A.O. Smith PCRT Instruction manual

A.O. Smith PCRT Instruction manual
Instruction Manual
RESIDENTIAL ELECTRIC
WATER HEATERS
FOR POTABLE WATER
HEATING ONLY
NOT SUITABLE FOR
SPACE HEATING
LISTED
GAMA certification applies to all
residential electric water heaters
with capacities of 20 to 120 gallons.
Input rating of 12 Kw or less.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED IN THE U.S.A 0805
1
PART NO. 184639-001
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. 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 indicates a potentially hazardous
situation which, if not avoided, may result
in minor or moderate injury.
CAUTION
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: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing, and electrical installation
of these appliances. This would include a thorough understanding of the requirements of the National Electrical Code and applicable local
electrical and plumbing codes (and tools necessary to confirm proper installation and operation of the water heater) as they relate to
the installation of electric water heaters. The qualified installer must have a thorough understanding of the water heater
Instruction Manual.
•
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, and electrical installation
of these appliances. This would include a thorough understanding of the requirements of the National Electrical Code and applicable local
electrical and plumbing codes (and tools necessary to confirm proper installation and operation of the water heater) as they relate to
the installation of electric water heaters. The service agency must have a thorough understanding of the water heater
Instruction Manual.
2
GENERAL SAFETY
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE .............................. 2
GENERAL SAFETY .................................................................. 3
TABLE OF CONTENTS .............................................................. 3
INTRODUCTION ........................................................................ 4
Preparing for the New Installation ................................... 4
NOTES ...................................................................................... 4
TYPICAL INSTALLATION .......................................................... 5
WIRING DIAGRAMS .................................................................. 6
MIXING VALVE USAGE ............................................................ 7
LOCATING THE NEW WATER HEATER ..................................... 8
Facts to Consider About Location ................................... 8
Insulation Blankets ........................................................... 8
INSTALLING THE NEW WATER HEATER .................................. 8
Water Piping ................................................................. 8-9
Temperature-Pressure Relief Valve ........................... 9-10
Filling the Water Heater .................................................. 10
T&P Valve and Pipe Insulation (Selected Models) ......... 10
TEMPERATURE REGULATION ................................................ 11
Temperature Adjustment ................................................ 11
FOR YOUR INFORMATION ..................................................... 12
Thermal Expansion ......................................................... 12
Strange Sounds ............................................................. 12
Operational Conditions ................................................... 12
Smelly Water .................................................................. 12
“Air” in Hot Water Faucets ............................................. 12
High Water Temperature Shut Off System .................... 12
PERIODIC MAINTENANCE ....................................................... 12
Anode Rod Inspection .............................................. 12-13
Temperature-Pressure Relief Valve Operation .............. 13
Draining .......................................................................... 13
Drain Valve Washer Replacement ................................. 13
Service ........................................................................... 13
LEAKAGE CHECKPOINTS ...................................................... 14
REPAIR PARTS LIST ............................................................... 15
TROUBLESHOOTING .............................................................. 16
WARRANTY ..................................................................... 17-18
3
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
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
(latest edition). The National Electric Code which may be ordered
from: National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
•
ASME - American Society of Mechanical Engineers
•
GAMA - Gas Appliance Manufacturer’s Association
•
NEC - National Electric Code
•
NFPA - National Fire Protection Association
•
UL - Underwriters Laboratory
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local utility or the
manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the water heater.
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN
THE FIELD INVOLVED. PLUMBING AND ELECTRICAL WORK ARE
REQUIRED.
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 will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURYAND/OR PROPERTY DAMAGE.
Examine the location to ensure the water heater complies with the
“Facts to Consider About the Location” section in this manual.
5. For California installation this water heater must be braced, anchored,
or strapped 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, 400 P Street,
Sacramento, CA 95814.
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. Since we cannot put everything
on the first few pages, 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.
NOTES
4
TYPICAL INSTALLATION
LOWBOYS
UPRIGHTS
COMPACTS
TABLE TOPS
INSTALL SUITABLE DRAIN PANS UNDER HEATERS
TO PREVENT DAMAGE DUE TO LEAKAGE. REFER
TO WATER HEATER LOCATION ON PAGE 8.
INSTALL VACUUM RELIEF IN COLD WATER
INLET LINE AS REQUIRED BY LOCAL CODES.
INSTALL THERMAL EXPANSION TANK OR DEVICE
IF WATER HEATER IS INSTALLED IN A CLOSED
WATER SYSTEM.
FIGURE 1.
5
WIRING DIAGRAMS
TURN OFF THE HEATER ELECTRICAL SUPPLY BEFORE SERVICING ANY ELECTRICAL COMPONENTS.
C-2
A-9
TWO WIRE CIRCUIT FOR SINGLE
ELEMENT HEATERS EQUIPPED
WITH HIGH LIMIT CONTROL
240 VOLT “OFF PEAK” NON-SIMULTANEOUS
OPERATION BOTTOM ELEMENT ON SEPARATE
TIME CLOCK OR “OFF PEAK” METER
S-1
THREE WIRE CIRCUIT FOR
ELECTRIC CO. CO-OP
PROGRAMS
A-6
TWO WIRE CIRCUIT FOR
NON-SIMULTANEOUS OPERATION,
HAS SINGLE HIGH LIMIT CONTROL
FIGURE 2.
6
MIXING VALVE USAGE
FIGURE 3.
Water (Potable) Heating: All models are considered suitable for
water (potable) heating only.
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 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/mentally handicapped. 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, shall be used at the hot water taps used by these
people or at the water heater. Mixing valves are available local plumbing
contractor. Consult a Qualified Installer or Service Agency. Follow
mixing valve manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
7
LOCATING THE NEW WATER HEATER
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector
or water shut-off device used in conjunction with a piped drain pan.
These devices are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various ways:
FACTS TO CONSIDER ABOUT THE LOCATION
•
•
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
appliance.
•
•
Whether replacing an old water heater or putting the water heater in a
new location, the following critical points must be observed:
Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
Sensors mounted in the drain pan that turn off the water supply to
the entire home when water is detected in the drain pan.
Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
Devices that will turn off the gas supply to a gas water heater while
at the same time shutting off its water supply.
INSULATION BLANKETS
1. Select a location indoors as close as practical or centralized
to the water piping system as possible. The water heater
should be located in an area not subject to freezing
temperatures.
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 National Appliance Energy Conversation Act standards
with respect to insulation and standby loss requirements, making an
insulation blanket unnecessary.
2. Selected location must provide adequate clearances (4”) for servicing
parts such as the thermostats, drain valve and relief valve. Adequate
clearance for servicing this appliance should be considered before
installation, such as changing the anodes, etc.
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.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under the water heater.
Drain pans are available from your local plumbing contractor. Such a
drain pan must have a minimum length and width of at least 2 inches
(51 mm) greater that the water heater dimensions and must be piped to
an adequate drain.
• 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.
INSTALLING THE NEW WATER HEATER
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. 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, shall be used at the hot water
taps used by these people or at the water heater. Valves for reducing
point of use temperature by mixing cold and hot water are also available.
WATER PIPING
Consult a Qualified Installer or Service Agency. Follow manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the “Temperature Regulation” section in
this manual.
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, cleaning and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to be permanently
8
TEMPERATURE-PRESSURE RELIEF VALVE
This water heater shall not be connected to any heating systems 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.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others, have installed devices such as pressure reducing valves, check
valves, back flow preventers, etc. to control these types of problems.
When these devices are not equipped with an internal by-pass, and no
other measures are taken, the devices cause the water system to be
closed. As water is heated, it expands (thermal expansion) and closed
systems do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of
the water heater’s temperature-pressure relief valve is reached, the
valve will relieve the excess pressure. The temperature-pressure
relief valve is not intended for the constant relief of thermal
expansion. This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a
closed system have a by-pass and/or the system have an expansion
tank or device to relieve the pressure built by thermal expansion in the
water system. Expansion tanks are available for ordering through a
local plumbing contractor. Contact the local water supplier and/or a
service agency for assistance in controlling these situations.
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric
unions or couplings be installed on this water heater when
connected to copper pipe.
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 and Automatic
Gas Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22 •
CSA 4.4, and the code requirements of ASME.
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.
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.
For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly into
the fitting of the water heater designed for the relief valve. Position the
valve downward and provide tubing so that any discharge will exit
only within 6 inches (153 mm) above, or at any distance below the
structural floor. 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.
FIGURE 4.
Figure 4 shows the typical attachment of the water piping to the water
heater. The water heater is equipped with 3/4 inch NPT water
connections.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless
a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge water
in quantities should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water flow may
cause property damage.
NOTE: If using copper tubing, solder tubing to an adapter
before attaching the adapter to the cold water inlet connection.
Do not solder the cold water supply line directly to the cold
water inlet, it will harm the dip tube and damage the tank.
9
in front of or around the outlet of the temperature-pressure relief valve
discharge line, and (2) the water manually discharged will not cause
any bodily injury or property damage because the water may be
extremely hot.
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 new one.
The Discharge Pipe:
FILLING THE WATER HEATER
• Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Shall terminate at an adequate drain.
• Shall not have any valve between the relief valve and tank.
Never use this water heater unless it is completely full of water. To
prevent damage to the tank, the tank must be filled with water. Water
must flow from the hot water faucet before turning “ON” electrical
supply to the water heater.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the right
(clockwise). The drain valve is on the lower front of the water
heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow
is obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as needed.
PIPE INSULATION
FIGURE 5.
FIGURE 6.
T&P VALVE and PIPE INSULATION
(On Selected Models)
Remove insulation for T&P Valve and pipe connections from carton.
Fit pipe insulation over the incoming cold water line and the hot water
line. Make sure that the insulation is against the top cover of the heater.
Fit T&P Valve insulation over valve. Make sure that the insulation does
not interfere with the lever or outlet of the T&P valve.
The temperature-pressure relief valve must be manually operated at
least once a year. Caution should be taken to ensure that (1) no one is
Secure all insulation using tape.
10
TEMPERATURE REGULATION
KEEPING THE THERMOSTAT SETTING AT 120°F WILL REDUCE THE
RISK OF SCALDS.
Due to the nature of the typical water heater, the water temperature in
certain situations may vary up to 30°F (16.7 °C) higher or lower at the
point of use such as, bathtubs, showers, sink, etc.
Figure 7 shows the approximate time-to-burn relationship for normal
adult skin. The thermostats on your water heater have a linear
relationship between degrees of angular rotation and the corresponding
change in temperature. Thus rotating the temperature adjustment
indicator 30 angular degrees will result in a 10 degree Fahrenheit
change in water temperature.
Any water heater’s intended purpose is to heat water. Hot water is
needed for cleansing, cleaning, and sanitizing (bodies, dishes, clothing).
Untempered hot water can present a scald hazard. Depending on the
time element, and the people involved (adults, children, elderly, infirm,
etc.) scalding may occur at different temperatures.
TEMPERATURE ADJUSTMENT
To change the temperature setting:
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 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/mentally
handicapped. 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,
shall 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 instructions for installation of the
valves. Before changing the factory setting on the thermostat, read
the “Temperature Regulation” section in this manual.
1. Turn off the heater electrical supply. Do not attempt to adjust
thermostat with power on.
2. Remove the thermostat access panels and covers from the
thermostats. Do not remove the plastic personnel protectors covering
the thermostats.
3. Using a flat tip screwdriver, rotate the adjustment knob to the desired
temperature setting.
4. Replace the covers and access panels and turn on heater electrical
supply.
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT
WATER TEMPERATURES DESIRED FOR AUTOMATIC
DISHWASHER AND LAUNDRY USE CAN CAUSE SCALDS
RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH.
THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE
PERSON’S AGE AND THE TIME OF THE EXPOSURE. THE SLOWER
RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS
INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL
CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN
BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON
UNATTENDED IN A BATHTUB OR SHOWER.
Temperature
Settings
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 (See Figure 3) be set for the lowest temperature
which satisfies your hot water needs. This will also provide the most
energy efficient operation of the water heater. Thermostat(s) are
factory set at 120°F (49°C) unless specified differently by state
requirements.
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
160°F (71°C)
About 1/2 second
150°F (66°C)
About 1-1/2 seconds
140°F (60°C)
Less than 5 seconds
130°F (54°C)
About 30 seconds
120°F (49°C)
More than 5 minutes
80°F (27°C)
----------------
FIGURE 7.
11
FOR YOUR INFORMATION
THERMAL EXPANSION
c. A sulfate reducing bacteria which has accumulated within the water
heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material, and
then chlorinating the water heater tank and all hot water lines. Contact
the local water heater supplier or service agency for further information
concerning an Anode Replacement Kit and this chlorination treatment.
If the smelly water persists after the anode replacement and chlorination
treatment, we can only suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others, have installed devices such as pressure reducing valves, check
valves, back flow preventers, etc. to control these types of problems.
When these devices are not equipped with an internal by-pass, and no
other measures are taken, the devices cause the water system to be
closed. As water is heated, it expands (thermal expansion) and closed
systems do not allow for the expansion of heated water.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of
the water heater’s temperature-pressure relief valve is reached, the
valve will relieve the excess pressure. The temperature-pressure
relief valve is not intended for the constant relief of thermal
expansion. This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a
closed system have a by-pass and/or the system have an expansion
tank or device to relieve the pressure built by thermal expansion in the
water system. Expansion tanks are available for ordering through a
local plumbing contractor. Contact the local water heater supplier or
service agency for assistance in controlling these situations.
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable and explosive.
To prevent the possibility of injury under these conditions, we
recommend the hot water faucet, located farthest away, be opened
for several minutes before any electrical appliances which are
connected to the hot water system are used (such as a dishwasher or
washing machine). If hydrogen gas is present, there will probably be
an unusual sound similar to air escaping through the pipe as the hot
water faucet is opened. There must be no smoking or open flame near
the faucet at the time it is open.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal parts
during periods of heat-up and cool-down do not necessarily represent
harmful or dangerous conditions.
OPERATIONAL CONDITIONS
SMELLY WATER
In each water heater there is installed at least one anode rod (see
parts sections) for corrosion protection of the tank. Certain water
conditions will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod is one of a
“rotten egg smell” in the hot water. This odor is derived from hydrogen
sulfide gas dissolved in the water. The smell is the result of four
factors which must all be present for the odor to develop:
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
A non-adjustable high temperature limit control operates before steam
temperatures are reached. The high limit is in the same area as the
upper thermostat and must be reset manually when it operates.
BECAUSE THE HIGH LIMIT OPERATES ONLY WHEN
ABNORMALLY HIGH WATER TEMPERATURES ARE PRESENT, IT
IS IMPORTANT THAT A QUALIFIED SERVICE AGENT BE CONTACTED
TO DETERMINE THE REASON FOR OPERATION BEFORE RESETTING.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
PERIODIC MAINTENANCE
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrifices itself to protect the tank. Instead of corroding the tank,
water ions attack and eat away the anode rod. This does not affect
the water’s taste or color. The rod must be maintained to keep the tank
in operating condition.
ANODE ROD INSPECTION
Anode deterioration depends on water conductivity, not necessarily
water condition. A corroded or pitted anode rod indicates high water
conductivity and should be checked and/or replaced more often then
an anode rod that appears to be intact. Replacement of a depleted
12
anode rod can extend the life of your water heater. Inspection should
be conducted by a qualified technician, and at a minimum should be
checked annually after the warranty period.
The water heater should be drained if being shut down during freezing
temperatures. Also periodic draining and cleaning of sediment from the
tank may be necessary.
TEMPERATURE-PRESSURE
RELIEF VALVE OPERATION
1. Turn electrical supply “OFF”.
2. CLOSE the cold water inlet valve to the water heater.
3. OPEN a nearby hot water faucet and leave open to allow for
draining.
4. Connect a hose to the drain valve and terminate to an adequate
drain.
5. OPEN the water heater drain valve to allow for tank draining.
NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. Close the drain valve.
The temperature-pressure relief valve must be manually operated at
least once a year.
7. Follow the instructions in the “Filling the Water Heater” section.
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, see Figure 8.
DRAIN VALVE WASHER REPLACEMENT
(See Figure 9)
1. Follow “Draining” instructions.
2. Turning counter clockwise (
screw handle.
), remove the hex cap below the
3. Remove the washer and put the new one in place.
4. Screw the handle and cap assembly back into the drain valve and
retighten using a wrench. DO NOT OVER TIGHTEN.
5. Follow instructions in the “Filling The Water Heater” section.
6. Check for leaks.
FIGURE 8.
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 new one.
If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal expansion. You
may have a check valve installed in the water line or a water meter
with a check valve. Consult your local water supplier or service
agency for further information. Do not plug the temperature-pressure
relief valve.
DRAINING
FIGURE 9.
SERVICE
If a condition persists or you are uncertain about the operation of the
water heater contact a service agency.
Use this guide to check a “Leaking” water heater. Many suspected
“Leakers” are not leaking tanks. Often the source of the water can be
found and corrected.
If you are not thoroughly familiar with your water heater and safety
practices, contact a qualified installer to check the water heater.
13
LEAKAGE CHECKPOINTS
Read this manual first. Then before checking the water heater make
sure the electrical power supply has been turned “OFF” before checking
the tank for leakage.
B
A
*A. Condensation and dripping may be seen on pipes if the water
temperature is low in humid weather or pipe connections may be
leaking.
A
*B. The anode rod fitting may be leaking.
C. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area. If the valve is not piped to an open drain the released water
could be mistaken for a leaking heater.
D
C
*D. The temperature-pressure relief valve may be leaking at the tank
fitting.
E. Water on the side of the tank may be condensation due to the
panel or insulation not being in place.
E
F. Water from a drain valve may be due to the valve being slightly
opened.
*G. The drain valve may be leaking at the tank fitting.
E
*H. Water in the water heater bottom or on the floor may be from
condensation, loose connections, or the relief valve. DO NOT
replace the water heater until a full inspection of all possible
water sources is made and necessary corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
G
*
H
F
14
To check where threaded portion enters tank, insert cotton swab
between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions in
the “Installing the New Water Heater” section.
REPAIR PARTS LIST
Key No.
Part Description
1
Upper Heating Element (If Dual Element Unit)
2
Lower Heating Element
3
Element Gasket
4
Lower Thermostat (If Dual Element Unit)
5
Upper Thermostat w/ECO (If Dual Element Unit)
6
Lower Thermostat w/ECO (If Single Element Unit)
7
Outer Door(s)
8
Inlet Tube
9
Drain Valve
10
Drain Valve Washer
11
Anode Rod
12
Anode Outlet/Heat Trap (If Applicable)
13
Temperature-Pressure Relief Valve
14
External Heat Trap Nipples (If Applicable)
15
Pipe Insulation (If Applicable)
16
T&P Insulation (If Applicable)
17
Drain Pan w/Side Drain
*
11
8
12
14
14
16
7
5
1 3
Instruction Manual
*Not Illustrated
4 6
2 3
Now that you have purchased this water heater, should a need
ever exist for repair parts or service, simply contact the company
it was purchased from or the manufacturer listed on the rating
plate on the water heater.
15
9 10
Be sure to provide all pertinent facts when you call or visit.
Selling prices will be furnished on request or parts will be
shipped at prevailing prices and you will be billed accordingly.
The model number of your Water Heater will be found on the
rating place located above or adjacent to outer door.
DRAIN PAN
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
• MODEL NUMBER
• SERIAL NUMBER
• PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
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17
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent.
Problem
Cause
WATER LEAKS
(See Leakage Checkpoints on 14)
Improperly sealed, hot or cold supply connection,
relief valve or drain valve.
Tighten threaded connections.
Leakage from other appliances or water lines.
Inspect other appliances near water heater.
Thermal expansion in closed water system.
Install thermal expansion tank
(DO NOT plug T&P valve).
Improperly seated valve.
Check relief valve for proper operation
(DO NOT plug T&P valve).
High sulfate or mineral content in water supply.
Drain and flush heater thoroughly, then refill.
Bacteria in water supply.
Chlorinate water supply.
Power supply to heater is not on.
Turn disconnect switch on or contact
electrician.
Thermostat set too low.
Refer to temperature regulation.
Heater undersized.
Reduce hot water use.
Incoming water is usually cold (Winter).
Allow more time for heat to reheat.
Leaking hot water from pipes or fixtures.
Have plumber check and repair leaks.
High temperature limit switch activated.
Contact dealer to determine cause. See
temperature regulation.
Thermostat set too high.
Refer to temperature regulation.
High temperature limit switch activated.
Contact dealer to determine cause. See
temperature regulation.
Scale accumulation on elements.
Contact dealer to clean or replace elements.
Sediment build-up on tank bottom.
Drain and flush heater thoroughly, then refill.
LEAKING TEMPERATURE
AND PRESSURE
RELIEF VALVE
HOT WATER ODORS
(CAUTION: UNAUTHORIZED REMOVAL OF THE
ANODE(S) WILL VOID THE WARRANTY FOR
FURTHER INFORMATION, CONTACT YOUR
DEALER)
NOT ENOUGH
OR
NO HOT WATER
HOT WATER TOO HOT
WATER HEATER SOUNDS
16
Solution
RESIDENTIAL ELECTRIC WARRANTY
THIS WARRANTY IS APPLICABLE TO THE ORIGINAL
OWNER ONLY. In accordance with the warranty terms
and conditions specified below.
A. O. Smith Water Heaters (the warrantor) will furnish the
ORIGINAL OWNER, 1) a replacement A. O. Smith water
heater of equivalent size and current model if the glasslined
tank in this water heater leaks and, 2) a replacement part
for any component part which fails.
THE A. O. SMITH WATER HEATERS REPLACEMENT
MODEL OR PART WILL BE WARRANTED FOR ONLY THE
UNEXPIRED PORTION OF THE ORIGINAL WARRANTY.
The warranty period will be determined by the original date
of purchase of the water heater, or in the absence of a Bill
of Sale verifying said date, from the date of manufacture
indicated on rating plate affixed to this water heater. This
warranty is not transferrable and applies to models listed
below:
Series
Tank
Parts
10-year
10-year
ProMax® 10-Year Models 10-year
6-year
®
Conservationist
This warranty shall apply only when the heater is:
•
•
•
•
•
•
•
•
•
•
•
PXHT, PXHS
•
PCRT, PCRS, PCT, PCS, PCL, PCJ, PLJC, PLSC
ProMax® 6-Year Models
6-year
•
•
•
6-year
ECRT, ECRS, ECT, ECS, ECL,
ECJ, ELJC, ESTT, ELSC, ECLN, ECJN
When the water heater has been used for other than single
family residential application;
1. The tank warranty shall be reduced to 1 year for 6 year
models and to 3 years for 10 year models.
2. The parts warranty shall be reduced to 1 year for all
models.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is
installed and operated in accordance with 1) all local fire
codes and plumbing codes, ordinances and regulations, 2)
the printed instructions provided with it, 3) good industry
practices, and 4) proper safety practices such as but not
limited to a properly sized drain pan if installed in an area
where leakage from the tank or its connections would result
in damage to the area adjacent to the heater. In addition, a
new temperature and pressure relief valve, certified by the
Canadian Gas Association must have been properly installed
and piped to the nearest drain.
17
owned by the original purchaser;
installed for indoor operation only;
used at temperatures not exceeding the maximum
calibrated setting of its thermostat;
used at water pressure not exceeding the working
pressure shown on the heater;
filled with potable water, free to circulate at all times
and with the tank free of damaging water sediment
or scale deposits;
used in a non-corrosive and non-contaminated
atmosphere;
used with factory approved anode(s) installed;
in its original installation location;
in the United States, its territories or possessions,
and Canada;
sized in accordance with proper sizing techniques
for residential water heaters;
bearing a rating plate which has not been altered,
defaced or removed except as required by the
warrantor;
used in an open system or in a closed system with
a properly sized and installed thermal expansion tank;
connected to the proper voltage or:
operated at the factory rated input;
installed with no attempted, nor actual modification
or alteration of the water heater’s design in any way,
including but not limited to, the attachment of noncompany approved appliances or equipment.
Any accident to the water heater or any part thereof
(including freezing, fire, floods, or lightning), any misuse,
abuse or alteration of it, any operation of it in a modified
form, any operation of the water heater on desalinated
(deionized) water, or any damage caused by attempts
to repair tank leaks or parts, will void this warranty. This
warranty does not cover water heaters replaced for
cosmetic reasons or for reasons of noise, taste, odor,
discolored and/or rusty water. This warranty does not
apply to water heaters used to heat pools, whirlpools or
hot tubs or used for space heating where its sizing does
not conform with specifications of the heating component
manufacturer.
This warranty gives you specific legal rights, and you
may have other rights which vary under the laws of each
state. If any provision of this warranty is prohibited or
invalid under applicable state law, that provision shall be
ineffective to the extent of the prohibition or invalidity
without invalidating the remainder of the affected provision
or the other provisions of this warranty.
Dealer replacements are made subject to in-warranty
validation by warrantor.
SERVICE AND LABOR RESPONSIBILITY
PROOF OF PURCHASE AND PROOF OF INSTALLATION
DATE ARE REQUIRED TO SUPPORT WARRANTY
CLAIM FROM ORIGINAL OWNER. THIS FORM DOES
NOT CONSTITUTE PROOF OF PURCHASE OR PROOF
OF INSTALLATION.
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:
DISCLAIMERS
NO EXPRESSED 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 OR PARTS. 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. Labor charges for service, removal, or reinstallation
of the water heater or part thereof.
b. Shipping and delivery charges for forwarding the new
water 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 handling and
administrative charges, and for any materials and/or
permits required for installation of the replacement
heater or part.
LIMITATION ON IMPLIED WARRANTIES
Should governmental regulations or industry standards
prohibit the Manufacturer from furnishing a comparable
model replacement under this warranty, the Owner will be
furnished with the closest comparable water heater meeting
the then current governmental regulations and industry
standards. A supplementary fee may be assessed to cover
the additional cost associated with the changes made to
meet applicable regulations and standards.
Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state
law are limited to one 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
limitations may not apply to you.
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 practical,
the owner should contact: A.O. Smith Corporation,
5621 W. 115th Street, Alsip, Illinois 60803. Phone:
1.800.323.2636 or visit our website: www.hotwater.com.
IMPORTANT INFORMATION
Model Number _______________________________
Serial Number _______________________________
INSTALLATION INFORMATION
For Canadian customers contact: A.O. Smith
Enterprises LTD., P.O. Box 310, 768 Erie Street,
Stratford, Ontario N5A6T3 or phone: 1.800.265.8520
Date Installed _______________________________
Company’s Name ____________________________
Replacement Parts may be ordered through authorized
servicers or distributors. Refer to your local Yellow
Pages for where to call or contact A.O. Smith Corporation,
5621 W. 115th Street, Alsip, Illinois 60803.
Phone: 1.800.433.2545 or visit our website at:
www.hotwater.com/parts.
Street or P.O. Box ____________________________
City, State, and Zip Code ______________________
Phone Number ______________________________
The warrantor will only honor replacement with identical
or similar water heater or parts thereof which are
manufactured or distributed by the warrantor.
Plumber’s Name _____________________________
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