A.O. Smith 6-119 User Manual

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Instruction Manual

RESIDENTIAL ELECTRIC

WATER HEATERS

MODELS 6-120

FOR POTABLE WATER

HEATING ONLY

NOT SUITABLE FOR

SPACE HEATING

LISTED

GAMA certification applies to all residential electric water heaters with capacities of 20 to 120 gallons. Input rating of 12 Kw or less.

ALLTECHNICALAND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOUARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED IN THE U.S.A 0207

PART NO. 185762-000

1

SUPERSEDES PART NO. 184639-002

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use, and servicing of this water heater.

Many safety-relatedmessages 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 indicates an imminently

 

 

DANGER

 

 

 

 

 

 

 

hazardous situation which, if not avoided,

 

 

 

 

could result in death or injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING indicates a potentially hazardous

 

 

WARNING

 

 

 

 

 

 

 

situation which, if not avoided, could result

 

 

 

 

in death or injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION indicates a potentially hazardous

 

 

CAUTION

 

 

 

 

 

 

 

situation which, if not avoided, may result

 

 

 

 

in minor or moderate injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION used without the safety alert

 

 

 

 

 

CAUTION

 

symbol indicates a potentially hazardous

 

 

situation which, if not avoided, could result

 

 

 

 

in property damage.

 

 

 

 

 

 

 

 

 

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

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low level exposure to some of the substances listed, including formaldehyde.

IMPORTANT DEFINITIONS

Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing and electrical installation of these appliances. This would include a thorough understanding of the requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools necessary to confirm proper installation and operation of the water heater) as they relate to the installation of electric water heaters. The qualified installer must have a thorough understanding of the water heater Instruction Manual.

Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing and electrical installation of these appliances. This would include a thorough understanding of the requirements of the National Electrical Code and applicable local electrical and plumbing codes (and tools necessary to confirm proper installation and operation of the water heater) as they relate to the installation of electric water heaters. The service agency must have a thorough understanding of the water heater Instruction Manual.

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GENERAL SAFETY

3

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

ASME - American Society of Mechanical Engineers

GAMA - Gas Appliance Manufacturers Association

NEC - National Electrical Code

NFPA - National Fire Protection Association

UL - Underwriters Laboratories Inc.

PREPARING FOR THE INSTALLATION

1.Read the “General Safety” section of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY 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 understand. 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.

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 code requirements follow NFPA-70,the National Electrical Code (current edition), which may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

3.If after reading this manual you have any questions or do not understand any portion of the instructions, call the local utility or the manufacturer whose name appears on the rating plate.

4.Carefully plan your intended placement of the water heater. INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING AND ELECTRICAL WORK ARE REQUIRED.

Examine the location to ensure the water heater complies with the “Facts to Consider About the Location” section in this manual.

5.For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Office of the State Architect, 400 P Street, Sacramento, CA 95814.

6.Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR2.00: State Plumbing Code and248-CMR5.00.

TABLE OF CONTENTS

 

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

2

GENERAL SAFETY .....................................................................................................................................................................................................

3

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

4

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

4

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

4

TYPICAL INSTALLATION ...........................................................................................................................................................................................

5

MIXING VALVE USAGE ..............................................................................................................................................................................................

6

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

6-7

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

6

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

7

INSTALLING THE NEW WATER HEATER ...............................................................................................................................................................

7

Water Piping .........................................................................................................................................................................................................

7

Temperature-PressureRelief Valve ...................................................................................................................................................................

9

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

10

T & P Valve and Pipe Insulation (Selected Models) ......................................................................................................................................

10

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

11

WIRING .......................................................................................................................................................................................................................

12

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

13

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

13

FOR YOUR INFORMATION .....................................................................................................................................................................................

14

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

14

Strange Sounds .................................................................................................................................................................................................

14

Operational Conditions .....................................................................................................................................................................................

14

Water Odor .........................................................................................................................................................................................................

14

“Air” in Hot Water Faucets ................................................................................................................................................................................

14

High Water Temperature Shut Off System .....................................................................................................................................................

14

PERIODIC MAINTENANCE ......................................................................................................................................................................................

15

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

15

Temperature-PressureRelief Valve Operation ...............................................................................................................................................

15

Draining ...............................................................................................................................................................................................................

15

Thermostat Removal/Replacement ............................................................................................................................................................

15-16

Element Cleaning/Replacement .................................................................................................................................................................

16-18

Drain Valve Washer Replacement ...................................................................................................................................................................

18

Service ................................................................................................................................................................................................................

18

LEAKAGE CHECKPOINTS .......................................................................................................................................................................................

19

TROUBLESHOOTING GUIDELINES ......................................................................................................................................................................

20

REPAIR PARTS LIST ...........................................................................................................................................................................................

21-23

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TYPICAL INSTALLATION

UPRIGHTS/LOWBOYS

COMPACTS

 

†ELECTRICAL CONNECTIONS MAY BE LOCATED ON THE TOP OR

 

SIDE, REFER TO YOUR UNIT. ACTUAL MODEL AND

 

ILLUSTRATION MAY VARY DEPENDENT ON MODEL CAPACITY

 

AND TYPE. SOME MODELS HAVE ALTERNATE INLET, OUTLET

 

AND T&P VALVE LOCATIONS. THESE ALTERNATE LOCATIONS

 

ARE IDENTIFIED BY THE LABELING ON THE UNIT.

 

 

TABLE TOPS

 

 

INSTALL THERMAL EXPANSION TANK OR DEVICE IF WATER

 

HEATER IS INSTALLED IN A CLOSED WATER SYSTEM.

 

 

 

INSTALL SUITABLE DRAIN PANS UNDER HEATERS TO PREVENT

INSTALL VACUUM RELIEF IN COLD WATER INLET LINE AS

DAMAGE DUE TO LEAKAGE. REFER TO WATER HEATER

REQUIRED BY LOCAL CODES.

LOCATION, SEE “INSTALLING THE NEW WATER HEATER”

 

SECTION.

 

 

FIGURE 1.

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MIXING VALVE USAGE

FIGURE 2.

Water (Potable) Heating: All models are considered suitable for water (potable) heating only.

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally 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 certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve, should be used at the hot water taps used by these people or at the water heater. Mixing valves are available from your local plumbing contractor. Consult a Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the

safety of the occupants in the building and for the most economical use of the appliance.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed:

1.Select a location indoors as close as practical or centralized to the water piping system as possible. The water heater should be located in an area not subject to freezing temperatures.

2.Selected location must provide adequate clearances (4”) for servicing parts such as the thermostats, drain valve, and relief valve. Adequate clearance for servicing this appliance should be considered before installation, such as changing the anodes, etc.

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3.The water heater should be located so it is not subject to physical damage by moving vehicles or area flooding.

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the flow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper floor. When such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available from your local plumbing contractor. Such a drain pan must have a minimum length and width of at least 2 inches (51 mm) greater that the water heater dimensions and must be piped to an adequate drain.

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-offdevice 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-offdevices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

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 National Appliance Energy Conservation Act 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.

INSTALLING THE NEW WATER HEATER

WATER PIPING

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally 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 certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater. Valves for reducing point of use temperature by mixing cold and hot water are also available.

Consult a Qualified Installer or Service Agency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

This water heater shall not be connected to any heating systems or component(s) used with a non-potablewater heating appliance.

Use properly sized water heaters for spa or hot tub use.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

Water supply systems may, because of such events as high line pressure, frequent cut-offs,the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc. to control these types of problems. When these devices are not equipped with an internalby-pass,and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.

The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressurerelief valve is reached, the valve will relieve the excess pressure.The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable condition and must be corrected. It is recommended that any devices installed which could create a closed system have aby-passand/or the system have an expansion tank or device to relieve the pressure built by thermal expansion in the water system. Expansion tanks are available for ordering through a local plumbing contractor.Contact the local water supplier and/or a service agency for assistance in controlling these situations.

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NOTE: To protect against untimely corrosion of hot and cold water fittings, it is strongly recommended thatdi-electricunions or couplings be installed on this water heater when connected to copper pipe.

Figure 3 shows the typical attachment of the water piping to the water heater.Thewaterheaterisequippedwith3/4inchNPT water connections.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. Do not solder the cold water supply line directly to the cold water inlet, it will harm the dip tube and damage the tank.

FIGURE 3.

WATER PIPING PRESSURE TEST

This section is only for the manufacturer installing the water heater when the installation is to comply with H.U.D. Standards.

When testing the water ways, H.U.D. Standards state: “Water distribution system: All water piping in the water distribution system shall be subjected to a pressure test. The test shall be made by subjecting the system to air or water at 100 psi for 15 minutes without loss of pressure. When air pressure is used, the water heater shall not be connected during the test.”

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TEMPERATUREPRESSURE RELIEF VALVE

This heater is provided with a properly 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 valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph.

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

For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged.

The temperature-pressurerelief valve must be installed directly into the fitting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 inches (153 mm) above an adequate drain, or external to the building or structure. 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 tubing directly to discharge drain unless a 6 inch air gap is provided. The relief valve must be allowed to discharge water in sufficient quantities, should circumstances demand, to prevent bodily injury, hazard to life, or property damage. 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-pressurerelief valve, and the discharge pipe.

Shall terminate at an adequate drain.

Shall not have any shut-offvalve between the relief valve and tank nor in the discharge pipe.

The temperature-pressurerelief 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 thetemperature-pressurerelief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot.

FIGURE 4.

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If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions, and replace the temperature-pressurerelief valve with a new one.

FILLING THE WATER HEATER

Never use this water heater unless it is completely full of water. To prevent damage to the tank and heating element, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” electrical supply to the water heater. The manufacturer will not warrant any elements damaged by failure to follow instructions.

To fill the water heater with water:

1.Close the water heater drain valve by turning the handle to the right (clockwise). The drain valve is on the lower front of the water heater.

2.Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open when the water heater is in use.

3.To insure complete filling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant flow is obtained. This will let air out of the water heater and the piping.

4.Check all water piping and connections for leaks. Repair as needed.

5.Never alter or modify the certified construction of the water heater or its components, or bypass any safety features. Doing so voids all warranties.

T&P VALVE and PIPE INSULATION (On Selected Models)

Remove insulation for T&P Valve and pipe connections from carton.

Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater.

Fit T&P Valve insulation over valve. Make sure that the insulation does not interfere with the lever or outlet of the T&P valve.

Secure all insulation using tape.

PIPE INSULATION

FIGURE 5.

10