A. O. Smith DRE-120 Service Manual

Service Handbook

COMMERCIAL ELECTRIC WATER HEATERS

MODELS DRE-52/80/120 SERIES 100

& DVE-52/80/120 SERIES 100

INSTALLATION CONSIDERATIONS - PRE SERVICE

CHECKS - WATER HEATER CONSTRUCTION -

500 Tennessee Waltz Parkway

Ashland City, TN 37015

OPERATION & SERVICE - TROUBLESHOOTING

SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT.

PRINTED IN THE U.S.A 0908 315014-000

COMMERCIAL ELECTRIC WATER HEATER

SERVICE MANUAL

INTRODUCTION .......................................................................2

Qualifications......................................................................2

Service Warning .................................................................2

Tools Required....................................................................3

INSTALLATION CONSIDERATIONS........................................4

Closed Water Systems.......................................................4

Thermal Expansion.............................................................4

Electrical Requirements......................................................5

PRE SERVICE CHECKS...........................................................6

Wiring Connections ............................................................6

Service Precautions............................................................5

WATER HEATER CONSTRUCTION ........................................7

Surface Mount Control Models........................................... 8

Electronic Control Models...................................................9

OPERATION & SERVICE........................................................10

Principles of Electricity......................................................10

Single And Three Phase Power ....................................... 12

Checking Single Phase Power..................................13

Checking Three Phase Power...................................14

Phase Conversions - Surface Mount Control Models.......15

Phase Conversions - Electronic Control Models ..............16

Fuses................................................................................17

Surface Mount Thermostats.............................................18

Thermostat & ECO Test.............................................19

Heating Elements .............................................................20

Heating Element Construction.................................. 20

Heating Element Amperage Test...............................23

Heating Element Voltage Test...................................24

Heating Element Resistance & Ground Test.............25

Replacing Heating Elements.....................................26

Element Sensors..............................................................27

Element Sensor Operation........................................28

Contactors........................................................................29

Contactor Configurations...........................................30

Contactor Inspection..................................................31

Contactor Coil Voltage - At Contactor........................32

Contactor Coil Voltage - At CCB................................33

Transformers ....................................................................34

120 V AC Control Circ uit Transformer Wiring.............34

120 V AC Control Circuit Transformer Test.................35

24 VAC Transformer Test..........................................36

Immersion Temperature Probes.......................................37

Temperature Sensor Resist ance Test........................38

Temperature Sensor DC Vo ltage Test................. ... ...39

ECO Continuity Test..................................................39

ECO Voltage Test......................................................40

ELECTRONIC CONTROLS.....................................................41

CCB - Central Control Board............................................42

CCB Socket & Wiring Terminal Identification ............43

CCB Enable Disable Circuit(s) Test...........................45

Checking Power And Ground To The CCB...............46

UIM - User Interface Module ............................................47

ELECTRONIC CONTROL SYSTEM.......................................48

Control System Features..................................................48

Control System Navigation...................................... ... ......48

The Desktop Screen.........................................................49

Status Icons...............................................................50

Operating States............................................ ............51

Control System Menus..............................................51

Temperatures Menu..........................................................52

Temperature Settings................................................53

Heater Status Menu..........................................................54

Economy Mode Setup Menu............................................55

Setpoint Adjustment Value........................................56

Time Clock Settings ..................................................57

Daily Operating Mode Settings..................................58

Alarm Output Setup Menu................................................59

Display Settings Menu......................................................60

Heater Information Menu..................................................61

Current Fault/Alert Menu..................................................62

Fault History Menu ............................ ... .. ..........................62

Fault Occurrence Menu...................................... ..............62

Restore Factory Defaults Menu........................................63

Factory Default User Settings ...................................63

TROUBLESHOOTING.............................................................64

Common Service Problems..............................................64

Surface Mount Control Models.........................................64

Electronic Control Models.................................................65

Fault Conditions ........................................................65

Alert Conditions.........................................................65

Resetting The Control System ..................................65

Control System Unresponsive....................................... ...65

UIM Display Is Blank.................................................65

UIM Is Inoperable......................................................66

Heating Cycle Disabled.............................................66

Fault & Alert Messages....................................................67

No Current Detected .................................................67

Temp Probe Open.....................................................68

Temp Probe Short.....................................................68

Energy Cut Out (ECO) ..............................................69

INTRODUCTION

This Service Manual is designed to be an aid in servicing and troubleshooting the commercial electric water heater models listed on the cover .The instructions, illustrations and procedures contained in this manual are used to verify proper operation and to diagnose and repair common service problems.

This Service Manual does not replace or supersede the Instruction Manual that came with the water heater. Always refer to the Instruction Manual that came with the water heater for complete installation instructions. If the Instruction Manual is not available copies can be obtained from the manufacturers web site or by calling the toll free phone number shown on the back cover of this Service Manual.

Review the Common Service Problems on page 64 prior to performing any service procedures.

QUALIFICATIONS - QUALIFIED SERVICE AGENT

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

ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

SERVICE WARNING

If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the service, diagnostic or troubleshooting procedures described in this manual. If you do not understand the instructions given in this manual or do not feel confident in your abilities to perform a given task do not attempt to perform any procedures outlined in this manual. Call the toll free phone number listed on the back cover of this manual for technical assistance.

IMPORTANT SERVICE REMINDER

When performing any troubleshooting step outlined in this manual always consider the wiring and connectors between components. Perform a close visual inspection of all wiring and connectors to and from a given component before replacement. Ensure wires were stripped before being crimped in a wire connector. Ensure wires are crimped tightly in their connectors. Ensure connection pins in sockets and plugs are not damaged or worn. Also ensure plugs and sockets are mating properly and providing good contact.

Failure to perform this critical step or failing to perform this step thoroughly often results in needless down time, unnecessary parts replacement, and customer dissatisfaction.

Servicing should only be performed by a Qualified Service Agent

INTRODUCTION

INSTRUCTION MANUAL

Have a copy of the Instruction Manual that came with the water heater on hand for the correct model water heater you are working with before servicing.

Installation information given in this Service Manual IS NOT a complete installation instruction. Installation information covered in this Service Manual has a limited focus as it applies to servicing. This Service Manual does not replace or supersede the Instruction Manual that came with the water heater. Always refer to the Instruction Manual that came with the water heater for complete installation instructions.

If the Instruction Manual is not on hand copies can be obtained from the manufacturers web site or by calling the toll free phone number shown on the back cover of this Service Manual.

TOOLS REQU IRED

• Instruction Manual that came with the water heater.

• All tools common to installation and service of commercial water heaters such as hand tools, torch, pipe wrenches etc.

• Electrical switch lock out device - used to secure disconnect switches/breaker panels while servicing.

• Insulated fuse puller(s).

• Adhesive numbered/colored wire markers - 3M ScotchCode SDR0-9 Numbered Wire Markers; 3M ScotchCode STD-C Colored Wire Markers or equivalent.

• Volt-Ohm Multi Meter - recommend Fieldpiece HS36, Fluke 187, UEI model DL289 or equivalent capable of measuring:

• AC Voltage up to 600 VAC

• DC Voltage up to 24 VDC

• Ohms up to 2,000,000 ohms

• AC amp meter - recommend UEI model DL289 or equivalent capable of measuring:

• AC amperage up to 400 amps

Servicing should only be performed by a Qualified Service Agent

INSTALLATION CONSIDERATIONS

If the instruction Manual that came with the water heater is not on hand copies can be obtained from the manufacturers web site or by calling the toll free phone number shown on the back cover of this Service Manual.

CLOSED WATER SYSTEMS

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

Virtually all commercial and most residential water supply systems are closed systems today. Closed water systems will experience thermal expansion which, if not controlled with a properly installed and sized thermal expansion tank, can cause premature failure (leakage) of the water heater. Water heater failure (leakage) on closed systems where there is not a thermal expansion tank installed is not covered under the limited warranty.

THERMAL EXPANSION

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

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

Servicing should only be performed by a Qualified Service Agent

INSTALLATION CONSIDERATIONS

ELECTRICAL REQUIREMENTS

Grounding

Review the electrical ground requirements given in the Instruction Manual that came with the water heater and ensure the water heater has been properly grounded.

The water heater must be grounded in accordance with the National Electric Code and/or local codes. These codes must be followed in all cases.

The water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.

Service Note: Electronic Control Models (see Figure 2 on page 9) covered in this manual may experience erratic control operation if the water heater is not properly grounded.

Power Supply

Review the electrical requirements listed on the water heater’s rating label and in the Instruction Manual that came with the water heater. Ensure the branch circuit supplying power to the water heater is within these requirements and properly connected.

Ensure the power supply phase (single or three phase / 1Ø, 3Ø) and power supply voltage match the water heater’s rating label - see pages 12-14. The electric water heater models covered by this manual are phase convertible - see pages 15 and 16.

Servicing should only be performed by a Qualified Service Agent

PRE SERVICE CHECKS

WIRING CONNECTIONS

With the power supply to the water heater turned off ensure the wiring connections are properly tightened to all components including: high voltage terminal blocks, fuse blocks, contactors, transformers and heating elements.

Loose connections at any connection point will cause increased amperage and excessive heat which can damage wiring and components. Whenever worn or damaged wiring and components must be replaced ensure all wiring connections are properly tightened before putting the water heater back in service.

SERVICE PRECAUTIONS

1 DO NOT energize the branch circuit supplying power to the water heater or test the

water heater electrical system before the water heater is completely filled with water. Read the start up procedures in the Instruction Manual that came with the water heater.

2 Be sure to turn off power and use a lock out device at the branch circuit power supply

disconnect switch or breaker when servicing the electrical system of the water heater. Never touch electrical components with wet hands or when standing in water.

PRE SERVICE CHECKS

3 When replacing heating elements ensure they are rated at the correct voltage and KW

for the water heater being serviced - see Heating Element Ratings and Heating Element Configurations on page 21 and Replacing Heating Elements on page 26.

4 When replacing fuses use an insulated fuse puller to remove and install fuses. Always

use the correct size for the circuit. See the Replacement Fuses Service Note on page 17 in this manual.

5 Using an AC volt meter measure the branch circuit power supply voltage to the water

heater. Ensure the measured voltage of the branch circuit supplying power to the water heater matches the water heater’s rating label - see pages 12 - 14.

6 Ensure the internal power phase configuration matches the power supply to the water

heater. The water heaters covered by this manual are phase convertible - see pages 15 and 16.

7 Electronic Control Models covered by this manual are equipped with contactors and will

have a multi tap control circuit transformer. This is a step down transformer that outputs 120 VAC (secondary winding) which is used to power the electronic control system and energize the contactor coils. The transformer can accommodate different power supply voltages and has multiple input voltage connections or “taps.” Ensure the input supply voltage (primary winding) wiring to the transformer is connected properly . See p age 34 in this manual.

Service Note - Contactor Chatter: Incorrect supply voltage wiring to the multiple tap 120 VAC Control Circuit Transformer on Electronic Control Models will cause low/high output voltage from the transformer. This can cause contactors to open and close their contacts rapidly (contactor chatter) and result in permanent damage to the contactors. Ensure the primary winding of the multiple tap 120 VAC Control Circuit Transformer is wired to match the power supply voltage - see pages 12 -14 and page 34.

Servicing should only be performed by a Qualified Service Agent

WATER HEATER CONSTRUCTION

There are two types of commercial electric water heaters covered in this manual. See Figure 1 on page 8 and Figure 2 on page 9.

SURFACE MOUNT CONTROL MODELS

The first type of water heater covered in this manual is equipped with surface mount thermostat/ECO controls - Surface Mount Control Models. There will be separate thermostat/ECO (energy cut out) combination controls mounted to the surface of the storage tank directly above the heating elements they control. IE: a water heater equipped with 9 heating elements will have 9 combination thermostat/ECO controls. These combination thermostat/ECO controls sense temperature directly from the surface of the storage tank. Each combination control will have a temperature setting adjustment screw. As the tank (water) temperature rises and falls each individual thermostat will de-energize and energize one heating element according to it’s temperature setting.

ELECTRONIC CONTROL MODELS

The second type of water heater covered in this manual is equipped with an electronic control system - Electronic Control Models. The control system senses temperature electrically from an Immersion Temperature Probe. The probe is installed in a threaded opening in the storage tank (wet well) and senses water temperature directly. As the stored water temperature rises and falls the control system de-energizes and energizes Banks of 3 heating elements indirectly using electromagnetic contactors. The control system energizes the electromagnetic contactor’s (120 VAC) coil causing the switch contacts of the contactor to close which in turn supplies power to the heating elements.

HEATING ELEMENT CONFIGURATIONS

Both types of water heaters covered in this manual are factory equipped with either 3, 6 or 9 heating elements depending on how they were ordered from the factory - see the Heating Element Configurations table on page 21. Each group of 3 heating elements (physically installed in diagonal rows of 3) is referred to as a “Bank” of heating elements. Bank 1 is the lowest group of 3 heating elements, Bank 2 is the middle group of 3 heating elements and Bank 3 is the upper group of 3 heating elements. See Figure 1 on page 8 and Figure 2 on page 9.

Heating Element Voltage and KW Conversion Kits

V oltage and heating element KW conversion kit s are available for the water heaters covered in this manual. Volt age and KW conversions are not covered in this manual. V olt age and KW conversion kits with instructions are available from local distributors and can be ordered from the manufacturer’s parts department by calling the toll free number listed on the back cover of this manual. Have the complete model and serial number along with the listed voltage and input KW from the rating label of the water heater on hand before calling.

Service Note: There are field conversion kits to increase/decrease KW input and change voltage. However, conversion kits do not allow adding heating elements to a water heater. Water heaters must remain as they were configured with 3, 6 or 9 heating elements from the factory. HEATING ELEMENTS CANNOT BE ADDED TO A WATER HEATER.

Servicing should only be performed by a Qualified Service Agent

WATER HEATER CONSTRUCTION

Figure 1

SURFACE MOUNT CONTROL MODELS

Servicing should only be performed by a Qualified Service Agent

WATER HEATER CONSTRUCTION

Figure 2

ELECTRONIC CONTROL MODELS

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

This section of the manual will cover the principles of electricity, single and three phase power , fuses, surface mount thermostat/ECO combination controls, heating element construction & operation, heating element sensors, contactors, common service procedures and more. Information and service procedures presented in this section will be referenced in the troubleshooting sections.

PRINCIPLES OF ELECTRICITY

Voltage

The unit of measurement used to quantify electrical pressure or the force that causes electrical energy to flow is the volt or voltage. V olt meters are used to determine if there is an adequate supply of electricity or voltage to a heating element.

Amperage

The unit of measurement used to quantify the rate at which electrical current is flowing is the ampere or amp. Amp meters are used to determine if a heating element is working - if there is adequate current flowing through the heating element.

Ohms

OPERATION & SERVICE

The unit of measurement used to quantify the opposition or “resistance” to the flow of electricity is the ohm. As resistance (ohms) in an electrical circuit increases current (amperage) will decrease and as resistance decreases current will increase. Ohm meters are used for measuring the resistance of heating elements, for open circuit continuity tests on heating elements and for shorted to ground continuity tests on heating elements.

Service Note: Volt, ohm and amp meter test instruments are necessary to perform the service and diagnostic procedures outlined in this manual - see Tools Required on page 3.

Wattage

The unit of measurement used to quantify the rate or amount of electrical energy being used is the watt. One thousand watts is referred to as one kilowatt. Heating elements are rated in kilowatts expressed as KW. The higher the kilowatt rating of a heating element the more power it will use and the more heat it will generate. One kilowatt generates 3412 Btu of heat.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

Ohms Law

A law that explains the relationship between voltage, current and resistance. The law states that the electric current flowing through a conductor is equal to the voltage divided by the resistance. The following equations further explain ohms law.

Ohms Law applied to “SINGLE PHASE” (1Ø) power:

V = Volts (electrical pressure) A = Amps (electrical flow/current) O = Ohms (resistance to electrical flow/current)

W = Watts (rate or amount of electricity used)

V ÷ A = O W ÷ V = A V ÷ O = A V x A = W A x O = V W ÷ A = V

Service Note: Heating elements used on the water heaters covered by this manual are “two wire” single phase elements. Though the power supply to the water heater may be three phase, calculations to determine amperage and resistance for individual heating elements is based on ohms law applied to single phase power. The KW rating of individual heating elements is marked on the end of each element - see page 21. Approximate current (amps) and resistance (ohms) for individual heating elements are provided in tables on page 22.

See the water heater’s rating label for the listed voltage/phase power supply requirements, total input KW and total/full load amp draw of the water heater being serviced.

Calculating Amps/Ohms/Volts/Watts

Using a 240 volt electric water heater equipped with a 4500 watt heating element as an example Ohms Law can be used to determine:

1 What the resistance of each heating element should be:

• 240 volts ÷ 18.75 amps = 12.8 ohms

2 What the correct amp reading should be:

• 4500 watts ÷ 240 volts = 18.75 amps

• 240 volts ÷ 12.8 ohms = 18.75 amps

3 How many watts are being used (how much heat is being generated):

• 240 volts x 18.75 amps = 4500 watts (4.5 KW)

4 What the voltage is:

• 18.75 amps x 12.8 ohms = 240 volts

• 4500 watts ÷ 18.75 amps = 240 volts

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

277 Volt 1Ø Power

208/240/480 Volt 1Ø Power

Power Distribution Block

(see Figures 1 & 2 on pages 8 and 9)

L1 L2 L3

208/240/480 Volt 3Ø Power

SINGLE AND THREE PHASE POWER

The water heaters covered in this manual can be field converted for a single or three phase power supply - see pages 15 and 16. These water heaters can be factory ordered for standard North American power supplies; 277/208/240/480 volt models. 277 volt models are single phase only. Voltage conversion kits with instructions are available from the manufacturer - voltage conversions are not covered in this manual. Verifying the power supply is adequate is typical first step during most service diagnostic procedures. The illustrations and instructions that follow outline how this is done using a standard AC volt meter - see Tools Required on page 3.

Service Warning: Never touch any wiring inside the water heater until the main power supply to the water heater has been secured. Secure power to the water heater by turning off the power supply breaker and/or disconnect switch AND verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater’s control panel.

Service Warning: Zero or low voltage readings between internal wiring and/or Power Distribution Block terminals and ground can be due to an inadequate earth ground. TREAT ALL WIRES AS BEING HOT until it has been determined there is no voltage present.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

277 Volt 1Ø Power

208/240/480 Volt 1Ø Power

Power Distribution Block

(see Figures 1 & 2 on pages 8 and 9)

L1 L2 L3

Checking Single Phase (1Ø) Power

A single phase power supply consists of two wires connected to the L1 and L2 terminals of the Power Distribution Block, the L3 terminal is not used. On a single phase (1Ø) 277 volt power supply one of the two wires is a “neutral” wire and does have voltage present. On a single phase (1Ø) 277 volt power supply the “hot” wire should be connected to the L1 terminal and the “neutral” wire should be connected to the L2 terminal. On 208, 240 and 480 volt power supplies both wires connected to L1 and L2 are “hot” with voltage present.

Voltage Between Terminals: With the power supply to the water heater turned on set the volt meter to an AC voltage range above the expected voltage (600 VAC or higher range initially) and carefully touch the two test probes to the L1 and L2 terminals of the water heater’s Power Distribution Block. The voltage readings should match the voltage listed on the water heater’s rating label by ± 5%.

Voltage to Ground: With the power supply to the water heater turned on check between the L1 terminal and the ground wire connection inside the water heater’s control panel. Check between L2 and ground in the same way. On a 277 volt power supply only one of the two terminals should read 277 volts, the neutral will read approximately zero volts. On 208/240 volt power supplies each reading should be approximately 120 volts to ground. On 480 volt power supplies each reading to ground should be approximately 277 volts.

If the voltage readings taken between L1 and L2 are more than ± 5% of the listed voltage on the water heater’s rating label or if the readings to ground were far less (at or near zero volts) than expected: check the fuses and the breaker and/or disconnect switch supplying power to the water heater. Contact a Qualified/Licensed electrician to restore power. If the voltage readings taken are a standard voltage (277/208/240/480) but do not match the listed voltage on the water heater’s rating label secure power to the water heater. DO NOT place it back in service. Contact the distributor and/or manufacturer to determine if the water heater can be field converted and/or replaced to match the power supply at the location.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

208/240/480 Volt 3Ø Power

Power Distribution Block

(see Figures 1 & 2 on pages 8 and 9)

L1 L2 L3

Checking Three Phase (3Ø) Power

A three phase power supply consists of three wires connected to the L1, L2 and L3 terminals of the Power Distribution Block. All three wires are “hot” with voltage present.

Voltage Between Terminals: Set the volt meter to an AC voltage range above the expected voltage (600 VAC or higher range initially). Checking three phase (3Ø) power requires that three voltage readings be taken between all possible parings of the terminals on the Power Distribution Block. Carefully touch the two test probes between:

1 L1 and L2 terminals of the water heater’s Power Distribution Block 2 L2 and L3 terminals of the water heater’s Power Distribution Block 3 L1 and L3 terminals of the water heater’s Power Distribution Block

All three voltage readings should match the voltage listed on the water heater’s rating label by ± 5%.

Voltage to Ground: Check between each of the three terminals (L1, L2 and L3) of the Power Distribution Block and the ground wire connection inside the water heater’s control panel. On some 208 volt power supplies each reading will be approximately 120 volts to ground. Some 208 volt models will have a “stinger leg” with one of the three readings to ground measuring 208 volts - 208 volt stinger legs should be connected to L2. On 240 volt power supplies each reading should be approximately 120 volts to ground. On 480 power supplies each reading to ground should be approximately 277 volts.

If the voltage readings taken between L1, L2 and L3 are more than ± 5% of the listed voltage on the water heater’s rating label or if the readings to ground were far less (at or near zero volts) than expected: check the fuses and the breaker and/or disconnect switch supplying power to the water heater. Contact a Qualified/Licensed electrician to restore power. If the voltage readings taken are a standard voltage (277/208/240/480) but do not match the listed voltage on the water heater’s rating label secure power to the water heater. DO NOT place it back in service. Contact the distributor and/or manufacturer to determine if the water heater can be field converted and/or replaced to match the power supply at the location.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

L1 L2 L3

Power Distribution Block

(see Figure 1 on page 8)

L1 L2 L3

Power Distribution Block

(see Figure 1 on page 8)

PHASE CONVERSIONS - SURFACE MOUNT CONTROL MODELS

Internal wiring connections between the Power Distribution Block and the heating elements are different on Surface Mount Control (see Figure 1 page 8) and Electronic Control (see Figure 2 page 9) model water heaters. Because of these differences there are two methods for field converting these models to work with single and three phase power supplies.

Service Note: 208 volt 54 KW models are 3 phase only and CAN NOT be converted to single phase. All other models can be phase converted.

SECURE MAIN POWER SUPPLY TO THE WATER HEATER AT THE MAIN BREAKER OR DISCONNECT SWITCH FIRST.

Service Warning: Never touch any wiring inside the water heater until the main power

supply to the water heater has been turned off. Verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater’s control panel.

Surface Mount Control Models Three Phase to Single Phase

1 Disconnect blue wires from terminal L-2. 2 Connect all blue wires to terminal L-1 (with black wires). 3 Disconnect all red wires from terminal l-3. 4 Connect all red wires to terminal L-2 (with yellow wires). 5 Incoming power will be connected to terminals L-1 and L-2.

Service Note: 208 volt 54 KW models are three phase only - these models CAN NOT be converted to single phase. Keep in mind when converting other models from three phase power to single phase power the current/amperage will increase significantly ensure breakers, fuses and wiring are properly sized to allow for the increased amperage before placing the water heater back in service. Contact a Qualified/Licensed electrician to make necessary changes.

Surface Mount Control Models Single Phase to Three Phase

1 Disconnect blue wires from terminal L-1 2 Disconnect red wires from terminal L-2. 3 Connect all blue wires to terminal L-2 (with yellow wires). 4 Connect red wires to terminal L-3. 5 Incoming power will be connected to terminals L-1, L-2 and

Service Note: Keep in mind when converting from single phase power to three phase power the current/amperage will decrease significantly - ensure breakers and fuses are not oversized before placing the water heater back in service. Contact a Qualified/ Licensed electrician to make necessary changes.

L-3.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

L1 L2 L3

Power Distribution Block

(see Figure 2 on page 9)

L1 L2 L3

Power Distribution Block

(see Figure 2 on page 9)

PHASE CONVERSIONS - ELECTRONIC CONTROL MODELS

Internal wiring connections between the Power Distribution Block and the heating elements is different on Surface Mount Control (see Figure 1 page 8) and Electronic Control (see Figure 2 page 9) model water heaters. Because of these differences there are two methods for field converting these models to work with single and three phase power supplies.

Service Note: 208 volt 54 KW models are 3 phase only and CAN NOT be converted to single phase. All other models can be phase converted.

SECURE MAIN POWER SUPPLY TO THE WATER HEATER AT THE MAIN BREAKER OR DISCONNECT SWITCH FIRST.

Service Warning: Never touch any wiring inside the water heater until the main power

supply to the water heater has been turned off. Verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater’s control panel.

Electronic Control Models Three Phase to Single Phase

1 Disconnect blue wires and yellow wires from terminal L-3. 2 Connect all blue wires to terminal L-1 (with black wires). 3 Connect all yellow wires to terminal L-2 (with red wires). 4 Incoming power will be connected to terminals L-1 and L-2.

Electronic Control Models Single Phase to Three Phase

1 Disconnect blue wires from terminal L-1. 2 Disconnect yellow wires from terminal L-2. 3 Connect all blue wires and yellow wires to terminal L-3. 4 Incoming power will be connected to terminals L-1, L-2 and

L-3.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

Volt Meter MethodOhm Meter Method

FUSES

The water heaters covered in this manual have power circuit fuses to protect the heating element circuits. Electronic Control models will have two additional fuses to protect the primary winding of the 120 Volt Control Circuit Transformer . See Figures 1 and 2 on pages 8 and 9 for location. Testing fuses requires an ohm meter, an AC volt meter and an insulated fuse puller - see Tools Required page 3.

Service Note - Replacement Fuses: Replacement power circuit fuses MUST BE of the same value and type as the factory installed fuses - Class G/SC-30 Amp/Time Delay. Replacement 120 Volt Control Circuit Transformer fuses MUST BE of the same value and type as the factory installed fuses - Class G/SC-3 Amp.

Ohm Meter Method

1 Secure power to the water heater at the main breaker or disconnect switch. 2 Remove each fuse to be tested with an insulated fuse puller. 3 Set the Ohm meter to it’s lowest resistance range (< 20 0) or to an audible be ep continuity test setting if

so equipped. 4 Touch the meter probes to both ends of each fuse simultaneously. 5 If the fuse being tested shows a low resistance (< 1 ohms) or the continuity test feature sounds an

audible beep the fuse being tested is good and can be re-installed. 6 If the fuse being tested shows infinite resistance (open circuit) or the continuity test feature does not

sound an audible beep the fuse being tested is blown and must be replaced.

Volt Meter Method

Fuses can also be checked using an AC volt meter. The power supply must be turned on and a call for heat must be active (all thermostats/contactors must be closed) during this test. Touch the two test probes to both ends of all fuses while still in their fuse blocks.

• A high voltage (at or above 120 VAC) reading indicates the fuse is blown.

• A zero volt read ing generally indicates the fuse is good. Next check for voltage between each end of the fuse and ground to ensure voltage is pre sent at both ends of the fuse. If no volt age is present b etween either e nd of the fuse and ground the test has not been conclusive - secure power to the wate r heater and per form th e ohm meter test method described above.

The voltage test method is a good way to quickly identify fuses that are blown but it is not always conclusive due to the dependence on power being present at both ends of the fuse, the switch contacts in thermostats/contactors being closed and correct wiring. Keep this in mind as there may be times when a fuse that is blown tests good due to one of these dependencies not being met. The ohm meter method described above is 100% conclusive.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

THERMOSTAT/ECO FRONT VIEW THERMOSTAT/ECO INTERNAL WIRING

L1 L3

Power Supply to L1 and L3 Terminals

ECO DPDT Contacts

Thermostat SPST Contacts

Heating Element

SURFACE MOUNT THERMOSTATS

The Surface Mount Control Model water heaters covered in this manual have “separate” thermostat/ECO (energy cut out) combination controls mounted to the surface of the storage tank directly above the heating elements they control. IE: a water heater equipped with 9 heating elements will have 9 thermostat/ECO controls. These controls contain two bimetal thermal switches that react to heat sensed from the surface of the water heater’s storage tank.

Thermostat: The thermostat portion of these controls is an automatic SPST (single pole single throw) switch - see the Internal Wiring illustration below. As the tank (water) temperature rises and falls each individual thermostat will de-energize (contact opens) and energize (contact closes) one heating element according to it’s temperature setting. The temperate setting is adjustable using the dial on the lower portion of the control. The adjustable range is 120°F/49°C to 180°F/82°C. The factory default setting is 140°F/60°C.

ECO: The ECO portion of these controls is a manual reset DPDT (double pole double throw) switch - see the Internal Wiring illustration below. The ECO is a high temperature limit switch designed to protect against excessively high water temperatures that can be caused by defective thermostats and grounded heating elements. The ECO temperature setting is non adjustable and fixed at 200°F/93°C. If the ECO activates (contacts open) in response to abnormally high temperatures the contacts will not close automatically, the ECO must be manually reset by pressing the red button on the top of the control. The tank temperature must cool to approximately 120°F/49°C before the ECO can be reset. When activated (contacts open) the ECO will interrupt all power supplied to the thermostat portion of the control and the heating element.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

L1 L3

STEP 6 CHECKING POWER TO THE CONTROL

STEP 7 CHECKING POWER TO THE HEATING ELEMENT

Thermostat & ECO Test

1 Secure power to the water heater at the main breaker or disconnect switch. 2 Ensure tank temperature is less than 100°F/38°C - dump wate r to lower tank temperature if necessary. 3 Press the red reset button firmly on all thermostat/ECO controls. 4 Raise the temperature setting on all thermostat/ECO controls to 140°F or higher. 5 Restore power to the water heater. 6 With an AC volt meter check for voltage between the L1 and L3 terminals on the control - see illustrations

below. Measured voltage should match the power supply to the water heater. Service Note: If the measured voltage is zero volts or not the correct voltage ensure heating element

power circuit wiring is correct (see wiring diagram on water heater) check fuses (page 17) and/or restore power to the water heater - see pages 12 - 14.

7 With an AC volt meter check for voltage between the L4 and T2 terminals on the control - see illustrations

below - if the measured voltage matches the power supply to the water heater the ECO is resetting properly. If the measured voltage between L4 and T2 is low or not present the control is defective - replace the control.

Service Note: Grounded heating elements, defective thermostats and/or a defective ECOs can all cause frequent ECO activation. If an ECO is being frequently rese t on an y of the thermostat/ECO controls check all heating elements to ensure they a re not gr ounded (see p age 26) fir st. Replace any grounded element s. If no elements are grounded replace the thermostat/ECO control(s) that require frequent resetting.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

Wiring Terminals

Heat element tube encloses wire conductor and insulating material

Internal View Heating Element Tube

Wire conductor inside tube

Top View

Side View

HEATING ELEMENTS

This section of the manual provides information on how to determine the actual voltage and wattage rating of a heating element along with tables showing heating element configurations, heating element amperage and heating element resistance/ohms.

This section also contains heating element test procedures to measure; amperage, voltage, resistance and check for grounded elements. These procedures are used to determine if a heating element is defective or working properly. An AC amp meter, AC volt meter and ohm meter are required - see Tools Required on page 3.

Heating Element Construction

The water heater(s) covered in this manual use electric heating elements to heat water. Heating elements convert electrical energy into heat energy.

Heating elements are constructed with metal tubing. Inside the tube is a wire conductor surrounded by an insulating material. The wire conductor inside the heating element has a relatively high resistance to the flow of electricity. Heat is generated when the electricity (voltage) applied to the heating element begins to flow (amperage) and encounters the resistance (ohms) of the wire conductor inside.

Servicing should only be performed by a Qualified Service Agent

OPERATION & SERVICE

Wattage and Voltage Ratings

Note: some heating elements are dual rated elements IE: 208/240 volts

208 VAC 240 / 277 / 480 VAC

620003 3 930003 3

12 4000 3 3

13.5 4500 3 3 15 5000 3 3 18 6000 N/A 3 18 3000 6 6 24 4000 6 6 27 4500 6 6 30 5000 6 6 36 6000 N/A 6 36 4000 9

40.5 4500 9

45 5000 9

54 6000 9

TOTAL

WATER HEATER

INPUT KW

HEATING

ELEMENT

WATTAGE

NUMBER OF FACTORY INSTALLED

HEATING ELEMENTS

Heating Element Ratings

Heating elements are labeled with their voltage and KW rating - see image below. The element shown here is a 6000 watt (6 KW) 240 volt element.

Heating Element Configurations

The table below shows how many heating elements are installed at the factory and the wattage of each heating element according to the rated voltage of the water heater. The table below represents all available tank sizes; 50, 80 and 120 gallon models.

Service Note: 208 volt 18 KW models are only available with six 3000 watt elements and 208 volt 36 KW models are only available with nine 4000 watt heating elements.

Servicing should only be performed by a Qualified Service Agent

+ 53 hidden pages

A. O. Smith DRE-120 Service Manual

TABLE OF CONTENTS

INTRODUCTION

QUALIFICATIONS - QUALIFIED SERVICE AGENT

SERVICE WARNING

IMPORTANT SERVICE REMINDER

INSTRUCTION MANUAL

TOOLS REQU IRED

INSTALLATION CONSIDERATIONS

CLOSED WATER SYSTEMS

THERMAL EXPANSION

ELECTRICAL REQUIREMENTS

Grounding

Power Supply

PRE SERVICE CHECKS

WIRING CONNECTIONS

SERVICE PRECAUTIONS

WATER HEATER CONSTRUCTION

SURFACE MOUNT CONTROL MODELS

ELECTRONIC CONTROL MODELS

HEATING ELEMENT CONFIGURATIONS

Heating Element Voltage and KW Conversion Kits

SURFACE MOUNT CONTROL MODELS

ELECTRONIC CONTROL MODELS

OPERATION & SERVICE

PRINCIPLES OF ELECTRICITY

Voltage

Amperage

Ohms

Wattage

Ohms Law

Ohms Law applied to “SINGLE PHASE” (1Ø) power:

Calculating Amps/Ohms/Volts/Watts

SINGLE AND THREE PHASE POWER

Checking Single Phase (1Ø) Power

Checking Three Phase (3Ø) Power

PHASE CONVERSIONS - SURFACE MOUNT CONTROL MODELS

Surface Mount Control Models Three Phase to Single Phase

Surface Mount Control Models Single Phase to Three Phase

PHASE CONVERSIONS - ELECTRONIC CONTROL MODELS

FUSES

Ohm Meter Method

Volt Meter Method

SURFACE MOUNT THERMOSTATS

Thermostat & ECO Test

HEATING ELEMENTS

Heating Element Construction

Heating Element Ratings

Heating Element Configurations