A.O. Smith BPD-80 Series Installation And Operating Manual
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A.O. Smith BPD-80 Series Installation And Operating Manual

Commercial gas water heaters
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COMMERCIAL GAS WATER HEATERS
WARNING: If the information in these instruc-
tions is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or death.
- Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of
this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas sup-
plier's instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
1808
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
Installation and Operating Manual
POWER DIRECT VENT GAS MODELS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
•
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
WITH HOT SURFACE IGNITION
MODELS BPD-80 SERIES 310, 311
•
For Your Safety
100299634_2000545244_ Rev. A

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  • Page 1 POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES MODELS BPD-80 SERIES 310, 311 WARNING: If the information in these instruc- tions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safe Installation, Use And Service ....3 Concentric Vent Termination ....30 General Safety .

  • Page 3: Safe Installation, Use And Service

    SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard.

  • Page 4: General Safety

    GENERAL SAFETY WARNING WARNING Read and understand instruction Fire Hazard manual and safety messages For continued protection against before installing, operating or risk of fire: servicing this water heater. • Do not install water heater on Failure to follow instructions and carpeted floor.
  • Page 5 GENERAL SAFETY CAUTION WARNING Improper Installation, use and service may result • Before servicing the water heater, make sure the blower assembly is unplugged in property damage. or the electrical supply to the water • Do not operate water heater if flood damaged. heater is tumed "OFF".

  • Page 6: Introduction

    INTRODUCTION Thank You for purchasing this water heater. Properly everything on the first few pages, READ ENTIRE installed and maintained, it should give you years of trouble MANUAL BEFORE ATTEMPTING TO INSTALL OR free service. OPERATE THE WATER HEATER. The installation must conform with these instructions and local code Abbreviations found in this Installation and Operating authority having jurisdiction.

  • Page 7: Installation Requirements For The Commonwealth Of Massachusetts

    INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
  • Page 8 INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM • If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following graphic during installation and during modifications to the water supply system. TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM EXPANSION TANK COLD WATER INLET...

  • Page 9: Typical Installation

    TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Termination Elbow with Rodent 18 *Metal Drain Pan 39 Gas Orifice (see Figure 3) Screen 19 *Floor Drain 40 Gas Manifold (see Figure 3) 2 *Vent Pipe 20 Flexible Manifold Tube (see 41 Hot-Surface Igniter (see Figure 3)

  • Page 10: Replacement Parts And Deliming Products

    REPLACEMENT PARTS AND DELIMING PRODUCTS Natural gas and Propane (LP) main burner with Replacement parts and recommended delimer may be igniter assembly. NG burner ordered through authorized servicers or distributors. When shown. LP burner similar ordering parts, provide complete model and serial numbers but with drain hole (item 17 (see rating plate), quantity and name of part desired.

  • Page 11: Water Piping - Mixing Valve Usage

    WATER PIPING - MIXING VALVE USAGE This appliance has been design certified as complying with ANSI/CSA Standard for water heaters and is considered Mixing Valves suitable for combination Water (Potable) Heating and Water temperature over DANGER Space Heating but not space heating only applications. 125°F can cause severe The water supply pressure should not exceed 80 psi.

  • Page 12: Water Heater Operation

    Some people are more likely to be permanently injured WATER HEATER OPERATION by hot water than others. These include the elderly, Figure 9 shows the water heater’s sequence of operation children, the infirm and the physically/mentally disabled. when a call for heat is initiated. The ignition control module Table 1 (published by U.S.

  • Page 13: Electrical Requirements & Wiring Diagram

    ELECTRICAL REQUIREMENTS & WIRING DIAGRAM CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN WARNING CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. Electric Shock Hazard POWER VENT WIRING SCHEMATIC. Disconnect power before NOTE: REFER TO THE “Installation Checklist” BEFORE servicing.

  • Page 14: Safety Lockouts

    SAFETY LOCKOUTS This water heater has several lockout features designed The switch will auto reset once the temperature drops to prevent the heater from operating in unsafe conditions. sufficiently. HIGH LIMIT CONTROLS (ENERGY CUT OFF) BLOWER AIR PRESSURE SWITCHES Thermostat/Water Temperature The blower/heater is equipped with two air pressure This feature is a part of the gas control valve/thermostat switches located in the junction box (see Figure 4, item...

  • Page 15: Clearances To Combustibles

    Clearances For Servicing WARNING When installing the heater, consideration must be given to proper location. Location selected should be as close to Fire or Explosion Hazard the wall as practicable and as centralized with the water piping system as possible. •...

  • Page 16: Important Notes And Warnings

    Important Notes and Warnings INSULATION BLANKETS • This heater is certified to be installed using Schedule Insulation blankets are available to the general public for 40 PVC or CPVC or polypropylene plastic vent material. external use on gas water heaters but are not necessary Only use approved material.

  • Page 17: Installing The New Water Heater

    INSTALLING THE NEW WATER HEATER WATER PIPING Before changing the factory setting on thermostat, read “Operating The Temperature Control System” section in Water temperature over DANGER this manual. 125°F can cause severe • This water heater should not be connected to any burns instantly resulting in severe injury or death.

  • Page 18: Combo Heating

    COMBO HEATING 2. Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating This section serves as a guide for the installation and use module without affecting the water heater. of “Combo”...

  • Page 19: Closed Water Systems

    CLOSED WATER SYSTEMS SHUT-OFF VALVE Water supply systems may, because of code requirements HOT-WATER COLD- OUTLET or such conditions as high line pressure, among others, WATER INLET have installed devices such as pressure-reducing valves, UNION UNION check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.

  • Page 20: Temperature-Pressure Relief Valve

    TEMPERATURE-PRESSURE RELIEF VALVE No valve or other obstruction is to be placed between the T&P valve and the tank. Do not connect discharge piping directly to the drain unless a maximum of 6 in. air gap is WARNING provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge Explosion Hazard water in adequate quantities should circumstances...

  • Page 21: Temperature-Pressure Relief Valve And Pipe

    Note: The purpose of a temperature-pressure relief valve HIGH ALTITUDE INSTALLATION is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant WARNING relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see “Closed Water Systems”...
  • Page 22 Make sure the gas supplied is the same type listed on the excess of 1/2 psi. It should be isolated from the gas supply model rating plate. The inlet gas pressure must not exceed piping system by closing its individual manual shut-off 14”...

  • Page 23: Sediment Traps

    SEDIMENT TRAPS FILLING THE WATER HEATER WARNING CAUTION Property Damage Hazard Fire and Explosion Hazard • Avoid water heater damage. • Contaminants in gas lines can cause fire or explosion. Fill tank with water before operating. • • Clean all gas piping before •...

  • Page 24: Venting

    VENTING Plan the vent system layout so that proper clearances are VENT KIT maintained from plumbing and wiring. Vent pipes serving A Vent Kit included with this water heater may be used for power vented appliances are classified by building codes as standard sidewall or roof termination.

  • Page 25: Termination Clearances (Side Wall)

    TERMINATION CLEARANCES (SIDE WALL) R N E E C O I N S I D D E T A Vent terminal Air supply inlet Area where terminal is not permitted F I X E S E D C L O R A B O P E F I X E...

  • Page 26: Side Wall Vent Termination (Standard)

    SIDE WALL VENT TERMINATION (STANDARD) 4. The air intake termination and the exhaust vent termination must penetrate the same side of roof. Important: When terminating the vent on a side wall, the 5. The centerline of the air intake termination and the following specifications pertaining to terminal location must centerline of the exhaust vent termination must not be followed (see Figure 21).

  • Page 27: Deluxe Horizontal Venting Kit

    DELUXE HORIZONTAL VENTING KIT “Mushroom” Vent Terminal The Deluxe Horizontal Venting kit was an optional through- “MUSHROOM” VENT TERMINAL the-wall-only concentric flue system for use only on U.S. residential and light duty commercial Power Direct Vent gas water heaters. This section gives directions for replacing series 300 and 310 PDV water heaters terminated with the Deluxe Horizontal Venting Kit.

  • Page 28: Connections To The Air Box

    Connections To The Air Box 1. Slide an O-ring over each of the fittings on the air box. Note: An appropriate sized O-ring can be ordered from the heater manufacturer. Request kit number 100269737. 2. Slide the exhaust vent piping over the exhaust fitting on the air box.

  • Page 29: Low Profile Side Wall Vent Termination

    LOW PROFILE SIDE WALL VENT TERMINATION 3. To fasten the Base to the wall, use the supplied screws and anchors. A 5mm (3/16”) hole, 30mm (1-3/16”) The Low Profile termination is certified to be used on all deep, will need to be drilled for the anchors. Locate PDV model series 300/301 and 310/311 water heaters.

  • Page 30: Concentric Vent Termination

    CONCENTRIC VENT TERMINATION 45° ELBOW (SEE A concentric vent termination kit (see Table 3) may be LOCAL CODES) used for vertical or horizontal terminations. Figure 32 PIPE NIPPLE illustrates the concentric vent kit for a horizontal (side wall) installation. To prevent rain water from entering the exhaust VENT SCREEN outlet, slope the vent kit at a downward pitch of 1/4”...

  • Page 31: Multiple Concentric Vent Termination

    MULTIPLE CONCENTRIC VENT TERMINATION When two concentric vent kits are being installed, the vent hood centers shall be either less than 9.5” apart or more than 43.5” apart. Spacings between 9.5” and 43.5” are not allowed due to the possibility of exhaust cross circulation (see Figure 34).

  • Page 32: Vent Pipe Material

    VENT PIPE MATERIAL 3. The vent piping shall be connected to the blower with the rubber coupling and secured with gear clamps. This heater is certified to be installed using Schedule 40 The coupling and clamps are provided with the heater. PVC or CPVC or polypropylene or ABS plastic vent material 4.
  • Page 33 PRESSURE SWITCH 2 PIPE CONC. VENT WATER HEATER VENT SIZE (INSIDE SETTINGS EQUIV. VENT LENGTH EQUIV. VENT LENGTH HEATER INPUT DIAM.) (in. W.C.) MODEL (BTU/HR) N.C. N.O. MAX. MIN. MAX. MIN. 7’ plus 7’ plus term. elbow 50’ term. elbow 45’...

  • Page 34: Vent Screens

    Vent Screens VENT VENT SCREEN WARNING SIZE (INSIDE RESTRICTIVE DEBRIS DIAM.) Breathing Hazard - Carbon Monoxide Gas Failure to install the appropriate screen could result in improper heater operation with attendant risk of property damage, personal injury or death by fire or carbon monoxide 3”...

  • Page 35: Vent Pipe Installation

    Vent Pipe Installation Vent Pipe Runs The following guidelines should be followed when installing 1. The exhaust vent system must not, under any the air intake and exhaust vent system: circumstances, be run downhill then run uphill thus • Venting should be as direct as possible with a minimum forming a valley.

  • Page 36: Vent Pipe Preparation

    VENT PIPE PREPARATION Primer: It is recommended that Tetrahydrofuran (THF) be 1. INITIAL PREPARATION used to prepare the surfaces of pipe and fittings for • Make sure the solvent cement you are planning to solvent welding. Do not use water, rags, gasoline use is designed for the specific application you are or any other substitutes for cleaning PVC or CPVC attempting.
  • Page 37 3. MAKING THE JOINT C. Test dry fit of the joint A. Cutting Tapered fitting sockets are designed so that Pipe must be squarely cut to allow for the proper an interfaced fit should occur when the pipe is interfacing of the pipe end and the fitting socket inserted about 1/3 to 2/3 of the way into the socket.
  • Page 38 Figure 40. F. Joint assembly Working quickly, insert the pipe into the fitting socket bottom and give the pipe or fitting a 1/4 turn to evenly distribute the cement. Do not continue to rotate the pipe after it has hit the bottom of the fitting socket.

  • Page 39: Blower Assembly Installation

    BLOWER ASSEMBLY INSTALLATION Connections To The Blower And Air Duct 1. The CPVC vent piping (5 ft. supplied) connects into 1. This power vented water heater comes with blower the rubber coupling located on the top of the blower assembly installed. assembly.
  • Page 40 Figure 43 shows heaters having 3” direct connection to The restrictive screen (see Figure 37) and the air intake the blower. piping should be secured in place with a screw. To prevent damage to the equipment, first position the restrictive 3”...

  • Page 41: Condensate (Exhaust)

    CONDENSATE (EXHAUST) CONDENSATE (INTAKE) In certain conditions, installations in unconditioned The air intake piping in a direct vent system will normally space or having long horizontal or vertical vent runs can not have any moisture accumulation in it. However, in accumulate condensate.

  • Page 42: Installation Checklist

    INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Vent Termination Water Heater Location Horizontal  Centrally located with the water piping system.  12 in. min. above grade/snow level. Located as close to gas piping and vent pipe system ...

  • Page 43: Lighting Instructions

    LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before This heater is equipped with a Honeywell gas control/ attempting to operate the water heater. Make sure the thermostat and a hot-surface igniter. This control is a burner viewport is not missing or damaged. Make sure combination gas valve, thermostat and ignition controller the tank is completely filled with water before operating for use on this power vented water heater.

  • Page 44: Operating The Temperature Control System

    OPERATING THE TEMPERATURE CONTROL SYSTEM It is recommended that lower water temperatures be used The water heater should be located in an area where to avoid the risk of scalding. It is further recommended, the general public does not have access. If a suitable in all cases, that the water temperature be set for the area is not available, a cover should be installed over the lowest temperature which satisfies your hot-water needs.

  • Page 45: Gas Control Valve/Thermostat

    GAS CONTROL VALVE/THERMOSTAT 140°F 155°F 165°F 181°F 130°F 110°F 70°F ON/OFF TEMPERATURE SWITCH SETTING DIAL Figure 46. Approximate Time to induce a 2nd Temperature Temperature and 3rd Degree burn Dial Setting °F to adult skin VERY HOT Less than 1 second Less than 1 second About 1.5 seconds Less than 5 seconds...

  • Page 46: For Your Information

    FOR YOUR INFORMATION START UP CONDITIONS OPERATIONAL CONDITIONS Condensate Smelly Water Whenever the water heater is filled with cold water, some Each water heater contains at least one anode rod for condensate will form while the burner is ON. A water corrosion protection of the tank.

  • Page 47: Periodic Maintenance

    PERIODIC MAINTENANCE GENERAL UPKEEP Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical Make it a habit to look around the heater, the vent piping, vapors. Spray can propellants, cleaning solvents, and the hot and cold water pipes.

  • Page 48: Combustion Chamber And Burner Cleaning

    operation, make sure that (1) no one is in front of or around the outlet of the T&P valve discharge line, and (2) that BLUE TIPS water discharge will not cause any property damage, as water may be extremely hot. Use care when operating LIGHT BLUE INNER INCORRECT CONES ARE...

  • Page 49: Draining And Flushing

    DRAINING AND FLUSHING To Flush The Water Heater Storage Tank Follow Step 1 through Step 7 in the Periodic draining and cleaning of sediment from the tank “To Drain The Water Heater Storage Tank” section. maybe necessary. It is recommended that the tank be 1.

  • Page 50: Anode Rod Maintenance

    ANODE ROD MAINTENANCE CAUTION Property Damage Hazard • Avoid water heater damage. • Inspection and replacement of anode rod required. Anode Rod. The anode rod is a sacrificial metal rod that helps avoid corrosion and premature failure (leaks) in the tank.

  • Page 51: Leakage Checkpoints

    LEAKAGE CHECKPOINTS SERVICE Leakage from other appliances, water lines, or ground seepage should also be checked. If a condition persists or you are uncertain about the * To check where threaded portion enters tank, insert operation of the water heater contact a service agency. cotton swab between jacket opening and fitting.

  • Page 52: Reference Parts Listing

    REFERENCE PARTS LISTING Replacement parts may be ordered 15 Drain Valve 41 Hot-Surface Igniter (see Figure 3) (see 16 Outer Gas Door also Figure 55) through your plumber or the local 17 Manifold Door Assembly (behind 42 Manifold Door Gasket (see distributor.
  • Page 53 Notes: Natural gas and Propane (LP) main burner with Items not supplied with the water heater. igniter assembly. NG burner ** The side recirculation loop connections may not be shown. LP burner similar used as the primary water inlet and outlet connections. but with drain hole (item 17 See “Combo Heating Inlet And Outlet Side Taps”.

  • Page 54: Troubleshooting Guidelines

    TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service IGNITION STATE AND TIMING agent. IGNITION STATE TIMING 5 seconds (NG models) RESETTING THE HEATER CONTROL Pre-purge • 15 seconds (LP models) Soft lockouts as diagnosed by the system error codes require the gas control to be reset.

  • Page 55: System Status And Error Codes

    SYSTEM STATUS AND ERROR CODES The micro-controller inside the gas control monitors the ignition sequence, temperature settings, and overall operation of the heater. If any of these parameters does not operate properly the controller will shut down the water heater, diagnose the failure and flash an error code.

  • Page 56: Corrective Actions

    CORRECTIVE ACTIONS See the table below for corrective actions corresponding to the Corrective Action Number in the “System Status And Error Codes” section above. If following those corrective actions does not resolve the error, refer to “Other Symptoms“ table later in this manual.
  • Page 57 Corrective Action Corrective Action Number 1. Gas supply is turned off or gas pressure is too low. Ensure supply pressure and manifold gas pressures are within requirements. Manifold pressure is nonadjustable, if gas supply pressure proves correct and manifold pressure is off by more than 0.3” WC replace the control. 2.

  • Page 58: Other Symptoms

    OTHER SYMPTOMS Problem Possible Cause(S) Corrective Action 1. Thermostat set too low 1. Turn temperature knob to higher setting 2. Leaking faucets/Wasted hot water 2. Repair faucets 3. Wrong piping connections 3. Correct piping: dip tube must be in cold inlet Insufficient 4.

  • Page 59: Limited Warranty

    LIMITED WARRANTY COMMERCIAL WATER HEATER LIMITED WARRANTY EFFECTIVE WHAT’S NOT COVERED For 3 Years, in the event of a tank leak, we will repair or, at our • Problems caused by improper: gas supply line sizing, gas type, discretion, replace the defective water heater. venting, connections, combustion air, voltage, wiring, or fusing For 1 Year, in the event of part failure, we will repair or, at our...
  • Page 60 500 Tennessee Waltz Parkway, Ashland City, TN 37015 • Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com Copyright © 2018 A. O. Smith Corporation. All rights reserved.

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