A.O. Smith DVE-150A, DVE-200A, DVE-250A, DVE-300A, DVE-400A Installation Manual
...
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property damage,
personal injury, or loss of life.
100303268_2000556051 Rev A
Commercial Electric
Water Hea ter
Installation & Service
Manual
Models: 0150 - 1000
HLW
WARNING
Save this manual for future reference.
This manual must only be used
by a qualified heating installer
/service technician. Read all
instructions, including this
manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
INTRODUCTION ................................................................ 4
RATINGS ........................................................................... 5
1. FEATURES AND COMPONENTS
Vertical Models ................................................................... 6
Horizontal Models............................................................... 7
Dimensions and Capacities Data ................................... 8-9
2. DETERMINE WATER HEATER LOCATION
Facts to Consider About the Location ......................... 10-11
3. INSTALLATION
Mixing Valve Usage ......................................................... 12
Chemical Vapor Corrosion ............................................... 12
Circulating Pump .............................................................. 12
Insulation Blankets .......................................................... 12
Temperature - Pressure Relief Valve ...........................12-13
Closed Water Systems ......................................................13
Thermal Expansion .......................................................... 13
4. ELECTRICAL
General ............................................................................. 14
Branch Circuit ................................................................... 14
Heater Circuits.................................................................. 14
Power Circuit .................................................................... 14
Amp Chart ................................................................... 15-16
Electrical and Recoveries Data ........................................ 17
208V - 240V Chart ............................................................18
5. OPERATION
General ............................................................................. 19
Filling the Water Heater ................................................... 19
Initial Start-up ................................................................... 19
Draining the Water Heater ............................................... 19
6. TEMPERATURE REGULATION
High Temperature Limit Controls (ECO) .......................... 20
Thermostat Controls ......................................................... 20
Temperature Adjustment .................................................. 20
7. CONTROL SYSTEM OPERATION
Heating Banks Operation ................................................. 21
Control System Features ................................................. 21
Control System Navigation ............................................... 21
The Display Screen .......................................................... 21
Control System Operation Tables ............................... 22-23
Temperatures Menu ......................................................... 24
Temperature Screens ...................................................... 25
Water Heater Status Menu .............................................. 26
Economy Mode Setup Menu ............................................ 27
Economy Mode Settings Tables ................................. 28-30
Alarm Output Setup Menu ............................................... 31
Display Settings Menu ..................................................... 31
Heater Information Menu ................................................. 32
Current Fault / Alert Menu ................................................ 32
Fault History Menu ........................................................... 32
Fault Occurrence Menu .................................................... 33
Restore Factory Defaults Menu ....................................... 34
8. MAINTENANCE
General ............................................................................. 35
Anode Rod Inspection ...................................................... 35
Flushing the Water Heater ............................................... 35
Sediment Removal ........................................................... 36
Lime Scale Removal ........................................................ 36
9. TROUBLESHOOTING
Checklist ........................................................................... 37
10. DIAGRAMS
Wiring Diagram .......................................................... 38-39
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
2
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Please read before proceeding
WARNING
NOTICE
Installer – Read all instructions before
installing. Perform steps in the order
given.
Have this water heater serviced/inspected
by a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death, or
substantial property damage.
When calling or writing about the water
heater – Please have the water heater
model and serial number from the water
heater rating plate.
Consider piping and installation when
determining water heater location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
When servicing the water heater –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow the water heater to cool
before performing maintenance.
• Do not use this water heater if any part has been under
water. The possible damage to a flooded appliance can
be extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Grounding Instructions –
• This water heater must be grounded in accordance
with the National Electrical Code and/or local codes.
These must be followed in all cases. Failure to ground
this water heater properly may also cause erratic
control system operation on ELECTRONIC
CONTROL models.
• This 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.
WARNING
WARNING
WARNING
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury, or loss of life.
The California Safe Drinking Water and
Toxic Enforcement Act requires the
Governor of California to publish a list of
substances known to the State of California
to cause cancer, birth defects, or other
reproductive harm, and requires businesses
to warn of potential exposure to such
substances.
This product contains a chemical known to
the State of California to cause cancer, birth
defects, or other reproductive harm. This
water heater can cause low level exposure
to some of the substances listed in the Act.
Hydrogen Gas (Flammable) –
Hydrogen gas can be produced in a hot water system,
served by this heater, that has not been used for a long
period of time (generally two weeks or more). Hydrogen
gas is extremely flammable. To reduce the risk of injury,
it is recommended that the hot water faucet be opened
for several minutes at the kitchen sink before using any
electrical appliance connected to the hot water system.
If hydrogen is present, there will probably be an unusual
sound, such as air escaping through the pipe as water
begins to flow.
WARNING
WARNING
WARNING
There should be no smoking or open
flame near the faucet at the time it
is open.
Flammable hydrogen gases may be
present.
Keep all ignition sources away from
faucet when turning on hot water.
3
Introduction
ank you for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble-free
service.
Abbreviations Used
Abbreviations found in this instruction manual include:
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
• AHRI - Air Conditioning, Heating, & Refrigeration
Institute
Preparing for the Installation
WARNING
Read the Please read before proceeding... section of this manual
rst, then read the entire manual carefully. If you don’t follow
the safety rules, the water heater may not operate safely, which
could result in death, serious bodily injury, and/or property
damage.
is manual contains instructions for the installation,
operation, and maintenance of the water heater. It also
contains warnings throughout the manual that you must
read and be aware of. All warnings and all instructions are
essential to the proper operation of the water heater and your
safety. Read the entire manual before attempting to install or
operate the water heater.
General outline diagrams are in this manual. ese diagrams
will serve to provide the installer with a reference for basic
installation of this product. It is necessary that all water piping
and electrical wiring be installed and connected as shown in
the diagrams.
Before removing any access panels
or servicing the water heater, make
sure the electrical supply to the water
heater is turned OFF. Failure to do
this could result in death, serious
bodily injury, or property damage.
e principle components of the heater are identi ed on pages
6 and 7. e model and rating plate on page 5 interprets certain
markings into useful information. Both of these references
should be used to identify the heater, its components, and
optional equipment.
e installation must conform with these instructions
and the local code authority having jurisdiction and the
requirements of the power company. In the absence of local
codes, the installation must comply with the current editions
of the National Electrical Code, NFPA 70 or the Canadian
Electrical Code, CSA C22.1. e National Electrical Code
may be ordered from: National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269. e Canadian
Electrical Code is available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131.
If a er reading this manual you have any questions or do not
understand any portion of the instructions, call the telephone
number on the back cover for further assistance. Please have
the model and serial number of the unit available for the
technician.
Carefully plan your intended placement of the water heater.
Examine the location to ensure the water heater complies with
the Determine Water Heater Location section in the manual.
Clearance must be maintained so that the heating elements
may be removed for servicing a er installation.
Installation and service of this water heater requires ability
equivalent to that of a licensed tradesman or quali ed agency
in the eld involved. Plumbing and electrical work are
required.
For installation in California, this water heater must be braced
or anchored to avoid falling or moving during an earthquake.
See instructions for correct installation procedures.
Instructions may be obtained from the California O ce of
the State Architect, 1102 Q Street, Suite 5100, Sacramento,
CA 95811.
Be sure to turn power OFF when working on or near the
electrical system of the water heater. Never touch electrical
components with wet hands or when standing in water. When
replacing fuses always use the correct size for the circuit. Use
the same size and type of fuse when replacing.
Detailed installation diagrams are in this manual. ese
diagrams will serve to provide the installer with a reference for
the materials and method of piping suggested. It is necessary
that all water piping and electrical wiring be installed and
connected as shown in the diagrams.
4
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.
Ratings
Rating & Model Plate
HLW
All models are listed
by Underwriters
Laboratories Inc.
>Kt>KEdEd
PHASEVOLTS, AC UPPER
VOLTS, AC UPPER
MODEL NUMBER
L
KILOWATTS
MODEL NUMBER BARCODE
XXXXXXXX
ELECTRIC STORAGE
TANK WATER HEATER
SERIAL NUMBER ITEM ID/PART NUMBERMODEL NUMBER
KILOWATTS
KILOWATTS
LOWER
KILOWATTS
LOWER
TOTAL kW
CONNECTED
ADDRESS
TOTAL kW
CONNECTED
CAPACITY
US GALLONS
CIRCUIT
SERIAL NUMBER BARCODE
SERIAL NUMB ER
5555
®
,,,,
MAX WORKING
PRESSURE
123456789
LISTED
932N
E
A
S
M
CERTIFIED BYLC
E
MAWPXXXPSI
123456
MAX ALLOWABLE INPUT
HLW
XXXXXXXXX BTU/HR
S/N123456789
YEAR BUILT YYWW
CRN XXXXXXXXXXXXXXXXXXXX
5
1 Features and Components
Vertical Models
Note: Model shown for illustration purposes only. Actual con gurations may vary.
6
1 Features and Components
Horizontal Models
CONTROLLER
TRANSFORMER (CONTROLLER)
MAIN VOLTAGE GROUND LUG
POWER BLOCK
CONTACTORS
MAIN VOLTAGE FUSE & BLOCK
LOW VOLTAGE FUSE & BLOCK
MAIN VOLTAGE TRANSFORMER
ELEMENTS
HIGH LIMIT
LOW VOLTAGE FUSE & BLOCK
LOW VOLTAGE GROUND LUG
LOW WATER CUT OFF PROBE
TEMPERATURE PROBE
PLUG
RELIEF VALVE
ANODE
HANDHOLE/
MANWAY
ACCESS
Note: Model shown for illustration purposes only. Actual con gurations may vary.
7
1 Features and Components
Specifications Data
ADDITIONAL
HEIGHT IF
REQUIRED
ELECTRONIC
CONTROL
CONTROL VOLTAGE
ON/OFF SWITCH
CLEANOUT
DRAIN
HOT WATER
OUTLET
B
3/4"
T & P
RELIEF
VALVE
CONNECTION
A
COLD WATER
INLET
D
3/4" OR 1" DRAIN
C
HINGED DOOR
TO ELECTRICAL
COMPARTMENT
ELECTRONIC
CONTROL
CONTROL VOLTAGE
ON/OFF SWITCH
CHANNEL (150 & 200 GALLON DO NOT HAVE CHANNELS)
B
HOT WATER
OUTLET
A & D ELEVATION FROM FINISHED FLOOR
T&P RELIEF VALVE
4.000
TOP VIEW
C 6.688
ADDITIONAL
HEIGHT IF
REQUIRED
HANDHOLE
INLET
D
EXTRA PANEL BOX MAY BE NECESSARY FOR INPUTS
HIGHER THAN 72KW. CONSULT FACTORY.
DRAIN
8
1 Features and Components (continued)
Specifications Data (continued)
Model
0150 162 65 1/2" 32" 38 3/4" 11 3/4" 1 1/2" 1 1/2" 650
0200 216 78" 32" 38 3/4" 11 3/4" 1 1/2" 1 1/2" 750
0250 270 91 3/8" 34" 40 3/4" 19 1/4" 1 1/2" 1 1/2" 1,165
0300 162 80" 40" 46 3/4" 20 3/4" 2" 2" 1,350
0400 162 80" 46" 52 3/4" 22 1/4" 2" 2" 1,590
0500 270 91 3/8" 46" 52 3/4" 22 1/4" 2" 2" 1,700
0600 270 92 5/8" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 2,010
0800 432 104" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 2,450
1000 486 128" 52" 58 3/4" 24 1/4" 2 1/2" 2 1/2" 3,160
1250 648 132 1/2" 64 1/2" 64 1/2" 23 1/4" 3" 3" 3,560
1500 918 128 1/2" 70 1/2" 70 1/2" 25 1/4" 3" 3" 4,120
2000 918 140 1/2" 76 1/2" 76 1/2" 27 1/4" 3" 3" 4,350
2500 918 146 1/2" 82 1/2" 82 1/2" 29" 3" 3" 5,750
0150 162 37" 68 1/2" 34 1/4" 12" 2" 2" 1,180
0200 198 37" 78" 34 1/4" 12" 2" 2" 1,370
0250 240 39" 90 1/4" 36 1/4" 13" 2" 2" 1,450
0300 300 45" 78 1/4" 42 1/4" 14 3/4" 2" 2" 1,530
0400 324 52" 78 1/4" 48 1/4" 16" 2" 2" 1,750
0500 432 52" 90 3/4" 48 1/4" 16" 2" 2" 1,860
0600 414 58" 90 3/4" 54 1/4" 13 1/2" 2 1/2" 2" 2,340
0800 468 58" 102 1/4" 54 1/4" 13 1/2" 2 1/2" 2" 2,850
1000 648 58" 126 1/4" 54 1/4" 13 1/2" 2 1/2" 2" 3,040
1250 648 64" 130 1/4" 60 1/4" 15" 3" 3" 3,750
1500 918 70" 126 1/4" 66 1/4" 16" 3" 3" 4,340
2000 918 76" 137 1/4" 72 1/4" 17 1/2" 3" 3" 4,580
2500 918 82" 144 1/4" 78 1/4" 16 1/2" 3" 3" 6,060
Maximum KW
Input
Height
A
Width
(Length)
B
VERTICAL ROUND ELECTRIC STORAGE HEATER
VERTICAL SQUARE ELECTRIC STORAGE HEATER
HORIZONTAL SQUARE ELECTRIC STORAGE HEATER
Depth
C
D
Inlet
Water
Connection
Outlet Water
Connection
Shipping
Weight (lbs)
9
2 Determine Water Heater Location
Determine Water Heater Location
CAUTION
Carefully choose a location for the new water heater. e
placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of
the appliance.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must be
observed. e water heater must be located:
1. On a level surface. Shim the channel-type skid base as
necessary if leveling is required.
2. Near a oor drain. e heater should be located in an area
where leakage of the tank or connections will not result in
damage to the area adjacent to the heater or to lower oors
of the structure. When such locations cannot be avoided, a
suitable drain pan should be installed under the heater. e
pan should be at least 2 inches deep, have a minimum length
and width of at least 2 inches greater than the dimensions of
the water heater, and should be piped to an adequate drain.
e discharge opening of the relief valve should always be
piped to an open drain.
3. Close to the point of major hot water usage and the power
supply.
All water heaters eventually leak. Do
not install without adequate drainage.
Hot water piping and branch circuit wiring should be as short as
possible. Insulate hot and cold water piping where heat loss and
condensation may be a problem.
Heater construction permits installation, maintenance, and
service work to be performed through the element box door and
control box door.
Suggested clearances from adjacent surfaces are 12 inches on
top, 30 inches in front of access doors, 24 inches for cleanout/
handhole/manway side, and 6 inches on the inlet water piping
side.
e heater may be installed on or against combustible surfaces.
e back may be placed ush against adjacent surfaces. Be sure
to place the cover plates over the rear crating couplings before
locating vertical model heaters that were shipped laying down.
e heater may be installed in a con ned space if adequate
ventilation is provided.
e temperature of the space in which the water heater is
installed must not go below 32F or above 122F.
10
2 Determine Water Heater Location (continued)
Figure 2-1 Clearances from Combustible Construction
←
TOP
CLEARANCE
12"
←
←
ACCESS DOOR
CLEARANCE
30"
←
MANWAY OR
HANDHOLE
CLEARANCE
24"
REAR
INLET WATER
PIPING
CLEARANCE
6"
RIGHT
MANWAY OR
HANDHOLE
CLEARANCE
←
←
24"
ACCESS DOOR
CLEARANCE
*30"
↓
LEFT
ACCESS DOOR
CLEARANCE
FRONT
CLEARANCE
36"
FRONT
↓
12"
↓
REAR
↓
*DISTANCE FOR DOOR TO OPEN
FRONT
↓
RIGHT
24"
↓
MANWAY OR
HANDHOLE
CLEARANCE
11
3 Installation
e installation must conform to these instructions and local
code authority having jurisdiction. Grounding and electrical
wiring connected to the water heater must also conform to the
National Electrical Code, NFPA 70. is publication is available
from e National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269.
CAUTION
e principle components of the heater are identi ed in the
Features and Components illustration on pages 6 and 7.
DANGER
Do NOT test electrical system before
heater is lled with water. Follow the
Start-up procedure in the Operation
section of this manual.
Water temperature over 125F (52C)
can cause severe burns instantly resulting
in severe injury or death. Children, the
elderly, and the physically or mentally
disabled are at highest risk for scald
injury. Feel water before bathing or
showering. Temperature limiting devices,
such as mixing valves, must be installed
when required by code and to ensure safe
temperatures at fixtures.
Mixing Valve Usage
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy 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. ese include the
elderly, children, the in rm, or the physically or developmentally
disabled. If anyone using hot water in your home ts into one
of these groups, or if there is a local code or state law requiring a
maximum water temperature at the hot water tap, then you must
take special precautions. In addition to using the lowest possible
temperature setting that satis es your hot water needs, a means
such as a mixing valve, should be used at the hot water taps or at
the water heater.
Mixing valves for reducing point-of-use temperature are
available. Consult a quali ed installer or service agency. Follow
all manufacturer’s instructions for installation of mixing valves.
Before changing the factory setting on the thermostat, read the
Temperature Regulation section in this manual.
WARNING
Toxic chemical hazard: Do not connect
to non-potable water system.
Chemical Vapor Corrosion
is water heater shall not be connected to any heating
system(s) or component(s) used with a non-potable water
heating appliance. Toxic chemicals, such as those used for boiler
treatment, shall not be introduced into this system. Water heater
corrosion and component failure can be caused by the heating and
breakdown of airborne chemical vapors. Spray can propellants,
cleaning solvents, refrigerator and air conditioning refrigerants,
swimming pool chemicals, water so ener chemicals, calcium
and sodium chloride, waxes, and process chemicals are typical
compounds which are potentially corrosive. ese materials
are corrosive at very low concentration levels with little or no
odor to reveal their presence. Products of this sort should not
be stored near the heater. Also, air which is brought in contact
with the water heater should not contain any of these chemicals.
If necessary, uncontaminated air should be obtained from
remote or outside sources.
Circulating Pump
Field-installed circulating pumps should be of all bronze
constructions. To optimize the total storage capacity of a
horizontal vessel, particularly under low draw conditions, it is
recommended to utilize a pump and recirculation line sized to
turn the entire storage capacity of the tank once each hour (i.e., a
600 gallon tank would require a 10 gpm pump).
Insulation Blankets
Insulation blankets are available to the general public for
external use on electric water heaters, but are not necessary with
this product. e purpose of an insulation blanket is to reduce
the standby heat loss encountered with storage tank heaters.
Your water heater meets or exceeds the EPACT and ASHRAE/
IES 90.1 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 the instructions below. Failure to follow these
instructions can result in 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.
Temperature - Pressure Relief Valve
WARNING
is water heater is provided with a properly rated/sized and
certi ed combination temperature-pressure relief valve by the
manufacturer. e valve is certi 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 temperature and pressure relief
valve must comply with ANSI Z21.22
and ASME code. A properly sized
temperature and pressure relief valve
must be installed in the opening
provided. Failure to install a relief
valve can result in overheating and
excessive tank pressure. Failure to
follow these instructions can cause
serious injury or death.
12
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