A.O. Smith 28 30 50 60 Supplement

WATER PRODUCTS
COMPANY
A DIVISION OF A. O. SMITH CORPORATION
XTRA HIGH EFFICIENCY
XTRAHIGHEFF
ICIENCY
XTRAHIGHEFF
ICIENCY
Installation
User and
Service Manual
28
30
50
60
Release R.1.3UK

your installer
www.aosmithinternational.com

Release R.1.3 UK 3
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
Any brand names mentioned in this manual are registered trademarks of their
respective owners.
Liability
A.O. Smith Water Products Company accepts no liability for claims from third
parties arising from improper use other than that stated in this manual and in
accordance with the General Conditions registered at the Eindhoven Chamber
of Commerce.
Refer further to the General Conditions. These are available on request, and
without charge.
Although considerable care has been taken to ensure a correct and suitably
comprehensive description of all relevant components, the manual may
nonetheless contain errors and inaccuracies.
Should you detect any errors or inaccuracies in the manual, we would be
grateful to receive notification. This helps us to further improve our
documentation.
More information
If you have any comments or queries concerning any aspect related to the
appliance, then please do not hesitate to contact A.O. Smith Water Products
Company.
A.O. Smith
Postbus 70
5500 AB Veldhoven
The Netherlands
Freephone: 008008 AOSMITH
008008 2 67 64 84
General: [phone]
Sales: [phone]
Help desk: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.aosmithinternational.com
In the event of problems with connecting to the gas, electricity or water supply,
please contact your installation’s supplier/installer.

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Table of contents
1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.1 About the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9
1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
1.6 Forms of notation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 11
2 Functioning of the appliance - - - - - - - - - - - - - - - - - - 13
2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.2 Functional description of the appliance - - - - - - - - - - - - - - - - - - 13
2.3 The appliance’s heating cycle - - - - - - - - - - - - - - - - - - - - - - 14
2.4 Protection for the appliance - - - - - - - - - - - - - - - - - - - - - - - 14
2.4.1 Water temperature protection - - - - - - - - - - - - - - - - - 15
2.4.2 Gas control - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.4.3 Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.4.4 Pressure switch - - - - - - - - - - - - - - - - - - - - - - - - 15
2.4.5 Ionisation rod - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.5.1 Unvented installation - - - - - - - - - - - - - - - - - - - - - 16
2.5.2 Vented installation- - - - - - - - - - - - - - - - - - - - - - - 16
2.5.3 T&P valve - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3.3 Environmental conditions- - - - - - - - - - - - - - - - - - - - - - - - - 17
3.3.1 Humidity and ambient temperature- - - - - - - - - - - - - - - 18
3.3.2 Maximum floor loading - - - - - - - - - - - - - - - - - - - - 18
3.3.3 Water composition - - - - - - - - - - - - - - - - - - - - - - 18
3.3.4 Working clearances - - - - - - - - - - - - - - - - - - - - - - 18
3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
3.6 Water connections, Unvented - - - - - - - - - - - - - - - - - - - - - - 25
3.6.1 Cold water side - - - - - - - - - - - - - - - - - - - - - - - - 25
3.6.2 Hot water side - - - - - - - - - - - - - - - - - - - - - - - - - 25
3.6.3 Circulation pipe - - - - - - - - - - - - - - - - - - - - - - - - 25
3.6.4 Condensation drainage - - - - - - - - - - - - - - - - - - - - 25
3.7 Water connections, Vented- - - - - - - - - - - - - - - - - - - - - - - - 26
3.7.1 Cold water side - - - - - - - - - - - - - - - - - - - - - - - - 26
3.7.2 Hot water side - - - - - - - - - - - - - - - - - - - - - - - - - 26
3.7.3 Circulation pipe - - - - - - - - - - - - - - - - - - - - - - - - 26
3.7.4 Condensation drainage - - - - - - - - - - - - - - - - - - - - 26
3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
3.9 Air supply and flue gas discharge- - - - - - - - - - - - - - - - - - - - - 27
3.9.1 Concentric wall flue terminal - - - - - - - - - - - - - - - - - - 28
3.9.2 Concentric roof flue terminal - - - - - - - - - - - - - - - - - - 29
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3.10 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.10.2 Preparation- - - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.10.3 Mains voltage - - - - - - - - - - - - - - - - - - - - - - - - - 31
3.10.4 Isolating Transformer - - - - - - - - - - - - - - - - - - - - - - 32
3.10.5 Continuous pump- - - - - - - - - - - - - - - - - - - - - - - - 32
3.10.6 program-controlled pump - - - - - - - - - - - - - - - - - - - - 32
3.10.7 Extra ON mode switch (“Tank ON”) - - - - - - - - - - - - - - - 32
3.10.8 Connecting extra error signal (“Alarm OUT”) - - - - - - - - - - 33
3.11 Checking the supply pressure and burner pressure - - - - - - - - - - - - 33
3.12 Conversion to a different gas category - - - - - - - - - - - - - - - - - - - 35
4 Filling and draining - - - - - - - - - - - - - - - - - - - - - - - 39
4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
4.2 Filling the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
4.2.1 Filling unvented installations - - - - - - - - - - - - - - - - - - 39
4.2.2 Filling vented installations- - - - - - - - - - - - - - - - - - - - 39
4.3 Draining the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - 41
4.3.1 Draining unvented installations - - - - - - - - - - - - - - - - - 41
4.3.2 Draining vented installations - - - - - - - - - - - - - - - - - - 41
5 The control panel - - - - - - - - - - - - - - - - - - - - - - - - 43
5.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
5.2 Operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
5.3 Explanation of the icons - - - - - - - - - - - - - - - - - - - - - - - - - - 44
5.4 ON/OFF switch of ThermoControl - - - - - - - - - - - - - - - - - - - - - 44
5.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
5.6 PC connection. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
6 Status of the appliance - - - - - - - - - - - - - - - - - - - - - 45
6.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
6.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
6.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
6.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
7 Starting up and shutting down - - - - - - - - - - - - - - - - - 49
7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
7.2 Starting up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
7.3 Shutting down- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
7.3.1 Shut the appliance down for a brief period (“OFF mode”) - - - - 50
7.3.2 Disconnect the appliance from the mains - - - - - - - - - - - - 50
7.3.3 Shut the appliance down for a longer period- - - - - - - - - - - 50
7.4 The appliance’s heating cycle - - - - - - - - - - - - - - - - - - - - - - - 51
8 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
8.2 Notational convention for menu-related instructions - - - - - - - - - - - - 53
8.3 Switching into “ON mode” - - - - - - - - - - - - - - - - - - - - - - - - - 54
8.4 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - - 54
8.4.1 Setting the water temperature via SETPOINT MENU - - - - - - 54
8.4.2 Setting water temperature during ON mode - - - - - - - - - - - 54

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8.5 Week programme - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
8.5.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 55
8.5.2 Starting up and shutting down the week program- - - - - - - - 55
8.5.3 Changing the appliance’s standard week program - - - - - - - 55
8.5.4 Adding times to a week program - - - - - - - - - - - - - - - - 57
8.5.5 Deleting times from a week program - - - - - - - - - - - - - - 58
8.6 Extra period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
8.6.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 60
8.6.2 Programming an extra period - - - - - - - - - - - - - - - - - 60
8.7 Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
8.7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 61
8.7.2 Setting menu language - - - - - - - - - - - - - - - - - - - - 61
8.7.3 Setting day and time- - - - - - - - - - - - - - - - - - - - - - 62
8.7.4 Displaying appliance specifications - - - - - - - - - - - - - - 62
9 Service program - - - - - - - - - - - - - - - - - - - - - - - - 65
9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
9.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - 65
9.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 65
9.4 Displaying the appliance history - - - - - - - - - - - - - - - - - - - - - 66
9.5 Display the selected appliance - - - - - - - - - - - - - - - - - - - - - - 66
9.6 Setting the pump on/off - - - - - - - - - - - - - - - - - - - - - - - - - 66
9.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 66
9.8 Setting the display contrast- - - - - - - - - - - - - - - - - - - - - - - - 67
9.9 Setting the backlight time- - - - - - - - - - - - - - - - - - - - - - - - - 67
9.10 Setting the display scroll speed- - - - - - - - - - - - - - - - - - - - - - 67
10 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 69
10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
10.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - 70
10.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - 72
11 Maintenance frequency - - - - - - - - - - - - - - - - - - - - 83
11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83
11.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - 83
12 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 85
12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
12.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 85
12.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 87
12.3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 87
12.3.2 Checking the anodes - - - - - - - - - - - - - - - - - - - - - 87
12.3.3 Descaling and cleaning the tank - - - - - - - - - - - - - - - - 87
12.3.4 Cleaning condensation water discharge - - - - - - - - - - - - 87
12.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 87
12.4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 87
12.4.2 Cleaning the burner - - - - - - - - - - - - - - - - - - - - - - 87
12.4.3 Cleaning the orifice - - - - - - - - - - - - - - - - - - - - - - 88
12.4.4 Cleaning heat exchanger - - - - - - - - - - - - - - - - - - - 88
12.5 Finalising maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - 88
13 Warranty (Certificate)- - - - - - - - - - - - - - - - - - - - - - 89
13.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

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13.2 Tank warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
13.3 Installation and conditions of use - - - - - - - - - - - - - - - - - - - - - 89
13.4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
13.5 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
13.6 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
13.7 Limitation of liability A.O. Smith - - - - - - - - - - - - - - - - - - - - - - 90
A Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
A.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
A.2 Electrical diagram BFC - - - - - - - - - - - - - - - - - - - - - - - - - - 92
IX Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

About the appliance
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1 Introduction
1.1 About the appliance This manual describes how to install, service and use the BFC appliance. The
BFC appliance is a condensing room-sealed water heater with a fan in the air
intake. A concentric chimney connector is fitted standard to the appliance.
Alternatively, the appliance can be connected using a parallel system.
Installation types possible with this appliance are C13, C33, C43, C53 and C63.
The information in this manual is applicable to types: BFC 28, BFC 30, BFC 50
and BFC 60.
The manner of construction and features of the appliance are in conformance
with the European standard for gas-fired storage water heaters for the
production of domestic hot water (ES 89). The appliances are therefore
compliant with the European Directive for Gas Appliances, and have the right to
bear the CE mark.
Warning
Read this manual carefully before starting up the water heater. Failure to
read the manual and to follow the printed instructions may lead to personal
injury and damage to the appliance.
1.2 What to do if you
smell gas 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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Furthermore, the installation must comply with the manufacturer’s instructions.
nRemark
Later amendments and/or additions to all regulations, requirements and
guidelines published on or prior to the moment of installing, will apply to the
installation.
1.4 Target groups The three target groups for this manual are:
• (end) users;
•installers;
• service and maintenance engineers.
Symbols on each page indicate the target groups for whom the information is
intended. See Table 1.1.
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.
nRemark
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.
nRemark
Regular maintenance extends the service life of the appliance.
1.6 Forms of notation The following notation is used in this manual:
nRemark
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.
Table 1.1 Target group symbols
Symbol Target group
g(End) user
iinstaller
sService and maintenance engineer