Bradford White RE120WV6 Wall Hung Electric Service manual

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Bradford White RE120WV6 Wall Hung Electric Service manual | Manualzz

RESIDENTIAL ELECTRIC AND LIGHT DUTY

COMMERCIAL ELECTRIC WATER HEATERS

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

Models Covered by This Manual:

Residential Energy Saver:

M1& M2(HE) UprightModels.

M1& M2 Lowboy Models.

M1& M2 UtilityModels.

M1& M2 Wall HungModels.

Light DutyEnergy Saver:

LD Upright Models.

LD Utility Models.

LD Lowboy.

LD WallHung.

Dairy Barn Deluxe Energy Saver:

DB Models.

Photo is of

M-2-50T6DS

Manual 238-47104-00A Save this manual for future reference

2

Residential and Light Duty

Commercial Electric Water Heaters

Table of Contents

Page Service Procedure

Introduction ………………………………………………………………………. 2

Tools……………………………………………………………………………… 2

General Information ……………………………………………………………… 3

Sequence of Operation …………………………………………………………… 6

Single Element Operation ……………………………………................... 6

Double Element, Non-Simultaneous, Single Phase………………………. 7

Double Element, Simultaneous, Single Phase, 4 wire Service …............... 8

Double Element, Non-Simultaneous, 3 Phase ………................................ 9

Double Element, Simultaneous, 3 Phase ………………………………… 10

Double Element, Non-Simultaneous, Single Phase, Off Peak …………... 11

Troubleshooting …………………………………………………………………. 12

Line Voltage and High Limit ECO Testing……………………………………… 14

Heating Element Testing ……………................................................................... 15

Residential Thermostat Testing ……..................................................................... 16

Single Element ……………………………............................................... 16

Double Element, Non-Simultaneous, Single Phase ………....................... 17

Double Element, Non-Simultaneous, 3 Phase …………………………... 19

Double Element, Simultaneous, 3 Phase ………………………………... 21

Double Element, Non-Simultaneous, Single Phase, Off Peak ………….. 23

Light Duty Commercial Thermostat Testing …..................................................... 25

Double Element, Non-Simultaneous, Single Phase ……………………... 25

Double Element, Simultaneous, Single Phase …………………………... 27

Double Element, Simultaneous, 3 Phase ………………………………... 31

RE IV

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

- - -

RE-I

RE-II

RE-III

Thermostat Removal and Replacement …………………………………………. 33

Heating Element Removal and Replacement ……………………………………. 34

Dip Tube and Anode Inspection and Replacement ……………………………… 35

RE-V

RE-VI

RE-VII

Generic Parts List ………………………………………………………………... 36 - - -

Introduction

This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair of

Bradford White residential electric and light duty commercial electric water heaters.

The text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshooting procedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using the methods described in this service manual.

- Multi Meter.

- 1-½ Deep Well Socket (element removal).

- ¼" Nut Driver.

Tools

- Phillips Head Screw Driver.

- Thermometer.

- Drain Hose.

- Various Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers,

Flash Light.

Page 2

GENERAL INFORMATION

Commonly Used Formulas

Amps = Watts (for single phase units) Example 4500W/240V = 18.75A

Volts

Amps = Watts (for balanced 3 phase units) Example 4500W/240V x 1.732 = 10.82A

Volts x 1.732

Watts = Amps x Volts Example 18.75A x 240V = 4500W

Ohms = Volts Example (240V) / 4500W = 12.8 Ohms

Watts

2

2

Common Service Wire Configurations

120 VOLT 240 VOLT

BLACK

Ungrounded

WHITE

Grounded

(Neutral)

BLACK

Ungrounded

120

120

0 240

120

120

Neutral

208 3Ph

A B

120

120

120

208

208

208

C

RED BLACK RED

Neutral

240 3Ph

A B

120

120

120

240

240

240

C

RED BLACK RED

Page 3

480 3Ph/277 1 Ph

Neutral A B C

277

277

277

480

480

480

RED BLACK RED

3

4

Wattage Limitations at Various Voltages

Residential Electric Upright M1 & M2 Series (Non-Simultaneous operation)

Residential High Efficiency Upright M2HE Series (Non-Simultaneous operation)

Residential Electric Lowboy M1 & M2 Series (Non-Simultaneous Operation)

Dairy Barn Deluxe DB Series (Non-Simultaneous Operation)

Voltage Maximum

Wattage

3,000

6,000

Element

Upper/Lower

3 , 0 0 0 / 3 , 0 0 0

6,000/6,000

1 2 0

208, 240

6,000 6,000/6,000 277, 480

Residential Electric Upright M1 & M2 Series (Simultaneous Operation)

Residential High Efficiency Upright M2HE Series (Simultaneous Operation)

Residential Electric Lowboy M1 & M2 Series (Simultaneous Operation)

Light Duty Commercial Electric LD Series (Non-Simultaneous Operation)

Light Duty Commercial Electric LD Series (Simultaneous Operation)

Dairy Barn Deluxe DB Series (Simultaneous Operation)

Voltage Maximum

Wattage

3,000

10,000

11,000

12,000

Element

Upper/Lower

1 , 5 0 0 / 1 , 5 0 0

5 , 0 0 0 / 5 , 0 0 0

5 , 5 0 0 / 5 , 5 0 0

6,000/6,000

1 2 0

2 0 8

2 4 0

277, 480

GENERAL INFORMATION

Residential Electric Utility Series (Single Element Operation)

Light Duty Utility Series (Single Element Operation)

Voltage Maximum

Wattage

3,000

6,000

6,000

6,000

Single

Element

3 , 0 0 0

6 , 0 0 0

6 , 0 0 0

6 , 0 0 0

1 2 0

2 0 8 , 2 4 0

2 7 7

4 8 0

Page 4

GENERAL INFORMATION

Surface Mounted Thermostats

Surface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the tank.

Surface mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperature settings and high limit (ECO) activation. It is import that the entire back surface of the thermostat is in full contact or flush with the tank. Improperly mounted thermostat will lead to improper heater operation.

Manual

ECO (high limit)

Reset button

Temperature control Dial

Temperature control Dial

Surface Mount

Combination Thermostat/

ECO (high limit)

89T Series

Surface Mount

Combination Thermostat/

ECO (high limit)

89T Series

Direct Immersion “Screw-in” Type Heating Element

Surface Mount

Thermostat

59T Series

1-½ Hex

Screw-in Flange

Terminal Block

Zinc Plated Copper or

Incoloy Sheath

Terminal Block

Screw

Element Rating Ink Stamped on side of Terminal Block.

Page 5

5

6

SEQUENCE OF OPERATION

Residential and light duty commercial electric water heaters are designed to operate using several different operating modes. The common modes and sequence of operation are as follows:

1. Single Element Operation.

2. Double Element Non-Simultaneous Operation (single phase).

3. Double Element Non-Simultaneous Operation (3 phase).

4. Double Element Simultaneous Operation (single phase).

5. Double Element Simultaneous Operation (3 phase).

Sequence of Operation- Single Element Operation.

1 Line voltage is applied across terminals

L1 &L3 of the thermostat. ECO is closed, so there is voltage at terminal L4 and to one side of the element.

1

ECO

Closed

2 Tank is cold therefore thermostat is closed at terminal T2 (calling for heat).

This completes the circuit and allows current to flow through the element.

Thermostat closed at terminal T2

2

3 When the thermostat is satisfied, it opens at terminal T2 interrupting current flow through the element. System is now in stand-by mode, waiting for the next call for heat.

Thermostat opens at terminal T2

3

Page 6

SEQUENCE OF OPERATION

Non-Simultaneous and Simultaneous Operation

Double element electric water heaters are designed to operate in a Non-Simultaneous or Simultaneous mode.

Non-Simultaneous Mode: Allows only one heating element to operate at a time. For example, when the tank is cold, the upper element is energized first, heating the top of the tank. Only when the upper thermostat is satisfied, the upper element is de-energized and power is directed to the lower thermostat, energizing the lower element and heating the bottom portion of the tank until the lower thermostat is satisfied. As hot water is drawn off the tank, it is replaced with cold water delivered through the dip tube to the bottom of the tank. The bottom of the tank cools, the lower thermostat will call for heat energizing the lower element. If enough hot water is drawn from the tank, the top portion of the tank cools and the upper thermostat will call for heat, de-energizing the lower element and allowing only the top element to energize until the upper thermostat is satisfied.

Sequence of Operation- Double Element, Non-Simultaneous Operation, Single Phase.

3

4

1

2

Line voltage is applied across terminals

L1 & L3 of the upper thermostat. ECO is closed, so there is voltage at terminal L4 and to one side of the upper and lower elements.

Tank is cold therefore both thermostats are closed at terminal T2 & 2 (calling for heat). The circuit is complete through the upper thermostat only, allowing current to flow through upper element.

When upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to terminal 1 of lower thermostat. This completes the circuit through the lower thermostat and allows current flow through lower element.

When the lower thermostat is satisfied, it opens at terminal 2 interrupting current flow through lower element. The system is now in stand-by mode waiting for the next call for heat

1

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

ECO

Closed Thermostat closed at terminal T2

Thermostat closed at terminal 2

5 The lower thermostat/element combination will generally cycle on and off more often then the upper. In some cases, such as a cold tank or in high demand periods, the upper thermostat will call for heat

(opening at terminal

Thermostat closed at terminal T4 T4 and closing at terminal T2) prior to the lower thermostat being satisfied. This will interrupt current flow through the lower thermostat and element and allow current to flow through the upper element only. When the upper thermostat is satisfied, it resumes operation as described in sequence #3 above.

3

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

Thermostat open between terminals

1 and 2

4

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

Thermostat closed at terminal T2

Thermostat closed between terminals

1 and 2

2

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

5

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

Page 7

7

8

SEQUENCE OF OPERATION

A 4 wire, double element heater wired for simultaneous operation is essentially two single element systems operating independently. The heaters are wired internally with two independent circuits, one circuit for each thermostat/element combination. When installed using a two wire service, the blue and red (or white) wires will be connected together, likewise black and yellow wires will be connected together.

Sequence of Operation- Double Element, Simultaneous Operation, Single Phase, 4 wire service installation.

Circuit two Circuit two

Circuit one

1

Circuit one

2

1

2

Line voltage from circuit one is applied across terminals L1 & L3 of the lower thermostat. Likewise, line voltage from circuit two is applied across terminals L1 &

L3 of the upper thermostat. ECO in both upper and lower thermostat is closed, so there is voltage at terminal L4 of each thermostat and to one side of the upper and lower elements.

Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat).

This completes the circuit through the thermostats and allows current to flow through the elements.

ECO

Closed

ECO

Closed

Thermostat closed at terminal T2

Thermostat closed at terminal T2

3 When either thermostat is satisfied, it will open at terminal T2, interrupting current flow through the corresponding element. As both thermostats satisfy, the system will be in stand-by mode waiting for the next call for heat. Thermostats will operate independent of the other.

Circuit one

3

Thermostat open at terminal T2

Circuit two

Thermostat open at terminal T2

Page 8

SEQUENCE OF OPERATION

Sequence of Operation- Double Element, Non-Simultaneous Operation, 3 Phase.

1

1

4

2

3

Line voltage is applied across terminals L1

& L3 of upper thermostat. Likewise, Line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements.

Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat).

The circuit is complete through the upper thermostat only allowing current to flow through the upper element.

When the upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to terminal L1 of lower thermostat. This completes the circuit through the lower thermostat allowing current flow through lower element.

When the lower thermostat is satisfied, it opens at terminal T2 interrupting the current flow through the lower element. The system is now in stand-by mode waiting for the next call for heat.

Thermostat closed at terminal T4

3

ECO

Closed

ECO

Closed

Thermostat closed at terminal T2

5 The lower thermostat/element combination will generally cycle on and off more often then the upper. In some cases, such as a cold tank or in high demand periods, the upper thermostat will call for heat (opening at terminal T4 and closing at terminal T2) prior to the lower thermostat being satisfied.

This will interrupt current flow through the lower thermostat and element and allow current to flow through the upper element only. When the upper thermostat is satisfied, it resumes operation as described in sequence #3 above.

Thermostat closed at terminal T2

5

Thermostat closed at terminal T2

Thermostat closed at terminal T2

Thermostat closed at terminal T4

Thermostat open at terminal T2

2

4

Thermostat closed at terminal T2

Page 9

9

10

SEQUENCE OF OPERATION

Sequence of Operation- Double Element, Simultaneous Operation, 3 Phase.

1 1

2

Line voltage is applied across terminals L1

& L3 of upper thermostat. Line voltage also extends to terminal L1 of lower thermostat.

Also, line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements.

Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat).

This completes the circuit through the thermostats and allows current to flow through the elements.

ECO

Closed

ECO

Closed

Thermostat closed at terminal T2

Thermostat closed at terminal T2

2

3 When either thermostat is satisfied, it will open at terminal T2, interrupting current flow through the corresponding element. As both thermostats satisfy, the system will be in stand-by mode waiting for the next call for heat. Thermostats will operate independent of the other.

Thermostat open at terminal T2

Thermostat open at terminal T2

3

Page 10

SEQUENCE OF OPERATION

Some electric utility companies will offer discounts for using electricity during “Off Peak” Times of the day. The system allows the use of an “Off Peak” meter, which interrupts power to the lower element during high power demand periods.

Sequence of Operation- Double Element, Non-Simultaneous Operation, Single Phase, Off Peak.

1

2

Line voltage is applied across terminals

L1 & L3 of the upper thermostat. Line voltage from off peak meter is supplied to terminal L1 of lower thermostat. ECO in the upper thermostat is closed, so there is voltage at terminal L4 of upper thermostat and to one side of the upper element.

Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat). The circuit is complete through the upper thermostat only, allowing current to flow through upper element.

From

Off Peak

Meter

3

4

When upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to one side of the lower element. This completes the circuit through the lower thermostat and off peak meter allowing current flow through lower element.

When the lower thermostat is satisfied, it opens at terminal T2 interrupting current flow through lower element. The system is now in stand-by mode waiting for the next call for heat

5 During peak power demand periods as determined by the local utility, the off peak meter will interrupt power to terminal L1 of lower thermostat. Only the top thermostat/element combination is allowed to operate during this period.

From

Off Peak

Meter

3 4

1

ECO

Closed

Thermostat closed at terminal T2

Thermostat closed at terminal T2

Off Peak

Power interrupted

2

5

Thermostat closed at terminal T4

Thermostat closed at terminal T2

Thermostat closed at terminal T2

Thermostat open at terminal T2

Page 11

11

12

TROUBLESHOOTING

Most common cause for improper electric water heater operation can be linked to heating element failure.

When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot

Water” Its always a good idea to check the heating elements first following the procedure on page 15.

Common Heating Element Failures Are:

1.

Dry Firing. Element may be partially submerged in water or most likely, completely exposed with no water in

tank. In some cases sediment or lime build up around an element can eventually cause an air pocket, and

within seconds, result in a dry fired element. At this point the element becomes inoperative. When element

replacement is required, be sure tank is full of water prior to energizing the water heater.

2.

Grounded Element. An element with a short circuit to ground will in most cases cause the circuit breaker in

the service panel to open or shut off. In some cases there may not be enough current draw for the circuit

breaker to open. This will allow the heating element to be in continuous operation resulting in over heated

water, limited only by the ECO or Energy Cut Off located in the thermostat. Repeated actuation of the ECO

reset button on the thermostat usually is the result of a grounded element.

3.

Sediment build up. Slow hot water recovery can usually be traced back to sediment or lime build up around

heating element. Sediment build up can also over time cause a dry fired element.

Illustration 1, below shows a common “Screw-In” type heating element identifying certain features commonly referred to throughout this manual.

1-½ Hex

Screw-in Flange

Terminal Block

Zinc Plated Copper or

Incoloy Sheath

Terminal Block

Screw

Element Rating Ink Stamped on side of Terminal Block.

Illustration 1

Typical Direct Immersion “Screw-In”

Type Heating Element

Page 12

TROUBLESHOOTING

Quick Step Plan to Hot Water

1. TURN OFF power to water heater and check all wire

connections to insure they are tight and corrosion free.

2. Turn power “ON” and determine that service voltage is

present, and the high limit (ECO) has not actuated

(see procedure on page 14).

3. Check for inoperative heating element (see procedure on page 15).

WARNING

High voltage exposure. Use caution when making voltage checks to avoid personal injury.

4. Check for proper thermostat operation (see procedures beginning on page 16). NOTE: Thermostat testing procedures

assume items 2 and 3 above are in working order.

SYMPTOM

No Hot Water

Not Enough Hot

Water

Slow Hot Water

Recovery

Over Heated

Water or

Continues

Operation

PROBABLE CAUSE

1. No Power to heater.

2. Loose wire connections.

3. Inoperative upper heating element.

4. Inoperative upper thermostat.

5. Open ECO.

1. Inoperative lower heating element.

2. Thermostat(s) set to low.

3. Inoperative thermostat(s).

4. Loose wire connection.

5. Sediment or lime build up on element(s).

6. High demand period.

7. Undersized heater.

8. Very cold inlet water to heater.

9. Plumbing connections reversed.

10. Damaged dip tube.

1. Sediment or lime build up on element(s).

2. Loose wire connections.

3. Inoperative thermostat(s).

4. Derated heating element installed.

1. Thermostat not in contact with tank.

2. Grounded heating element(s).

3. Thermostat set to high.

4. Inoperative thermostat(s).

5. Inoperative ECO.

6. Undersized water heater.

CORRECTIVE ACTION

SERVICE

PROCEDURE

1. Check fuses or circuit breakers in service

panel.

2. Check all wire connections.

3. Check heating element(s). Replace as

needed.

4. Check thermostat(s) operation. Replace as

needed.

5. Check ECO. Reset or replace

thermostat(s) as needed.

1. Check heating element(s), replace as

needed.

2. Increase thermostat setting.

3. Check thermostat(s), replace as needed.

4. Check all wire connection.

5. Remove heating element(s) and check for

lime build up.

6. Reduce demand.

7. Replace with larger heater.

8. Temper water to heater.

9. Correct plumbing connections.

10. Check dip tube, replace as needed.

1. Remove heating element(s) and check for

lime build up.

2. Check all wire connections.

3. Check thermostat(s), replace as needed.

4. Check terminal block of element for proper

voltage and wattage rating.

1. Position thermostat flush with tank surface.

2. Check heating element(s). Replace as

needed.

3. Adjust thermostat(s) to desired setting.

4. Check thermostat(s), replace as needed.

5. Check ECO, replace thermostat as

needed.

6. Replace with larger heater.

3. See Service Procedure

RE-II, Page 15.

4. See Service Procedure

RE-III, Page 16.

5. See Service Procedure

RE-I, Page 14.

1. See Service Procedure

RE-II, Page 15.

3. See Service Procedure

RE-III, Page 16.

5. See Service Procedure

RE-VI, Page 34.

10. See Service Procedure

RE-VII, Page 35.

1. See Service Procedure

RE-VI, Page 34.

3. See Service Procedure

RE-III, Page 16.

1. See Service Procedure

RE-V, Page 33.

2. See Service Procedure

RE-II, Page 15.

4. See Service Procedure

RE-III, Page 16.

5. See Service Procedure

RE-I, Page 14.

Noisy (singing or hissing) Elements

1. Lime formation on elements.

1. Remove and clean heating elements.

Replace as needed.

1. See Service Procedure

RE-VI, Page 34.

Page 13

13

14

SERVICE PROCEDURE RE-I

Line Voltage & High Limit (ECO)

Testing

Line Voltage Testing WARNING

High voltage exposure. Use caution when making voltage checks to avoid personal injury.

1. Turn “OFF” power to water heater.

2. Remove access cover(s) from front of water

heater. Remove insulation and plastic cover

from thermostat.

3. Set multi-meter to volts AC.

4. Turn power “ON” to water heater.

5. Check voltage across terminals L1 & L3

of upper thermostat (see illustration 2).

A) Rated voltage IS present, power to the water

heater is okay.

B) Rated voltage NOT present, Check circuit breaker

at service panel.

Illustration 2

ECO reset button

Illustration 3

High Limit (ECO) Testing

1. Check voltage across terminals L1 & L4 upper thermostat (see illustration 3).

A) Rated Voltage IS present, ECO is okay.

B) Rated voltage NOT present, proceed to step 2.

2. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s). Turn power “ON” and recheck

voltage across terminals L1 & L4 of upper thermostat

(see illustration 3).

A) Rated voltage IS present, the ECO has opened indicating the water in the tank is or has over heater.

Check the following:

1. Thermostat must be in full contact with tank.

2. Be sure heating element(s) is not shorted to ground (see page 15).

3. Proper thermostat operation (see procedures beginning on page 16).

B) Rated voltage NOT present, water in tank may be over heated.

1. If water is hot, turn “OFF” power to water heater and flow water through tank to cool below set point

of upper thermostat. Recheck voltage per step 1.

2. If water is cool, Replace upper thermostat.

Page 14

SERVICE PROCEDURE RE-II

Heating Element Testing

Testing For Open Or Burned Out Element.

Step 1.

TURN OFF POWER TO WATER HEATER.

Step 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element.

Step 4. Set multi-meter to “ohms” setting.

Step 5. Touch probes of multi-meter to screw terminals of heating element

(see illustration 4).

Step 6. Reading should be 12.8 ohms (±6%) for a 240 volt, 4500 watt element:

Ohms = Volts

Watts

2

A reading outside the range using the formula above (±6%), indicates a bad element and the element must be replaced.

WARNING

High voltage exposure. Be sure power is turned

OFF to water heater prior to performing this procedure.

Meter Probe

Element Screw Terminals

Illustration 4

Testing For Heating Element Short Circuit To

Ground.

Step 1.

TURN OFF POWER TO WATER HEATER.

Step 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element.

Step 4. Set multi-meter to “ohms” setting.

Step 5. Touch one probe of multi-meter to either screw terminal of heating element and the other on the element flange (see illustration 5). There should be no reading on the ohm meter. Any reading indicates a grounded element and the element must be replaced. Repeat this step for the other screw terminal.

Element Screw Terminal

Meter Probe

Element Flange

Illustration 5

Page 15

15

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Single Element Operation or

Double Element, 4 Wire, Simultaneous, Single Phase

Operation.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Water In Tank Is Cold With Power ON.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

A) Rated voltage NOT present,

thermostat to element.

Illustration 6 Illustration 7

16

Water Temperature In Tank Is Above Thermostat Setting.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

Page 16

Reference 4 Wire, Simultaneous, Single Phase

Wiring diagram.

NOTE: Wiring consists of two single element configurations operating independently.

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Single Phase

Operation.

Water In Tank Is Cold With Power ON.

1. This procedure assumes line voltage, ECO and

elements are in working order.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

4. Check across terminals L4 and T2 of

upper thermostat (see illustration 8).

A) Rated voltage NOT present,

Recheck ECO. If ECO is okay,

replace thermostat.

B) Rated voltage IS present,

proceed to next step.

5. Check across element terminals

(see illustration 9).

A) Rated voltage NOT present,

check wire connections from

thermostat to element.

B) Rated voltage IS present,

Repeat element testing

see page 15.

Illustration 8

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 9

Tank Does Not Deliver Enough Hot Water.

2. Turn power “ON” to water heater and set multi-meter to “Volts AC”.

B) Rated voltage NOT present, replace upper thermostat.

A) Rated voltage NOT present, replace upper thermostat.

B) Rated voltage IS present, thermostat is okay. Go to step 7 on next page.

Illustration 10

Page 17

17

18

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Single Phase

Operation (continued).

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Not Enough Hot Water (continued).

7. Check voltage across terminal L4 of upper

thermostat and terminal 1 of lower thermostat

(see illustration 11).

A) Rated voltage NOT present,

- check wire connection between thermostats.

B) Rated voltage IS present, okay, go to step 8.

8. Adjust lower thermostat to highest setting. Water temperature in

tank must be below the lower thermostat setting for this test.

9. Check voltage across terminal L4 of upper

thermostat and terminal 2 of lower thermostat (see illustration 12).

A) Rated voltage NOT present, replace lower thermostat.

B) Rated voltage IS present, thermostat is ok.

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 11

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes Line voltage, ECO and elements are in working

order.

2. Adjust upper and lower thermostats to the lowest setting.

3. Turn power “ON” to water heater and set multi-meter to “Volts AC”.

4. Check across terminals L4 and T2 of upper thermostat

(see illustration 8 on page 17).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay. Go to step

5 below.

C) Lower than rated voltage IS present, recheck for grounded upper

element (see page 15).

5. Check across terminals L4 and 2 of lower thermostat (see illustration 12).

A) Rated voltage IS present, replace lower thermostat.

B) Rated voltage NOT present, lower thermostat is okay.

C) Lower than rated voltage IS present, recheck for grounded lower

element (see page 15).

Page 18

Illustration 12

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Three Phase

Operation.

Water In Tank Is Cold With Power ON.

1. This procedure assumes line voltage, ECO and

elements are in working order.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

4. Check across terminals L4 and T2 of

upper thermostat (see illustration 13).

A) Rated voltage NOT present,

Recheck ECO. If ECO is okay,

replace thermostat.

B) Rated voltage IS present,

proceed to next step.

5. Check across element terminals

(see illustration 14).

A) Rated voltage NOT present,

check wire connections from

thermostat to element.

B) Rated voltage IS present,

Repeat element testing,

see page 15.

Illustration 13

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 14

Tank Does Not Deliver Enough Hot Water.

2. Turn power “ON” to water heater and set multi-meter to “Volts AC”

B) Rated voltage NOT present, replace upper thermostat.

5. Adjust temperature setting of upper thermostat to the minimum setting.

Water temperature in tank must be above thermostat setting for this test.

A) Rated voltage NOT present, replace upper thermostat.

Page 19

Illustration 15

19

20

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,

Three Phase Operation (continued).

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Tank Does Not Deliver Enough Hot Water (continued)

7. Check voltage across terminal L1 & L3 of lower thermostat (see illustration 16).

A) Rated voltage NOT present, check wire connection between thermostats.

B) Rated voltage is present, okay, go to step 8.

8. Adjust lower thermostat to highest setting. Water temperature in tank must be below

the lower thermostat setting for this test.

9. Check voltage across terminal L4 & T2 of lower thermostat (see illustration 17).

A) Rated voltage NOT present, recheck ECO (see page 14). If ECO okay,

replace lower thermostat.

B) Rated voltage IS present, thermostat is ok. Check wire connection to lower

element. If connection okay, recheck lower element (see page 15).

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 16

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes Line voltage, ECO and elements are in working

order.

2. Adjust upper and lower thermostats to the lowest setting.

3. Turn power “ON” to water heater and set multi-meter to “Volts AC”.

4. Check across terminals L4 and T2 of upper thermostat

(see illustration 13 on page 19).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay. Go to step

5 below.

C) Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

5. Check across terminals L4 and T2 of lower thermostat (see illustration 17).

A) Rated voltage IS present, replace lower thermostat.

B) Rated voltage NOT present, lower thermostat is okay.

C) Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

Illustration 17

Page 20

Double Element, Simultaneous, Three Phase

Operation.

Water In Tank Is Cold Or Not Enough Hot

Water With Power ON.

2. Adjust temperature setting for both

thermostats to the highest setting.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

Recheck ECO (see page 14).

thermostat.

Illustration 18

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 19

Repeat element testing

see page 15.

B) Rated voltage IS present,

proceed to next step.

8. Check across lower element terminals.

A) Rated voltage NOT present,

thermostat to element.

Illustration 20 Illustration 21

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Page 21

21

22

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Simultaneous, Three Phase

Operation (continued).

Water Temperature In Tank Is Above Thermostat

Setting.

1. This procedure assumes Line voltage, ECO and

elements are in working order.

2. Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC”.

5. Check across terminals L4 and T2 of

upper thermostat (see illustration 22).

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) Lower than rated voltage IS present,

recheck for grounded upper element

(see page 15).

6. Check across terminals L4 and T2 of

lower thermostat (see illustration 23).

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) Lower than rated voltage IS present,

recheck for grounded lower element

(see page 15).

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 22

Illustration 23

Page 22

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Single Phase,

Off Peak Operation.

Water In Tank Is Cold With Power ON.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

B) Rated voltage IS present,

see page 15.

Illustration 24

Tank Does Not Deliver Enough Hot Water.

2. Turn power “ON” to water heater and set multi-meter to “Volts AC”.

3. Adjust temperature setting of upper & lower thermostat to the

setting for this test.

B) Rated voltage NOT present, replace upper thermostat.

setting. Water temperature in tank must be above thermostat setting

for this test.

A) Rated voltage NOT present, replace upper thermostat.

Page 23

Illustration 25

Illustration 26

23

24

Double Element, Non-Simultaneous,

Single Phase, Off Peak Operation.

(continued)

N ot Enough Hot Water (continued).

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

B) Rated voltage is present, okay,

go to step 8.

A) Rated voltage NOT present,

thermostats & element.

Repeat element testing

see page 15.

Illustration 27

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 28

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes Line voltage, ECO and elements are in working order.

2. Adjust upper and lower thermostats to the lowest setting.

3. Turn power “ON” to water heater and set multi-meter to “Volts AC”.

4. Check across terminals L4 and T2 of upper thermostat (see illustration 24 on page 23).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay. Go to step 5 below.

C) Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

5. Check across terminals T4 of upper thermostat and T2 of lower thermostat (see illustration 27 above).

A) Rated voltage IS present, replace lower thermostat.

B) Rated voltage NOT present, lower thermostat is okay.

C) Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

Page 24

Double Element, Non-Simultaneous, Single Phase

Operation.

Water In Tank Is Cold With Power ON.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”.

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Recheck ECO (see page 14). If

ECO is okay, replace thermostat.

Illustration 29

Tank Does Not Deliver Enough Hot Water.

2. Turn power “ON” to water heater and set multi-meter to “Volts AC”

Highest setting. Water temperature in tank must be below thermostat

setting for this test.

B) Rated voltage NOT present, replace upper thermostat.

A) Rated voltage NOT present, replace upper thermostat.

Page 25

Illustration 30

Illustration 31

25

Double Element, Non-Simultaneous,

Single Phase Operation (continued)

Tank Does Not Deliver Enough Hot

Water (continued).

B) Rated voltage is present, okay,

go to step 8.

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

26

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 32

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes line voltage, ECO and elements are in working order.

2, Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater and Set multi-meter to “Volts AC”

A) Rated voltage IS present, replace lower thermostat.

B) Rated voltage NOT present, okay, go to step 5 below.

C) Lower than rated voltage IS present, recheck for grounded lower

element see page 15.

5. Check across terminal L4 & T2 of upper thermostat (see illustration 34).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay.

Illustration 33

Illustration 34

Page 26

Double Element, Simultaneous, Single Phase

Operation.

Water In Tank Is Cold Or Not Enough Hot

Water With Power ON.

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC”

Recheck upper ECO

is okay, replace upper thermostat.

6. Check across upper element terminals

(see illustration 36).

Illustration 35

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 36

B) Rated voltage IS present,

proceed to next step.

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 37

Page 27

Illustration 38

27

28

Double Element, Simultaneous, Single Phase

Operation (continued)

Water Temperature In Tank Is Above Thermostat

Setting.

1. This procedure assumes line voltage, ECO and

elements are in working order.

2. Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC”

5. Check across terminals L4 and T2 of

upper thermostat (see illustration 39).

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) lower than rated voltage IS present,

recheck for grounded upper element

see page 15.

6. Check across terminal L3 of upper thermostat and

T2 of lower thermostat (see illustration 40).

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) lower than rated voltage IS present,

recheck for grounded lower element

see page 15.

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 39

Page 28

Illustration 40

Double Element, Non-Simultaneous, Three Phase

Operation.

Water In Tank Is Cold With Power ON.

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC”

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

B) Rated voltage IS present,

see page 15.

Illustration 41

Tank Does Not Deliver Enough Hot Water.

1. This procedure assumes line voltage, ECO and elements are in

working order.

2. Turn power “ON” to water heater and set multi-meter to “Volts AC”

A) Rated voltage IS present, okay, upper thermostat is calling

for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

A) Rated voltage NOT present, replace upper thermostat.

Page 29

Illustration 42

Illustration 43

29

Double Element, Non-Simultaneous,

Three Phase Operation (continued).

Tank Does Not Deliver Enough Hot Water

(continued).

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

8. Check voltage across lower element

(see illustration 45).

30

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 44

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes line voltage, ECO and elements are in working order.

2. Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater and Set multi-meter to “Volts AC”.

A) Rated voltage IS present, replace lower thermostat.

B) Rated voltage NOT present, okay, go to step 5 below.

C) lower than rated voltage IS present, recheck for grounded lower

element.

5. Check across terminal L4 & T2 of upper thermostat (see illustration 46).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay.

Page 30

Illustration 45

Illustration 46

Double Element, Simultaneous, Three Phase

Operation.

Water In Tank Is Cold Or Not Enough Hot

Water With Power ON.

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC”

A) Rated voltage NOT present,

Recheck upper ECO

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 47 Illustration 48

thermostats. If okay, replace

lower thermostat.

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

Illustration 49

Page 31

Illustration 50

31

32

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Three Phase

Operation (continued).

Water Temperature In Tank Is Above Thermostat

Setting.

1. This procedure assumes line voltage, ECO and

elements are in working order.

2. Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC”

5. Check across terminals L4 and T2 of

upper thermostat (see illustration 51).

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) lower than rated voltage IS present,

recheck for grounded upper element

see page 15.

6. Check across terminals L4 & T2 of lower thermostat

(see illustration 52).

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) lower than rated voltage IS present,

recheck for grounded lower element.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 51

Page 32

Illustration 52

SERVICE PROCEDURE RE-V

Thermostat Removal and Replacement

Thermostat Removal

1. Turn power “OFF” To water heater.

2. Remove access cover and insulation.

3. Remove plastic thermostat protector from thermostat.

WARNING

High voltage exposure. Be sure power is

“OFF” when performing this procedure.

5. Note thermostat temperature setting for proper setting of new thermostat.

6. Slide thermostat upwards and out of mounting bracket.

Thermostat Replacement

1. Use a stiff brush to remove any debris or loose scale from tank surface where new thermostat will be installed.

completely flat or flush to tank surface. An improperly installed thermostat will cause improper water heater

operation.

4. Set thermostat to the original thermostat setting found on the old thermostat.

5. Re-install plastic thermostat protector.

6. Re-install insulation and access cover.

7. Restore power to water heater and verify proper heater operation.

Tank Surface

Proper Thermostat mounting flush with tank surface

Thermostat

Improper Thermostat mounting.

Thermostat not flush with tank surface

Thermostat mounting bracket

Front View

Thermostat Mounting

Side View

Proper Thermostat

Mounting

Page 33

Side View

Improper Thermostat

Mounting

33

34

SERVICE PROCEDURE RE-VI

Heating Element Removal and Replacement

Heating Element Removal

1. Turn power “OFF” To water heater.

2. Turn off cold water supply to heater. Connect hose to drain

spigot of water heater and route to an open drain. Open

a nearby hot water faucet to vent heater for draining. Open

drain spigot of water heater and allow heater to drain

to a point below the Element(s).

3. Close drain spigot and remove hose.

4. Remove access cover and insulation.

5. Remove plastic thermostat protector from thermostat.

6. Disconnect wires from element terminals.

WARNING

High voltage exposure. Be sure power is

“OFF” when performing this procedure.

WARNING

Heater components and stored water may be

HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

8. Be sure to remove old element gasket from the tank. It is not recommended to be re-used.

Heating Element Replacement

3. Clean any debris from element fitting on tank. Lubricate element threads as needed with thread lubricant.

5. Reconnect wires to element, be sure wires are snug and corrosion free. Do not over tighten, doing so may damage

terminal block.

6. Resume water supply to heater, be sure tank is full of water and check for leaks.

7. Re-install plastic thermostat protector.

8. Re-install insulation and access cover.

9. To resume operation, BE SURE TANK IS FULL OF WATER and restore power to water heater. Verify proper heater

Date Code

Element Rating.

Example: (4500 Watt, 240 Volt)

Element Flange

Element Gasket Seated Flat Against

Element Flange Without Rolls or Gaps

Terminal

Block

Manufacturer Identification

Page 34

SERVICE PROCEDURE RE-VII

Dip Tube and Anode Inspection and

Replacement

Dip Tube Inspection and Replacement

WARNING

Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Turn power “OFF” to water heater.

Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.

Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the inlet connection nipple.

Close drain spigot and remove hose.

Disconnect inlet nipple from plumbing system.

With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage nipple threads.

Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage.

Hydro-jets located near the bottom of the dip tube should be open and free of any blockage.

Anti-siphon hole located approximately 6" from the bottom of nipple, should be free of any blockage.

Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable and the inlet nipple/dip tube must be replaced.

Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Connect nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with water.

To resume operation, BE SURE TANK IS FULL OF WATER and turn power “ON” to water heater.

Anode Inspection and Replacement

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Turn power “OFF” to water heater.

Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.

Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the outlet connection nipple.

Close drain spigot and remove hose.

Disconnect outlet nipple from plumbing system.

With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage nipple threads.

Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.

If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Connect nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with water.

To resume operation, BE SURE HEATER IS FULL OF WATER and turn power “ON” to water heater.

Page 35

35

Generic Parts List

36

1. T&P Relief Valve

2. Heat Trap Insert (Outlet)

3. Hot Water Outlet/Anode

4. Cover Conduit/Ground

5. Junction Box Cover

6. Heat Trap Insert (Inlet)

7. Cold Water Inlet Dip Tube

8. Thermostat Protector (Large)

9. Thermostat w/High Limit (89T33)

10. Thermostat Mounting Bracket

Page 36

11. Heating Element

12. Element Gasket

13. Access Cover

14. Lower Thermostat Protector (Small)

15. Thermostat (59T)

16. Brass Drain Valve

17. Thermostat w/High Limit (89T13)

18. ASSE Approved Mixing Device

19. Kit Heat Trap

20. Kit Dairy Barn Leg

NOTES

37

38

NOTES

NOTES

39

Email [email protected]

[email protected]

www.bradfordwhite.com

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