A.O. Smith 185762-000 User Manual

Instruction Manual

RESIDENTIAL ELECTRIC

WATER HEATERS

MODELS 6-120

FOR POTABLE WATER

HEATING ONLY

NOT SUITABLE FOR

SPACE HEATING

LISTED

LOW LEAD

NTENT

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

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE 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

PRINTED IN THE U.S.A 1112 PART NO. 185762-002 SUPERSEDES PART NO. 185762-001

WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

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

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

DANGER indicates an imminently

DANGER

WARNING

CAUTION

hazardous situation which, if not avoided, will result in death or injury.

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

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

CAUTION used without the safety alert

CAUTION

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.

Warning: 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.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

IMPORTANT DEFINITIONS

• Qualiﬁ ed Installer: A qualiﬁ ed installer must have ability equivalent to a licensed tradesman in the ﬁ elds 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 conﬁ rm proper installation and operation of the water heater) as they relate to the installation of electric water heaters. The qualiﬁ ed 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 ﬁ elds 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 conﬁ rm 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.

GENERAL SAFETY

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

• AHRI - Air Conditioning, Heating and Refrigeration Institute

• 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 ﬁ rst 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

TABLE OF CONTENTS

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 Ofﬁ ce of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95814. Instructions can also be downloaded to your computer at www. dsa.dgs.ca.gov/Pubs.

6. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

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-Pressure Relief 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-Pressure Relief Valve Operation ................................................................................................................................................... 15

Draining .............................................................................................................................................................................................................. 15

Thermostat Removal/Replacement .................................................................................................................................................................... 16

Element Cleaning/Replacement .................................................................................................................................................................... 16-18

Drain Valve Washer Replacement ...................................................................................................................................................................... 18

Service ............................................................................................................................................................................................................... 18

LEAKAGE CHECKPOINTS ........................................................................................................................................................................................ 19

TROUBLESHOOTING GUIDELINES ......................................................................................................................................................................... 20

REPAIR PARTS LIST ............................................................................................................................................................................................ 21-23

TYPICAL INSTALLATION

UPRIGHTS / LOWBOYS

6” (152.4 mm) MAXIMUM AIR GAP

COMPACTS

6” (152.4 mm) MAXIMUM AIR GAP

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

INSTALL SUITABLE METAL DRAIN PANS UNDER HEATERS TO PREVENT DAMAGE DUE TO LEAKAGE. REFER TO WATER HEATER LOCATION, SEE “INSTALLING THE NEW WATER HEATER” SECTION.

FIGURE 1.

MIXING VALVE USAGE

DISCHARGE PIPE

(DO NOT PLUG)

(PROVIDE 6” (152.4 mm)

MAXIMUM AIR GAP BETWEEN

PIPE AND DRAIN.)

(152.4 mm)

FIGURE 2.

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

water (potable) heating only.

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

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 inﬁ rm, or physically/mentally disabled. If anyone using hot water in your home ﬁ ts 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 satisﬁ es 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 Qualiﬁ ed 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.

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”/101.6 mm) 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.

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

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the ﬂ ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper ﬂ oor. When such locations cannot be avoided, a suitable metal 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-off device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or turn off

the incoming water to the water heater when leakage is detected.

• Sensors mounted in the drain pan that turn off the water supply to

the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water pressure differential between the cold water and 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 ﬁ re, 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 inﬁ rm, or physically/mentally disabled. If anyone using hot water in your home ﬁ ts 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 satisﬁ es 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.

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

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

A properly-sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank.

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.

NOTE: To protect against untimely corrosion of hot and cold

TEMPERATURE-

PRESSURE

RELIEF VALVE

COLD WATER

INLET

SHUT-OFF

VALV E

UNION

(OPTIONAL TOP

T & P RELIEF VALVE

NOT SHOWN)

DISCHARGE PIPE

(DO NOT CAP OR PLUG)

6” (152.4 mm) MAXIMUM

AIR GAP

FLOOR DRAIN

DRAIN VALVE

HOT WATER

INLET

3/4” SWEAT

FITTINGS

3/4” SWEAT

FITTINGS

water ﬁ ttings, it is strongly recommended that di-electric unions 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. 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.

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.”

FIGURE 3.

FIGURE 3A.

TEMPERATURE-PRESSURE RELIEF VALVE

TEMPERATURE-

PRESSURE

RELIEF VALVE

COLD

SHUT-OFF VALVE

UNION

OPTIONAL TOP

T & P LOCATION

HOT

UNION

(OPTIONAL TOP

T & P RELIEF VALVE

NOT SHOWN)

DISCHARGE PIPE

(DO NOT CAP OR PLUG)

6” (152.4 mm) MAXIMUM

AIR GAP

FLOOR DRAIN

DRAIN VALVE

This heater is provided with a properly certified combination temperature - pressure relief valve by the manufacturer.

The valve is certiﬁ ed 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.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

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

• Shall terminate at an adequate drain.

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

If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certiﬁ ed 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 = 1,034.21 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate (Electric heaters - watts x 3.412 equal BTU/hr rate).

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

The temperature-pressure relief valve must be installed directly into the ﬁ tting 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 (152.4 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 sufﬁ cient 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 ﬂ ow may cause property damage.

The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot.

FIGURE 4.

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