Bradford White Corp Water Heater 900kW User Manual

CHP-I&S-01  
INSTALLATION AND SERVICE MANUAL  
Commercial Electric  
Water Heaters  
9kW – 900kW Input Models  
Installation and service must be performed by  
Qualified Service Personnel Only.  
SPECIAL INSTRUCTIONS  
TO OWNER  
WARRANTY  
WARNING:  
Factory warranty (shipped with unit) does not  
apply to units improperly installed or improperly  
operated.  
Improper Installation, Adjustment,  
Alteration, Service or Maintenance  
can cause injury or property damage. Refer  
to this manual. For assistance or additional  
information consult a qualified installer,  
service agency or the electric utility.  
Experience has shown that improper installation  
or system design, rather than faulty equipment, is  
the cause of most operating problems.  
CHECKING EQUIPMENT  
Excessive water hardness causing a lime/scale  
build-up in the heater and/or on the immersion  
heating elements is not the fault of the equipment  
and is not covered under the manufacturers  
warranty. (See Water Treatment and Water  
Chemistry)  
This manual supplies information for the  
installation, operation and servicing of the  
appliance. It is strongly recommended that this  
manual be reviewed completely before  
proceeding with an installation. Upon receiving  
equipment, check for signs of shipping damage.  
Pay particular attention to parts accompanying  
the water heater, which may show signs of being  
hit or otherwise being mishandled. Verify total  
number of pieces shown on packing slip with  
those actually received. In case there is damage  
or a shortage, immediately notify carrier.  
Do not energize electrical system before heater  
is completely filled with water. Damage caused  
to the immersion heating elements by dry fire is  
not covered under the manufacturers warranty.  
Follow start up procedure in the manual.  
Water heater corrosion and component failure  
caused by air-borne chemical vapors is not  
covered under the manufacturers warranty.  
Corrosion damage caused by current leakage due  
to improper grounding of electrical systems or  
electronic components to the storage tank and  
related piping is not covered by the  
manufacturers warranty. Under no circumstance  
will the manufacturer be liable for consequential  
damages resulting from the installation or use of  
this equipment. Correct installation procedure  
and local codes must be adhered to.  
DO NOT  
USE THIS APPLIANCE IF ANY  
PART HAS BEEN UNDER WATER. THE  
POSSIBLE DAMAGE TO A FLOODED  
APPLIANCE CAN BE EXTENSIVE AND  
PRESENT NUMEROUS SAFETY HAZARDS.  
ANY APPLIANCE THAT HAS BEEN UNDER  
WATER MUST BE REPLACED.  
WARNING:  
If the information in this  
manual is not followed exactly, a fire or  
explosion may result causing property  
damage, personal injury or loss of life.  
Do not store or use gasoline or other  
flammable vapors and liquids in the vicinity of  
this or any other appliance.  
NOTE: Retain this manual for future reference.  
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FIG. 1 Front View Vertical Round Models  
FIG. 2 Front View Vertical Square Models  
FIG. 3 Front View Horizontal Models  
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These shall be carefully followed in all cases.  
Authorities having jurisdiction shall be consulted  
before installations are made. In the absence of  
such requirements, the installation shall conform  
to the latest edition of the National Electrical  
Code, NFPA 70. When the appliance is installed  
in Canada, it must conform to the CAE C22.1,  
Canadian Electrical Code, Part 1 and/or local  
Electrical Codes.  
OWNER WARNING  
The information contained in this manual  
is intended for use by qualified professional  
installers, service technicians or the electric  
utility. Consult your local expert for  
proper installation or service procedures.  
IMPORTANT:  
Consult and follow  
local Electrical Codes, Building and Fire  
Regulations and other Safety Codes that  
apply to this installation. Consult local  
codes officials and electric utility company  
to authorize and inspect all field installed  
electrical connections.  
APPROVALS  
This complete appliance is design certified and  
Listed by Underwriters Laboratories as a  
commercial storage electric water heater. This  
water heater bears the UL certification for the  
United States as tested under the Standard for  
Electric Booster and Commercial Storage Tank  
Water Heaters, UL1453 and C-UL in Canada as  
tested under the Standard for Construction and Test  
of Electric Storage Tank Water Heaters,  
CAN/CSA-C22.2 No. 110-M90. All water heater  
storage tanks conform to the latest edition of the  
ASME Boiler and Pressure Vessel Code, Section IV.  
CAUTION:  
Be sure to turn off power  
when working on or near the electrical  
system of the water heater. Never touch  
electrical components with wet hands or  
when standing in water. When replacing  
fuses, always use the correct size for the  
circuit. Do not test electrical system before  
the water heater is completely filled with  
water. Follow the start-up procedure.  
INSTALLATION PROCEDURE  
LOCATION OF UNIT  
WARNING:  
To minimize the possibility  
of serious personal injury, fire or damage to  
your appliance, never violate the following  
safety rules.  
1.  
Locate the appliance so that if water  
connections should leak, water damage  
will not occur. When such locations  
cannot be avoided, it is recommended that  
a suitable drain pan, adequately drained,  
be installed under the unit. Under no  
circumstances is the manufacturer to be  
held responsible for water damage in  
connection with this unit, or any of its  
components.  
1.  
Always keep the area around your  
appliance free of combustible  
materials, gasoline, and other  
flammable liquids and vapors.  
2.  
Never cover your appliance, lean  
anything against it, store trash or  
debris near it, stand on it or in any  
way block the access to your  
appliance.  
2.  
Insure that the appliance is located near  
an acceptable drain so that the vessel can  
be properly drained when performing  
service or maintenance. The drain must  
also provide adequate drainage in the  
event of leakage the tank or related  
piping. The drain must prevent water  
damage to the adjacent area and lower  
floors of the structure.  
CODES  
The equipment shall be installed in accordance  
with those installation regulations in force in the  
local area where the installation is to be made.  
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3.  
4.  
The appliance must be installed so that  
the electrical components are protected  
from water (dripping, spraying, etc.)  
during appliance operation and service  
(replacing of fuses, elements, etc.)  
Drain Pan on Horizontal Models  
and Vertical Square Models  
1250 Gallons and Larger  
The lower pan of the horizontal water heater  
jacket or vertical square water heater jacket is  
Appliances located in a garage or parking specially constructed to function as a drain pan.  
structure shall be installed so that the A water discharge opening is located in either end  
jacket and all piping shall be located or of the pan. The discharge opening(s) used must  
protected so that it is not subject to be piped to a suitable floor drain. If only one  
physical damage by a moving vehicle.  
discharge opening in the jacket pan is piped to a  
floor drain, the unused opening must be plugged.  
5.  
6.  
The appliance must be installed on a level This jacket pan provides an extra margin of  
floor. Shim the base as necessary if protection against water damage on vertical  
leveling is required.  
square or horizontally constructed models.  
The floor on which the appliance is  
installed must be capable of supporting  
the total weight of the water heater when  
CAUTION:  
This water heater, as well as all water  
heaters will eventually leak. Installation of  
the water heater should be accomplished in  
such a manner that if the tank, piping or  
any connections should leak, the flow of  
water will not cause damage to the  
structure. For this reason, it is not  
advisable to install the water heater in an  
attic or upper floor. When such locations  
can not be avoided, a suitable drain pan  
must be installed under the water heater.  
Drain pans may be fabricated or  
purchased from your plumbing wholesaler.  
The drain pan must be piped to an  
adequate drain. Under no circumstances is  
the manufacturer to be held liable for any  
water damage in connection with this  
water heater.  
completely  
filled  
with  
water.  
Combustible floor locations may be used.  
Maintain required clearances from  
combustible surfaces.  
7.  
8.  
The appliance must not be installed on  
carpet.  
The appliance must be installed indoors  
where it is protected from exposure to  
wind, rain and weather.  
9.  
Locate the appliance as close as possible  
to the point of major hot water usage, the  
water piping and branch electrical circuit  
wiring.  
10.  
11.  
Insulate water piping to control heat loss  
and possible condensation.  
The appliance must be located in an area  
that is not subject to freezing. The  
ambient temperature of the space where  
the appliance is installed must not go  
below 32° F (0° C) or above 104° F (40° C).  
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CLEARANCES FROM COMBUSTIBLE CONSTRUCTION  
12"  
12"  
6"  
6"  
36"  
36"  
FIG. 4 Clearances from Combustible Construction  
FIG. 5 Clearances from Combustible Construction  
6"  
12"  
FIG. 6 Clearances from Combustible Construction  
TABLE A  
CLEARANCES FROM COMBUSTIBLE CONSTRUCTION  
Right Side -  
6" (15cm) (24" (0.61m) for high kW vertical square models with an  
additional control panel on right side)  
Rear -  
0"  
Left Side -  
Front -  
Top -  
0"  
36" (0.91m) for service access to controls and heating elements  
12" (30cm) for service access to electrical service, water connections and piping  
1" (25.4mm)  
Water Pipes -  
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Maintain minimum specified clearances for  
adequate operation. All installations must allow  
sufficient space for servicing the electrical  
components, water pipe connections, piping and  
other auxiliary equipment, as well as the appliance.  
TEMPERATURE & PRESSURE  
RELIEF VALVE  
HOT WATER  
OUTLET  
Multiple appliances may be installed in a modular  
water heater installation. Multiple appliances  
may be installed side by side with minimum  
clearance between the sides of adjacent  
appliances because no service access is required  
from the sides on most models. Note that high  
kW input vertical square water heaters may have  
an additional control access panel located on the  
right side of the jacket requiring an additional  
service access from the right side.  
HANDHOLE  
CLEANOUT  
COLD WATER  
INLET  
DRAIN  
FIG. 7 Water Connections- Vertical Round Models  
TEMPERATURE & PRESSURE  
RELIEF VALVE  
MOUNTING  
HOT WATER  
OUTLET  
The water heater should be mounted to the floor  
following applicable architectural and local code  
requirements or accepted standards for the specific  
site and model purchased. In areas prone to seismic  
activity, it is recommended that the water heater be  
mounted to the floor according to recommended  
procedures for the site. In some geographic areas,  
additional strapping or braces may be required,  
consult local codes for specific requirements.  
Proper mounting will help to make the water heater  
less susceptible to seismic damage.  
COLD WATER  
INLET  
DRAIN PAN  
CONNECTION  
WATER CONNECTIONS  
FIG. 8 Water Connections- Vertical Square Models  
HOT WATER  
OUTLET  
TEMPERATURE & PRESSURE  
RELIEF VALVE  
MANWAY (OPTIONAL)  
COLD WATER  
INLET  
DRAIN  
FIG. 9 Water Connections- Horizontal Models  
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(871˚C) to insure a molecular fusing of glass and  
steel to protect the steel base metal against  
corrosion . A magnesium anode(s) is standard to  
help prevent dissipation of the tank material by  
electrolytic action.  
NOTE:  
Before  
making  
any  
connections to the cold water inlet or hot  
water outlet, insure that all piping is clean and  
free of material or scale. This can usually be  
accomplished by blowing out the pipe.Any  
foreign material or scale entering the water  
heater can adversely affect operation and  
performance.  
RELIEF VALVE  
This water heater is supplied with a temperature  
and pressure relief valve(s) sized in accordance  
with ASME Boiler and Pressure Vessel Code,  
Section IV. Some water heaters may be supplied  
with an optional pressure only relief valve. The  
relief valve(s) is installed in the vertical position  
and mounted in the tapping provided in the  
storage tank. No valve is to be placed between  
the relief valve and the water heater. To prevent  
water damage, the discharge from the relief valve  
must be piped to a suitable floor drain for  
disposal when relief occurs. No reducing  
couplings or other restrictions shall be installed in  
the discharge line. The discharge line shall allow  
complete drainage of the valve and line. Relief  
valves should be manually operated at least once  
a year. A relief valve that fails to completely  
reseat and continues to discharge water must be  
immediately replaced with a new, properly sized,  
temperature and pressure relief valve.  
NOTE: ꢁ  
When using copper tubing,  
solder tubing to an adapter before attaching  
to the threaded nipple connection provided  
on the water heater. Soldering directly to the  
threaded connection may harm a lining in the  
nipple or damage the tank lining.  
Inlet and Outlet Connections  
For ease of service, install unions on the cold  
water inlet and hot water outlet of the water  
heater. The cold water inlet connection is located  
on the lower right side of the water heater. A  
manual shutoff valve should be installed  
upstream on the cold water source as an isolation  
device. The hot water outlet connection is located  
on the top center of the water heater. A manual  
shutoff valve should be installed downstream on  
the hot water outlet source as an isolation device  
in case the water heater must be disconnected  
from the system.  
CAUTION:  
Avoid contact with hot  
discharge water. Insure that no one is in  
front of or around the relief valve discharge  
line. Make sure that the extremely hot  
water manually discharged from the relief  
valve will not cause bodily injury or  
property damage.  
STORAGE TANK  
This appliance uses a glass lined steel tank to  
store the heated water for use. The storage tank  
is constructed in accordance with the ASME  
Boiler and Pressure Vessel Code requirements,  
stamped and registered with the National Board  
of Boiler and Pressure Vessel Inspectors. The  
tank is furnished with threaded connections for  
cold water inlet, hot water outlet, a relief valve  
and a drain connection. The storage tank has a  
hand hole for ease of inspection, cleanout and  
service. An optional manhole may be specified  
for greater ease of inspection. The interior of the  
storage tank is glass lined and fired to 1600˚F  
THERMAL EXPANSION OF WATER  
A relief valve that discharges periodically may be  
due to thermal expansion in a closed system. A  
water heater installed in a closed system, such as  
one with a backflow preventer or check valve  
installed in the cold water supply, shall be  
provided with means to control expansion.  
Contact the water supplier or local plumbing  
inspector on how to correct this situation.  
DO NOT plug or cap the relief valve.  
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discharge!  
CATHODIC PROTECTION  
WARNING:  
WATER HEATER IS  
EQUIPPED FOR OPERATION ON ONE  
VOLTAGE ONLY. Check the rating plate on  
the front of the control panel access for the  
correct voltage and phase. DO NOT use this  
water heater with any other voltage other than  
the voltage specified on the rating plate.  
Failure to use the correct voltage can cause  
problems that can result in death, serious  
bodily injury or property damage.  
Hydrogen gas can be produced in a hot water  
system that has not been used for a long period of  
time (generally two weeks or more). Hydrogen  
gas is extremely flammable. To prevent the  
possibility of injury under these conditions, we  
recommend the hot water faucet be open for  
several minutes at a sink close to the water heater  
before you use any electrical appliance which is  
connected to the hot water system. If hydrogen is  
present, there will be an unusual sound such as air  
escaping through the pipe as the hot water begins  
to flow. There should be no smoking or open  
flames near the faucet at the time it is open.  
CAUTION:  
DO NOT CONNECT THE  
WATER HEATER TO AN IMPROPER  
SOURCE OF ELECTRICITY!  
ELECTRICAL CONNECTIONS  
The appliance, when installed, must be  
electrically grounded in accordance with the  
requirements of the authority having  
jurisdiction or in the absence of such  
requirements, with the latest edition of the  
National Electrical Code, NFPA No. 70.  
When the appliance is installed in Canada, it  
must conform to the CAE C22.1, Canadian  
Electrical Code, Part 1 and/or local Electrical Codes.  
All installation procedures involving electric  
power connection should only be performed by a  
trained, certified electrician.  
1. Use copper conductors only. All wiring  
between the appliance and field installed devices  
shall be made with copper wire suitable for at  
least 75° C (167° F) temperature rating. If the  
wiring from an old water heater installation was  
aluminum, replace the old wire with copper wire.  
ELECTRIC  
ACCESS  
HINGED DOOR  
TO ELECTRICAL  
COMPARTMENT  
FIG. 10 Electric Power Connections –  
Electrical Control Panel Round Models  
2. The factory internal wiring is attached to a  
terminal block inside the unit. The branch  
circuit is connected to the terminal block  
through an opening provided on the top of the  
water heater electrical access panel.  
3. Line voltage wire exterior to the appliance  
must be enclosed in approved conduit or  
approved metal clad cable.  
ELECTRIC ACCESS  
HINGED DOOR TO  
ELECTRIC CONTROL  
COMPARTMENT  
4. To avoid serious damage, DO NOT energize  
the appliance until the system is full of  
water. Ensure that all air is removed from the  
storage tank and piping before beginning  
FIG. 11 Electric Power Connections –  
Electrical Control Panel Square Models  
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initial operation. Operation of a water heater  
without a completely filled tank may result in  
serious damage to the appliance and heating  
element burn out.  
STANDARD EQUIPMENT  
Your commercial electric water heater is  
equipped with the following as standard  
equipment.  
5. The water heater should be connected with a  
separate grounded branch circuit with over  
current protection and disconnect switch. The  
water heater should be grounded in accordance  
with national and local codes. A ground  
terminal is provided for ground connection only.  
Low watt density immersion heating  
elements with an incoloy sheath.  
Internal fusing of all elements in  
a
maximum of 48 amp increments provides  
additional safety. Fuse cartridges are  
related at 1,000,000 amps interrupting  
capacity.  
6. Provide the appliance with proper overload  
protection in the branch circuit. It is suggested  
that the electrician size the branch circuit at 125  
percent of the heater ampere rating and further  
increase wire size as necessary to compensate  
for voltage drop in long runs. Branch circuit  
voltage drop should not exceed 3% at the heater.  
A galvanized steel outer jacket and  
electrical control panel are provided.  
Channel iron skid base.  
Electrical control panel is provided with a  
hinged door and key lock.  
A glass lined steel tank constructed to  
ASME specifications and provided with  
magnesium anode(s).  
7. Voltage applied to the heater should not vary  
more than +5% to -10% of the model and  
rating plate marking for satisfactory operation.  
ASME rated temperature and pressure relief  
valve provided by factory to insure safe  
heater operation.  
8. A wiring diagram is provided with the water  
heater for the electricians use.  
Terminal block connections are installed by  
the factory for safe easy wiring connection.  
CAUTION:  
Never turn on the electric  
Manual reset high water temperature limit  
power or attempt to use this electric water  
heater unless it is completely full of water.  
Water must flow from the hot water faucet  
before turning electrical power ON.”  
Operation of a water heater without a  
completely filled tank may result in serious  
damage to the appliance and heating  
element burn out  
control.  
Immersion thermostat (one per 54kW of  
input as standard).  
180˚F (82.2˚C) temperature operation is possible  
to provide water for sanitizing applications.  
Insulated to meet the latest edition of  
ASHRAE  
standards.  
90.1  
energy  
efficiency  
JACKET ASSEMBLY  
3 year limited warranty provides protection  
against failure of tanks due to defects in  
material and workmanship in commercial  
application.  
Outer Jacket The outer jacket assembly is  
constructed from steel, galvanized on both sides.  
The galvanized surface is specially prepared and  
phosphate coated to allow application of a  
multiple coat enamel paint process. This coating  
process insures a long life from the jacket  
assembly.  
Underwriters Laboratories, Inc. listing for  
all models as a commercial electric water  
heater.  
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OPTIONAL EQUIPMENT  
COMPONENTS AND CONTROLS  
The following items are available as extra cost  
options.  
TERMINAL BLOCK  
GROUND LUG  
Electronic low water cut-off prevents  
energizing of the heater when it is not filled  
with water.  
Pilot lights Monitor on-off cycle of  
CONTROL  
CIRCUIT  
FUSE BLOCK  
contactors.  
POWER CIRCUIT FUSE BLOCK  
Manual limiting switches with indicating  
lights to permit heater kW input to be  
manually limited as desired.  
Temperature and pressure gauges are  
available installed flush with the jacket to  
monitor heater performance.  
IMMERSION  
THERMOSTAT  
TRANSFORMER  
Electronic step controller modulates power  
LOW WATER  
CUTOFF  
(IF EQUIPPED)  
CONTACTOR  
(IF EQUIPPED)  
in-put and balances load to demand.  
CONTROL  
CIRCUIT  
FUSE BLOCK  
Safety door interlock prevents opening of  
access door while heater is energized.  
FIG. 12 Electrical Panel Component Location  
Drawing  
Shunt trip disconnect provides power  
disconnect upon  
malfunction.  
a
control sensed  
TERMINAL BLOCK  
Alarm bell provides an audible alarm to  
warn of various control failures.  
Time clock to control off-on cycles of the  
heater as programmed by the owner or  
electric utility requirements.  
Low water pressure switch.  
High water pressure switch.  
LOAD  
LINE  
FIG. 13 Main Power Terminal Block  
A main power terminal block is provided for field  
connection of the branch power supply to the  
electric water heater. All internal power circuits  
to the immersion heating elements are connected  
to the load side of the main terminal block. The  
line side of the terminal block has individual lug  
type connections properly sized for the  
recommended copper field wire size.  
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The power to the immersion electric heating  
elements is switched by a definite purpose  
magnetic contactor. The contactor is supplied  
with 120 VAC from the control circuit when the  
immersion thermostat senses a drop in stored  
water temperature below the desired set point. A  
magnetic coil in the contactor is energized to  
complete the electrical circuit supplying power to  
the immersion heating elements. When the  
thermostat is satisfied, the contactor coil is de-  
energized and power to the heating elements is  
turned off.  
FUSE AND FLUE BLOCKS  
CONTROL CIRCUIT TRANSFORMER  
FIG. 14  
Fuse Block with Power Circuit Fuses  
Each internal power circuit is fused for safety.  
Each power circuit to an immersion element is  
fused at a maximum of 48 amps. Power circuits  
may be fused at lower current levels as needed to  
balance current on three phase units. The power  
circuit fuses are held by a spring loaded fuse  
block rated for the voltage specified to operate  
the water heater.  
The control circuit is also fused on both the  
primary and secondary sides of the control circuit  
transformer.  
FIG. 16 Control Circuit Transformer  
A transformer is used to reduce the line voltage to  
120 VAC for internal control operation. The  
transformer is fused on both the primary and  
secondary side. The common side of the  
secondary control circuit is grounded. The VA  
rating of the control circuit transformer is based  
on the load of the various components in the  
water heater control circuit.  
CONTACTORS  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
Before opening the electrical access panel  
to adjust the thermostat or servicing the  
water heater, make sure the electrical  
supply to the water heater is turned OFF.  
Failure to do this could result in death,  
serious bodily injury or property damage.  
FIG. 15 Magnetic Contactor  
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DANGER:  
IMMERSION THERMOSTAT(S)  
Full power is present whenever the cabinet  
door is opened, even with the pilot  
switch(es) turned off.  
Set temperature control to the lowest setting  
which satisfies the hot water requirements of the  
system. Lower water temperatures help minimize  
scale formation on the heating elements. See  
thermostat information below. For sequencer  
specifications, consult controller literature.  
WATER TEMPERATURE SETTINGS  
FIG. 17 Immersion Thermostat withAdjustment Knob  
This water heater has an adjustable thermostat to  
control water temperature. The thermostat is  
factory pre-set at approximately 125˚ F (51.7° C)  
or less. Households with small children or  
invalids may require a 120˚ F (48.9° C) or lower  
temperature setting to reduce risk of scald injury.  
Some states may require a lower temperature  
setting. Check with your local codes or electric  
utility for local requirements governing the  
temperature setting. Remember, no water heating  
system will provide exact temperatures at all  
times. Allow a few days of operation at the  
setting to determine the correct temperature  
setting consistent with your needs.  
This water heater uses an immersion  
thermostat(s) to activate magnetic contactors  
allowing current to flow to the immersion heating  
elements. The standard control system uses one  
immersion thermostat for each 54kW of electric  
heating power in a water heater. As an option,  
additional immersion thermostats may be  
provided to add additional steps of thermostatic  
control. The sensing bulb for each immersion  
thermostat is immersed in the stored water in the  
tank to provide quick, accurate response to  
changes in water temperature, The thermostat  
sensing bulb is located in the tank just above the  
elements it is controlling. The immersion  
thermostat set point is adjustable by rotating a  
knob on the control. Turning the knob counter  
clockwise decreases the temperature set point and  
turning the knob clockwise increases the set  
point. The temperature setting shown at the top  
of the knob is the selected set point. The  
immersion thermostat has a fixed 6°F (3.3°C)  
differential.  
NOTE: ꢁ  
(1) This water heater, when set at the lower  
temperature setting, is not capable of  
producing hot water of sufficient temperature  
for sanitizing purposes.  
(2) Higher stored water temperature increases  
the ability of the heater to supply desired  
quantities of hot water, however remember:  
TEMPERATURE REGULATION  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
Before opening the electrical access panel  
to adjust the thermostat make sure the  
electrical supply to the water heater is  
turned OFF.  
CAUTION:  
Hotter water increases the  
risk of scald injury. Setting the temperature  
selector dial higher provides hotter water,  
which increases the risk of scald injury.  
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TEMPERATURE ADJUSTMENT  
D A N G E R  
• Water temperature over 125˚F can  
1. Turn OFFthe electrical power to the water  
heater. If the power disconnect point is out of  
sight, lock it in the open (OFF) position  
and tag to prevent unexpected application  
of power.  
cause severe burns instantly or  
death from scalds.  
• Children, disabled and elderly are  
at highest risk of being scalded.  
• See instruction manual before  
setting temperature at heating  
appliance.  
HOT!  
• If this appliance is used to produce  
water that could scald if too hot,  
such as domestic hot water use,  
adjust the outlet control (limit) or  
use temperature limiting valves to  
obtain a maximum water temperature  
of 125˚F. SEE MANUAL.  
2. Open the water heaters electrical access panel.  
BURN  
3. Adjust each immersion thermostat to the  
desired temperature setting by turning the  
adjusting knob. Each thermostat will be  
factory pre-set to approximately 125° F  
(51.7° C) or less as shipped.  
FIG. 18  
WARNING:  
WARNING: SHOULD OVERHEATING  
OCCUR OR THE TEMPERATURE  
CONTROLS FAILTO SHUT OFF,TURN OFF  
OR DISCONNECT THE ELECTRICAL  
SUPPLY AT THE MAIN POWER  
DISCONNECT EXTERNAL TO THE  
APPLIANCE.  
4. Close the water heaters electrical access panel.  
5. Turn ONthe electrical power to the  
water heater.  
CAUTION:  
The maximum temperature  
setpoint that should be set for the  
Immersion Thermostats or programmed  
into the Electronic Temperature Control  
Sequencer is 190° F ( 88° C)  
DANGER:  
Water temperature over 125˚ F (51.7°C)  
can cause severe burns instantly or death  
from scalding.  
ELECTRONIC  
CONTROL SEQUENCER  
TEMPERATURE  
ELECTRONIC TEMPERATURE  
Children, disabled and elderly are at  
highest risk of being scalded.  
See instruction manual before setting  
temperature at heating appliance.  
Feel water before bathing or showering.  
If this appliance is used to produce water  
that could scald if too hot, such as  
domestic hot water use, adjust the outlet  
control (limit) or use temperature  
limiting valves to obtain a maximum  
water temperature of 125˚ F (51.7° C).  
Always close the electrical control panel door  
after making a temperature adjustment. Turn on  
electricity.  
FIG. 19 Electronic Temperature Control  
with Digital Display  
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The water heater uses an optional adjustable Access to the control is achieved by opening the  
electronic temperature control to provide staged hinges control panel door covering the electrical  
ON/OFF control of the electric heating elements. components.  
Four programming keys are  
Operation is based on temperature input from an provided to program set point and differential  
immersion temperature sensor. The sensor is a values for each stage and to control the display.  
positive coefficient platinum thermistor. The The four keys are Select, Up arrow, Down arrow  
sensor is placed in a well located above the and Enter.  
heating elements it is controlling. A liquid crystal  
display is provided to indicate sensed temperature Select Key - Sequentially prompts the user as to  
and operating parameters. The temperature what parameter is being displayed: set point,  
control may operate in as many as four stages of differential, stage energized, operation mode  
control. For more stages of operation, multiple (heat), indication of assigned stage (1,2,3). Once  
electronic temperature control sequencers are the last parameter value has been viewed,  
installed and wired to operate in series.  
pressing the Select key will display the control  
values again from the beginning of the display  
loop.  
Up and Down Arrow Keys - Allow the displayed  
parameter to be increased or decreased. After  
pressing the Select key, a control value can be  
changed by using the Arrow keys. Control  
values will be increased or decreased by 1° F for  
each time the Arrow keys are depressed.  
125  
1 2 3 4  
Enter Key - Places the new value into the  
memory of the microprocessor.  
IMPORTANT:  
A control value or  
operation will not be entered in the memory of  
the microprocessor until the Enter key is  
pressed.  
FIG. 20  
Digital Display and Programming Keys  
Electronic Temperature  
Control  
Control values and operation selection will  
remain in the device memory even after power  
is removed.  
SPECIFICATIONS  
Set Point Adjustment Range: Max setting  
220° F (105° C).  
Select and Enter Keys simultaneously  
pressed - Changes operation mode of the  
control from heat to cool mode. DO NOT  
CHANGE THIS SETTING. This control  
must always be in the HEATposition for  
proper operation of the water heater.  
Temperature Accuracy: +/- 1° F.  
Display Resolution: 1° F via Liquid Crystal  
Display (LCD). Sensor: Thermistor 4.8 ohms/° F.  
When all stages have been programmed the  
display will revert back to sensed temperature  
and load energized status.  
Operating Humidity: 5 - 95% RH  
Noncondensing.  
OperatingAmbientTemperature: -30° to 125° F.  
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point and differential the control will sequence  
both stages on and off with only a slight delay  
DISPLAY  
Once power is applied to the temperature between switching of the stages. The control is  
controller the display will countdown from 210 normally programmed with a few degrees  
until the display reads zero. All outputs are difference between the set point of each stage to  
de-energized at this time. This countdown sequence individual stages on as required by  
process will repeat each time main power is demand. This will allow input to be balanced to  
interrupted. To avoid viewing this entire system demand. The exact settings will be  
countdown, press the Select key. The display will determined by your system hot water  
now show normal readings: load (sensed) requirements.  
temperature and stages energized. At any time  
during the programming procedure, the display Based on your system requirements, determine  
will revert back to showing the sensed the set point and switching differential for each  
temperature and stage status indication 60 stage of operation and enter into the worksheet  
seconds after the last programming key is pushed. below.  
SETUP OF THE TEMPERATURE  
CONTROLLER  
Programming Worksheet  
Stage 1:  
Each stage on the controller has its own  
independent set point and differential which are  
determined by the programming keys. Each  
Set Point 1 ___________ Off at ___________  
Differential 1 ________ On at __________  
stage of heating is de-energized as the sensed Stage 2:  
temperature reaches the programmed set point.  
Each available stage of heating is energized as the  
sensed temperature reaches the set point minus  
the differential.  
Set Point 2 ___________ Off at ___________  
Differential 2 ________ On at __________  
Stage 3:  
Set Point 3 ___________ Off at __________  
Differential 3 ________ On at _________  
EXAMPLE:  
Using stage one of the control as an example, the  
corresponding load would be energized and Stage 4:  
de-energized at the following temperatures based  
on the programmed settings.  
Set Point 4 ___________ Off at __________  
Differential 4 ________ On at _________  
Settings  
These values will be programmed into the  
temperature controller.  
o
Set point: 160 F  
o
Differential: 8 F  
Output Energized  
o
Stage One: Energized at 152 F  
Output De-energized  
o
Stage One: De-energized at 160 F  
Each available stage of operation must be  
programmed with a set point and a differential. If  
two stages are programmed with the same set  
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PROGRAMMING  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
Full power is present whenever the cabinet  
door is open and the main power  
disconnect is in the ONposition, even  
with the pilot switch(es) turned off.  
NOTE: ꢁ  
When power is initially  
applied to a new water heater, the control  
points will be pre-programmed. The  
factory final quality test sets the unit for  
test firing. The preset values are as follows:  
5. To override this time delay, press Select.  
Stage Set Point Differential  
6. Press Select to display the current stage  
1
2
3
4
125˚ F  
123˚ F  
121˚ F  
120˚ F  
2˚ F  
2˚ F  
2˚ F  
2˚ F  
set point.  
7. Press Up Arrow key to increase or Down  
Arrow key to decrease to the desired  
set point.  
Re-program the set points and differentials to  
meet your system hot water requirements.  
8. Press Enter to enter the displayed value  
into memory.  
The operating control uses a Liquid Crystal  
Display for interactive prompting during  
programming and display of sensed and assigned  
set point and differential values. Programming is  
accomplished through the use of the four  
programming keys.  
9. Press Select to display the current stage  
switching differential.  
10. Press Up Arrow key to increase or Down  
Arrow key to decrease to the desired  
switching differential.  
TEMPERATURE ADJUSTMENT  
11. Press Enter to enter the displayed value  
1. Turn OFFthe electrical power to the water  
heater. If the power disconnect point is out of  
sight, lock it in the open (OFF) position and  
tag to prevent unexpected application  
of power.  
into memory.  
12. Repeat steps 6 through 11 to program each  
additional stage.  
13. Press Select, Select, Select, Select (4 times)  
to return to stage 1 parameters. Scroll  
through the programming loop a second  
time to confirm that the appropriate values  
have been entered into memory by  
pressing Select.  
2. Open the water heaters electrical access panel.  
3. Verify that the unit is properly applied and the  
model number on the rating plate correctly  
identifies the unit.  
4. Turn the electrical power switch to the ON”  
position. The control will begin counting  
down from 210. This countdown sequence  
will last for approximately 3-1/2 minutes.  
14. Press Select after viewing the switching  
differential for the final stage to display  
stored water temperature.  
15. Close the water heaters electrical  
access panel.  
16. The temperature control is now ready  
for operation.  
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OE - ROM Error  
NOTE: ꢁ  
The  
control  
values  
The internal ROM of the microprocessor in  
the boilers electronic temperature control is  
defective. This error cannot be field repaired.  
Replace the water heaters electronic  
temperature control.  
programmed into memory will not be lost  
because of a power failure.  
ERROR MESSAGES DISPLAYED BY THE  
ELECTRONIC TEMPERATURE CONTROL  
AE - RAM Error  
There are seven error messages that can be  
displayed in response to software or hardware  
problems with the boilers internal electronic  
temperature control. The error codes that may be  
seen flashing on the display are:  
The internal RAM of the microprocessor in  
the boilers electronic temperature control is  
defective. This error cannot be field repaired.  
Replace the water heaters electronic  
temperature control.  
SF - Sensor Failure  
HIGH WATER TEMPERATURE  
LIMIT CONTROL  
The display flashing SF indicates an  
out-of-range or defective sensor. Make sure  
sensors are properly installed, wired and  
connected to the control. Correct sensor  
installation or replace sensor.  
EF- EEPROM Failure  
The values read form the EEPROM are not  
the same as the values written into the  
EEPROM. This error cannot be field  
repaired. Replace the water heaters  
electronic temperature control.  
CF - Calibration Failure  
FIG. 21  
High Water Temperature Limit Control  
- Fixed Setting  
The calibration resistor reading was not  
within the range of the Analog to Digital  
converter. This error cannot be field repaired.  
Replace the water heaters electronic  
temperature control.  
The unit is equipped with a fixed setting, manual  
reset high water temperature limit control. The  
water heater temperature limit control has a fixed  
limit setting of 195° F (90.6° C). If water  
temperature exceeds the limit set point, the limit  
will break the control circuit and shut down the  
unit. The limit control can only be reset after the  
water temperature has cooled below the set point  
of the limit. The high water temperature limit  
control is mounted on the surface of the tank,  
above the heating element installed at the highest  
point in the tank. The high limit control is reset  
by pushing the red reset button on the control.  
Operation of the limit control usually indicates a  
major problem with the thermostat, contactors or  
heating elements. Do not continue to push the  
OF - Stray Interrupt Failure  
An unused interrupt occurred. This error  
cannot be field repaired. Replace the water  
heaters electronic temperature control.  
CE - Configuration Error  
The device hardware was configured to a  
nonexistent device. This error cannot be field  
repaired. Replace the water heaters electronic  
temperature control.  
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reset multiple times. The source of the problem element blades are mounted on a single hex-head  
must be found and corrected to insure proper screw-in mounting flange. The element flange  
operation. The limit control is covered with an mounts into a 1 1/2NPT threaded connection  
insulation blanket which must be removed to welded to the storage tank. The hex-head screw-  
push the red reset button. The blanket of in mounting flange seals to the tank with an O”  
insulation must be replaced before the power is ring gasket at the base of the threaded portion of  
turned on and the water heater is returned to the flange. The tank flange has a matching recess  
service.  
for the Oring gasket to insure a proper water  
tight seal. . The Oring element gasket must be  
replaced with a new gasket when an element is  
removed for inspection, cleaning or replacement.  
CAUTION:  
to the heater before opening the element  
access panel to reset the high limit control.  
Disconnect the main power  
SAFETY DOOR INTERLOCK (Optional)  
NOTE: ꢁ  
The high limit control will not  
reset until the water temperature has  
dropped below the set point of the high limit.  
IMMERSION HEATING ELEMENT  
FIG. 23 Safety Door Interlock  
The optional safety door interlock is an  
electrically operated locking pawl that is  
energized when main power to the water heater is  
turned ON.The interlock is mounted to the  
inside of the electrical control panel door and  
extends behind a locking flange when energized.  
Main power may be turned off and the electrical  
access door may be opened for service.  
FIG. 22 Immersion Heating Element  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
Before opening the access panel to remove or  
service the immersion heating elements,  
make sure the electrical supply to the water  
heater is turned OFF. Failure to do this  
could result in death, serious bodily injury  
or property damage.  
With the door open, main power may be  
energized if required to service or troubleshoot  
the operation of selected components.  
DANGER:  
The heating input to this commercial electric  
water heater is provide by low watt density  
immersion heating elements. The heating  
elements are constructed from an incoloy sheath  
with a tin plate on the exterior surface. Three  
HAZARD OF ELECTRICAL SHOCK –  
Full power is present whenever the cabinet  
door is opened and main power is turned  
ON, even with the pilot switch(es) turned off.  
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LOW WATER PRESSURE SWITCH  
(Optional)  
LOW WATER CUTOFF (Optional)  
A low water pressure switch is available as an  
option on this water heater. A water pressure  
switch is used to monitor the water pressure in the  
water heater storage tank. If the water pressure  
drops below an adjustable set point, the control  
circuit is opened and operation of the water  
heater is shut down. The low water pressure  
switch may be specified with either a auto-reset  
function or a manual reset function on low water  
pressure.  
LED  
Control Board  
HIGH WATER PRESSURE SWITCH  
(Optional)  
Probe  
FIG. 24 Electronic Low Water Cut-off Control  
This water heater may be equipped with an  
optional electronic low water cut-off installed at  
the factory. This low water cut-off device uses a  
water level sensing probe located above the  
heating element installed in the highest point in  
the storage tank. If the internal water level drops  
below this point, the low water cut-off will shut  
down operation of the heating elements. An  
electronic type low water cut-off is available as a  
factory supplied option on all models. The  
optional electronic low water cut-off has an LED  
located on the main circuit board. This LED will  
be illuminated and the control circuit will be  
completed between the common and normally  
open contacts on the circuit board when the  
sensing probe is below the water level in the  
storage tank. An optional manual reset function  
and test button is available on the electronic low  
water cut-off. The operation of a low water cut-  
off should be inspected every six months.  
FIG. 26 High Water Pressure Switch  
A high water pressure switch is available as an  
option on this water heater. A water pressure  
switch is used to monitor the water pressure in the  
water heater storage tank. If the water pressure  
rises above an adjustable set point, the control  
circuit is opened and operation of the water  
heater is shut down. The low water pressure  
switch may be specified with either a auto-reset  
function or a manual reset function on high water  
pressure.  
MANUAL LIMITING SWITCHES (Optional)  
As an option, a switch or multiple switches may be  
provided to interrupt the 120 VAC control circuit  
feed to the contactor coil or coils from the  
immersion heating thermostat(s). This switch may  
be used to manually turn off a portion of the heating  
element input. This feature may be used to reduce  
FIG. 25 Low Water Pressure Switch  
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electrical input of the water heater in the summer  
months when ground water temperatures are  
PILOT LIGHTS (Optional)  
warmer and full electrical input from the The water heater may be provided with optional  
immersion heating elements is not required. The pilot lights to provide an external indicator for  
water heater may be restored to full input by each contactor or stage of heating elements that is  
moving the switches to the ONposition.  
energized. Each pilot light is wired in parallel  
with the 120 VAC control circuit feed to the  
contactor coil(s). The pilot will be turned on as  
the contactor coil(s) is energized by the  
temperature controls.  
TIME CLOCK (Optional)  
SHUNT TRIP DISCONNECT (Optional)  
Shunt trip disconnect provides a power  
disconnect upon a control sensed malfunction via  
a circuit breaker installed in the main power  
supply to the water heater. The circuit breaker is  
shipped as a separate item that must be field  
installed. The water heater 120 VAC control  
circuit provides a feed to the circuit breaker that  
will shut down main power on either a low water  
level condition (if equipped) or high water  
FIG. 27 Time Clock  
The water heater may be provided with an temperature. Once the water heater is installed  
optional time clock. The time clock will allow and all power is connected, the toggle switch that  
the water heater to be turned on and off with a arms the shunt trip must be placed in the on  
pre-set schedule. The time clock may be position to provide the shunt trip function on the  
specified with a 24 hour scheduling period or desired control sensed malfunction.  
with a 7 day scheduling period. By the  
adjustment of the setpoints on the time clock, the  
water heater may be turned off when hot water is  
not needed or in periods when the building may  
not be occupied. The time clock allows the water  
heater to automatically cycle on in advance of the  
time when hot water may be needed. This will  
insure that hot water is always available yet save  
energy when there are scheduled periods when  
there will be no requirement for hot water. This  
feature is especially useful for schools and  
building that are occupied on a fixed schedule.  
As an additional feature, time clocks may be  
furnished with a spring wound carry-over  
function to insure that a switching schedule is  
maintained in periods where there may be power  
interruptions. The time clock works by making  
and breaking the 120 VAC control circuit to the  
contactor coils to shut down operation of the  
heating elements in the desired time periods.  
ALARM BELL (Optional)  
FIG. 28 Alarm Bell  
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An alarm bell with silencing switch is available as the water heaters temperature and pressure relief  
an option on this water heater. The alarm bell can valve opens to relieve the excess pressure. The  
be used to provide an audible indication of a temperature and pressure relief valve is not  
control sensed malfunction. The user must intended for the constant relief of thermal  
specify the safety function or multiple safety expansion. This is an unacceptable condition and  
functions that the alarm bell will sound on when must be corrected. Do not plug or cap the relief  
the water heater is ordered from the factory. The valve discharge! A properly sized expansion  
alarm bell typically is used to indicate a low water tank is typically installed in the potable water  
condition or a high water temperature condition. system to relieve the pressure built up by thermal  
The alarm is furnished with a silencing switch to expansion of heated water. Consult your local  
turn off the audible alarm while trouble shooting plumbing contractor and plumbing wholesaler for  
a control sensed malfunction that is indicated by assistance in properly selecting an expansion tank  
an audible alarm. Once the control sensed for your system.  
malfunction is corrected, the silencing switch  
must be returned to the ONposition to As the water heater operates, there may be noises  
re-establish the audible alarm function.  
generated by the expansion and contraction of the  
metal parts of the water heater and related piping.  
These noises may occur during periods of heat up  
or cool down. They do not represent harmful or  
dangerous conditions.  
START-UP PROCEDURE  
Never operate the heating elements without  
being certain the water heater is filled with  
water and a temperature and pressure relief  
valve is installed in the relief valve opening on  
top of the heater.  
FILLING THE WATER HEATER  
1. Insure that the electrical power to the water  
heater is in the OFFposition. If the power  
disconnect point is out of sight, lock it in the  
open (OFF) position and tag to prevent  
unexpected application of power.  
The pilot switch(es) (if equipped) mounted on the  
control cabinet permit the heater to be turned on and off  
without having to operate the electrical disconnect  
switch. The pilot switch interrupts only the 120 VAC  
control circuit in the water heater. Full power is still  
present at the terminal block, fuses and contactors.  
2. Close the water heater drain valve(s).  
DANGER:  
3. Open a nearby hot water faucet to allow the  
air in the system to escape as the tank fills.  
Full power is present whenever the cabinet  
door is opened, even with the pilot  
switch(es) turned off.  
4. Fully open the cold water inlet valve to the  
water heater to begin filling the heater and piping.  
THERMAL EXPANSION OF WATER  
NOTE: ꢁ  
The cold water supply must be  
A relief valve that discharges periodically may be  
due to thermal expansion in a closed system.  
Many water systems are equipped with pressure  
reducing valves, check valves or back flow  
preventers which may cause the water system to  
be closed. As water is heated it will expand in  
volume due to thermal expansion. The system  
must make allowance for this expansion. If an  
expansion tank is not provided in the system,  
water pressure may increase to the point where  
left in the open position when the water  
heater is in use.  
5. Check the nearby hot water faucet to verify  
that air is exiting the tank as it fills with water.  
Allow water to run until a constant flow is  
obtained at the faucet. This will insure that all  
air is purged from the system.  
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13. As the water heater starts heating, check the  
contactors for buzzingor chattering”  
during operation. If noise is detected, turn off  
main power, open the control panel and clean  
the contact points of the magnetic  
contactor(s). Remove any dust, dirt or foreign  
matter that may have found its way into the  
contactor or other electrical components in  
the control panel during shipping, installation  
or service.  
CAUTION:  
The power supply must  
remain off until the water heater and all  
related piping are completely filled with water  
to insure that there will not be a possible  
problem with heating element burn out.  
6. While the tank is filling, open the electrical  
control panel and set the thermostat(s) to the  
desired water temperature. If equipped with  
multiple thermostats, all individual  
thermostats may be adjusted to the same  
temperature set point or they may be set a 2°F  
to 4°F (1˚C to 2˚C) apart to step the elements  
on in stages.  
14. Close the electrical control panel and turn on  
main power.  
15. The water heater is now ready for normal  
operation.  
7. Insure that any pilot switches or manual  
limiting switches are placed in the  
ONposition.  
INITIAL START-UP CHECKS  
8. When a constant flow is obtained at the  
faucet, it may be turned off. The temperature  
and pressure relief valve should be manually  
opened to insure that there is no captive air in  
the storage tank. A constant stream of water  
must flow from the manually opened relief  
valve. Release the handle on the relief valve  
and allow it to close after water flow is observed.  
The following checks should be made by the  
installer when the water heater is placed into  
operation for the first time.  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
Before opening the access panel to perform  
service on any electrical component, make  
sure the electrical supply to the water  
heater is turned OFF. Failure to do this  
could result in death, serious bodily injury  
or property damage.  
9. Carefully check the tank, pipe and fittings for  
any sign of a water leak. Immediately repair  
as needed. Open the access door to the  
immersion heating elements and check for  
leaks at the element mounting flanges. If any 1. Allow the water heater to heat for  
leak is detected, tighten the screwin element.  
approximately thirty minutes after following  
the filling and start up procedures.  
START-UP  
10. Insure that the electrical access panel (field  
wiring compartment) is closed and the  
heating element access panel is in place  
before proceeding.  
2. Turn off the main electrical power to the  
water heater. If the power disconnect point  
is out of sight, lock it in the open (OFF)  
position and tag to prevent unexpected  
application of power.  
11. After assuring that the tank is completely  
filled with water and no leaks are detected,  
you are now ready to start operation of the  
water heater.  
3. Open the electrical control panel door and  
feel each wire connection and fuse clip for  
excessive temperature. If any connection is  
found to be excessively hot, check the  
tightness of the connection. Check all factory  
internal wiring connections and the field  
made main power connections for tightness.  
12. Turn on the electric power at the main  
disconnect point. The contactors should be  
energized as the elements start to heat the  
water in the tank.  
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4. Close and lock the electrical control panel door. 6. The water heater is now shut down and ready  
for service or maintenance.  
5. Turn on the main electrical power to the  
water heater.  
7. Follow the filling and start up procedure to  
place the water heater back into service.  
6. Temperature control and contactor operation  
should be checked by allowing the water  
heater to come up to temperature and shut off  
automatically.  
MAINTENANCE  
Listed below are items that must be checked to  
insure safe reliable operations. Verify proper  
7. The water heater is now ready continuous operation after servicing.  
normal operation.  
WARNING:  
HAZARD OF ELECTRICAL SHOCK –  
SHUTDOWN PROCEDURE  
Draining the Water Heater  
Before opening the access panel to perform  
service on any electrical component, make  
sure the electrical supply to the water  
heater is turned OFF. Failure to do this  
could result in death, serious bodily injury  
or property damage.  
1. Turn off the main electrical power to the  
water heater. If the power disconnect point is  
out of sight, lock it in the open (OFF)  
position and tag to prevent unexpected  
application of power.  
CAUTION:  
Label all wires prior to  
disconnection when servicing controls.  
Wiring errors can cause improper and  
dangerous operation.  
2. Turn the valve in the water heaters cold water  
supply to the closed or OFFposition.  
3. Turn the valve in the water heaters hot water  
outlet to the closed or OFFposition.  
TEMPERATURE AND PRESSURE  
RELIEF VALVE OPERATION  
4. Manually open the temperature and pressure  
relief valve to remove any pressure from the  
storage tank.  
The temperature and pressure relief valve(s)  
should be manually operated at least once a year.  
A relief valve that fails to completely reseat after  
manual operation and continues to discharge  
water must be immediately replaced with a new,  
properly sized, temperature and pressure relief  
valve.  
CAUTION:  
Any water discharged from  
the manually opened relief valve may be hot  
and cause a scald injury.  
5. Allow the system to cool and then open the  
drain valve to empty the storage tank. It will  
be necessary to manually hold the  
temperature and pressure relief valve in the  
open position to break the vacuum in the tank  
and allow it to vent and drain. Insure that the  
water heater drain is routed to a properly sized  
floor drain to allow the water to be removed  
from the tank. If a floor drain is not available,  
a hose may be attached to the water heater  
drain to take the water outdoors.  
The relief valve(s) should be installed in the  
vertical position and mounted in the tapping  
provided in the storage tank. No valve should be  
placed between the relief valve, and the water  
heater. To prevent water damage, the discharge  
from the relief valve must be piped to a suitable  
floor drain for disposal when relief occurs. No  
reducing couplings or other restrictions shall be  
installed in the discharge line. The discharge line  
shall allow complete drainage of the valve and  
line. The discharge line from the relief valve  
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should be metallic pipe or a high temperature Water heater maintenance includes periodic tank  
plastic pipe (CPVC, etc.) to insure that hot water flushing, cleaning and removal of lime scale from  
flow will not damage the discharge piping from the heating elements. Where used, the water  
the relief valve.  
heating system circulating pump should be oiled.  
CAUTION:  
FLUSHING THE STORAGE TANK  
Avoid contact with hot  
discharge water. Insure that no one is in  
front of or around the relief valve  
discharge line. Make sure that the  
extremely hot water manually discharged  
from the relief valve will not cause bodily  
injury or property damage.  
1. Turn off main power at the electrical  
disconnect switch.  
2. Open the drain valve. Allow water to flow  
until it runs clean.  
3. Close the drain valve when finished flushing.  
WATER CHEMISTRY  
4. Turn on the electrical disconnect switch  
(after filling).  
In hard water areas, water treatment should be  
used to reduce the introduction of minerals to the  
system. Minerals in the water can collect in the  
storage tank and on the immersion heating  
SEDIMENT REMOVAL  
elements causing noise on operation. Excessive Water born impurities consist of dissolved  
build up of minerals on the surface of the heating minerals which precipitate out of the heated water  
elements can reduce the service life of the and fine particles of soil and sand which settle out  
elements and lead to a non-warrantable failure.  
and form a layer of sediment on the bottom of the  
tank. In time, if not removed, the level of  
Proper operation of this electric water heater is sediment might reach the heating elements.  
based on heating potable water with a hardness of  
5 to 25 grains per gallon and a total dissolved For convenience, sediment removal and element  
solids not exceeding 350 PPM. Consult the lime scale removal should be performed at the  
manufacturer when heating potable water same time as follows:  
exceeding these specifications. Heating of high  
hardness and/or high total dissolved solids water Sediment and Lime Scale Removal  
may require frequent cleaning of the storage tank  
and heating elements to achieve proper operation. Sediment and lime scale accumulation on the  
The higher the level of dissolved solids or water heating elements is a normal condition  
hardness, the faster the dissolved minerals in the common to all immersion type elements. Factors  
water will precipitate out and form scale deposits which affect the amount of this formation are:  
on the heating elements and in the storage tank.  
The level of scale formation is also accelerated 1. Amount of hot water used. As the volume  
as stored water temperature increases. Water with  
a hardness of less than 5 grains per gallon will  
of water increases, more scale results.  
usually have a low pH which can be aggressive 2. Water temperature. As the temperature of the  
and corrosive causing non-warrantable damage to  
the storage tank, heating elements and associated  
piping. Corrosion due to water chemistry  
water is increased, more scale is deposited on  
the elements.  
generally shows up first in the hot water system 3. Characteristics of water supply. Regardless  
because heated water increases the rate of  
corrosive chemical reactions.  
of water treatment, the elements should be  
examined regularly.  
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Scale accumulation in the bottom of the storage 3. Disconnect the wires attached to the element  
tank may be removed by turning off main power  
and draining the tank. Once all water is removed,  
the hand hole access can be removed. This will  
terminals. Try not to disturb the wiring  
unnecessarily and reconnection will be easier.  
allow large accumulations of scale to be cleaned 4. Loosen the screw-in element flange with a  
from the bottom of the tank.  
socket and breaker bar. Do not use an impact  
gun (air or electric) to remove the element  
flanges from the tank. Mark the location of  
each element in the tank openings so they may  
be returned to their original position.  
All gaskets on disassembled  
clean-out openings must be  
NOTE: ꢁ  
replaced with new gaskets on re-assembly.  
Gaskets are available from your distributor.  
5. Remove the elements from the opening with a  
twisting, pulling action if the elements are  
scaled beyond the size of the tank flange  
openings. Brush loose scale from elements.  
Water scale accumulations on the immersion  
heating element reduce the ability of the elements  
to heat water and may cause noise to occur during  
operation. It is recommended that a heating  
element be removed at least once a year for 6. Place scaled ends of heating elements into a  
examination. If it is scaled, all of the elements  
should be removed and cleaned. The element  
gasket must be replaced when the element is  
removed for cleaning.  
delimer solution and allow scale to dissolve.  
Do not permit delimer or water to contact  
heating element electrical terminals.  
7. Flush clean ends of elements with water when  
deliming or cleaning is completed.  
Small accumulations of lime scale may be  
removed with a stiff bristle brush. Severe  
accumulations of lime scale should be removed 8. Clean remaining gasket recess on each  
by dissolving the accumulation in a commercial  
delimer. Do not use muratic or hydrochloric acid  
base deliming solutions to remove lime scale  
screw-in element flange. Do not reuse  
element gaskets.  
from the elements. Do not pour delimer into 9. Install a new gasket on each element. Install  
tank. Deliming solutions may damage the  
glass lined interior of the tank  
element into the tank opening where it was  
originally installed. Tighten the flange with  
the socket and breaker bar used to remove  
the element.  
DANGER:  
Keep all delimers away from anode rods to  
prevent the formation of flammable and  
explosive gas.  
10.Attach wires to element terminals from which  
they were removed.  
11.Follow FILLING THE WATER HEATER”  
instructions to restore hot water service.  
Check for water leaks around elements and  
proper operation when heater is filled.  
1. Drain the heater following SHUTDOWN  
PROCEDUREinstructions.  
2. On some high kW input models it is necessary  
to remove a side panel to gain access to the  
exposed ends of the elements which are not  
accessible through the front element access door.  
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5. Cold incoming water temperature will  
lengthen the time required to heat water to the  
desired temperature. If the heater was  
installed in the summer when incoming water  
temperature was warm, colder ground water  
in the winter months can create the effect of  
less hot water.  
TROUBLE SHOOTING  
Checklist  
Before calling for service, check the following  
points to see if the cause of trouble can be  
identified and corrected. Reviewing this checklist  
may eliminate the need of a service call and  
quickly restore hot water service.  
6. Look for wasted hot water and leaking or  
open hot water faucets.  
Not enough or no hot water  
1. Ensure that the electrical disconnect switch  
serving the water heater is in the ON”  
position. The pilot switch(es) on the cabinet  
should also be in the on position. In some  
areas, water heater electrical service may be  
limited by the power company. If the heater  
operates on a controlled circuit, heater  
recovery may be affected.  
7. Sediment or lime scale may be affecting water  
heater operation. Refer to Maintenance”  
for details.  
Water is too hot  
Refer to Temperature Regulationand reset the  
thermostat setpoint to a lower temperature that  
will meet requirements for hot water  
2. Check the fuses. The electrical disconnect  
switch usually contains fuses. The water  
heater has fuses located behind the cabinet  
front door. When replacing internal fuses in  
the water heater control panel, insure that the  
same type and size of fuse is used.  
Water heater makes sounds  
1. Sediment or lime scale accumulation on the  
elements causes sizzling and hissing noises,  
when the heater is operating. If this occurs,  
the tank bottom and elements should be  
cleaned. Refer to MAINTENANCE”  
for details.  
3. If the water was excessively hot and is now  
cold, the manual reset high limit may  
have operated.  
2. Some of the electrical components of the  
water make sounds which are normal.  
Contactors will clickor snap as the heater  
starts and stops. Transformers and contactors  
often hum.  
To reset, turn off electricity and push the reset  
button. The high limit is located above the  
upper most heating element in the storage tank.  
On some high input models additional hi  
limits may be located behind the side access  
panel. Repeat operation of the high  
temperature cut-off should be investigated by  
your mechanical contractor or by a qualified  
technician. A contactor or thermostat may be  
malfunctioning.  
Water leakage is suspected  
1. Check to see if the drain valve is  
tightly closed.  
2. The apparent leakage may be condensation  
which forms on cool surfaces of the heater  
and piping.  
4. The capacity of the heater may have been  
exceeded by a large demand for hot water.  
Large demands require a recovery period to  
restore water temperature.  
3. If the outlet of the relief valve if leaking, it  
may represent:  
a. Excessive water pressure.  
b. Excessive water temperature.  
c. Faulty relief valve.  
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Excessive water pressure is not the most common  
cause of relief valve leakage. It is often caused by  
a closed system.A check valve, back flow  
preventer or pressure reducing valve, in the inlet  
system will not permit the expanded hot water  
volume to equalize pressure with the main. A  
relief valve must release this water or the water  
heater and plumbing system will be damaged.  
When such a condition is encountered, local  
codes or inspection agency should be consulted to  
determine which of the following procedures is  
acceptable in your area.  
Installation of an expansion tank.  
Removal of the check valve.  
4. Examine the flange area of the elements for  
gasket leakage. Tighten the screw-in flange  
or, if necessary, follow the Water and Lime  
Scale Removalprocedure to remove the  
element and replace the Oring gaskets that  
seal each element.  
IF YOU CANNOT IDENTIFY OR  
CORRECT THE SOURCE OF  
MALFUNCTION:  
1. Place the water heater electrical disconnect  
switch on the OFFposition.  
2. Contact your mechanical contractor or  
service technician.  
CP-5M-5/02-Reprinted in U.S.A.  
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