OPERATING AND MAINTENANCE MANUAL FOR
COMMERCIAL HORIZONTAL CEILING-HUNG
ELECTRIC WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODELS “ HE and HSE ”
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TABLE OF CONTENTS
SECTION TITLE
PAGE #
I
II
GENERAL DESCRIPTION AND CONSTRUCTION
INSTALLATION
5
8
III
IV
V
SCHEDULED MAINTENANCE AND OPERATION
TROUBLESHOOTING
11
13
14
20
SERVICING AND REPLACEMENT OF PARTS
MISCELLANEOUS CHARTS AND FORMULAS
VI
3
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4
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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This book describes a packaged electric water heater that is a stationary, self-contained unit. The
complete assembly consists of the storage tank, immersion electric heating element(s), thermostat,
safety relief valve, safety high temperature cut out, and any other required electrical operating control.
Optional equipment may be supplied with your unit. Please consult the product drawing for details
specific to your assembly. The unit is factory assembled, insulated, jacketed, wired, tested, and ready
for electrical and plumbing service connections.
CONSTRUCTION
TANK
The standard storage tank is constructed of steel and internally lined with specially formulated
Hydrastone cement to a ½-inch minimum thickness. The tank is designed for a maximum allowable
working pressure of 150 psi (300 psi TP).
TANK CONNECTIONS
The heater is supplied with separate cold water and hot water connections. Water entering the cold
water inlet is deflected by means of a baffle within the tank. A ¾-inch FNPT connection is located on
the side of the heater for mounting a combination safety temperature and pressure relief valve. An
overflow line should be utilized from the relief valve outlet to a floor drain. A ¾-inch GHT connection
is supplied for draining. See drawing for locations and sizes.
CONTROL THERMOSTAT
The water heater is supplied with an immersion thermostatic switch that
is installed and wired at the factory. The immersion thermostat can be
adjusted through a range of 100° - 190° F and is adjustable with a flat tip
screwdriver. An optional low range (30° - 110° F) thermostat may be
supplied.
5
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TEMPERATURE HIGH LIMIT SWITCH
As a safety device, a surface mounted high temperature cut-off switch with manual reset, factory set at
190° F is provided. In the event of an over-temperature condition, the thermostat will disengage the
power from the unit, (in the HSE model the thermostat will disengage the operating coils in the
magnetic contactor). The high limit must be manually reset thereafter to restart the heater.
Manual Reset
HEATING ELEMENT
The water heater is supplied with an electric immersion heating element assembly(s), composed of
incoloy or copper sheathed elements that are brazed into a brass flange. Each assembly is fastened to a
corresponding tank flange using a gasket and four (4) 3/8-16 x 1-inch long hex head steel bolts and
nuts. See drawing for voltage and power ratings.
3-Phase Incoloy Sheathed Element
Single Phase Copper Sheathed Element
6
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MAGNETIC CONTACTOR (HSE Models Only)
The magnetic contactor(s) is a heavy-duty resistive load type
rated for 100,000 cycles. The contactor supplies power to the
heating element(s) based on the resistive load (non-inductive) of
the heater only when the thermostatic switch is engaged, thereby
pulling in the contacts until the desired temperature is reached.
At this point, the contacts will drop out, which in turn
disconnects power from the elements.
OUTER SHELL AND INSULATION
The tank is encapsulated in 2-inch thick polyurethane foam insulation. The insulation is protected by a
high impact non-corroding colorized composite protective jacket.
DRIP PAN (Optional)
A drip pan assembly may be supplied as an option with the unit. It is designed to mount directly
beneath the water heater as shown in the sketch on page 4.
SWAY RESISTANT MOUNTS (Optional)
Optional sway resistant mounts may be supplied to further secure the tank from longitudinal
movement. Additional 3/8” diameter threaded rods (not supplied) are fastened into additional nuts that
are welded to the support mount.
3/8” Threaded Tie-Rod
Connected to Building
Structure
Standard Mount
Optional Sway Resistant Mount
7
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SECTION II – INSTALLATION
WARNING / CAUTION
DO NOT TURN ON THE ELECTRIC POWER SUPPLY to this equipment until heater is
completely filled with water and all air has been released. If the heater is NOT filled with water when
the power is turned on, the heating elements will burn out.
For protection against excessive pressures and temperatures, local codes require the installation of a
temperature-and-pressure (T&P) relief valve certified by a nationally recognized laboratory that
maintains periodic inspection of production of listed equipment of materials, as meeting the
requirements for Relief Valves and Automatic Gas Shutoff for Hot Water Supply Systems. ANSI
Z21.22-1971. THE CUSTOMER IS RESPONSIBLE TO PROTECT PROPERTY AND
PERSONNEL FROM HARM WHEN THE VALVE FUNCTIONS.
All water heaters have a risk of leakage at some unpredictable time. IT IS THE CUSTOMER'S
RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER ADEQUATE MEANS, SO THAT
THE RESULTANT FLOW OF WATER WILL NOT DAMAGE FURNISHINGS OR PROPERTY.
WATER HEATER PLACEMENT
1. Locate heater in a dry location nearest to the point of most frequent hot water use.
2. Mount tank using 3/8” diameter threaded rod (not supplied) to suitable ceiling supports (not
supplied).
3. Install 3/8” diameter threaded rod (not supplied) into the four (4) mounting assemblies on the
tank.
4. Install drip pan, if supplied.
5. The water heater should be protected from freezing and waterlines insulated to reduce energy
and water waste.
6. Leave a minimum of 13” clearance for element withdrawal, if necessary.
7. Do not install in an area where flammable liquids or combustible vapors are present.
8
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PIPING INSTALLATION
NOTE: The most effective means for preventing deterioration from accelerated corrosion due to
galvanic and stray current is the installation of dielectric fittings/unions. The installation of these
fittings is the responsibility of the installing contractor.
1. Thread cold water inlet and diffuser assembly into tank. Diffuser slots must be pointing down
toward the bottom of the tank.
Cold Water Inlet
Diffuser
Diffuser Slots
Drain Valve
2. Connect the cold water inlet and hot water outlet to the appropriate connections as shown;
refer to the drawing for location and sizes.
3. Install in-line vacuum breaker, if supplied.
4. Install in-line pressure and temperature gauge, if supplied.
5. Install the combination temperature and pressure safety relief valve in the tapping provided.
Note that this is required by law for safety considerations.
Outlet to floor drain
Install into provided tapping
Manual Release
Lever
Temperature Probe
6. Install a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of any type
should be installed between the relief valve and tank or in the drain line.
9
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FILLING THE HEATER
1. Completely close the drain valve.
2. Open the highest hot water faucet to allow all air to escape from piping.
3. Open the valve to the cold water inlet and allow the heater and piping system to completely
fill, as indicated by a steady flow of water from the open faucet.
ELECTRICAL INSTALLATION
1. Enter electric enclosure with properly sized feeder leads. Single-phase installations require
two (2) leads; three phase installations require three (3) leads.
2. Install these power leads onto terminals ‘1’ and ‘3’ of the high temperature cut-off, for single
phase installation, or the magnetic contactor for 3-phase installation.
3. Torque screws per torque chart included in Section VI.
4. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed
3. After the water is heated for the first time, monitor the water temperature as described in
Section III, Quarterly Inspection.
10
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SECTION III - SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before performing any maintenance procedure, make certain power supply is OFF and cannot
accidentally be turned on.
MAINTENANCE AND OPERATION
The water heater is automatic in its operation. It will maintain a full tank of water at the temperature
setting of the thermostat. The water heater should not be turned on without first making sure that the
tank is full of water and that all air has been released.
FREEZING
The tank should be fully drained in the event the electricity has been turned off and if there is danger
of freezing.
QUARTERLY INSPECTION
1. Monitor thermostat
a. Let water heater completely heat to a designated thermostat setting.
b. After thermostat satisfies (that is, when the thermostat actually clicks off), draw water from
heater.
c. Compare water temperature of drawn water to the temperature setting of the thermostat when
it satisfies. Normal variation between the two points is approximately + 5°F.
d. If these two readings do not coincide within acceptable tolerances and verification has been
made of the accuracy of the temperature-reading gauge, replace the thermostat.
2. Lift test lever on relief valve and let water run through valve for a period of approximately 10
seconds. This will help flush away any sediment that might build up in water passageways.
3. Inspect element flange for leakage as follows:
a. Shut off Power Supply.
b. Remove element housing cover.
c. Visually inspect heating element gasket for evidence of leaks.
d. Rub finger around gasket that is between the heating element and tank flange for any
evidence of moisture. If moisture is present or a water drip is observed, follow procedure
outlined in Section V.
11
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4. Inspect ceiling supports for tightness and/or damage.
5. Check for loose electrical connections. Tighten as necessary.
ANNUAL INSPECTION
1. Flush tank as follows
a. Shut off power supply.
b. Close valve on hot water outlet piping.
c. Open valve on drain piping.
d. Cold water inlet line pressure will be strong enough to flush sediment from the bottom of the
tank out through the drain. Let water run for 3-4 minutes.
e. Close drain valve.
f. Open hot water valve.
g. Turn power supply ON.
12
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SECTION IV – TROUBLESHOOTING
Symptom
No hot water
Probable Cause
Circuit breaker tripped at source. Reset circuit breaker.
Corrective Action / Remedy
High limit switch tripped.
Reset high limit switch.
Loose wires.
Tighten wires. Torque screws per torque
chart included in Section VI.
Heating element inoperable.
Check heating element operation by
clamping an Amprobe around each wire
to the element. The ampere reading
should agree with the nameplate ‘AMP’
figure.
Low line voltage.
Faulty thermostat.
Have source electrical system checked
by an electrician.
Move thermostat dial through full range.
A definite ‘click’ should be heard. If not,
replace thermostat.
Magnetic contactor does not
energize.
Replace complete magnetic contactor.
Because of the design of this particular
contactor, it is more desirable to replace
complete control rather than rebuilding
coil, contacts and springs, etc.
Check thermostat adjustment. Monitor
thermostat as described in Section III,
Quarterly Inspection. Replace if
necessary.
Water temperature
below settings at all
times
Faulty thermostat.
Heating element not working on Check to see that heating element is
all phases
working on all phases, by checking the
resistance (ohms) value for each
element and comparing with the chart
included in Section VI.
Heater improperly sized
Verify heater is properly sized for the
flow rate and temperature rise of your
system. See formulas included in
Section VI. Replace elements with
proper size as necessary.
Relief valve discharges
continuously
Excessive temperature or
pressure in tank
Temperature and pressure relief valves
are made to operate if the water
temperature exceeds 210°F or water
pressure exceeds the pressure rating of
the safety relief valve. If trouble is
excessive temperature, then thermostat is
not shutting off at the right setting and
thermostat must be replaced.
13
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SECTION V - SERVICING & REPLACEMENT OF PARTS
WARNING / CAUTION
Before servicing or replacing any part make sure to turn the power supply switch to the OFF position.
SURFACE TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover.
3. Disconnect the four (4) 14 gauge wires.
Control Wires
4. Remove the two (2) mounting screws.
Mounting Screws
5. Replace control and install new high limit switch by performing above steps in reverse order.
14
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HEATING ELEMENT
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on outgoing
water line.
5. Drain water from tank.
6. Disconnect the wires from the heating element terminals.
7. Remove the 3/8-16 nuts.
Tank Flange
Element Terminals
Nuts
8. Withdraw element assembly and remove gasket.
Gasket
Element Assembly
9. Install new gasket and insert new heating element.
10. For 3-phase heaters, rewire the element according to the voltage and phase rating of the unit
as shown below. For single phase operations, connect wires to terminals.
11. Fill tank and check around gasket for any leaks.
15
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IMMERSION THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Remove high limit cover screw and cover.
Cover
Cover Screw
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tube
5. Remove capillary tube and bulb from thermowell.
6. Remove two (2) mounting screws.
Mounting Screws
7. Replace thermostat using reverse procedure. (Note: Be sure to
place capillary tube into slot in base prior to installing cover.)
17
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MAGNETIC CONTACTOR
1. Disconnect power from unit.
2. Disconnect line and load wires to contactor.
3. Disconnect two (2) 14 gauge control circuit wires.
Control Wires
Line Wires
Load Wires
4. Loosen two (2) holding screws and remove contactor.
Mounting Screws
(Bottom screw not shown)
5. Replace with new contactor using reverse
procedure.
18
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RELIEF VALVE
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Lift test lever on relief valve to relieve pressure in tank.
4. Disconnect overflow piping.
5. Unscrew relief valve, remove assembly and replace with new one.
6. Connect overflow piping.
7. Turn on incoming water supply and check for leaks.
8. Turn safety switch to ON position.
Test Lever
Overflow Piping Outlet
Tank Connection
Temperature Probe
19
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SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS
FORMULAS
3-PHASE ELEMENT CHART
Resistance (Ohms)
Power (kW)
208V 240V 480V
Immersion
Length
Element
Part #
Hairpin
57.6
43.2
34.4
27.9
21.6
17.1
14.4
12.1
9.1
1 Φ
19.2
14.4
11.5
9.3
7.2
5.7
4.8
4.0
3 Φ DELTA 3 Φ WYE
2-38683N
3-38683N
4-38683N
5-38683N
6-38683N
7-38683N
8-38683N
9-38683N
10-38683N
3
4
4
5
13"
13"
13"
13"
13"
13"
13"
15"
15"
15"
57.6
43.2
34.4
27.9
21.6
17.1
14.4
12.1
9.1
38.6
28.9
23.0
18.7
14.5
11.5
9.6
8.1
6.1
5.0
2.5
3
4
5
6
8
5
6
6
8
8
10
12
15
20
----
10
12
15
20
10
12
15
3.0
11-38683N 17.3 ---- ----
7.5
2.5
7.5
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SINGLE PHASE ELEMENT CHART
Power (Watts)
Immersion
Element
Element Part #
Length Resistance (Ohms)
120V
----
----
----
2000
----
----
----
----
----
1500
----
----
2500
500
----
----
----
----
----
----
----
----
----
----
208V
3500
4000
5000
6000
----
240V
----
277V
----
480V
----
CH-FO-358
11 3/8"
11 3/8"
13 1/4"
13 3/8"
9 3/4"
12.36
10.82
8.65
CH-FO-408
----
----
----
CH-FO-508
----
----
----
CH-FO-608
----
----
----
7.21
CH-FO-304
3000
3500
4000
4500
5000
6000
----
4000
----
----
19.20
16.46
14.40
12.80
11.52
9.60
CH-FO-354
2500
3000
----
----
9 3/4"
CH-FO-404
----
----
11 1/2"
11 1/2"
11 1/2"
13 1/2"
7 5/8"
CH-FO-454
----
----
CH-FO-504
----
----
----
CH-FO-604
4500
----
----
----
TGB-1203-480
TGB-1353-480
TGB-2257L
----
2000
3500
----
83.23
47.56
5.76
500
----
----
1000
----
12 1/2"
9 5/8"
----
TGB-1207-240
TGB-1303-480
TGB-1403-480
TGB-2257-240
TGB-2257-480
TGB-2457-277
TGB-2457-480
TGB-2503-480
TGB-2507-277
TGB-2603-277
TGB-2603-480
1500
----
2000
2500
990
1350
3500
----
----
13 3/8"
10 1/2"
13 5/8"
10 5/8"
13 1/4"
13 1/8"
13 1/4"
9 3/4"
28.80
55.49
41.62
23.04
66.59
17.05
36.99
33.29
15.35
12.79
27.74
3000
4000
----
----
1000
2500
----
2000
----
2500
----
----
----
4500
1500
----
----
----
4500
5000
----
1000
----
----
----
5000
6000
2000
15"
----
----
----
15 1/2"
15 1/2"
----
1500
6000
*Red wattage indicates the stamped element rating
21
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TORQUE VALUES
SILICON ALUMINUM
18-8 S/S
IN.-LBS. IN.-LBS.
BRASS
316 S/S MONEL
IN.-LBS. IN.-LBS.
BOLT SIZE
BRONZE
IN.-LBS.
4.8
2024-T4
IN.-LBS.
2.9
4-40
4-48
5.2
6.6
4.3
5.4
5.5
6.9
5.3
6.7
6.1
3.6
5-40
7.7
6.3
7.1
4.2
8.1
7.8
5-44
9.4
7.7
8.7
5.1
9.8
9.6
6-32
6-40
8-32
8-36
9.6
7.9
9.9
8.9
5.3
6.6
10.1
12.7
20.7
23.0
23.8
33.1
78.8
99.0
138
147
247
271
393
9.8
12.1
19.8
22.0
22.8
31.7
75.2
94.0
132
142
236
259
376
11.2
18.4
20.4
21.2
29.3
68.8
87.0
123
131
219
240
349
12.3
20.2
22.4
25.9
34.9
85.3
106.0
149
160
266
294
427
16.2
18.0
18.6
25.9
61.5
77.0
107
116
192
212
317
327
422
443
558
615
907
1016
1249
1220
1905
1895
2815
2545
10.8
12.0
13.8
19.2
45.6
57.0
80
86
143
157
228
242
313
328
413
456
715
798
980
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
400
517
541
682
371
480
502
632
418
542
565
713
451
584
613
774
752
697
787
855
1110
1244
1530
1490
2328
2318
3440
3110
1030
1154
1416
1382
2140
2130
3185
2885
1160
1301
1582
1558
2430
2420
3595
3250
1330
1482
1832
1790
2775
2755
4130
3730
958
1495
1490
2205
1995
7/8-14
1-8
1-14
22
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