COMMERCIAL ELECTRIC ENERGY SAVER
WATER HEATER
MII SERIES
IMMERSION AND SURFACE MOUNTED
THERMOSTAT MODELS
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
MII50(A)-*-**-(SF,CF,SCF)-***
MII80(A)-*-**-(SF,CF,SCF)-***
MII120(A)-*-**-(SF,CF,SCF)-***
*Denotes kW Rating
**Denotes Warranty Years
***Denotes Wiring Code
Manual 238-47174-00B
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GENERAL INFORMATION
Bradford White MII Series Commercial Electric water heaters can be manufactured with a choice between two
different types of thermostat control options as follows:
Surface Mounted Thermostats.
Immersion Thermostat (contactor models).
The model number is coded to identify the specific thermostat control system used for a particular unit. Below is
typical model number and coded definitions:
MII50 12 3 SF 018
Wiring Code
C-Contactor (Immersion Thermostat)
CF-Contactor w/Fuse (Immersion Thermostat)
S-Surface Thermostat
SF-Surface Thermostat w/Fuse
SC-Surface Thermostat (w/Contactors)
SCF-Surface Thermostat w/Fuse (w/Contactors)
Warranty
kW Rating
Tank
The wiring code at the end of the model number is used at the factory to facilitate proper construction based on the
electrical characteristics such as voltage, phase, kW rating and amp draw. In the field this information is determined
from the heaters rating plate located on the front of the water heater.
BRADFORD WHITE CORPORATION
200 LAFAYETTE ST. MIDDLEVILLE MI 49333
Model No: MII50123SF018
Serial No: ZB2564812
Model Number
Cap.
Press:
50(gal.)/189.3(liters)
Test 300(psi), Working 150(psi)
Volts
240
Max Temp 180°
Amps 29
Phase
Three
Electrical Characteristics
kW Each 4
Wattage Rating Based Upon 60 Hz
Total kW 12
3 Elements
Typical Rating Plate
Located On Front Of Water Heater
3
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GENERAL INFORMATION
Contactor Models
General Controls Layout
Ground Lug
Terminal Block
Fuse Block(s)
Contactor(s)
Upper
Control Box
High Limit (ECO)
Thermostat
Direct Immersion Bulb
Direct Immersion Bulb
High Limit (ECO) Control
Immersion Thermostat
Control
Lower
Control Box
Heating Elements
Surface Mounted Thermostat Models
General Controls Layout
Ground Lug
Terminal Block
Fuse Block(s)
Upper
Control Box
Surface Mounted Thermostats
With ECO
Lower
Control Box
Heating Elements
4
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GENERAL INFORMATION
600V Surface Thermostat (w/Contactors) Models
General Controls Layout
Terminal Block
Ground Lug
Upper
Control Box
Contactor(s)
High Limit (ECO) Control
Surface Thermostats
Lower
Control Box
Heating Elements
5
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GENERAL INFORMATION
Surface Mounted Thermostats
Surface mounted thermostats are mounted into a bracket above each heating element. The bracket holds the
thermostat against the side of the tank responding to tank surface temperatures to sense a call for heat, set point
temperature and high limit (ECO) activation. As each element has a dedicated thermostat (for all models excluding
600V), it is possible to sequence the elements by varying the settings on the thermostats.
Manual
Surface Mount
ECO (high limit)
Combination Thermostat/
Reset button
ECO (high limit)
89T Series
Temperature
control Dial
Immersion Style Thermostat Control for
Contactor Models
The thermostat will complete control circuit
voltage upon a call for heat. Likewise, the control
will interrupt control circuit voltage when the water
temperature is sufficient to satisfy the adjustable
temperature limit of control.
Direct
Immersion
bulb
Immersion Style High Limit (ECO) Control for
Contactor Models
The high limit (ECO) control will interrupt control circuit voltage
causing the heater to shut down when the high temperature limit of
the control is reached (196°F 4°F). Once the cause for over
heated water has been determined, The control must be manually
reset to restore normal operation.
Manual Reset
Buttons
Direct
Immersion
bulb
6
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GENERAL INFORMATION
Surface Mounted Thermostats (w/Contactors) for
600V Models
600V models use contactors to deliver line voltage to the heating elements. However, rather than the immersion type
high limit and thermostat devices, surface mounted thermostats are used to operate the control circuit of the water
heater.
Surface Mounted
Surface Mounted
Thermostat
59T Series
ECO (High Limit)
Manual Reset
Button
Temperature
control Dial
7
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GENERAL INFORMATION
Contactor
Contactor operation is achieved by energizing an operating coil in response to a call for heat from the immersion
thermostat. Upon a call for heat, one or more contactors will energize all heating elements simultaneously. The
operating coils are voltage specific, When contactor replacement is required be sure to order the proper operating coil
base on the voltage rating found on the rating plate located on the front of the water heater.
Terminal connections of
contactor operating coil.
Terminal connections to the
fuse block and/or terminal block
Terminal connections to the
heating elements
Direct Immersion “Screw-in” Type Heating Element
1-½” Hex
Screw-in Flange
Terminal Block
Zinc Plated Copper or
Incoloy Sheath
Terminal Block
Screw
Element Rating Ink Stamped
on side of Terminal Block.
8
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GENERAL INFORMATION
Commonly Used Formulas
(balanced 3 phase)
(Single phase)
Watts
Volts2
Watts
Watts
Amps =
Watts = Amps x Volts
Ohms =
Amps =
Volts x 1.732
Volts
Common Service Wire
Configurations
240V 1Ph
BLACK
GREEN
Grounding
Ungrounded
RED
Ungrounded
240
120
120
208 3Ph
240 3Ph
480 3Ph/277 1Ph
Neutral
A
B
C
Neutral
A
B
C
Neutral
A
B
C
120
208
120
240
277
480
120
120
120
120
277
277
208
208
240
240
480
480
RED
BLACK
RED
RED
BLACK
RED
RED
BLACK
RED
Full Load Current Amps
208 Volt
240 Volt
277 Volt 380 Volt 415 Volt
480 Volt
1 Ph 3 Ph
600 Volt
3 Ph
5.8
kW
6
9
1 Ph
28.8
3 Ph
16.6
25.0
33.3
37.5
41.6
50.0
66.7
75.0
83.3
100.0
125.0
150.0
1 Ph
25.0
3 Ph
14.4
21.6
28.9
32.5
36.1
43.4
57.8
65.0
72.2
86.7
108.3
130.0
1 Ph
21.6
3 Ph
9.1
3 Ph
8.3
12.5
18.7
25.0
28.1
31.2
37.5
50.0
56.2
62.5
75.0
93.7
112.5
7.2
43.2
57.6
37.2
50.0
32.4
43.3
48.7
54.1
64.0
86.6
97.4
108.3
129.9
162.4
194.9
13.6
18.2
20.5
22.7
27.3
36.4
41.0
45.6
54.7
68.4
82.0
12.5
16.7
18.8
20.9
25.0
33.4
37.5
41.7
50.1
62.6
75.1
10.8
14.4
16.2
18.0
21.6
28.9
32.5
36.1
43.3
54.1
65.0
8.7
12
13.5
15
18
24
27
30
36
45
54
11.5
13.0
14.4
17.3
23.1
26.0
28.9
34.6
43.3
52.0
64.9
72.1
56.2
62.5
86.5
75.0
115.4
129.8
144.2
173.0
216.3
259.6
100.0
112.5
125.0
150.0
187.5
225.0
9
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SEQUENCE OF OPERATION
MII Series Commercial Electric Water Heaters can use either immersion thermostat (contactor models) or
surface mounted thermostats. Sequence of operation for each configuration is explained below. It would be impractical
to show all wire diagrams applicable to both configurations. A “typical wiring diagram” is illustrated to aid in
understanding the principles of the operating sequence.
Immersion Thermostat (Contactor Models): Configured to use a single immersion thermostat to control one or more
contactors to energize or de-energize all elements simultaneously. In addition, a separate high limit (ECO) control with
manual reset is wired in series with the thermostat. Both controls use a direct immersion bulb inserted into the tank to
sense water temperature. Immersion thermostat and high limit control are mounted to provide temperature adjustment
and manual reset access from the exterior of the unit.
Surface Mounted Thermostats: Surface mounted thermostats are mounted inside the lower control box, in a bracket
above each heating element. The bracket holds the thermostat against the side of the tank responding to tank surface
temperatures to sense a call for heat, set point temperature and high limit (ECO) activation. As each element is controlled
by a dedicated thermostat, it is possible to sequence the elements by varying the settings on the thermostat. However,
600V models w/ surface mounted thermostats operate contactors in the same manner as an immersion thermostat
model, only using surface thermostats to sense the call for heat.
Line Voltage
Sequence of operation for each system is explained below.
Sequence of Operation:
Immersion Thermostat (Contactor Models).
The system has two distinct circuits.
OR
Terminal Block
Fuse Block
1. Power circuit (shown solid line).
2. Control Circuit (shown dotted line).
Line voltage is applied across terminals of fuse block
1
or a terminal block. Line voltage continues down and
connects to terminals L1, L2 & L3 of one or more
contactors.
Contactor
Coil
ECO
(High Limit)
Contactor
A) Contactor is open (no call for heat), so there is no
voltage across terminal T1, T2 & T3
of contactor.
T’stat
B) The contactor is controlled by the control circuit
consisting of the immersion thermostat,
ECO (hi limit) and contactor coil.
When the thermostat calls for heat, contacts close
inside the thermostat completing the circuit through
the ECO and energizing the contactor coil.
2
The energized contactor coil causes the contactor to
close energizing the elements from terminals T1, T2
& T3 of the contactor.
3
4
When the temperature setting of the thermostat is
reached, the contacts in the thermostat open. This
interrupts current flow through the control circuit de-
energizing the contactor coil.
Heating Elements
The de-energized contactor coil causes the contactor
to open, interrupting current flow through the
elements. The heater is now in stand-by waiting for
the next call for heat.
5
10
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SEQUENCE OF OPERATION
Line Voltage
OR
Sequence of Operation:
1
Surface Mounted Thermostats.
Fuse Block
Terminal Block
Line voltage is applied across terminals of fuse block or a
terminal block. Line voltage continues down and connects
to surface mounted thermostats at terminals L1 & L3.
1
2
ECO (high limit) in
2
thermostat is closed, so
there is line voltage present
at terminal L4 of thermostats
and to one side of each
element.
ECO Closed
Power to one
side of element
Surface Mounted
Thermostat
Heating Element
Water in tank is cold, so
3
Thermostat closed
at terminal T2
3
all thermostats are
closed at terminal T2
(calling For heat). This
completes the circuit and
allows current to flow
through heating elements.
4
As each thermostat is
satisfied, it opens at
4
Thermostat open
at terminal T2
terminal T2 interrupting
current flow through the
respective element. The
system is now in stand-by
mode, waiting for the next
call for heat.
11
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SEQUENCE OF OPERATION
Sequence of Operation:
600V Surface Mounted Thermostats (w/Contactors).
The system has two distinct circuits.
Line Voltage
6 Element Configuration Shown
(9 Elements Possible)
1. Power circuit - Line Voltage (600V)
2. Control Circuit - 120V
Fuse Block
Transformer
60VA
Line voltage is applied across terminals of fuse block
1
or a terminal block. Line voltage continues down and
connects to terminals L1, L2 & L3 of one or more
contactors.
A) Contactor is open (no call for heat), so there is no
voltage across terminal T1, T2 & T3
of contactor.
B) The contactor is controlled by the control circuit
consisting of the surface mounted thermostat,
ECO (hi limit) and contactor coil.
Contactor
When the thermostat calls for heat, contacts close
inside the thermostat completing the circuit through
the ECO and energizing the contactor coil.
2
The energized contactor coil causes the contactor to
close, energizing the elements from terminals T1, T2
& T3 of the contactor.
3
4
When the temperature setting of the thermostat is
reached, the contacts in the thermostat open. This
interrupts current flow through the control circuit de-
energizing the contactor coil.
High Limit
The de-energized contactor coil causes the contactor
to open, interrupting current flow through the
elements. The heater is now in stand-by waiting for
the next call for heat.
5
6
59T
59T
Notice in the wiring diagram at right that each row of
elements is equipped with a surface mounted
thermostat on the highest element in the row. These
thermostats are individually wired in series to the
contactor whose line voltage corresponds to the same
row of elements. Each thermostat and contactor
combination are wired to the high limit (ECO) device
in parallel. This allows for each row of elements to be
powered “ON” independent of the other element rows.
However, the high limit (ECO) is wired in series so
that voltage can be interrupted to the entire control
circuit if the ECO senses that the tank water has
become overheated.
Heating Elements
12
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TROUBLESHOOTING
Most common cause for improper electric water heater operation can be linked to heating element
failure.
When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot
Water” It is always a good idea to check the heating elements first following the procedure on page 15.
Common Heating Element Failures Are:
1. Dry Firing. Elements may be partially submerged in water or most likely, completely exposed with no water
in the tank at all. In open air, an energized element (Dry Fired) will become completely inoperable within
seconds. In some cases sediment or lime build up around an element can eventually cause an air pocket,
resulting in a dry fired element. When element replacement is required, be sure tank is full of water prior to
energizing the water heater.
2. Grounded Element. In most cases, an element with a short circuit to ground will 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 Off located in the thermostat circuit. Repeated actuation of the
ECO usually is the result of a grounded heating 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.
If a heating element is found to be inoperative, it must be replaced. Follow service procedure MCE-XV on page 30.
The illustration below shows a common “Screw-In” type heating element identifying certain features commonly referred
to throughout this manual.
1-½ Hex
Screw-in Flange
Zinc Plated Copper or
Incoloy Sheath
Terminal Block
Terminal Block
Screw
Element Rating Ink Stamped
on side of Terminal Block.
Typical Direct Immersion “Screw-In”
Type Heating Element
13
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TROUBLESHOOTING
Quick Step Plan to Hot Water
WARNING
High voltage exposure. Use caution when
making voltage checks to avoid hazard to
life or property.
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Check all wire connections to insure they are snug
and corrosion free.
3. Reset high limit (ECO) (page 18-20).
4. Check for inoperative heating element (page 15).
5. Check line voltage (pg 16), and internal fuses (page 17).
6. Refer to table below if items 1 through 5 above do not correct problem.
SERVICE
SYMPTOM
PROBABLE CAUSE
CORRECTIVE ACTION
PROCEDURE
1. No power to heater.
1. Check circuit breakers at service panel.
2. Check water heater fuses.
3. Check all wire connections.
4. Check heating element(s).
5. Check thermostat(s) operation.
6. Reset (check) ECO.
2. Blown water heater fuses.
3. Loose wire connections.
4. Inoperative heating elements.
5. Inoperative thermostat(s).
6. Open ECO.
2. MCE-III, Page 17
4. MCE-I, Page 15.
5. MCE-VII-IX, Page 21-23.
6. MCE-IV-VI, Page 18-20.
7. MCE-X, Page 24,25
No Hot Water
7. Inoperative contactor(s).
7. Check contactor operation.
1. Inoperative heating element.
2. Sediment or lime build up on element(s).
3. Thermostat(s) set to low.
4. Inoperative thermostat(s).
5. Inoperative contactor(s).
1. Check heating element(s).
2. Clean or replace heating element(s)
3. Increase thermostat setting.
4. Check thermostat(s).
5. Check contactor operation.
6. Check all wire connection.
7. Reduce demand.
8. Replace with larger heater.
9. Temper water to heater.
10. Correct plumbing connections.
Not Enough Hot
Water or
1. MCE-I, Page 15.
2. MCE-XV, Page 30.
4. MCE-VII-IX, Page 21-23.
5. MCE-X, Page 24,25
6. Loose wire connection.
Continues
7. High demand period.
8. Undersized heater.
9. Very cold inlet water to heater.
10. Plumbing connections reversed.
Operation
1. Sediment or lime build up on element(s).
2. Loose wire connections.
1. Clean or replace heating elements.
2. Check all wire connections.
1. MCE-XV, Page 30.
3. MCE-VII-IX, Page 21-23.
4. MCE-X, Page 24-25
5. See page 8.
Slow Hot Water
Recovery
3. Inoperative thermostat(s).
3. Check thermostat(s).
4. Inoperative contactor(s).
5. Derated heating element installed.
4. Check contactor operation.
5. Verify element voltage and wattage rating.
1. Surface thermostat(s) not flush with tank.
2. Grounded heating element(s).
3. Thermostat set to high.
4. Inoperative thermostat(s).
5. Inoperative ECO.
1. Check surface thermostat(s) mounting.
2. Check heating element(s).
3. Adjust thermostat(s) to desired setting.
4. Check thermostat(s).
1. MCE-XI, Page 26.
Over Heated
Water
2. MCE-I, Page 15.
4. MCE-VII-IX, Page 21-23.
5. MCE-IV-VI, Page 18-20.
5. Check ECO.
Noisy (singing or
hissing) Elements
1. Lime formation on elements.
2. High or low line voltage.
1. Clean or replace heating elements.
2. Verify line voltage to heater.
1. MCE-XV, Page 30.
2. MCE-II, Page 16.
1. Low line voltage.
1. Verify line voltage to heater
2. Replace contactor.
2. Debris between contactor plates.
3. Incorrect or defective operating coil.
4. Loose wire connections.
1. MCE-II, Page 16
Noisy Contactor
3. Replace contactor.
4. Check wire connections.
14
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SERVICE PROCEDURE MCE-I
Heating Element Testing
Test for Open or Burned Out Element.
DANGER
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned OFF
to water heater while performing this
procedure.
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Remove access cover from lower control box.
Remove insulation from inside of control box.
3. Disconnect wires from heating element.
4. Set multi-meter to “ohms” setting.
5. Touch probes of multi-meter to screw
terminals of heating element
(see illustration 1).
6. Reading should be 12.8 ohms ( 6%) for a 240
NOTE
Disconnect
element
Wires
volt, 4500 watt element, see table below for other elements.
Ohms = Volts2
Watts
A reading outside the range using the formula
above ( 6%), indicates a bad element and the
element must be replaced.
Ohms of electrical Resistance
For commonly Used Elements
Element Screw Terminals
Illustration 1
Voltage Rating of Element
Element
Wattage
208
240
480
2000
3000
4000
4500
5000
6000
21.6
14.4
10.8
9.6
28.8
19.2
14.4
12.8
11.5
9.6
115.2
76.8
57.6
51.2
46.1
38.4
8.7
7.2
Test For Grounded Heating Element
(damaged heating element with short circuit to ground).
NOTE
Disconnect
element
Wires
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Remove access cover from lower control box.
Remove insulation from inside of control box.
3. Disconnect wires from heating element.
4. Set multi-meter to “ohms” setting.
Element Flange
5. Touch one probe of multi-meter to either screw
terminal of heating element and the other on
the element flange (see illustration 2). There
should be no reading on the ohm meter. Any
reading indicates a grounded element and the
element must be replaced. Repeat this step for
the other screw terminal.
Element
Screw Terminal
Illustration 2
15
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SERVICE PROCEDURE MCE-II
Line Voltage Testing
Line Voltage Testing
DANGER
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
Line voltage (single phase or three phase) will
connect to a terminal block or directly to a fuse block
located inside control panel.
Determine heaters voltage and phase by referring to the rating plate located on the front of the heater. Apply the
appropriate phase procedure below to determine if proper line voltage is present.
Single Phase Line Voltage Testing
Line voltage from
service panel
connected to Terminal block
of heater
Line voltage from
service panel
connected to Fuse block
of heater
OR
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Open upper control panel door.
3. Determine connection point for line voltage
from service panel, terminal block or
fuse block
4. Set multi-meter to volts AC. Be sure to scale
meter for appropriate voltage.
5. Use caution and turn power “ON” to water heater.
6. Use caution and check voltage across top terminals
where service voltage connects to water heater.
(see illustration 3).
A) Rated voltage IS present, power to
the water heater is okay.
Check voltage across
top terminals.
B) Rated voltage NOT present, Check
service panel.
Illustration 3
Three Phase Line Voltage Testing
1. STOP, DANGER! Turn power “OFF” to water heater.
Line voltage from
service panel
connected to Terminal block
of heater
Line voltage from
service panel
2. Open upper control panel door.
OR
connected to Fuse block
of heater
3. Determine connection point for line voltage
from service panel, terminal block or
fuse block
4. Set multi-meter to volts AC. Be sure to scale
meter for appropriate voltage.
5. Use caution and turn power “ON” to water heater.
6. Use caution and check voltage across top terminals
where service voltage connects to water heater.
(see illustration 4).
A) Rated voltage IS present, power to
the water heater is okay.
Check voltage across
top terminals.
B) Rated voltage NOT present, Check
service panel.
Illustration 4
16
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SERVICE PROCEDURE MCE-III
Fuse Testing
Fuse Testing
DANGER
High voltage exposure. To avoid hazard to Life
or property, be sure power is turned OFF to
water heater while performing this procedure.
1. Turn “OFF” power to water heater.
2. Open upper control box to allow access
to fuse block.
3. Locate fuse block and remove fuses.
4. Set multi-meter to the “Ohms” setting.
5. Check continuity across fuse
(see illustration 5).
A) Continuity IS present, fuse is okay.
B) Continuity NOT present, Replace with new fuse
Illustration 5
17
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SERVICE PROCEDURE MCE-IV
High Limit (ECO) Testing
DANGER
High Limit Control (ECO) Testing for
Surface Thermostat models (not including 600V)
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
1. This procedure assumes line voltage and
fuses are in working order.
2. This procedure illustrates testing of just one
surface thermostat. Repeat this procedure for all
surface thermostats on the unit.
ECO reset
button
3. Turn power “OFF” to water heater.
4. Remove lower control box cover and remove insulation
from inside of control box.
5. Remove plastic cover from thermostat(s).
6. Turn power “ON” to water heater.
7. Check voltage across terminals L1 & L4 for all thermostats
(see illustration 6).
Illustration 6
A) Rated Voltage IS present, ECO is okay.
B) Rated voltage NOT present, proceed to step 8.
8. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s).
Turn power “ON” to water heater and recheck voltage across terminals L1 & L4 of thermostat(s).
A) Rated voltage IS present, the ECO has previously opened indicating the water in the tank, at
some point did overheat, Check the following:
1. Thermostat must be in full contact with tank.
2. Be sure heating element(s) is not shorted to ground (see page 15).
3. Proper thermostat operation (see page 21).
B) Rated voltage NOT present, water in tank may be over heated.
1. If water is overheated, turn “OFF” power to water heater and flow water through tank to cool below
set point of upper thermostat. Reset ECO and recheck voltage.
2. If water is cool, Replace thermostat(s).
18
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SERVICE PROCEDURE MCE-V
High Limit (ECO) Testing
DANGER
High Limit Control (ECO) Testing for
600V Surface Thermostat Models
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
1. This procedure assumes line voltage, transformer,
fuses, and thermostat are in working order.
ECO reset
button
2. Turn power “OFF” to water heater.
3. Remove lower control box cover and remove insulation
from inside of control box.
4. Check for continuity across terminals 1 & 2.
(see illustration 7)
A) Continuity IS present, ECO is okay.
B) Continuity NOT present, proceed to step 5.
5. Verify power to the water heater is “OFF”, firmly press the ECO
reset button. Recheck continuity across terminals 1 & 2
(see illustration 7).
Illustration 7
A) Continuity IS present, the ECO has previously opened indicating the water in the tank, at
some point did overheat, Check the following:
1. Thermostat must be in full contact with tank.
2. Be sure heating element(s) is not shorted to ground (see page 15).
3. Proper thermostat operation (see page 22).
B) Continuity NOT present, water in tank may be over heated.
1. If water is overheated, verify that power to water heater is “OFF”. Flow water through the tank to cool
below set point of upper thermostat. Reset ECO and recheck continuity.
2. If water is cool, Replace ECO (High Limit).
19
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SERVICE PROCEDURE MCE-VI
High Limit (ECO) Testing
High Limit Control (ECO) Testing for
Contactor Models
Switch Contacts:
Normally closed.
Open on rise @ 196°F 4°F
Manual Reset.
Observe heating cycle.
Does switch open?
N
Is water temp
over 196°F
Y
N
Y
1. Determine if Hi-Limit has actuated. This can be done by simply
depressing the reset buttons. If you hear and/or feel
a small click, the switch has actuated.
Is water temp
over 196°F
Y
Switch OK
N
2. Use caution and turn power on to water heater and observe
heating cycle following the Hi-Limit Heating Cycle flow chart.
Replace switch
High Limit Heating Cycle Flow Chart
High Limit Control Continuity Testing for
Contactor Models
DANGER
1. STOP, DANGER! Turn power “OFF” to water heater.
High voltage exposure. To avoid
hazard to Life or property, be sure
power is turned OFF to water heater
while performing this procedure.
2. Water temperature must be below 196°F 4°F
3. Remove Hi-Limit switch from control panel. It is not necessary
to remove immersion bulb from tank at this time. See
general controls layout on page 4 for location.
4. Disconnect wire leads to Hi-Limit Control during this test.
5. Depress reset buttons to insure switch contacts are closed.
6. Set multi-meter to Ohms setting, Check continuity Thru circuit A & B as shown in the illustrations below.
- Continuity IS present, Switch is okay.
- Continuity NOT present, Replace switch.
NOTE
Disconnect
Wire Leads to Control
Circuit “A” Continuity Testing
Circuit “B” Continuity Testing
20
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SERVICE PROCEDURE MCE-VII
Thermostat Testing
Surface Mounted Thermostat.
DANGER
Operation Testing (not including 600V models)
High voltage exposure. To avoid hazard to
life or property, use extreme caution when
making voltage checks .
Water In Tank Is Cold With Power ON.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. TURN OFF POWER TO WATER HEATER.
3. Remove access cover from lower control box.
Remove insulation from inside of control box.
Remove plastic cover from thermostat.
4. Turn power “ON” to water heater.
5. Set multi-meter to “Volts AC”.
6. Check across terminals L1 & L3 of thermostat
(see illustration 8)
A) Rated voltage NOT present,
Check fuses and or line voltage.
B) Rated voltage IS present,
proceed to next step.
Illustration 8
Illustration 9
7. Check across terminals L4 and T2 of thermostat (see illustration 9).
A) Rated voltage NOT present, Recheck ECO. If ECO is okay, replace thermostat.
B) Rated voltage IS present, okay, thermostat is calling for heat, go to next step.
8. Check across element terminals (see illustration 10).
A) Rated voltage NOT present, check wire connections from thermostat to element.
B) Rated voltage IS present, Repeat element testing, see page 15.
Water Temperature In Tank Is Above Thermostat Setting.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater.
Illustration 10
3. Set multi-meter to “Volts AC”.
4. See illustration 9 above, check across terminals L4 and T2 of thermostat.
A) Rated voltage IS present, replace thermostat.
B) Rated voltage NOT present, thermostat is okay.
C) Lower than rated voltage IS present, recheck for grounded element
(see page 15).
21
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SERVICE PROCEDURE MCE-VIII
Thermostat Testing
600V Surface Mounted Thermostat Models.
Operation Testing
DANGER
High voltage exposure. To avoid hazard to
life or property, use extreme caution when
making voltage checks .
Water In Tank Is Cold With Power ON.
1. This procedure assumes line voltage, ECO, transformer
thermostat, and elements are in working order.
2. TURN OFF POWER TO WATER HEATER.
3. Remove access cover from lower control box.
Remove insulation from inside of control box.
4. Using a phillips head screw driver, disconnect the wire lead at
terminal 2 of the thermostat. Only check one thermostat at a time
to insure wires are correctly reinstalled upon completion.
Mark wires if necessary for reinstallation.
5. Set multi-meter to check continuity.
6. Check continuity across terminals 1 & 2 of thermostat
(see illustration 11).
A) Continuity NOT present, replace thermostat.
B) Continuity IS present, thermostat is okay.
Illustration 11
Water Temperature In Tank Is Above Thermostat Setting.
1. This procedure assumes line voltage, ECO, thermostat, transformer, and
elements are in working order.
2. TURN OFF POWER TO WATER HEATER.
3. Remove access cover from lower control box.
Remove insulation from inside of control box.
4. Using a phillips head screw driver, disconnect the wire lead at
terminal 2 of the thermostat. Only check one thermostat at a time
to insure wires are correctly reinstalled upon completion.
Mark wires if necessary for reinstallation.
5. Set multi-meter to check continuity.
6. See illustration 11 above, check across terminals 1 & 2 of thermostat.
A) Continuity IS present, replace thermostat.
B) Continuity NOT present, thermostat is okay.
22
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SERVICE PROCEDURE MCE-IX
Thermostat Testing
Immersion Thermostat Operation Testing
DANGER
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
Thermostat Specification:
Calibration: 184°F/176°F
Max Differential: 6°F
Operating Range 80 to 180°F
Providing the water temperature in tank is within the operating range of the
thermostat, checking thermostat operation can be as simple as rotating the
thermostat dial and listening to the contactor(s) to see if they respond to a call
for heat.
Use caution and turn Power “ON” and rotate the thermostat dial to call for heat.
With water temperature below the thermostat setting, the contactor(s) close.
With the contacts closed, use caution and check for rated voltage across lower
terminals of contactor(s) (see illustration 12), If rated voltage is present, the
thermostat is calling for heat.
L1 L2 L3
T1 T2 T3
Rotate thermostat dial to the minimum setting. With water temperature above
the thermostat setting the contactor(s) will open. With the contacts open,
voltage should not be present at lower terminals of contactor(s).
Follow the procedure below If preliminary testing above does not verify
thermostat operation.
Illustration 12
Check voltage across
lower terminals of contactor(s)
Thermostat Control Continuity Testing.
1. This procedure assumes line voltage, ECO and contactor(s) are in working order.
2. STOP, DANGER! Turn power “OFF” to water heater.
3. Remove lower control box cover and insulation.
4. Locate thermostat control (see general controls layout on page 4) and remove wire leads to control screw terminals.
5. Water temperature in tank must be within operating range of thermostat for this test. If above or below, it will be
necessary to drain tank and remove thermostat immersion bulb from tank to warm or cool the bulb to be
within operating range of thermostat.
Thermostat Immersion Bulb
6. Set multi-meter to the “Ohms” setting.
7. Rotate thermostat dial to highest setting.
8. Check across screw terminals of control
Thermostat
(see illustration 13).
Dial
A) Continuity IS present, okay,
Go to step 9.
B) Continuity NOT present,
replace thermostat.
9. Rotate thermostat dial to lowest setting.
10. Check across screw terminals of control
(see illustration 13).
NOTE: Disconnect
Wire Leads to Control
Screw Terminals
A) Continuity NOT present, thermostat is okay,
Illustration 13
B) Continuity IS present, replace thermostat.
23
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SERVICE PROCEDURE MCE-X
Contactor Testing
Contactor Operation Testing
Noisy Contactor
DANGER
High voltage exposure. To avoid hazard to
life or property, use extreme caution when
making voltage checks .
Noisy or chattering contactor operation in most cases is due to voltage variations being supplied to the water heater.
Extended periods of voltage variations will cause damage to the operating coil of the contactor causing noisy operation.
Determine that service voltage to the unit meets the electrical requirements per the rating plate located on the front of
the water heater.
In addition, debris between the contact plates will cause noisy operation.
Contactor Operating Coils
Contactor operation is achieved by energizing an operating coil in response to a call for heat from the thermostat. There
are three different operating coils used depending on voltage rating of the water heater as follows:
Description
Color Code
208/240 Volt Coil
277 Volt Coil
Green
Blue
480 Volt Coil
Black
All the coils have a color code for visual conformation. In addition, the 277 & 480 volt coils are labeled with voltage rating
for proper identification. All contactors supplied for replacement are equipped with The 208/240 volt operating coil. By
removing the rear mounting plate of the contactor, the operating coils can be changed based on desired service voltage.
When contactor replacement is required be sure to order the proper operating coil base on the voltage rating found on
the rating plate located on the front of the water heater.
Rear Mounting Plate
Operating Coil
Color Code Location
Identification Label Location
24
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SERVICE PROCEDURE MCE-X
Contactor Testing
Contactor Operation Testing (continued)
DANGER
This procedure assumes control circuit is operating correctly.
High voltage exposure. To avoid hazard to
life or property, use extreme caution when
making voltage checks .
Providing the water temperature in tank is within the operating
range of the thermostat, checking contactor operation can be
as simple as rotating the thermostat dial and listening to the
contactor(s) to see if they respond to a call for heat.
1. Turn Power “ON” and rotate thermostat dial to the maximum
setting, with water temperature in tank below the
thermostat setting, the contactor(s) will close. With the
contacts closed, check for line voltage across operating coil
terminals (see illustration 14).
A) Line voltage IS present, okay, go to step 2.
B) Line voltage NOT present, verify control circuit
operation.
2. Check for rated voltage across lower terminals of
contactor(s) (see illustration 15).
A) Rated voltage IS present, okay,
go to step 3.
B) Rated voltage NOT present, replace
contactor.
3. Rotate thermostat dial to the minimum setting.
With water temperature in tank above thermostat
setting, the contactor(s) will open. With the contacts
open, voltage should not be present at lower terminals
of contactor(s).
4. Check for line voltage across operating coil
terminals (see illustration 14).
Illustration 14
A) Line voltage IS present, verify control circuit
operation.
B) Line voltage NOT present, okay go to step 5.
5. Check for rated voltage across lower terminals
of contactor(s) (see illustration 15).
L1 L2 L3
T1 T2 T3
A) Rated voltage IS present, replace contactor.
B) Rated voltage NOT present, contactor is okay.
Illustration 15
Check voltage across
lower terminals of contactor(s)
25
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SERVICE PROCEDURE MCE-XI
Thermostat Removal and Replacement
DANGER
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned OFF
to water heater while performing this
procedure.
Surface Mounted Thermostat Removal
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Remove access cover from lower control box.
Remove insulation from inside of control box.
Remove plastic cover from thermostat.
3. Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connection to
new thermostat.
4. Note thermostat temperature setting for proper setting of new thermostat.
5. Slide thermostat upwards and out of mounting bracket.
Surface Mounted Thermostat Replacement
1. Use a stiff brush to remove any debris or loose scale from tank surface where new thermostat will be installed.
2. Slide new thermostat down into thermostat bracket until it snaps into place. IMPORTANT! Thermostat must set
completely flat or flush to tank surface. An improperly installed thermostat will cause improper water heater
operation.
3. Refer to the wire diagram located on the inside of the upper control box cover and re-connect wires to the thermostat.
Be sure wire connections are snug and corrosion free. Do not over tighten, doing so may damage thermostat.
4. Set thermostat to the original thermostat setting found on the old thermostat.
5. Restore power to water heater and verify proper
heater operation.
Tank Surface
Proper Thermostat mounting
flush with tank surface
Thermostat
Improper Thermostat mounting.
Thermostat not flush with tank surface
Thermostat
mounting
bracket
Front View
Thermostat Mounting
Side View
Improper Thermostat
Mounting
Side View
Proper Thermostat
Mounting
26
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SERVICE PROCEDURE MCE-XII
Thermostat Removal and Replacement
DANGER
Immersion Thermostat Removal & Replacement
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned
OFF to water heater while performing this
procedure.
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Turn off cold water supply to heater. Connect hose to drain
spigot of water heater and route to an open drain. Open
a nearby hot water faucet to vent heater for draining. Open
drain spigot of water heater and allow heater to drain
to a point below the Immersion bulb location
(see illustration 16 ).
3. Close drain spigot and remove hose.
4. Remove lower control box cover and insulation.
5. Locate thermostat inside lower control box mounted to
the right side of the box, below the ECO control
(see illustration 16).
6. Follow copper capillary tube from thermostat to the
immersion bulb location and remove immersion bulb
from tank, 11/16 wrench.
Immersion
Thermostat Bulb
Location
7. Remove (pull) thermostat control dial from stem of
thermostat.
ECO
Control
8. Remove the two thermostat mounting screw screws
located under thermostat dial (see illustration 16).
Thermostat control
Mounting Screws
Located Under
Copper Capillary
Tube
9. Once thermostat is removed, disconnect
wire leads to the thermostat. NOTE: It may be
necessary to identify wires for proper reconnection to
new thermostat.
Thermostat Dial
Immersion
Thermostat
control
10. Refer to wiring diagram located on the inside of the
upper control box cover and properly reconnect wire
leads to new thermostat and remount control inside
control box using screws from step 8.
11. Replace control dial to stem of thermostat.
12. Loosen ferrule nut of immersion bulb.
(see illustration 17)
Immersion
Illustration 16
Ferrule
nut
bulb
Copper
capillary
tube
Tank
nut
Illustration 17
13. Position tank nut at end of immersion bulb as shown in illustration 17. Insert immersion bulb into tank and tighten
tank nut.
14. Gently pull copper capillary tube to insure the immersion bulb is in a horizontal position as shown in illustration 17
and tighten ferrule nut.
15. Resume water supply, fill tank and check for leaks.
16. Be sure tank is full or water and resume power supply to water heater. Verify proper thermostat operation.
27
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SERVICE PROCEDURE MCE-XIII
Contactor Model High Limit (ECO) Control
Removal and Replacement
DANGER
Contactor Model High Limit (ECO) Control
Removal and Replacement
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned
OFF to water heater while performing this
procedure.
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Turn off cold water supply to heater. Connect hose to drain
spigot of water heater and route to an open drain. Open
a nearby hot water faucet to vent heater for draining. Open
drain spigot of water heater and allow heater to drain
to a point below the Immersion bulb location
(see illustration 18).
3. Close drain spigot and remove hose.
4. Remove lower control box cover and insulation.
5. Locate ECO control inside lower control box mounted to
the right side of the box, above the thermostat control
(see illustration 18).
ECO
Immersion Bulb
6. Follow copper capillary tube from ECO control to the
immersion bulb location and remove immersion bulb
from tank, 11/16 wrench.
Location
ECO
Control
Copper Capillary
Thermostat
Control
7. Remove the two ECO control mounting screws
located outside the lower control box.
Tube
8. Once ECO control is removed, disconnect
wire leads to the control. NOTE: It may be
necessary to identify wires for proper reconnection to
new control.
9. Refer to wiring diagram located on the inside of the
upper control box cover and properly reconnect wire
leads to new ECO control and remount control inside
control box using screws from step 7.
10. Loosen ferrule nut of immersion bulb.
(see illustration 19)
Illustration 18
Immersion
bulb
Ferrule
nut
Copper
capillary
tube
Tank
nut
Illustration 19
11. Position tank nut at end of immersion bulb as shown in illustration 19. Insert immersion bulb into tank and tighten
tank nut.
12. Gently pull copper capillary tube to insure the immersion bulb is in a horizontal position as shown in illustration 19
and tighten ferrule nut.
13. Resume water supply, fill tank and check for leaks.
14. Be sure tank is full of water and resume power supply to water heater. Verify proper ECO operation.
28
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SERVICE PROCEDURE MCE-XIV
600V Model High Limit (ECO) Control
Removal and Replacement
DANGER
600V Surface Thermostat Model
High Limit (ECO) Control
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned
OFF to water heater while performing this
procedure.
Removal and Replacement
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Remove lower control box cover and insulation.
3. Locate high limit switch mounted to the tank above the
element spuds (see illustration 20).
4. Disconnect wire leads to the high limit. NOTE: It may be
necessary to identify wires for proper reconnection to
new control.
5. Remove the two high limit mounting nuts holding the
sensor to the tank. Take care not to damage the
mounting studs.
6. Fasten the replacement high limit to the tank using the
nuts from step 5. Take care not to damage the mounting
studs. Refer to wiring diagram located on the inside of
the upper control box cover and properly reconnect wire
leads to new high limit.
High Limit Switch
7. Verify proper ECO operation.
Mounting Stud
Illustration 20
29
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SERVICE PROCEDURE MCE-XV
Heating Element Removal
and Replacement
DANGER
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned OFF
to water heater while performing this
procedure.
Heating Element Removal
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Turn off cold water supply to heater. Connect hose to drain
spigot of water heater and route to an open drain. Open
a nearby hot water faucet to vent heater for draining. Open
drain spigot of water heater and allow heater to drain
to a point below the Element(s).
WARNING
3. Close drain spigot and remove hose.
Heater components and stored water may be
HOT when performing the following steps in
this procedure. Take necessary precaution to
prevent personal injury.
4. Remove access cover from lower control box.
Remove insulation from inside of control box.
Remove plastic cover from thermostat.
5. Disconnect wires from element terminals.
6. Remove element from tank using 1-½” deep well socket or appropriate wrench. Unscrew element counter-clockwise
to remove from tank.
7. Be sure to remove old element gasket from the tank. It is not recommended to be re-used.
Heating Element Replacement
1. Check new element terminal block for proper electrical rating. NOTE: Some elements have dual ratings, be sure to
check all surfaces of the element terminal block (see illustration below).
2. Apply new element gasket to the new element. Be sure gasket is seated flat against element flange without rolls or
gaps (see illustration below).
3. Clean any debris from element fitting on tank.
4. Thread new element clockwise into tank. Tighten element using 1-½” deep well socket or appropriate wrench. Do not
over tighten, over tightening may damage element gasket.
5. Reconnect wires to element, be sure connections are snug and corrosion free. Do not over tighten, doing so may
damage terminal block.
6. Resume water supply to heater, be sure tank is full of water and check for leaks.
7. Re-install plastic thermostat protector(s).
8. Re-install insulation and control box cover.
9. To resume operation, BE SURE TANK IS FULL OF WATER and restore power to water heater. Verify proper heater
operation.
Element Rating.
Example: (4500 Watt, 240 Volt)
Date Code
Element Flange
Element Gasket Seated Flat Against
Element Flange Without Rolls or Gaps
Terminal
Block
Manufacturer Identification
30
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SERVICE PROCEDURE MCE-XVI
Anode Inspection and Replacement
Anode Inspection and Replacement
DANGER
High voltage exposure. To avoid hazard to Life
or property, be sure power is turned OFF to
water heater while performing this procedure.
WARNING
Heater components and stored water may be HOT when performing the following steps in
this procedure. Take necessary precaution to prevent personal injury.
1. Turn power “OFF” to water heater.
2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.
Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow
heater to drain to a point below the anode locations at the top of the tank.
3. Close drain spigot and remove hose.
4. Remove the plastic anode access plugs at the anode locations.
5. Remove anode from the water heater (1-1/16" socket).
6. Visually Inspect anode. Anode should show signs of depletion, this is normal.
If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is
recommended. If any of the steel core of the anode is exposed, replacement is recommended.
7. Upon completion of inspection or subsequent replacement, reinstall anode into heater. resume water supply, refill
heater with water and check for leaks.
8. To resume operation, BE SURE HEATER IS FULL OF WATER and turn power “ON” to water heater.
Anode Rod Locations
31
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Generic Parts List
32
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Generic Parts List
Item
1
2
3
3A
4
5
5A
6
7
8
Description
Item
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Description
Anode.
Heating Element Gasket.
Cold Water Inlet Nipple.
Plastic Snap Bushing.
Lower Control Box.
Upper Control Box.
Terminal Block (Block A)
Terminal Block End (used for block A).
Terminal Block 2 pole.
Terminal Block 3 Pole.
Screw.
Hot Water Outlet Nipple.
T&P Nipple.
T&P Coupling.
T&P Relief Valve.
High Limit Switch.
Surface High Limit Switch.
Hex Nut
Lock Washer
Screw
High Limit Spacer.
Cleanout O-Ring.
Cleanout Gasket (ASME).
Cleanout Cover.
Cleanout Cover (ASME).
Cleanout Cover Screw.
Cleanout Cover Screw (ASME)
Cleanout Access Cover.
Brass Drain Valve.
Escutcheon.
Drain Extender.
Thermostat Dial
Screw.
Immersion Thermostat.
Heating Element.
Surface thermostat Bracket.
Surface Thermostat.
Surface Thermostat Cover.
Lower Control Box Cover.
Heating Element Plug.
9
Fuse Block 2 Pole Class G
Fuse Block 3 Pole Class G
Fuse Block 3 Pole Class J
Contactor 3 Pole.
Contactor 4 Pole.
Screw.
Contactor Coil
Fuse Class G
Fuse Class J
Fuse Class J
Ground Lug Small.
Ground Lug Large.
Screw.
¾ NPT Plug.
Transformer - 120V
10
10A
11
11A
12
12A
13
14
15
16
17
18
19
20
21
22
23
24
25
Glossary of Terms
Term
Definition
Unit of measure
Volts
Voltage -
Current-
Resistance-
Electrical potential
Rate of voltage flow
Amperes (amp)
Ability of a device to dissipate Ohms
power irreversibly
Ability to do work
Energy per unit of time
Energy-
Power-
kW/hr, Joule
Watts, kW, VA
One kilowatt (1kW) = 1,000 Watts. = 3,412 BTU
DC = Direct Current
BTUH = British thermal units per hour
PSI = Pounds per square inch
GPM = Gallons per minute
AC = Alternating Current
Hz = Hertz
GPH = Gallons per hour
ECO = Energy cut off
°F = Degrees Fahrenheit
°C = Degree Centigrade
NPT = National pipe thread
ASME = American Society of Mechanical Engineers
33
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NOTES
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NOTES
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