lined steel tank of) a (replacement) water heater that
it has supplied under the terms of this warranty, nor on any other grounds.
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A
Appendices
is
A.2 Electrical diagram
BFC
= brown
= blue
ꢃ
ꢄ
= yellow/green
ꢅ
= black
ꢆ
= white (flat ca-
= grey/beige
ꢁ
ꢂ
TERMINAL STRIP CONNECTIONS:
O
P
Q
R
S
T
Fan
A
Earth
Neutral
Phase input of controller
Phase input of isolating transformer (primary side)
Phase output of isolating transformer (secondary side)
Phase input of program-controlled pump
Phase input of continuous pump
Temperature sensor (T2 - bottom of tank)
Dummy
Temperature sensor (T1 - top of tank)
Selection resistor
N
1
L
2
L
3
L
Pressure switch
4
L
5
L
CONTROLLER CONNECTIONS:
J1 Connector for display to controller
J2 Connector for power supply to controller
J19 Connector for extra error signal
J20 Connector for gas control
J21 Connector for program-controlled pump
J24 Connector for fan
JP2 Connector for ionisation rod and glow igniter
JP3 Connector for temperature sensor T2
JP4 Connector for dummy
JP5 Connector for temperature sensor T1
JP6 Connector for selection resistor and pressure switch
JP8 Connector for extra ON mode switch
COMPONENTS:
A
B
C
D
E
F
Controller
Ionisation rod
Glow igniter
Gas control
Burner earth connection
Extra ON mode switch
Continuous pump
Program-controlled pump
Extra error signal
Isolating transformer
Double-pole mains switch
ON/OFF switch control
Display/Flat cable
G
H
J
K
L
M
N
F1 Fuse
F2 Fuse
Figure A.1 Electrical diagram BFC
92
Instruction Manual BFC
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Download from Www.Somanuals.com. All Manuals Search And Download.
Index
gis
IX Index
A
appliance
F
G
H
I
gas
B
C
check
condensation drainage
condition
connect
icon
installation types
L
liability - - - - - - - - - - - - - - - - - - - - - 3
D
data
M
Maintenance
E
Release R.1.3 UK
95
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IX
Index
gis
maintenance
shutting down
state
symbol
N
O
operating mode
T
temperature sensor
trademarks - - - - - - - - - - - - - - - - - - - 3
P
U
W
water
R
S
Instruction Manual BFC
0306 059
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