100278842_2000537422_Rev A_CHP Upgrade.indd

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
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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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