Bradford-White M-2-50T6DS User Manual

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R DENTIAL ELECTRIC AND LI

C ERCIAL ELECTRIC WATER HEATERS

Photo is of

M-2-50T6DS

S ICE MANUAL

T eshooting Guide a structions for Service

(To be performed ONLY by qua ce providers)

M

Covered

b

 

Reside

nergy Saver:

M1& M2(HE) UprightModels.

M1& M2 Lowboy Models.

M1& M2 UtilityModels.

M1& M2 Wall HungModels.

Light DutyEnergy Saver:

LD Upright Models.

LD Utility Models.

LD Lowboy.

LD WallHung.

Dairy Barn Deluxe Energy Saver:

DB Models.

M

l 238-47104-00A

Save this manual for future reference

Residential and Light Duty

Commercial Electric Water Heaters

Table of Contents

Page

Introduction ………………………………………………………………………. 2 Tools……………………………………………………………………………… 2 General Information ……………………………………………………………… 3

Sequence of Operation ……………………………………………………………

6

Single Element Operation ……………………………………................... 6

Double Element, Non-Simultaneous,Single Phase………………………. 7

Double Element, Simultaneous, Single Phase, 4 wire Service …............... 8

Double Element, Non-Simultaneous,3 Phase ………................................ 9

Double Element, Simultaneous, 3 Phase …………………………………

10

Double Element, Non-Simultaneous,Single Phase, Off Peak …………... 11

Troubleshooting ………………………………………………………………….

12

Line Voltage and High Limit ECO Testing………………………………………

14

Heating Element Testing ……………................................................................... 15

Residential Thermostat Testing ……..................................................................... 16 Single Element ……………………………............................................... 16 Double Element, 4 wire, Simultaneous, Single Phase …………………... 16 Double Element, Non-Simultaneous,Single Phase ………....................... 17 Double Element,Non-Simultaneous,3 Phase …………………………... 19 Double Element, Simultaneous, 3 Phase ………………………………... 21 Double Element,Non-Simultaneous,Single Phase, Off Peak ………….. 23

Light Duty Commercial Thermostat Testing …..................................................... 25 Double Element, Non-Simultaneous,Single Phase ……………………... 25 Double Element, Simultaneous, Single Phase …………………………... 27 Double Element,Non-Simultaneous,3 Phase …………………………... 29 Double Element, Simultaneous, 3 Phase ………………………………... 31

Thermostat Removal and Replacement …………………………………………. 33 Heating Element Removal and Replacement ……………………………………. 34 Dip Tube and Anode Inspection and Replacement ……………………………… 35 Generic Parts List ………………………………………………………………... 36

Service Procedure

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RE-IRE-IIRE-III

RE IV

RE-VRE-VIRE-VII

- - -

Introduction

This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair of Bradford White residential electric and light duty commercial electric water heaters.

The text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshooting procedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using the methods described in this service manual.

 

 

Tools

 

- Multi Meter.

- Phillips Head Screw Driver.

- 1-½Deep Well Socket (element removal).

- Thermometer.

- ¼" Nut Driver.

- Drain Hose.

- Various Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers, Flash Light.

Page 2

2

 

 

 

 

 

 

GENERAL INFORMATION

 

 

 

 

 

 

Commonly Used Formulas

 

 

 

 

 

Amps = Watts

(for single phase units) Example 4500W/240V = 18.75A

 

 

 

Volts

 

 

 

 

Amps = Watts

(for balanced 3 phase units) Example 4500W/240V x 1.732 = 10.82A

 

Volts

 

 

 

x 1.732

 

Watts = Amps x Volts Example 18.75A x 240V = 4500W

 

Ohms = Volts 2

Example (240V)2 / 4500W = 12.8 Ohms

 

 

Watts

 

 

 

Common Service Wire Configurations

 

120 VOLT

 

 

240 VOLT

 

BLACK

WHITE

GREEN

BLACK

RED

GREEN

Grounded

Ungrounded

(Neutral)

Grounding

Ungrounded

Ungrounded

Grounding

 

 

120

 

0

 

 

 

 

 

240

 

120

 

 

 

 

 

120

 

 

 

 

 

120

 

 

 

 

 

208 3Ph

 

 

240 3Ph

 

480 3Ph/277 1 Ph

Neutral

A

B

 

C

Neutral

A

 

B

C

Neutral

A

 

B

C

 

 

120

 

 

 

 

120

 

 

 

 

277

 

 

120

 

 

 

120

 

 

 

277

 

 

 

 

120

 

208

 

120

 

240

 

277

 

 

480

 

 

 

208

208

 

 

 

240

240

 

 

 

480

480

 

 

RED

BLACK

RED

 

RED

BLACK

RED

RED

BLACK

RED

 

 

 

 

 

 

Page 3

 

 

 

 

 

 

 

3

GENERAL INFORMATION

Wattage Limitations at Various Voltages

Residential Electric Upright M1 & M2 Series (Non-Simultaneousoperation)

Residential High Eff ncy Upright M2HE Series (Non-Simultaneousoperation)

Residential Electric Lowboy M1 & M2 Series (Non-SimultaneousOperation)

Dairy Barn Deluxe DB Series (Non-SimultaneousOperation)

Maximum

Element

Voltage

Wattage

Upper/Lower

 

3,000

3,000/3,000

120

 

 

 

6,000

6,000/6,000

208, 240

 

 

 

6,000

6,000/6,000

277, 480

 

 

 

Residential Electric Upright M1 & M2 Series (Simultaneous Operation)

Residential High Efficiency Upright M2HE Series (Simultaneous Operation)

Residential Electric Lowboy M1 & M2 Series (Simultaneous Operation)

Light Duty Commercial Electric LD Series (Non-SimultaneousOperation)

Light Duty Commercial Electric LD Series (Simultaneous Operation)

Dairy Barn Deluxe DB Series (Simultaneous Operation)

Maximum

Element

Voltage

Wattage

Upper/Lower

 

3,000

1,500/1,500

120

 

 

 

10,000

5,000/5,000

208

 

 

 

11,000

5,500/5,500

240

 

 

 

12,000

6,000/6,000

277, 480

 

 

 

Residential Electric Utility Series (Single Element Operation)

L

ngle Element Operation)

 

 

 

 

Maximum

Single

Voltage

Wattage

Element

 

3,000

3,000

120

 

 

 

6,000

6,000

208, 240

 

 

 

6,000

6,000

277

 

 

 

6,000

6,000

480

 

 

 

Page 4

4

GENERAL INFORMATION

Surface Mounted Thermostats

Surface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the tank. Surface mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperature settings and high limit (ECO) activation. It is import that the entire back surface of the thermostat is in full contact or flush with the tank. Improperly mounted thermostat will lead to improper heater operation.

Manual

ECO (high limit)

Reset button

Temperature

 

Temperature

control Dial

 

control Dial

Surface Mount

Surface Mount

Surface Mount

Combination Thermostat/

Combination Thermostat/

Thermostat

ECO (high limit)

ECO (high limit)

59T Series

89T Series

89T Series

 

Direct Immersion “Screw-in”Type Heating Element

1-½Hex

Screw-inFlange

Terminal Block

Screw

Terminal Block

Zinc Plated Copper or

Incoloy Sheath

Element Rating Ink Stamped

on side of Terminal Block.

Page 5

5

SEQUENCE OF OPERATION

Residential and light duty commercial electric water heaters are designed to operate using several different operating modes. The common modes and sequence of operation are as follows:

1.Single Element Operation.

2.Double Element Non-SimultaneousOperation (single phase).

3.Double Element Non-SimultaneousOperation (3 phase).

4.Double Element Simultaneous Operation (single phase).

5.Double Element Simultaneous Operation (3 phase).

Sequence of Operation- Single Element Operation.

1Line voltage is applied across terminals L1 &L3 of the thermostat. ECO is closed, so there is voltage at terminal L4 and to one side of the element.

2Tank is cold therefore thermostat

is closed at terminal T2 (calling for heat). This completes the circuit and allows current to flow through the element.

1

ECO

Closed

2

Thermostat closed at terminal T2

3 When the thermostat is satisfied, it opens at

3

terminal T2 interrupting current flow through the

 

element. System is now in stand-bymode, waiting

 

for the next call for heat.

 

 

Thermostat opens

 

at terminal T2

Page 6

6

SEQUENCE OF OPERATION

Non-Simultaneousand Simultaneous Operation

Double element electric water heaters are designed to operate in a Non-Simultaneousor Simultaneous mode.

Non-Simultaneous Mode: Allows only one heating element to operate at a time. For example, when the tank is cold, the upper element is energized first, heating the top of the tank. Only when the upper thermostat is satisfied, the upper element isde-energizedand power is directed to the lower thermostat, energizing the lower element and heating the bottom portion of the tank until the lower thermostat is satisfied. As hot water is drawn off the tank, it is replaced with cold water delivered through the dip tube to the bottom of the tank. The bottom of the tank cools, the lower thermostat will call for heat energizing the lower element. If enough hot water is drawn from the tank, the top portion of the tank cools and the upper thermostat will call for heat,de-energizingthe lower element and allowing only the top element to energize until the upper thermostat is satisfied.

Simultaneous mode: allows both heating elements to operate at the same time. That is, if either thermostat (upper or lower) is calling for heat, the corresponding heating element is energized independent of the other.

Sequence of Operation- Double Element,Non-SimultaneousOperation, Single Phase.

1Line voltage is applied across terminals L1 & L3 of the upper thermostat. ECO is closed, so there is voltage at terminal L4 and to one side of the upper and lower elements.

2Tank is cold therefore both thermostats

are closed at terminal T2 & 2 (calling for heat). The circuit is complete through the upper thermostat only, allowing current to flow through upper element.

3When upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to terminal 1 of lower thermostat. This completes the circuit through the lower thermostat and allows current flow through lower element.

4When the lower thermostat is satisfied, it opens at terminal 2 interrupting current flow through lower element. The system is now in stand-bymode waiting for the next call for heat

1

2

ECO

 

Closed

Thermostat closed

 

at terminal T2

Upper

Upper

T’stat

T’stat

Upper

Upper

Element

Element

 

Thermostat closed

 

at terminal 2

Lower

Lower

T’stat

T’stat

Lower

Lower

Element

Element

5

The lower thermostat/element

 

 

combination will generally

 

 

cycle on and off more often

3

 

then the upper. In some cases,

 

such as a cold tank or in high

 

demand periods, the upper

 

thermostat will call for heat

 

(opening at terminal

Thermostat closed

 

T4 and closing at

at terminal T4

 

 

 

terminal T2) prior to the lower

T’stat

 

 

Upper

thermostat being satisfied. This

 

will interrupt current flow

 

 

through the lower thermostat

 

and element and allow current

Element

 

 

Upper

to flow through the upper

 

 

element only. When the upper

 

thermostat is satisfied, it

 

T’stat

resumes operation as

 

 

 

Lower

described in sequence #3

 

above.

 

Lower

 

 

Element

4

5

Thermostat open between terminals 1 and 2

 

Thermostat closed

 

at terminal T2

Upper

Upper

T’stat

T’stat

Upper

Upper

Element

Element

 

Thermostat closed

 

between terminals

 

1 and 2

Lower

Lower

T’stat

T’stat

Lower

Lower

Element

Element

Page 7

7

SEQUENCE OF OPERATION

A 4 wire, double element heater wired for simultaneous operation is essentially two single element systems operating independently. The heaters are wired internally with two independent circuits, one circuit for each thermostat/element combination. When installed using a two wire service, the blue and red (or white) wires will be connected together, likewise black and yellow wires will be connected together.

Sequence of Operation- Double Element, Simultaneous Operation, Single Phase, 4 wire service installation.

1Line voltage from circuit one is applied across terminals L1 & L3 of the lower thermostat. Likewise, line voltage from circuit two is applied across terminals L1 & L3 of the upper thermostat. ECO in both upper and lower thermostat is closed, so there is voltage at terminal L4 of each thermostat and to one side of the upper and lower elements.

2Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat). This completes the circuit through the thermostats and allows current to flow through the elements.

3When either thermostat is satisfied, it will open at terminal T2, interrupting current flow through the corresponding element. As both thermostats satisfy, the system will be in stand-bymode waiting for the next call for heat. Thermostats will operate independent of the other.

1

Circuit two

 

2

Circuit two

 

 

 

Circuit one

 

 

Circuit one

 

 

 

ECO

Thermostat closed

 

 

 

Closed

 

 

 

at terminal T2

 

 

 

 

 

ECO

Closed

Thermostat closed at terminal T2

3

Circuit two

 

Circuit one

Thermostat open at terminal T2

Thermostat open at terminal T2

Page 8

8

SEQUENCE OF OPERATION

Sequence of Operation- Double Element,Non-SimultaneousOperation, 3 Phase.

1Line voltage is applied across terminals L1 & L3 of upper thermostat. Likewise, Line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements.

1

2

ECO

Closed Thermostat closed at terminal T2

2Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat). The circuit is complete through the upper thermostat only allowing current to flow through the upper element.

3When the upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to terminal L1 of lower thermostat. This completes the circuit through the lower thermostat allowing current flow through lower element.

4When the lower thermostat is satisfied, it opens at terminal T2 interrupting the current flow through the lower element. The system is now in stand-bymode waiting for the next call for heat.

5The lower thermostat/element combination will generally cycle on and off more often then the upper. In some cases, such as a cold tank or in high demand periods, the upper thermostat will call for heat (opening at terminal T4 and closing at terminal T2) prior to the lower thermostat being satisfied. This will interrupt current flow through the lower thermostat and element and allow current to flow through the upper element only. When the upper thermostat is satisfied, it resumes operation as described in sequence #3 above.

ECO

 

Closed

Thermostat closed

 

at terminal T2

3

4

Thermostat closed

Thermostat closed

at terminal T4

at terminal T4

Thermostat closed

at terminal T2 Thermostat open at terminal T2

5

Thermostat closed at terminal T2

Thermostat closed at terminal T2

Page 9

9

SEQUENCE OF OPERATION

Sequence of Operation- Double Element, Simultaneous Operation, 3 Phase.

1Line voltage is applied across terminals L1 & L3 of upper thermostat. Line voltage also extends to terminal L1 of lower thermostat. Also, line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements.

2Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat). This completes the circuit through the thermostats and allows current to flow through the elements.

3When either thermostat is satisfied, it will open at terminal T2, interrupting current flow through the corresponding element. As both thermostats satisfy, the system will be in stand-bymode waiting for the next call for heat. Thermostats will operate independent of the other.

1

2

ECO

 

Closed

Thermostat closed

 

at terminal T2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECO

Thermostat closed

 

 

 

Closed

 

 

 

 

at terminal T2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

Thermostat open at terminal T2

Thermostat open at terminal T2

Page 10

10

SEQUENCE OF OPERATION

Some electric utility companies will offer discounts for using electricity during “Off Peak” Times of the day. The system allows the use of an “Off Peak” meter, which interrupts power to the lower element during high power demand periods.

Sequence of Operation- Double Element,Non-SimultaneousOperation, Single Phase, Off Peak.

1Line voltage is applied across terminals

L1 & L3 of the upper thermostat. Line voltage from off peak meter is supplied to terminal L1 of lower thermostat. ECO in the upper thermostat is closed, so there is voltage at terminal L4 of upper thermostat and to one side of the upper element.

Tank is cold therefore both thermostats

2are closed at terminal T2 (calling for heat). The circuit is complete through the upper thermostat only, allowing current to flow through upper element.

3When upper thermostat is satisfied, it opens at terminal T2 interrupting current flow through upper element, and closes at terminal T4 allowing voltage to pass to one side of the lower element. This completes the circuit through the lower thermostat and off peak meter allowing current flow through lower element.

4When the lower thermostat is satisfied, it opens at terminal T2 interrupting current flow through lower element. The system is now in stand-bymode waiting for the next call for heat

5During peak power demand periods as determined by the local utility, the off peak meter will interrupt power to terminal L1 of lower thermostat. Only the top thermostat/element combination is allowed to operate during this period.

From

1

 

2

Off Peak

 

 

 

Meter

 

 

 

 

 

ECO

Thermostat closed

 

 

Closed

 

 

at terminal T2

 

 

 

Thermostat closed at terminal T2

From

3

4

5

Off Peak

 

 

Off Peak

Meter

 

 

Power interrupted

Thermostat closed

 

 

Thermostat closed

at terminal T4

 

 

at terminal T2

Thermostat closed

Thermostat open

at terminal T2

at terminal T2

Page 11

11

TROUBLESHOOTING

Most common cause for improper electric water heater operation can be linked to heating element failure.

When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot Water” Its always a good idea to check the heating elements first following the procedure on page 15.

Common Heating Element Failures Are:

1.Dry Firing. Element may be partially submerged in water or most likely, completely exposed with no water in tank. In some cases sediment or lime build up around an element can eventually cause an air pocket, and within seconds, result in a dry fired element. At this point the element becomes inoperative. When element replacement is required, be sure tank is full of water prior to energizing the water heater.

2.Grounded Element. An element with a short circuit to ground will in most cases cause the circuit breaker in the service panel to open or shut off. In some cases there may not be enough current draw for the circuit breaker to open. This will allow the heating element to be in continuous operation resulting in over heated water, limited only by the ECO or Energy Cut Off located in the thermostat. Repeated actuation of the ECO reset button on the thermostat usually is the result of a grounded element.

3.Sediment build up. Slow hot water recovery can usually be traced back to sediment or lime build up around heating element. Sediment build up can also over time cause a dry fired element.

Illustration 1, below shows a common“Screw-In”type heating element identifying certain features commonly referred to throughout this manual.

1-½Hex

 

Terminal Block

Screw-inFlange

 

 

 

Zinc Plated Copper or

Incoloy Sheath

0642 4500W 240V

RC02404524

Terminal Block

 

 

 

 

Element Rating Ink Stamped

Screw

 

 

 

 

on side of Terminal Block.

 

 

 

 

 

 

 

 

Illustration 1

 

 

Typical Direct Immersion “Screw-In”

 

 

 

Type Heating Element

 

Page 12

12

TROUBLESHOOTING

Quick Step Plan to Hot Water

1.TURN OFF power to water heater and check all wire connections to insure they are tight and corrosion free.

2.Turn power “ON” and determine that service voltage is present, and the high limit (ECO) has not actuated (see procedure on page 14).

WARNING

High voltage exposure. Use caution when making voltage checks to avoid personal injury.

3.Check for inoperative heating element (see procedure on page 15).

4.Check for proper thermostat operation (see procedures beginning on page 16). NOTE: Thermostat testing procedures assume items 2 and 3 above are in working order.

SYMPTOM

No Hot Water

Not Enough Hot

Water

Slow Hot Water

Recovery

Over Heated

Water or

Continues

Operation

Noisy (singing or hissing) Elements

 

 

PROBABLE CAUSE

 

CORRECTIVE ACTION

 

 

SERVICE

 

 

 

 

 

 

 

 

 

 

PROCEDURE

 

 

 

1.

Check fuses or circuit breakers in service

 

 

 

 

 

 

 

 

 

 

3. See Service Procedure

1.

No Power to heater.

 

panel.

2.

Check all wire connections.

 

RE-II,Page 15.

2.

Loose wire connections.

 

3.

Check heating element(s). Replace as

4. See Service Procedure

3.

Inoperative upper heating element.

 

needed.

 

RE-III,Page 16.

4.

Inoperative upper thermostat.

 

 

4.

Check thermostat(s) operation. Replace as

5. See Service Procedure

5. Open ECO.

 

needed.

 

RE-I,Page 14.

 

 

 

 

 

5.Check ECO. Reset or replace thermostat(s) as needed.

 

 

1.

Check heating element(s), replace as

 

 

1.

Inoperative lower heating element.

 

needed.

1.

See Service Procedure

2.

Thermostat(s) set to low.

2.

Increase thermostat setting.

3.

Inoperative thermostat(s).

3.

Check thermostat(s), replace as needed.

 

RE-II,Page 15.

4.

Loose wire connection.

4.

Check all wire connection.

3.

See Service Procedure

5.

Sediment or lime build up on element(s).

5.

Remove heating element(s) and check for

 

RE-III,Page 16.

6.

High demand period.

 

lime build up.

5.

See Service Procedure

7.

Undersized heater.

6.

Reduce demand.

 

RE-VI,Page 34.

8.

Very cold inlet water to heater.

7.

Replace with larger heater.

10. See Service Procedure

9.

Plumbing connections reversed.

8.

Temper water to heater.

 

RE-VII,Page 35.

10. Damaged dip tube.

9.

Correct plumbing connections.

 

 

 

 

10. Check dip tube, replace as needed.

 

 

 

 

1.

Remove heating element(s) and check for

1.

See Service Procedure

1.

Sediment or lime build up on element(s).

 

lime build up.

2.

Loose wire connections.

2.

Check all wire connections.

 

RE-VI,Page 34.

3.

Inoperative thermostat(s).

3.

Check thermostat(s), replace as needed.

3.

See Service Procedure

4.

Derated heating element installed.

4.

Check terminal block of element for proper

 

RE-III,Page 16.

 

 

 

voltage and wattage rating.

 

 

1.

Thermostat not in contact with tank.

1.

Position thermostat flush with tank surface.

1.

See Service Procedure

2.

Check heating element(s). Replace as

 

RE-V,Page 33.

2.

Grounded heating element(s).

 

needed.

2.

See Service Procedure

3.

Thermostat set to high.

3.

Adjust thermostat(s) to desired setting.

 

RE-II,Page 15.

4.

Inoperative thermostat(s).

4.

Check thermostat(s), replace as needed.

4.

See Service Procedure

5.

Inoperative ECO.

5.

Check ECO, replace thermostat as

 

RE-III,Page 16.

6.

Undersized water heater.

 

needed.

5.

See Service Procedure

 

 

6.

Replace with larger heater.

 

RE-I,Page 14.

1.

Lime formation on elements.

1.

Remove and clean heating elements.

1.

See Service Procedure

 

 

 

Replace as needed.

 

RE-VI,Page 34.

Page 13

13

SERVICE PROCEDURE RE-I

Line Voltage & High Limit (ECO)

Testing

Line Voltage Testing

1.Turn “OFF” power to water heater.

2.Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat.

WARNING

High voltage exposure. Use caution when making voltage checks to avoid personal injury.

3. Set multi-meterto volts AC.

4.Turn power “ON” to water heater.

5.Check voltage across terminals L1 & L3 of upper thermostat (see illustration 2).

A)Rated voltage IS present, power to the water heater is okay.

B)Rated voltage NOT present, Check circuit breaker at service panel.

Illustration 2

ECO reset button

Illustration 3

High Limit (ECO) Testing

1.Check voltage across terminals L1 & L4 upper thermostat (see illustration 3).

A)Rated Voltage IS present, ECO is okay.

B)Rated voltage NOT present, proceed to step 2.

2.Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s). Turn power “ON” and recheck voltage across terminals L1 & L4 of upper thermostat

(see illustration 3).

A)Rated voltage IS present, the ECO has opened indicating the water in the tank is or has over heater. Check the following:

1.Thermostat must be in full contact with tank.

2.Be sure heating element(s) is not shorted to ground (see page 15).

3.Proper thermostat operation (see procedures beginning on page 16).

B)Rated voltage NOT present, water in tank may be over heated.

1.If water is hot, turn “OFF” power to water heater and flow water through tank to cool below set point of upper thermostat. Recheck voltage per step 1.

2.If water is cool, Replace upper thermostat.

Page 14

14

SERVICE PROCEDURE RE-II

Heating Element Testing

Testing For Open Or Burned Out Element.

Step 1. TURN OFF POWER TO WATER HEATER.

Step 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element.

Step 4. Set multi-meterto “ohms” setting.

Step 5. Touch probes of multi-meterto screw terminals of heating element

(see illustration 4).

Step 6. Reading should be 12.8 ohms (±6%) for a 240 volt, 4500 watt element:

Ohms = Volts2 Watts

A reading outside the range using the formula above (±6%), indicates a bad element and the element must be replaced.

Testing For Heating Element Short Circuit To

Ground.

Step 1. TURN OFF POWER TO WATER HEATER.

Step 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element.

Step 4. Set multi-meterto “ohms” setting.

WARNING

High voltage exposure. Be sure power is turned

OFF to water heater prior to performing this

procedure.

Meter Probe

Element Screw Terminals

Illustration 4

Element Screw Terminal

Step 5. Touch one probe of multi-meterto either screw terminal of heating element and the other on the element flange (see illustration 5). There should be no reading on the ohm meter. Any reading indicates a grounded element and the element must be replaced. Repeat this step for the other screw terminal.

Meter Probe

Element Flange

Illustration 5

Page 15

15

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Single Element Operation or

Double Element, 4 Wire, Simultaneous, Single Phase Operation.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Water In Tank Is Cold With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”.

4.Check across terminals L4 and T2 of thermostat (see illustration 6).

A) Rated voltage NOT present,

 

Recheck ECO. If ECO is okay,

 

replace thermostat.

 

B) Rated voltage IS present,

 

proceed to next step.

 

5. Check across element terminals

 

(see illustration 7).

 

A) Rated voltage NOT present,

Illustration 6

check wire connections from

 

thermostat to element.

 

B) Rated voltage IS present,

 

Repeat element testing

 

see page 15.

 

Water Temperature In Tank Is Above Thermostat Setting.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”.

4.See illustration 6 above, check across terminals L4 and T2 of thermostat.

A)Rated voltage IS present, replace thermostat.

B)Rated voltage NOT present, thermostat is okay.

C)Lower than rated voltage IS present, recheck for grounded element

(see page 15).

Illustration 7

Reference 4 Wire, Simultaneous, Single Phase

Wiring diagram.

NOTE: Wiring consists of two single element configurations operating independently.

Page 16

16

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

WARNING

Double Element, Non-Simultaneous,Single PhaseHigh voltage exposure. Use caution to avoid Operation.

personal injury during this procedure.

Water In Tank Is Cold With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”.

4.Check across terminals L4 and T2 of upper thermostat (see illustration 8).

A) Rated voltage NOT present, Recheck ECO. If ECO is okay, replace thermostat.

B)Rated voltage IS present, proceed to next step.

5.Check across element terminals (see illustration 9).

A)Rated voltage NOT present, check wire connections from thermostat to element.

B) Rated voltage IS present,

Illustration 8

Illustration 9

Repeat element testing

 

 

 

see page 15.

 

 

 

Tank Does Not Deliver Enough Hot Water.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater and set multi-meterto “Volts AC”.

3.Adjust temperature setting of upper thermostat to the highest setting. Water temperature in tank must be below thermostat setting for this test.

4.

See illustration 8 above, check voltage across terminals L4 and T2 of upper

 

 

thermostat.

 

 

A) Rated voltage IS present, okay, upper thermostat is

 

 

calling for heat. Go to step 5 below.

 

 

B) Rated voltage NOT present, replace upper thermostat.

 

5.

Adjust temperature setting of upper thermostat to the minimum setting.

 

 

Water temperature in tank must be above thermostat setting for this test.

 

6.

Check voltage across terminals L4 and T4 of upper thermostat

 

 

(see illustration 10).

 

 

A) Rated voltage NOT present, replace upper thermostat.

 

 

B) Rated voltage IS present, thermostat is okay. Go to step 7 on next page.

Illustration 10

Page 17

17

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,Single Phase

Operation (continued).

Not Enough Hot Water (continued).

7.Check voltage across terminal L4 of upper thermostat and terminal 1 of lower thermostat (see illustration 11).

A)Rated voltage NOT present,

-check wire connection between thermostats.

B)Rated voltage IS present, okay, go to step 8.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

8.Adjust lower thermostat to highest setting. Water temperature in tank must be below the lower thermostat setting for this test.

9.Check voltage across terminal L4 of upper

thermostat and terminal 2 of lower thermostat (see illustration 12).

A) Rated voltage NOT present, replace lower thermostat.

B) Rated voltage IS present, thermostat is ok.

WARNING

 

Be sure thermostats are reset to their original

Illustration 11

temperature settings as found prior to

thermostat testing

 

Water Temperature In Tank Is Above Thermostat Setting.

1.This procedure assumes Line voltage, ECO and elements are in working order.

2. Adjust upper and lower thermostats to the lowest setting.

3. Turn power “ON” to water heater and set multi-meterto “Volts AC”.

4. Check across terminals L4 and T2 of upper thermostat (see illustration 8 on page 17).

A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay. Go to step 5 below.

C) Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

5. Check across terminals L4 and 2 of lower thermostat (see illustration 12).

A) Rated voltage IS present, replace lower thermostat.

Illustration 12

B)Rated voltage NOT present, lower thermostat is okay.

C)Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

Page 18

18

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,Three Phase

Operation.

Water In Tank Is Cold With Power ON.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”.

4. Check across terminals L4 and T2 of upper thermostat (see illustration 13).

A)Rated voltage NOT present, Recheck ECO. If ECO is okay, replace thermostat.

B)Rated voltage IS present, proceed to next step.

5.Check across element terminals (see illustration 14).

A)Rated voltage NOT present, check wire connections from thermostat to element.

B) Rated voltage IS present,

Illustration 13

Repeat element testing,

 

see page 15.

 

Tank Does Not Deliver Enough Hot Water.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater and set multi-meterto “Volts AC”

3.Adjust temperature setting of upper thermostat to the highest setting. Water temperature in tank must be below thermostat setting for this test.

4.See illustration 13 above, check voltage across terminals L4 & T2 of upper thermostat.

A)Rated voltage IS present, okay, upper thermostat is calling for heat. Go to step 5 below.

B)Rated voltage NOT present, replace upper thermostat.

5.Adjust temperature setting of upper thermostat to the minimum setting. Water temperature in tank must be above thermostat setting for this test.

6.Check voltage across terminals T4 of upper thermostat & L3 of lower thermostat (see illustration 15).

A)Rated voltage NOT present, replace upper thermostat.

B)Rated voltage IS present, upper thermostat is okay. Go to step 7 on next page.

Illustration 14

Illustration 15

Page 19

19

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,

Three Phase Operation (continued).

Tank Does Not Deliver Enough Hot Water (continued)

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

7.Check voltage across terminal L1 & L3 of lower thermostat (see illustration 16).

A)Rated voltage NOT present, check wire connection between thermostats.

B)Rated voltage is present, okay, go to step 8.

8.Adjust lower thermostat to highest setting. Water temperature in tank must be below the lower thermostat setting for this test.

9.Check voltage across terminal L4 & T2 of lower thermostat (see illustration 17).

A)Rated voltage NOT present, recheck ECO (see page 14). If ECO okay, replace lower thermostat.

B) Rated voltage IS present, thermostat is ok. Check wire connection to lower element. If connection okay, recheck lower element (see page 15).

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to

thermostat testing

Illustration 16

Water Temperature In Tank Is Above Thermostat Setting.

1.This procedure assumes Line voltage, ECO and elements are in working order.

2.Adjust upper and lower thermostats to the lowest setting.

3.Turn power “ON” to water heater and set multi-meterto “Volts AC”.

4.Check across terminals L4 and T2 of upper thermostat (see illustration 13 on page 19).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present, upper thermostat is okay. Go to step 5 below.

C)Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

5. Check across terminals L4 and T2 of lower thermostat (see illustration 17). A) Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, lower thermostat is okay.

C)Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

Illustration 17

Page 20

20

 

SERVICE PROCEDURE RE-III

 

Residential Thermostat Testing

Double Element, Simultaneous, Three Phase

WARNING

Operation.

High voltage exposure. Use caution to avoid

 

 

personal injury during this procedure.

Water In Tank Is Cold Or Not Enough Hot

Water With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Adjust temperature setting for both thermostats to the highest setting.

2. Turn power “ON” to water heater.

3.

Set multi-meterto “Volts AC”.

 

 

4.

Check across terminals L4 and T2 of

 

 

 

upper thermostat (see illustration 18).

 

 

 

A) Rated voltage NOT present,

 

 

 

Recheck ECO (see page 14).

 

 

 

If ECO is okay, replace

 

 

 

thermostat.

 

 

 

B) Rated voltage IS present,

 

 

 

proceed to next step.

 

 

5.

Check across upper element terminals

 

 

 

(see illustration 19).

Illustration 18

Illustration 19

A)Rated voltage NOT present, check wire connections from thermostat to element.

B)Rated voltage IS present, Repeat element testing see page 15.

6.Check across terminals L1 & L3 of lower thermostat (see illustration 20).

A)Rated voltage NOT present, check wire connections from upper to lower thermostats.

B)Rated voltage IS present, okay, go to step 7.

7.Check across terminals L4 and T2 of lower thermostat (see illustration 21).

A) Rated voltage NOT present,

Recheck ECO (see page 14). If

ECO is okay, replace thermostat.

B)Rated voltage IS present, proceed to next step.

8. Check across lower element terminals.

Illustration 20

Illustration 21

A) Rated voltage NOT present,

 

 

check wire connections from

WARNING

 

thermostat to element.

 

B) Rated voltage IS present,

Be sure thermostats are reset to their original

temperature settings as found prior to

Repeat element testing

see page 15.

thermostat testing

 

Page 21

21

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Simultaneous, Three Phase

Operation (continued).

Water Temperature In Tank Is Above Thermostat

Setting.

1.This procedure assumes Line voltage, ECO and elements are in working order.

2.Adjust upper and lower thermostat to the lowest setting.

3.Turn power “ON” to water heater.

4.Set multi-meterto “Volts AC”.

5.Check across terminals L4 and T2 of upper thermostat (see illustration 22).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C)Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

6.Check across terminals L4 and T2 of lower thermostat (see illustration 23).

A)Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, lower thermostat is okay.

C)Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 22

Illustration 23

Page 22

22

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,Single Phase,

Off Peak Operation.

Water In Tank Is Cold With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”.

4.Check across terminals L4 and T2 of upper thermostat (see illustration 24).

A)Rated voltage NOT present, Recheck ECO (see page 14).

If ECO is okay, replace thermostat.

B)Rated voltage IS present, proceed to next step.

5.Check across element terminals (see illustration 25).

A)Rated voltage NOT present, check wire connections from thermostat to element.

B)Rated voltage IS present, Repeat element testing see page 15.

Tank Does Not Deliver Enough Hot Water.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 24

 

Illustration 25

1.This procedure assumes line voltage, ECO and elements are in working order. Be sure OFF PEAK meter has not interrupted line voltage.

2.Turn power “ON” to water heater and set multi-meterto “Volts AC”.

3.Adjust temperature setting of upper & lower thermostat to the Highest setting. Water temperature in tank must be below thermostat setting for this test.

4.See illustration 24 above. Check voltage across terminals L4 & T2 of upper thermostat.

A)Rated voltage IS present, okay, upper thermostat is calling for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

5. Adjust temperature setting of upper thermostat to the minimum setting. Water temperature in tank must be above thermostat setting for this test.

6. Check voltage across terminals T4 of upper thermostat & L1 of lower thermostat (see illustration 26).

A) Rated voltage NOT present, replace upper thermostat.

 

B) Rated voltage IS present, upper thermostat is okay. Go to

Illustration 26

step 7 on next page.

Page 23

23

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous,

Single Phase, Off Peak Operation.

(continued)

Not Enough Hot Water (continued).

7.Check voltage across terminal T4 of upper thermostat & T2 of lower Thermostat. (see illustration 27).

A)Rated voltage NOT present, Replace lower thermostat.

B)Rated voltage is present, okay, go to step 8.

8.Check voltage across lower element (see illustration 28).

A)Rated voltage NOT present, Check wire connections between thermostats & element.

B)Rated voltage IS present, Repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 27

Illustration 28

 

 

 

WARNING

Be sure thermostats are reset to their original

temperature settings as found prior to

thermostat testing

Water Temperature In Tank Is Above Thermostat Setting.

1.This procedure assumes Line voltage, ECO and elements are in working order.

2.Adjust upper and lower thermostats to the lowest setting.

3.Turn power “ON” to water heater and set multi-meterto “Volts AC”.

4.Check across terminals L4 and T2 of upper thermostat (see illustration 24 on page 23).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present, upper thermostat is okay. Go to step 5 below.

C)Lower than rated voltage IS present, recheck for grounded upper element (see page 15).

5.Check across terminals T4 of upper thermostat and T2 of lower thermostat (see illustration 27 above).

A)Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, lower thermostat is okay.

C)Lower than rated voltage IS present, recheck for grounded lower element (see page 15).

Page 24

24

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous,Single Phase

WARNING

High voltage exposure. Use caution to avoid

Operation.

 

personal injury during this procedure.

Water In Tank Is Cold With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3. Set multi-meterto “Volts AC”.

4. Check across terminals L4 and T2 of

 

upper thermostat (see illustration 29).

 

A) Rated voltage NOT present,

 

Recheck ECO (see page 14). If

 

ECO is okay, replace thermostat.

 

B) Rated voltage IS present,

 

proceed to next step.

 

5. Check across element terminals

 

(see illustration 30).

 

A) Rated voltage NOT present,

 

check wire connections from

 

thermostat to element.

 

B) Rated voltage IS present,

 

Repeat element testing

Illustration 29

see page 15.

Tank Does Not Deliver Enough Hot Water.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater and set multi-meterto “Volts AC”

3.Adjust temperature setting of upper & lower thermostat to the Highest setting. Water temperature in tank must be below thermostat setting for this test.

4.See illustration 29 above. Check voltage across terminals L4 & T2 of upper thermostat.

A)Rated voltage IS present, okay, upper thermostat is calling for heat. Go to step 5 below.

B)Rated voltage NOT present, replace upper thermostat.

5.Adjust temperature setting of upper thermostat to the minimum setting. Water temperature in tank must be above thermostat setting for this test.

6.Check voltage across terminals L3 & T4 of upper thermostat (see illustration 31).

A)Rated voltage NOT present, replace upper thermostat.

B)Rated voltage IS present, upper thermostat is okay. Go to step 7 on next page.

Illustration 30

Illustration 31

Page 25

25

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous,

WARNING

Single Phase Operation (continued)

High voltage exposure. Use caution to avoid

 

 

personal injury during this procedure.

Tank Does Not Deliver Enough Hot

Water (continued).

7.Check voltage across terminal L3 of upper thermostat & T2 of lower Thermostat. (see illustration 32).

A)Rated voltage NOT present, Replace lower thermostat.

B)Rated voltage is present, okay, go to step 8.

8.Check voltage across lower element (see illustration 33).

A) Rated voltage NOT present, Check wire connections between thermostats & element.

B) Rated voltage IS present, Repeat element testing see page 15.

WARNING

 

 

Be sure thermostats are reset to

Illustration 32

Illustration 33

their original temperature settings

as found prior to thermostat

 

 

testing

 

 

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes line voltage, ECO and elements are in working order. 2, Adjust upper and lower thermostat to the lowest setting.

3. Turn power “ON” to water heater and Set multi-meterto “Volts AC”

4.See illustration 32 above. Check across terminal L3 of upper thermostat

&T2 of lower thermostat.

A)Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, okay, go to step 5 below.

C)Lower than rated voltage IS present, recheck for grounded lower element see page 15.

5.Check across terminal L4 & T2 of upper thermostat (see illustration 34).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present, upper thermostat is okay.

C) lower than rated voltage IS present, recheck for grounded upper

Illustration 34

element see page 15.

 

 

Page 26

26

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Single Phase

WARNING

Operation.

High voltage exposure. Use caution to avoid

 

 

personal injury during this procedure.

Water In Tank Is Cold Or Not Enough Hot

Water With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Adjust temperature setting for both thermostats to the highest setting.

3. Turn power “ON” to water heater.

4. Set multi-meterto “Volts AC”

5.Check across terminals L4 and T2 of upper thermostat (see illustration 35).

A)Rated voltage NOT present, Recheck upper ECO

(see page 14). If ECO

is okay, replace upper thermostat.

B)Rated voltage IS present, proceed to next step.

6.Check across upper element terminals (see illustration 36).

A) Rated voltage NOT present,

Illustration 35

check wire connections from

 

thermostat to upper element.

 

B)Rated voltage IS present, Repeat element testing see page 15.

7.Check across terminal L3 of upper thermostat and T2 of lower thermostat (see illustration 37).

A)Rated voltage NOT present, Check ECO (see page 14) & wire connections at upper & lower thermostats. If okay,

replace lower thermostat.

B)Rated voltage IS present, proceed to next step.

8.Check across lower element terminals (see illustration 38).

A)Rated voltage NOT present, check lower element wire connections to the thermostats.

B) Rated voltage IS present, Repeat lower element testing see page 15

WARNING

Be sure thermostats are reset to

their original temperature settings Illustration 37 as found prior to thermostat

testing

Page 27

Illustration 36

Illustration 38

27

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Single Phase

Operation (continued)

Water Temperature In Tank Is Above Thermostat

Setting.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Adjust upper and lower thermostat to the lowest setting.

3.Turn power “ON” to water heater.

4.Set multi-meterto “Volts AC”

5.Check across terminals L4 and T2 of upper thermostat (see illustration 39).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C)lower than rated voltage IS present, recheck for grounded upper element see page 15.

6.Check across terminal L3 of upper thermostat and T2 of lower thermostat (see illustration 40).

A)Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, lower thermostat is okay.

C)lower than rated voltage IS present, recheck for grounded lower element see page 15.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 39

Illustration 40

Page 28

28

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous,Three Phase

Operation.

Water In Tank Is Cold With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater.

3.Set multi-meterto “Volts AC”

4.Check across terminals L4 and T2 of upper thermostat (see illustration 41).

A)Rated voltage NOT present, Recheck upper ECO. If ECO is okay, replace thermostat.

B)Rated voltage IS present, proceed to next step.

5.Check across element terminals (see illustration 42).

A)Rated voltage NOT present, check wire connections from thermostat to element.

B)Rated voltage IS present, Repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 41

Illustration 42

 

 

 

Tank Does Not Deliver Enough Hot Water.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Turn power “ON” to water heater and set multi-meterto “Volts AC”

3.Adjust temperature setting of upper & lower thermostat to the Highest setting. Water temperature in tank must be below thermostat setting for this test.

4. See illustration 41 above. Check voltage across terminals L4 & T2 of upper thermostat.

A) Rated voltage IS present, okay, upper thermostat is calling

 

for heat. Go to step 5 below.

 

B) Rated voltage NOT present, replace upper thermostat.

 

5. Adjust temperature setting of upper thermostat to the minimum

 

setting. Water temperature in tank must be above thermostat setting

 

for this test.

 

6. Check voltage across terminals L3 & T4 of upper

 

thermostat (see illustration 43).

 

A) Rated voltage NOT present, replace upper thermostat.

 

B) Rated voltage IS present, upper thermostat is okay. Go to

Illustration 43

step 7 on next page.

Page 29

29

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous,

Three Phase Operation (continued).

Tank Does Not Deliver Enough Hot Water (continued).

7.Check voltage across terminal L1 of upper thermostat & T2 of lower Thermostat. (see illustration 44).

A)Rated voltage NOT present, Replace lower thermostat.

B)Rated voltage is present, okay, go to step 8.

8.Check voltage across lower element (see illustration 45).

A)Rated voltage NOT present, Check wire connections between thermostats & element.

B)Rated voltage IS present, Repeat element testing see page 15.

WARNING

Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 44

 

Illustration 45

Water Temperature In Tank Is Above Thermostat Setting.

1. This procedure assumes line voltage, ECO and elements are in working order.

2. Adjust upper and lower thermostat to the lowest setting. 3. Turn power “ON” to water heater and Set multi-meterto “Volts AC”.

4. See illustration 44 above. Check across terminal L1 of upper thermostat & T2 of lower thermostat.

A) Rated voltage IS present, replace lower thermostat. B) Rated voltage NOT present, okay, go to step 5 below.

C) lower than rated voltage IS present, recheck for grounded lower element.

5. Check across terminal L4 & T2 of upper thermostat (see illustration 46). A) Rated voltage IS present, replace upper thermostat.

B) Rated voltage NOT present, upper thermostat is okay.

C) lower than rated voltage IS present, recheck for grounded upper element, see page 15.

Illustration 46

Page 30

30

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Three Phase

Operation.

Water In Tank Is Cold Or Not Enough Hot Water With Power ON.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Adjust temperature setting for both thermostats to the highest setting.

3.Turn power “ON” to water heater.

4.Set multi-meterto “Volts AC”

5.Check across terminals L4 and T2 of upper thermostat (see illustration 47).

A)Rated voltage NOT present, Recheck upper ECO

(see page 14). If ECO

is okay, replace upper thermostat.

B)Rated voltage IS present, proceed to next step.

6.Check across upper element terminals (see illustration 48).

A)Rated voltage NOT present, check wire connections from thermostat to upper element.

B)Rated voltage IS present, Repeat element testing see page 15

7.Check across terminal L4 of upper thermostat and T2 of lower thermostat (see illustration 49).

A)Rated voltage NOT present, Check ECO (see page 14) & wire connections at upper & lower thermostats. If okay, replace lower thermostat.

B)Rated voltage IS present, proceed to next step.

8.Check across lower element terminals (see illustration 50).

A)Rated voltage NOT present, check lower element wire connections to thermostat.

B)Rated voltage IS present, Repeat lower element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 47

 

Illustration 48

 

WARNING

 

 

Be sure thermostats are reset to

Illustration 49

Illustration 50

their original temperature settings

as found prior to thermostat

 

 

testing

 

 

 

Page 31

 

31

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Three Phase

Operation (continued).

Water Temperature In Tank Is Above Thermostat

Setting.

1.This procedure assumes line voltage, ECO and elements are in working order.

2.Adjust upper and lower thermostat to the lowest setting.

3.Turn power “ON” to water heater.

4.Set multi-meterto “Volts AC”

5.Check across terminals L4 and T2 of upper thermostat (see illustration 51).

A)Rated voltage IS present, replace upper thermostat.

B)Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C)lower than rated voltage IS present, recheck for grounded upper element see page 15.

6.Check across terminals L4 & T2 of lower thermostat (see illustration 52).

A)Rated voltage IS present, replace lower thermostat.

B)Rated voltage NOT present, lower thermostat is okay.

C)lower than rated voltage IS present, recheck for grounded lower element.

WARNING

High voltage exposure. Use caution to avoid personal injury during this procedure.

Illustration 51

Illustration 52

Page 32

32

SERVICE PROCEDURE RE-V

Thermostat Removal and Replacement

Thermostat Removal

1.Turn power “OFF” To water heater.

2.Remove access cover and insulation.

WARNING

High voltage exposure. Be sure power is “OFF” when performing this procedure.

3.Remove plastic thermostat protector from thermostat.

4.Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connectionto new thermostat.

5.Note thermostat temperature setting for proper setting of new thermostat.

6.Slide thermostat upwards and out of mounting bracket.

Thermostat Replacement

1.Use a stiff brush to remove any debris or loose scale from tank surface where new thermostat will be installed.

2.Slide new thermostat down into thermostat bracket until it snaps into place. IMPORTANT! Thermostat must set completely flat or flush to tank surface. An improperly installed thermostat will cause improper water heater operation.

3.Refer to the wire diagram located on the inside of the access cover and re-connectwires to the thermostat. Be sure wire connections are snug and corrosion free. Do not over tighten, doing so may damage thermostat.

4.Set thermostat to the original thermostat setting found on the old thermostat.

5.Re-installplastic thermostat protector.

6.Re-installinsulation and access cover.

7.Restore power to water heater and verify proper heater operation.

Tank Surface

Proper Thermostat mounting flush with tank surface

Thermostat

Improper Thermostat mounting.

Thermostat not flush with tank surface

Thermostat mounting bracket

Front View

Thermostat Mounting

Side View

Side View

Proper Thermostat

Improper Thermostat

Mounting

Mounting

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SERVICE PROCEDURE RE-VI

 

Heating Element Removal

 

and Replacement

 

WARNING

Heating Element Removal

High voltage exposure. Be sure power is

1. Turn power “OFF” To water heater.

“OFF” when performing this procedure.

 

2. Turn off cold water supply to heater. Connect hose to drain

WARNING

spigot of water heater and route to an open drain. Open

a nearby hot water faucet to vent heater for draining. Open

Heater components and stored water may be

drain spigot of water heater and allow heater to drain

HOT when performing the following steps in

to a point below the Element(s).

this procedure. Take necessary precaution to

3. Close drain spigot and remove hose.

prevent personal injury.

4.Remove access cover and insulation.

5.Remove plastic thermostat protector from thermostat.

6.Disconnect wires from element terminals.

7.Remove element from tank using 1-½deep well socket or appropriate wrench. Unscrew elementcounter-clockwiseto remove from tank.

8.Be sure to remove old element gasket from the tank. It is not recommended to be re-used.

Heating Element Replacement

1.Check element terminal block for proper electrical rating. NOTE: Some elements have dual ratings, be sure to check all surfaces of the element terminal block (see illustration below).

2.Apply new element gasket to the new element. Be sure gasket is seated flat against element flange without rolls or gaps (see illustration below).

3.Clean any debris from element fitting on tank. Lubricate element threads as needed with thread lubricant.

4.Thread new element clockwise into tank. Tighten element using 1-½deep well socket or appropriate wrench. Do not over tighten, over tightening may damage element gasket.

5.Reconnect wires to element, be sure wires are snug and corrosion free. Do not over tighten, doing so may damage terminal block.

6.Resume water supply to heater, be sure tank is full of water and check for leaks.

7.Re-installplastic thermostat protector.

8.Re-installinsulation and access cover.

9.To resume operation, BE SURE TANK IS FULL OF WATER and restore power to water heater. Verify proper heater operation.

 

 

Element Rating.

 

 

Example: (4500 Watt, 240 Volt)

Date Code

 

Element Flange

 

 

 

 

Element Gasket Seated Flat Against

 

 

Element Flange Without Rolls or Gaps

0642

4500W 240V

RC02404524

Terminal

 

 

Block

 

 

 

 

Manufacturer Identification

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SERVICE PROCEDURE RE-VII

Dip Tube and Anode Inspection and

Replacement

Dip Tube Inspection and Replacement

WARNING

Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Turn power “OFF” to water heater.

Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the inlet connection nipple.

Step 3. Close drain spigot and remove hose.

Step 4. Disconnect inlet nipple from plumbing system.

Step 5. With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage nipple threads.

Step 6. Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage. Hydro-jetslocated near the bottom of the dip tube should be open and free of any blockage.Anti-siphonhole located approximately 6" from the bottom of nipple, should be free of any blockage.

Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable and the inlet nipple/dip tube must be replaced.

Step 7. Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Connect nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with water.

Step 8. To resume operation, BE SURE TANK IS FULL OF WATER and turn power “ON” to water heater.

Anode Inspection and Replacement

Step 1.

Turn power “OFF” to water heater.

Step 2.

Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.

 

Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow

 

heater to drain to a point below the outlet connection nipple.

Step 3.

Close drain spigot and remove hose.

Step 4.

Disconnect outlet nipple from plumbing system.

Step 5.

With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage

 

nipple threads.

Step 6.

Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.

 

If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is

 

recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 7.

Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Connect

 

nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with

 

water.

Step 8.

To resume operation, BE SURE HEATER IS FULL OF WATER and turn power “ON” to water heater.

 

 

 

 

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Generic Parts List

1.T&P Relief Valve

2.Heat Trap Insert (Outlet)

3.Hot Water Outlet/Anode

4.Cover Conduit/Ground

5.Junction Box Cover

6.Heat Trap Insert (Inlet)

7.Cold Water Inlet Dip Tube

8.Thermostat Protector (Large)

9.Thermostat w/High Limit (89T33)

10.Thermostat Mounting Bracket

11.Heating Element

12.Element Gasket

13.Access Cover

14.Lower Thermostat Protector (Small)

15.Thermostat (59T)

16.Brass Drain Valve

17.Thermostat w/High Limit (89T13)

18.ASSE Approved Mixing Device

19.Kit Heat Trap

20.Kit Dairy Barn Leg

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36

NOTES

37

NOTES

38

NOTES

39

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