Installation and Operating Manual COMMERCIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES MODELS BPD-80 SERIES 210, 211 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.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . . 3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Qualified Installer Or Service Agency . . . . . . . . . . . . 6 Preparing For The Installation . . . . . . . . . . . . . . . . . . 6 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7 TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . .
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. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY DANGER Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. HOT Temperature limiting valves are available. BURN Read instruction manual for safe temperature setting. WARNING Fire or Explosion Hazard • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
GENERAL SAFETY DANGER WARNING Breathing Hazard - Carbon Monoxide Gas • Install vent system in accordance with codes. • Do not operate water heater if flood damaged. • For operation above 10,100’, a high altitude orifice must be installed. • Do not operate if soot buildup is present. • Do not obstruct water heater air intake with insulating jacket. FLAMMBLE Flammable Vapors • Do not obstruct blower air intake. • Do not place chemical vapor emitting products near water heater.
INTRODUCTION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations found in this Installation and Operating manual: • CSA - Canadian Standards Association • ANSI - American National Standards Institute • NFPA - National Fire Protection Association • ASME - American Society of Mechanical Engineers • UL - Underwriters Laboratories Inc. • AHRI - Air Conditioning, Heating and Refrigeration Institute.
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 n
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 TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Termination Elbow with Rodent Screen 2 *Vent Pipe 3 *Coupling (if required) 4 CPVC Vent Pipe (5 ft.
Natural gas and Propane (LP) main burner with igniter assembly. NG burner shown. LP burner similar but with drain hole (item 17 in Figure 1). 39 Flare Nut †† 20 40 38 41 42 46 43 45 44 Figure 3 Shown with Junction Box Cover removed for clarity. 33 31 32 47 52 48 51 50 49 Figure 4 Vacuum relief valve install per local codes (not supplied with heater). Figure 5 Notes: * Items not supplied with the water heater.
WATER PIPING - MIXING VALVE USAGE Mixing Valves DANGER Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. HOT BURN Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures.
Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm and the physically/mentally disabled. Table 1 (published by U.S. Government Memorandum, 1978) shows the approximate time-to-burn relationship for normal adult skin.
CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. POWER VENT WIRING SCHEMATIC. ELECTRICAL REQUIREMENTS & WIRING DIAGRAM WARNING Electric Shock Hazard Disconnect power before servicing. NOTE: REFER TO THE “Installation Checklist” BEFORE OPERATING THIS HEATER. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
SAFETY LOCKOUTS This water heater has several lockout features designed to prevent the heater from operating in unsafe conditions. HIGH LIMIT CONTROLS (ENERGY CUT OFF) Thermostat/Water Temperature This feature is a part of the gas control valve/thermostat (see Figure 1, item 12) and limits the maximum water temperature. In the event of the water overheating, this safety feature shuts off the fuel supply to the burner.
LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed: 1.
Clearances To Combustibles Minimum clearances between water heater and combustibles are 0 in. at the sides and rear, 5.5 in. from the front and 12 in. from top (standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater (see Figure 12). Floors With Carpeting This water heater must not be installed directly on carpeting.
Important Notes and Warnings • This heater is certified to be installed using Schedule • • • • • 40 PVC or CPVC or polypropylene plastic vent material. Only use approved material. All venting material and components must be joined with the approved primer/ cleaner and solvent cement or mechanical seals. To join PVC and CPVC materials, use ATSM F-493 compliant cement. Do not common vent this heater with any other appliance.
INSTALLING THE NEW WATER HEATER WATER PIPING DANGER Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. HOT BURN Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures. The water supply pressure should not exceed 80 psi.
COMBO HEATING This section serves as a guide for the installation and use of “Combo” heating systems utilizing a domestic water heater that has been specifically approved for such use. It is written for those knowledgeable in the required trades and professionals involved in the design and installation of Combo Heating Systems. It is the responsibility of the installer/designer to follow all applicable codes to ensure the effectiveness and safety of the installation.
CLOSED WATER SYSTEMS Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure-reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. Note: To protect against untimely corrosion of hot and cold water fittings, it is recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe.
For safe operation of the water heater, the temperaturepressure relief valve must not be removed from its designated opening nor plugged. The T&P valve must be installed directly into the fitting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit the pipe within 6 in. above an adequate floor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building.
5. Spread the slit open and slip the insulation over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure it is fully seated around the pipe. Also, ensure the base of the insulation is flush with the water heater. Once seated, secure the insulation with duct tape, electrical tape, or equivalent. 6. Repeat steps 4 and 5 for the hot water (outlet) pipe. 7. Add additional sections of pipe insulation as needed.
SEDIMENT TRAPS WARNING WARNING Fire and Explosion Hazard • Use joint compound or tape compatible with natural gas and propane. • Leak test before operating heater. • Disconnect gas piping and shut-off valve before pressure testing system. Use pipe joint compound or Teflon tape marked as being resistant to the action of gases. Fire and Explosion Hazard • Contaminants in gas lines can cause fire or explosion. • Clean all gas piping before installation. • Install sediment trap in accordance with NFPA 54.
FILLING THE WATER HEATER CAUTION CAUTION Improper Installation, use and service may result in property damage. Property Damage Hazard This unit includes an air intake terminal and an exhaust vent terminal. • Avoid water heater damage. • Fill tank with water before operating. WARNING • Do not insert the power cord into the electrical receptacle until the heater has been fully installed.
This water heater has a direct vent system in which all air for combustion is taken from the outside atmosphere and all combustion products are discharged to the outdoors. This water heater must be properly vented for removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the safe and efficient operation of this water heater and is an important factor in the life of the unit. A Vent Kit included with this water heater consists of: 1.
TERMINATION CLEARANCES (SIDEWALL) R RNE E CO INSIDDETAIL V Vent terminal X Air supply inlet G Area where is not permitted V A D E V B B V C D FIXE D SE CLO V L B V B E ERABL OP F D FIXE ED LOS BLE C RA OPE V B V V I M V X X K J A B Gas meter / regulator Figure 21 Vent terminal clearances for “Power Direct Vent” installations.
Side Wall Vent Terminal Installation Important: When terminating the vent on a side wall, the following specifications pertaining to terminal location must be followed (see Figure 22). 1. The air intake terminal and the exhaust vent terminal must terminate on the same exterior wall. 2. The vertical centerline of the air intake terminal must be located at a minimum of 8 in. and not more than 24 in. from the vertical centerline of the exhaust vent terminal. 3.
ORIENTATION OF EXHAUST PIPING AND COMBUSTION AIR PIPING RELATIVE TO EACH OTHER MAY BE VERTICAL (AS SHOWN) OR AT ANY OTHER ANGLE TO SUIT THE INSTALLATION. STRAP (FIELD SUPPLIED) PIPE NIPPLE (USE WITH ELBOW) 90° ELBOW (SEE LOCAL CODES) COMBUSTION AIR EXHAUST SLOPE 1/4 in. OVER 5 ft. COMBUSTION AIR 1 in. MAXIMUM WALL SCREEN INSIDE ELBOW (FIELD SUPPLIED) Figure 25 VENT DIA. P/N 3” 9006328005 NOTE: IF AN ELBOW IS REQUIRED BY LOCAL CODES INSTALL SCREEN IN ELBOW INSTEAD OF CONCENTRIC VENT EXHAUST.
WATER HEATER MODEL HEATER INPUT (Btu/hr) VENT SIZE (Inside Diam.) 2 PIPE MAX. EQUIV. VENT LENGTH 2 PIPE MIN. EQUIV. VENT LENGTH CONC. VENT MAX. EQUIV. VENT LENGTH 50’ + term. elbow 7’ + term. elbow 30’ + term. elbow and screen* and screen* and screen* 75 gal. 76,000 125’ + term. elbow 50’ + term. elbow 4” N/A and screen* and screen* * see Figure 29, “Venting Terminations And Sizing” and “Vent Screen Installation”.
with 3” venting (short) VENT LENGTH LESS THAN OR EQUAL TO 20 EQUIVALENT FT. USE THIS SCREEN (SUPPLIED). with 3” venting (long) VENT LENGTH GREATER THAN 20 EQUIVALENT FT. USE THIS SCREEN (SUPPLIED). with 4” venting VENT LENGTH GREATER THAN 50 EQUIVALENT FT. USE THIS SCREEN (SUPPLIED).
WARNING Fire or Explosion Hazard • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • Avoid all ignition sources if you smell gas. • Do not expose water heater control to excessive gas pressure. • Use only gas shown on rating plate. • Maintain required clearances to combustibles. • Keep ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing water heater.
C. Test dry fit of the joint Tapered fitting sockets are designed so that an interfaced fit should occur when the pipe is inserted about 1/3 to 2/3 of the way into the socket. Occasionally, when pipe fitting dimensions are at the tolerance extremes, it will be possible to fully insert dry pipe to the bottom of the fitting socket. When this happens, a sufficient quantity of cement must be applied to the joint to fill the gap between the pipe and fitting.
Vent Pipe Installation The following guidelines should be followed when installing the air intake and exhaust vent system: • Venting should be as direct as possible with a minimum number of pipe fittings. • Vent diameter must not be reduced unless specifically noted in the installation instructions. • Support all horizontal pipe runs every 4 ft. and all vertical pipe runs every 5 ft. or according to local codes or venting manufacturer’s instructions.
b. Cut the flexible power cord, leaving enough to be able to make connections. Remove the strain relief fitting from the box. c. Install a suitable conduit fitting inside the enclosure. d. Splice field wiring into existing wiring using code authorized method (wire nuts, etc). e. Be certain that the neutral and line connections are not reversed when making these connections. f. Ground heater properly.
Coupling Installations According To Vent Sizes 3” INLET PIPE 3” CPVC VENT PIPE SOUND SUPPRESSOR WITH SCREEN INTA VENKE T TERM INAL 3” RUBBER COUPLING (SUPPLIED) EXHAUST VENT TERMINAL BLOWER AIR DUCT ADAPTER CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 3” VENTING. (OPTIONAL CONFIGURATION FOR LO-INPUT HEATERS CONNECTED TO 3” VENTING.) Figure 40 Figure 37 4” CPVC VENT PIPE 3”-4” CPVC ADAPTER (FIELD SUPPLIED) 4” INLET PIPE 3” CPVC VENT PIPE, 3 in. MAX LENGTH 3” RUBBER COUPLING (SUPPLIED.
INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Water Heater Location Centrally located with the water piping system. Located as close to gas piping and vent pipe system as possible. Located indoors and in a vertical position. Protected from freezing temperatures. Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor.
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner viewport is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch” and must be turned on before the water heater is operational. Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas.
OPERATING THE TEMPERATURE CONTROL SYSTEM It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisfies your hot-water needs. This will also provide the most energy efficient operation of the water heater.
GAS CONTROL VALVE/THERMOSTAT 140°F ON/OFF SWITCH TEMPERATURE SETTING DIAL 155°F 165°F 130°F 110°F 181°F 70°F Figure 41 Approximate Temperature Temperature Dial Setting °F Time to induce a 2nd and 3rd Degree burn to adult skin VERY HOT 181 Less than 1 second C 165 Less than 1 second B 155 About 1.5 seconds A 140 Less than 5 seconds HOT 130 More than 30 seconds LOW 110 Normal shower temp VAC 70 N/A Table 5 Note: The temperatures indicated are approximate.
FOR YOUR INFORMATION START UP CONDITIONS Condensate Whenever the water heater is filled with cold water, some condensate will form while the burner is ON. A water heater may appear to be leaking when in fact the water is condensate. This usually happens when: a. A new water heater is filled with cold water for the first time. b. Burning gas produces water vapor in water heaters, particularly high efficiency models where flue temperatures are lower. c.
PERIODIC MAINTENANCE GENERAL UPKEEP Make it a habit to look around the heater, the vent piping, and the hot and cold water pipes. Do not allow any material to be piled up against the heater. Do not place any object on top of the vent pipes. Every 3 - 6 months or as necessary: • Clean lint from blower, top of heater. Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors.
BLUE TIPS LIGHT BLUE INNER CONES ARE SATISFACTORY INCORRECT FLAME LAZY YELLOW CORRECT FLAME SOFT BLUE Figure 43 COMBUSTION CHAMBER AND BURNER CLEANING In the event your burner or burner air openings require cleaning, Call your service agency to remove and clean the burner and correct the problem that required the burner to be cleaned.
DRAINING AND FLUSHING Periodic draining and cleaning of sediment from the tank maybe necessary. It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. See “Typical Installation” section in this manual for location of the water heater components described below. DANGER • Burn hazard. • Hot water discharge.
ANODE ROD MAINTENANCE Each water heater contains at least one anode rod, which will slowly deplete (due to electrolysis) prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water usage, hydronic heating devices, and water softening methods can increase the rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak.
LEAKAGE CHECKPOINTS SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a service agency. Use this guide to check a “leaking” water heater. Many suspected “leakers” are not leaking tanks. Often the source of the water can be found and corrected. If you are not thoroughly familiar with gas codes, your water heater and safety practices, contact your gas supplier or qualified installer to check the water heater.
REFERENCE PARTS LISTING Replacement parts may be ordered through your plumber or the local distributor. When ordering replacement parts, always have the following information ready: 1. Model, Serial and Product number 2. Type of gas 3. Item number 4. Parts description 1 Termination Elbow with Rodent Screen 2 *Vent Pipe 3 *Coupling (if required) 4 CPVC Vent Pipe (5 ft.
Natural gas and Propane (LP) main burner with igniter assembly. NG burner shown. LP burner similar but with drain hole (item 17 in Figure 1). 39 Flare Nut †† 40 38 41 42 46 43 45 44 Figure 50 Shown with Junction Box Cover removed for clarity. 33 31 32 47 52 48 51 50 49 Figure 51 Notes: * Items not supplied with the water heater. ** The side recirculation loop connections may not be used as the primary water inlet and outlet connections. See “Combo Heating Inlet And Outlet Side Taps”.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent. RESETTING THE HEATER CONTROL • Soft lockouts as diagnosed by the system error codes • • require the gas control to be reset. To reset the control, slide the “ON/OFF” switch to the “OFF” position. Wait for 10 seconds and move the switch back to the “ON” position. If the problem that caused the control to lock out has not been corrected, the control will remain or again go back into lockout.
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. The table below lists the System Status Codes for the Honeywell control. Refer to it and to the “Ignition State And Timing” to diagnose the problem before attempting corrective action.
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. Corrective Action Number Corrective Action 1 Normal operation, no action necessary. 2 Normal operation, no action necessary. 3 1. Flame rod not properly seated in flame, reposition rod. 2.
Corrective Action Number Corrective Action 8 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. Low supply voltage - should be 115 - 125 VAC 3. Ensure flame sensor is making good contact with the burner flame and flame is steady. 4.
OTHER SYMPTOMS Problem Insufficient Hot Water Water Is Too Hot Slow Hot Water Recovery Drip From Relief Valve Smelly Water Condensation Possible Cause(S) 1. 2. 3. 4. 5. 6. 7. Thermostat set too low Leaking faucets/Wasted hot water Wrong piping connections Water heater too small Sediment or lime in tank Long runs of exposed piping Hot-water piping in outside wall 52 1. 2. 3. 4. 5. 6. 7.
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 discretion, replace the defective water heater. • Problems caused by improper: gas supply line sizing, gas type, venting, connections, combustion air, voltage, wiring, or fusing For 1 Year, in the event of part failure, we will repair or, at our • Failure to follow applicable codes discretion, replace the defective part.
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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 © 2013 A. O. Smith Corporation. All rights reserved.
