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A.O. Smith PREFERRED BPD 400 Installation, Operation, Service, Maintenance, Limited Warranty

Gas-fired induced draft for domestic hot water
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AOS PREFERRED-BPD 400 DIRECT VENT
COMMERCIAL GAS WATER HEATER
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
WARNING: If the information in these
instructions 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
flammable 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 supplier'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.
Thank you for buying this energy efficient water heater from
A.O. Smith Water Products Company. We appreciate your
confidence in our products.
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED IN U.S.A. 0206
GAS-FIRED INDUCED DRAFT
FOR DOMESTIC HOT WATER
CAUTION
A DIVISION OF A.O. SMITH CORPORATION
Mc BEE, SOUTH CAROLINA
1
Part Number 197279-000

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  Summary of Contents for A.O. Smith PREFERRED BPD 400

  • Page 1 Thank you for buying this energy efficient water heater from A.O. Smith Water Products Company. We appreciate your confidence in our products. CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY.
  • Page 2: Rough-In Dimensions

    40 F 50 F 60 F 70 F 17 C 22 C 28 C 33 C 39 C 1316 (4981) (3735) (2988) (2490) (2135) GAS VALVE PIPING BPD-400 3/4" NPT "F" "G" "H" "I" LINE 21.75 63.50 2.25 58.00 1.00 900 lbs.
  • Page 3: Typical Installation

    TYPICAL INSTALLATION INTAKE FOR COMBUSTION AIR VENT TO OUTDOORS FLUE PRODUCTS DISCHARGE PIPE SUPPLY Installation Information: for Model BPD 400 100 Series ELECTRICAL CLEARANCES 120/24VAC 60Hz FRONT 6 "= (15 cm) UNIT IS POLARITY SENSITIVE AIR INTAKE PIPE TEMPERATURE PRESSURE RELIEF VALVE PRESSURES SIDES...
  • Page 4: Table Of Contents

    FOREWORD These designs comply with the current version of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3 as automatic circulating tank water heaters, and automatic storage water heaters. Detailed installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary.
  • Page 5: General Safety Information

    INSULATION BLANKETS Insulation blankets available to the general public for external use on gas water heaters are not approved for use on your A.O. Smith water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. Your A.O.Smith water heater meets or exceeds the ASHRAE/ IES 90.1b -1999 standards...
  • Page 6: Features

    foot of air. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction would result in an over-firing of the heater causing sooting, poor combustion and/or unsatisfactory heater performance.
  • Page 7: Electronic Ignition Control

    between 15 and 25 psi (103 kPa and 173 kPa). Flow pressures above 25 psi (173 kPa), or below 15 psi (103 kPa), will result in improperly sanitized dishes. Where pressures are high, a water pressure reducing or flow regulating control valve should be used in 180°F (82°C) line to the dishwashing machine, and should be adjusted to deliver water between these limits.
  • Page 8: Step Down Transformer

    STEP DOWN TRANSFORMER The controls system utilizes a 120/24 VAC step down transformer. Most of the control system utilizes 24 VAC for operation. See wiring diagram for those components utilizing 24 VAC and 120 VAC. P120/24 VAC STEP DOWN TRANSFORMER BURNER TRAY ASSEMBLY The appliance is equipped with a user friendly burner tray assembly.
  • Page 9: High Limit Switch

    HIGH LIMIT SWITCH The surface mounted high limit switch monitors the flue gases escaping through the blower assembly to ensure the temperatures do not exceed the rating for the CPVC/PVC vent pipe utilized on the venting. FIGURE 4 HIGH LIMIT SWITCH SHROUD ASSEMBLY The shroud assembly protects the top of the appliance where the blower and junction box are located.
  • Page 10: Clearances

    CLEARANCES The unit is approved for installation on combustible flooring in an alcove when the minimum clearance to combustibles is maintained per Figure 6 and the table below. (RIGHT SIDE) (LEFT SIDE) 0" (0cm) 0" (0cm) 0" (0cm) A service clearance of 24" (61 cm) should be maintained from serviceable parts, such as relief valves, flue baffles, flue damper devices, thermostats, cleanout openings or drain valves.
  • Page 11: Facts To Consider About The Location

    WARNING THE LOCATION SELECTED MUST PROVIDE CLEARANCES FOR SERVICING AND PROPER OPERATION OF THE WATER HEATER. WARNING VENT TERMINATION MUST NOT BE WITHIN 4 FEET OF ANY ITEMS SUCH AS GAS METERS, GAS VALVES OR OTHER GAS REGULATING EQUIPMENT. WARNING FAILURE TO HAVE REQUIRED CLEARANCES BETWEEN WATER HEATER AND COMBUSTIBLE MATERIAL WILL RESULT IN A FIRE HAZARD.
  • Page 12: Water Piping

    FIGURE 10 WATER PIPING WARNING HOTTER WATER CAN SCALD: WATER HEATERS ARE INTENDED TO PRODUCE HOT WATER. WATER HEATED TO A TEMPERATURE WHICH WILL SATISFY CLOTHES WASHING, DISH WASHING, AND OTHER SANITIZING NEEDS CAN SCALD AND PERMANENTLY INJURE YOU UPON CONTACT. SOME PEOPLE ARE MORE LIKELY TO BE PERMANENTLY INJURED BY HOT WATER THAN OTHERS.
  • Page 13: Filling The Water Heater

    FILLING THE WATER HEATER CAUTION NEVER USE THIS WATER HEATER UNLESS IT IS COMPLETELY FILLED WITH WATER. TO PREVENT DAMAGE TO THE TANK, THE TANK MUST BE FILLED WITH WATER. WATER MUST FLOW FROM THE HOT WATER FAUCET BEFORE TURNING "ON" GAS TO THE WATER HEATER. To fill the water heater with water: 1.
  • Page 14 WIRING DIAGRAM FOR ROBERTSHAW CONTROL SYSTEM - NATURAL GAS ONLY NOTE: If any of the original wire as supplied with the water heater must be replaced, it must be replaced with 105°C thermoplastic AWM wire or its equivalent. LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
  • Page 15: Venting

    VENTING WARNING TO INSURE PROPER VENTING OF THIS GAS-FIRED WATER HEATER, THE CORRECT VENT PIPE DIAMETER MUST BE UTILIZED. ANY ADDITIONS OF OTHER GAS APPLIANCES ON VENT WITH THIS WATER HEATER ARE PROHIBITED AS THEY WILL ADVERSELY AFFECT THE OPERATION OF THE WATER HEATER.
  • Page 16 VENTING (CONT'D) TYPICAL INSTALLATION - UP TO 110' (33.5 m) Follow illustration above if making an immediate horizontal run of vent off the blower fittings on top of the water heater. 1. The water heater requires its own (separate) venting system. 2.
  • Page 17 3. Minimum vent length is 18" (46 cm) when 4" pipe is used and 45' (13.7 m) when 6" pipe is used. CEMENTING PVC OR CPVC PIPE AND FITTINGS Read and observe all safety information printed on primer, cleaner, and cement containers. DANGER PRIMER, CLEANER, AND CEMENTS ARE EXTREMELY FLAMMABLE.
  • Page 18 The 4" or 6" PVC Schedule 40 or CPVC Schedule 40 or 80 vent pipes can be run from the water heater through the wall or from the wall to the water heater, whichever is most convenient. The vent pipes must extend a minimum of 1 1/2"...
  • Page 19: Venting Through Roof

    CONNECTING VENT TO BLOWER - 6" VENT PIPING 1. If making an immediate horizontal run of vent off the blower, a 7 1/ 4" (18.4cm) min. long PVC Schedule 40 pipe section and an elbow are required for the inlet pipe. A 4" min. long CPVC Schedule 40 pipe section (supplied), one CPVC Schedule 40 or 80 regular elbow and one CPVC Schedule 40 or 80 street elbow are required for the outlet vent.
  • Page 20: Gas Piping

    3. 4" or 6" PVC Schedule 40 or CPVC Schedule 40 or 80 piping and fittings are acceptable materials for the inlet vent system and for the outlet vent system after the first ten feet. See vent length chart below. 4.
  • Page 21: Sediment Trap

    Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible.
  • Page 22: Operational Sequence- Natural Gas Models Only

    Before the water heater will operate: 1. The control system must be connected to a 110/120 power supply. This control system has an overall rating of 12 amps or less. The water heater must be securely and adequately grounded in accordance with the local codes or, in the absence of local codes, with the current edition of the National Electrical Code, ANSI/NFPA 70.
  • Page 23: For Your Safety

    FOR Y Y Y Y Y OUR SAFETY READ BEFORE OPERA OUR SAFETY READ BEFORE OPERA OUR SAFETY READ BEFORE OPERA OUR SAFETY READ BEFORE OPERA OUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 24: Temperature Regulation

    TEMPERATURE REGULATION DANGER HOT WATER CAN SCALD: WATER HEATERS ARE INTENDED TO PRODUCE HOT WATER. WATER HEATED TO A TEMPERATURE THAT WILL SATISFY SPACE HEATING, CLOTHES WASHING, DISH WASHING, AND OTHER SANITIZING NEEDS CAN SCALD AND PERMANENTLY INJURE YOU UPON CONTACT. SOME PEOPLE ARE MORE LIKELY TO BE PERMANENTLY INJURED BY HOT WATER THAN OTHERS.
  • Page 25: Smoke/Odor

    SMOKE/ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while. THERMAL EXPANSION Water supply systems may, because of such events as high line pressure, frequent cutoffs, the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc...
  • Page 26: Water Is Too Hot

    pilot. If the water was extremely hot and is now cold, the high limit safety temperature shut off may have put out the burner and pilot. Refer to “High Temperature Shut Off System” in this section. 4. The gas control knob must be turned to the “ON” position. 5.
  • Page 27: Housekeeping

    for cleaning, call the local gas utility to remove and clean the burner and correct the problem that required the burner to be cleaned. HOUSEKEEPING Vacuum around base of water heater for dust, dirt, and lint on a regular basis. WARNING TO INSURE SUFFICIENT VENTILATION AND COMBUSTION AIR SUPPLY, PROPER CLEARANCES FROM THE WATER HEATER MUST...
  • Page 28: Installation Diagrams

    INSTALLATION DIAGRAMS ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION ONE TEMPERATURE - ONE HEATER HORIZONTAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 24. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT...
  • Page 29 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE FIXTURES. TEMPERATURE CONTROL WARNING ON PAGE 24. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
  • Page 30 TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER HEATER) MUST BE IDENTICAL HEATERS FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT SPECIFICATIONS, PAGE 33. CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK-FLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED.
  • Page 31 TWO TEMPERATURE - TWO HEATERS (ONE PRE-HEATER/ONE BOOSTER HEATER) DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 24. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES WITH OR WITHOUT BUILDING RECIRCULATION * PIPE RELIEF VALVE TO OPEN DRAIN...
  • Page 32 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 24. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
  • Page 33: Manifold Kits

    MANIFOLD KITS Precision cut type “L” all copper A.O. Smith manifold kits assure water flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life.
  • Page 34: Sediment Removal

    Replacement parts may be ordered through A.O. Smith dealers, authorized servicers or distributors. Refer to the Yellow Pages for where to call or contact A.O. Smith Water Heater Parts Fulfillment, 125 Southeast Parkway, Franklin, TN, 1-800-527-1953. When ordering parts be sure to state the quantity, part number as it appears on the product.
  • Page 35: Model Bpd 400 Limited Warranty

    Model BPD 400 Limited Warranty A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. 1. THE TANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years after initial installation, the warrantor will supply a complete new A.
  • Page 36 A.O. SMITH WATER PRODUCTS CO. 500 Tennessee Waltz Parkway, Ashland City, TN 37015 PHONE: 1-800-433-2545 • FAX: 1-800-433-2515 www.hotwater.com / email: parts@hotwater.com...