Instruction Manual
COMMERCIAL ELECTRIC WATER HEATERS
MODELS
500 Tennessee Waltz Parkway
Ashland City, TN 37015
PCE-6/10/17/20 10MSA Series 102
PCE-30/40/50 2OLSA Series 110
& PCE-30/40/52/66/82/120 2ORTA Series 110
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED 0912
1
195202-004
SAFE INSTALLATION, USE, AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
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.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
water heater can cause low level exposure to some of the substances listed in the Act.
IMPORTANT DEFINITIONS
• Qualified Installer or Service Agency:
Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the
field involved. Installation skills such as plumbing, electrical supply are required in addition to electrical testing skills when performing
service.
• ANSI Z223.1 2006 Sec. 3.3.83:
“Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of
appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all
the requirements of the authority having jurisdiction.”
2
GENERAL SAFETY INFORMATION
Precautions
Hydrogen Gas (Flammable)
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualified service technician
to inspect the water heater and to replace any part of the control
system which has been under water.
If the unit is exposed to the following, do not operate heater until
all corrective steps have been made by a qualified service agency.
1. External fire.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
Hydrogen gas can be produced in a hot water system served by this
heater that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas 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. If hydrogen is present
there will probably 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.
This water heater must be grounded in accordance with the
National Electrical Code and/or local codes. These must be
followed in all cases.
This water heater must be connected to a grounded metal, permanent
wiring system; or an equipment grounding conductor must be run with
the circuit conductors and connected to the equipment grounding
terminal or lead on the water heater.
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
3
TABLE OF CONTENTS
Thermal Expansion..................................................................... 10
electrical.......................................................................................11
General.........................................................................................11
Branch Circuit...............................................................................11
Calculating Amperage/Overcurrent Protection.............................11
WIRING DIAGRAMS........................................................................... 12
OPERATION........................................................................................ 13
General........................................................................................ 13
Filling the Water Heater............................................................... 13
Initial Start Up.............................................................................. 13
Draining the Water Heater........................................................... 13
TEMPERATURE REGULATION......................................................... 14
Temperature Adjustment............................................................. 14
MAINTENANCE.................................................................................. 15
General........................................................................................ 15
Anode Rod Inspection................................................................. 15
TROUBLESHOOTING CHECKLIST................................................... 16
Checklist...................................................................................... 16
Leakage Checkpoints.................................................................. 17
nOTES................................................................................................ 18
Repair Parts List.......................................................................... 20
SAFE INSTALLATION, USE, AND SERVICE....................................... 2
GENERAL SAFETY INFORMATION..................................................... 3
Precautions................................................................................... 3
Hydrogen Gas (Flammable).......................................................... 3
Introduction................................................................................... 4
Preparing for the Installation......................................................... 4
dimensions and capacities data............................................... 5
APPROVALS......................................................................................... 6
model and rating........................................................................... 6
FEATURES AND COMPONENTS........................................................ 7
LOCATING THE NEW WATER HEATER.............................................. 8
Facts to Consider About the Location........................................... 8
Clearances.................................................................................... 8
iNSTALLATION..................................................................................... 9
Required Ability............................................................................. 9
General.......................................................................................... 9
Contaminated Water...................................................................... 9
Circulating Pump........................................................................... 9
Insulation Blankets........................................................................ 9
Temperature-Pressure Relief Valve............................................... 9
Closed Water Systems................................................................ 10
Introduction
Be sure to turn off power when working on or near the
electrical system of the heater. Never touch electrical
components with wet hands or when standing in water.
When replacing fuses always use the correct size for the
circuit. see page 12.
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
The model and rating plates on page 6 interprets certain
markings into useful information. Both of these references should
be used to identify the heater, its components and optional
equipment.
Preparing for the Installation
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 local codes, the
installation must comply with the latest editions of the National
Electrical Code, NFPA 70 or the Canadian Electrical Code CSA
C22.1. The National Electrical Code may be ordered from:
National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269. The Canadian Electrical Code is available
from the Canadian Standards Association, 8501 East Pleasant
Valley Road, Cleveland, OH 44131.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the toll free
number listed on the back cover of this manual for technical
assistance.
1. Read the “General Safety Information” section of this manual
first and then the entire manual carefully. If you don’t follow
the safety rules, the water heater may not operate safely. It
could cause DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
A sample rating plate is shown on page 6 of this manual. In
order to expedite your request, please have full model and serial
number available for the technician.
4. Carefully plan your intended placement of the water heater.
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
This manual contains instructions for the installation, operation,
and maintenance of the electric water heater. It also contains
warnings throughout the manual that you must read and be
aware of. All warnings and all instructions are essential to the
proper operation of the water heater and your safety. READ
THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL
OR OPERATE THE WATER HEATER.
4
Installation and service of this water heater requires ability
equivalent to that of a licensed tradesman or qualified agency
(page 2) in the field involved. Plumbing and electrical work
are required.
dimensions and capacities data
Figure 1
Table 1 - Rough-in dimensions
Models
Dimensions
No. of
Elements
PCE 6 1OMSA
PCE 10 1OMSA
PCE 17 1OMSA
PCE 20 1OMSA
PCE 30 2OLSA
PCE 40 2OLSA
PCE 50 2OLSA
PCE 30 2ORTA
PCE 40 2ORTA
PCE 52 2ORTA
PCE 60 2ORTA
PCE 82 2ORTA
PCE 120 2ORTA
1
1
1
1
2
2
2
2
2
2
2
2
2
Tank Capacity
US Gals.
6
10
15
20
30
40
50
30
40
50
66
80
119
Litres
23
38
57
76
114
151
189
114
151
189
250
303
450
A
inches
15 1/2
18 1/4
26
22 1/4
30 7/8
32 1/4
32 1/4
34 1/2
45 1/8
54 7/8
60 3/4
59 3/8
62 7/16
B
mm
394
464
660
565
784
819
819
876
1146
1394
1543
1508
1586
inches
14 1/4
18
18
21 3/4
21 3/4
24
26 1/2
20 1/2
20 1/2
20 1/2
21 3/4
24
29 3/8
C
mm
362
457
457
552
552
610
673
521
521
521
552
610
746
inches
11
12 1/2
20 1/2
15 3/8
24 1/8
25 9/16
25 1/8
-
Approx.
Shipping Weight
Lbs.
Kg.
35
15.9
54
24.5
58
26.3
73
33.1
100
45.4
125
56.7
166
75.3
98
44.5
113
51.3
131
59.4
176
79.8
211
95.7
326
147.9
D
mm
279
318
521
391
613
649
638
-
inches
8
8
8
8
8
8
8
8
8
mm
203
203
203
203
203
203
203
203
203
Table 2 - Recovery capacities
U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED
Element
INPUT
Wattage
F°
36F°
40F°
54F°
60F°
72F°
80F°
90F°
100F°
108F°
KW
(Upper/Lower)
C°
20C°
22.2C°
30C° 33.3C° 40C°
44.4C°
50C°
55.5C°
60C°
NON-SIMULTANEOUS
/1500
GPH
17
15
11
10
8
8
7
6
6
1.5
LPH
64
58
43
38
32
29
26
23
21
/2000
GPH
23
20
15
14
11
10
9
8
8
2.0
LPH
85
77
57
51
43
38
34
31
28
/2500
GPH
28
25
19
17
14
13
11
10
9
2.5
LPH
107
96
71
64
53
48
43
38
36
3000/3000
GPH
34
30
23
20
17
15
14
12
11
3.0
LPH
128
115
85
77
64
58
51
46
43
4000/4000
GPH
45
41
30
27
23
20
18
16
15
4.0
LPH
170
153
114
102
85
77
68
61
57
4500/4500
GPH
51
46
34
30
25
23
20
18
17
4.5
LPH
192
173
128
115
96
86
77
69
64
5000/5000
GPH
56
51
38
34
28
25
23
20
19
5.0
LPH
213
192
142
128
107
96
85
77
71
6000/6000
GPH
68
61
45
41
34
30
27
24
23
6.0
LPH
256
230
170
153
128
115
102
92
85
SIMULTANEOUS OPERATION
3000/3000
GPH
68
61
45
41
34
30
27
24
23
6
LPH
256
230
170
153
128
115
102
92
85
4000/4000
GPH
90
81
60
54
45
41
36
32
30
8
LPH
341
307
227
205
170
153
136
123
114
4500/4500
GPH
101
91
68
61
51
46
41
36
34
9
LPH
384
345
256
230
192
173
153
138
128
5000/5000
GPH
113
101
75
68
56
51
45
41
38
10
LPH
426
384
284
256
213
192
170
153
142
6000/6000
GPH
135
122
90
81
68
61
54
49
45
12
LPH
511
460
341
307
256
230
205
184
170
120F°
66.6C°
126F°
70C°
5
19
7
26
8
32
10
38
14
51
15
58
17
64
20
77
5
18
6
24
8
30
10
37
13
49
14
55
16
61
19
73
20
77
27
102
30
115
34
128
41
153
19
73
26
97
29
110
32
122
39
146
Recovery capacities at 100° F rise equal: for non-simultaneous element operation = 4.1 gal. x KW of one element; for simultaneous element operation = 4.1 gal. x 2/3 KW of
both elements. For other rises multiply element KW as previously explained by 410 and divide by temperature rise. Full load current for single phase = total watts : voltage.
5
APPROVALS
All models are listed by
Underwriters Laboratories Inc.
model and rating
PCE 6/10/17/20 1OMSA
PCE 30/40/50 2OLSA & PCE 30/40/52/66/80/120 2ORTA
6
FEATURES AND COMPONENTS
This page shows typical water heater installations by model designations.
PCE DUAL ELEMENT HEATER
PCE SINGLE ELEMENT HEATER
INSTALL SUITABLE DRAIN PANS UNDER WATER HEATERS
TO PREVENT DAMAGE DUE TO LEAKAGE. REFER TO WATER
HEATER LOCATION ON page 8.
I NSTALL THER M AL
E X PANS I ON TANK
IF CHECK VALVE OR
PRESSURE REDUCING
VALV E I S USED I N
SUPPLY LINE.
INSTALL VACUUM RELIEF
IN COLD WATER INLET
LINE AS REQUIRED BY
LOCAL CODES.
† OVER CURRENT PROTECTION MUST BE SUPPLIED IN WATER HEATER CIRCUIT.
CONSULT LOCAL CODE OR NEC FOR PROPER INSTALLATION.
* INSTALL IN ACCORDANCE WITH ALL LOCAL CODES.
Figure 2
7
LOCATING THE NEW WATER HEATER
Facts to Consider About the Location
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:
• 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.
The water heater should be located as close as possible to/or
centralized to the water piping system. The water heater should
be located in an area not subject to freezing temperatures.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and how water
pipes connected to the water heater.
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 heater or to lower floors of the structure.
• Devices that will turn off the gas supply to a gas water heater
while at the same time shutting off its water supply.
Clearances
When such locations cannot be avoided, a suitable drain pan
should be installed under the heater.
A minimum clearance of 4” must be allowed for access to
replaceable parts such as thermostats, drain valve and relief
valve.
Such pans should be at least two inches deep, have a minimum
length and width of at least two inches greater than the diameter
of the heater and should be piped to an adequate drain.
Adequate clearance for servicing this water heater should be
considered before installation, such as changing the anodes, etc.
Drain pans suitable for these water heaters are available from
your distributor or State Water Heaters, 500 Tennessee Waltz
Parkway, Ashland City, TN 37015.
FLOOD WARNING
IF THE HEATER BECOMES IMMERSED IN WATER UP
TO OR ABOVE THE LEVEL OF THE BOTTOM OF THE
ELEMENT DOORS, THE HEATER SHOULD BE EXAMINED
BY A QUALIFIED SERVICE AGENT BEFORE IT IS PLACED
IN OPERATION.
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
8
iNSTALLATION
Required Ability
Contaminated Water
Installation and service of this water heater requires ability equivalent
to that of a qualified installer or service agency (page 2) in the
field involved. Plumbing and electrical work is required.
This water heater shall not be connected to any heating system(s)
or component(s) used with a non-potable water heating appliance.
Toxic chemicals, such as those used for boiler treatment shall not
be introduced into this system.
General
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 local codes, the installation must comply
with the latest editions of the National Electrical Code, NFPA 70 or
the Canadian Electrical Code CSA C22.1. The National Electrical
Code may be ordered from: National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical
Code is available from the Canadian Standards Association, 8501
East Pleasant Valley Road, Cleveland, OH 44131.
Circulating Pump
Field installed circulating pumps should be of all bronze
construction.
Insulation Blankets
Insulation blankets are available to the general public for
external use on electric water heaters but are not necessary with
this product. The purpose of an insulation blanket is to reduce
the standby heat loss encountered with storage tank heaters.
Your water heater meets or exceeds the EPACT and ASHRAE/
IES 90.1 standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
Do NOT test electrical system before heater is filled with water, follow
the START UP procedure in the OPERATION section of this manual.
The principal components of the heater are identified in the
Features and Components illustrations on page 7.
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions below. Failure to follow
these instructions can result in fire, serious personal injury,
or death.
• Do not cover the temperature and pressure relief (T & P) valve
with an insulation blanket.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels for placement on
the blanket directly over the existing labels.
Temperature-Pressure Relief Valve
MIXING VALVE USAGE:
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 injured by hot water than others. These include
the elderly, children, the infirm, or physically/developmentally
disabled. If anyone using hot water in your home fits into one of
these groups or if there is a local code or state law requiring a
maximum water temperature at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means
such as a MIXING VALVE, should be used at the hot water taps
used by these people or at the water heater.
MIXING VALVES for reducing point of use temperature are available
and are to be set at a maximum of 125 degree F. Consult a qualified
installer or service agency. Follow all manufacturer’s Instructions
for installation of these valves. Before changing the factory setting
on the thermostat, read the “Temperature Regulation” section in
this manual.
This water heater is provided with a properly rated/sized and
certified combination temperature - pressure relief valve by the
manufacturer. The valve is certified by a nationally recognized
testing laboratory that maintains periodic inspection of production
of listed equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA
4.4, and the code requirements of ASME.
If replaced, the new valve must meet the requirements of local
codes, but not less than a combination temperature and pressure
relief valve rated/sized and certified as indicated in the above
9
paragraph. The new 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 Btu/hr or KW input rate as shown on
the water heater’s model rating plate.
For safe operation of the water heater, the temperature and pressure
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.
Install discharge piping so that any discharge will exit only within 6
inches (15.2 cm) 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.
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 in front of or around the outlet of the temperature-pressure
relief valve discharge line, and (2) the water manually discharged
can cause 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 in this manual, and replace the temperature-pressure
relief valve with a properly rated/sized new one.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect discharge piping directly to the drain
unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury,
hazard to life, or property damage, the relief valve must be allowed
to discharge water in adequate 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.
If you do not understand these instructions or have any questions
regarding the temperature-pressure relief valve call the toll free
number listed on the back cover of this manual for technical assistance.
Closed Water Systems
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
devices such as pressure reducing valves, check valves, and back
flow preventers. Devices such as these cause the water system to
be a closed system.
Thermal Expansion
As water is heated, it expands (thermal expansion). In a closed system
the volume of water will grow when it is heated. As the volume of
water grows there will be a corresponding increase in water pressure
due to thermal expansion. Thermal expansion can cause premature
tank failure (leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause intermittent
temperature-pressure relief valve operation: water discharged from
the valve due to excessive pressure build up. This condition is not
covered under the limited warranty. The temperature-pressure relief
valve is not intended for the constant relief of thermal expansion.
The Discharge Pipe:
• 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.
• Must terminate a maximum of six inches above a floor drain or
external to the building. In cold climates, it is recommended that the
discharge pipe be terminated at an adequate drain inside the building.
• Shall not have any valve or other obstruction between the relief
valve and the drain.
A properly sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a local plumbing service agency to have a thermal expansion
tank installed.
10
electrical
This is an example of calculating heater amperage for both types
of element operation. From this, the branch circuit conductor and
overcurrent protection sizing can be established.
The example is of a three-phase 240 volt unit with two, 6 kw
elements. The notations are for units field converted to single-phase.
Check the heater model and rating plate for actual specifications
and substitute those values in the following.
Table 3
Non-simultaneous:
(as factory wired)
Simultaneous:
(Field conversion)
3000 : 240 = 12.5 amps*
3000 : 240 = 12.5 amps*
12.5 x 1.73 = 21.6 amps
NOTE: as a single-phase
*NOTE: as a single-phase non- *simultaneous
unit the total is:
simultaneous unit.
12.5 x 2 = 25 amps
General
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 local codes, the installation must comply
with the current editions of the National Electrical Code, NFPA 70 or
the Canadian Electrical Code CSA C22.1.
The rating of the overcurrent protection should be computed on the
basis of 125 percent of the total connected load amperage. Where the
standard ratings and settings do not correspond with this computation,
the next higher standard rating or setting should be selected.
Portion of Table 310-16 (NFPA-70) follows:
Allowable Ampacities of Insulated Copper Conductors. Not more
than three conductors in Raceway or Cable or Direct Burial (Based
on Ambient Temperature of 30° C, 86° F).
An electrical ground is required to reduce risk of electrical shock
or possible electrocution. The water heater should be connected
to a separate grounded branch circuit with over-current protection
and disconnect switch. The water heater should be grounded in
accordance with national and local codes.
These ampacities relate only to conductors described in Table
310-13 in Code.
Voltage applied to the heater should not vary more than +5% to -10%
of the model and rating plate marking for satisfactory operation.
For ambient temperatures over 30° C (86° F), see Correction
Factors, Note 13 in Code.
DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON
BEFORE THE HEATER TANK IS FILLED WITH WATER. DOING
SO WILL CAUSE THE HEATING ELEMENTS TO BURN OUT AND
VOID WARRANTY.
For ambient temperatures over 30° C (86° F), see Correction
Factors, Note 13 in Code.
Table 4
The factory wiring is attached to a terminal block within the external
junction box unit. The branch circuit is connected to the terminal
block within this junction box. The water heater should be connected
to a separate, grounded, branch circuit with overcurrent protection
and disconnect switch. The water heater should be grounded in
accordance with national and local codes.
Size
AMG
MCM
18
16
14
12
10
8
6
4
3
Branch Circuit
The branch circuit wire size should be established through reference
to the current edition of NFPA-70, the National Electrical Code
or other locally approved source in conjunction with the heater
amperage rating. For convenience, portions of the wire size tables
from the Code are reproduced here. The branch circuit should be
sized at 125 percent of the heater rating and further increase wire
size as necessary to compensate for voltage drop in long runs.
Temperature Rating of Conductor
See Table 310-13 in Code
60°C
75°C
(140°F)
(167°F)
Types:
Types:
RH, RHW, RUH, (14-2),
RUW, (14-2), T, TW, UF
THW, THWN, XHHW, USE
--------15
15
20
20
30
30
40
45
55
65
70
85
80
100
Portion of Table 310-18 follows:
Allowable Ampacities of Insulated Aluminum and Copper -Clad
Aluminum Conductors.
Calculating Amperage/Overcurrent Protection
The heaters come from the factory in two configurations:
1. Two wire C-2 circuit for single element heater equipped with a
high limit control, single phase power input.
2. Four wire A-8 circuit for dual element heater equipped with two
high limit controls, single phase or three phase power input.
Not more than three conductors in Raceway or Cable or Direct Burial
(Based on Ambient Temperature of 30° C, 86° F. These ampacities
relate only to conductors described in Table 310-13 in Code.
For ambient temperatures over 30° C (86° F), see Correction Factors,
Note 13 in Code.
The heater with dual elements is factory wired for connection to
a three wire, three-phase delta branch circuit, non-simultaneous
operation. In addition a ground conductor is required.
Table 5
Element connection is for non-simultaneous operation. This means
only one element at a time operates. The wiring diagram, on page
12, shows the heater may be field converted to simultaneous
element operation by moving the red wire on “J” terminal to L1. It is
then possible for both elements to operate at once as determined
by the thermostats. Regardless of element connection the heater
operates in an “unbalanced” fashion.
Size
AMG
MCM
12
10
8
6
4
3
2
1
The heater may be field converted to single-phase operation by moving
the wire on L3 of the terminal block to L2. L3 is not used, see page 12.
The heater, now in single-phase non-simultaneous operation, may
be field-converted to single phase simultaneous operation by moving
the red wire on terminal “J” to L1, see page 12.
11
Temperature Rating of Conductor
See Table 310-13 in Code
60°C
75°C
(140°F)
(167°F)
Types:
Types:
RH, RHW, RUH, (12-2),
RUW, (12-2), T, TW, UF
THW, THWN, XHHW, USE
15
15
25
25
30
40
40
50
55
65
65
75
75
90
85
100
WIRING DIAGRAMS
A-8 CIRCUIT FOR DUAL ELEMENT HEATER
C-2 CIRCUIT
FOR SINGLE
ELEMENT HEATERS
EQUIPPED WITH HIGH
LIMIT CONTROL
FACTORY WIRED
---------- FIELD WIRING
† WHITE FOR 120V & 277V
Figure 3
12
OPERATION
General
Initial Start Up
Refer to the Features and Components section of this manual (page
7) for the location of components mentioned in the instructions
that follow.
The following checks should be made by the installer when the heater
is placed into operation for the first time.
NEVER turn on power to the water heater without being certain the
water heater is filled with water and a temperature and pressure
relief valve is installed in the relief valve opening.
2. Open the front panel or top access cover, check all water and
electrical connections for tightness. Also check connections on top
and or sides of heater. Repair water leaks and tighten electrical
connections as necessary.
1. Turn off the electrical disconnect switch.
DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS
FILLED WITH WATER. FOLLOW FILLING AND START-UP
INSTRUCTIONS IN OPERATION SECTION.
3. Depress the red manual reset button on each Thermostat/ECO
combination control. (See Figure 5)
4. Turn on the electrical disconnect switch.
5. Observe the operation of the electrical components during the first
heating cycle. Use care as the electrical circuits are energized.
6. Close the front panel or top access cover.
Temperature control and contactor operation should be checked by
allowing heater to come up to temperature and shut off automatically.
Use care as the electrical circuits are energized.
Draining the Water Heater
The water heater must be drained if it is to be shut down and exposed
to freezing temperatures. Maintenance and service procedures may
also require draining the heater.
Filling the Water Heater
1. Turn off the electrical disconnect switch.
2. Open a hot water valve until the water is cool, then close the
supply water inlet valve to heater.
3. Attach hose to outlet opening of drain valve and direct end to drain.
4. Open a nearby hot water faucet and the heater drain valve.
5. If the heater is being drained for an extended shutdown, it is
suggested the drain valve be left open during this period. The
hose may be removed.
Follow FILLING instructions when restoring hot water service.
1. Turn off the electrical disconnect switch.
2. Close the water heater drain valve.
3. Open a nearby hot water faucet to permit the air in the system
to escape.
4. Fully open the cold water inlet pipe valve allowing the heater and
piping to be filled.
5. Close the hot water faucet as water starts to flow. The
heater is now ready for STARTUP and TEMPERATURE
REGULATION.
INSTALLATION
13
TEMPERATURE REGULATION
Temperature Adjustment
The water temperature is controlled by surface mounted thermostats
with ECO high limit. There is one mounted firmly against the tank
directly above each element. The thermostats of A-8 circuit are
adjustable from approximately 120°F (49°C) (lowest setting) to 180°F
(82°C) (highest setting). The thermostat of C-2 circuit is adjustable
from approximately 110°F (43°C) to 170°F (77°C). The over
temperature device (ECO high limit) attached to each thermostat
has a manual reset.
THE WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT
WATER AT 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 TIME OF EXPOSURE. THE SLOWER
RESPONSE TIME OF CHILDREN , AGED OR DISABLED PERSONS
INCREASES THE HAZARD 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.
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 thermostats (See Figure 4) 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.
NOTE: It is not necessary to adjust the upper thermostat for a dual
element unit. However, if it is adjusted above the factory set point
120°F (49°C) it is recommended that it not be set higher than the
lower thermostat setting.
Figure 4 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.
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
Figure 5
To change the temperature setting:
1.
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
DANGER: Turn off the heater electrical supply. Do not attempt
to adjust thermostat with power on.
2. Open the junction box door (for upper thermostat of dual
element water heater only) and/or remove the (lower) thermostat
access panel. Do not remove the plastic personnel protectors
covering the thermostats. The thermostat is factory pre-set at
120°F (49°C).
110 (43)
(normal shower temp.)
116 (47)
(pain threshold)
116 (47)
35 minutes
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (68)
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
3. Using a flat tip screwdriver, rotate the adjusting knob to the
desired temperature setting.
4.
Figure 4
14
Replace the covers and access panels, and turn on heater
electrical supply.
MAINTENANCE
General
Anode Rod Inspection
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 tank, water ions attack
and eat away the anode rod. This does not affect water’s taste or
color. The rod must be maintained to keep tank in operating condition.
Periodically the drain valve should be opened and the water
allowed to run until it flows clean. This will help to prevent
sediment buildup in the tank bottom.
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 than
an anode rod that appears to be intact. Replacement of a depleted
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.
Periodically check the temperature and pressure relief valve
to ensure that it is in operating condition. Lift the lever at the
top of the valve several times until the valve seats properly
and operates freely.
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
Water heater maintenance includes periodic tank flushing and
cleaning, and removal of lime scale from the heating element.
The use of a water softener may decrease the life of the water
heater tank.
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates
its replacement. The anode rod is not covered by the limited warranty.
The heater tank is equipped with an anode rod to aid in
corrosion control.
NOTE: Artificially softened water requires the anode rod to be
inspected annually.
15
TROUBLESHOOTING CHECKLIST
Checklist
ABNORMAL SOUNDS
Before calling for service, check the following points to see if the
cause of trouble can be identified and corrected.
1. Sediment or lime scale accumulations on the elements causes
sizzling and hissing noises when the heater is operating.
• The sounds are normal, however, the tank bottom and
elements should be cleaned. See the Maintenance section
of this manual.
Reviewing this checklist may eliminate the need of a service call
and quickly restore hot water service. See Figure 2 on page 7 in this
manual to identify and locate water heater components.
Water leakage is suspected
Refer to Leakage Checkpoint on the following page 17.
1. Check to see if the heater drain valve is tightly closed.
2. If the outlet of the relief valve is leaking it may represent:
• Excessive water temperature.
• Faulty relief valve.
• Excessive water pressure.
3. Excessive water pressure is the most common cause of relief valve
leakage. It is often caused by a “closed system”. See “Closed
Water Systems” and “Thermal Expansion” in the Installation
section of this manual for more information.
4. Examine the area around the element for gasket leakage.
• Tighten the elements or, if necessary, replace the gaskets.
Not enough or no hot water
1. Be certain the electrical disconnect switch serving the water heater
is in the ON position.
IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF
MALFUNCTION
2. Check the fuses.
• The electrical disconnect switch usually contains fuses.
1. Turn the power supply to the water heater off.
3. If the water was excessively hot, and is now cold, the high limit
switch may have activated.
• See the Temperature Regulation section of this manual for
more information on how to reset the ECO high limit controls.
2. Close the supply water inlet valve to the heater.
3. Contact a Qualified Service Agency in your area. Call the toll free
phone number on the back cover of this Instruction Manual for
assistance in locating a service agency in your area.
4. The capacity of the heater may have been exceeded by a large
demand for hot water.
• Large demands require a recovery period to restore water
temperature.
REPLACEMENT PARTS
Call the toll free phone number on the back cover of this Instruction
Manual for assistance in locating replacement parts.. When ordering
parts, specify complete model no., serial no., (see rating plate),
quantity and name of part desired. Standard hardware items should
be purchased locally.
5. Cooler incoming water temperature will lengthen the time required
to heat water to the desired temperature.
6. Look for hot water leakage.
7. Sediment or pipe scale may be affecting water heater operation.
16
Leakage Checkpoints
Instructions: Use this illustration as a guide when checking for sources of water leakage. You or your dealer may be able to correct what
appears to be a problem. NOTE: Cover and Insulation shown removed to reveal tank top.
Where possible remove or lift top cover to
examine threads of fittings installed into tank
for evidence of leakage. Correct fitting leaks
as necessary.
Relief Valve
Condensation and dripping may appear
on pipes when cold water temperature is
low. Pipe fitting may be leaking.
Water leaks at the elements may be due
to:
1. Defective element which leaks at
terminals or thru flange. Replace
element*.
To Open Drain
Anode Rod (Some Models)
2. Loose element/gasket leak:
(a) Screw-in type: tighten with 1-1/2”
socket wrench. If leak continues,
remove element*, discard gasket
and clean thread areas. Apply
nonhardening Permatex Number 2
to thread areas, install new gasket
and screw element into fitting until
it seats. Tighten 1/2 to 3/4 turn with
wrench.
(b) Flange type: tighten screw with
wrench. If leak continues remove
element* and discard gasket. Clean
gasket seating areas and re-install
element with new gasket. A new
element may be required where
threads have become rusted or
damaged, preventing tightening.
Relief valve operation and leakage
may be due to water expansion during
heating cycle or foreign material on seat
of valve. If the valve is not piped to an
open drain the released water could be
mistaken for a leaking heater. To check
where threaded material between jacket
opening and swab spud area. Remove
valve* if indicated and repair with pipe
joint compound.
To Open Drain
Water on the side of the tank may
be condensation due to the panel or
insulation not being in place.
All water which appears at the water
heater bottom or on the surrounding floor
may be caused by condensation, loose
connections or relief valve operation
and leakage. Do not replace the water
heater until full inspection of all potential
leak points is made and corrective steps
taken to stop the leak. Leakage from other
appliances, water lines or ground (see
page 16) should also be suspected until
proven otherwise.
Drain valve leakage could be from the
valve itself.* To check for leakage where
threaded portion enters tank, insert Q-tip
or similar absorbent material between
jacket opening and valve to swab spud
area. Remove valve* if leak is indicated
and repair with pipe joint compound.
Figure 6
17
*Contact your dealer as it is necessary to
shut off electricity and drain tank to perform
procedure.
nOTES
18
nOTES
19
Repair Parts List
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 direct from the manufacturer listed on the rating
plate on the water heater.
Be sure to provide all pertinent facts when you call or visit.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
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
plated located above the lower access panel.
•
•
•
•
MODEL NUMBER
VOLTAGE AND ELEMENT WATTAGE
SERIAL NUMBER
PART DESCRIPTION
PCE 6/10/17/20 (refer to repair parts table).
DRAIN VALVE
(not supplied with heater)
Part No. 26273-5
Figure 7
20
ItemDescriptionPCE-61OSMAPCE-101OSMAPCE-171OSMAPCE-201OSMA
Series 102Series 102Series 102Series 102
1A........ Anode, Alum... . .................................. 9003942005.......... 9003942005......... 9003942005........ 9003944005
1B........ Anode, Mag. (SMR P72 and S19)...... 9001909005.......... 9001909005......... 9001909005........ 9003721005
2......... Collar, Pipe...........................................9004610115.......... 9004610115..........9004610115........ 9004610115
3......... Cover, Front........................................ 9003900005.......... 9003900005......... 9003900005........ 9003900005
4......... ELEMENT, HEATING.................................... .SEE ELEMENT CHART ON page 23......................... 5......... Gasket, Element.................................. 9000308005.......... 9000308005......... 9000308005........ 9000308005
6......... Opening Insulation...............................043307-000...........043307-000..........043307-000........ 043307-000
7......... *Instruction Manual..............................195202-004...........195202-004..........195202-004........ 195202-004
10........ Personnel Protector............................ 9003899015.......... 9003899015......... 9003899015........ 9003899015
11......... Pipe Nipple.............................................. 194130.................194130-3..............194130-3............ 194130-3
12........ Plate, Knockout.......................................43293-1.................43293-1................43293-1.............. 43293-1
PLUG
15/16...... Thermostat with High Limit Switch...... 9003945005.......... 9003945005......... 9003945005........ 9003945005
17........ Bracket, Thermostat............................ 9003898015.......... 9003898015......... 9003898015........ 9003898015
18........ Valve, Relief........................................ 9003484005.......... 9003741005......... 9003741005........ 9003741005
*Not Illustrated.
Standard Hardware Items May Be Purchased Locally. Underlined Parts Are Recommended For Emergency Replacement.
PCE 30 2OLSA thru PCE 50 2OLSA
(Refer to Repair Parts Table on page 22)
PCE 30 2ORTA thru PCE 120 2ORTA
(Refer to Repair Parts Table on page 22)
Figure 8
Figure 9
21
ItemDescription
PCE 30 2OLSAPCE 40 2OLSAPCE 50 2OLSAPCE 30 2ORTAPCE 40 2ORTAPCE 52 2ORTAPCE 66 2ORTAPCE 52 2ORTAPCE 120 2ORTA
Series 110Series 110Series 110Series 110Series 110Series 110Series 110Series 110Series 110
1A.....Anode, Alum. ............................. 9003944005.....9003944005.... 9003944005.....9003944005....9003944005.... 9003944005.... 9000029005..... 9003892005.....9003892005
1B.....Anode, Mag.(SMR P72)............ 9003721005.....9003721005.... 9003721005.....9003721005....9003721005.... 9003721005.... 9003721005..... 9001829005.....9001829005
2......T&P Relief Valve......................... 9003741005.....9003741005.... 9003741005.....9000071005....9000071005.... 9000071005.... 9000071005..... 9000071005.....9000071005
3......Gasket, Element......................... 9000308045.....9000308045.... 9000308045.....9000308045....9000308045.... 9000308045.... 9000308045..... 9000308045.....9000308045
4......ELEMENT, each................................................................................................ (SEE ELEMENT & WATTAGE CHART page 23 )���������������������������������������������������������������������
5......Upper Thermostat w/Hi Limit..... 9003896215.....9003896215.... 9003896215.....9003896215....9003896215.... 9003896215.... 9003896215..... 9003896215.....9003896215
6......Lower Thermostat w/Hi Limit..... 9004533215.....9004533215.... 9004533215.....9004533215....9004533215.... 9004533215.... 9004533215..... 9004533215.....9004533215
7......Thermostat Bracket, each.......... 9003898215.....9003898215.... 9003898215.....9003898215....9003898215.... 9003898215.... 9003898215..... 9003898215.....9003898215
8......Personal Protector...................... 9003899015.....9003899015.... 9003899015.....9003899015....9003899015.... 9003899015.... 9003899015..... 9003899015.....9003899015
9......Lower Access Panel................... 9003900005.....9003900005.... 9003900005.....9003900005....9003900005.... 9003900005.... 9003900005..... 9003900005.....9003900005
10.....Dip Tube..................................... 9003902005.....9003902005.... 9003902005.....9003902005....9003903005.... 9003904005.... 9003905005..... 9003905005.....9005709205
11.....Power Terminal........................... 9005719215.....9005719215.... 9005719215.....9005719215....9005719215.... 9005719215.... 9005719215..... 9005719215.....9005719215
12.....Drain Valve................................. 9003906015.....9003906015.... 9003906015.....9003906015....9003906015.... 9003906015.... 9003906015..... 9003906015.....9003906015
15*....Junction Box Assembly...................195171.............195171............ 195171.............195171............. 195171.............195171.............195171..............195171.............195171
*Not Illustrated.
Standard Hardware Items May Be Purchased Locally.
Underlined Parts Are Recommended For Emergency Replacement.
22
Figure 10
Table 6 - COPPER SHEATH ELEMENT AND WATTAGE CHART
120V
240V
277V
480V
PART NO.
PART NO.
PART NO.
PART NO.
9002863115
90001431005
---
---
9000145005
9002864005
9001225115
---
9002858005
9000145005
9004709115
---
9002859005
9004712105
9002860005
9002890005
9002861005
9002862005
9002868005
9003959005
9003958005
9003961005
---
9003950005
9004712105
---
---
K.W.
ELEMENT
WATTAGE
PART NO.
1.0
1000W
---
1.5
1500W
9002963005
2.0
2000W
9003947005
2.5
2500W
3.0
3000W
3500W
3.5
208V
MAX 3.5KW INPUT FOR 6 GALLON UNITS, ELEMENTS BELOW DOTTED LINE CANNOT BE USED ON 6 GALLON UNITS
4.0
4000W
---
9002867005
9002868005
9001229005
9002869005
4.5
4500W
---
9003952005
9003950100
9003960005
9001225005
5.0
5000W
---
9001224005
9003957005
9001231005
9001236005
5.5
5500W
---
9002871005
9002867005
---
9002872005
6.0
6000W
---
9003953005
9003952005
9002874005
9002875005
Table 7 - Incoloy Sheath Element and Wattage Chart (for SMR P72)
K.W.
ELEMENT
WATTAGE
120 V
208 V
240 V
277 V
480 V
PART NO.
PART NO.
PART NO.
PART NO.
PART NO.
1.5
1500 W
9004279005
9004283005
9004290005
9004736105
Not Available
2.0
2000 W
9004280005
9004284005
9004283005
9004290005
9004298005
2.5
2500 W
9004281005
9004285005
9004291005
9004295005
9004299005
INCOLOY ELEMENTS BELOW THIS LINE CANNOT BE USED ON 6 GALLON UNITS BECAUSE OF ELEMENT LENGTH
3.0
3000 W
9004282005
9004751115
9000664005
9004296005
9004300005
3.5
3500 W
Not Available
9003210005
9004292005
Not Available
Not Available
4.0
4000 W
Not Available
9004294005
9004751115
9000664005
Not Available
4.5
4500 W
Not Available
9004287005
9003210005
9004297005
9004301005
5.0
5000 W
Not Available
9004753105
9004293005
Not Available
Not Available
5.5
5500 W
Not Available
9004288005
9004294005
Not Available
Not Available
6.0
6000 W
Not Available
9004289005
9004287005
Not Available
Not Available
23
www.statewaterheaters.com
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Tech Support: 800-365-0024
Parts: 800-821-2017
Copyright © 2012 State Water Heaters, All rights reserved.
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