Bradford White LE120L3-3, LE130L3-3, LE140L3-3, LE150L3-3 User Manual

Residential & Light Duty

Commercial Electric Water Heaters

SERVICE MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

Models Covered

by This Manual:

Residential:

RE1 & RE3 Upright Models.

RE1 & RE2 Lowboy Models.

RE1 Utility Models.

RE1 Wall Hung Models.

Light Duty:

LE Upright Models.

LE Utility Models.

LE Lowboy.

LE Wall Hung.

Manual 238-51544-00A REV 08/18

Save this manual for future reference

Residential and Light Duty

Commercial Electric Water Heaters

	Page		Service Procedure
Introduction……………………………………………………………………	2	- - -
Tools……………………………………………………………………………	2	- - -
General Information…………………………………………………………..	3	- - -
Sequence of Operation………………………………………………………	6	- - -
Single Element Operation……………………………………..........	6	- - -
Double Element Non-Simultaneous Single Phase……………….	7	- - -
Double Element Simultaneous Single Phase 4 wire Service……	8	- - -
Double Element Non-Simultaneous 3 Phase………....................	9	- - -
Double Element Simultaneous 3 Phase…………………………..	10	- - -
Double Element Non-Simultaneous Single Phase Off Peak …..	11	- - -
Troubleshooting……………………………………………………………...	12	- - -
Line Voltage and High Limit ECO Testing…………………………………	14		RE-I
Heating Element Testing……………......................................................	15		RE-II
Residential Thermostat Testing ……......................................................	16		RE-III
Single Element …………………………….....................................	16
Double Element, 4 wire, Simultaneous, Single Phase …………..	16
Double Element, Non-Simultaneous, Single Phase ……….........	17
Double Element, Non-Simultaneous, 3 Phase …………………...	19
Double Element, Simultaneous, 3 Phase …………………………	21
Double Element, Non-Simultaneous, Single Phase, Off Peak …	23
Light Duty Commercial Thermostat Testing ….......................................	25		RE IV
Double Element, Non-Simultaneous, Single Phase……………...	25
Double Element, Simultaneous, Single Phase …………………...	27
Double Element, Non-Simultaneous, 3 Phase ……………………	29
Double Element, Simultaneous, 3 Phase ………………………….	31
Thermostat Removal and Replacement ……………………………………	33		RE-V
Heating Element Removal and Replacement ……………………………..	34		RE-VI
DipTube and Anode Inspection and Replacement ……………………….	35		RE-VII
Generic Parts List …………………………………………………………….	36	- - -

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

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

- Multi Meter	- Phillips Head Screw Driver
- 1-½ Deep Well Socket	- Thermometer
- ¼" Nut Driver	- Drain Hose

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

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									GENERAL INFORMATION
		Commonly Used Formulas
		Amps =	Watts					(for single phase units) Example: 4500W/240V = 18.75A
			Volts
		Amps =	Watts					(for balanced 3 phase units) Example: 4500W/240V x 1.732 = 10.82A
			Volts x 1.732
		Watts = Amps x Volts						Example: 18.75A x 240V = 4500W
				Volts2				2
		Ohms =						Example: (240V) / 4500W = 12.8 Ohms
				Watts

BLACK	WHITE	GREEN	BLACK	RED	GREEN
	Grounded
Ungrounded	(Neutral)	Grounding	Ungrounded	Ungrounded	Grounding

	120							0						240							120
			120													120

Neutral	A	B	C
	120
120
120			208
	208		208

RED BLACK RED

Neutral	A		B	C	Neutral	A		B	C
		120					277
120					277
120			240		277			480
		240	240				480	480
	RED	BLACK		RED		RED	BLACK		RED

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GENERAL INFORMATION

Wattage Limitations at Various Voltages

Residential Electric Upright RE2 & RE3 Series (Non-Simultaneous Operation)

Residential High Efficiency Upright RE2 Series (Non-Simultaneous Operation)

Residential Electric Lowboy RE2 Series (Non-Simultaneous Operation)

Maximum	Element	Voltage
Wattage	Upper/Lower
3,000	3,000/3,000	120
6,000	6,000/6,000	208, 240
6,000	6,000/6,000	277, 480

Residential Electric Upright RE2 & RE3 Series (Simultaneous Operation)

Residential High Efficiency Upright RE2 Series (Simultaneous Operation)

Residential Electric Lowboy RE2 Series (Simultaneous Operation)

Light Duty Commercial Electric LE Series (Non-Simultaneous Operation)

Light Duty Commercial Electric LE Series (Simultaneous Operation)

Maximum	Element	Voltage
Wattage	Upper/Lower
3,000	1,500/1,500	120
10,000	5,000/5,000	208
11,000	5,500/5,500	240
12,000	6,000/6,000	277, 480

Residential Electric Utility Series (Single Element Operation)

Light Duty Utility Series (Single Element Operation)

Maximum	Single	Voltage
Wattage	Element
3,000	3,000	120
6,000	6,000	208, 240
6,000	6,000	277
6,000	6,000	480

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GENERAL INFORMATION

Surface Mounted Thermostats

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

Manual
ECO (high limit)
Reset button
Temperature	Temperature
control Dial	control Dial

Surface Mount	Surface Mount	Surface Mount
Combination Thermostat/	Combination Thermostat/	Thermostat
ECO (high limit)	ECO (high limit)	59T Series
59T/66T Series	59T/66T Series

Direct Immersion “Screw-in” Type Heating Element

1-½ Hex		Terminal Block
Screw-in Flange

Zinc Plated Copper or

Incoloy Sheath

Terminal Block		Element Rating Ink Stamped
Screw		on side of Terminal Block.

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SEQUENCE OF OPERATION

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

1.Single Element Operation.

2.Double Element Non-Simultaneous Operation (single phase).

3.Double Element Non-Simultaneous Operation (3 phase).

4.Double Element Simultaneous Operation (single phase).

5.Double Element Simultaneous Operation (3 phase).

Sequence of Operation- Single Element Operation.

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

2Tank is cold therefore thermostat

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

1

ECO

Closed

2

Thermostat closed at terminal T2

3 When the thermostat is satisfied, it opens at	3
terminal T2 interrupting current flow through the
element. System is now in stand-by mode, waiting
for the next call for heat.
	Thermostat opens
	at terminal T2

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SEQUENCE OF OPERATION

Non-Simultaneous and Simultaneous Operation

Double element electric water heaters are designed to operate in either Non-Simultaneous or Simultaneous mode.

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

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

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

1 Line voltage is applied across terminals
L1 & L3 of the upper thermostat. ECO is
closed, so there is voltage at terminal L4
and to one side of the upper and lower
elements.	1	2

2	Tank is cold. Therefore, the thermostats
	are closed at terminals T2 & 2 (calling for heat).
	The circuit is complete through the upper		ECO	Thermostat closed
	thermostat only, allowing current to flow through		Closed	at terminal T2
	upper element.
3	When the upper thermostat is satisfied, it opens at	Upper		Upper
	terminal T2, interrupting current flow through the	T’stat		T’stat
	upper element. Terminal T4 closes, allowing voltage
	to pass to terminal 1 of the lower thermostat. This	Upper		Upper
	completes the circuit through the lower thermostat	Element		Element
	and allows current flow through the lower element.			at terminal 2
				Thermostat closed
4	When the lower thermostat is satisfied, it opens at	T’stat		T’stat
	terminal 2, interrupting current flow through lower
		Lower		Lower
	element. The system is now in stand-by mode
	waiting for the next call for heat.	Lower
				Lower
		Element
				Element

5	The lower thermostat/element
	combination will generally
	cycle on and off more often		3
	than the upper. In some cases,
	such as a cold tank or in high
	demand periods, the upper
	thermostat will call for heat
	(opening at terminal	Thermostat	closed
	T4 and closing at	at terminal T4
	terminal T2) prior to the lower
	thermostat being satisfied. This		Upper
	will interrupt current flow		T’stat
	through the lower thermostat
	and element and allow current		Upper
	to flow through the upper		Element
	element only. When the upper
	thermostat is satisfied, it
	resumes operation as		T’stat
	described in sequence #3
			Lower
	above.
			Lower
			Element

4

5

Thermostat open between terminals 1 and 2

Upper

T’stat

Upper

Element

Lower

T’stat

Thermostat closed

at terminal T2

Upper

T’stat

Upper

Element

Thermostat closed

between terminals

1 and 2

Lower

T’stat

Lower	Lower
Element	Element

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SEQUENCE OF OPERATION

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

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

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

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

1	Circuit two

Circuit one

2	Circuit two

Circuit one

	ECO	Thermostat closed
	Closed
		at terminal T2

ECO

Closed

Thermostat closed at terminal T2

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

3	Circuit two

Circuit one

Thermostat open at terminal T2

Thermostat open at terminal T2

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SEQUENCE OF OPERATION

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

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

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

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

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

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

1

2

ECO	Thermostat closed
Closed
	at terminal T2

ECO

Closed Thermostat closed at terminal T2

3	4
Thermostat closed	Thermostat closed
at terminal T4	at terminal T4

Thermostat closed
at terminal T2	Thermostat open
	at terminal T2

5

Thermostat closed at terminal T2

Thermostat closed at terminal T2

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SEQUENCE OF OPERATION

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

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

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

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

1	2
ECO
Closed	Thermostat closed
	at terminal T2

ECO

Closed Thermostat closed at terminal T2

3

Thermostat open at terminal T2

Thermostat open at terminal T2

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SEQUENCE OF OPERATION

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

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

1Line voltage is applied across terminals

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

Tank is cold therefore both thermostats

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

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

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

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

From

Off Peak

Meter

1		2
	ECO	Thermostat closed
	Closed
		at terminal T2

Thermostat closed at terminal T2

From	3	4	5
Off Peak			Off Peak
Meter			Power interrupted
Thermostat closed			Thermostat closed
at terminal T4			at terminal T2

Thermostat closed	Thermostat open
at terminal T2	at terminal T2

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TROUBLESHOOTING

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

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

Common Heating Element Failures:

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

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

usually the result of a grounded element.

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

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

1-½ Hex		Terminal Block
Screw-in Flange

Zinc Plated Copper or

Incoloy Sheath

				0642			4500W 240V	RC02404524

Terminal Block		Element Rating Ink Stamped
Screw		on side of Terminal Block.

Figure 1

Typical Direct Immersion “Screw-In”

Type Heating Element

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