Residential Electric and Light Duty Commercial Electric Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: Residential: RE1, RE2 & RE3 Upright Models. RE1 & RE2 Lowboy Models. RE1 Utility Models. RE1 Wall Hung Models. Light Duty: LE Upright Models. LE Utility Models. LE Lowboy. LE Wall Hung.
Residential and Light Duty Commercial Electric Water Heaters Page Service Procedure Introduction…………………………………………………………………… 2 --- Tools…………………………………………………………………………… 2 --- General Information………………………………………………………….. 3 --- Sequence of Operation……………………………………………………… Single Element Operation…………………………………….......... Double Element Non-Simultaneous Single Phase………………. Double Element Simultaneous Single Phase 4 wire Service…… Double Element Non-Simultaneous 3 Phase………....................
GENERAL INFORMATION Commonly Used Formulas Amps = Watts Volts Amps = Watts Volts x 1.732 (for balanced 3 phase units) Example: 4500W/240V x 1.732 = 10.82A Watts = Amps x Volts Example: 18.75A x 240V = 4500W Ohms = Volts Watts (for single phase units) Example: 4500W/240V = 18.75A 2 2 Example: (240V) / 4500W = 12.
GENERAL INFORMATION Wattage Limitations at Various Voltages Residential Electric Upright RE2 & RE3 Series (Non-Simultaneous Operation) Residential High Efficiency Upright RE2 Series (Non-Simultaneous Operation) Residential Electric Lowboy RE2 Series (Non-Simultaneous Operation) Maximum Wattage Element Upper/Lower Voltage 3,000 3,000/3,000 120 6,000 6,000/6,000 208, 240 6,000 6,000/6,000 277, 480 Residential Electric Upright RE2 & RE3 Series (Simultaneous Operation) Residential High Efficiency U
GENERAL INFORMATION Surface Mounted Thermostats Surface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the tank. Surface mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperature settings and high limit (ECO) activation. It is important that the entire back surface of the thermostat is in full contact or flush with the tank. Improperly mounted thermostat will lead to improper water heater operation.
SEQUENCE OF OPERATION Residential and light duty commercial electric water heaters are designed to operate using several different operating modes. The common modes and sequence of operation are as follows: 1. Single Element Operation. 2. Double Element Non-Simultaneous Operation (single phase). 3. Double Element Non-Simultaneous Operation (3 phase). 4. Double Element Simultaneous Operation (single phase). 5. Double Element Simultaneous Operation (3 phase). Sequence of Operation- Single Element Operation.
SEQUENCE OF OPERATION Non-Simultaneous and Simultaneous Operation Double element electric water heaters are designed to operate in either Non-Simultaneous or Simultaneous mode. Non-Simultaneous Mode: Allows only one heating element to operate at a time. For example, when the tank is cold, the upper element is energized first, heating the top of the tank.
SEQUENCE OF OPERATION A 4 wire, double element heater wired for simultaneous operation is essentially two single element systems operating independently. The heaters are wired internally with two independent circuits, one circuit for each thermostat/element combination. When installed using a two wire service, the blue and red (or white) wires will be connected together, likewise black and yellow wires will be connected together.
SEQUENCE OF OPERATION Sequence of Operation- Double Element, Non-Simultaneous Operation, 3 Phase. 1 1 2 3 4 5 Line voltage is applied across terminals L1 & L3 of upper thermostat. Likewise, Line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements. ECO Closed Tank is cold therefore both thermostats are closed at terminal T2 (calling for heat).
SEQUENCE OF OPERATION Sequence of Operation- Double Element, Simultaneous Operation, 3 Phase. 1 2 1 Line voltage is applied across terminals L1 & L3 of upper thermostat. Line voltage also extends to terminal L1 of lower thermostat. Also, line voltage is applied to terminal L3 of lower thermostat. ECO in both upper & lower thermostat is closed, so there is voltage at terminal L4 of both thermostats and to one side of both upper & lower elements.
SEQUENCE OF OPERATION Some electric utility companies will offer discounts for using electricity during “Off Peak” Times of the day. The system allows the use of an “Off Peak” meter, which interrupts power to the lower element during high power demand periods. Sequence of Operation- Double Element, Non-Simultaneous Operation, Single Phase, Off Peak. 1 2 3 Line voltage is applied across terminals L1 & L3 of the upper thermostat.
TROUBLESHOOTING Most common cause for improper electric water heater operation can be linked to heating element failure. When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot Water,” It’s always a good idea to check the heating elements first by following the procedure on page 15. Common Heating Element Failures: 1. Dry Firing. Element may be partially submerged in water or most likely, completely exposed with no water in tank.
TROUBLESHOOTING Quick Step Plan to Hot Water WARNING High voltage exposure. Use caution when making voltage checks to avoid personal injury. 1. TURN OFF power to water heater and check all wire connections to ensure they are tight and corrosion free. 2. Turn power “ON” and determine that service voltage is present, and the high limit (ECO) has not actuated (see procedure on page 14). 3. Check for inoperative heating element (see procedure on page 15). 4.
SERVICE PROCEDURE RE-I Line Voltage & High Limit (ECO) Testing Line Voltage Testing WARNING High voltage exposure. Use caution when making voltage checks to avoid personal injury. 1. Turn “OFF” power to water heater. 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat. ECO reset button 3. Set multi-meter to “Volts AC.” 4. Turn power “ON” to water heater. 5. Check voltage across terminals L1 & L3 of upper thermostat (see Figure 2).
SERVICE PROCEDURE RE-II Heating Element Testing Testing For Open Or Burned Out Element Step 1. TURN OFF POWER TO WATER HEATER Step 2. Remove access cover(s) from front of water heater. Remove insulation and plastic cover from thermostat. WARNING High voltage exposure. Be sure power is turned OFF to water heater prior to performing this procedure. Step 3. Disconnect wires from heating element(s). Step 4. Set multi-meter to “ohms” setting. Step 5.
SERVICE PROCEDURE RE-III Residential Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Single Element Operation or Double Element, 4 Wire, Simultaneous, Single Phase Operation Water In Tank Is Cold With Power ON 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of thermostat (see Figure 6).
SERVICE PROCEDURE RE-III Residential Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Double Element, Non-Simultaneous, Single Phase Operation. Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of upper thermostat (see Figure 8). A) Rated voltage NOT present, Recheck ECO.
SERVICE PROCEDURE RE-III Residential Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Double Element, Non-Simultaneous, Single Phase Operation (continued). Not Enough Hot Water (continued). 7. Check voltage across terminal L4 of upper thermostat and terminal 1 of lower thermostat (see Figure 11). A) Rated voltage NOT present, - check wire connection between thermostats. B) Rated voltage IS present, okay, go to step 8. 8.
SERVICE PROCEDURE RE-III Residential Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Double Element, Non-Simultaneous, Three Phase Operation. Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of upper thermostat (see Figure 13). A) Rated voltage NOT present, recheck ECO.
SERVICE PROCEDURE RE-III Residential Thermostat Testing Double Element, Non-Simultaneous, Three Phase Operation (continued). WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Tank Does Not Deliver Enough Hot Water (continued) 7. Check voltage across terminal L1 & L3 of lower thermostat (see Figure 16). A) Rated voltage NOT present, check wire connection between thermostats. B) Rated voltage is present, okay, go to step 8. 8.
SERVICE PROCEDURE RE-III Residential Thermostat Testing Double Element, Simultaneous, Three Phase Operation. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water In Tank Is Cold Or Not Enough Hot Water With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust temperature setting for both thermostats to the highest setting. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4.
SERVICE PROCEDURE RE-III Residential Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Double Element, Simultaneous, Three Phase Operation (continued). Water Temperature In Tank Is Above Thermostat Setting. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust upper and lower thermostat to the lowest setting. 3. Turn power “ON” to water heater. 4. Set multi-meter to “Volts AC.” 5.
SERVICE PROCEDURE RE-III Residential Thermostat Testing Double Element, Non-Simultaneous, Single Phase, Off Peak Operation. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of upper thermostat (see Figure 24).
SERVICE PROCEDURE RE-III Residential Thermostat Testing Double Element, Non-Simultaneous, Single Phase, Off Peak Operation. (continued) WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Not Enough Hot Water (continued). 7. Check voltage across terminal T4 of upper thermostat & T2 of lower thermostat. (see Figure 27). A) Rated voltage NOT present, replace lower thermostat. B) Rated voltage is present, okay, go to step 8. 8.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Non-Simultaneous, Single Phase Operation. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of upper thermostat (see Figure 29).
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Non-Simultaneous, Single Phase Operation (continued) WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Tank Does Not Deliver Enough Hot Water (continued). 7. Check voltage across terminal L3 of upper thermostat & T2 of lower Thermostat. (see Figure 32). A) Rated voltage NOT present, replace lower thermostat. B) Rated voltage is present, okay, go to step 8. 8.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Simultaneous, Single Phase Operation. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water In Tank Is Cold Or Not Enough Hot Water With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust temperature setting for both thermostats to the highest setting. 3. Turn power “ON” to water heater. 4. Set multi-meter to “Volts AC.” 5.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Simultaneous, Single Phase Operation (continued) WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water Temperature In Tank Is Above Thermostat Setting. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust upper and lower thermostat to the lowest setting. 3. Turn power “ON” to water heater. 4. Set multi-meter to “Volts AC.” 5.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Non-Simultaneous, Three Phase Operation. Water In Tank Is Cold With Power ON. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater. 3. Set multi-meter to “Volts AC.” 4. Check across terminals L4 and T2 of upper thermostat (see Figure 41).
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Double Element, Non-Simultaneous, Three Phase Operation (continued). Tank Does Not Deliver Enough Hot Water (continued). 7. Check voltage across terminal L1 of upper thermostat & T2 of lower thermostat. (see Figure 44). A) Rated voltage NOT present, Replace lower thermostat. B) Rated voltage is present, okay, go to step 8. 8.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Simultaneous, Three Phase Operation. Water In Tank Is Cold Or Not Enough Hot Water With Power ON. WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust temperature setting for both thermostats to the highest setting. 3. Turn power “ON” to water heater. 4. Set multi-meter to “Volts AC.” 5.
SERVICE PROCEDURE RE-IV Light Duty Commercial Thermostat Testing Double Element, Simultaneous, Three Phase Operation (continued). WARNING High voltage exposure. Use caution to avoid personal injury during this procedure. Water Temperature In Tank Is Above Thermostat Setting. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Adjust upper and lower thermostat to the lowest setting. 3. Turn power “ON” to water heater. 4. Set multi-meter to “Volts AC.” 5.
SERVICE PROCEDURE RE-V Thermostat Removal and Replacement Thermostat Removal WARNING High voltage exposure. Be sure power is “OFF” when performing this procedure. 1. Turn power “OFF” to water heater. 2. Remove access cover and insulation. 3. Remove plastic thermostat protector from thermostat. 4. Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connection to new thermostat. 5. Note thermostat temperature setting for proper setting of new thermostat. 6.
SERVICE PROCEDURE RE-VI Heating Element Removal and Replacement WARNING High voltage exposure. Be sure power is “OFF” when performing this procedure. Heating Element Removal 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 element(s). 3.
SERVICE PROCEDURE RE-VII Dip Tube and Anode Inspection and Replacement Diptube Inspection and Replacement WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Turn power “OFF” to water heater. Step 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.
Generic Parts List 11. Heating Element 12. Element Gasket 13. Access Cover 14. Lower Thermostat Protector 15. Lower Thermostat (59T) 16. Brass Drain Valve 17. Thermostat w/High Limit (59T/66T) 18. ASSE Approved Mixing Device 19. Kit Heat Trap 1. T&P Relief Valve 2. Heat Trap Insert (Outlet) 3. Hot Water Outlet/Anode 4. Cover Conduit/Ground 5. Junction Box Cover 6. Heat Trap Insert (Inlet) 7. Cold Water Inlet Diptube 8. Upper Thermostat Protector 9. Upper Thermostat 10.
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