State EDT 662ORT, EDT 802ORT, EDT 1202ORT Instruction Manual

Instruction Manual

COMMERCIAL ELECTRIC WATER HEATERS

MODELS EDT662ORT, EDT802ORT & EDT120ORT

Series 200

INSTALLATION - OPERATION - SERVICE

- MAINTENANCE - LIMITED WARRANTY

500 Tennessee Waltz Parkway

Ashland City, TN 37015

Tech Support: 800-365-8170

Parts: 800-821-2017

®

Thank you for buying this energy efficient water heater.

We appreciate your confidence in our products.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED 0120

1

100326527_2000198516_Rev B

SAFE INSTALLATION, USE, AND SERVICE

The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER

WARNING

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

IMPORTANT DEFINITIONS

• Qualified Installer or Service Agency:

Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, electrical supply are required in addition to electrical testing skills when performing service.

• ANSI Z223.1 2006 Sec. 3.3.83:

“Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

2

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN

EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system which has been under water.

If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service technician.

1. External fire.

2. Damage.

3. Firing without water.

HYDROGEN GAS (FLAMMABLE)

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 can be produced in a hot water system served by this heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable.

To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. THERE SHOULD BE NO SMOKING

OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.

CAUTION

Improper installation, use and service may result in property damage.

• Do not operate water heater if any part has been

exposed to flooding or water damage.

• Inspect anode rods regularly, replace when significantly depleted.

• Install in location with drainage.

• Fill tank with water before operation.

• Properly sized thermal expansion tanks are required on all

closed water systems.

Refer to this manual for installation and service.

3

TABLE OF CONTENTS

SAFE INSTALLATION, USE, AND SERVICE.......................................

2

GENERAL SAFETY INFORMATION ....................................................

3

Precautions ..................................................................................

3

Hydrogen Gas (Flammable) .........................................................

3

TABLE OF CONTENTS ........................................................................

4

INTRODUCTION ..................................................................................

4

Preparing for the Installation ........................................................

4

DIMENSIONS AND CAPACITIES DATA ..............................................

5

APPROVALS ........................................................................................

6

MODEL AND RATING ..........................................................................

6

FEATURES AND COMPONENTS .......................................................

7

LOCATING THE NEW WATER HEATER .............................................

8

Facts to Consider About the Location ..........................................

8

Clearances ...................................................................................

8

INSTALLATION ....................................................................................

9

Required Ability ............................................................................

9

General .........................................................................................

9

Contaminated Water .....................................................................

9

Circulating Pump ..........................................................................

9

Insulation Blankets .......................................................................

9

Temperature-Pressure Relief Valve ..............................................

9

Closed Water Systems ...............................................................

10

Thermal Expansion ....................................................................

10

ELECTRICAL ......................................................................................

11

General ........................................................................................

11

Branch Circuit ..............................................................................

11

Calculating Amperage/Overcurrent Protection ............................

11

WIRING DIAGRAMS ..........................................................................

12

OPERATION .......................................................................................

13

General .......................................................................................

13

Filling the Water Heater ..............................................................

13

Initial Start Up .............................................................................

13

Draining the Water Heater ..........................................................

13

TEMPERATURE REGULATION ........................................................

14

Temperature Adjustment ............................................................

14

MAINTENANCE .................................................................................

15

General .......................................................................................

15

Anode Rod Inspection ................................................................

15

TROUBLESHOOTING CHECKLIST ..................................................

16

Checklist .....................................................................................

16

Leakage Checkpoints .................................................................

17

Repair Parts List .........................................................................

18

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

Abbreviations Found In This Instruction Manual:

• ANSI - American National Standards Institute

• AHRI - Air-Conditioning, Heating and Refrigeration Institute

• NEC - National Electrical Code

• NFPA - National Fire Protection Association

• UL - Underwriters Laboratory

PREPARING FOR THE INSTALLATION

1. Read the “General Safety Information” section of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater may not operate safely. It could cause DEATH, SERIOUS BODILY INJURY AND/OR

PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of the electric water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. READ

THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL

OR OPERATE THE WATER HEATER.

4

Be sure to turn off power when working on or near the electrical system of the heater. Never touch electrical components with wet hands or when standing in water.

When replacing fuses always use the correct size for the circuit, see tables on page 11.

The model and rating plates on page 6 interprets certain markings into useful information. Both of these references should be used to identify the heater, its components and optional equipment.

2. The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company. In the absence of local codes, the installation must comply with the latest editions of the National

Electrical Code, NFPA 70 or the Canadian Electrical Code CSA

C22.1. The National Electrical Code may be ordered from:

National Fire Protection Association, 1 Batterymarch Park,

Quincy, MA 02269. The Canadian Electrical Code is available from the Canadian Standards Association, 8501 East Pleasant

Valley Road, Cleveland, OH 44131.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number listed on the back cover of this manual for technical assistance.

A sample rating plate is shown on page 6 of this manual. In order to expedite your request, please have full model and serial number available for the technician.

4. Carefully plan your intended placement of the water heater.

Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

Installation and service of this water heater requires ability equivalent to that of a licensed tradesman or qualified agency

( page 2 ) in the field involved. Plumbing and electrical work are required.

DIMENSIONS AND CAPACITIES DATA

HOT

CONNECTION

8"

C

ANODE

ROD

COLD

CONNECTION

A

B

FIGURE 1

Tank Capacity

US Gals.

66

80

119

Litres

250

303

450

Inches

60.13

60.50

61.38

A

TABLE 1 - ROUGH-IN DIMENSIONS

B cm

153

154

156

Inches

52.75

52.25

54.38

cm

134

133

138

Inches

22

24

28

C cm

56

61

71

Approx.

Shipping Weight

Lbs.

146

Kg.

66.22

174

268

78.93

121.56

TABLE 2 - RECOVERY CAPACITIES

Element

Wattage

(Upper/Lower)

NON-SIMULATANEOUS

3000/3000

INPUT

KW

3.0

4000/4000

4.0

4500/4500

4.5

5000/5000

5.0

SIMULATANEOUS OPERATION

3000/3000

6

4000/4000

8

4500/4500

9

5000/5000

10

F°

C°

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

GPH

LPH

36F°

U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED

40F° 54F° 60F° 72F°

20C° 22.2C° 30C° 33.3C° 40C°

80F°

44.4C°

90F°

50C°

100F°

55.5C°

108F°

60C°

34

128

45

170

51

192

56

213

68

256

90

341

101

384

113

426

30

115

41

153

46

173

51

192

61

230

81

307

91

345

101

384

34

128

38

142

23

85

30

114

45

170

60

227

68

256

75

284

20

77

27

102

30

115

34

128

41

153

54

205

61

230

68

256

25

96

28

107

17

64

23

85

34

128

45

170

51

192

56

213

23

86

25

96

15

58

20

77

30

115

41

153

46

173

51

192

20

77

23

85

14

51

18

68

27

102

36

136

41

153

45

170

18

69

20

77

12

46

16

61

24

92

32

123

36

138

41

153

17

64

19

71

11

43

15

57

23

85

30

114

34

128

38

142

120F° 126F°

66.6C° 70C°

15

58

17

64

10

38

14

51

20

77

27

102

30

115

34

128

14

55

16

61

10

37

13

49

29

110

32

122

19

73

26

97

Recovery capacities at 100° F rise equal: for non-simultaneous element operation = 4.1 gal. x KW of one element; for simultaneous element operation = 4.1 gal. x 2/3 KW of both elements. For other rises multiply element KW as previously explained by 410 and divide by temperature rise. Full load current for single phase = total watts : voltage.

5

All models are listed by

Underwriters Laboratories Inc.

APPROVALS

®

MODEL AND RATING

COMMERCIAL STORAGE

TANK WATER HEATER

22U1

MODEL NUMBER

VOLTS - AC PHASE

WATTS

UPPER

WATTS

LOWER

SERIAL NUMBER

CIRCUIT

MAX WORKING

PRESSURE PSI

LLC

ITEM ID / PART NUMBER

TOTAL WATTS CONNECTED

INTERLOCK

1 PH / 3 PH

SIMULTANEOUS

1 PH 3 PH

CAPACITY US GAL

RATED MEASURED

STANDBY LOSS

% WATTS

6

FEATURES AND COMPONENTS

ELECTRICAL

JUNCTION BOX

(ACCESS PANEL)

ACCESS

PANELS

ANODE

COLD

DRAIN VALVE

INSTALL SUITABLE DRAIN PANS UNDER WATER HEATERS

TO PREVENT DAMAGE DUE TO LEAKAGE. REFER TO WATER

HEATER LOCATION ON PAGE 8.

INSTALL THERMAL

E X PA N S I O N TA N K

IF CHECK VALVE OR

PRESSURE REDUCING

VALVE IS USED IN

SUPPLY LINE.

INSTALL VACUUM RELIEF

IN COLD WATER INLET

LINE AS REQUIRED BY

LOCAL CODES.

FIGURE 2

7

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

The water heater should be located as close as possible to/or centralized to the water piping system. The water heater should be located in an area not subject to freezing temperatures.

The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower floors of the structure.

When such locations cannot be avoided, a suitable drain pan should be installed under the heater.

Such pans should be at least two inches deep, have a minimum length and width of at least two inches greater than the diameter of the heater and should be piped to an adequate drain.

Drain pans suitable for these water heaters are available from your distributor.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.

• Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water pressure differential between the cold water and how water pipes connected to the water heater.

• Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

CLEARANCES

A minimum clearance of 4” must be allowed for access to replaceable parts such as thermostats, drain valve and relief valve.

Adequate clearance for servicing this water heater should be considered before installation, such as changing the anodes, etc.

8

INSTALLATION

REQUIRED ABILITY

Installation and service of this water heater requires ability equivalent to that of a qualified installer or service agency ( page 2 ) in the field involved. Plumbing and electrical work is required.

GENERAL

The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company. In the absence of local codes, the installation must comply with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National Electrical

Code may be ordered from: National Fire Protection Association,

1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical

Code is available from the Canadian Standards Association, 8501

East Pleasant Valley Road, Cleveland, OH 44131.

Do NOT test electrical system before heater is filled with water, follow the START UP procedure in the OPERATION section of this manual.

The principal components of the heater are identified in the

Features and Components illustrations on page 7 .

CONTAMINATED WATER

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.

CIRCULATING PUMP

Field installed circulating pumps should be of all bronze construction.

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters.

Your water heater meets or exceeds the EPACT and ASHRAE/

IES 90.1 standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death.

• Do not cover the temperature and pressure relief (T & P) valve

with an insulation blanket.

• Do not cover the instruction manual. Keep it on the side of the

water heater or nearby for future reference.

• Do obtain new warning and instruction labels for placement on

the blanket directly over the existing labels.

TEMPERATURE-PRESSURE RELIEF VALVE

MIXING VALVE USAGE:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/developmentally disabled. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a maximum water temperature at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a MIXING VALVE , should be used at the hot water taps used by these people or at the water heater.

MIXING VALVES for reducing point of use temperature are available and are to be set at a maximum of 125 degree F. Consult a qualified installer or service agency. Follow all manufacturer’s Instructions for installation of these valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

This water heater is provided with a properly rated/sized and certified combination temperature - pressure relief valve by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for

Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA

4.4, and the code requirements of ASME.

If replaced, the new valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve rated/sized and certified as indicated in the above

9

paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or KW input rate as shown on the water heater’s model rating plate.

For safe operation of the water heater, the temperature and pressure relief valve must not be removed from its designated opening nor plugged. The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve.

Install discharge piping so that any discharge will exit only within 6 inches (15.2 cm) above, or at any distance below the structural floor.

Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.

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 be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve and the discharge pipe.

• Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

• Shall not have any valve or other obstruction between the relief valve and the drain.

The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged can cause bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the temperature-pressure relief valve with a properly rated/sized new one.

If you do not understand these instructions or have any questions regarding the temperature-pressure relief valve call the toll free number listed on the back cover of this manual for technical assistance.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion.

A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion.

Contact a local plumbing service agency to have a thermal expansion tank installed.

10

ELECTRICAL

This is an example of calculating heater amperage for both types of element operation. From this, the branch circuit conductor and overcurrent protection sizing can be established.

GENERAL

The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company. In the absence of local codes, the installation must comply with the current editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1.

An electrical ground is required to reduce risk of electrical shock or possible electrocution. The water heater should be connected to a separate grounded branch circuit with over-current protection and disconnect switch. The water heater should be grounded in accordance with national and local codes.

Voltage applied to the heater should not vary more than +5% to -10% of the model and rating plate marking for satisfactory operation.

DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON

BEFORE THE WATER HEATER TANK IS FILLED WITH WATER.

DOING SO WILL CAUSE THE HEATING ELEMENTS TO BURN

OUT AND VOID WARRANTY.

The factory wiring should be connected to the branch circuit wiring within the provided junction box. The water heater should be connected to a separate, grounded, branch circuit with overcurrent protection and disconnect switch. The water heater should be grounded in accordance with national and local codes.

BRANCH CIRCUIT

The branch circuit wire size should be established through reference to the current edition of NFPA-70, the National Electrical Code or other locally approved source in conjunction with the heater amperage rating. For convenience, portions of the wire size tables from the Code are reproduced here. The branch circuit should be sized at 125 percent of the heater rating and further increase wire size as necessary to compensate for voltage drop in long runs.

CALCULATING AMPERAGE/OVERCURRENT PROTECTION

The water heaters come from the factory in two configurations:

1. Two wire T-6 circuit for dual element water heater equipped with a single high limit control and single phase power input.

2. Four wire T-4 circuit for dual element water heater equipped with two high limit controls and single phase power input.

The example (T-4) is of a single-phase 240 volt unit with two, 3 kw elements. Check the water heater model and rating plate for actual specifications and substitute those values in the following.

TABLE 3

Non-simultaneous:

(T6 - Circuit)

3000 ÷ 240 = 12.5 amps*

*NOTE: as a single-phase nonsimultaneous unit.

Simultaneous:

(T4 - Circuit)

6000 ÷ 240 = 25 amps*

*NOTE: as a single-phase simultaneous unit.

The rating of the overcurrent protection should be computed on the basis of 125 percent of the total connected load amperage. Where the standard ratings and settings do not correspond with this computation, the next higher standard rating or setting should be selected.

Portion of Table 310-16 (NFPA-70) follows:

Allowable Ampacities of Insulated Copper Conductors. Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F).

These ampacities relate only to conductors described in Table

310-16 in Code.

For ambient temperatures over 30° C (86° F), see Correction

Factors, Note 13 in Code.

Size

AMG

MCM

10

8

6

4

3

18

16

14

12

TABLE 4

Temperature Rating of Conductor

See Table 310-16 in Code

60°C

(140°F)

Types:

RUW, (14-2), T, TW, UF

75°C

(167°F)

Types:

RH, RHW, RUH, (14-2),

- - -

- - -

15

20

30

40

55

70

80

THW, THWN, XHHW, USE

- - -

- - -

15

20

30

45

65

85

100

Portion of Table 310-18 follows:

Allowable Ampacities of Insulated Aluminum and Copper -Clad

Aluminum Conductors.

Not more than three conductors in Raceway or Cable or Direct Burial

(Based on Ambient Temperature of 30° C, 86° F. These ampacities relate only to conductors described in Table 310-18 in Code.

For ambient temperatures over 30° C (86° F), see Correction Factors,

Note 13 in Code.

Size

AMG

MCM

2

1

4

3

12

10

8

6

TABLE 5

Temperature Rating of Conductor

See Table 310-18 in Code

60°C

(140°F)

Types:

RUW, (12-2), T, TW, UF

75°C

(167°F)

Types:

RH, RHW, RUH, (12-2),

15

25

30

40

55

65

75

85

THW, THWN, XHHW, USE

15

25

40

50

65

75

90

100

11

T-6

208 or 240 VOLT

NON-SIMULTANEOUS

SINGLE PHASE OPERATION

SUPPLY LEADS

L1 L2

WIRING DIAGRAMS

T-4

208 or 240 VOLT

SIMULTANEOUS OPERATION

SINGLE PHASE OPERATION

SUPPLY LEADS

L1 L2

GND

GND

GREEN

GREEN

FIGURE 3

12

GENERAL

OPERATION

Refer to the Features and Components section of this manual ( page

7 ) for the location of components mentioned in the instructions that follow.

2. Open the front panel or top access cover, check all water and electrical connections for tightness. Also check connections on top and or sides of heater. Repair water leaks and tighten electrical connections as necessary.

3. Depress the red manual reset button on each Thermostat/ECO combination control. (See Figure 5, or Figure 6)

NEVER turn on power to the water heater without being certain the water heater is filled with water and a temperature and pressure relief valve is installed in the relief valve opening.

4. Turn on the electrical disconnect switch.

5. Observe the operation of the electrical components during the first heating cycle. Use care as the electrical circuits are energized.

DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS

FILLED WITH WATER. FOLLOW FILLING AND START-UP

INSTRUCTIONS IN OPERATION SECTION.

6. Close the front panel or top access cover.

FILLING THE WATER HEATER

Temperature control and contactor operation should be checked by allowing heater to come up to temperature and shut off automatically.

Use care as the electrical circuits are energized.

1. Turn off the electrical disconnect switch.

2. Close the water heater drain valve.

DRAINING THE WATER HEATER

The water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater.

1. Turn off the electrical disconnect switch.

2. Open a hot water valve until the water is cool, then close the supply water inlet valve to heater.

3. Attach hose to outlet opening of drain valve and direct end to drain.

4. Open a nearby hot water faucet and the heater drain valve.

5. If the heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this period. The hose may be removed.

3. Open a nearby hot water faucet to permit the air in the system to escape.

Follow FILLING instructions when restoring hot water service.

4. Fully open the cold water inlet pipe valve allowing the heater and piping to be filled.

5. Close the hot water faucet as water starts to flow. The heater is now ready for STARTUP and TEMPERATURE

REGULATION.

INITIAL START UP

The following checks should be made by the installer when the heater is placed into operation for the first time.

1. Turn off the electrical disconnect switch.

INSTALLATION

13

TEMPERATURE REGULATION

THE WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE

THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT

WATER AT TEMPERATURES DESIRED FOR AUTOMATIC

DISHWASHER AND LAUNDRY USE CAN CAUSE SCALDS

RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH.

THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH

THE PERSON’S AGE AND TIME OF EXPOSURE. THE SLOWER

RESPONSE TIME OF CHILDREN , AGED OR DISABLED PERSONS

INCREASES THE HAZARD TO THEM. NEVER ALLOW SMALL

CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN

BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON

UNATTENDED IN A BATHTUB OR SHOWER.

It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature thermostats (See Figure 4) be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater.

Figure 4 shows the approximate time-to-burn relationship for normal adult skin. The thermostats on your water heater have a linear relationship between degrees of angular rotation and the corresponding change in temperature. Thus rotating the temperature adjustment indicator 30 angular degrees will result in a 10 degree

Fahrenheit change in water temperature.

Water Temperature

°F (°C)

110 (43)

116 (47)

116 (47)

122 (50)

131 (55)

140 (60)

149 (65)

154 (68)

Time for 1st Degree Burn

(Less Severe Burns)

(normal shower temp.)

(pain threshold)

35 minutes

1 minute

5 seconds

2 seconds

1 second instantaneous

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

45 minutes

5 minutes

25 seconds

5 seconds

2 seconds

1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

FIGURE 4

TEMPERATURE ADJUSTMENT

The thermostats are adjustable from approximately 120°F (49°C)

(lowest setting) to 181°F (83°C) (highest setting) (See Figure 5).

These thermostats are set from the factory at approximately the

140°F (60°C) setting. The over temperature device (ECO high limit) attached to each thermostat has a manual reset.

T-4 THERMOSTAT

(UPPER & LOWER)

T-6 THERMOSTAT

(UPPER)

FIGURE 5

T-6 THERMOSTAT

(LOWER)

NOTE: It is not necessary to adjust the upper thermostat for a dual element unit. However, if it is adjusted above the factory set point

140°F (60°C) it is recommended that it not be set higher than the lower thermostat setting.

To change the temperature setting:

1. DANGER: Turn off the heater electrical supply. Do not attempt to adjust thermostat with power on.

2. Remove the upper and/or lower element access panel. Do not remove the plastic personnel protectors covering the thermostats. The thermostat is factory pre-set at 140°F (60°C).

3. Using a flat tip screwdriver, rotate the adjusting knob to the desired temperature setting.

4. Replace the access panels, and turn on heater electrical supply.

14

GENERAL

MAINTENANCE

ANODE ROD INSPECTION

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.

Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale from the heating element.

The heater tank is equipped with an anode rod to aid in corrosion control.

The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifices itself to protect the tank. Instead of corroding tank, water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition.

Anode deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by a qualified technician, and at a minimum should be checked annually after the warranty period.

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 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.

15

TROUBLESHOOTING CHECKLIST

CHECKLIST

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. See Figure 2 on page 7 in this manual to identify and locate water heater components.

ABNORMAL SOUNDS

1. Sediment or lime scale accumulations on the elements causes sizzling and hissing noises when the heater is operating.

• The sounds are normal, however, the tank bottom and elements should be cleaned. See the Maintenance section of this manual.

WATER LEAKAGE IS SUSPECTED

Refer to Leakage Checkpoint on the following page 17 .

1. Check to see if the heater drain valve is tightly closed.

2. If the outlet of the relief valve is leaking it may represent:

• Excessive water temperature.

• Faulty relief valve.

• Excessive water pressure.

3. Excessive water pressure is the most common cause of relief valve leakage. It is often caused by a “closed system”. See “Closed

Water Systems” and “Thermal Expansion” in the Installation section of this manual for more information.

4. Examine the area around the element for gasket leakage.

• Tighten the elements or, if necessary, follow the WATER

AND LIME SCALE REMOVAL procedure to replace the gaskets.

NOT ENOUGH OR NO HOT WATER

1. Be certain the electrical disconnect switch serving the water heater is in the ON position.

2. Check the fuses.

• The electrical disconnect switch usually contains fuses.

3. If the water was excessively hot, and is now cold, the high limit switch may have activated.

• See the Temperature Regulation section of this manual for more information on how to reset the ECO high limit controls.

4. The capacity of the heater may have been exceeded by a large demand for hot water.

• Large demands require a recovery period to restore water temperature.

5. Cooler incoming water temperature will lengthen the time required to heat water to the desired temperature.

6. Look for hot water leakage.

7. Sediment or pipe scale may be affecting water heater operation.

IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF

MALFUNCTION

1. Turn the power supply to the water heater off.

2. Close the supply water inlet valve to the heater.

3. Contact a Qualified Service Agency in your area. Call the toll free phone number on the back cover of this Instruction Manual for assistance in locating a service agency in your area.

REPLACEMENT PARTS

Call the toll free phone number on the back cover of this Instruction

Manual for assistance in locating replacement parts.. When ordering parts, specify complete model no., serial no., (see rating plate), quantity and name of part desired. Standard hardware items should be purchased locally.

16

LEAKAGE CHECKPOINTS

Instructions: Use this illustration as a guide when checking for sources of water leakage. You or your dealer may be able to correct what appears to be a problem. NOTE: Cover and Insulation shown removed to reveal tank top.

Where possible remove or lift top cover to examine threads of fittings installed into tank for evidence of leakage. Correct fitting leaks as necessary.

Water leaks at the elements may be due to:

1. Defective element which leaks at terminals or thru flange. Replace element*.

2. Loose element/gasket leak:

(a) Screw-in type: tighten with 1-1/2” socket wrench. If leak continues, remove element*, discard gasket and clean thread areas.Apply nonhardening Permatex Number 2 to thread areas, install new gasket and screw element into fitting until it seats. Tighten 1/2 to 3/4 turn with wrench.

(b) Flange type: tighten screw with wrench. If leak continues remove element* and discard gasket. Clean gasket seating areas and re-install element with new gasket. A new element may be required where threads have become rusted or damaged, preventing tightening.

All water which appears at the water heater bottom or on the surrounding floor may be caused by condensation, loose connections or relief valve operation and leakage. Do not replace the water heater until full inspection of all potential leak points is made and corrective steps taken to stop the leak. Leakage from other appliances, water lines or ground (see page 16) should also be suspected until proven otherwise.

Relief Valve

Anode Rod (Some Models)

To Open Drain

Condensation and dripping may appear on pipes when cold water temperature is low. Pipe fitting may be leaking.

Relief valve operation and leakage may be due to water expansion during heating cycle or foreign material on seat of valve. If the valve is not piped to an open drain the released water could be mistaken for a leaking heater. To check where threaded material between jacket opening and swab spud area. Remove valve* if indicated and repair with pipe joint compound.

To Open Drain

Water on the side of the tank may be condensation due to the panel or insulation not being in place.

Drain valve leakage could be from the valve itself.* To check for leakage where threaded portion enters tank, insert Q-tip or similar absorbent material between jacket opening and valve to swab spud area. Remove valve* if leak is indicated and repair with pipe joint compound.

*Contact your dealer as it is necessary to shut off electricity and drain tank to perform procedure.

FIGURE 6

17

REPAIR PARTS LIST

Now that you have purchased this water heater, should a need ever exist for repair parts or service, simply contact the company it was purchased from or direct from the manufacturer listed on the rating plate on the water heater.

Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly.

The model number of your Water Heater will be found on the rating plated located above the lower access panel.

Be sure to provide all pertinent facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

• MODEL NUMBER

• VOLTAGE AND ELEMENT WATTAGE

• SERIAL NUMBER

• PART DESCRIPTION

KEY

NO.

12

13

14

15

7

8

9

10

11

4

5

6

1

2

3

PART DESCRIPTION

Extension Nipple

Combo Dip Tube

Primary Anode Rod

T&P Valve

Element Gasket

Upper Element

Thermostat Bracket

Upper Thermostat w/Hi Limit

Terminal Protector

Upper Access Panel

Lower Access Panel

Lower Thermostat w/Hi Limit

Lower Element

Brass Drain Valve

Drain Pan

10

1

9

8

7

6

5

4

14

2 3

11

13

12

15

FIGURE 7

18

FIGURE 8

TABLE 6 - COPPER SHEATH ELEMENT AND WATTAGE CHART

K.W.

3.0

3.5

4.0

4.5

5.0

5.5

ELEMENT WATTAGE

3000

3500

4000

4500

5000

5500

208V

PART NO.

100109641

100108283

100109633

100108884

100108509

---

240V

PART NO.

100108316

100109629

100109641

100108283

100109643

100109633

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500 Tennessee Waltz Parkway, Ashland City, TN 37015

Tech Support: 800-365-8170

Parts: 800-821-2017

Copyright © 2020 State Industries, Inc., All rights reserved.

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