A.O. Smith BPD-400 manual

1 A DIVISION OF A.O. SMITH CORPORA TION Mc BEE, SOUTH CAROLINA PLACE THESE INSTRUCTIONS ADJACENT T O HEA TER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE. PRINTED IN U . S .A. 0206 Part Number 197279-000 W ARNING: If the information in these instructions is not followed exactly , a fire or explosion may result causing property damage, personal inj[...]

2 Input Ca pac ity SHIPPING B T U Gallon GAS WEIGHT Model (kw-H r . ) (Liters) " A " " B " " C " "D" "E " "F" " G" "H" " I" LINE ST D ASM E BPD - 400 390,000 95 82.25 80.25 30.25 8.75 4 or 6 21.75 63.50 2.25 58.00 1.00 9 00 lb s. 1 1 00 l bs . (1 14.3) (360) ([...]

3 TYPICAL INST ALLA TION INT A KE FOR COMBUSTION AIR VENT TO OUTDOORS FLUE PRODUCTS DISCHARGE PIPE AIR INT AKE PIPE TEMPERA TURE PRESSURE RELIEF VA LV E V ACUUM RELIEF REQUIRED BY SOME CODES (REFER TO LOCAL CODES) SHUTOFF V AL V E COL D W A TER INLET MIXING V AL V E * TEMPERED W A TER OUTLET HOT W A TER OUTLET GAS SUPPL Y Installation Information: [...]

4 These designs comply with the current version of the American National S t andard for Gas W ater Heaters, V olume 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 referenc[...]

5 SERVED BY THIS HEA TER THA T HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALL Y TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMEL Y FLAMMABLE. T o reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the ho[...]

6 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. Ratings specified by manufacturers for most appliances[...]

7 ROBER TSH A W 47484A PILO T SENSOR R O BER TSHA W DERHC-S7C NA TURAL 1" x 1" GAS V AL VE GAS V AL VE The gas valve is used to supply the gas to the unit during heat up periods. The ignition control module monitors the thermostat's call for heat and sends a signal to the gas valve when to open to allow gas flow. PRESSURE SWITCH The [...]

8 STEP DOWN TRANSFORMER The controls system utilizes a 120/24 V AC step down transformer. Most of the control system utilizes 24 V AC for operation. See wiring diagram for those components utilizing 24 V AC and 120 V AC. P1 20/24 V AC STEP DOWN TRANSFORMER BURNER TRA Y ASSEMBL Y The appliance is equipped with a user friendly burner tray assembly . [...]

9 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 ASSEMBL Y The shroud assembly protects the top of the appliance where the blower and junction[...]

10 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 . AB C D (RIGHT SIDE) (LEFT SIDE) (BACK) (CEILING) 0" (0cm) 0" (0cm) 0" (0cm) 12" (30.5 cm) A service clearance of 24" (61 cm) should be maintaine[...]

11 FIGURE 9 WIRE FENCE When the water heater outlet terminal is low enough to be touched accidentally , or is accessible to small children, a wire mesh chain link fence (as shown in Figure 9) may be used. Care should be taken to maintain adequate ventilation around the outlet terminal. If a chain link fence is installed, it must not be used as a st[...]

12 FIGURE 10 W A TER PIPING WARNING HOTTER W A TER CAN SCALD: W A TER HEA TERS ARE INTENDED T O PRODUCE HOT W A TER. W A TER HEA TED T O A TEMPERA TURE WHICH WILL SA TISFY CLOTHES W ASHING , DISH W ASHING , AND OTHER SANITIZING NEEDS CAN SCALD AND PERMANENTL Y INJURE YOU UPON CONT AC T . SOME PEOPLE ARE MORE LIKEL Y TO BE PERMANENTL Y INJURED BY HO[...]

13 FILLING THE W A TER HEA TER CAUTION NEVER USE THIS W A TER HEA TER UNLESS IT IS COMPLETEL Y FILLED WITH W A TER. T O PREVENT DAMAGE TO THE T ANK, THE T ANK MUST BE FILLED WITH W A TER. W A TER MUST FLOW FROM THE HOT WA TER F AUCET BEFORE TURNING "ON" GAS TO THE W A TER HEA TER. T o fill the water heater with water: 1. Close the water h[...]

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. CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPER[...]

15 VENTING WARNING T O INSURE PROPER VENTING OF THIS GAS-FIRED W A TER HEA TER, THE CORRECT VENT PIPE DIAMETER MUST BE UTILIZED. ANY ADDITIONS OF OTHER GAS APPLIANCES ON VENT WITH THIS W A TER HEA TER ARE PROHIBITED AS THEY WILL ADVERSEL Y AFFECT THE OPERA TION OF THE W A TER HEA TER. WARNING OBSTRUCTED OR DETERIORA TED VENT SYSTEMS MA Y PRESENT SE[...]

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. Only 6" CPVC Schedule 40 or 80 piping and fittings are acceptable materials for [...]

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 EXTREMEL Y FLAMMABLE. THEY ARE HARMFUL OR F A T AL IF SW[...]

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" (3.8 cm) through the exterior wall. Extending the vent caps as far as possible from the surface of t[...]

19 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[...]

20 gas control valve could result in a fire or explosion from leaking gas. WARNING If the main gas line shutoff serving all gas appliances is used, also turn “OFF” the gas at each appliance. Leave all gas appliances shut off until the water heater installation is complete. CORRECT GAS PIPE SIZE FOR W A TER HEA TERS OPERA TING ON NA TURAL GAS TO[...]

21 Before attaching the gas line be sure that all gas pipe is clean on the inside. T o 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. Install in accordance with the “Gas Piping” section. Refer to the current edit[...]

22 Before the water heater will operate: 1. The control system must be connected to a 1 10/120 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 Electric[...]

23 A . This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERA TING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor . WHA T TO DO IF YOU SMELL GAS • Do not try to[...]

24 TEMPERA TURE REGULA TION DANGER HOT W A TER CAN SCALD: W A TER HEA TERS ARE INTENDED TO PRODUCE HOT W A TER. W A TER HEA TED TO A TEMPERA TURE THA T WILL SA TISFY SP ACE HEA TING , CLOTHES W ASHING , DISH W ASHING , AND OTHER SANITIZING NEEDS CAN SCALD AND PERMANENTL Y INJURE YOU UPON CONT ACT . SOME PEOPLE ARE MORE LIKEL Y T O BE PERMANENTL Y I[...]

25 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, ha[...]

26 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. The temperature adjustment dial may be set too low. See the “Temperature Re[...]

27 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 BE MA[...]

28 ONE TEMPERA TURE - ONE HEA TER HORIZONT AL ST ORAGE T ANK FORCED CIRCULA TION WITH OR WITHOUT BUILDING RECIRCULA TION DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE TEMPERA TURE A T FIXTURES. SEE W A TER TEMPERA TURE CONTROL W ARNING ON P AGE 24. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY T O OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANT[...]

29 * PIPE RELIEF V AL VE TO OPEN DRAIN. NOTE: IF TEMPERED WA TER IS RECIRCULA TED, RETURN LINE SHOULD BE CONNECTED A T POINT “A”. INST ALL IN ACCORDANCE WITH LOCAL CODES. TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE TEMPERA TURE A T FIXTURES. SEE W AT[...]

30 TWO TEMPERA TURE - TWO HEA TERS HIGH TEMPERA TURE WITH OR WITHOUT BUILDING RECIRCULA TION TWO TEMPERA TURE - THREE HEA TERS (TWO PRE-HEA TERS/ONE BOOSTER HEA TER) WITH OR WITHOUT BUILDING RECIRCULA TION MUST BE IDENTICAL HEA TERS FOR MUL TIPLE HEA TER INST ALLA TION SEE MANIFOLD KIT SPECIFICA TIONS, P AGE 33. CAUTION : IF BUILDING COLD W A TER S[...]

31 * PIPE RELIEF V A L VE TO OPEN DRAIN * * 140°F (60°C)TO 150°F (66°C) SHOULD BE MAXIMUM WA TER TEMPERA TURE MAINT AINED IN THE PRE-HEA TERS. 120°F (49°C) SHOULD BE THE MINIMUM TEMPERA TURE OF W A TER IN THE PRE- HEA TERS. CONNECT CIRCULA TING LINE FROM FIXTURES, IF USED, T O COLD W A TER SUPPL Y LINE OF PRE-HEA TER. CONNECT CIRCULA TING LIN[...]

32 NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C) W ATER CIRCULA TION. INST ALL ON OR CLOSE TO DISHW ASHER. TOGGLE SWITCH MUST BE CLOSED (ON) DURING THE RINSE OPERA TION AND OPEN (OFF) WHEN DISHW ASHER IS NOT OPERA TING OR WHEN ON LONG ST ANDBY . NOTE 2: INST ALL LINE TEMPERA TURE CONTROL IN AN UNINSULATED TEE BEYOND THE DISHWASHER T AKEOFF IN THE S[...]

33 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. Unions shown in piping diagrams are not included in the man[...]

34 SEDIMENT REMOVAL Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank. For convenience, sediment removal and lime scale removal should be performed at the same time. LIME SCALE REMOVAL The amount of calcium carbonate (lime) released from water is in direct proport[...]

35 Model BPD 400 Limited Warranty A. O. Smith Corporation, the warrantor, extends the following LIMITED W ARRANTY to the owner of this water heater . 1. THE T ANK 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[...]

36 A.O. SMITH WATER PRODUCTS CO. 500 T ennessee Waltz Parkw a y, Ashland City, TN 3701 5 PHONE: 1-800-433-2545 • FAX: 1-800- 433-2515 www.hotwater.com / email: parts@hotwater.com[...]