Bradford White RE1 Lowboy, RE2 Lowboy, RE1 Utility, RE1 Wall Hung, LE Upright User Manual

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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

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Residential and Light Duty

Commercial Electric Water Heaters

Page Service Procedure

Introduction……………………………………………………………………

Tools……………………………………………………………………………

General Information…………………………………………………………..

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

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

Double Element Non-Simultaneous Single Phase………………. Double Element Simultaneous Single Phase 4 wire Service……

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

Double Element Simultaneous 3 Phase………………………….. Double Element Non-Simultaneous Single Phase Off Peak …..

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

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

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

Residential Thermostat Testing ……......................................................

Single Element …………………………….....................................

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

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

Double Element, Non-Simultaneous, 3 Phase …………………... Double Element, Simultaneous, 3 Phase ………………………… Double Element, Non-Simultaneous, Single Phase, Off Peak …

Light Duty Commercial Thermostat Testing ….......................................

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

Thermostat Removal and Replacement ……………………………………

Heating Element Removal and Replacement ……………………………..

DipTube and Anode Inspection and Replacement ……………………….

Generic Parts List …………………………………………………………….

2 ---

3 ---

6 --6 --7 --8 ---

9 --10 - - 11 - - -

12 - - -

14 RE-I

15 RE-II

16 RE-III 16 16 17 19 21 23

25 RE IV 25 27 29 31

33 RE-V

34 RE-VI

35 RE-VII

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.

Page 2

ABC

Commonly Used Formulas

GENERAL INFORMATION

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

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

Watts = Example: 18.75A x 240V = 4500W

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

Watts

Volts

Watts

Volts x 1.732

Amps x Volts

Volts

Watts

WHITE

BLACK

Ungrounded

Grounded

(Neutral)

GREEN

Grounding

BLACK

Ungrounded

RED

Ungrounded

GREEN

Grounding

120 0

ABCNeutral

120

120 208

208 208

RED BLACK RED

120

ABCNeutral

120

120 240

240 240

RED BLACK RED

Page 3

240 120

120

Neutral

277

277 480

480 480

RED BLACK RED

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

Wattage

3,000

6,000

Element

Upper/Lower

3,000/3,000 120

6,000/6,000 208, 240

6,000/6,000

Voltage

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

Wattage

3,000

10,000

11,000

12,000

Element

Upper/Lower

1,500/1,500 120

5,000/5,000 208

5,500/5,500 240

6,000/6,000

Voltage

277, 480

Residential Electric Utility Series (Single Element Operation) Light Duty Utility Series (Single Element Operation)

Maximum

Wattage

3,000

6,000

Single

Element

3,000 120

6,000 208, 240

6,000 277

6,000 480

Page 4

Voltage

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

Surface Mount

Combination Thermostat/

ECO (high limit)

59T/66T Series

Temperature

control Dial

Surface Mount

Combination Thermostat/

ECO (high limit)

59T/66T Series

Temperature

control Dial

Direct Immersion “Screw-in” Type Heating Element

1-½ Hex Screw-in Flange

Terminal Block Screw

Terminal Block

Zinc Plated Copper or Incoloy Sheath

Element Rating Ink Stamped on side of Terminal Block.

Surface Mount

Thermostat

59T Series

Page 5

SEQUENCE OF OPERATION

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

1. Single Element Operation.

2. Double Element Non-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.

Line 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.

ECO

Closed

Tank is cold therefore thermostat

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

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

Thermostat closed

at terminal T2

Thermostat opens

at terminal T2

Page 6

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.

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.

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

1 2

ECO

Thermostat closed

Closed

at terminal T2

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

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

The 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

Thermostat closed

at terminal T4

terminal T2) prior to the lower thermostat being satisfied. This will interrupt current flow

Upper T’stat

through the lower thermostat and element and allow current to flow through the upper

Upper

Element

element only. When the upper thermostat is satisfied, it resumes operation as described in sequence #3 above.

Lower T’stat

Lower

Element

Upper T’stat

Upper

Element

Thermostat closed

at terminal 2

Lower T’stat

Lower

Element

Thermostat open

between terminals

1 and 2

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Thermostat closed

at terminal T2

Thermostat closed between terminals

1 and 2

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Upper

T’stat

Upper

Element

Lower

T’stat

Lower

Element

Page 7

SEQUENCE OF OPERATION

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

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

Line 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.

Tank 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.

When 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.

Circuit one

Thermostat open

at terminal T2

Circuit two

ECO

Closed

ECO

Closed

Circuit one

Thermostat closed

at terminal T2

Circuit two

Thermostat open

at terminal T2

Page 8

SEQUENCE OF OPERATION

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

1 2

Line 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.

Tank 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.

When 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.

Thermostat closed

at terminal T4

ECO

Closed

ECO

Closed

Thermostat closed

at terminal T2

Thermostat closed

at terminal T2

Thermostat closed

at terminal T4

When 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.

The 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.

Thermostat closed

at terminal T2

Thermostat closed

at terminal T2

Thermostat closed

at terminal T2

Thermostat open

at terminal T2

Page 9

SEQUENCE OF OPERATION

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

Line 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.

Tank 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.

Thermostat open

at terminal T2

ECO

Closed

ECO

Closed

Thermostat closed

at terminal T2

Thermostat closed

at terminal T2

Thermostat open

Page 10

at terminal T2

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.

Line 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 are closed at terminal T2 (calling for heat). The

circuit is complete through the upper thermostat only, allowing current to flow through upper element.

When 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.

From

Off Peak

Meter

1 2

ECO

Thermostat closed

Closed

Thermostat closed

at terminal T2

When 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

During 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

Thermostat closed

at terminal T4

Thermostat closed

at terminal T2

Thermostat open

at terminal T2

4 5

Off Peak

Power interrupted

Thermostat closed

at terminal T2

Page 11

TROUBLESHOOTING

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

When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot Water,” 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 Screw-in Flange

Terminal Block

Zinc Plated Copper or Incoloy Sheath

0642

4500W 240V

RC02404524

Terminal Block Screw

Typical Direct Immersion “Screw-In”

Type Heating Element

Element Rating Ink Stamped on side of Terminal Block.

Figure 1

Page 12

TROUBLESHOOTING

Quick Step Plan to Hot Water

WARNING

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

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

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

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

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

1. No Power to heater.

2. Loose wire connections.

No Hot Water

Not Enough Hot

Water

Slow Hot Water

Recovery

Over Heated

Water or

Continued

Operation

3. Inoperative upper heating element.

4. Inoperative upper thermostat.

5. Open ECO.

1. Inoperative lower heating element.

2. Thermostat(s) set to low.

3. Inoperative thermostat(s).

4. Loose wire connection.

5. Sediment or lime build up on element(s).

6. High demand period.

7. Undersized heater.

8. Very cold inlet water to heater.

9. Plumbing connections reversed.

10. Damaged diptube.

1. Sediment or lime build up on element(s).

2. Loose wire connections.

3. Inoperative thermostat(s).

4. Derated heating element installed.

1. Thermostat not in contact with tank.

2. Grounded heating element(s).

3. Thermostat set too high.

4. Inoperative thermostat(s).

5. Inoperative ECO.

6. Undersized water heater.

High voltage exposure. Use caution when

making voltage checks to avoid personal

injury.

SERVICE

PROCEDURE

1. Check fuses or circuit breakers in service panel.

2. Check all wire connections.

3. Check heating element(s). Replace as needed.

4. Check thermostat(s) operation. Replace as needed.

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

1. Check heating element(s), replace as needed.

2. Increase thermostat setting.

3. Check thermostat(s), replace as needed.

4. Check all wire connection.

5. Remove heating element(s) and check for lime build up.

6. Reduce demand.

7. Replace with larger heater.

8. Temper water to heater.

9. Correct plumbing connections.

10. Check dip tube, replace as needed.

1. Remove heating element(s) and check for lime build up.

2. Check all wire connections.

3. Check thermostat(s), replace as needed.

4. Check terminal block of element for proper voltage and wattage rating.

1. Position thermostat flush with tank surface.

2. Check heating element(s). Replace as needed.

3. Adjust thermostat(s) to desired setting.

4. Check thermostat(s), replace as needed.

5. Check ECO, replace thermostat as needed.

6. Replace with larger heater.

3. See Service Procedure RE-II, Page 15.

4. See Service Procedure RE-III, Page 16.

5. See Service Procedure RE-I, Page 14.

1. See Service Procedure RE-II, Page 15.

3. See Service Procedure RE-III, Page 16.

5. See Service Procedure RE-VI, Page 34.

10. See Service Procedure

RE-VII, Page 35.

1. See Service Procedure RE-VI, Page 34.

3. See Service Procedure RE-III, Page 16.

1. See Service Procedure RE-V, Page 33.

2. See Service Procedure RE-II, Page 15.

4. See Service Procedure RE-III, Page 16.

5. See Service Procedure RE-I, Page 14.

Noisy (singing or

hissing) Elements

1. Lime formation on elements. 1. Remove and clean heating elements. Replace as needed.

Page 13

1. See Service Procedure RE-VI, Page 34.

SERVICE PROCEDURE RE-I

Line Voltage & High Limit (ECO)

Testing

Line Voltage Testing

1. Turn “OFF” power to water heater.

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

3. Set multi-meter to “Volts AC.”

4. Turn power “ON” to water heater.

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

A) Rated voltage IS present, power to the water

heater is okay.

B) Rated voltage NOT present, Check circuit breaker

at service panel.

High Limit (ECO) Testing

WARNING

High voltage exposure. Use caution when

making voltage checks to avoid personal injury.

ECO reset

button

Figure 3

Figure 2

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

A) Rated Voltage IS present, ECO is okay.

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

2. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s). Turn power “ON” and recheck voltage across terminals L1 & L4 of upper thermostat (see Figure 3).

A) Rated voltage IS present, the ECO has previously opened indicating the water in the tank, at

some point did overheat, check the following:

1. Thermostat must be in full contact with tank.

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

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

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

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

2. If water is cool, Replace upper thermostat.

Page 14

SERVICE PROCEDURE RE-II

Heating Element Testing

Testing For Open Or Burned Out Element

Step 1. TURN OFF POWER TO WATER HEATER

Step 2. Remove access cover(s) from front of water

heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element(s).

Step 4. Set multi-meter to “ohms” setting.

Step 5. Touch probes of multi-meter to screw

terminals of heating element(s) (see Figure 4).

Step 6. Reading should be 12.8 ohms (±6%) for a 240

volt, 4500 watt element:

Ohms = Volts

Watts

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

WARNING

High voltage exposure. Be sure power is turned

OFF to water heater prior to performing this

procedure.

Meter Probe

Element Screw Terminals

Figure 4

Testing For Heating Element Short Circuit To Ground

Step 1. TURN OFF POWER TO WATER HEATER

Step 2. Remove access cover(s) from front of water

heater. Remove insulation and plastic cover from thermostat.

Step 3. Disconnect wires from heating element(s).

Step 4. Set multi-meter to “ohms” setting.

Step 5. Touch one probe of multi-meter to either screw

terminal of heating element and the other on the element flange (see figure 5). There should be no reading on the ohm meter. Any reading indicates a grounded element and the element must be replaced. Repeat this step for the other screw terminal.

Element Screw Terminal

Meter Probe

Element Flange

Figure 5

Page 15

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

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

Water In Tank Is Cold With Power ON

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

Recheck ECO. If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

5. Check across element terminals (see Figure 7).

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

Repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 6

Figure 7

Water Temperature In Tank Is Above Thermostat Setting

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage IS present,

replace thermostat.

B) Rated voltage NOT present,

thermostat is okay.

C) Lower than rated voltage IS present,

recheck for grounded element (see page 15).

Reference 4 Wire, Simultaneous, Single Phase

Wiring diagram.

NOTE: Wiring consists of two single element configurations

operating independently.

Page 16

SERVICE PROCEDURE RE-III Residential Thermostat Testing

Double Element, Non-Simultaneous, Single Phase Operation.

Water In Tank Is Cold With Power ON.

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

Recheck ECO. If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

Repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 8

Figure 9

Tank Does Not Deliver Enough Hot Water.

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

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

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

4. See Figure 8 above, check voltage across terminals L4 and T2 of upper thermostat.

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

calling for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

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

6. Check voltage across terminals L4 and T4 of upper thermostat (see Figure 10).

A) Rated voltage NOT present, replace upper thermostat.

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

Page 17

Figure 10

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Single Phase Operation (continued).

Not Enough Hot Water (continued).

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

A) Rated voltage NOT present,

- check wire connection between thermostats.

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

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

9. Check voltage across terminal L4 of upper thermostat and terminal 2 of lower thermostat (see Figure 12).

A) Rated voltage NOT present, replace lower thermostat.

B) Rated voltage IS present, thermostat is ok.

High voltage exposure. Use caution to avoid

WARNING

Be sure thermostats are reset to their original

temperature settings as found prior to

thermostat testing

WARNING

personal injury during this procedure.

Figure 11

Water Temperature In Tank Is Above Thermostat Setting.

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

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

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

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

A) Rated voltage IS present, replace upper thermostat.

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

5 below.

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

element (see page 15).

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

A) Rated voltage IS present, replace lower thermostat.

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

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

element (see page 15).

Page 18

Figure 12

SERVICE PROCEDURE RE-III Residential Thermostat Testing

Double Element, Non-Simultaneous, Three Phase Operation.

Water In Tank Is Cold With Power ON.

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

recheck ECO. If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

repeat element testing, see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 13 Figure 14

Tank Does Not Deliver Enough Hot Water.

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

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

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

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

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

calling for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

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

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

A) Rated voltage NOT present, replace upper thermostat.

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

page.

Page 19

Figure 15

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Non-Simultaneous, Three Phase Operation (continued).

High voltage exposure. Use caution to avoid

WARNING

personal injury during this procedure.

Tank Does Not Deliver Enough Hot Water (continued)

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

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

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

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

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

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

replace lower thermostat.

B) Rated voltage IS present, thermostat is ok. Check wire connection to lower

element. If connection okay, recheck lower element (see page 15).

WARNING

Be sure thermostats are reset to their original

temperature settings as found prior to

thermostat testing

Figure 16

Water Temperature In Tank Is Above Thermostat Setting.

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

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

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

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

A) Rated voltage IS present, replace upper thermostat.

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

5 below.

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

element (see page 15).

5. Check across terminals L4 and T2 of lower thermostat (see Figure 17).

A) Rated voltage IS present, replace lower thermostat.

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

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

element (see page 15).

Figure 17

Page 20

SERVICE PROCEDURE RE-III Residential Thermostat Testing

Double Element, Simultaneous, Three Phase Operation.

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

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

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

4. Check across terminals L4 and T2 of upper thermostat (see Figure 18).

A) Rated voltage NOT present,

recheck ECO (see page 14). If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

5. Check across upper element terminals (see Figure 19).

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

repeat element testing see page 15.

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

A) Rated voltage NOT present,

check wire connections from upper to lower thermostats.

B) Rated voltage IS present,

okay, go to step 7.

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

A) Rated voltage NOT present,

recheck ECO (see page 14). If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

8. Check across lower element terminals.

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

Be sure thermostats are reset to their original

repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 18

Figure 20

Figure 19

Figure 21

WARNING

temperature settings as found prior to

thermostat testing

Page 21

SERVICE PROCEDURE RE-III

Residential Thermostat Testing

Double Element, Simultaneous, Three Phase Operation (continued).

Water Temperature In Tank Is Above Thermostat Setting.

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

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

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC.”

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

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) Lower than rated voltage IS present,

recheck for grounded upper element (see page 15).

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

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 22

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) Lower than rated voltage IS present,

recheck for grounded lower element (see page 15).

Figure 23

Page 22

SERVICE PROCEDURE RE-III Residential Thermostat Testing

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

Water In Tank Is Cold With Power ON.

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

recheck ECO (see page 14). If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

Repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 24

Figure 25

Tank Does Not Deliver Enough Hot Water.

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

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

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

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

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

for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

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

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

A) Rated voltage NOT present, replace upper thermostat.

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

step 7 on next page.

Figure 26

Page 23

SERVICE PROCEDURE RE-III Residential Thermostat Testing

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

(continued)

Not Enough Hot Water (continued).

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

A) Rated voltage NOT present,

replace lower thermostat.

B) Rated voltage is present, okay,

go to step 8.

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

A) Rated voltage NOT present,

check wire connections between thermostats & element.

B) Rated voltage IS present,

repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 27

Figure 28

WARNING

Be sure thermostats are reset to their original

temperature settings as found prior to

thermostat testing

Water Temperature In Tank Is Above Thermostat Setting.

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

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

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

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

A) Rated voltage IS present, replace upper thermostat.

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

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

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

A) Rated voltage IS present, replace lower thermostat.

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

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

Page 24

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous, Single Phase Operation.

Water In Tank Is Cold With Power ON.

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

4. Check across terminals L4 and T2 of upper thermostat (see Figure 29).

A) Rated voltage NOT present,

recheck ECO (see page 14). If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

5. Check across element terminals (see Figure 30).

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 29 Figure 30

Tank Does Not Deliver Enough Hot Water.

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

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

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

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

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

for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

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

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

A) Rated voltage NOT present, replace upper thermostat.

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

step 7 on next page.

Figure 31

Page 25

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous, Single Phase Operation (continued)

Tank Does Not Deliver Enough Hot

Water (continued).

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

A) Rated voltage NOT present,

replace lower thermostat.

B) Rated voltage is present, okay,

go to step 8.

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

A) Rated voltage NOT present,

Check wire connections between thermostats & element.

B) Rated voltage IS present,

repeat element testing see page 15.

WARNING

Be sure thermostats are reset to

their original temperature settings

as found prior to thermostat

testing

Figure 32

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 33

Water Temperature In Tank Is Above Thermostat Setting.

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

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

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

4. See Figure 32 above. Check across terminal L3 of upper thermostat & T2 of lower thermostat.

A) Rated voltage IS present, replace lower thermostat.

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

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

element see page 15.

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

A) Rated voltage IS present, replace upper thermostat.

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

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

element see page 15.

Page 26

Figure 34

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Single Phase Operation.

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

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

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

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

recheck upper ECO (see page 14). If ECO is okay, replace upper thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to upper element.

B) Rated voltage IS present,

repeat element testing see page 15.

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

A) Rated voltage NOT present,

check ECO (see page 14) & wire connections at upper & lower thermostats. If okay, replace lower thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check lower element wire connections to the thermostats.

B) Rated voltage IS present,

repeat lower element testing see page 15

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 35 Figure 36

WARNING

Be sure thermostats are reset to

their original temperature settings

as found prior to thermostat

testing

Figure 37 Figure 38

Page 27

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Single Phase Operation (continued)

Water Temperature In Tank Is Above Thermostat Setting.

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

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

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC.”

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

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) Lower than rated voltage IS present,

recheck for grounded upper element see page 15.

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

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 39

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) Lower than rated voltage IS present,

recheck for grounded lower element see page 15.

Figure 40

Page 28

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous, Three Phase Operation.

Water In Tank Is Cold With Power ON.

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

2. Turn power “ON” to water heater.

3. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

recheck upper ECO. If ECO is okay, replace thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to element.

B) Rated voltage IS present,

repeat element testing see page 15.

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 41 Figure 42

Tank Does Not Deliver Enough Hot Water.

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

working order.

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

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

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

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

for heat. Go to step 5 below.

B) Rated voltage NOT present, replace upper thermostat.

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

6. Check voltage across terminals L3 & T4 of upper thermostat (see Figure 43).

A) Rated voltage NOT present, replace upper thermostat.

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

step 7 on next page.

Figure 43

Page 29

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Non-Simultaneous, Three Phase Operation (continued).

Tank Does Not Deliver Enough Hot Water (continued).

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

A) Rated voltage NOT present,

Replace lower thermostat.

B) Rated voltage is present, okay,

go to step 8.

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

A) Rated voltage NOT present,

check wire connections between thermostats & element.

B) Rated voltage IS present,

repeat element testing see page 15.

WARNING

Be sure thermostats are reset to

their original temperature settings

as found prior to thermostat

testing

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 44

Figure 45

Water Temperature In Tank Is Above Thermostat Setting.

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

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

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

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

A) Rated voltage IS present, replace lower thermostat.

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

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

element.

5. Check across terminal L4 & T2 of upper thermostat (see Figure 46).

A) Rated voltage IS present, replace upper thermostat.

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

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

element, see page 15.

Page 30

Figure 46

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Three Phase Operation.

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

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

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

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC.”

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

A) Rated voltage NOT present,

recheck upper ECO (see page 14). If ECO is okay, replace upper thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check wire connections from thermostat to upper element.

B) Rated voltage IS present,

repeat element testing see page 15

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

A) Rated voltage NOT present,

check ECO (see page 14) & wire connections at upper & lower thermostats. If okay, replace lower thermostat.

B) Rated voltage IS present,

proceed to next step.

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

A) Rated voltage NOT present,

check lower element wire connections to thermostat.

B) Rated voltage IS present,

repeat lower element testing see page 15.

Figure 47

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 48

WARNING

Be sure thermostats are reset to

their original temperature settings

as found prior to thermostat

testing

Figure 49

Page 31

Figure 50

SERVICE PROCEDURE RE-IV

Light Duty Commercial

Thermostat Testing

Double Element, Simultaneous, Three Phase Operation (continued).

Water Temperature In Tank Is Above Thermostat Setting.

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

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

3. Turn power “ON” to water heater.

4. Set multi-meter to “Volts AC.”

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

A) Rated voltage IS present,

replace upper thermostat.

B) Rated voltage NOT present,

upper thermostat is okay. Go to step 6 below.

C) Lower than rated voltage IS present,

recheck for grounded upper element see page 15.

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

WARNING

High voltage exposure. Use caution to avoid

personal injury during this procedure.

Figure 51

A) Rated voltage IS present,

replace lower thermostat.

B) Rated voltage NOT present,

lower thermostat is okay.

C) Lower than rated voltage IS present,

recheck for grounded lower element.

Figure 52

Page 32

SERVICE PROCEDURE RE-V

Thermostat Removal and

Replacement

Thermostat Removal

1. Turn power “OFF” to water heater.

2. Remove access cover and insulation.

High voltage exposure. Be sure power is

“OFF” when performing this procedure.

WARNING

3. Remove plastic thermostat protector from thermostat.

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

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

6. Slide thermostat upwards and out of mounting bracket.

Thermostat Replacement

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

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

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

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

5. Re-install plastic thermostat protector.

6. Re-install insulation and access cover.

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

Front View

Thermostat Mounting

Tank Surface

Thermostat

mounting

bracket

Side View

Proper Thermostat

Mounting

Proper Thermostat mounting

flush with tank surface

Improper Thermostat mounting.

Thermostat not flush with tank surface

Side View

Improper Thermostat

Mounting

Page 33

SERVICE PROCEDURE RE-VI

Heating Element Removal

and Replacement

Heating Element Removal

1. Turn power “OFF” To water heater.

WARNING

High voltage exposure. Be sure power is

“OFF” when performing this procedure.

2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the element(s).

3. Close drain spigot and remove hose.

Heater components and stored water may be

HOT when performing the following steps in

this procedure. Take necessary precaution to

prevent personal injury.

WARNING

4. Remove access cover and insulation.

5. Remove plastic thermostat protector from thermostat.

6. Disconnect wires from element terminals.

7. Remove element from tank using 1-½ deep well socket or appropriate wrench. Unscrew element counter-clockwise to

remove from tank.

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

Heating Element Replacement

1. Check element terminal block for proper electrical rating. NOTE: Some elements have dual ratings, be sure to check

all surfaces of the element terminal block (see illustration below).

2. Apply new element gasket to the new element. Be sure gasket is seated flat against element flange without rolls or

gaps (see illustration below).

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

4. Thread new element clockwise into tank. Tighten element using 1-½ deep well socket or appropriate wrench. Do not

over tighten, over tightening may damage element gasket.

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

terminal block.

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

7. Re-install plastic thermostat protector.

8. Re-install insulation and access cover.

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

operation.

Date Code

Terminal

Block

Element Rating. Example: (4500 Watt, 240 Volt)

Element Flange

0642

4500W 240V

RC02404524

Manufacturer Identification

Element Gasket Seated Flat Against Element Flange Without Rolls or Gaps

Page 34

SERVICE PROCEDURE RE-VII Dip Tube and Anode Inspection and

Replacement

Diptube Inspection and Replacement

WARNING

Heater components and stored water may be HOT when performing the following steps in

this procedure. Take necessary precaution to prevent personal injury.

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

Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.

Step 3. Close drain spigot and remove hose.

Step 4. Disconnect inlet nipple from plumbing system.

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

Step 6. Visually inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage.

Step 7. Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Ensure pipe dope

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

Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the inlet connection nipple.

nipple threads.

Hydro-jets located near the bottom of the dip tube should be open and free of any blockage. Anti-siphon hole located approximately 6" from the bottom of nipple, should be free of any blockage.

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

is used on the nipple’s threads. Connect nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with water.

Anode Inspection and Replacement

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

Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.

Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the outlet connection nipple.

Step 3. Close drain spigot and remove hose.

Step 4. Disconnect outlet nipple from plumbing system.

Step 5. With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage

nipple threads.

Step 6. Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.

If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 7. Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Ensure pipe

dope is used on the nipple’s threads. Connect nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with water.

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

Page 35

Generic Parts List

1. T&P Relief Valve

2. Heat Trap Insert (Outlet)

3. Hot Water Outlet/Anode

4. Cover Conduit/Ground

5. Junction Box Cover

6. Heat Trap Insert (Inlet)

7. Cold Water Inlet Diptube

8. Upper Thermostat Protector

9. Upper Thermostat

10. Thermostat Mounting Bracket

11. Heating Element

12. Element Gasket

13. Access Cover

14. Lower Thermostat Protector

15. Lower Thermostat (59T)

16. Brass Drain Valve

17. Thermostat w/High Limit (59T/66T)

18. ASSE Approved Mixing Device

19. Kit Heat Trap

Page 36

Bradford White RE1 Lowboy, RE2 Lowboy, RE1 Utility, RE1 Wall Hung, LE Upright User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual