A.O. Smith WATER HEATERS User Manual

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Instruction Manual

RESIDENTIAL ELECTRIC

WATER HEATERS

WATER

ONLY

FOR

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.IFYOUAREUNSUCCESSFUL,PLEASEWRITETOTHECOMPANYLISTEDONTHERATINGPLATEONTHEWATERHEATER.

KEEPTHIS MANUALIN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED IN THE U.S.A 1203

1

PART NO. 184639-000

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.

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.

2

GENERAL SAFETY

TABLE OF CONTENTS

SAFE INSTALLATION, USEAND SERVICE ..............................

2

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

11

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

3

FORYOUR INFORMATION .....................................................

12

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

3

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

12

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

4

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

12

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

4

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

12

NOTES ......................................................................................

4

Smelly Water ..................................................................

12

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

5

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

12

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

6

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

12

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

7

PERIODICMAINTENANCE .......................................................

12

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

8

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

12-13

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

8

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

13

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

8

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

13

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

8

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

13

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

8-9

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

13

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

9-10

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

14

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

10

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

15

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

10

TROUBLESHOOTING ..............................................................

16

TEMPERATUREREGULATION ................................................

11

WARRANTY .....................................................................

Insert

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 -AmericanNational Standards Institute

ASME - American Society of Mechanical Engineers

GAMA - GasAppliance Manufacturer’s Association

NEC - National Electric Code

NFPANational Fire ProtectionAssociation

UL - Underwriters Laboratory

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, SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.

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. Since we cannot put everything on the first few pages, READ THE ENTIRE MANUAL BEFORE

ATTEMPTING TO INSTALL OROPERATETHEWATERHEATER.

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 code requirements follow NFPA-70(latest edition). The National Electric Code which may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA02269.

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 the place where you are going to put the water heater. INSTALLATIONORSERVICEOFTHISWATERHEATERREQUIRES ABILITY EQUIVALENTTO THAT OFALICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBINGAND ELECTRICALWORKARE REQUIRED.

Examine the location to ensure the water heater complies with the “Facts to ConsiderAbout 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.

NOTES

4

TYPICAL INSTALLATION

LOWBOYS

UPRIGHTS

INSTALL SUITABLE DRAIN PANS UNDER HEATERS TO PREVENT DAMAGE DUE TO LEAKAGE. REFER TO WATER HEATER LOCATION ON PAGE 8.

INSTALL VACUUM RELIEF IN COLD WATER INLET LINE AS REQUIRED BY LOCAL CODES.

INSTALL THERMAL EXPANSION TANK OR DEVICE IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM.

COMPACTS

TABLE TOPS

FIGURE1.

5

WIRING DIAGRAMS

TURN OFF THE HEATER ELECTRICAL SUPPLY BEFORE SERVICING ANY ELECTRICAL COMPONENTS.

 

A-9

C-2

TWO WIRE CIRCUIT FOR SINGLE

240 VOLT “OFF PEAK” NON-SIMULTANEOUS

ELEMENTHEATERSEQUIPPED

OPERATION BOTTOM ELEMENT ON SEPARATE

WITH HIGH LIMIT CONTROL

TIME CLOCK OR “OFF PEAK” METER

S-1

THREE WIRE CIRCUIT FOR

ELECTRIC CO. CO-OP

PROGRAMS

A-6

TWO WIRE CIRCUIT FOR

NON-SIMULTANEOUSOPERATION,

HAS SINGLE HIGH LIMIT CONTROL

FIGURE2.

6

MIXING VALVE USAGE

FIGURE3.

Water (Potable) Heating: All models are considered suitable for

HOTTERWATERCANSCALD:

water (potable) heating only.

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 handicapped. 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, shall be used at the hot water taps used by these

 

people or at the water heater. Mixing valves are available 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.

7

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.

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.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

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 Conversation 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 handicapped. 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, shall 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.

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.

8

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.

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 4 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT 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.

TEMPERATURE-PRESSURERELIEF 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 andAutomatic Gas Shut-offDevices 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, 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 tubing directly to discharge drain unless a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in 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.

FIGURE4.

9

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 valve between the relief valve and tank.

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.

FIGURE5.

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, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” electrical supply to the water heater.

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.

PIPE INSULATION

FIGURE6.

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.

10