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100278842_2000537422_Rev A Commercial Electric Water Heater Installation & Service Manual Models: CHV and CHH 0150 - 1000 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. HLW WARNING This manual must only be used by a qualified heating installer /service technician. Read all instructions, including this manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage. Save this manual for future reference. Contents HAZARD DEFINITIONS .................................................... 2 PLEASE READ BEFORE PROCEEDING ........................ 3 INTRODUCTION ................................................................ 4 RATINGS ........................................................................... 5 1. FEATURES AND COMPONENTS CHV Models (Vertical Water Heater) ................................. 6 CHH Models (Horizontal Water Heater)............................. 7 Dimensions and Capacities Data ................................... 8-9 2. DETERMINE WATER HEATER LOCATION Facts to Consider About the Location ......................... 10-11 3. INSTALLATION Mixing Valve Usage ......................................................... 12 Chemical Vapor Corrosion ............................................... 12 Circulating Pump .............................................................. 12 Insulation Blankets .......................................................... 12 Temperature - Pressure Relief Valve...........................12-13 Closed Water Systems...................................................... 13 Thermal Expansion .......................................................... 13 4. ELECTRICAL General............................................................................. 14 Branch Circuit ................................................................... 14 Heater Circuits.................................................................. 14 Power Circuit .................................................................... 14 Amp Chart ................................................................... 15-16 Electrical and Recoveries Data ................................... 17-18 5. OPERATION General............................................................................. 19 Filling the Water Heater ................................................... 19 Initial Start-up ................................................................... 19 Draining the Water Heater ............................................... 19 6. TEMPERATURE REGULATION High Temperature Limit Controls (ECO) .......................... 20 Thermostat Controls ......................................................... 20 Temperature Adjustment .................................................. 20 7. CONTROL SYSTEM OPERATION Heating Banks Operation ................................................. 21 Control System Features ................................................. 21 Control System Navigation............................................... 21 The Display Screen .......................................................... 21 Control System Operation Tables ............................... 22-23 Temperatures Menu ......................................................... 24 Temperature Screens ...................................................... 25 Water Heater Status Menu .............................................. 26 Economy Mode Setup Menu ............................................ 27 Economy Mode Settings Tables ................................. 28-30 Alarm Output Setup Menu ............................................... 31 Display Settings Menu ..................................................... 31 Heater Information Menu ................................................. 32 Current Fault / Alert Menu................................................ 32 Fault History Menu ........................................................... 32 Fault Occurrence Menu.................................................... 33 Restore Factory Defaults Menu ....................................... 34 8. MAINTENANCE General............................................................................. 35 Anode Rod Inspection ...................................................... 35 Flushing the Water Heater ............................................... 35 Sediment Removal ........................................................... 36 Lime Scale Removal ........................................................ 36 9. TROUBLESHOOTING Checklist ........................................................................... 37 10. DIAGRAMS Wiring Diagram .......................................................... 38-39 Revision Notes .................................................. Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious WARNING injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate CAUTION injury. CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. NOTICE NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage. 2 Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions before installing. Perform steps in the order given. Have this water heater serviced/inspected by a qualified service technician, at least annually. Failure to comply with the above could result in severe personal injury, death, or substantial property damage. NOTICE When calling or writing about the water heater – Please have the water heater model and serial number from the water heater rating plate. Consider piping and installation when determining water heater location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated. WARNING Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage. WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. WARNING 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. When servicing the water heater – • To avoid electric shock, disconnect electrical supply before performing maintenance. • To avoid severe burns, allow the water heater to cool before performing maintenance. • Do not use this water heater if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced. Grounding Instructions – • This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation on ELECTRONIC CONTROL models. • 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. Hydrogen Gas (Flammable) – 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, 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 water begins to flow. WARNING There should be no smoking or open flame near the faucet at the time it is open. WARNING Flammable hydrogen gases may be present. WARNING Keep all ignition sources away from faucet when turning on hot water. 3 Installation & Operation Manual Introduction Thank you for purchasing this water heater. Properly installed and maintained, it should give you years of trouble-free service. Abbreviations Used Abbreviations found in this instruction manual include: • ANSI - American National Standards Institute • ASME - American Society of Mechanical Engineers • NEC - National Electrical Code • NFPA - National Fire Protection Association • UL - Underwriters Laboratory • CSA - Canadian Standards Association • AHRI - Air Conditioning, Heating, & Refrigeration Institute Preparing for the Installation WARNING Before removing any access panels or servicing the water heater, make sure the electrical supply to the water heater is turned OFF. Failure to do this could result in death, serious bodily injury, or property damage. Read the Please read before proceeding... section of this manual first, then read the entire manual carefully. If you don’t follow the safety rules, the water heater may not operate safely, which could result in death, serious bodily injury, and/or property damage. This manual contains instructions for the installation, operation, and maintenance of the 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. General outline diagrams are in this manual. These diagrams will serve to provide the installer with a reference for basic installation of this product. It is necessary that all water piping and electrical wiring be installed and connected as shown in the diagrams. Be sure to turn power OFF when working on or near the electrical system of the water heater. Never touch electrical components with wet hands or when standing in water. When replacing fuses always use the correct size for the circuit. Use the same size and type of fuse when replacing. Detailed installation diagrams are in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping suggested. It is necessary that all water piping and electrical wiring be installed and connected as shown in the diagrams. 4 The principle components of the heater are identified on pages 6 and 7. The model and rating plate on page 5 interprets certain markings into useful information. Both of these references should be used to identify the heater, its components, and optional equipment. 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 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. If after reading this manual you have any questions or do not understand any portion of the instructions, call the telephone number on the back cover for further assistance. Please have the model and serial number of the unit available for the technician. Carefully plan your intended placement of the water heater. Examine the location to ensure the water heater complies with the Determine Water Heater Location section in the manual. Clearance must be maintained so that the heating elements may be removed for servicing after installation. Installation and service of this water heater requires ability equivalent to that of a licensed tradesman or qualified agency in the field involved. Plumbing and electrical work are required. For installation in California, this water heater must be braced or anchored to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from the California Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95811. 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. Installation & Operation Manual Ratings HLW All models are listed by Underwriters Laboratories Inc. Rating & Model Plate 5, ELECTRIC STORAGE TANK WATER HEATER >Kt>KEdEd MODEL NUMBER ® SERIAL NUMBER VOLTS, AC PHASE KILOWATTS UPPER VOLTS, AC KILOWATTS UPPER KILOWATTS LOWER TOTAL kW CONNECTED KILOWATTS LOWER LISTED 932N ITEM ID/PART NUMBER CAPACITY US GALLONS TOTAL kW CONNECTED MAX WORKING PRESSURE CIRCUIT ADDRESS SERIAL NUMBER BARCODE MODEL NUMBER BARCODE SERIAL NUMBER 123456789 MODEL NUMBER XXXXXXXX L E 123456 A SM CERTIFIED BY LC E MAWP XXX PSI MAX ALLOWABLE INPUT HLW XXXXXXXXX BTU/HR S/N123456789 YEAR BUILT YYWW CRN XXXXXXXXXXXXXXXXXXXX 5 Installation & Operation Manual 1 Features and Components CHV Models (Vertical Water Heater) Note: Model shown for illustration purposes only. Actual configurations may vary. 6 Installation & Operation Manual 1 Features and Components CHH Models (Horizontal Water Heater) CONTROLLER RELIEF VALVE TRANSFORMER (CONTROLLER) ANODE MAIN VOLTAGE GROUND LUG POWER BLOCK MAIN VOLTAGE FUSE & BLOCK HANDHOLE/ MANWAY ACCESS LOW VOLTAGE FUSE & BLOCK MAIN VOLTAGE TRANSFORMER LOW WATER CUT OFF PROBE TEMPERATURE PROBE PLUG ELEMENTS CONTACTORS HIGH LIMIT LOW VOLTAGE FUSE & BLOCK LOW VOLTAGE GROUND LUG Note: Model shown for illustration purposes only. Actual configurations may vary. 7 Installation & Operation Manual 1 Features and Components (continued) Specifications Data B 3/4" T&P RELIEF VALVE CONNECTION HOT WATER OUTLET ADDITIONAL HEIGHT IF REQUIRED ELECTRONIC CONTROL 3/4" OR 1" DRAIN CONTROL VOLTAGE ON/OFF SWITCH C A COLD WATER INLET CLEANOUT HINGED DOOR TO ELECTRICAL COMPARTMENT D DRAIN TOP VIEW CHANNEL (HV* 150 & HV* 200 DO NOT HAVE CHANNEL) B HOT WATER OUTLET 6.688 T&P RELIEF VALVE C ADDITIONAL HEIGHT IF REQUIRED ELECTRONIC CONTROL HANDHOLE 4.000 CONTROL VOLTAGE ON/OFF SWITCH INLET D A & D ELEVATION FROM FINISHED FLOOR 8 DRAIN EXTRA PANEL BOX MAY BE NECESSARY FOR INPUTS HIGHER THAN 72KW. CONSULT FACTORY. Installation & Operation Manual 1 Features and Components Specifications Data (continued) (continued) Width (Length) B Depth C Inlet Water Connection Outlet Water Connection Shipping Weight (lbs) 1 1/2" 1 1/2" 650 Maximum KW Input Height A CHV0150 162 65 1/2" 32" 38 3/4" CHV0200 216 78" 32" 38 3/4" 8 1/4" 1 1/2" 1 1/2" 750 CHV0250 270 91 3/8" 34" 40 3/4" 19 1/4" 1 1/2" 1 1/2" 1,165 CHV0300 162 80" 40" 46 3/4" 20 3/4" 2" 2" 1,350 CHV0400 162 80" 46" 52 3/4" 22 1/4" 2" 2" 1,590 CHV0500 270 91 3/8" 46" 52 3/4" 22 1/4" 2" 2" 1,700 CHV0600 270 92 5/8" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 2,010 CHV0800 432 104" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 2,450 CHV1000 486 128" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 3,160 Model* D VERTICAL ROUND ELECTRIC STORAGE HEATER 8 1/4" VERTICAL SQUARE ELECTRIC STORAGE HEATER CHV1250 648 132 1/2" 64 1/2" 64 1/2" 23 1/4" 3" 3" 3,560 CHV1500 918 128 1/2" 70 1/2" 70 1/2" 25 1/4" 3" 3" 4,120 CHV2000 918 140 1/2" 76 1/2" 76 1/2" 27 1/4" 3" 3" 4,350 CHV2500 918 146 1/2" 82 1/2" 82 1/2" 29" 3" 3" 5,750 HORIZONTAL SQUARE ELECTRIC STORAGE HEATER CHH0150 162 37" 68 1/2" 34 1/4" 12" 2" 2" 1,180 CHH0200 198 CHH0250 240 37" 78" 34 1/4" 12" 2" 2" 1,370 39" 90 1/4" 36 1/4" 13" 2" 2" CHH0300 1,450 300 45" 78 1/4" 42 1/4" 14 3/4" 2" 2" 1,530 CHH0400 324 52" 78 1/4" 48 1/4" 16" 2" 2" 1,750 CHH0500 432 52" 90 3/4" 48 1/4" 16" 2" 2" 1,860 CHH0600 414 58" 90 3/4" 54 1/4" 13 1/2" 2 1/2" 2" 2,340 CHH0800 468 58" 102 1/4" 54 1/4" 13 1/2" 2 1/2" 2" 2,850 CHH1000 648 58" 126 1/4" 54 1/4" 13 1/2" 2 1/2" 2" 3,040 CHH1250 648 64" 130 1/4" 60 1/4" 15" 3" 3" 3,750 CHH1500 918 70" 126 1/4" 66 1/4" 16" 3" 3" 4,340 CHH2000 918 76" 137 1/4" 72 1/4" 17 1/2" 3" 3" 4,580 CHH2500 918 82" 144 1/4" 78 1/4" 16 1/2" 3" 3" 6,060 FOR EASE IN ORDERING BY MODEL NUMBER L CA I RT VE ER W O -P HI L H RO IT NT D W CO AR AY BO SPL DI X 072 0250 ON LL GA V T AT W LO KI H E AG LT VO C This unit is a Control Board with Display, Hi-Power, Vertical, 480 Volt, Three Phase, 72 Kilowatt, 250 Gallon Water Heater. 9 Installation & Operation Manual 2 Determine Water Heater Location Determine Water Heater Location CAUTION All water heaters eventually leak. Do not install without adequate drainage. Hot water piping and branch circuit wiring should be as short as possible. Insulate hot and cold water piping where heat loss and condensation may be a problem. Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. Heater construction permits installation, maintenance, and service work to be performed through the element box door and control box door. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed. The water heater must be located: Suggested clearances from adjacent surfaces are 12 inches on top, 30 inches in front of access doors, 24 inches for cleanout/ handhole/manway side, and 6 inches on the inlet water piping side. 1. On a level surface. Shim the channel-type skid base as necessary if leveling is required. 2. Near a floor drain. The heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan should be installed under the heater. The pan should be at least 2 inches deep, have a minimum length and width of at least 2 inches greater than the dimensions of the water heater, and should be piped to an adequate drain. The discharge opening of the relief valve should always be piped to an open drain. 3. Close to the point of major hot water usage and the power supply. 10 The heater may be installed on or against combustible surfaces. The back may be placed flush against adjacent surfaces. Be sure to place the cover plates over the rear crating couplings before locating vertical model heaters that were shipped laying down. The heater may be installed in a confined space if adequate ventilation is provided. The temperature of the space in which the water heater is installed must not go below 320F or above 1220F. Installation & Operation Manual 2 Determine Water Heater Location (continued) ← Figure 2-1 Clearances from Combustible Construction TOP CLEARANCE 12" ACCESS DOOR CLEARANCE REAR ← ← INLET WATER PIPING CLEARANCE MANWAY OR HANDHOLE CLEARANCE 30" ← 6" 24" RIGHT MANWAY OR HANDHOLE CLEARANCE ACCESS DOOR CLEARANCE ← 36" 24" FRONT ← LEFT FRONT CLEARANCE ↓ 12" ↓ REAR ACCESS DOOR CLEARANCE ↓ ↓ ↓ *30" 24" ↓ FRONT *DISTANCE FOR DOOR TO OPEN MANWAY OR HANDHOLE CLEARANCE RIGHT 11 Installation & Operation Manual 3 Installation The installation must conform to these instructions and local code authority having jurisdiction. Grounding and electrical wiring connected to the water heater must also conform to the National Electrical Code, NFPA 70. This publication is available from The National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. CAUTION Do NOT test electrical system before heater is filled with water. Follow the Start-up procedure in the Operation section of this manual. The principle components of the heater are identified in the Features and Components illustration on pages 6 and 7. DANGER Water temperature over 1250F (520C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature limiting devices, such as mixing valves, must be installed when required by code and to ensure safe temperatures at fixtures. Mixing Valve Usage Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy 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 the physically or 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 or at the water heater. Mixing valves for reducing point-of-use temperature are available. Consult a qualified installer or service agency. Follow all manufacturer’s instructions for installation of mixing valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual. WARNING Toxic chemical hazard: Do not connect to non-potable water system. Chemical Vapor Corrosion This water heater shall not be connected to any heating system(s) or component(s) used with a non-potable water heating appliance. Toxic chemicals, such as those used for boiler treatment, shall not be introduced into this system. Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, water softener chemicals, calcium and sodium chloride, waxes, and process chemicals are typical 12 compounds which are potentially corrosive. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence. Products of this sort should not be stored near the heater. Also, air which is brought in contact with the water heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. Circulating Pump Field-installed circulating pumps should be of all bronze constructions. To optimize the total storage capacity of a horizontal vessel, particularly under low draw conditions, it is recommended to utilize a pump and recirculation line sized to turn the entire storage capacity of the tank once each hour (i.e., a 600 gallon tank would require a 10 gpm pump). 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. Should you choose to apply an insulation blanket to this heater, you should follow the 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 WARNING The temperature and pressure relief valve must comply with ANSI Z21.22 and ASME code. A properly sized temperature and pressure relief valve must be installed in the opening provided. Failure to install a relief valve can result in overheating and excessive tank pressure. Failure to follow these instructions can cause serious injury or death. 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. Installation & Operation Manual 3 Installation (continued) 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 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 external to the structure. Do not pipe the discharge to a crawl space. 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. 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. 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 NOT be exposed to freezing temperatures. • Shall be of material listed for hot water distribution. • Shall be installed in such a way that allows 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. CAUTION The temperature-pressure relief valve discharge pipe must terminate at adequate drain. The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that no one is in front of or around the outlet of the temperaturepressure relief valve discharge line, and that 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 in this manual, and replace the temperature-pressure relief valve with a properly rated/sized new one. If you do not understand these instructions or have any questions regarding the temperature-pressure relief valve, call the telephone number listed on the back cover of this manual for technical assistance. Water temperature over 1250F (520C) DANGER can cause severe burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature limiting devices, such as mixing valves, must be installed when required by code and to ensure safe temperatures at fixtures. Read instruction manual for safe temperature setting. 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. A properly sized thermal expansion tank must 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. 13 Installation & Operation Manual 4 Electrical General Power Circuit Check the water heater model and rating plate information against the characteristics of the branch circuit electrical supply. Do NOT connect the heater to an improper source of electricity. Power circuit wiring is type THHN (or equivalent) rated 600 volts, 105°C, sized as necessary. Voltage applied to the heater should not vary more than +5% to -10% of the model and rating plate marking for satisfactory operation. The factory wiring is attached to a terminal block on the unit. The branch circuit is connected to the block through an opening provided on the heater. The factory terminal block has 500 MCM maximum copper wire size capacity in each opening. If apparent field wire size is over 500 MCM, multiple terminal blocks will be furnished. If other opening sizes are desired, they should be specified when the unit is ordered. 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. Branch Circuit The branch circuit wire size should be established through reference to the NEC (National Electrical Code) or other locally approved sources in conjunction with the water heater amperage rating. Wire rated at 75°C should be used. Please see Table 4-1 for additional information. It is suggested that the electrician size the branch circuit at 125% of the heater rating and further increase wire size as necessary to compensate for voltage drop in long runs. Voltage drop should not exceed 3% at the water heater. Heater Circuits The water heater’s electrical components are pictured and identified by the Features and Components illustrations on pages 6 and 7. The model and rating plate illustration identifies the heater electrical characteristics. The heater has two electrical circuits. • Control Circuit: 120V circuit containing all safety and control devices. The control circuit operates the contactors in the power circuit. • Power Circuit: High voltage, single or three-phase circuit that carries the heating element load. The following section and pages describe the water heater circuits. See pages 38 - 39 for the wiring diagram. 14 The wiring diagrams at the end of this manual are included to show typical arrangements of electrical components in the control and power circuits by voltage and phase characteristics. They are to be used as a reference by the installer or servicer in performing their work. An actual diagram of the water heater wiring is furnished with the heater. Installation & Operation Manual 4 Electrical (continued) Table 4-1 Amp Chart Total AMPS Total Ele. KW KW Qnty Volt 15 15 1 18 18 24 Main Line Field Wire Fuse Per Leg Total Ele. Total AMPS 10 30 10 30 10 30 KW KW Qnty Volt 208 240 380 400 415 480 600 73 63 ** ** ** ** ** 42 36 23 22 21 18 14 110 110 ** ** ** ** ** 60 50 30 30 30 25 20 3 4 ** ** ** ** ** 6 8 10 10 10 10 12 72 18 4 1 208 240 380 400 415 480 600 87 75 ** ** ** ** ** 50 44 27 26 25 22 17 110 110 ** ** ** ** ** 70 60 35 35 35 30 25 2 3 ** ** ** ** ** 4 6 8 8 8 10 12 90 15 12 2 208 240 380 400 415 480 600 115 100 ** ** ** ** ** 67 58 36 35 33 29 23 150 150 ** ** ** ** ** 90 80 50 50 50 40 30 0 0 ** ** ** ** ** 3 4 6 6 6 8 10 108 30 15 2 208 240 380 400 415 480 600 145 125 ** ** ** ** ** 83 72 46 43 42 36 29 200 175 ** ** ** ** ** 110 100 60 60 60 50 40 3/0 2/0 ** ** ** ** ** 2 2 6 6 6 6 8 36 18 2 208 240 380 400 415 480 600 174 150 ** ** ** ** ** 100 87 55 52 50 43 35 225 200 ** ** ** ** ** 150 110 70 70 70 60 45 4/0 3/0 ** ** ** ** ** 45 15 3 208 240 380 400 415 480 600 217 188 ** ** ** ** ** 125 108 68 65 63 54 43 300 250 ** ** ** ** ** 175 150 90 90 80 70 60 54 18 3 208 240 380 400 415 480 600 260 225 ** ** ** ** ** 150 130 82 78 75 65 52 350 300 ** ** ** ** ** 60 15 4 208 240 380 400 415 480 600 289 250 ** ** ** ** ** 167 144 91 87 83 72 58 400 350 ** ** ** ** ** Main Line Fuse Field Wire Per Leg 10 30 10 30 10 30 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 200 173 109 104 100 87 69 ** ** ** ** ** ** ** 250 225 150 150 125 110 90 ** ** ** ** ** ** ** 250 4/0 0 0 1 2 3 6 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 250 217 137 130 125 108 87 ** ** ** ** ** ** ** 350 300 175 175 175 150 110 ** ** ** ** ** ** ** 500 350 3/0 3/0 3/0 2/0 2 18 6 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 300 260 164 156 150 130 104 ** ** ** ** ** ** ** 400 350 225 200 200 175 150 ** ** ** ** ** ** ** (2) 3/0 500 4/0 4/0 3/0 2/0 0 120 15 8 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 333 289 182 173 167 144 115 ** ** ** ** ** ** ** 450 400 250 225 225 200 150 ** ** ** ** ** ** ** (2) 4/0 (2) 3/0 250 250 4/0 3/0 0 0 2 4 4 4 6 8 135 15 9 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 375 325 205 195 188 162 130 ** ** ** ** ** ** ** 500 450 300 250 250 225 175 ** ** ** ** ** ** ** (2) 250 (2) 4/0 350 350 250 4/0 2/0 300 250 ** ** ** ** ** 3/0 2/0 3 3 4 4 6 144 18 8 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 400 346 219 208 200 173 139 ** ** ** ** ** ** ** 500 450 300 300 250 225 175 ** ** ** ** ** ** ** (2) 250 (2) 4/0 350 300 250 4/0 2/0 200 175 110 100 100 90 70 400 350 ** ** ** ** ** 4/0 3/0 2 2 2 3 4 162 18 9 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 450 390 246 234 225 195 156 ** ** ** ** ** ** ** 600 500 350 300 300 250 200 ** ** ** ** ** ** ** (2) 350 (2) 250 500 350 350 250 3/0 225 200 125 110 110 100 80 500 400 ** ** ** ** ** 4/0 4/0 1 1 2 2 4 180 18 10 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 500 433 273 260 250 217 173 ** ** ** ** ** ** ** 700 600 350 350 350 300 225 ** ** ** ** ** ** ** (2) 500 (2) 350 500 500 500 350 4/0 15 Installation & Operation Manual 4 Electrical Table 4-1 Amp Chart (continued) Total AMPS Total Ele. KW KW 216 18 12 234 18 252 Field Wire Per Leg Total Ele. Total AMPS Qnty Volt Main Line Fuse Field Wire Per Leg 10 30 10 30 10 30 KW KW 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 600 520 328 312 301 260 208 ** ** ** ** ** ** ** 800 700 450 400 400 350 300 ** ** ** ** ** ** ** (3) 300 (2) 500 (2) 4/0 (2) 3/0 (2) 3/0 500 350 360 18 20 13 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 650 563 356 338 326 281 225 ** ** ** ** ** ** ** 1000 800 500 450 450 400 300 ** ** ** ** ** ** ** (2) 400 (2) 300 (2) 250 (2) 4/0 (2) 4/0 (2) 3/0 350 378 18 18 14 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 694 606 383 364 351 303 242 ** ** ** ** ** ** ** 1000 800 500 500 450 400 350 ** ** ** ** ** ** ** (3) 400 (3) 300 (2) 250 (2) 4/0 (2) 4/0 (2) 3/0 500 396 270 18 15 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 749 650 410 390 376 325 260 ** ** ** ** ** ** ** 1000 1000 600 500 500 450 350 ** ** ** ** ** ** ** (3) 400 (3) 400 (2) 350 (2) 250 (2) 250 (2) 4/0 500 288 18 16 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 799 693 438 416 401 346 277 ** ** ** ** ** ** ** 1000 1000 600 600 600 450 350 ** ** ** ** ** ** ** (3) 400 (3) 400 (2) 350 (2) 350 (2) 350 (2) 4/0 500 306 18 17 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 849 736 465 442 426 368 294 ** ** ** ** ** ** ** 1200 1000 600 600 600 500 400 ** ** ** ** ** ** ** (4) 350 (3) 400 *CONSULT FACTORY FOR 432 KW AND HIGHER. (2) 350 (2) 350 (2) 350 (2) 250 (2) 3/0 324 18 18 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 899 779 492 468 451 390 312 ** ** ** ** ** ** ** 1200 1000 700 600 600 500 400 ** ** ** ** ** ** ** (4) 350 (3) 400 (2) 500 (2) 350 (2) 350 (2) 250 (2) 3/0 342 18 19 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 949 823 520 494 476 411 329 ** ** ** ** ** ** ** 1200 1200 700 700 600 600 450 ** ** ** ** ** ** ** (4) 350 (4) 350 (2) 500 (2) 350 (2) 350 (2) 350 (2) 4/2 16 Qnty Volt Main Line Fuse 10 30 10 30 10 30 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 999 866 547 520 501 433 346 ** ** ** ** ** ** ** 1600 1200 700 700 700 600 450 ** ** ** ** ** ** ** (5) 400 (4) 350 (2) 500 (2) 500 (2) 500 (2) 350 (2) 4/0 21 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 1049 909 574 546 526 455 364 ** ** ** ** ** ** ** 1600 1200 800 700 700 600 500 ** ** ** ** ** ** ** (5) 400 (4) 350 (3) 300 (2) 500 (2) 500 (2) 350 (2) 250 18 22 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 1099 953 602 572 551 476 381 ** ** ** ** ** ** ** 1600 1200 800 800 700 600 500 ** ** ** ** ** ** ** (5) 400 (4) 350 (3) 300 (2) 500 (2) 500 (2) 350 (2) 250 414 18 23 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 1149 996 629 598 576 498 398 ** ** ** ** ** ** ** 1600 1600 800 800 800 700 500 ** ** ** ** ** ** ** (5) 400 (5) 400 (3) 300 (3) 300 (3) 300 (2) 500 (2) 250 432 18 24 208 240 380 400 415 480 600 ** ** ** ** ** ** ** 1199 1039 656 624 601 520 416 ** ** ** ** ** ** ** 1600 1600 1000 800 800 700 600 ** ** ** ** ** ** ** (5) 400 (5) 400 (3) 400 (3) 300 (3) 300 (2) 500 (2) 350 Installation & Operation Manual 4 Electrical (continued) Table 4-2_Electrical and Recoveries Data Number of Contactors Standard KW Ratings KW of Element Maximum Number of Elements Number of Elements per Bank Number of Banks Number of Control Boards BTU Input GPH Recovery 208V/240V 1Ø 208V/240V 3Ø 480V/600V 3Ø 15 15 1 1 1 1 51,180 61 1 1 1 18 18 1 1 1 1 61,416 74 2 2 1 24 12 2 1 2 1 81,888 98 2 2 2 30 15 2 1 2 1 102,360 123 2 2 2 36 12 3 1 3 1 122,832 147 3 3 3 36 18 2 1 2 1 122,832 147 4 4 2 45 15 3 1 3 1 153,540 184 3 3 3 48 12 4 1 4 1 163,776 197 4 4 4 54 18 3 1 3 1 184,248 221 6 6 3 60 12 5 1 5 1 204,720 246 5 5 5 60 15 4 1 4 1 204,720 246 4 4 4 72 12 6 2 3 1 245,664 295 6 6 72 18 4 1 4 1 245,664 295 8 4 75 15 5 5 1 1 255,900 307 5 5 90 15 6 2 3 1 307,080 369 6 3 90 18 5 1 5 1 307,080 369 10 5 96 12 8 2 4 1 327,552 393 8 4 108 12 9 3 3 1 368,496 442 9 6 108 18 6 2 3 1 368,496 442 12 6 120 12 10 2 5 1 409,440 492 10 5 120 15 8 2 4 1 409,440 492 8 8 135 15 9 3 3 1 460,620 553 9 6 144 18 8 2 4 1 491,328 590 16 8 150 15 10 2 5 1 511,800 614 10 5 162 18 9 3 3 1 552,744 664 18 9 180 12 15 3 5 1 614,160 737 15 10 180 15 12 3 4 1 614,160 737 12 12 180 18 10 2 5 1 614,160 737 20 10 192 12 16 2 8 2 655,104 786 16 8 210 15 14 2 7 2 716,520 860 14 14 216 12 18 3 6 2 736,992 885 18 9 216 18 12 3 4 1 736,992 885 24 8 225 15 15 3 5 1 767,700 922 15 10 240 12 20 2 10 3 818,880 983 20 10 240 15 16 2 8 2 818,880 983 16 16 252 18 14 2 7 2 859,824 1,032 28 14 270 15 18 3 6 2 921,240 1,106 18 12 270 18 15 3 5 1 921,240 1,106 30 10 288 12 24 3 8 2 982,656 1,180 24 12 288 18 16 2 8 2 982,656 1,180 32 16 300 15 20 2 10 3 1,023,600 1,229 20 20 17 Installation & Operation Manual 4 Electrical Table 4-2_Electrical and Recoveries Data (continued) Number of Contactors Standard KW Ratings KW of Element Maximum Number of Elements Number of Elements per Bank Number of Banks Number of Control Boards BTU Input GPH Recovery 315 15 21 3 7 2 1,074,780 324 12 27 3 9 2 1,105,488 324 18 18 3 6 2 1,105,488 360 15 24 3 8 2 1,228,320 1,475 24 16 360 18 20 2 10 3 1,228,320 1,475 40 20 378 18 21 3 7 2 1,289,736 1,548 42 21 390 15 26 2 13 3 1,330,680 1,597 26 26 396 18 22 2 11 3 1,351,152 1,622 44 22 405 15 27 3 9 2 1,381,860 1,659 27 18 420 15 28 2 14 3 1,433,040 1,720 28 28 432 18 24 3 8 2 1,473,984 1,769 48 16 18 208V/240V 1Ø 208V/240V 3Ø 480V/600V 3Ø 1,290 21 14 1,327 27 18 1,327 36 12 Installation & Operation Manual 5 Operation General Initial Start-up Refer to the Features and Components section of this manual for the location of components mentioned in the instructions that follow. The following checks should be made by the installer when the water heater is placed into operation for the first time: NEVER operate the heating elements without being certain the water heater is filled with water and a temperature and pressure relief valve is installed in the relief valve opening on top of the heater. A low water cutoff is provided on all heaters as standard equipment. The water probe is installed near the top of the tank to monitor the presence of water. The control circuit is opened if the water level is below this point. The pilot switch (power on/off toggle switch) on the cabinet front permits the heater to be turned on and off without having to operate the electrical disconnect switch. DANGER Full power is present whenever the cabinet door is opened, even with the pilot switch turned off. Optional manual override switches on the cabinet front allow elements to be manually de-energized if full capacity is not needed. Filling the Water Heater CAUTION In order to avoid heating element damage, fill the tank with water before operating. To fill the water heater with water: 1. Turn OFF the electrical disconnect switch. 2. Turn OFF the ON/OFF switch. 3. Close the heater drain valve. 4. Open a nearby hot water faucet to allow the air in the system to escape. 5. Fully open the cold water inlet valve, filling the heater and piping. 6. Close the hot water faucet when the water starts to flow from the faucet. Leave the cold water inlet valve fully open. The heater is now ready for start-up and temperature regulation. 7. Close the cabinet door and perform the start-up checks listed below before turning on the electricity. 1. Check all factory and field-made water and electrical connections for tightness. Also check connections on top of the heater. Repair water leaks and tighten electrical connections as necessary. 2. Turn on the electrical disconnect switch and pilot toggle switch. The pilot toggle switch is located on the cabinet. 3. Observe the operation of the electrical components during the first heating cycle. Exercise care as the electrical circuits are energized. Temperature control and contactor operation should be checked by allowing the heater to come up to temperature and shut off automatically. Exercise care as the electrical circuits are energized. Draining the Water Heater The water heater must be drained if it is to be shut down and/ or exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater. 1. Turn OFF the electrical disconnect switch. 2. Turn OFF the ON/OFF switch. 3. Close the cold water inlet valve to heater. 4. Open a nearby hot water faucet to vent the system. 5. Open the drain valve. 6. If the the heater is being drained for an extended shutdown, it is suggested that the drain valve be left open during this period. Follow Filling the water heater instructions when restoring hot water service. See the list above. DANGER Burn hazard. Keep clear of drain valve discharge outlet. 19 Installation & Operation Manual 6 Temperature Regulation High Temperature Limit Controls (ECO) If a dry bulb style high limit is used in place of a surface mount in the limit, it should not be set above 190°F/88°C. When the high limit switch contacts open, the electronic control system locks out and displays a fault message. Voltage to the contactor coils and heating elements is terminated to prevent further heating operation. Once the water temperature has cooled below this point, press the manual reset button. Then the power supply to the water heater must be turned off and then back on to reset the control system. DANGER Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures. Read the instruction manual for safe temperature setting. Thermostat Controls The water heaters covered in this instruction manual are equipped with adjustable thermostat controls to control water temperature. Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. The temperature at which injury occurs varies with the person’s age and duration of exposure. The slower response time of children, the elderly, or disabled persons increases the hazards to them. Never allow small children to use a hot water tap or draw their own bath water. Never leave a child or disabled person unattended in a bathtub or shower. The water heater should be located in an area where the general public does not have access to set temperatures. Temperature Adjustment DANGER Full power is present whenever the cabinet door is opened, even with the ON/OFF switch turned off. The water heaters covered in this instruction manual are equipped with an electronic control system. The control system senses temperature from a factory-installed immersion temperature probe. See the Features and Components illustrations at the beginning of this manual for location. The Operating Set Point is adjusted to control water temperature. This is an adjustable user setting in the control system’s Temperature Menu. This and all control system menus are accessed through the UIM (User Interface Module) located on the front panel of the water heater. (FIG. 6-1). The operating set point is adjustable from 90°F/42°C to 190°F/88°C. The factory setting is 120°F/49°C. See the Control System Operation section of this manual for instructions on how to adjust the Operating Set Point and other user settings. Set the Operating Set Point at the lowest setting which produces an acceptable hot water supply. This will always give the most energy efficient operation. Figure 6-1_UIM (User Interface Module) Setting the water heater temperatures at 120°F will reduce the risk of scalds. Some states require settings at specific lower temperatures. Table 6-1_Approximate time to burn normal adult skin Water Temperature °F Time for 1st Degree Burn (Less Severe Burns) 110 (normal shower temp.) 116 (pain threshold) 116 35 minutes Time for Permanent Burns 2nd & 3rd Degree (Most Severe Burns) 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds 149 1 second 2 seconds 154 Instantaneous 1 second (U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978) 20 Installation & Operation Manual 7 Control System Operation Heating Banks Operation Progressive Sequencing: Banks are energized and de-energized according to adjustable (1 to 20°F) differential set points for each bank. The first bank on is rotated with each successive call for heat (bank rotation). The first heating bank energized at the beginning of a heating cycle is the first bank de-energized at the end of the heating cycle (First on/first off ). Successive heating cycles would progress as follows on a model equipped with three (3) heating bank: • First heating cycle: Banks come on [1, 2, 3] and cycle off [1, 2, 3] • Second heating cycle: Banks come on [2, 3, 1] and cycle off [2, 3, 1] • Third heating cycle: Banks come on [3, 1, 2] and cycle off [3, 1, 2] • Fourth heating cycle: Pattern repeats - same as first heating cycle Control System Features Up & down Buttons These buttons are used to navigate (up and down) and to select (highlight) menu items. They are also used to adjust or change (increase/decrease, on/off, set time) various user settings. Operational Buttons The three (3) operational buttons are multifunctional. Their current function is defined by the text that appears directly above each button on the LCD screen. The function will change depending on what menu is currently displayed or what menu item is selected. When no text appears on the LCD screen above an operational button, there is no function assigned. The Display Screen The illustration below shows the control system display screen. This is the default screen. If there are no active fault or alert conditions and no user input for approximately 10 minutes the control system will return to this screen automatically. • Model Information: Model information and menu titles are shown in the black bar at the top of the display screen. • Tank Temperature: Current water temperature as sensed from the immersion temperature probe. • Operating Set Point: Temperature at which the control system will maintain tank (water) temperature in the normal mode. This line of text will read ECONOMY SET POINT whenever the control system is operating in the Economy Mode. • Status: The operating state of the control system is displayed beneath the operating set point. Advanced Diagnostics Plain English text and animated icons display detailed operational and diagnostic information. The LCD screen on the front of the water heater displays the sequence of operation in real time. Fault or alert messages are displayed when operational problems occur. The Advanced Service Menu displays a list of possible causes for current fault and alert conditions to aid in servicing. Economy Mode Operation The control system automatically lowers the Operating Set Point by a programmed value during user defined time periods. This helps reduce operating costs during unoccupied or peak demand periods. Control System Navigation The UIM (User Interface Module) is located on the front cabinet of the water heater. All operational information and user settings are displayed and accessed using the UIM. The UIM includes five (5) snap-acting (momentary) user input buttons; an UP, DOWN, and three (3) operational buttons (FIG 7-1). Figure 7-2_The Display Screen Service Note: The Desktop Screen displays text and animated icons that convey operational information. Review the Status Icons explanation in Table 7-1 on page 18. Learning to use this real time visual display of the operating sequence will help to quickly and accurately diagnose STATUS operational problems. ICONS Figure 7-1_Control System Navigation • Menu: The left operational button is pressed to enter the main menu where all control system menus are accessed. See Table 7-3 for a list of control system menus. • Help: The right operational button is pressed to access instructions and explanations for user settings, operating states, status icons, manufacturer’s web address, technical support phone number, and service agent contact information. 21 Installation & Operation Manual 7 • Control System Operation Day/Time/Operating Mode: The current time and day are also displayed on the display screen. CLOCK NOT SET will be displayed until the time clock has been initially set. Day and time are adjusted in the Economy Mode Setup Menu. The current operating mode, either Normal Mode or Economy Mode, is displayed beneath the day and time. • Discreet Menu Contact Information: From the display screen, press and hold down the middle (unmarked) operational button for 30 seconds, then release it. This will launch a discreet menu where personalized contact information can be entered. Installing contractors and/or service agents can enter their company name and telephone number. This contact information will be displayed with all fault and alert messages. Table 7-1_Status Icons ICON DESCRIPTION Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the immersion Temperature Probe. Water temperature in the tank has reached the Operating Set Point. Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the immersion Temperature Probe. The control is unable to initiate a heating cycle. This will happen whenever a Fault condition is detected by the control system or when either of the two Enable/Disable circuits are open circuits. The control system is in Heating Mode and has energized the electromagnetic contactor coils for at least one heating bank. This animated icon DOES NOT indicate current has been sensed from the heating banks, only that there is a call for heat present and the control system has initiated heating bank operation. The control has detected/declared a Fault Condition. Fault message details can be viewed in the Current Fault menu. Heating operation is discontinued (locked out) until the condition that caused the fault is corrected. Power to the water heater must be cycled off and on to reset the control system. Note; cycling power will not reset the control system if the condition that caused the fault has not been corrected. The control has detected/declared an Alert Condition. The water heater will continue to operate during an Alert Condition but in the Current Alert menu. Table 7-2_Operating States STATE DESCRIPTION Standby The water heater is not in an active heating cycle. This usually indicates the temperature in the tank has reached the Operating Set Point and the control system has terminated the heating cycle. Heating The control system is in the Heating Mode. At least one heating bank has been energized. Alert Fault 22 The control system has detected/declared an Alert Condition. The controls system will continue heating operation. The control system has detected/declared a Fault Condition. The control system will discontinue heating operation and “lock out.” Power to the water heater must be cycled off and on to reset the control system. Note; cycling power will not reset the control system until the condition that caused the fault has been corrected. Installation & Operation Manual 7 Control System Operation (continued) Table 7-3_Control System Menus MENUS DESCRIPTION Temperatures Operating Set Point, Differential settings, Tank Temperature and Tank Probe Offset are located in this menu. Heater Status Current Operating State/Mode (heating/standby etc) and status (open/closed - on/off - yes/no) of monitored water heater functions and components are displayed in this menu. Economy Mode Setup Seven day 24 hour time clock with temperature set back capability to reduce operating costs during unoccupied or reduced demand periods. The control system’s CCB (Central Control Board - see wiring diagram) features on board SPDT (single pole Alarm Output Setup relay activation. Display Settings Temperature units (°F or °C), appearance (brightness contrast) and backlight delay user adjustable settings are located in this menu. Heater Information Elapsed time of operation, total heating cycle time, heating cycle count, heating bank(s) cycle count and on time along with UIM and CCB software revisions can be viewed in this menu. Current Fault/Alert Displays any current Alert or Fault messages. Fault History Retains 9 event history of Fault/Alert messages with time stamp. The Fault History is useful when dealing with intermittent operational problems or when the customer has reset the control system prior to a service agent’s arrival. Fault Occurrence Total accumulated number each individual Fault condition has occurred is displayed in this menu. This running total of Fault Occurrences can be useful in determining which (if any) operational problems have been persistent. Restore Factory Defaults This control system feature allows the user to restore control system user settings to their factory default settings. Alarm Output Setup and Display Settings menu items ARE NOT changed when factory defaults are restored. Help Menu Accessible by pressing the corresponding Operational Button from most menus and screen displays. This menu provides access to instructions and explanations for user settings, Operating States, Status Icons, manufacturer’s web address, technical support phone number and service agent contact information. 23 Installation & Operation Manual 7 Control System Operation Temperatures Menu Tank Temperature Operating Set Point Non-adjustable information display. Current water temperature as sensed by the control system from the immersion temperature probe. User adjustable setting 90°F to 190°F range; factory default is 120°F. When the water temperature sensed by the control system from the immersion temperature probe reaches the operating set point the control system will end the heating cycle. A call for heat will be activated again when the water temperature drops below the operating set point minus the first differential setting. Example: Operating set point is 120°F, the first differential setting is 2°F (factory default). A call for heat will be activated when the sensed water temperature drops to 118°F. Tank Probe Offset User adjustable setting -5°F to +5°F range; factory default is 0°F. If the current tank temperature is sensed from the immersion temperature probe at 120°F and the offset is adjusted to -5°F, the control system would calibrate, or offset, the tank temperature to 115°F. Heating cycles would then start and stop based on the calibrated tank temperature. Used to calibrate for slight differences in control system temperature sensing. This can improve the precision of temperature control in the storage tank and at points of use. This feature can also be used to compensate for building recirculation loops (hot water returning to the storage tank) that may cause the heating cycle to terminate prematurely. Figure 7-3_Operating Set Point Temperature Settings The Operating Set Point and the Differential Settings are adjusted in the Temperatures Menu. The following instructions, on page 25, explain how to adjust these user settings and navigate the control system menus. Differential Settings Adjustable user setting(s) 1°F to 20°F range; factory default is 2°F. The water heaters covered in this manual will have between one (1) and five (5) heating banks per control board. There is at least one differential setting on all models. There will be additional differential settings for each additional heating bank installed. Operating Sequence Example On a water heater equipped with three (3) heating banks, with an operating set point of 120°F, and all differential settings at 2°F, the on/off sequencing of heating banks would be as follows in Table 7-4. Table 7-4_Sequencing of Heating Banks BANK NUMBER DIFFERENTIAL SETTING TURN ON TEMP TURN OFF TEMP Bank 1 2°F 118°F 120°F Bank 2 2°F 116°F 118°F Bank 3 2°F 114°F 116°F 24 Installation & Operation Manual 7 Control System Operation (continued) Table 7-5_Temperature Screens ACTION DISPLAY From the Desktop Screen, press the Operational Button underneath “MENU” to enter the Main Menu. Notice how the text above the Operational Buttons on the display changes as you navigate through the various menus and screens. With Temperatures selected (highlight in black) in the Main Menu, press the Operational Button underneath “SELECT” to enter the Temperature Menu. If Temperatures is not selected use the Up and Down buttons to select this menu item. With the Operating Set Point selected (highlighted in black) in the Temperatures Menu, press the Operational Button underneath “CHANGE” to activate the adjustment mode for this menu item. Press the Up and Down buttons to adjust the Operating Set Point to the desired setting. setting. Press the Operational Button underneath “CANCEL” to discard the new setting and retain the previous setting. The new Operating Set Point value should now be displayed as the current value. NOTE: Use this same procedure to adjust the Differential settings and the Tank Probe Offset in the Temperatures Menu. This same procedure is used to change user settings in other control system menus. 25 Installation & Operation Manual 7 Control System Operation Water Heater Status Menu This menu displays non-adjustable operational information. Use the up and down buttons to navigate to the bottom of this menu. Figure 7-4_Status Menu Screens TOP OF MENU Status Banks On ECO Contact Enable / Disable 1 Enable / Disable 2 Bank 1 On Bank 2 On Heating 1 Closed Closed Closed Yes No Enable / Disable 1 & 2 Displays the current state, open or closed, of the two enable/ disable circuits (J7 socket on the CCB - see wiring diagrams) provided for external supervisory controls such as building EMS (Energy Management System). Both of these enable/disable circuits must be closed to enable heating operation. If either enable/disable circuit is open for any reason, heating operation will be disabled. There is a plug with two jumper wires installed from the factory in the CCB J7 socket to enable heating operation when external controls are not in use. NOTE: If a supervisory control is used to enable or disable heating operation, install field wiring between the J7 socket on the CCB and a set of dry contacts on the external control per all applicable building codes. This is a switching circuit only. DO NOT apply any external voltage or connect any load (i.e., relay coil) to either circuit. Element # On Displays the on/off status of each heating bank. Yes = On, No = Off. BOTTOM OF MENU Tank Full Enable / Disable 2 Bank 1 On Bank 2 On Bank 3 On Tank Full Alarm Condition Alarm Relay Output Closed Yes No No Yes No Open Displays the status of the LWCO (Low Water Cut Off ) device. Yes = water level is acceptable, No = water level is low. Alarm Condition Displays the status of the user definable alarm output function - see alarm output setup menu. Yes = alarm condition has been met, No = alarm condition has not been met. Alarm Relay Output Status Displays the current operating state of the control system, such as heating, standby, and fault. Banks On # Displays the number of heating elements the control system has energized. ECO Contact Displays the current state of the ECO high temperature limit switch contacts. 26 Displays the state of the normally open contacts of the alarm output relay. This relay (J3 contacts on the CCB - see wiring diagrams) is used for building EMS (Energy Management System) notification of operational conditions such as fault conditions. Installation & Operation Manual 7 Control System Operation Economy Mode Setup Menu This menu contains settings used to establish an economy set point and economy mode operating periods, or night setback. This control system feature can help reduce operating costs during unoccupied, low load, or peak demand periods. Figure 7-5_Economy Mode Screens DISPLAY SCREEN DURING ECONOMY MODE (continued) Daily Operating Mode (Sun - Mon - Tue - Wed Thu - Fri - Sat) Seven daily sub menus are listed at the bottom of the Economy Mode Setup menu. There are 3 Operating Modes in each sub menu. Normal Operation All Day, Economy Mode All Day, and Normal Operation Between. Only one Operating Mode can be active. The factory default is Normal Operation All Day. Normal Operation All Day: When this operating mode is active, the normal Operating Set Point is used for the entire day. Economy Mode All Day: When this operating mode is active the Economy Set Point is used for the entire day. Normal Operation Between: When this operating mode is active, there will also be start and stop times to program. The normal Operating Set Point is used between the programmed start and stop times, and the Economy Set Point will be in effect during the rest of the day. There is one start time and one stop time event per day. ECONOMY MODE SETUP MENU Set Point Adjustment Adjustable user setting (2°F to 50°F - factory default is 20°F) the control system uses to calculate the Economy Set Point. The Economy Set Point is the normal operating set point minus the programmed set point adjustment value. The Economy Set Point is the water temperature that the control system maintains during programmed economy mode time periods. ECONOMY SET POINT is displayed instead of OPERATING SET POINT, and ECONOMY MODE appears beneath the current time on the display screen during economy mode time periods. Current Time Seven Day 24 hr clock. Use this menu item to set the current time and day of the week. Current day and time are not set from the factory. CLOCK NOT SET will be displayed on the display until the time/day has been initially set. NOTE: The time will not self adjust for Daylight Savings Time. 27 Installation & Operation Manual 7 Control System Operation Table 7-6_Economy Mode Settings - Setpoint Adjustment Value ACTION From the Display Screen, press the Operational Button underneath “MENU” to enter the Main Menu. Notice how the text above the Operational Buttons on the display changes as you navigate through the various menus and screens. Use the Up/Down buttons to select (highlight in black) the Economy Mode Setup menu from the Main Menu. Press the Operational Button underneath “SELECT” to enter the Economy Mode Setup menu. Use the Up/Down buttons to select (highlight in black) Setpoint Adjustment. Press the Operational Button underneath “CHANGE” to activate the adjustment mode for the Setpoint Adjustment value. Use the Up/Down buttons to change the Setpoint Adjustment to the desired value. The Setpoint Adjustment value is adjustable from 2°F to 50°F. The factory default is 20°F. Notice how the text above the Operational Buttons on the display changes to “UPDATE” & “CANCEL” when the adjustment mode is activated and how the current value is outlined rather than highlighted in black. the new value. Pressing the Operational Button underneath “CANCEL” would discard the new value and retain the previous value. The new Setpoint Adjustment value should now be displayed as the current value. 28 DISPLAY Installation & Operation Manual 7 Control System Operation (continued) Table 7-7_Economy Mode Settings - Time Clock Settings ACTION DISPLAY Use the Up/Down buttons to select (highlight in black) Current Time sub menu. Press the Operational Button underneath “CHANGE” to enter the Current Time sub menu. Use the Up/Down buttons to select the “Weekday” setting. Press the Operational Button underneath “CHANGE” to activate the adjustment mode for this setting. Press the Up/Down buttons to adjust the Weekday setting to the current day. Notice how the text above the Operational Buttons on the display changes to “ACCEPT” & “CANCEL” when the adjustment mode is activated and how the current setting is outlined rather than highlighted in black. the new setting. Pressing the Operational Button underneath “CANCEL” would discard the new setting and retain the previous setting. Use the Up/Down and the CHANGE/ACCEPT Operational Buttons to individually select and change the remaining time settings (Hour, Minutes, AM/PM) to the current time in the same way as outlined above. display will automatically return to the Economy Mode Setup menu. The new settings should be displayed as the Current Time. 29 Installation & Operation Manual 7 Control System Operation Table 7-8_Economy Mode Settings - Daily Operating Mode Settings ACTION Economy Mode All Day: From the Economy Mode Setup menu use the Up/Down buttons to select (highlight in black) the Daily sub menu for “Sun.” Press the Operational Button underneath “CHANGE” to enter this menu. Use the Up/Down buttons to select (highlight in black) the “Economy Mode All Day” setting. Press the Operational Button underneath “SELECT” to change from the factory default Normal Operation All Day setting to the Economy Mode All Day setting. new setting and update the control system. You will be returned to the Economy Mode Setup menu. The new setting should now be displayed for Sun. Normal Operation Between: From the Economy Mode Setup menu Use the Up/Down and CHANGE buttons to enter the Mon sub menu as described above. Use the Up/Down buttons to select (highlight in black) the “Normal Operation Between” setting. Press the Operational Button underneath “SELECT” to change the operating mode for Monday to Normal Operation Between. Note that when this setting is selected Start and Stop time user settings appear on the display. Use the Up/Down buttons to navigate between the Start and Stop time Hour, Minutes and AM/PM settings. With each item selected press the Operational Button underneath “CHANGE” to activate the adjustment mode for each setting. Use the Up/Down buttons to change the value to the desired setting. Press the Operational Button underneath “ACCEPT” to enter the new setting or “CANCEL” to discard the new setting and retain the previous setting. will return to the Economy Mode Setup menu with the new settings shown for Mon. 30 DISPLAY Installation & Operation Manual 7 Control System Operation Alarm Output Setup Menu This menu permits the user to set the condition (from a list of options) for when the CCB’s integral alarm output relay will be energized. Alarm relay connections (common, normally open, and normally closed) are located on the J3 terminal strip on the CCB - see wiring diagrams. Alarm output relay contacts are capable of switching 1 amp maximum at 120 VAC. Figure 7-6_Alarm Output Setup Menu (continued) Temp < Heater SP: Used for external notification when current tank temperature drops below Operating Set Point. Temp < Alarm SP: Used for external notification when current tank temperature drops below programmable Alarm SP. Fault or Alert: Used for external notification whenever a fault or alert condition is active. Fault: Used for notification whenever a fault condition is active. Disabled: Disables the Alarm Relay Output function. Alarm SP Adjustable user setting (90°F to 190°F) the control system uses for the Temp < Alarm SP function described above. This setting has no effect with any other Alarm Output functions. Alarm Output Settings Changing the user settings in this menu is done using the same methods for changing the Operating Set Point. NOTE: Adjustable user settings in the Alarm Output Setup menu are unaffected by Restore Factory Defaults. Display Settings Menu This menu permits the user to set display options for viewing information on the UIM’s LCD screen. Figure 7-7_Display Settings Menu The alarm relay operates in the background according to the settings in this menu, and it is not capable of disabling water heater operation. The alarm relay is used for external notification/verification of various operational conditions such as fault conditions and heating mode status. This relay can be used with Building Management Systems and other external supervisory controls. Output Function Adjustable user setting. Available options for the alarm output function setting are: Heating Mode: Used for heating mode on/off status notification. Enable / Disable Closed: Used for notification and/or verification of the enable/disable circuits open/closed status. There are two enable/disable circuits available for external supervisory control(s) at the J7 socket on the CCB - see wiring diagrams. Enable/disable circuit(s) status can be viewed in the Heater Status Menu. Temperature Units Adjustable user setting that changes the temperature units display to Celsius °C or Fahrenheit °F. Backlight Delay Adjustable user setting that determines how long the UIM’s LCD backlight remains illuminated after a key has been pressed. Available settings are: Always Off, 10, 30, or 60 seconds, and Always On. Contrast Adjustable user setting to adjust the UIM’s LCD screen contrast between text and background. 31 Installation & Operation Manual 7 Control System Operation Display Settings CCB Version Changing the user settings in this menu is done using the same methods for changing the Operating Set Point. Software version for Central Control Board. NOTE: Adjustable user settings in the Display Settings menu are unaffected by Restore Factory Defaults. UIM Version Software version for User Interface Module. Heater Information Menu Current Fault / Alert Menu This menu displays non-adjustable operational information. This menu displays non-adjustable operation information. With the Fault History sub menu selected in Main Menu, press the Operational button underneath SELECT to display the current fault or alert message. If there is not a fault or alert condition currently active NONE is displayed to the right of this menu. Figure 7-8_Heater Information Menu TOP OF MENU Figure 7-9_Main Menu - Current Fault Selected Elapsed Time 7 days 18 hrs 35 mins Total Heating Time 2 days 46 mins Cycle Count 00000042 Bank 1 Cycles 00000035 Bank 1 On Time BOTTOM OF MENU Bank 2 On Time Bank 3 Cycles Bank 3 On Time CCB Version UIM Version 1 day 4 hrs 44 mins 00000025 8 hrs 30 mins 0.00 0.00 Elapsed Time Total accumulated time the control system (water heater) has been energized. Total Heating Time Total accumulated time the control system has been in the heating mode (i.e., any heating elements have been energized). Bank # Cycles Total accumulated count of heating cycles for each heating bank. Bank # On Time Total accumulated heating on time for each heating bank. 32 Fault History Menu This menu displays non-adjustable operational information. The control system records and stores the last nine (9) fault and alert messages in chronological order and displays them in this menu. The most recent message will be at the top of the list. A time stamp is displayed below each listed fault and alert message showing when the fault or alert condition occurred. The Fault History is useful when dealing with intermittent operation problems or when the customer has reset the control system prior to a service agent’s arrival. With a fault or alert item selected, press the Operational Button underneath VIEW to display the details for the fault or alert message. The Fault/Alert message screen displays a brief description of the condition, contact information, and access to the Advanced Service Information sub menu. Installation & Operation Manual 7 Control System Operation (continued) Figure 7-10_Fault History Screens FAULT HISTORY MENU CURRENT / HISTORY FAULT MESSAGE Fault Occurrence Menu This menu displays the total accumulated number of times each individual fault condition has occurred. This running total of fault occurrences can be useful in determining which, if any, operational problems have been persistent. Figure 7-11_Fault Occurrence Menu 33 Installation & Operation Manual 7 Control System Operation Restore Factory Defaults Menu This control system menu allows the user to restore most of the control system’s user settings to their factory default settings. User settings in the Alarm Output Setup and Display Settings menus are unaffected by executing Restore Factory Defaults. Table 7-9_Restore Factory Defaults ACTION From the Main Menu use the Up/Down buttons to select (highlight in black) the “Restore Factory Defaults” menu. Press the Operational Button underneath “SELECT.” The Restore Factory Defaults menu will be displayed. From the Restore Factory Defaults menu press the Operational Button default settings have been restored. Press the Operational Button underneath “BACK” to exit the Restore Factory Defaults menu. 34 DISPLAY Installation & Operation Manual 8 Maintenance General DANGER Burn hazard. Keep clear of drain valve discharge outlet. 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. 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. The following are typical, but not all, signs of a depleted anode rod: • The majority of the rods diameter is less than 3/8". • Significant sections of the support wire (approximately 1/3 or more of the anode rod’s length) are visible. If the anode rod shows signs of either or both, it should be replaced. NOTE: Whether re-installing or replacing the anode rod, check for any leaks and immediately correct if found. To replace the anode: 1. Turn OFF electric supply to the water heater. Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale from the heating element. 2. Shut OFF the water supply and open a nearby hot water faucet to depressurize the water tank. The heater tank is equipped with an anode rod to aid in corrosion control and should be inspected periodically (see Anode Rod Inspection). 3. Drain the tank. Refer to Draining and Flushing for proper procedures. Close the drain valve. 4. Remove the old anode rod. 5. Use Teflon® tape or approved pipe sealant on threads, and install a new anode rod. 6. Turn ON water supply and open a nearby hot water faucet to purge air from the water system. Check for any leaks and immediately correct any if found. 7. Restart the water heater as directed in this manual. See the Features and Components illustrations for anode rod location. Anode Rod Inspection CAUTION All water heaters eventually leak. Do not install without adequate drainage. Each water heater contains at least one (1) anode rod, which will slowly deplete, due to electrolysis, prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water usage, hydronic heating devices, and water softening methods can increase the rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak. Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. The use of a water softener may decrease the life of the water heater tank. The anode rod should be inspected after a maximum of three (3) years and annually thereafter until the condition of the anode rod dictates its replacement. NOTE: Artificially softened water requires the anode rod to be inspected annually. Flushing the Water Heater 1. Turn OFF the electrical supply to the water heater at the breaker or disconnect switch. 2. Ensure the cold water inlet valve is open. 3. Open a nearby hot water faucet and let the water run until the water is no longer hot, then close the hot water faucet. 4. Connect a hose to the water heater drain valve and terminate it to an adequate drain. 5. Ensure that the drain hose is secured before and during the entire flushing procedure. Flushing is performed with system water pressure applied to the water heater. 6. Open the water heater drain valve to flush the storage tank. 7. Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean. 8. Close the water heater drain valve when flushing is completed. 9. Remove the drain hose. 10. Fill the water heater (see the Filling the Water Heater section in this manual). 11. Turn ON the electrical supply to the water heater. 12. Place the water heater back in operation. Allow the water heater to complete several heating cycles to ensure it is operating properly. 35 Installation & Operation Manual 8 Maintenance Sediment Removal Other Scale Removal: 1. Flush cleaned ends of banks with water when deliming or cleaning is completed. 2. Remove sediment and scale from the tank bottom through the access provided by the bank openings or drain valve opening. The cold water inlet valve and drain valve may be opened to aid the clean-out process. 3. Clean remaining gasket material from the tank and bank flanges. Do NOT reuse original bank gaskets. Lime scale accumulations on the heating banks is a normal condition, common to all immersion-type banks. Factors which affect the amounts of this formation are: 4. Put new gaskets on each bank and install into tank openings. Uniformly tighten bank bolts. Torque to approximately 32 ft./lbs. 1. The amount of hot water used. As the volume of water heated increases, more scale results. 5. Attach bank wires to the connection points from which they were removed. 2. Water temperature. As the temperature of the water is increased, more scale is deposited on the banks. 6. 3. Characteristics of water supply. Follow Filling instructions to restore hot water service. Check for water leaks around the banks, and check for proper operation when the heater is filled. Close the front panel. Water borne impurities consist of fine particles of soil and sand, which settle out and form a layer of sediment on the bottom of the tank. In time, if not removed, the level of sediment might reach the heating banks and cause their failure. For convenience, sediment removal and bank lime scale removal should be performed at the same time as follows in this chapter. Lime Scale Removal Regardless of water treatment, it is recommended that the banks be inspected periodically. This can be completed by viewing the element through the cleanout, optional 4"x 6" handhole, 12"x 16" manway, ore removing the element. Lime scale accumulations may cause noises to occur during operation. It is recommended that a heating bank be removed periodically for examination. If it is scaled, all of the banks should be removed and cleaned. If the tank bottom has an accumulation of sediment, it should be removed. Lime scale should be removed by dissolving the accumulation in delimer. Do NOT use muriatic or hydrochloric acid based deliming solutions to remove lime scale from the banks. The process for lime scale removal is as follows: 1. Turn OFF electrical disconnect switch. 2. Drain the heater following Draining instructions. 3. Open front panel. 4. Disconnect the bank wiring. Try not to disturb the wiring unnecessarily and reconnection will be easier. 5. Unscrew each bank. 6. Remove the banks and gaskets from the openings. Use a twisting, pulling action to remove banks scaled beyond the size of the tank openings. Brush loose scale from the banks. 7. Remove lime scale by placing the limed ends of the heating banks into delimer and allow scale to dissolve. Do NOT permit delimer or water to contact the heating bank electrical terminals. Silicates, sulfates, and aluminates must be removed by scraping or other mechanical means. Lime scale dissolvents will not remove these types of scale which are occasionally encountered. 36 Installation & Operation Manual 9 Troubleshooting Checklist Water Heater Makes Strange Sounds Before calling for service, check the following points to see if the cause of trouble can be identified and corrected. Reviewing this checklist may eliminate the need of a service call and quickly restore hot water service. WARNING Before removing any access panels or servicing the water heater, make sure the electrical supply to the water heater is turned OFF. Failure to do this could result in death, serious bodily injury, or property damage. Not Enough or No Hot Water 1. Be certain the electrical disconnect switch serving the water heater is in the ON position. The pilot toggle switch on the cabinet should be ON. In some areas, water heater electrical service may be limited by the power company. If the heater operates on a controlled circuit, heater recovery may be affected. The optional manual override switches on the cabinet front may be turned off, de-energizing the elements. 2. Check the fuses. The electrical disconnect switch usually contains fuses. The water heater has fuses located behind the cabinet front door (see the Features and Components section of this manual for their location). 1. Sediment or lime scale accumulations on the elements causes sizzling and hissing noises when the heater is operating. The sounds are normal, however, the tank bottom and elements should be cleaned. Refer to the Maintenance section of this manual for details. 2. Some of the electrical components of the water heater make sounds which are normal (i.e., contactors will “click” or snap as the heater starts and stops). Leakage Checkpoints 1. Check to see if the drain valve is tightly closed. 2. The apparent leakage may be condensation which forms on cool surfaces of the heater and piping. 3. If the outlet of the relief valve is leaking it may represent excessive water pressure, excessive water temperature, or a faulty temperature and pressure relief valve. Excessive water pressure is the most common cause of relief valve leakage. Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. 3. If the water was excessively hot, and is now cold, the ECO 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. Repeated activation of the ECO high limit switch should be investigated by a qualified service agent. As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause intermittent temperature-pressure relief valve operation, or 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. 4. The storage capacity and/or recovery rate of the water heater may have been exceeded by a large demand for hot water. Large demands require a recovery period to restore water temperature. A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local qualified service agency to have a thermal expansion tank installed. 5. Cold incoming water temperature will lengthen the time required to heat water to the desired temperature. If the heater was installed when incoming water temperature was warm, colder water creates the effect of less hot water. 4. 6. Sediment or lime scale may be affecting water heater operation. If You Cannot Identify or Correct the Source of Malfunction: Water is Too Hot Refer to the Temperature Regulation section of this manual. Examine the flange area of the elements for gasket leakage. Tighten the bolts or, if necessary, follow the Water and Lime Scale Removal procedure in the Maintenance section of this manual to replace the gaskets. 1. Place the water heater electrical disconnect switch in the OFF position. 2. Close the cold water inlet valve to the heater. 3. Contact a Qualified Service Agency in your area. Replacement Parts Call the telephone number listed on this manual for assistance in locating replacement parts. When ordering parts, specify complete model number, serial number (see rating plate), quantity, and name of part desired. Standard hardware items should be purchased locally. 37 Installation & Operation Manual 10 Diagrams Figure 10-1 Wiring Diagram 208 - 600/3PH GND PRIMARY FUSES RD SECONDARY PILOT SWITCH 120V SEC FUSE BK W BK BL RD BL SDI W BK PUMP FUSES W BK CONTACTORS CABLE (CAT 5) 2 3 4 5 6 W BK (ONE (1), TWO (2), OR THREE (3) ELEMENTS PER BANK) G 24V BK BANK 7 BANK 8 BANK 9 W N BK BK BANK 5 1 BANK 6 BANKS BK BK R1 REQUIRED IF AT LEAST ONE FOLLOWER BOARD IS USED. BK BLACK W WHITE G GREEN RD RED J3 1 2 RED BLK BLK RED 120V NOTES: STD WIRING OPT'L WIRING 3 1 4 5 RD 4 J5 J7 JUMPER J9 OUT J11 IN CABLE (CAT 5) 38 Installation & Operation Manual 10 Diagrams (continued) Figure 10-1 Wiring Diagram (continued) BK G W BANK 2 BK BANK 3 N BANK 1 24V BANK 1 BANK 2 BANK 3 BANK 5 BANK 4 W N BANK 4 24V 1 R1 3 1 J3 RED BLK BLK RED 120V BK 2 3 1 4 BK BK JUMPER/BMS 5 4 3 2 1 BK BLK 4 1 J9 OUT J11 IN CABLE (CAT 5) CABLE (CAT 5) TEMP PROBE RD J10 RD RD HI TEMP LIMIT SW. HI TEMP LIMIT SW. RD LEADER PROBE DISPLAY TEMP PROBE J9 OUT J11 IN LWCO RD (SINGLE CONTROL BOARD) JUMPER/BMS J7 CABLE (CAT 5) J10 PROBE J3 J5 J7 RD RD BK 5 4 J5 LWCO BK BK BK BK BK RED BLK BLK RED BK BK 120V G R1 SEE NOTES BK BK BK (MULTIPLE CONTROL BOARDS) DISPLAY W RD G 3 1 BK 4 5 BK RD 4 J3 BK 1 2 BK 3 1 J5 4 4 J5 J7 J7 JUMPER JUMPER J9 OUT J11 IN J9 OUT J11 IN BK 5 BK BK RD J3 BK 1 2 BK 3 1 BANK 20 BANK 21 BANK 22 BANK 23 BANK 15 BANK 16 BANK 17 BANK 18 BANK 19 BANK 10 BK W N RED BLK BLK RED 2 BANK 11 BANK 12 BANK 13 BANK 14 1 BK RED BLK BLK RED J3 BK RED BLK BLK RED 120V BK 24V W N BANK 24 24V W N 120V 24V G 120V G BK BK RD 4 5 4 J5 J7 JUMPER J9 OUT J11 IN RD CABLE (CAT 5) CABLE (CAT 5) CABLE (CAT 5) 39 Revision Notes: Revision A (PCP# 3000005344 / CN# 500005576) initial release. MM #100278842_DIR #2000537422_Rev A 12/16
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