AO Smith Compact 6 Commercial Light Duty Electric Water Heaters Instruction Manual
- June 12, 2024
- AO Smith
Table of Contents
Compact 6 Commercial Light Duty Electric Water Heaters
Product Information:
This is an instruction manual for Commercial Light Duty Electric
Water Heaters. The manual provides information on installation,
operation, service, and maintenance of the water heaters. The
manual is applicable to various models including Compact 6/10/15/20
Models, Lowboy 30/40/50 Models, and Tall 30/40/52 Models. The
manual is printed on 7/25/2022 7:17 AM CT and contains important
safety messages.
Product Usage Instructions:
1. Read and understand the instruction manual and safety
messages before installing, operating, or servicing the water
heater. Failure to follow these instructions and safety messages
may result in death or serious injury.
2. Keep the instruction manual with the water heater at all
times.
3. If the water heater becomes immersed in water up to or above
the level of the bottom of the element doors, it should be examined
by a qualified service agency before being placed in operation.
4. Place these instructions adjacent to the heater and notify
the owner to keep them for future reference.
5. Keep this manual in the pocket on the heater for future
reference whenever maintenance, adjustment, or service is
required.
6. Follow the safe installation, use, and service guidelines
provided in the manual.
7. Take necessary precautions to ensure safety during
installation, operation, and maintenance of the water heater.
8. Limit the risk of scalding by following the recommended
guidelines.
9. Be aware of the potential presence of hydrogen gas
(flammable) and take appropriate precautions.
10. Familiarize yourself with the hazard messages provided in
the manual.
11. Follow the preparation steps before installing the water
heater.
12. Understand the features and components of the water
heater.
13. Consider the installation requirements, including proper
location and clearances.
14. Ensure you have the required ability and knowledge for
installation.
15. Follow the specific installation instructions provided in
the manual.
16. Take into account any issues related to contaminated water,
circulating pump, insulation blankets, closed water systems,
thermal expansion, and electrical connections during
installation.
17. Follow the startup procedures, including limiting the risk
of scalding, filling the water heater, initial startup, and
draining the water heater.
http://waterheatertimer.org/3-phase-water-heaters.html Instruction Manual
COMMERCIAL LIGHT DUTY ELECTRIC WATER HEATERS
Compact 6/10/15/20 Models Lowboy 30/40/50 Models Tall 30/40/52 Models
INSTALLATION – OPERATION – SERVICE – MAINTENANCE
LOW LEAD CONTENT
Printed on 7/25/2022 7:17 AM CT
Read and understand this instruction manual and the safety messages herein
before installing, operating or servicing this water heater.
Failure to follow these instructions and safety messages could result in death
or serious injury.
This manual must remain with the water heater.
Thank you for buying this energy efficient water heater. We appreciate your confidence in our products.
Electrical Shock Hazard
If the water heater becomes immersed in water up to or above the level of the
bottom of the element doors, the heater should be examined by a qualified
service agency before it is placed in operation.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 0322
100357051_2000605443B
CONTENTS
SAFE INSTALLATION, USE, AND SERVICE ………………..3 Important Definitions
…………………………………………………3
APPROVALS ………………………………………………………………3
GENERAL SAFETY INFORMATION…………………………….4 Precautions ……………………………………………………………..4
Limiting the Risk of Scalding ………………………………………4 Hydrogen Gas (Flammable)
……………………………………….4 Hazard Messages …………………………………………………….4
INTRODUCTION ………………………………………………………..7 Preparing for the Installation
………………………………………7
FEATURES AND COMPONENTS………………………………..8 Model and Rating
……………………………………………………..9
INSTALLATION CONSIDERATIONS ………………………….10 Locating the Water
Heater………………………………………..10 Clearances ……………………………………………………………. 11
INSTALLATION …………………………………………………………12 Required Ability ………………………………………………………12
General………………………………………………………………….12 Contaminated Water………………………………………………..12
Circulating Pump …………………………………………………….12
Insulation Blankets ………………………………………………….12 Temperature-Pressure Relief
Valve……………………………12 Closed Water Systems …………………………………………….13 Thermal Expansion
…………………………………………………13 Electrical ……………………………………………………………….. 13
START UP ………………………………………………………………..15 Limiting the Risk of Scalding
…………………………………….15 Filling the Water Heater……………………………………………15 Initial Start
Up…………………………………………………………15 Draining the Water Heater………………………………………..15
TEMPERATURE REGULATION…………………………………16 Temperature Adjustment
………………………………………….16
MAINTENANCE ………………………………………………………..18 Draining and Flushing
……………………………………………..18 Lime Scale Removal ……………………………………………….18 Anode
Maintenance ………………………………………………..19 Temperature-Pressure Relief Valve Test
…………………….19
TROUBLESHOOTING ………………………………………………21 Checklist ……………………………………………………………….. 21
Checking for Leaks………………………………………………….22
WIRING DIAGRAM……………………………………………………23
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SAFE INSTALLATION, USE, AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safetyrelated messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential
injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Keep this manual near the water heater.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in injury or death.
WARNING CAUTION CAUTION
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in injury or death.
CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage.
All safety messages will generally tell you about the type of hazard, what can
happen if you do not follow the safety message, and how to avoid the risk of
injury.
IMPORTANT DEFINITIONS
· Qualified Installer or Service Agency:
Installation and service of this water heater requires ability equivalent to
that of a Qualified Agency (as defined by ANSI below) in the field involved.
Installation skills such as plumbing, electrical supply are required in
addition to electrical testing skills when performing service.
· ANSI Z223.1 2006 Sec. 3.3.83:
“Qualified Agency” – “Any individual, firm, corporation or company that either
in person or through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the connection,
installation, testing, repair or servicing of appliances and equipment; that
is experienced in such work; that is familiar with all precautions required;
and that has complied with all the requirements of the authority having
jurisdiction.”
APPROVALS
LOW LEAD CONTENT
3
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GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN EXPOSED TO FLOODING OR WATER
DAMAGE. Immediately call a qualified service technician to inspect the water
heater and to replace any part of the control system which has been under
water.
If the unit is exposed to the following, do not operate heater until all
corrective steps have been made by a qualified service technician.
1. External fire. 2. Damage. 3. Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National Electrical
Code and/or local codes. These must be followed in all cases. Failure to
ground this water heater properly may also cause erratic control system
operation on ELECTRONIC CONTROL models.
This water heater must be connected to a grounded metal, permanent wiring
system; or an equipment grounding conductor must be run with the circuit
conductors and connected to the equipment grounding terminal or lead on the
water heater.
LIMITING THE RISK OF SCALDING
For a variety of reasons, water heaters can produce water that is much hotter
than its temperature setting. Take precautions to prevent this higher
temperature water from reaching the water fixtures.
Burn Hazard
To reduce the risk of unusually hot water reaching the fixtures in the house,
install thermostatic mixing valves at each point of use.
A properly adjusted thermostatic mixing valve at each point of use allows you
to set the tank temperature to a higher setting without increasing risk of
scalds. A higher temperature setting allows the tank to provide much more hot
water and can help provide proper water temperatures for appliances such as
dishwashers and washing machines.
HYDROGEN GAS (FLAMMABLE)
Explosion Hazard
Flammable hydrogen gases may be present.
Keep all ignition sources away from faucet when turning on hot water.
Hydrogen gas can be produced in a hot water system served by this heater that
has not been used for a long period of time (generally two weeks or more).
Hydrogen gas is extremely flammable. To reduce the risk of injury under these
conditions, it is recommended that the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance connected to
the hot water system. If hydrogen is present there will probably be an unusual
sound such as air escaping through the pipe as the water begins to flow. THERE
SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
HAZARD MESSAGES
Read and understand this instruction manual and the safety messages herein
before installing, operating or servicing this water heater.
Failure to follow these instructions and safety messages could result in death
or serious injury.
This manual must remain with the water heater.
Electrical Shock Hazard
If the water heater becomes immersed in water up to or above the level of the
bottom of the element doors, the heater should be examined by a qualified
service agency before it is placed in operation.
4
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Burn Hazard
To reduce the risk of unusually hot water reaching the fixtures in the house,
install thermostatic mixing valves at each point of use.
Explosion Hazard
Flammable hydrogen gases may be present.
Keep all ignition sources away from faucet when turning on hot water.
Electrical Shock Hazard
Before removing any access panels or servicing the water heater, make sure the
the electrical supply to the water heater is turned OFF.
Failure to follow these instructions can result in personal injury or death.
CAUTION
Property Damage Hazard
· All water heaters eventually leak. · Do not install without adequate
drainage.
Water temperature over 125°F (52°C) can cause severe burns instantly resulting
in severe injury or death. Children, the elderly and the physically or
mentally disabled are at highest risk for scald injury. Feel water before
bathing or showering. Temperature limiting devices such as thermostatic point-
of-use mixing valves must be installed when required by codes and to ensure
safe temperatures at fixtures.
Explosion Hazard
Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME
code. Properly sized temperaturepressure relief valve must be installed in
opening provided. Can result in overheating and excessive tank pressure. Can
cause serious injury or death.
Property Damage Hazard
The temperature-pressure relief-valve discharge pipe must terminate at an
adequate drain.
Electrical Shock Hazard Full power is present whenever the cabinet door is
opened, even with the pilot switch turned off.
Burn Hazard
If you choose a higher temperature setting, install thermostatic mixing valves
at each point-of-use to help avoid scalding.
CAUTION
Property Damage Hazard
To avoid water heater damage, fill tank with water before operating.
· Burn hazard. · Hot water discharge. · Keep hands clear of drain valve
discharge.
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Burn hazard. Hot water discharge. Keep clear of TemperaturePressure Relief
Valve discharge outlet.
Property Damage Hazard
Avoid damage. Inspection and replacement of anode rod required.
6
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INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
wet hands or when standing in water. When replacing fuses
maintained, it should give you years of trouble free service.
always use the correct size for the circuit. See Wiring Diagram
Abbreviations Found In This Instruction Manual:
(page 23).
· ANSI – American National Standards Institute · AHRI – Air-Conditioning, Heating and Refrigeration Institute
The model and rating plate on page 9 interprets certain markings into useful information. Both of these references
· NEC – National Electrical Code · NFPA – National Fire Protection Association
should be used to identify the heater, its components and optional equipment.
· UL – Underwriters Laboratory
2. The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of
PREPARING FOR THE INSTALLATION
the power company. In the absence of local codes, the installation
must comply with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National
Electrical Shock Hazard
Electrical Code may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The
Before removing any access panels or servicing the water heater, make sure the the electrical supply to the water heater is turned OFF.
Canadian Electrical Code is available from the Canadian Standards Association,
8501 East Pleasant Valley Road, Cleveland, OH 44131.
3. If after reading this manual you have any questions or do not
Failure to follow these instructions can result in personal injury or death.
understand any portion of the instructions, call the toll free number listed on the back cover (page 24) of this manual for technical
assistance.
A sample rating plate is shown in Model and Rating (page 9).
1. Read the “General Safety Information” section of this manual
In order to expedite your request, please have full model and
first and then the entire manual carefully. If you don’t follow the
serial number available for the technician.
safety rules, the water heater may not operate safely. It could
cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY 4. Carefully plan your intended placement of the water heater.
DAMAGE.
Examine the location to ensure the water heater complies with
Locating the Water Heater (page 10).
This manual contains instructions for the installation, operation,
and maintenance of the electric water heater. It also contains
Installation and service of this water heater requires ability
warnings throughout the manual that you must read and be
equivalent to that of a licensed tradesman or qualified agency
aware of. All warnings and all instructions are essential to the
in the field involved. Plumbing and electrical work are required.
proper operation of the water heater and your safety. READ
See Important Definitions (page 3).
THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
Be sure to turn off power when working on or near the electrical system of the heater. Never touch electrical components with
7
FEATURES AND COMPONENTS
This page shows typical water heater installations by model designations. Lowboy 30/40/50 & All Tall Water Heaters
Single-Element Water Heater
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Install suitable drain pans under water heaters to prevent damage due to leakage. See Locating the Water Heater (page 10).
Install thermal expansion tank if check valve or pressure reducing valve is used in supply line.
Install vacuum relief in cold water inlet line as required by local codes.
OVER CURRENT PROTECTION MUST BE SUPPLIED IN WATER HEATER CIRCUIT. CONSULT LOCAL CODE OR CURRENT EDITION OF NEC FOR PROPER INSTALLATION.
- INSTALL IN ACCORDANCE WITH ALL LOCAL CODES.
Figure 1. Typical Water Heater Installations
8
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Table 1. Recovery Capacities
Element Wattage (Upper/Lower)
Input kW
U.S. Gallons/Hr and Liters/Hr at Temperature Rise Indicated F° 36F° 40F° 54F° 60F° 72F° 80F° 90F° 100F° 108F° 120F° 126F° C° 20C° 22.2C° 30C° 33.3C° 40C° 44.4C° 50C° 55.5C° 60C° 66.6C° 70C°
NON-SIMULTANEOUS
/1500
GPH 17 15 11 10
8
8
7
6
6
5
5
1.5 LPH 64 58 43 38 32 29
26 23 21 19 18
/2000
GPH 23 20 15 14
11
10
9
8
8
7
6
2.0 LPH 85 77 57 51 43 38
34 31 28 26 24
/2500
GPH 28 25 19 17 14 13
11 10
9
8
8
2.5 LPH 107 96 71 64 53 48
43 38 36 32 30
3000/3000
GPH 34 30 23 20 17 15
14 12 11 10 10
3.0 LPH 128 115 85 77 64 58
51 46 43 38 37
4000/4000
GPH 45 41 30 27 23 20
18 16 15 14 13
4.0 LPH 170 153 114 102 85 77
68 61 57 51 49
4500/4500
GPH 51 46 34 30 25 23
20 18 17 15 14
4.5 LPH 192 173 128 115 96 86
77 69 64 58 55
5000/5000
GPH 56 51 38 34 28 25
23 20 19 17 16
5.0 LPH 213 192 142 128 107 96
85 77 71 64 61
6000/6000
GPH 68 61 45 41 34 30
27 24 23 20 19
6.0 LPH 256 230 170 153 128 115 102 92 85 77 73
SIMULTANEOUS OPERATION
3000/3000
GPH 68 61 45 41 34 30
27 24 23 20 19
6 LPH 256 230 170 153 128 115 102 92 85 77 73
4000/4000
GPH 90 81 60 54 45 41
36 32 30 27 26
8 LPH 341 307 227 205 170 153 136 123 114 102 97
4500/4500
GPH 101 91 68 61 51 46
41 36 34 30 29
9 LPH 384 345 256 230 192 173 153 138 128 115 110
5000/5000
GPH 113 101 75 68 56 51
45 41 38 34 32
10 LPH 426 384 284 256 213 192 170 153 142 128 122
6000/6000
GPH 135 122 90 81 68 61
54 49 45 41 39
12 LPH 511 460 341 307 256 230 205 184 170 153 146
Recovery capacities at 100° F rise equal: for non-simultaneous element operation = 4.1 gal. x kW of one element; for simultaneous
element operation = 4.1 gal. x 2/3 KW of both elements. For other rises multiply element KW as previously explained by 410 and
divide by temperature rise. Full load current for single phase = total watts : voltage.
MODEL AND RATING
ELECTRIC STORAGE TANK WATER HEATER
LLC
MODEL NUMBER
SERIAL NUMBER
LISTED 932N
ITEM ID/PART NUMBER
VOLTS – AC
PHASE
WATTS UPPER
WATTS LOWER
TOTAL WATTS CONNECTED
CAPACITY US GAL.
MAX WORKING PRESSURE
VOLTS – AC
ALTERNATE RATINGS
WATTS UPPER
WATTS LOWER
TOTAL WATTS CONNECTED
CIRCUIT
9
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OUTLET 3/4″ (FEMALE)
NPT
ANODES D
INSTALLATION CONSIDERATIONS
INLET 3/4″ (FEMALE)
NPT
ANODE
OUTLET
3/4″ (FEMALE)
NPT
D
INLET 3/4″ (FEMALE)
NPT
JUNCTION BOX
TOP VIEW DEL 30/40/50
2 1/2″ (63.5 mm)
B
3/4″ NPT RELIEF VALVE
OPENING
DRAIN VALVE
FRONT VIEW DEL 30/40/50
CA
JUNCTION BOX
2 1/2″
(63.5 mm) TOP VIEW DEN 30 – 52
B
3/4″ NPT RELIEF VALVE
OPENING
DRAIN VALVE
FRONT VIEW DEN 30-52
CA
TOP VIEW DEL 6/10/15/20
OUTLET 3/4″ (FEMALE)
NPT
ALTERNATE OUTLET 3/4″ (FEMALE) NPT
3/4″ NPT RELIEF VALVE
OPENING
B
ELECTRICAL CONNECTION
CA
INLET 3/4″ (FEMALE)
NPT
FRONT VIEW DEL 6/10/15/20 *(NO SIDE OUTLET AVAILABLE FOR DEL-6 MODELS)
Models Di- No. of mensions Elements
Compact-6
1
Compact-10 1
Compact-15 1
Compact-20 1
Lowboy-30
2
Lowboy-40
2
Lowboy-50
2
Tall-30
2
Tall-40
2
Tall-52
2
Tank Capacity
US Gals 6 10 15 20 36 38 51 40 50 55
Liters 23 38 57 76 136 144 193 151 189 208
Figure 2. Rough-In Dimensions
Table 2. Rough-In Dimensions
A
B
C
Inches
mm
Inches
mm
Inches
mm
15.50
394
14.25
362
11.00
279
18.25
464
18.00
457
12.50
318
26.00
660
18.00
457
20.50
521
22.25
565
21.75
552
15.38
391
32.00
813
24.00
610
24.00
610
32.00
813
23.00
584
24.00
610
36.00
914
26.50
673
25.00
635
49.75 1264 20.50 521 53.25 1353
59.00 1499 20.50 521 51.25 1302
56.50 1435 24.00 610 48.50 1232
D
Inches
mm
–
–
–
–
–
–
–
–
8.00
203
8.00
203
8.00
203
8.00
203
8.00
203
8.00
203
Approx.
Shipping Weight
Lbs.
kg.
35 15.9
54 24.5
58 26.3
73 33.1
118 53.5
118 53.5
172 78.0
118 53.5
125 56.7
145 65.8
LOCATING THE WATER HEATER
CAUTION
Property Damage Hazard
· All water heaters eventually leak. · Do not install without adequate
drainage.
The water heater should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent to the heater or to
lower floors of the structure.
When such locations cannot be avoided, a suitable drain pan should be
installed under the heater.
Such pans should be at least two inches deep, have a minimum length and width
of at least two inches greater than the diameter of the heater and should be
piped to an adequate drain.
The water heater should be located as close as possible to/or centralized to the water piping system. The water heater should be located in an area not subject to freezing temperatures.
Drain pans suitable for these water heaters are available from your distributor or A.O. Smith Water Heater Parts Fulfillment, 125 Southeast Parkway, Franklin, TN 37068.
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Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property damage,
even with the use of a drain pan piped to a drain. However, unanticipated
damage can be reduced or prevented by a leak detector or water shut-off device
used in conjunction with a piped drain pan. These devices are available from
some plumbing supply wholesalers and retailers, and detect and react to
leakage in various ways: · Sensors mounted in the drain pan that trigger an
alarm or turn
off the incoming water to the water heater when leakage is detected. · Sensors
mounted in the drain pan that turn off the water supply to the entire home
when water is detected in the drain pan. · Water supply shut-off devices that
activate based on the water pressure differential between the cold water and
how water pipes connected to the water heater. · Devices that will turn off
the gas supply to a gas water heater while at the same time shutting off its
water supply. CLEARANCES A minimum clearance of 4″ must be allowed for access
to replaceable parts such as thermostats, drain valve and relief valve.
Adequate clearance for servicing this water heater should be considered before
installation, such as changing the anodes, etc.
Electrical Shock Hazard
If the water heater becomes immersed in water up to or above the level of the
bottom of the element doors, the heater should be examined by a qualified
service agency before it is placed in operation.
11
INSTALLATION
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REQUIRED ABILITY
Installation and service of this water heater requires ability equivalent to
that of a qualified installer or service agency in the field involved. See
Important Definitions (page 3). Plumbing and electrical work is required.
GENERAL
WARNING
Toxic Chemical Hazard
Do not connect to non-potable water system.
The installation must conform with these instructions and the local code
authority having jurisdiction and the requirements of the power company. In
the absence of local codes, the installation must comply with the latest
editions of the National Electrical Code, NFPA 70 or the Canadian Electrical
Code CSA C22.1. The National Electrical Code may be ordered from: National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The
Canadian Electrical Code is available from the Canadian Standards Association,
8501 East Pleasant Valley Road, Cleveland, OH 44131.
Do NOT test electrical system before heater is filled with water, follow the
START UP procedure in the OPERATION section of this manual.
The principal components of the heater are identified in the Features and
Components (page 8).
Water temperature over 125°F (52°C) can cause severe burns instantly resulting
in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest
risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as thermostatic point-of-use mixing valves
must be installed when required by codes and to ensure safe temperatures at
fixtures.
CONTAMINATED WATER
This water heater shall not be connected to any heating system(s) or
component(s) used with a non-potable water heating appliance.
Toxic chemicals, such as those used for boiler treatment shall not be
introduced into this system.
CIRCULATING PUMP Field installed circulating pumps should be of all bronze
construction.
INSULATION BLANKETS
Insulation blankets are available to the general public for external use on
electric water heaters but are not necessary with this product. The purpose of
an insulation blanket is to reduce the standby heat loss encountered with
storage tank heaters.
Should you choose to apply an insulation blanket to this heater, you should
follow these instructions below. Failure to follow these instructions can
result in fire, serious personal injury, or death. · Do not cover the
temperature and pressure relief (T & P) valve
with an insulation blanket. · Do not cover the instruction manual. Keep it on
the side of the
water heater or nearby for future reference. · Do obtain new warning and
instruction labels for placement on
the blanket directly over the existing labels.
MIXING VALVE USAGE
TEMPERATURE-PRESSURE RELIEF VALVE
Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/developmentally disabled. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a maximum water temperature at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a MIXING VALVE, should be used at the hot water taps used by these people or at the water heater.
Explosion Hazard
Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME
code.
Properly sized temperaturepressure relief valve must be installed in opening
provided.
Can result in overheating and excessive tank pressure.
MIXING VALVES for reducing point of use temperature are available and are to be set at a maximum of 125 degree F. Consult a qualified installer or service agency. Follow all manufacturer’s Instructions for installation of these valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certified
combination temperature – pressure relief valve by the manufacturer. The valve
is certified by a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment of materials as meeting
the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 ·
CSA 4.4, and the code requirements of ASME.
12
If replaced, the new valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve rated/sized and certified as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or KW input rate as shown on the water heater’s model rating plate.
one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged can cause bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the temperature- pressure relief valve with a properly rated/sized new one.
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For safe operation of the water heater, the temperature and pressure relief
valve must not be removed from its designated opening nor plugged. The
temperature-pressure relief valve must be installed directly into the fitting
of the water heater designed for the relief valve. Install discharge piping so
that any discharge will exit only within 6 inches (15.2 cm) above, or at any
distance below the structural floor. Be certain that no contact is made with
any live electrical part. The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length, over 30 feet (9.14 m), or
use of more than four elbows can cause restriction and reduce the discharge
capacity of the valve.
No valve or other obstruction is to be placed between the relief valve and the
tank. Do not connect discharge piping directly to the drain unless a 6″ (15.2
cm) air gap is provided. To prevent bodily injury, hazard to life, or property
damage, the relief valve must be allowed to discharge water in adequate
quantities should circumstances demand. If the discharge pipe is not connected
to a drain or other suitable means, the water flow may cause property damage.
Property Damage Hazard
The temperature-pressure relief-valve discharge pipe must terminate at an
adequate drain.
If you do not understand these instructions or have any questions regarding
the temperature-pressure relief valve call the toll free number listed on the
back cover (page 24) of this manual for technical assistance.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such conditions as
high line pressure, among others, have installed devices such as pressure
reducing valves, check valves, and back flow preventers. Devices such as these
cause the water system to be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed system the
volume of water will grow when it is heated. As the volume of water grows
there will be a corresponding increase in water pressure due to thermal
expansion. Thermal expansion can cause premature tank failure (leakage). This
type of failure is not covered under the limited warranty. Thermal expansion
can also cause intermittent temperature-pressure relief valve operation: water
discharged from the valve due to excessive pressure build up. This condition
is not covered under the limited warranty. The temperature-pressure relief
valve is not intended for the constant relief of thermal expansion.
The Discharge Pipe:
· Shall not be smaller in size than the outlet pipe size of the valve, or have
any reducing couplings or other restrictions.
· Shall not be plugged or blocked. · Shall be of material listed for hot water
distribution. · Shall be installed so as to allow complete drainage of both
the
temperature-pressure relief valve and the discharge pipe. · Must terminate a
maximum of six inches above a floor drain
or external to the building. In cold climates, it is recommended that the
discharge pipe be terminated at an adequate drain inside the building. · Shall
not have any valve or other obstruction between the relief valve and the
drain.
Water temperature over 125°F (52°C) can cause severe burns instantly resulting
in severe injury or death.
A properly sized thermal expansion tank should be installed on all closed
systems to control the harmful effects of thermal expansion. Contact a local
plumbing service agency to have a thermal expansion tank installed.
ELECTRICAL
Electrical Shock Hazard
Before removing any access panels or servicing the water heater, make sure the
the electrical supply to the water heater is turned OFF.
Failure to follow these instructions can result in personal injury or death.
Children, the elderly and the physically or mentally disabled are at highest
risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as thermostatic point-of-use mixing valves
must be installed when required by codes and to ensure safe temperatures at
fixtures.
The temperature-pressure relief valve must be manually operated at least once
a year. Caution should be taken to ensure that (1) no
GENERAL
The installation must conform with these instructions and the local code
authority having jurisdiction and the requirements of the power company. In
the absence of local codes, the installation must comply with the current
editions of the National Electrical Code, NFPA 70 or the Canadian Electrical
Code CSA C22.1.
An electrical ground is required to reduce risk of electrical shock or
possible electrocution. The water heater should be connected to a separate
grounded branch circuit with over-current protection
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and disconnect switch. The water heater should be grounded in accordance with
national and local codes.
Voltage applied to the heater should not vary more than +5% to -10% of the
model and rating plate marking for satisfactory operation.
DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON BEFORE THE HEATER TANK IS
FILLED WITH WATER. DOING SO WILL CAUSE THE HEATING ELEMENTS TO BURN OUT AND
VOID WARRANTY.
The factory wiring is attached to a terminal block within the external
junction box unit. The branch circuit is connected to the terminal block
within this junction box. The water heater should be connected to 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.
BRANCH CIRCUIT
The branch circuit wire size should be established through reference to the
current edition of NFPA-70, the National Electrical Code or other locally
approved source in conjunction with the heater amperage rating. For
convenience, portions of the wire size tables from the Code are reproduced
here. The branch circuit should be sized at 125 percent of the heater rating
and further increase wire size as necessary to compensate for voltage drop in
long runs.
CALCULATING AMPERAGE/OVER-CURRENT PROTECTION
The heaters come from the factory in two configurations:
1. Two wire C-2 circuit for single element heater equipped with a high limit
control, single phase power input.
2. Four wire A-8 circuit for dual element heater equipped with two high limit
controls, single phase or three phase power input.
The heater with dual elements is factory wired for connection to a three wire,
three-phase delta branch circuit, non-simultaneous operation. In addition a
ground conductor is required.
Element connection is for non-simultaneous operation. This means only one
element at a time operates. The wiring diagram shows the heater may be field
converted to simultaneous element operation by moving the red wire on “J”
terminal to L1. See Wiring Diagram (page 23). It is then possible for both
elements to operate at once as determined by the thermostats. Regardless of
element connection the heater operates in an “unbalanced” fashion.
The heater may be field converted to single-phase operation by moving the wire
on L3 of the terminal block to L2. L3 is not used. See Wiring Diagram (page
23).
The heater, now in single-phase non-simultaneous operation, may be field-
converted to single phase simultaneous operation by moving the red wire on
terminal “J” to L1. See Wiring Diagram (page 23).
This is an example of calculating heater amperage for both types of element
operation. From this, the branch circuit conductor and over-current protection
sizing can be established.
The example is of a three-phase 240 volt unit with two, 6 kw elements. The
notations are for units field converted to single-phase. Check the heater
model and rating plate for actual specifications and substitute those values
in the following.
Table 3. Example Calculation
Non-simultaneous:
Simultaneous:
(Factory wired)
(Field conversion)
3000 : 240 = 12.5 amps*
3000 : 240 = 12.5 amps* 12.5 x 1.73 = 21.6 amps
*NOTE: as a single-phase nonsimultaneous unit.
*NOTE: as a single-phase simultaneous unit the total is: 12.5 x 2 = 25 amps
The rating of the over-current protection should be computed on the basis of 125 percent of the total connected load amperage. Where the standard ratings and settings do not correspond with this computation, the next higher standard rating or setting should be selected.
PORTION OF TABLE 310-16 (NFPA-70) FOLLOWS:
Allowable Ampacities of Insulated Copper Conductors. Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F).
These ampacities relate only to conductors described in Table 310-13 in Code.
For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code.
Size
AMG MCM
18 16 14 12 10 8 6 4 3
Portion of Table 310-16 (NFPA-70)
Temperature Rating of Conductor
See Table 310-13 in Code
60°C
75°C
(140°F)
(167°F)
Types: RUW, (14-2), T, TW, UF
Types: RH, RHW, RUH, (14-2), THW, THWN, XHHW, USE
– – –
– – –
– – –
– – –
15
15
20
20
30
30
40
45
55
65
70
85
80
100
PORTION OF TABLE 310-18 FOLLOWS:
Allowable Ampacities of Insulated Aluminum and Copper -Clad Aluminum Conductors.
Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F. These ampacities relate only to conductors described in Table 310-13 in Code.
For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code.
Size
AMG MCM
12 10 8 6 4 3 2 1
Portion of Table 310-18 (NFPA-70)
Temperature Rating of Conductor
See Table 310-13 in Code
60°C
75°C
(140°F)
(167°F)
Types: RUW, (14-2), T, TW, UF
Types: RH, RHW, RUH, (14-2), THW, THWN, XHHW, USE
15
15
25
25
30
40
40
50
55
65
65
75
75
90
85
100
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START UP
See Features and Components (page 8) for the location of 1. Turn off the electrical disconnect switch.
components mentioned in the instructions that follow.
2. Close the water heater drain valve.
NEVER turn on power to the water heater without being certain the 3. Open a nearby hot water faucet to permit the air in the system
water heater is filled with water and a temperature and pressure
to escape.
relief valve is installed in the relief valve opening.
4. Fully open the cold water inlet pipe valve allowing the heater and
DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS FILLED
piping to be filled.
WITH WATER. FOLLOW FILLING AND START-UP INSTRUCTIONS 5. Close the hot water faucet as water starts to flow. The heater is
IN OPERATION SECTION.
now ready for STARTUP and TEMPERATURE REGULATION.
INITIAL START UP
Electrical Shock Hazard
Full power is present whenever the cabinet door is opened, even with the pilot
switch turned off.
LIMITING THE RISK OF SCALDING
For a variety of reasons, water heaters can produce water that is much hotter
than its temperature setting. Take precautions to prevent this higher
temperature water from reaching the water fixtures.
Burn Hazard
To reduce the risk of unusually hot water reaching the fixtures in the house,
install thermostatic mixing valves at each point of use.
A properly adjusted thermostatic mixing valve at each point of use allows you
to set the tank temperature to a higher setting without increasing risk of
scalds. A higher temperature setting allows the tank to provide much more hot
water and can help provide proper water temperatures for appliances such as
dishwashers and washing machines.
Burn Hazard
If you choose a higher temperature setting, install thermostatic mixing valves
at each point-of-use to help avoid scalding.
The following checks should be made by the installer when the heater is placed
into operation for the first time.
1. Turn off the electrical disconnect switch.
2. Open the front panel or top access cover, check all water and electrical
connections for tightness. Also check connections on top and or sides of
heater. Repair water leaks and tighten electrical connections as necessary.
3. Depress the red manual reset button on each Thermostat/ECO combination
control. See Temperature Regulation (page 16)
4. Turn on the electrical disconnect switch.
5. Observe the operation of the electrical components during the first
heating cycle. Use care as the electrical circuits are energized.
6. Close the front panel or top access cover.
Temperature control and contactor operation should be checked by allowing
heater to come up to temperature and shut off automatically. Use care as the
electrical circuits are energized.
DRAINING THE WATER HEATER
The water heater must be drained if it is to be shut down and exposed to
freezing temperatures. Maintenance and service procedures may also require
draining the heater.
1. Turn off the electrical disconnect switch.
2. Open a hot water valve until the water is cool, then close the supply
water inlet valve to heater.
3. Attach hose to outlet opening of drain valve and direct end to drain.
4. Open a nearby hot water faucet and the heater drain valve.
5. If the heater is being drained for an extended shutdown, it is suggested
the drain valve be left open during this period. The hose may be removed.
Follow the instructions in Filling the Water Heater (page 15) when restoring
hot water service.
FILLING THE WATER HEATER
CAUTION
Property Damage Hazard
· Burn hazard. · Hot water discharge. · Keep hands clear of drain valve discharge.
To avoid water heater damage, fill tank with water before operating.
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TEMPERATURE REGULATION
Water temperature over 125°F (52°C) can cause severe burns instantly resulting
in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest
risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as thermostatic point-of-use mixing valves
must be installed when required by codes and to ensure safe temperatures at
fixtures.
Table 4. Burn Time at Various Temperatures
Water Temperature °F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree (Most Severe Burns)
110 (43)
(normal shower temp.)
116 (47)
(pain threshold)
116 (47)
35 minutes
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (68)
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
THE WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER
TEMPERATURE. HOT WATER AT TEMPERATURES DESIRED FOR AUTOMATIC DISHWASHER AND
LAUNDRY USE CAN CAUSE SCALDS RESULTING IN SERIOUS PERSONAL INJURY AND/OR
DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND
TIME OF EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN , AGED OR DISABLED
PERSONS INCREASES THE HAZARD TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT
WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED
PERSON UNATTENDED IN A BATHTUB OR SHOWER.
It is recommended that lower water temperatures be used to avoid the risk of
scalding. It is further recommended, in all cases, that the water temperature
thermostats (See Temperature Adjustment) be set for the lowest temperature
which satisfies your hot water needs. This will also provide the most energy
efficient operation of the water heater.
Burn Hazard
If you choose a higher temperature setting, install thermostatic mixing valves
at each point-of-use to help avoid scalding.
Temperature Adjustment shows the approximate time-to-burn relationship for
normal adult skin. The thermostats on your water heater have a linear
relationship between degrees of angular rotation and the corresponding change
in temperature. Thus rotating the temperature adjustment indicator 30 angular
degrees will result in a 10 degree Fahrenheit change in water temperature.
Burn Hazard
To reduce the risk of unusually hot water reaching the fixtures in the house,
install thermostatic mixing valves at each point of use.
TEMPERATURE ADJUSTMENT
A-8 circuit thermostats are adjustable from approximately 120°F (49°C) (lowest
setting) to 181°F (83°C) (highest setting). The C-2 circuit thermostat is
adjustable from approximately 110°F (43°C) to 170°F (77°C). These thermostats
are set from the factory at approximately the 140°F (60°C) setting. The over
temperature device (ECO high limit) attached to each thermostat has a manual
reset.
L1
L3
RESET
RESET
L2
L4
T1
T2
T4
89T THERM O DISC
L1
L3
RESET
RESET
L2
L4
T1
T2
T4
THERM-O-DISC
83°C
181°F
120°F 49°C
140°F 60°C
170°F
110°F
140°F
Figure 3. A-8 Thermostat
Figure 4. C-2 Thermostat
Note: It is not necessary to adjust the upper thermostat for a dual element unit. However, if it is adjusted above the factory set point 140°F (60°C) it is recommended that it not be set higher than the lower thermostat setting.
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To change the temperature setting:
Electrical Shock Hazard
Before removing any access panels or servicing the water heater, make sure the
the electrical supply to the water heater is turned OFF.
Failure to follow these instructions can result in personal injury or death.
1. DANGER: Turn off the heater electrical supply. Do not attempt to adjust
thermostat with power on.
2. Open the junction box door (for upper thermostat of dual element water
heater only) and/or remove the (lower) thermostat access panel. Do not remove
the plastic personnel protectors covering the thermostats. The thermostat is
factory pre-set at 140°F (60°C).
3. Using a flat tip screwdriver, rotate the adjusting knob to the desired
temperature setting.
4. Replace the covers and access panels, and turn on heater electrical
supply.
Burn Hazard
If you choose a higher temperature setting, install thermostatic mixing valves
at each point-of-use to help avoid scalding.
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MAINTENANCE
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Component Tank
Tank
Tank
Moving Parts Powered Anodes T&P Valve
Table 5. Maintenance Schedule
Operation
Interval
Reference
Drain and Flush
Every 6 Months
See Draining and Flushing
Lime Scale Re-
moval (Water Less Than
Not Required
N/A
25 Grains Hard)
Lime Scale Removal
(Water Greater Than 25 Grains
Hard)
Annually See Lime Scale Removal.
Lubrication
Not Required
N/A
Inspection/ Cleaning
Annually
See Anode Maintenance (page 19)
Test Operation
Semi Annually
See Temperature-Pressure Relief Valve Test. (page 19).
4. Close the cold water inlet valve to the water heater.
5. Connect a hose to the water heater drain valve and terminate it to an
adequate drain.
6. Open the water heater drain valve and allow all the water to drain from
the storage tank.
7. Close the water heater drain valve when all water in the storage tank has
drained.
8. Close the hot water faucet opened in Step 3.
9. If the water heater is going to be shut down for an extended period, the
drain valve should be left open.
FLUSHING THE WATER HEATER STORAGE TANK
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve discharge outlet.
Periodically the drain valve should be opened and the water allowed to run
until it flows clean. This will help to prevent sediment buildup in the tank
bottom.
Periodically check the temperature and pressure relief valve to ensure that it
is in operating condition. Lift the lever at the top of the valve several
times until the valve seats properly and operates freely.
Water heater maintenance includes periodic tank flushing and cleaning, and
removal of lime scale from the heating element.
The heater tank is equipped with an anode rod to aid in corrosion control.
1. Turn off the electrical supply to the water heater.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the water is no
longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate drain.
5. Ensure the drain hose is secured before and during the entire flushing
procedure. Flushing is performed with system water pressure applied to the
water heater.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and allow the water
to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10. Fill the water heater. See Filling the Water Heater (page 15).
11. Turn on the electrical supply to place the water heater back in
operation.
12. Allow the water heater to complete several heating cycles to ensure it is
operating properly.
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained and flushed
every 6 months to reduce sediment buildup. The water heater should be drained
if being shut down during freezing temperatures. See Figure 1 (page 8) for the
location of the water heater components described below.
· Burn hazard. · Hot water discharge. · Keep hands clear of drain valve
discharge.
LIME SCALE REMOVAL
When water is heated, dissolved minerals in the water such as calcium and
magnesium carbonate (lime scale) become less soluble. As the water temperature
rises these minerals will precipitate or “fall out” of solution.
The amount of lime scale released from water is in direct proportion to water
temperature and usage. The higher the water temperature or water usage, the
more lime deposits are dropped out of the water.
Water hardness also affects lime scale accumulation. With the temperature and
usage being the same, hard water will release more lime scale than softer
water.
DRAINING THE WATER HEATER STORAGE TANK 1. Turn off the electrical supply to the water heater.
Lime scale reduces heating efficiency as it accumulates inside a water heater. Heating transfer surfaces become coated with lime scale deposits which increases fuel costs to operate the water heater. Lime scale deposits can also cause rumbling and pounding noises as air molecules trapped in the lime scale escape when heated. Lime scale accumulation also reduces the life span of water heaters. For these reasons a regular schedule for deliming should be set up.
2. Ensure the cold water inlet valve is open.
CHEMICAL LIME SCALE REMOVAL
Open a nearby hot water faucet and let the water run until the water is no longer hot.
To dissolve and remove more stubborn lime scale deposits, UNLIME® Professional Delimer should be used.
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UN-LIME® Professional Delimer is an easy to handle patented food grade acid
formulated specifically for lime scale removal from all types of water using
equipment. Hydrochloric base acids must not be used to delime the water
heaters covered in this manual.
Follow the instructions on the UN-LIME® to delime the water heater. Note:
Contact Technical Support for assistance in ordering the UN-
LIME® Professional Delimer.
ANODE MAINTENANCE
Property Damage Hazard
Avoid damage. Inspection and replacement of anode rod required.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from tank. See Draining and
Flushing (page 18) for proper procedures. Close drain valve.
4. Remove old anode rod.
5. Use Teflon® tape or approved pipe sealant on threads and install new anode
rod.
6. Turn on water supply and open a nearby hot water faucet to purge air from
water system. Check for any leaks and immediately correct any if found.
7. Restart the water heater as directed in this manual. See Figure 1 (page 8)
for anode rod location.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifices itself to protect the tank. Instead of corroding tank, water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition.
Anode deterioration depends on water conductivity, not necessarily water
condition. A corroded or pitted anode rod indicates high water conductivity
and should be checked and/or replaced more often than an anode rod that
appears to be intact. Replacement of a depleted anode rod can extend the life
of your water heater. Inspection should be conducted by a qualified
technician, and at a minimum should be checked annually.
Artificially softened water is exceedingly corrosive because the process
substitutes sodium ions for magnesium and calcium ions.
The use of a water softener may decrease the life of the water heater tank.
The anode rod should be inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
· The majority of the rods diameter is less than 3/8″. · Significant sections
of the support wire (approx. 1/3 or more of
the anode rod’s length) are visible.
It is recommended that the Temperature-Pressure Relief Valve should be checked
to ensure that it is in operating condition every 6 months.
When checking the Temperature-Pressure Relief Valve operation, make sure that
(1) no one is in front of or around the outlet of the Temperature-Pressure
Relief Valve discharge line, and (2) that the water discharge will not cause
any property damage, as water may be extremely hot. Use care when operating
valve as the valve may be hot.
To check the temperature-pressure relief valve, lift the lever at the end of
the valve several times. See Figure 6. The valve should seat properly and
operate freely.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to the
water heater and drain the water heater. See Draining and Flushing (page 18).
Replace the Temperature-Pressure Relief Valve with a properly rated/sized new
one. See Temperature-Pressure Relief Valve (page 12) for instructions on
replacement.
Figure 5. Anode Depletion
If the anode rod show signs of either or both it should be replaced. Note:
Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found. Dot the following to replace the
anode: 1. Turn off the power supply to the water heater.
Figure 6. Testing the Temperature-Pressure Relief Valve
If the Temperature-Pressure Relief Valve on the water heater weeps or
discharges periodically, this may be due to thermal expansion.
Note: Excessive water pressure is the most common cause of Temperature-
Pressure Relief Valve leakage. Excessive water system pressure is most often
caused by “thermal expansion” in a “closed system.” See Closed Water Systems
(page 13) and Thermal Expansion (page 13). The Temperature-Pressure
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Relief Valve is not intended for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build up in a closed
system that does not have a thermal expansion tank installed is not covered
under the limited warranty. Thermal expansion tanks must be installed on all
closed water systems. DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF VALVE
OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.
Explosion Hazard
· Temperature-Pressure Relief Valve must comply with ANSI Z21.22-CSA 4.4 and
ASME code.
· Properly sized temperature-pressure relief valve must be installed in
opening provided.
· Can result in overheating and excessive tank pressure.
· Can cause serious injury or death.
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TROUBLESHOOTING
CHECKLIST
ABNORMAL SOUNDS
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. See Figure 1 (page 8) to identify and locate water
heater components.
8. Sediment or lime scale accumulations on the elements causes sizzling and
hissing noises when the heater is operating. · The sounds are normal, however,
the tank bottom and elements should be cleaned. See the Maintenance section of
this manual.
WATER LEAKAGE IS SUSPECTED
Electrical Shock Hazard
Before removing any access panels or servicing the water heater, make sure the
the electrical supply to the water heater is turned OFF.
Failure to follow these instructions can result in personal injury or death.
NOT ENOUGH OR NO HOT WATER
1. Be certain the electrical disconnect switch serving the water heater is in
the ON position.
2. Check the fuses. · The electrical disconnect switch usually contains
fuses.
3. If the water was excessively hot, and is now cold, the high limit switch
may have activated. · See Temperature Regulation (page 16) for more
information on how to reset the ECO high limit controls.
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.
5. Cooler incoming water temperature will lengthen the time required to heat
water to the desired temperature.
6. Look for hot water leakage. 7. Sediment or pipe scale may be affecting
water heater operation.
See Checking for Leaks (page 22).
1. Check to see if the heater drain valve is tightly closed.
2. If the outlet of the relief valve is leaking it may represent: · Excessive
water temperature. · Faulty relief valve. · Excessive water pressure.
3. Excessive water pressure is the most common cause of relief valve leakage.
It is often caused by a “closed system”. See “Closed Water Systems” and
“Thermal Expansion” in the Installation section of this manual for more
information.
4. Examine the area around the element for gasket leakage. · Tighten the
elements or, if necessary, follow the instructions in Lime Scale Removal (page
18) to replace the gaskets.
IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF MALFUNCTION
1. Turn the power supply to the water heater off.
2. Close the supply water inlet valve to the heater.
3. Contact a Qualified Service Agency in your area. Call the toll free phone
number on the back cover (page 24) of this Instruction Manual for assistance
in locating a service agency in your area.
REPLACEMENT PARTS
Call the toll free phone number on the back cover (page 24) of this
Instruction Manual for assistance in locating replacement parts.. When
ordering parts, specify complete model no., serial no., (see rating plate),
quantity and name of part desired. Standard hardware items should be purchased
locally.
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CHECKING FOR LEAKS
Use this illustration as a guide when checking for sources of water leakage.
You or your dealer may be able to correct what appears to be a problem.
Note: Cover and insulation are show removed to reveal tank top.
All water which appears at the water heater bottom or on the surrounding floor
may be caused by condensation, loose connections or relief valve operation and
leakage. Do not replace the water heater until full inspection of all
potential leak points is made and corrective steps taken to stop the leak.
Leakage from other appliances, water lines or ground should also be suspected until proven otherwise. See Water Leakage Is Suspected (page 21).
Never use this water heater unless it is completely filled with water.
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To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning the water
heater.
1 3 4
RESET RESET
L1
L3
RESET
L2
L4
T1
T2
T4
89T THERM O DISC
181°F
120°F
140°F
L1
L3
RESET
L2
L4
T1
T2
T4
89T THERM O DISC
181°F
120°F
140°F
10
6 7
8
6 7 8 5
9
1. Where possible remove or lift top cover to examine threads of fittings
installed into tank for evidence of leakage. Correct fitting leaks as
necessary.
2. Condensation may be seen on pipes in humid weather or pipe connections
may be leaking.
3. The anode rod fitting may be leaking.
4. The temperature-pressure relief valve may be leaking at the tank fitting.
5. Small amounts of water from temperature-pressure relief valve may be due
to thermal expansion or high water pressure in your area.
6. Water on the side of the tank may be condensation due to the panel or
insulation not being in place.
7. Defective element which leaks at terminals or thru flange. Replace
element
8. Loose element/gasket leak a. Screw-in type: tighten with 1-1/2″ socket
wrench. If leak continues, remove element, discard gasket and clean thread
areas. Apply non-hardening Permatex Number 2 to thread areas, install new
gasket and screw element into fitting until it seats. Tighten 1/2 to 3/4 turn
with wrench. b. Flange type: tighten screw with wrench. If leak continues
remove element and discard gasket. Clean gasket seating areas and re-install
element with new gasket. A new element may be required where threads have
become rusted or damaged, preventing tightening.
9. Water from a drain valve may be due to the valve being slightly opened.
10. *The drain valve may be leaking at the tank fitting.
Figure 7. Leakage Checkpoints
Read and understand this instruction manual and the safety messages herein
before installing, operating or servicing this water heater. Failure to follow
these instructions and safety messages could result in death or serious
injury. This manual must remain with the water heater.
Leakage from other water heaters, water lines, or ground seepage should also be checked.
- To check where threaded portion enters tank, insert cotton swab between jacket opening and fitting. If cotton is wet, follow “Draining” instructions in the “Periodic Maintenance” section and then remove fitting. Put pipe dope or teflon tape on the threads and replace. Then follow “Filling the Water Heater” instructions in the “Installing the New Water Heater” section.
*Contact your dealer as it is necessary to shut off electricity and drain tank to perform procedure.
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WIRING DIAGRAM
A-8 CIRCUIT FOR DUAL ELEMENT HEATER
C-2 CIRCUIT FOR SINGLE ELEMENT HEATERS EQUIPPED WITH HIGH LIMIT CONTROL
Printed on 7/25/2022 7:17 AM CT
FACTORY WIRED
———-
FIELD WIRING
WHITE FOR 120V & 277V
Figure 8. A8 and C2 Circuit Wiring Diagrams
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Printed on 7/25/2022 7:17 AM CT
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Tech Support: 800-527-1953 Parts:
800-433-2545
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