COMMERCIAL ELECTRIC ENERGY SAVER WATER HEATER ASME SERIES IMMERSION THERMOSTAT WITH CONTACTORS SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: CEA6, CEA12, CEA20,CEA30, CEA40, CEA50,CEA80, CEA120 Manual 238-53684-00A REV 7/19 Save this manual for future reference
Table of Contents Page Service Procedure Introduction ………………………………………………………………………… 2 --- Tools………………………………………………………………………………… 2 --- General Information ………………………………………………………………. 3 --- Sequence of Operation ………………………………………………………… 10 --- Troubleshooting …………………………………………………………………… 13 --- Heating Element Testing ……………............................................................. 15 ACE-I Line Voltage Testing………………...…………………………………………. 16 ACE-II Fuse Testing…........................................
GENERAL INFORMATION Model Number Breakdown CEA120 - 24 - 3 - 108B - BBG Pressure Gage Option Control Circuit Option Code. Any combination of the following optional controls: - Heating Element Time Delay Sequencing NOTE: Code - Low Water Power Interrupt “AA” - Panel Door Interlock denotes no - High Pressure Power Interrupt optional - Low Pressure Power Interrupt controls used.
GENERAL INFORMATION General Controls Layout Standard Controls Contactor Contactor operation is achieved by energizing a 120 volt operating coil located within the contactor 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. Optionally, time delay sequencers may be used to stage contactor activation thereby reducing the inrush of current to the water heater.
GENERAL INFORMATION Standard Controls (continued) Immersion Style Thermostat Control 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.
GENERAL INFORMATION Standard Controls (continued) Direct Immersion “Screw-in” Type Heating Element Optional Controls Certain control components are available as “Optional.“ When these optional components are installed with the water heater, the control circuit wiring diagram accordingly will include these components.
GENERAL INFORMATION Optional Controls (continued) Low Water Level Control This control will interrupt the electrical current to the contactor coil when a low water level condition is sensed inside the water heater tank. When the low water level condition is corrected the control will automatically sense the new situation and electrical current will again energize the contactor coil. Normal water heater operation will be resumed.
GENERAL INFORMATION Optional Controls (continued) Electrical Door Lock An electrical door lock is offered in order to secure the access to the water heater control cabinet. This device will lock the control cabinet door when the 120VAC control circuit voltage is applied to it. Note: Once the door is opened, the water heater can be re-energized, if necessary, for service diagnosis.
GENERAL INFORMATION Commonly Used Formulas (Single Phase) (balanced 3 phase) Watts Volts Watts Amps= Volts x 1.
GENERAL INFORMATION Sequence of Operation This water heater has two distinct electrical systems. One system, referred to as the “Control Circuit”, controls the water heater operation, while the other system, referred to as the “Power Circuit”, connects the electrical power to the heating elements. The electrical contactors interconnect these two systems. In order to clearly illustrate the electrical circuits, two wiring diagrams are provided.
Control Circuit Sequence (continued) Certain other control components are available as “Optional“. These controls are specified when the installation has unique requirements that must be safeguarded. When these optional components are installed the control circuit wiring diagram accordingly will include these components.
Power Circuit Description The Power Circuit Wiring Diagram illustrates the electrical connections from the incoming power supply through the contactors to the heating elements. The power circuits are available with internal circuit fusing and without internal circuit fusing. As it would be impractical to show all wired configurations in this service manual, a reference wiring diagram is illustrated below to aid in the understanding of the power circuit operating sequence.
Troubleshooting The 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.
Quick Step Plan to Hot Water 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Check all wire connections to ensure they are snug and corrosion free. 3. Reset High-Limit (ECO) (page 18). 4. Check for inoperative heating element (page 15). 5. Check line voltage (page 16), and internal fuses (page 17). 6. Refer to table below if items 1 through 5 above do not correct problem. SYMPTOM No Hot Water Not Enough Hot Water Slow Hot Water Recovery Over Heated Water PROBABLE CAUSE 1.No power to heater. 2.
Heating Element Testing 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control panel access door. 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 Figure 1). 6. Reading should be 12.8 ohms (±6%) for a 240 volt, 4500 watt element, see table below for other elements.
Line Voltage Testing Line voltage (single phase or three phase) will connect to a terminal block or directly to a fuse block located inside the control panel. Determine the heater’s 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 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control panel door. 3.
Fuse Testing 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control panel door 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 Figure 5). A) Continuity IS present, fuse is okay.
High Limit Control (ECO) Operation Observe heaƟng cycle. N Does the switch open? Switch Contacts: Normally closed Is water temp over 196°F? Open on rise @ 196°F ±4°F Manual Reset 1. Determine if High-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. 2. Use caution and turn power on to water heater and observe heating cycle following the High-Limit Heating Cycle flow chart.
Immersion Thermostat Operation Testing Thermostat Specification: Calibration: 184°F/176°F Max Differential: 6°F Operating Range 80 to 180°F Provided that the water temperature in the 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. Using caution, turn Power “ON” and rotate the thermostat dial to call for heat.
Contactor Operating Coil Contactor operation is achieved by energizing an operating coil located within the contactor. The contactor coil is considered part of the control circuit operating at 120 volts as described on page 10. Noisy Contactor In most cases, noisy or chattering contactor operation 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.
Immersion Thermostat Removal 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control box door. 3. 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 Figure 10 for location). 4. Close drainspigot and remove hose. 5.
High Limit Control (ECO) Removal 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control box door. 3. 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 the drain spigot of the water heater and allow heater to drain to a point below the Immersion bulb location (see Figure 12). 4. Close drainspigot and remove hose. 5.
Heating Element Removal 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open control box door. 3. 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 heating element(s). 4. Close drainspigot and remove hose. 5. Disconnect wires from heating element terminals. 6.
Anode Inspection and Replacement 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 anode locations at the top of the tank. 3. Close drainspigot and remove hose. 4. Remove the plastic anode access plugs at the anode locations. 5.
25
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Item Description T&P Relief Valve Nipple Plastisert Hot Water Outlet Nipple Magnesium Anode Nipple Galvanized Pipe Tee Galvanized Combination T&P Gage (optional) High Pressure Switch (optional) Low Pressure Switch (optional) Screw Immersion Thermostat Thermostat Dial Hex Nut Lock Washer Screw High Limit Spacer High Limit Switch Cleanout Access Cover Cleanout Cover Screw Cleanout Cover 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 3
