American Water Heater | Solar Storage Tank Water Heater | Use & care guide | American Water Heater Solar Storage Tank Water Heater Use & care guide

Solar Storage Tank
Water Heater
Installation
Instructions and
Use & Care Guide
To obtain technical, warranty or service assistance during or
after the installation of this water heater, call toll free 1-800999-9515
When calling for assistance, please have the following
information ready:
1. Model number
2. 7 Digit product number
3. Serial number
4. Date of installation
5. Place of Purchase
Table Of Contents
Water Heater Safety .....................................................................
Installing Your Electric Water Heater ........................................
Unpacking Instructions ................................................
Location Requirements ................................................
Electrical Requirements ...............................................
Water System Piping ...................................................
Installation Checklist ....................................................
Operating Your Water Heater .......................................................
Water Temperature Regulation ....................................
Adjusting the Thermostat .....................................................
Operational Conditions ........................................................
Maintenance of Your Water Heater .................................................
Trouble Shooting Chart .............................................................
Repair Parts Illustration .............................................................
PAGE
2
3-8
3
4
4-5
6-8
9
10-12
10
11
12
12-13
14
15
6510237
November 2001
Supercedes 6510165
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:
You can be killed or seriously injured if you don't
immediately follow instructions.
You can be killed or seriously injured if you don't
follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.
Important Safety Instructions
CAUTION: Hydrogen gas is produced in a hot water system served by this heater that has not been used for a long
period of time (2 weeks or more). Hydrogen is extremely flammable. To reduce the risk of injury under these conditions,
it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical
appliance connected to the hot water system. When hydrogen is present, there will be an unusual sound such as air
escaping through the pipe as the water begins to flow. There should be no smoking or open flame near the faucet at
the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde.
2
INSTALLING YOUR WATER HEATER
Consumer Information
This water heater should be installed in accordance with
the local code authority having jurisdiction, the power
company or electric utility, and this installation manual.
In the absence of local code requirements, follow the
regulations set forth in the latest edition of The National
Electric Code, NFPA 70. This is available from the
following:
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
American National Standards Institute
1430 Broadway
New York, NY 10018
Check your phone listings for the local authorities having
jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation and maintenance of your electric
water heater and to provide important safety information
in these areas.
We urge you to read all of the instructions thoroughly
before attempting the installation or operation of this
water heater. This manual should be kept for future
reference.
The manufacturer of this water heater will not be liable
for any damages caused by failure to comply with the
installation and operating instructions outlined in this
manual.
If you lack the necessary skills required to properly install
this water heater or you have difficulty following the
directions, you should not proceed but have a qualified
person perform the installation of this water heater.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR section 2.00 and 5.00.
A data plate identifying your water heater can be found
adjacent to the element door. When referring to your
water heater always have the information listed on the
data plate readily available.
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
WARNING
Excessive Weight Hazard
Use two or more people to move and install
water heater.
Failure to do so can result in back or other
injury.
Removing Packaging Materials
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater
or on the inside of panels.
·
Remove exterior packaging and place installation
components aside.
·
Inspect all parts for damage prior to installation
and start-up.
·
Completely read all instructions before attempting
to assemble and install this product.
·
After installation, dispose of packaging material
in the proper manner.
3
Location Requirements
Site location
Select a location near the center of the water piping
system. The water heater must be installed indoors and
in a vertical position on a level surface.
Note: The water heater shall be located so it is not subject
to physical damage by moving vehicles or area flooding.
FIGURE 1
RESIDENTIAL GARAGE
INSTALLATION
The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) may
require the water piping and drain piping to be insulated
to protect against freezing. The drain and controls must
be easily accessible for operation and service.
VEHICLE
STOP
Do not use this water heater in conjunction with a spa
or hot tub.
Note: Local codes and requirements in your area may
require the installation of your water heater to be
accomplished in a way such that the bottom element is
elevated from the floor at least 18 inches.
Important: The water 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 water heater
or to lower floors of the structure. Due to the normal
corrosive action of water, the tank will begin to leak after
an extended period of time. It is recommended that a
suitable drain pan be installed under the water heater
as shown below. This pan is to protect the property from
damage which may occur from normal condensate
formation on the tank or leaks in the tank and pipe
connections. The pan must limit the water level to a
maximum depth of 2-1/2 inches and be two inches wider
than the heater and piped to an adequate drain. Locate
the water heater near a suitable indoor drain. Outside
drains are subject to freezing temperatures which can
obstruct the drain line. The piping should be at least 3/4”
ID and pitched for proper drainage.
Under no circumstance will the manufacturer be held
liable for any water damage in connection with this
water heater.
DRAIN
PAN
State of California
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
1-800-999-9515 and request instructions.
Electrical Requirements
WARNING
Electrical Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
WARNING
Fire Hazard
Use proper size solid copper
wire.
Use a UL approved strain relief.
Connect ground wire to green
ground screw.
Failure to do so can result in
death, fire, or electrical shock.
2 1/2” MAX
PIPE TO
ADEQUATE
DRAIN
AT LEAST 2” INCHES GREATER
THAN THE DIAMETER OF THE
WATER HEATER.
4
DRAIN
If you lack the necessary skills required to properly install
the electrical wiring to this water heater, do not proceed
but have a qualified electrician perform the installation.
When making the electrical connections, always make
sure:
·
The electrical supply has the proper overload fuse
or breaker protection.
·
Wire sizes and connections comply with all
applicable codes.
·
Wiring enclosed in approved conduit (if required
by local codes).
·
The water heater and electrical supply are properly
grounded.
Important: Do not use an extension cord to supply
power to this water heater. Be sure the power supply is
completely grounded before making connections.
Figures 4, 5, and 6 are provided as reference drawings
for the 120/240v 2-wire models only. Always reference
the wiring diagram located on the water heater for the
correct electrical connections.
When installing the electrical wiring to the water heater:
1.
Be sure tank is completely filled with water before
making any electrical connections. (See Figure 2)
FIGURE 4
120/240V 2-WIRE MODELS
GREEN
GROUND
SCREW
JUNCTION BOX
COVER
GROUND
WIRE
CONDUIT
FIGURE 2
HEATING ELEMENT
WHITE WIRE (120V MODELS)
RED WIRE (240V MODELS)
FIGURE 5
WIRING DIAGRAM
120V MODELS ONLY
OVERLOAD
PROTECTION
BLACK WIRE
CIRCUIT
BREAKER
APPROVED CONNECTORS
Notice: Applying electrical power to elements that are not
submerged in water will destroy them. The manufacturer
will not warranty any elements damaged in this manner.
2.
3.
4.
5.
Shut-off the power to the unit.
Loosen the screw holding the junction box cover
to the top of the water heater. Set the cover aside.
Connect the electrical supply to the water heater
in accordance with local utility requirements and
codes. A standard 1/2 inch opening has been made
in the junction box for conduit connections.
Ground the water heater by connecting a grounding
wire from the electrical service ground terminal to
the green grounding screw in the junction box of
the water heater.
Sensor (Furnished by Installer)
Wires are provided from the sensor mounting stud to the top
of the solar storage tank. Attach the tank sensor to these
wires and mount the sensor to the solar storage tank using
the stud provided. The stud is located behind the lower
electrical access cover (See Figure 3). Connect the two
wires that exit through the top of the solar storage tank
enclosure to the solar control. These wires are designed to
be connected to an NEC CLASS II circuit only.
FIGURE 3
SENSOR MOUNTING STUD
WIRES TO TOP OF
HEATER
BLACK
HOT
TO 120/160V
POWER SUPPLY
WHITE
NEUTRAL
GROUND
SCREW
ELECTRICAL
SERVICE GROUND
FIGURE 6
WIRING DIAGRAM
208/240V MODELS ONLY
OVERLOAD
PROTECTION
CIRCUIT
BREAKER
APPROVED CONNECTORS
BLACK
L1
RED
L2
GROUND
SCREW
TO 208/240V
@60Hz
1 PHASE
POWER SUPPLY
ELECTRICAL
SERVICE GROUND
ELEMENT
PLUG
SENSOR
MOUNTING
STUD
5
Water System Piping
FIGURE 7
JACKET TOP WATER CONNECTION LOCATIONS
COLD INLET
HOT OUTLET
ANODE
119
GALLON
ONLY
SOLAR IN
SOLAR OUT
ALTERNATE T&P
LOCATION
Piping Installation
Piping, fittings, and valves should be installed according
to the installation drawing (Figure 8). If the indoor
installation area is subject to freezing temperatures, the
water piping must be protected by insulation.
FIGURE 8
WATER PIPING INSTALLATION
TEMPERING
VALVE
SOLAR OUT
IN A CLOSED SYSTEM
USE EITHER:
SOLAR IN
1.
2.
Important: Some models may contain energy saving
heat traps to prevent the circulation of hot water within
the pipes. Do not remove these inserts.
2. The installation of unions in both the hot and cold
water supply lines are recommended for ease of
removing the water heater for service or replacement.
3. The manufacturer of this water heater recommends
installing a tempering valve in the domestic hot water
line as shown in Figure 9. These valves reduce
the point-of-use temperature of the hot water by
mixing cold and hot water and are readily available.
Contact a licensed plumber or the local plumbing
authority. Install a spring check valve in the cold
water inlet to the tempering valve (See Figure 9).
Connect the piping that will carry the water from
the solar storage tank to the solar connectors, then
to the fitting marked “SOLAR OUT.” Connect the
return line from the connectors to the fitting marked
“SOLAR IN.”
FIGURE 9
TEMPERING VALVE
TOP WATER CONNECTIONS
SOLAR OUT
THERMAL EXPANSION TANK
PRESSURE RELIEF VALVE
HOT
COLD
WATER
INLET
SOLAR IN
PRESSURE REDUCING
VALVE WITH BYPASS
HOT WATER
OUTLET
UNION
COLD WATER
INLET VALVE
COLD WATER
INLET
TEMPERED
WATER TO
FIXTURES
TEMPERATURE AND
PRESSURE RELIEF VALVE (ALTERNATE
LOCATION ON TOP OF HEATER)
DISCHARGE LINE
6 INCHES MAXIMUM
ABOVE DRAIN
1 INCH
MIN.
DRAIN PAN
2-1/2 INCH DEPTH MAX.
DRAIN LINE
3/4 INCH ID
MINIMUM
DRAIN
SPRING
CHECK VALVE
TEMPERING VALVE
(SET TO 120° F)
MASSACUHSETTS: INSTALL A
VACUUM RELIEF IN COLD WATER
LINE PER SECTION 19 MGL 142.
Water supply pressure should not exceed 80% of the working
pressure of the water heater. The working pressure is stated
on the water heater’s data plate. If water supply pressure
does exceed 80% of the working pressure, a pressure limiting
valve with a bypass may need to be installed in the cold
water supply line. This should be placed on the supply to the
entire house in order to maintain equal hot and cold water
pressures.
Important: Heat cannot be applied to the water fittings on
the heater as they may contain nonmetallic parts. If solder
connections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
Important: Always use a good grade of joint compound and
be certain that all fittings are tight.
1. Install the water piping and fittings as shown in
Figure 8. Connect the cold water supply (3/4 NPT)
to the fitting marked “C”. Connect the hot water
supply (3/4 NPT) to the fitting marked “H”.
6
4. Recirculation return lines should be connected to an
auxiliary water heater (see Figure 10, Page 7). DO
NOT connect recirculation lines to the solar storage
tank. Recirculation pumps should be controlled by
a timer which will stop circulation at night or any time
hot water is not being used.
5. If components in the solar control system have
maximum working pressures that are lower than the
maximum water supply pressure, a pressure reducing
valve with an intregal strainer and by-pass should
be installed in a cold water supply line. The pressure
reducing valve must be adjusted to the lowest working
pressure of the solar control components.
6. If installing the water heater in a closed water system,
install a relief valve or expansion tank in the cold
water line as specified under “Closed System/Thermal
Expansion.
7. Install a shut off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.
General Information
8. Install a temperature and pressure relief valve and
discharge line in the opening marked "T & P RELIEF
VALVE". Install as specified under "Temperature and
Pressure Relief Valve."
9. After piping has been properly connected to the water
heater, open the nearest hot water faucet and allow
the tank to completely fill with water. To purge the
lines of any excess air and sediment, keep the hot
water faucet open for 3 minutes after a constant flow
of water is obtained. Close the faucet and check all
connections for leaks.
Please note the following:
DO NOT install this water heater with iron piping. The
system should be installed only with new piping that is
suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. DO NOT use PVC water piping.
DO NOT use any pumps, valves, or fittings that are not
compatible with potable water.
DO NOT use valves that may cause excessive restriction
to water flow. Use full flow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based
solder) in potable water lines. Use 95/5 tin-antimony or
other equivalent material.
DO NOT tamper with the thermostat, heating elements,
electrical connections, or temperature and pressure
relief valve. Tampering voids all warranties. Only qualified
technicians should service these components.
DO NOT use with piping that has been treated with
chromate's, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping which
will contaminate the potable water supply.
FIGURE 10
TEMPERING VALVE
TEMPERING VALVE
TEMPERED
WATER
SPRING CHECK VALVE
HOT WATER
DEMAND
SPRING CHECK VALVE
TEMPERED
WATER
COLD
WATER
SUPPLY
COLD WATER SUPPLY
HOT
HOT
COLD
HOT
COLD
COLD
RECIRCULATION
RETURN
AUXILLARY WATER HEATER
SOLAR STORAGE TANK
ELECTRIC ASSISTED
SOLAR STORAGE TANK
TEMPERING VALVE PLUMBING
7
Closed System/Thermal Expansion
Periodic discharge of the temperature and pressure relief
valve may be due to thermal expansion in a closed water
supply system. The water utility supply meter may contain a
check valve, backflow preventer or water pressure reducing
valve. This will create a closed water system. During the
heating cycle of the water heater, the water expands causing
pressure inside the water heater to increase. This may cause
the temperature and pressure relief valve to discharge small
quantities of hot water. To prevent this from happening, there
are two recommendations:
1.
Install a diaphragm-type expansion tank that is
suitable for potable water on the cold water supply
line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons
of stored water.
2.
Install a 125 PSI pressure relief valve in the cold
water supply line. Make sure the discharge of
this valve is directed to an open drain and
protected from freezing.
Contact the local water supplier or plumbing inspector for
information on how to control this situation. Do not plug
the temperature and pressure relief valve.
Solar Control Systems
Solar control systems used with this solar storage tank must
not allow temperatures in the tank to exceed 180°F and
must protect the system from freeze damage when the
temperatures approach freezing.
This solar storage tank does not contain a heat exchanger;
therefore, only potable (drinkable) water may be allowed to
enter the tank. If this solar storage tank is installed in a
system using any heat transfer fluid other than potable
water, a seperate heat exchanger must be installed. Heat
exchanges used in conjunction with this solar storage tank
must provide adequate protection of contamination of potable
water by toxic fluids used in heat exchange systems.
If this water heater is used as a solar storage heater or as
a backup for the solar storage system, the water supply
temperatures to the water heater tank may be in excess of
120°F. A tempering valve or other temperature limiting
device must be installed in the water supply line to limit the
supply temperature to 120°F.
Temperature and Pressure
Relief Valve
WARNING
Explosion Hazard
If the temperature and pressure relief valve
is dripping or leaking, have a licensed
plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death, or explosion.
For protection against excessive pressures and
temperatures, a temperature and pressure relief valve
must be installed in the opening marked “T & P RELIEF
VALVE” (See Figure 11).
FIGURE 11
TEMPERATURE AND PRESSURE
RELIEF VALVE INSTALLATION
OPTIONAL LOCATION
SOME MODELS ONLY
TEMPERATURE AND
PRESSURE VALVE
DISCHARGE LINE
3/4 INCH MIN.
DO NOT CAP OR PLUG
DRAIN PAN
6 INCH
MAXIMUM
DRAIN
Caution: To reduce the risk of excessive pressures and
temperatures in this water heater, install temperature and
pressure relief protective equipment required by local codes,
but no less than a combination temperature and pressure
relief valve certified by a nationally recognized testing
laboratory that maintains periodic inspection of the production
of listed equipment or materials, as meeting the requirements
for Relief Valves and Automatic Shutoff Devices for Hot
Water Supply Systems, ANSI Z21.22 - 1986. This valve
must be marked with the maximum set pressure not to
exceed the marked maximum working pressure of the water
heater. Install the valve into an opening provided and marked
for this purpose in the water heater, and orient it or provide
tubing so that any discharge from the valve exits only within
6 inches above, or at any distance below, the structural
floor, and does not contact any live electrical part. The
discharge opening must not be blocked or reduced in size
under any circumstance.
8
Important: Only a new temperature and pressure relief
valve should be used with your water heater. Do not use
an old or existing valve as it may be damaged or not
adequate for the working pressure of the new water heater.
Do not place any valve between the relief valve and the
tank.
The Temperature & Pressure Relief Valve:
·
·
·
Must not be in contact with any electrical part.
Must be connected to an adequate discharge line.
Must not be rated higher than the working pressure
shown on the data plate of the water heater.
The Discharge Line:
·
Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in
the discharge line.
·
Must not be capped, blocked, plugged or contain
any valve between the relief valve and the end of
the discharge line.
·
Must terminate a maximum of 6 inches above a
floor drain or external to the building.
·
·
Installation Check List
Water Heater Location
·
·
Centrally located with the water piping system.
·
Provisions made to protect the area from water
damage. Drain pan installed and piped to an
adequate drain.
·
Sufficient room to service the water heater.
Located indoors and in a vertical position. Protected
from freezing temperatures.
Water System Piping
·
Temperature and pressure relief valve properly
installed with a discharge line run to an open drain
and protected from freezing.
·
·
·
All piping properly installed and free of leaks.
Must be capable of withstanding 250°F (121°C)
without distortion.
·
Must be installed to allow complete drainage of
both the valve and discharge line.
Tempering valve installed per manufacturer’s
instructions.
Electrical Connections
Heater completely filled with water. (See Figure 3)
Closed system pressure buildup precautions
installed.
·
Wiring and connections comply with all applicable
codes.
·
Water heater and electrical supply are properly
grounded.
·
Proper overload fuse or circuit breaker protection
installed.
9
OPERATING YOUR WATER HEATER
Before operating the water heater, perform the
following:
1. Make sure the water heater has been properly
installed.
2. Completely fill the tank with water. (See Figure 3)
3. Apply power to the water heater only after the tank
is completely filled with water.
4. Carefully read and understand the "Water
Temperature Regulation" section of this manual.
5. Adjust the thermostat to the desired temperature
setting as directed under "Adjusting the Thermostat/
High Limit Control".
Important: Do not attempt to operate this water heater
if the thermostat(s), or surrounding insulation has been
exposed to water in any way. Immediately call a qualified
service technician to inspect the water heater and replace
any thermostat or insulation that has been exposed to
water. Do not attempt to repair these parts. Water heaters
subjected to flood conditions or any time the thermostat(s)
have been submerged in water require replacement of
the entire water heater.
Safety Shut-off
This water heater is designed to automatically shut-off
in the event that the water temperature exceeds 170°F
or 77°C (190°F or 88°C in LDCE Models). A high limit
control switch is used to shut off the power to the elements
if the water temperature exceeds 170°F or 77°C (190°F
or 88°C in LDCE Models). The high limit control can be
reset by firmly pushing in the red reset button located
on the thermostat. Follow the instructions under "Adjusting
the Thermostat/High Limit Control" to properly reset the
high limit control.
Water Temperature
Regulation
WARNING
Water temperature over 125°F can cause
severe burns instantly or death from
scalds.
Children, disabled and elderly are at
highest risk of being scalded.
See instructions manual before setting
temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available.
The thermostat is adjusted to a temperature setting of
120°F or lower when it is shipped from the factory.
Water temperature can be regulated by adjusting the
thermostat to the preferred setting as shown in " Adjusting
the Thermostat/High limit Control." The preferred
starting point is 120°F. There is a hot water scald
potential if the thermostat is set too high.
Important: Adjusting the thermostat past 120°F on the
thermostat will increase the risk of scald injury. Hot
water can produce first degree burns within:
120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71°C) at less than 1 second
During low demand periods when hot water is not being
used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs.
If hot water use is expected to be more than normal, a
higher thermostat setting may be required to meet the
increased demand.
When leaving your home for extended periods
(vacations, etc.) turn the thermostat to its lowest setting.
This will maintain the water at low temperatures with
minimum energy losses and prevent the tank from
freezing during cold weather.
10
Adjusting the Thermostat/High Limit Control
This water heater is equipped with one or more adjustable temperature regulating thermostats and a manual reset
high limit control. The following procedures must be performed when changing the temperature of the stored water
or resetting the high limit control.
Before attempting to adjust the thermostat, make sure you read and understand the section of "Water
Temperature Regulation" and familiarize yourself with Figure 12 (below). Any other adjustments must be
made by qualified service personnel.
1. Shut-off the power to the water heater.
2. Remove the access cover and fold the insulation outward and away from the thermostat. Do not
remove the plastic cover.
3. Using a screwdriver to adjust the thermostat pointer, set the thermostat to the desired water temperature.
Be sure the RED reset button (High Limit Control) is properly set: push in firmly to reset.
4. Replace the insulation. Make sure the thermostat is well covered. Replace the access cover.
5. Apply power to the water heater.
FIGURE 12
THERMOSTAT
RED RESET BUTTON
150°F
90°F
125°F
ACCESS
COVERS
150°F
90°F
SCREW
SLOT
SOLAR SENSOR
125°F
THERMOSTAT SETTING
AND ADJUSTMENT
11
SINGLE ELEMENT
HEATER
Operation Conditions
Anode Rod/Water Odor
Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank
from corrosion and prolonging the life of the water heater.
Certain water conditions will cause a reaction between
this rod and the water. Once the anode is depleted, the
tank will start to corrode, eventually developing a leak.
The most common complaint associated with the anode
rod is a “rotten egg smell” produced from the presence
of hydrogen sulfide gas dissolved in the water. Do not
remove this rod permanently as it will void any
warranties, stated or implied. The water supply system
may require special filtration equipment from a water
conditioning company to successfully eliminate all water
odor problems.
Artificially softened water is exceedingly corrosive
because the process substitutes sodium ions for
magnesium and calcium ions. The use of a water softener
may decrease the life of the water heater tank.
The anode rod should be removed from the water heater
tank every 3 years for inspection. If the rod is more than
50% depleted, the anode rod should be replaced.
For replacing the anode, shut-off the power to the water
heater. Be sure the cold water supply to the heater is
turned off. Open the hot water faucet to depressurize
the water tank. Drain out 5 gallons of water from the
drain valve at the bottom of the heater. Remove the
anode rod. See the "Repair Parts Illustration" for anode
rod location(s) on page 15.
Water Heater Sounds
During the normal operation of the water heater, sounds
or noises may be heard. These noises are common and
may result from the following:
1.
Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.
2.
Sediment buildup in the tank bottom will create
varying amounts of noise and may cause
premature tank failure. Drain and flush the tank
as directed under “Draining and Flushing”.
Stacking
Stacking occurs when a series of short draws of hot
water (3 gallons or less) are taken from the water heater
tank. This causes increased cycling of the heater elements
and can result in increased water temperatures at the
hot water outlet. An anti-scald device is recommended
in the hot water supply line to reduce the risk of scald
injury.
Maintenance
Temperature and Pressure
Relief Valve
WARNING
Explosion Hazard
If the temperature and pressure relief valve
is dripping or leaking, have a licensed
plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death, or explosion.
Manually operate the temperature and pressure relief
valve at least once a year to make sure it is working
properly. To prevent water
damage, the valve must
be properly connected to
a discharge line which
terminates at an adequate
drain.
Standing clear of the
outlet (discharged water
may be hot), slowly lift and
release the lever handle
on the temperature and
pressure relief valve to allow the valve to operate freely
and return to its closed position (see Figure 13). If the
valve fails to completely reset and continues to release
water, immediately shut-off the electrical power and the
cold water inlet valve and call a qualified service
technician.
12
Draining and Flushing
The water heater should be drained if being shut down
during freezing temperatures. It is recommended that
the tank be drained, and flushed every 6 months to
remove sediment which may buildup during operation.
To drain the tank perform the following steps:
1. Turn off the power to water heater.
2. Close the cold water inlet valve and open a nearby
hot water faucet.
3. Connect a hose to the drain valve and terminate it
to an adequate drain.
Important: Drain hose should be rated for at least 200°F.
If the drain hose does not have this rating, open the cold
water inlet valve and a nearby hot faucet until water is no
longer hot.
4. Open the water heater drain valve and the nearest
hot water faucet. Allow all the water to drain from the
tank. Flush the tank with water as needed to remove
sediment.
5. Close the drain valve, refill the tank, and restore
power.
If the water heater is going to be shut down for an
extended period, the drain valve should be left open.
Self Cleaning (Some Models)
Some water heaters may include a self cleaning device
that inhibits the build-up of lime and other sediment on
the metal surfaces of the water heater. As cold water
passes through the dip tube, lime-causing particles and
minerals are suspended automatically. This controls
sediment and lime build-up within the tank and results
in higher efficiencies and lower operation costs.
Heating Element
Replacement
3. Remove the access cover. Fold the insulation
outward and away from the heater element.
Remove the plastic thermostat cover from the
thermostat making sure to disengage the
attachment point from the thermostat.
4. Disconnect the electric wires from the heating element
(Figure 14). Remove the screw-in elements by turning
the element counterclockwise with a 1-1/2 inch
socket wrench. Remove the existing gasket.
FIGURE 14
WIRES
ELEMENT
SCREWS
5. Clean the area where the gasket fits to the tank. If
you are replacing the bottom element, remove the
accumulated sediment on the bottom of the tank.
6. Make sure the replacement element has the correct
voltage and wattage rating. Position the new gasket
on the element and insert it into the water heater
tank (Figure 15). Tighten the element by turning it
clockwise until secure.
FIGURE 15
THERMOSTAT
HOLDING
BRACKET
SCREW-IN
ELEMENT
SPUD
WARNING
Electrical Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
Replacement heating elements must be of the same
style and voltage/wattage rating as the ones presently
in the water heater. This information can be found on
the flange or terminal block of the element or on the
water heater data plate.
1. Shut-off the electric power to the water heater.
2. Drain the water heater as directed under "Draining
and Flushing".
13
GASKET
7. Close the drain valve. Open the nearest hot water
faucet and allow the tank to fill completely with water.
To purge the lines of any excess air and sediment,
keep the hot water faucet open for 3 minutes after a
constant flow of water is obtained.
8. Check for leaks around the element.
9. Connect the electric wires to the heater element.
Make sure the wires are secure. Replace the plastic
thermostat cover making sure the attachment points
are engaged on the thermostat.
10. Replace the access cover.
11. Make certain the tank is filled with water. Applying
electric current to heater elements not submerged in
water will destroy them.
12. Restore the electric power supply to the water heater.
TROUBLESHOOTING
POSSIBLE CAUSE(S)
PROBLEM
CORRECTIVE ACTION
1. Turn on electrical switch. Check for blown fuses or
tripped breaker
2. High Temperature Limit Switch open 2. Reset. Check for source of trouble and correct
3. Defective thermostat
3. Replace thermostat
NO HOT WATER
1. No power to heater
INSUFFICIENT HOT WATER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Defective thermostat
Defective element
Improper calibration
Thermostat set too low
Sediment or lime in tank
Heater too small for job
Wrong piping connections
Leaking faucets
Wasted hot water
Long runs of exposed pipe
Hot water piping on outside wall
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Replace thermostat
Replace element
Replace thermostat
Set thermostat to desired temperature
Drain. Determine if water treatment is needed
Install adequate water heater
Correct piping
Repair faucets
Advise customer
Insulate piping
Insulate piping
HIGH OPERATION COSTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Improper Calibration
Thermostat set too high
Sediment or lime in tank
Heater too small for job
Wrong piping connections
Leaking faucets
Wasted hot water
Long runs of exposed piping
Hot water piping in exposed wall
1.
2.
3.
4.
5.
6.
7.
8.
9.
Replace thermostat
Set thermostat to desired setting
Drain. Flush-Provide water treatment if needed
Install adequate heater
Correct piping
Repair faucets
Advise customer
Insulate piping
Insulate piping
SLOW HOT WATER
RECOVERY
1. Defective element
1. Replace element
1. Excessive water pressure
2. Closed system
1. Use Pressure Reducing Valve and Pressure Relief
Valve
2. See page 8, "Closed System"
THERMOSTAT FAILS TO
SHUT OFF
1. Defective thermostat
2. Improper calibration
1. Replace thermostat
2. Replace thermostat
WATER ODOR
1. Sulfides in the water
1. See page 11, "Water Odor"
DRIP FROM RELIEF VALVE
14
REPAIR PARTS ILLUSTRATION
ALTERNATE
T&P
LOCATION
5
6
7
5
5
2
1
3 and 4
8
10
11
12
13
6
8
15
14
16
9
13
REPAIR PARTS
Repair parts may be ordered through your plumber, local
distributor, home improvement center, or by calling 1800-999-9515. When ordering repair parts always give
the following information:
1. Model, serial and product number
2. Item number
3. Parts description
REPAIR PARTS LIST
LEGEND
Not supplied on some models
Electrical Assisted only
15
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PARTS DESCRIPTION
COLD INLET NIPPLE/DIPTUBE
SOLAR INLET/OUTLET DIPTUBE
ANODE ROD (80 GALLON 1 ANODE)
ANODE ROD (120 GALLON 2 ANODES)
NIPPLE
T&P VALVE
JUNCTION BOX COVER
ELEMENT GASKET
ELEMENT PLUG
ELEMENT
THERMOSTAT
THERMOSTAT COVER
ELECTRICAL ACCESS COVER
DRAIN VALVE
SENSOR STUD
FLANGE
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