Bradford White RE230LN6, RE240LN6, RE230L6, RE240L6, RE250LN6 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 238-51544-00B REV 08/18

Save this manual for future reference

Residential and Light Duty

Commercial Electric Water Heaters

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 …………………………………………………………….

Page

6 6 7 8 9

10 11

16 16 16 17 19 21 23

25 25 27 29 31

Service Procedure

---

RE-I

RE-II

RE-III

RE IV

RE-V

RE-VI

RE-VII

---

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

- 1-½ Deep W ell Socket

- ¼" Nut Driver

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

Page 2

- Phillips Head Screw Driver

- Thermometer

- Drain Hose

Commonly Used Formulas

ABC

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 =

Watts

Volts

Watts

Volts x 1.732

Amps x Volts

Volts

Watts

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

WHITE

BLACK

Ungrounded

Grounded

(Neutral)

GREEN

Grounding

BLACK

Ungrounded

RED

Ungrounded

GREEN

Grounding

120 0 240 120

120 120

Neutral ABC

120

208120

208 208

RED

BLACK

RED

Neutral ABCNeutral

120

240120

RED

Page 3

240 240

BLACK

RED RED

277

480277

480 480

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

6,000 6,000/6,000

Element

Upper/Lower

3,000/3,000 120

6,000/6,000 208, 240

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 T 2

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.

ECO

Closed

Thermostatclosed

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.

Thermostatclosed

at terminal T4

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.

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Thermostatclosed

at terminal 2

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Thermostatclosed

at terminal T2

Thermostatopen

between terminals

1 and 2

Upper T’stat

Upper

Element

Lower T’stat

Lower

Element

Thermostatclosed between terminals

1 and 2

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.

Circuit two Circuit two

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.

Circuit one Circuitone

ECO

Closed

ECO

Closed

Thermostat closed

at terminal T2

Thermostat closed

at terminal T2

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

Page 8

Thermostat open

at terminal T2

Circuit two

SEQUENCE OF OPERATION

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

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

Page 10

Thermostat open

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

ECO

Thermostat closed

Closed

at terminal T2

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

3 5

Thermostat

at terminal

pen

Off Peak

Power inter rupted

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 Screw

0642

4500W 240V

RC02404524

Terminal Block

Zinc Plated Copper or Incoloy Sheath

Element Rating Ink Stamped on side of Terminal Block.

Figure 1

Typical Direct Immersion “Screw-In”

Type Heating Element

Page 12

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