BFM Balanced Flue Commerial Water Heater 0311818 5015 - Changes Reserved. BFM - 30/50/80/100/120 Installation, User and Service Manual Innovation has a name.
your installer A.O. Smith UK, Unit B8 Amstrong Mall, Southwood Business Park, Farnborough, Hampshire GU14 0NR www.aosmith.co.uk “A.O. Smith Water Heaters” is a trading name of Advance Services (Sales) Ltd. Reg.
gis Read this manual carefully Warning Read this manual carefully before starting up the water heater. Failure to read this manual and to follow the instructions in this manual may lead to accidents, personal injury, and damage to the appliance. Copyright © 2015 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.
gis 4 Instruction manual BFM
gis Table of contents 1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 - - - - - - - - - - - - - - - - - - - - - - - - 7 7 7 8 8 8 9 Working principle of the appliance- - - - - - - - - - - - - - - 11 2.1 2.2 2.3 2.4 2.
Table of contents 8 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 51 8.1 8.2 8.3 9 Starting and running - - - - - - - - - - - - - - - - - - - - - - 53 9.1 9.2 9.3 10 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 Starting the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 53 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 55 10.1 10.2 10.
gis 1 1.1 About the appliance Introduction This manual describes how to install, service and use the BFM appliance. The BFM appliance is a gas-fired sealed boiler with a fan in the air supply. The parallel or concentric chimney connections are appliance-dependent. Possible installation types are C13 or C33. The information in this manual applies to the: BFM 30, BFM 50, BFM 80, BFM 100 and BFM 120.
1 1.4 Maintenance gis 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. Note 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 within three months following installation.
gis 1.7 Overview of this document The table provides an overview of the contents of this document. Contents of this document Chapter Target groups Description Working principle of the appliance This chapter describes how the appliance functions. Installation This chapter describes the installation activity to be completed before you actually start up the appliance. Filling This chapter describes how to fill the appliance. Draining This chapter describes how to drain the appliance.
1 10 Introduction gis Instruction manual BFM
gis 2 2.1 Introduction Instruction manual BFM Working principle of the appliance Topics covered in this chapter: • General working principle of the appliance; • The appliance's heating cycle; • Protection for the appliance; • Safety of the installation.
2 2.2 gis Working principle of the appliance The figure shows a cut-away view of the appliance. General working principle of the appliance Cut-away view of the appliance 22 22 47 47 18 18 48 5 2 9 11 42 10 39 43 24 38 44 41 40 49 12 46 21 14 45 51 52 16 15 8 50 36 16 IMD-0240 R2 Legend Only applicable numbers are mentioned. 2. hot water outlet 5. pressure switch 8. combustion chamber 9. anode 10. tank 11. heat exchanger 12. inspection and cleaning opening 14.
gis In this appliance, the cold water enters the bottom of the tank through the cold water inlet (14). The heat of combustion is conducted to the water by the combustion chamber (50) and heat exchanger (11). The heated tap water leaves the tank through the hot water outlet (2). Once the appliance is completely filled with water, it will constantly be under mains water pressure. When hot water is drawn from the appliance, it is immediately replenished with cold water.
2 2.4 gis Working principle of the appliance Protection for the appliance 2.4.1 Introduction The burner control monitors the water temperature by means of thermostats, and ensures that the combustion is safe. This takes place using: • 2.4.2 the Water temperature protection; • the Flame probe; • the Pressure switch. Water temperature protection By means of the frost, high-limit and safety thermostats, the burner control monitors three temperatures that are important for safety.
gis 2.4.4 Flame probe To ensure that no gas can flow when there is no combustion, the water heater is fitted with a flame probe (21). The burner control uses the ionisation-detecting properties of this probe for flame detection. The burner control closes the gas valve the instant it determines that there is a gas flow but no flame is present. 2.
2 16 Working principle of the appliance gis Instruction manual BFM
is 3 Installation Warning Installation work should be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations"). 3.
3 3.3 is Installation Ambient conditions The appliance has a sealed combustion chamber, and obtains its air supply independently of the boiler room. There are therefore no additional ventilation requirements. Possible installation types are C13 and C33. 3.3.1 Air humidity and ambient temperature The boiler room must be frost-free, or be protected against frost.
is 3.3.4 Working clearances For access to the appliance, it is recommended that the following clearances are observed (see figure): • AA: around the appliance's control column and cleaning openings: 100 cm. • BB: all sides of the appliance: 50 cm. • Above the appliance (room to replace the anodes): - 100 cm if using fixed anodes, or - 50 cm if using flexible anodes. If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered.
3 3.4 is Installation The appliance is supplied without accessories. Check the dimensions (3.4.1 "Dimensions of the appliance"), gas data (3.4.3 "Gas data") and other specifications (3.4.2 "General and electrical specifications") of any accessories you plan to use. Technical specifications 3.4.
Instruction manual BFM Dimensions (all measurements in mm unless otherwise indicated) Dimension Description Unit BFM 30 BFM 50 BFM 80 BFM 100 BFM 120 A Total height mm 2000 2000 2020 2020 2020 B Height of top of appliance mm 1800 1800 1820 1820 1820 C Position on pallet mm 580 580 580 580 580 D Appliance diameter mm 710 710 710 710 710 E Depth mm 1000 1000 1000 1000 1000 F Width mm 755 755 755 755 755 G Diameter of chimney flue mm 80 100 130 130
3.4.2 General and electrical specifications General and electrical specifications Description Unit BFM 30 BFM 50 BFM 80 BFM 100 BFM 120 Volume ltr.
Instruction manual BFM 3.4.3 Gas data Gas data Description Unit BFM 30 BFM 50 BFM 80 BFM 100 BFM 120 Orifice diameter mm 2.60 2.50 2.70 3.20 3.30 Diameter of pilot flame orifice mm 0.56/0.41 0.56/0.41 0.56/0.41 0.56/0.41 0.56/0.41 (1) = Blank plate (2) = Burner pressure regulator 1 or 2 2 2 2 2 2 Nominal load (gross calorific value) kW 32.2 52.2 83.3 113.3 127.7 Nominal output kW 26.4 42.3 67.5 90.8 102.
Description Unit BFM 30 BFM 50 BFM 80 BFM 100 BFM 120 Orifice diameter mm 1.45 1.40 1.50 1.95 2.30 Diameter of pilot flame orifice mm 0.25 0.25 0.25 0.25 0.25 (1) = Blank plate (2) = Burner pressure regulator 1 or 2 1 1 1 1 2 Nominal load (upper value) kW 30.4 47.8 77.2 110.9 125.0 Nominal output kW 25.5 39.6 63.9 90.8 102.
is 3.5 Installation diagram 3.5.1 Installation This figure shows the installation diagram. This diagram is used in the sections in which the actual connection process is described. Installation diagram Legend UNVENTED Only applicable numbers are mentioned. 1. pressure reducing valve (mandatory) 3. T&P valve 4. stop valve (recommended) 5. non-return valve (mandatory) 6. circulation pump (optional) 7. top to bottom circulation pump 4 (optional) 6 5 9. drain valve 4 10. manual gas valve (mandatory) 11.
3 3.6 is Installation Water connections, Vented 3.6.1 Warning The installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "Regulations"). Cold water side See (A) in the installation diagram (3.5 "Installation diagram"). 1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the appliance, as required by regulations (1.3 "Regulations"). 3.6.
is 3.6.5 Circulation pipe See (C) in the installation diagram (3.5 "Installation diagram"). If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort and reduces water wastage. 1. Fit a circulation pump (6) of the correct capacity for the length and resistance of the circulation system. 2. Fit a non-return valve (5) behind the circulation pump to guarantee the direction of circulation. 3. Fit two stop valves for service purposes (4). 4.
3 is Installation 3.7.4 Drain valve 1. Fit the standard drain valve (9) supplied with the appliance. 2. If applicable, fit a circulation pipe (3.6.5 "Circulation pipe"). If not, fit the blind threaded plug and gasket (C) supplied with the drain valve, as shown in the figure. C IMD-0122 R1 3.7.5 Circulation pipe See (C) in the installation diagram (3.5 "Installation diagram"). If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed.
is 3.9 Air supply and flue 3.9.1 Introduction Warning The installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "Regulations"). The BFM 30, 50 and 80 differ from the BFM 100 and 120 in how the air supply and chimney flue are connected. 3.9.2 Installing chimney flue components for BFM 30, 50, 80 The BFM-appliances are approved for installation types C13 and C33. The instruction manual describes these types.
3 is Installation 3.9.3 Concentric wall flue terminal BFM 30-50-80 Wall flue terminal . B A IMD-0060 R2 3.9.4 C13 concentric wall flue terminal specifications (BFM 30, 50, 80) C13 Concentric wall flue terminal specifications Subject Description Wall flue terminal set: Art. No. • 1x Wall flue terminal (incl.
is 3.9.5 Concentric roof flue terminal BFM 30, 50, 80 Roof flue terminal . C B A 3.9.6 C33 concentric roof flue terminal specifications (BFM 30, 50, 80) C33 concentric roof flue terminal specifications Subject Roof flue terminal set: • 1x Roof flue terminal (incl. clamping ring) • 1x pipe 1000 mm • 1x mounting flange Pipe material Pipe diameters Description 0302 5181 0302 5071 0302 3271 Art. No.
3 is Installation 3.9.7 Installing chimney flue components for BFM 100, 120 The air supply duct (1) and chimney flue (2) for the BFM 100 and 120 emerge separately from the top box. They must be connected to the concentric wall flue terminal or roof flue terminal by means of a transition piece. Parallel connection BFM 100, 120 Legend 1. Air supply 2. chimney flue 1 2 IMD-0252 R1 A.O.
is 3.9.8 Concentric wall flue terminal BFM 100, 120 Wall flue terminal . B A IMD-0226 R1 3.9.9 C13 concentric wall flue terminal specifications (BFM 100, 120) C13 Concentric wall flue terminal specifications Subject Wall flue terminal set: • 1x Wall flue terminal (incl. wall flange & clamping ring) • 1x Clamping ring • 1x Transition piece • 2x Pipe 500 mm • 2x Bend 90° Pipe material Pipe diameters Description Art. No.
3 is Installation 3.9.10 Concentric roof flue terminal BFM 100, 120 Roof flue terminal . C B A 3.9.11 C33 concentric roof flue terminal specifications (BFM 100, 120) C33 concentric roof flue terminal specifications Subject Roof flue terminal set: • 1x Wall flue terminal (incl. clamping ring) • 1x Pipe 1000 mm • 1x Mounting flange Pipe material Pipe diameters Description Art. No.
is 3.10 Electrical connection Warning The installation should be carried out by an authorised installation engineer, in compliance with general and local regulations (1.3 "Regulations"). This paragraph describes the electrical connections. The figure shows a view of the electrical connector block, and the table shows the appropriate connections. Connector block Legend A. screws B. protective cap C.
3 is Installation 3.10.1 Connecting the mains power The appliance is supplied without a power cable and isolator. Note In order to receive electrical power, the appliance has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the appliance. The power cable must have cores of at least 3 x 1.0 mm2.
is 3.11 Checking the supply pressure and burner pressure Note Before starting the appliance and/or checking the supply pressure and burner pressure, you must fill (5 "Filling") the appliance. Caution Before starting up for the first time or after conversion, you must always check the supply pressure and burner pressure. Note The easiest way to check the gas pressures is by using two pressure gauges. This procedure assumes that these two gauges are available.
3 is Installation Gas control valve for BFM 120 Legend 1. burner pressure regulator 3. burner pressure regulator adjustment screw 6. supply pressure test nipple 7. gas control valve 8. manifold test nipple 6 7 3 8 1 IMD-0257 R1 1. Isolate the appliance from the power supply (10.3 "Isolating the appliance from the mains"). 2. There are two test nipples on the gas control valve. Test nipple (6) is used to check the supply pressure. The other test nipple on the gas control valve is not used.
is 11. Use the pressure gauge to read the burner pressure at nipple (8). Refer to the gas data table (3.4.3 "Gas data"). Note If the burner pressure is incorrect and the appliance is fitted with a blank plate or high-low control, then you cannot adjust the pressure. In this case, consult your installation engineer or supplier. If the appliance is indeed fitted with a burner pressure regulator, then you can adjust the pressure. BFM 30, 50, 80, 100 12. Remove the cap (2) from the burner pressure regulator.
3 40 Installation is Instruction manual BFM
is 4 Conversion to a different gas category Caution The conversion may only by carried out by an authorised installation engineer. If the appliance must operate on a family of gases (LP gas or natural gas) or other gas category than that for which the appliance has been set at the factory, the appliance will have be adapted using a special conversion kit. Caution You must check the supply pressure and burner pressure once the conversion is complete. 4.1 Conversion 1. Isolate (10.
4 4.2 Orifice replacement is Conversion to a different gas category Gas control valve assembly removed 1. strain relief 2. spark electrode lead 3. flame probe lead 7 4. burner control 4 5. gas control valve connector(s) 6 6. gas control valve 5 7. gas coupling 8. burner tray 1 7 5 6 5 8 2 3 IMD-0254 R1 1. Remove the protective cover from the control column: undo the 4 screws and remove the protective cover by lifting it. The electrical section will now be exposed. 2.
is 8. If the gas table (3.4.3 "Gas data") indicates that the main burner orifices need to be replaced: a. Remove the main orifices (5). b. Fit the main orifices from the conversion set. Check the required orifice diameter against the value given in the gas table (3.4.3 "Gas data"). The orifice diameter is stamped on the orifice itself. 9. If necessary, replace the blank plate or burner pressure regulator. 10. Re-fit the burner tray and fasten it using the screws. 11.
4 44 Conversion to a different gas category is Instruction manual BFM
gis 5 Filling Installation diagram Legend UNVENTED Only applicable numbers are mentioned. 1. pressure reducing valve (mandatory) 3. T&P valve 4. stop valve (recommended) 5. non-return valve (mandatory) 6. circulation pump (optional) 4 7. top to bottom circulation pump 6 (optional) 5 9. drain valve 4 10. manual gas valve (mandatory) 11. service stop valve (mandatory) C 12. temperature gauge (recommended) 14. hot water draw-off points 15. expansion valve (mandatory) 16. expansion vessel (mandatory) 17.
5 5.1 Filling unvented installations gis Filling To fill the appliance, proceed as follows: 1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6). 2. Close the drain valve (9). 3. Open the nearest hot water draw-off point (14). 4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the appliance. 5. Completely fill the appliance. When a full water jet flows from the nearest draw-off point, the appliance is full.
gis 6 Draining Installation diagram Legend UNVENTED Only applicable numbers are mentioned. 1. pressure reducing valve (mandatory) 3. T&P valve 4. stop valve (recommended) 5. non-return valve (mandatory) 6. circulation pump (optional) 4 7. top to bottom circulation pump 6 (optional) 5 9. drain valve 4 10. manual gas valve (mandatory) 11. service stop valve (mandatory) C 12. temperature gauge (recommended) 14. hot water draw-off points 15. expansion valve (mandatory) 16. expansion vessel (mandatory) 17.
6 6.1 Draining unvented installations gis Draining Some service activities require the appliance to be drained. The procedure is as follows: 1. Shut down the appliance by setting the ON/OFF switch on the control panel to position 0. 2. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0. 3. Shut off the gas supply (10). 4. Close the stop valve (11) in the hot water pipe. 5.
gis 7 7.1 The control panel Introduction 7.5 Topics covered in this chapter: • • Explanation of icons; ON/OFF switch; • Control thermostat; • Burner control reset button. 7.2 Use the rotary knob of the control thermostat to set the desired water temperature between ± 40 °C and ± 70 °C. The range is continuous and is labeled 1 through 4. The table shows the temperatures coresponding to the numbers on the knob.
7 50 The control panel gis Instruction manual BFM
gis 8 8.1 Status of the appliance Introduction Topics covered in this chapter: • Operating modes; • Error conditions; 8.2 Operating modes 8.3 When the appliance is in an error condition, the heat demand is (temporarily) ignored, and you cannot draw hot water. The frost protection is also out of action.
8 52 Status of the appliance gis Instruction manual BFM
gis 9 9.1 Starting and running Introduction Topics covered in this chapter: • Starting the appliance; • The appliance's heating cycle. 9.2 Starting the appliance The entire cycle is explained in the example below. Note The cycle has the same steps when frost protection is activated. 2. Open (3.5 "Installation diagram") the manual gas valve. 1. The control thermostat sensor measures the temperature.
9 54 Starting and running gis Instruction manual BFM
gis 10 Shutting down 10.1 Introduction Topics covered in this chapter: • • • • Shutting down the appliance for a brief period (OFF mode); Isolating the appliance from the mains; Shutting the appliance down for a long period; Disposal. 10.2 Shutting down the appliance for a brief period (OFF mode) To shut the appliance down for a brief period, you must activate frost protection using the appliance's heating cycle (2.3 "The appliance's heating cycle").
10 56 Shutting down gis Instruction manual BFM
gis 11 11.1 Introduction Troubleshooting This chapter deals with the following problems with the appliance: • Gas smell. • Water leakage. • Explosive ignition. • Poor flame profile. • No hot water. • Insufficient hot water. When the appliance is in an error condition, the heat demand is (temporarily) ignored, and you cannot draw hot water. The frost protection is also out of action.
is 11.2 Troubleshooting: general errors Warning Maintenance may only be performed by a qualified service and maintenance engineer. General errors Symptom Cause Gas smell Gas leak Solution Warning Close the main gas valve immediately. Warning Do not operate any switches. Remark Warning Contact your installation engineer or local gas company immediately. Warning No naked flames. Warning Ventilate the boiler room.
is 11.3 Troubleshooting: insufficient hot water Warning Maintenance may only be performed by a qualified service and maintenance engineer. Insufficient hot water Symptom Cause Solution Remark Set the control thermostat (7.5 "Control thermostat") to a higher Insufficient hot water Water temperature setting (Tset) is too low value Hot water supply is used up 1. Reduce hot water consumption and give the appliance time to heat up.
is 11.4 Troubleshooting: No hot water No hot water Symptom Cause Solution Remark No attempt to start heating cycle No supply voltage present 1. Check if the isolator is ON. See the BFM electrical diagram (14 "Electrical diagram") If the error cannot be rectified, contact your installation engineer 2. Check whether there is power to the isolator 3. Check whether there is power to the electrical connector block 4. Check whether there is power to the burner control 5.
is Symptom Cause Solution Burner control reset button (burner control lock out error) There are three possible causes for this error. In order to determine the cause, you must cause the error to appear again: Remark see the appliance's heating cycle (9.3 "The appliance's heating cycle") 1. Reset the appliance by pressing the reset button 1x 2. Cause (a) occurs between step 4 and step 5 of the heating cycle 3. Cause (b) occurs in step 5 or 6 4.
is Instruction manual BFM 62
s 12 12.1 Introduction Performing maintenance Caution Maintenance may only by carried out by an approved service and maintenance engineer. At each service, the appliance undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order. 1. Water-side maintenance 2. Water-side maintenance 3. Gas-side maintenance 4.
12 s Performing maintenance 12.3 Water-side maintenance 12.3.1 Introduction The following steps must be carried out on the water side: 1. Checking the anodes. 2. Descaling and cleaning the tank. 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.
s 12.3.3 Descaling and cleaning the tank Scale and lime buildup prevent effective conduction of the heat to the water. Periodic cleaning and descaling prevents buildup of these deposits. This increases the service life of the appliance, and also improves the heating process. Take the rate of scale formation into account when deciding on maintenance frequency. Scale formation depends on the local water composition, the water consumption and the water temperature setting.
12 s Performing maintenance 1 5 3 4 6 2 IMD-0282 R1 7. Close the cleaning opening. To avoid damage to the tank, tighten the bolts that fasten the lid with a torque no greater than 50 Nm. Use suitable tools for this. For the best possible watertight seal of the cleaning opening, the bolts in the lid should be torqued down in the sequence shown in the figure. 12.4 Gas-side maintenance 12.4.1 Introduction The following steps must be carried out on the gas side: 1. Clean the burner(s). 2.
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 appliance supplied by A.O. Smith water Products Company B.V. of Veldhoven, The Netherlands (hereinafter "A.O. Smith") the right to the warranty set out below, defining the commitments of A.O. Smith to the owner. 13.
13 13.4 Exclusions Warranty (certificate) gis The warranty set out in articles 1 and 2 will not apply in the event of: a. damage to the water heater caused by an external factor; b. misuse, neglect (including frost damage), modification, incorrect and/or 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.
is 14 14.1 Introduction Instruction manual BFM Electrical diagram This chapter shows the electrical diagram(s) and accompanying legend.
14 Electrical diagram is 14.2 BFM Electrical Diagram.
is COMPONENTS: OPTIONAL COMPONENTS: A Mantle S Clock B Isolating transformer T Potentiostat C DPS (Differential air pressure switch) D Filter E Reset button F Frost thermostat G Control thermostat H ON/OFF switch K Safety thermostat L High-limit thermostat M Burner control N Terminal block P Earth strip R Relay Instruction manual BFM 71
is Instruction manual BFM 72
gis Index A M ambient temperature 18 mains power 35, 36 maintenance anode 64 burner 66 finalising 66 gas-side 66 orifice 66 perform 63 preparation 63 water-side 64 B burner pressure 37 C claims 68 connect air supply 29 circulation piping 27, 28 cold water side 26, 27 electrical 35, 36 gas 28 hot water side 27 shut pipe 26, 27 connecting air supply 29 connecting circulation pipe 27, 28 connecting cold water side 26, 27 connecting flue gas discharge 29 connecting hot water side 27 control thermostat 49 co
Index 0311 818 1.
