Instruction Manual
COMMERCIAL ELECTRIC WATER HEATERS
MODELS DVE-150 THRU DVE-10000
DHE-200 THRU DHE 10000
INSTALLATION - OPERATION - SERVICE MAINTENANCE - LIMITED WARRANTY
A DIVISION OF A.O. SMITH CORPORATION
RENTON, WASHINGTON
ASME
Thank you for buying this energy efficient water
heater from A.O. Smith Water Products Company. We
appreciate your confidence in our products.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED IN THE U.S.A 1207
1
09063340-000
SAFE INSTALLATION, USE, AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
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. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, could result
in death or injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
• Qualified Installer or Service Agency:
Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field
involved. Installation skills such as plumbing, air supply, venting, gas supply, electrical supply are required in addition to electrical testing
skills when performing service.
• ANSI Z223.1 2006 Sec. 3.3.83:
“Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of
appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all
the requirements of the authority having jurisdiction.”
2
GENERAL SAFETY
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
3
TABLE OF CONTENTS
WIRING DIAGRAMS......................................................... 12-13
OPERATION............................................................................14
General............................................................................14
Filling the Water Heater...................................................14
Start Up............................................................................14
Draining the Water Heater...............................................14
TEMPERATURE REGULATION.............................................14
Temperature Adjustment..................................................15
High Termperature Devices.............................................15
MAINTENANCE......................................................................15
General............................................................................15
Temperature-Pressure Relief Valve Operation.......... 15-16
Flushing...........................................................................16
Sediment Removal..........................................................16
Water and LIme Scale Removal......................................16
Strange Sounds......................................................... 16-17
TROUBLESHOOTING CHECKLIST.......................................17
Not Enough or No Water..................................................17
Water Is Too Hot..............................................................17
Water Heater Makes Strange Sounds.............................17
Leakage Checkpoints......................................................17
If You Cannot Identify or Correct the Source of Malfunction............ 17
SAFE INSTALLATION, USE AND SERVICE............................2
GENERAL SAFETY..................................................................3
TABLE OF CONTENTS.............................................................4
INTRODUCTION.......................................................................4
Preparing for the New Installation......................................4
DIMENSIONS AND CAPACITIES DATA...................................5
FEATURES AND COMPONENTS........................................ 6-7
LOCATING THE NEW WATER HEATER..................................8
INSTALLATION.........................................................................8
Required Ability..................................................................8
General..............................................................................8
Mixing Valve Usage...........................................................8
Chemical Vapor Corrosion.................................................8
Circulating Pump...............................................................9
Insulation Blankets.............................................................9
Temperature-Pressure Relief Valve...................................9
ELECTRICAL..........................................................................10
General............................................................................10
Branch Circuit..................................................................10
Heater Circuits.................................................................10
Control Circuits................................................................10
Power Circuits..................................................................10
WARRANTY............................................................................18
NOTES....................................................................................19
ELECTRICAL AND RECOVERIES DATA................................11
INTRODUCTION
2. The installation must conform with these instructions and the
local code authority having jurisdiction and the requirements of
the power company. In the absence of code requirements, follow
NFPA-70 (current edition). The National Electrical Code may be
ordered from: National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269.
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, contact A.O. Smith
Water Products Customer Care Center at 1-800-527-1953.
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
4. Carefully plan your intended placement of the water heater.
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
• UL - Underwriters Laboratory
Preparing for the Installation
1. Read the “General Safety” section of this manual first and then
the entire manual carefully. If you don’t follow the safety rules,
the water heater may not operate safely. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
A sample rating plate and barcode tag are shown on page 3 of this
manual. In order to expedite your request, please have the serial
number and item ID from the barcode tag available for the technician.
INSTALLATION AND SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN OR QUALIFIED AGENCY (Page 2) IN THE
FIELD INVOLVED. PLUMBING AND ELECTRICAL WORK ARE
REQUIRED.
5. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may
be obtained from California Office of the State Architect, 1102 Q
Street, Suite 5100, Sacramento, CA 95811.
This manual contains instructions for the installation, operation,
and maintenance of the electric water heater. It also contains
warnings throughout the manual that you must read and be aware
of. All warnings and all instructions are essential to the proper
operation of the water heater and your safety. READ THE ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE
THE WATER HEATER.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
4
dimensions and capacities data
5
FEATURES AND COMPONENTS
NOTE: Your actual configuration may vary.
DVE
Vertical Water Heater (typical).
6
FEATURES AND COMPONENTS
NOTE: Your actual configuration may vary.
DHE
Horizontal Water Heater (typical).
7
LOCATING THE NEW WATER HEATER
Facts to Consider About the Location
The pan should be at least 2 inches deep, have a minimum
length and width of at least 2 inches greater than the dimensions
of the water heater and should be piped to an adequate drain.
The discharge opening of the relief valve should always be piped
to an open drain.
3. Close to the point of major hot water usage and the power
supply.
Hot water piping and branch circuit wiring should be as short as
possible.
Insulate hot and cold water piping where heat loss and condensation
may be a problem.
Carefully choose a location for the new water heater. 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.
Heater construction permits installation, maintenance, and service
work to be performed through the front and right side openings.
Whether replacing an old water heater or putting the water heater in
a new location, the following critical points must be observed. The
water heater must be located:
Suggested clearances from adjacent surfaces are 12 inches on
top, 30 inches in front and 24 inches on right side for access
to the unit.
1. On a level surface. Shim the channel type skid base as necessary
if levelling is required.
The heater may be installed on or against combustible surfaces. The
left side and back may be placed flush against adjacent surfaces.
Be sure to place the cover plates over the rear crating couplings
before locating vertical model heaters. The heater may be installed
in a confined space if adequate ventilation is provided.
2. Near a floor drain. The heater should be located in an area where
leakage of the tank or connections will not result in damage to the
area adjacent to the heater or to lower floors of the structure.
The temperature of the space in which the water heater is installed
must not go below 32°F or above 122°F.
When such locations cannot be avoided, a suitable drain pan
should be installed under the heater.
INSTALLATION
REQUIRED ABILITY
dish washing, cleaning 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. These include
the elderly, children, the infirm, or physically/developmentally
disabled. If anyone using hot water in your home fits into one of
these groups or if there is a local code or state law requiring a
maximum water temperature at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means
such as a MIXING VALVE, should be used at the hot water taps
used by these people or at the water heater.
INSTALLATION AND SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A QUALIFIED
AGENCY (PAGE 2) IN THE FIELD INVOLVED. PLUMBING AND
ELECTRICAL WORK IS REQUIRED.
general
The installation must conform to these instructions and the local code
authority having jurisdiction. Grounding and electrical wiring connected
to the water heater must also conform to the National Electrical Code,
NFPA 70. This publication is available from The National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
MIXING VALVES for reducing point of use temperature are available.
Consult a qualified installer or service agency. Follow all manufacturer’s Instructions for installation of these valves. Before changing the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual, see Page 14.
Do NOT test electrical system before heater is filled with water, follow
the START UP procedure in the OPERATION section of this manual.
The principal components of the heater are identified in the
Features and Components illustrations on pages 6 and 7.
Chemical Vapor Corrosion
This water heater shall not be connected to any heating system(s) or
component(s) used with a non-potable water heating appliance.
Toxic chemicals, such as those used for boiler treatment shall not
be introduced into this system.
MIXING VALVE USAGE:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
8
Water heater corrosion and component failure can be caused by
the heating and breakdown of air borne chemical vapors. Spray
can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, water softener chemicals,
calcium and sodium chloride, waxes, and process chemicals are
typical compounds which are potentially corrosive. These materials
are corrosive at very low concentration levels with little or no odor to
reveal their presence.
If replaced, the valve must meet the requirements of local codes,
but not less than a combination temperature and pressure relief
valve certified as indicated in the above paragraph. Contact the
A.O. Smith Customer Care Center for replacement
temperature & pressure relief valves 800-527-1953.
Products of this sort should not be stored near the heater. Also, air
which is brought in contact with the water heater should not contain
any of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources.
CIRCULATING PUMP
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than
the water heater input rate as shown on the model rating plate.
The temperature setting of the relief valve should not exceed
210°F.
Field installed circulating pumps should be of all bronze
constructions.
For safe operation of the water heater, the relief valve must NOT
be removed from its designated opening nor plugged.
To optimize the total storage capacity of a horizontal vessel,
particularly under low draw conditions, it is recommended to utilize a
pump and recirculation line sized to turn the entire storage capacity
of the tank once each hour (i.e., a 600 gallon tank would require a
10 gpm pump).
The temperature-pressure relief valve must be installed directly
into the fitting of the water heater designed for the relief valve.
Provide tubing so that any discharge will exit only within 6 inches
(153 mm) above an adequate drain or external to the building
or structure. Be certain that no contact is made with any live
electrical part. The discharge opening must NOT be blocked
or reduced in size under any circumstances. Excessive length,
over 30 feet (9.14 m), or use of more than four elbows can cause
restriction and reduce the discharge capacity of the valve.
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on electric water heaters but are not necessary with this product. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the EPACT and ASHRAE/IES 90.1 standards with respect
to insulation and standby loss requirements, making an insulation
blanket unnecessary.
Do NOT place shut-off valve or other obstruction between the
temperature-pressure relief valve and the tank. Relief valve
discharge piping must be provided by the installer. The discharge
tube must be threaded directly into the relief valve opening
and routed to the nearest drain. There cannot be any valves
or obstructions in the discharge piping and excessive lengths
should be avoided. Improper installation of the relief valve
discharge tubing can result in system failure, property damage,
injury, or death.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death.
• Do not cover the temperature and pressure relief (T & P) valve
with an insulation blanket.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels for placement on
the blanket directly over the existing labels.
TEMPERATURE-PRESSURE RELIEF VALVE
Once the water heater is installed and filled with water, check
the operation of the temperature-pressure relieve valve. Follow
the instructions in the Maintenance section of this manual, see
Page 15.
A.O. Smith Water Products Company has provided this water heater
with a properly certified temperature & pressure relief valve.
If after manually operating the valve it fails to completely reset
and continues to release water, immediately close the cold water
inlet to the water heater, follow the “Draining” instructions and
replace the temperature-pressure relief valve with a properly
rated/sized new one.
The valve is certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of Listed equipment
of materials as meeting the requirements for Relief Valves for Hot
Water Supply Systems, ANSI Z21.22 and the ASME code.
9
ELECTRICAL
General
Check the water heater model and rating plate information against
the characteristics of the branch circuit electrical supply. Do not
connect the heater to an improper source of electricity.
Voltage applied to the heater should not vary more than +5% to -10%
of the model and rating plate marking for satisfactory operation.
Do NOT energize the branch circuit for any reason before the water
heater tank is filled with water. Doing so may cause the heating
elements to fail.
The factory wiring is attached to a terminal block on the unit. The
branch circuit is connected to the block through an opening provided
on the heater. Factory terminal block has 500 MCM maximum copper
wire size capacity in each opening. If apparent field wire size is over
500 MCM multiple terminal blocks will be furnished. If other opening
sizes are desired they should be specified when unit is ordered.
The installation must conform to these instructions and the local
code authority having jurisdiction. Grounding and electrical wiring
connected to the water heater must also conform to the National Electrical
Code, NFPA 70. This publication is available from The National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
Branch Circuit
The branch circuit wire size should be established through reference
to the NEC (National Electrical Code) or other locally approved
sources in conjunction with the water heater amperage rating.. Wire
rated at 75°C should be used. For convenience, portions of the wire
size tables from the Code are reproduced in Table 1. It is suggested
the electrician size the branch circuit at 125 percent of the heater
rating and further increase wire size as necessary to compensate
for voltage drop in long runs. Voltage drop should not exceed 3%
at the water heater.
Heater Circuits
The water heater’s electrical components are pictured and identified
by the Features and Components illustrations on pages 6 and 7.
The model and rating plate illustration identifies the heater electrical
characteristics. The heater has two electrical circuits:
Control Circuit: 120V circuit containing all safety and control devices.
The control circuit operates the contactors in the power circuit.
These ampacities relate only to conductors
described in Table 310-13 of the NEC.
For ambient temperatures over 30°C, see
Correction Factors, Note 13 in the NEC.
Power Circuit: High voltage, single or three phase circuit that carries
the heating element load.
TABLE 1. BRANCH CIRCUIT WIRE SIZE.
The following section and pages describe the water heater circuits
and includes wiring diagrams.
Additional instructional literature is provided with heaters equipped
with modulating solid state step control or a sequencer.
Control Circuits
All control circuits are operated on single-phase 120 volt current.
The heater is equipped with one of the following control circuits,
resulting in:
Control circuit wiring is 14 Awg, AWM (Appliance Wiring Material)
type, rated 600 volts, 105°C.
A. Thermostats (mechanical)... where all of the heating elements
are switched on/off by one or more thermostats. Heaters
with thermostat control are adjusted as described in TEMPERATURE
REGULATION section of this manual, see Page 14.
Standard equipment includes control circuit fusing.
Power Circuit
B. Step controlled element operation...where elements are staged
on/off individually or in groups rotationally by the controller.
An optional feature is modulation which operates in conjunction with
the staged on/off element operation.
Power circuit wiring is type THHN (or equivalent) rated 600 volts,
105°C, sized as necessary.
The following wiring diagrams are included in this manual to show
typical arrangements of electrical components in the control and power
circuits by voltage and phase characteristics. They are to be used as a
reference by the installer or servicer in performing their work. An actual
diagram of the water heater wiring is furnished with the heater.
C. Sequencer... operates in conjunction with a thermostat (mechanical).
The sequence is activated by a thermostat then the sequence
switches on the heater elements in 3 sequences (multiple elements
and contactors are required).
10
electrical and recoveries data
TABLE 2.
11
WIRING DIAGRAMS
TURN OFF THE HEATER ELECTRICAL SUPPLY BEFORE SERVICING ANY ELECTRICAL COMPONENTS.
300-600 VOLTS STANDARD THERMOSTAT CONTROL WIRING (WYE).
12
WIRING DIAGRAMS
TURN OFF THE HEATER ELECTRICAL SUPPLY BEFORE SERVICING ANY ELECTRICAL COMPONENTS.
208-240 VOLTS, STANDARD THERMOSTAT CONTROL WIRING (DELTA)
13
OPERATION
GENERAL
6. Close the hot water faucet when water starts to flow from the
faucet. Leave the cold water inlet valve fully open. The heater
is now ready for start up and temperature regulation.
7. Close the cabinet door and perform start up checks listed below
before turning on the electricity.
Refer to the Features and Components section of this manual
(pages 6 & 7) for the location of components mentioned in the
instructions that follow.
NEVER operate the heating elements without being certain the water
heater is filled with water, and a temperature and pressure relief valve
is installed in the relief valve opening on top of the heater.
START UP
The following checks should be made by the installer when the water
heater is placed into operation for the first time:
An electric type low water cutoff is provided on all heaters as standard
equipment. The water probe is installed near the top of the tank to
monitor the presence of water. The control circuit is opened if the
water level is below this point.
1. Check all factory and field made water and electrical connections
for tightness. Also check connections on top of the heater. Repair
water leaks and tighten electrical connections as necessary.
2. Turn on the electrical disconnect switch and pilot toggle switch.
The pilot toggle switch is located on cabinet.
3. Observe the operation of the electrical components during the
first heating cycle. Use care as the electrical circuits
are energized.
The pilot switch (power on/off toggle switch) on the cabinet front
permits the heater to be turned on and off without having to operate
the electrical disconnect switch.
Temperature control and contactor operation should be checked
by allowing heater to come up to temperature and shut off automatically.
USE CARE AS THE ELECTRICAL CIRCUITS ARE ENERGIZED.
DRAINING THE WATER HEATER
The water heater must be drained if it is to be shut down and/
or exposed to freezing temperatures. Maintenance and service
procedures may also require draining the heater.
1. Turn off the electrical disconnect switch.
2. Turn off pilot toggle switch.
3. Close the cold water inlet valve to heater.
4. Open a nearby hot water faucet to vent the system.
5. Open drain valve.
6. If the heater is being drained for an extended shutdown, it is
suggested the drain valve be left open during this period.
Optional manual override switches on the cabinet front allow elements
to be manually de-energized if full capacity is not needed.
Filling the Water Heater
Follow FILLING instructions when restoring hot water service, see
the list above.
To fill the water heater with water:
1. Turn off the electrical disconnect switch.
2. Turn off pilot toggle switch.
3. Close the heater drain valve.
4. Open a nearby hot water faucet to allow the air in the system to escape.
5. Fully open the cold water inlet valve, filling the heater and piping.
TEMPERATURE REGULATION
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which will
satisfy space heating, clothes washing, dish washing, and other
sanitizing needs can instantly scald and permanently injure you
upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly,
children, the infirm, or physically/developmentally disabled.
If anyone using hot water in your home fits into one of these
groups or if there is a local code or state law requiring a certain
temperature water at the hot water tap, then you must take special
precautions. In addition to using the lowest possible temperature
setting that satisfies your hot water needs, a means such as
a mixing valve, should be used at the hot water taps used by
these people or at the water heater. Mixing valves are available
from your local plumbing contractor. Follow manufacturer’s
14
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the entire “Temperature Regulation”
section in this manual.
Without the circulating pump, horizontal model heaters should be
set not higher than 165°F. Vertical models may be set as desired,
not to exceed 185°F.
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 thermostat be set for the lowest temperature
which satisfies your hot water needs. This will also minimize water
scale formations on the heating elements and provide the most
energy efficient operation of the water heater. Thermostat(s) are
factory set at 120°F (49°C) unless specified differently by state
requirements.
Where multiple thermostats are used on a vertical model
heater, they may all be set at the same temperature or 2° to 4°F apart
to achieve “step control”. The bottom thermostat is set the hottest
and the top thermostat the coolest.
Temperature Settings
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
KEEPING THE THERMOSTAT SETTING AT 120°F WILL REDUCE
THE RISK OF SCALDS.
180°F (82°C)
160°F (71°C)
150°F (66°C)
140°F (60°C)
130°F (54°C)
120°F (49°C)
80°F (27°C)
Nearly Instantaneous
About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
----------------
Figure 1 shows the approximate time-to-burn relationship for
normal adult skin.
TEMPERATURE ADJUSTMENT
FIGURE 1.
TEMPERATURE CONTROL (MECHANICAL THERMOSTAT)
FIGURE 2A.
Solid State Step Control (with or without modulation)
Additional instructional literature is provided with the heater
sequencer control.
HIGH TEMPERATURE DEVICES
Thermostat Temperature Control
A manual reset temperature high limit is in the control circuit
in addition to the automatic device previously described. The
contacts open at 210°F and must be manually reset after the
temperature hi-limit switch has been activated and the water
temperature is below 210°F.
When the water heater circulating pump (optional) is provided,
horizontal and vertical model heater thermostats may be set to 185°F
if dishwasher rinse water is supplied by the heater.
The reset button is located on the temperature hi-limit in the
control cabinet of the heater. Disconnect the power before
opening the door to push the reset button.
Always close and lock the cabinet door after making a temperature
adjustment. Turn on electricity.
MAINTENANCE
General
ANODE INSPECTION AND REPLACEMENT
Water heater maintenance includes inspection and testing of the
Temperature Pressure Relief Valve, periodic tank flushing and
cleaning, and removal of lime scale from the heating elements.
Where used, water heating system circulating pumps should
be oiled.
This water heater is equipped with a sacrificial anode. Anodes
protect the glass-lined tank from corrosion by sacrificing
themselves through electrolysis. When the anode material is
consumed, there is no more protection and corrosion of the tank
accelerates.
Tank flushing and circulating pump lubrication should be
performed in accordance with the maintenance schedule, see
Table 6 on page 16. Tank sediment removal and element lime
scale removal must be performed when needed as determined
by periodic inspections.
Inspection of the anode every 6 to 12 months allows you to identify
a spent anode and replace it. Replace the anode when its diameter
is 3/8” (1 cm) of an inch, or annually which ever is first. Aggressive,
very hot and softened water causes rapid consumption of the
anode requiring frequent inspections. Anodes are available from
your distributor or A.O. Smith.
15
Temperature-Pressure Relief Valve Operation
WATER AND LIME SCALE REMOVAL
Water and lime scale accumulations on the heating elements is a
normal condition, common to all immersion type elements. Factors
which affect the amount of this formation are:
1. Amount of hot water used. As the volume of water heated
increases, more scale results.
2. Water temperature. As the temperature of the water is increased,
more scale is deposited on the elements.
3. Mineral level characteristics of the water supply. Regardless of
water treatment, the elements should be examined regularly.
STRANGE SOUNDS
The temperature-pressure relief valve must be
manually operated at least once a month. Lift the lever at the top
of valve several times until the valve seats properly and operates
freely, see Figure 2B.
Water scale accumulations may cause noises to occur during
operation.
It is recommended that a lower heating element be removed
periodically for examination. If it is scaled, all of the elements should
be removed and cleaned. If the tank bottom has an accumulation of
sediment, it should be cleaned.
When checking the temperature-pressure relief valve operation, make
sure that (1) no one is in front of or around the outlet of the temperaturepressure relief valve discharge line, and (2) that the water discharge
will not cause any property damage, as the water may be extremely
hot. Use care when operating valve as the valve may be hot.
Lime scale should be removed by dissolving the accumulation in
UN-LINE delimer. UN-LIME is a non-muriatic delimer, available
through water heater distributors. Do not use muriatic or
hydrochloric acid base deliming solutions to remove lime scale
from the elements.
All models: do not pour delimer into tank.
1. Turn off electrical disconnect switch.
2. Drain heater following DRAINING instructions, see Page 14.
3. Disconnect the wires attached to the elements terminals. Try not to
disturb the wiring unnecessarily and reconnection will be easier.
4. Remove the bolts from each element and remove the elements
from the openings.
FIGURE 2B.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions in the Operation
section of this manual, and replace the temperature-pressure relief
valve with a properly rated/sized new one, see Page 9.
If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal expansion. Consult your
local water supplier or a Qualified Service Agency for further information.
Do not plug the temperature-pressure relief valve.
Component
Tank
Elements
Operation
Interval
Flushing
Monthly
Sediment
Removal
As Needed
Lime Scale
Removal
As Needed
Use a twisting, pulling action to remove elements scaled beyond
the size of the tank openings.
Brush loose scale from elements.
Silicates, sulfates and aluminates must be removed by scraping or
other mechanical means. Lime scale dissolvents will not remove
these types of scale which are occasionally encountered.
5. Lime scale removal:
Place limed ends of heating elements into UN-LIME delimer and
allow scale to dissolve. Do not permit delimer or water to contact
heating element electrical terminals.
Required
6. Flush cleaned ends of elements with water when deliming or
cleaning is completed.
7. Remove sediment and scale from the tank bottom through the
access provided by the element opening or tank cleanout, if
furnished.
UN-LIME delimer
and element
gaskets
The cold water inlet valve and drain valve may be opened to air
the cleanout process.
8. Clean remaining gasket material from tank and element flanges.
Do not reuse original element gasket.
table 6. maintenance schedule.
FLUSHING
9. Replace elements as follows:
1.
2.
3.
4.
Put a new gasket on each element.
Install into tank opening from which element was removed.
Uniformly tighten element bolts. Torque to approximately 32 ft/lbs.
Turn off the electrical disconnect switch.
Open the drain valve. Allow water to flow until it runs clean.
Close the drain valve when finished flushing.
Turn on the electrical disconnect switch.
SEDIMENT REMOVAL
10.Attach wires to element terminals from which they were
removed.
Water borne impurities consist of fine particles of soil and sand which
settle out and form a layer of sediment on the bottom of the tank. In time,
if not removed, the level of sediment might reach the heating elements
causing premature heating element failure.
11.Follow FILLING instructions in the Operation section of this
manual to restore hot water service, see Page 14.
For convenience, sediment removal and element lime scale removal
should be performed at the same time as follows:
16
Check for water leaks around elements and proper operation
when heater is filled and during operation.
TROUBLESHOOTING CHECKLIST
Before calling for service, check the following points to see if the
cause of trouble can be identified and corrected. Reviewing this
checklist may eliminate the need of a service call and quickly restore
hot water service.
7. Sediment or lime scale may be affecting water heater operation.
Refer to the MAINTENANCE section of this manual for details.
The illustration in the Features and Components section of this
manual identifies the location of most of the heater components,
see Pages 6 and 7.
Refer to the TEMPERATURE REGULATION section of this manual.
Water is too hot
Water Heater makes strange sounds
1. Sediment or lime scale accumulations on the elements causes
sizzling and hissing noises when the heater is operating.
The sounds are normal, however, the tank bottom and elements
should be cleaned. Refer to MAINTENANCE section of this manual
for details.
2. Some of the electrical components of the water heater make
sounds which are normal ie. contactors will “Click” or snap as the
heater starts and stops.
Leakage checkpoints
1. Check to see if the drain valve is tightly closed.
2. The apparent leakage may be condensation which forms on cool
surfaces of the heater and piping.
BE SURE TO TURN OFF THE ELECTRICITY (ELECTRICAL
DISCONNECT SWITCH) WHEN CHECKING EQUIPMENT.
3. If the outlet of the relief valve is leaking it may represent:
Excessive water pressure.
Excessive water temperature.
Faulty relief valve.
Not enough or no hot water
1. Be certain the electrical disconnect switch serving the water
heater is in the ON position. The pilot toggle switch on the cabinet
should be ON.
Excessive water pressure is the most common cause of relief valve
leakage. 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.
In some areas water heater electrical service may be limited by the
power company. If the heater operates on a controlled circuit, heater
recovery may be affected.
The optional manual override switches on the cabinet front may be
turned off, de-energizing the elements.
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase in
water pressure due to thermal expansion. Thermal expansion can
cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build
up. This condition is not covered under the limited warranty. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion.
2. Check the fuses.
The electrical disconnect switch usually contains fuses.
The water heater has fuses located behind the cabinet front door,
see the Features and Components section of this manual on pages
6 and 7.
3. If the water was excessively hot, and is now cold, the temperature
hi-limit cutoff may have tripped open.
A properly sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a local qualified service agency to have a thermal expansion
tank installed.
To reset, turn off the electricity, open the control cabinet door, and
push the reset button.
4. Examine the flange area of the elements for gasket leakage.
Repeated operation of the temperature hi-limit cutoff should be
investigated by a qualified installer or service agency.
Tighten the bolts or, if necessary, follow the WATER AND LIME
SCALE REMOVAL procedure in the MAINTENANCE section of this
manual to replace the gaskets.
4. The storage capacity and/or recovery rate of the water heater
may have been exceeded by a large demand for hot water. See
pages 5 and 11.
IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE
OF MALFUNCTION:
Large demands require a recovery period to restore water temperature.
1. Place the water heater electrical disconnect switch in the OFF
position.
5. Cold incoming water temperature will lengthen the time required
to heat water to the desired temperature.
2. Close the cold water inlet valve to the heater.
If the heater was installed when incoming water temperature was
warm, colder water creates the effect of less hot water.
3. Contact the A.O. Smith Water Products Company Customer Care
Center at 800-527-1953.
17
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. O. Smith water heater of equivalent size
and current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale
of a model of equivalent size and construction, A. O. Smith will provide a model which complies with the regulations of your area, in which case
the consumer will be charged the difference in price between the like replacement and the energy efficient model required. The warranty on the
replacement water heater will be limited to the unexpired term of the original warranty.
2. ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective in
material or workmanship, the warrantor will repair or replace such part or portion at its option.
3. CONDITIONS and EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by A.G.A.and
approved by the American Society of Mechanical Engineers, must have been installed.
a. This warranty shall apply only when the heater is used:
(1) at temperatures not exceeding the maximum setting of its thermostat;
(2) at water pressure not exceeding the working pressure shown on the water heater;
(3) when filled with potable water, free to circulate at all times;
(4) in a noncorrosive and non-contaminated atmosphere;
(5) in the United States, its territories or possessions, and Canada.
(6) used with factory approved anode(s) installed;
(7) in its original installation location;
(8) sized in accordance with proper sizing techniques for commercial water heaters;
(9) bearing a rating plate which has not been altered, defaced or removed except as required by the warrantor;
(10) not used in a closed system without a properly sized and installed thermal expansion tank;
(11) fired at the proper voltage and wattage;
(12) maintained in accordance with the instructions printed in the manual included with the heater.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, or any attempt to repair tank leaks will void this warranty.
4. SERVICE and REPAIR EXPENSE
Under this limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other costs.
Such costs may include but are not limited to:
a. Labor charges for service, removal, repair, or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor;
c. All cost necessary or incidental for any materials and/or permits required for installation of the replacement heater or part.
5. LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration for the
heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
6. CLAIM PROCEDURE
Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products.
If this is not practicable, the owner should contact:
U.S. Customers
Canadian Customers
a.
b.
7.
A. O. Smith Water Products Company
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Telephone: 1-800-323-2636
A. O. Smith Enterprises, Ltd.
P. O. Box 310 - 768 Erie Street
Stratford, Ontario N5A 6T3
Telephone: 1-800-265-8520
The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.
Dealer replacements are made subject to in-warranty validation by warrantor.
DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE
MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR, OR REPLACEMENT OF THE HEATER. THE
WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE
TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS
WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND
WHETHER ARISING IN CONTRACT OR IN TORT.
a.
b.
Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the
heater’s rating plate.
Model No.________________________________________Serial No.________________________________Date Installed ________________
Dealer’s Name_________________________________________________________________________________________________________
Dealer’s Address _______________________________________________________________________Phone No. _______________________
City and State __________________________________________________________________________Zip ____________________________
18
NOTES
19
www.aosmithwaterheaters.com
20