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COMMERCIAL ELECTRIC WATER HEATERS

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1. 2 76 No Current Detected 76 Temp Probe ice eh esed Ede 77 Temp 77 Energy Cut QUE EGO tec ee 78 EW CO rci cH 79 No Anode Current osse n n ap es rers P OR eai 80 INTRODUCTION INTRODUCTION This Service Manual is designed to be an aid in servicing and troubleshooting the commercial electric water heater models listed on the cover The instructions illustrations and procedures contained in this manual are used to verify proper operation and to diagnose and repair common service problems This manual does not replace or supersede the Instruction Manual that came with the water heater Always refer to the Instruction Manual that came with the water heater for complete installation instructions If the Instruction Manual is not available copies can be obtained from the manufacturers web site or by calling the technical support phone number shown on the back cover of this manual Review the Common Service Problems on page 73 prior to performing any service procedures QUALIFICATIONS QUALIFIED SERVICE AGENT servicing the products referenced in this manual 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 diagno
2. Two ends Two ends Two ends Resistive Circuits of loop1 ofloop2 ofloop3 Three resistive wire conductors inside three U shaped loops that are permanently fitted into a flange form the heating element Servicing should only be performed by a Qualified Service Agent 16 OPERATION amp SERVICE Heating Element Wiring This section will provide more detailed information on heating elements and how they are wired in single phase three phase Delta and three phase Y configurations See Single And Three Phase Power on page 12 Six and Three Wire Heating Elements Depending on how a water heater is ordered and factory configured it will be equipped with heating elements that have six wiring leads or three wiring leads Six wire elements can be used with single or three phase power Three wire also called Y configured heating elements are used with three phase power only Each heating element has 3 loops each loop is a resistive circuit see Heating Element Construction on page 16 Six wire heating elements have a wire lead connected to both ends of the three loops Three wire heating elements Y configured have a metal bar that joins or splices together one end from each of the three loops and a wire lead connected to the remaining end of each loop See the illustrations below see also pages 18 22 for details on wiring between the heating elements and contactors Six Wire Element Three Wire Element Y Configured Single amp Three
3. 13 Checking Three Phase 14 BUILD 15 Heating ntc kd du 16 Heating Element 16 Six and Three Wire Heating Elements 17 Single Phase Element Wiring 18 19 Three Phase Element Wiring 20 22 Heating Element Ratings amp Configurations 23 Heating Element Amperage Tables 24 Heating Element Amperage Test 25 Heating Element Voltage Test 26 Heating Element Resistance Tables 28 Heating Element Resistance Test 29 Heating Element Ground Test 30 Replacing Heating Elements 31 Heating Element Sensors eaae 32 Element Sensor Operation 33 34 Contactor 35 Contactor Ins DecllOD 36 Contactor Coil Voltage At Contactor 37 Contactor Coil Voltage At 38 Tratistor Pte S cosi ctia oun o mc coa 39 120 VAC Control Circuit Transformer
4. 1 2 Ensure the main breaker or disconnect switch is turned on Verify the CCB has the correct input voltage at the J2 socket and is properly grounded perform the Checking Power and Ground To The CCB tests on page 54 Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC Check for 120 VAC to the ECO With the J5 plug installed in the J5 socket on the CCB page 50 insert one of the two volt meter probes into pin 1 of J5 plug as shown in the 120 VAC To ECO image below Volt meter probe may have to be pressed firmly into the plug to make contact with the metal conductor inside Touch the other volt meter probe to the ground wire connection on the water heater The measured voltage should be approximately 120 VAC e f the measured voltage is approximately 120 VAC proceed to Step 5 e fthe measured voltage is zero or considerably less or more than 120 VAC and all Steps above have been performed call the toll free Technical Support phone number listed on the back cover of this manual for further assistance Check for 120 VAC from the ECO With the J5 plug installed in the J5 socket on the CCB page 50 insert one of the two volt meter probes into pin 1 of J5 plug as shown in the 120 VAC From ECO image below Volt meter probe may have to be pressed firmly into the plug to make contact with the metal conductor inside Touch the other volt meter probe to the ground wire connection on the water heater The mea
5. 4 INSTALLATION CONSIDERATIONS ELECTRICAL REQUIREMENTS Grounding Review the electrical ground requirements given in the Instruction Manual that came with the water heater and ensure the water heater has been properly grounded The water heater must be grounded in accordance with the National Electric Code and or local codes These codes must be followed in all cases The 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 Service Note The water heaters covered in this manual are equipped with electronic controls that may experience erratic operation if the water heater is not properly grounded These water heaters are also equipped with a LWCO low water cut off Some models will also be equipped with a powered anode rod LWCO devices and powered anode rods require an adequate earth ground to work properly See pages 47 and 48 Power Supply Review the electrical requirements listed on the water heater s rating label and in the Instruction Manual that came with the water heater Ensure the branch circuit supplying power to the water heater is within these requirements and properly connected Ensure the power supply phase single or three phase 10 30 and power supply voltage match the water heater s rating label Some of the commercial electric water heate
6. all models at the lower terminals of the contactor s Servicing should only be performed by a Qualified Service Agent 14 OPERATION amp SERVICE FUSES Depending on total amp draw and how they were ordered some water heaters will be equipped with power circuit fuses to protect the heating element circuits All models will have two fuses to protect the primary winding of the 120 Volt Control Circuit Transformer See Figures 1 and 2 on pages 8 and 9 for location Testing fuses requires an ohm meter an AC volt meter and an insulated fuse puller see Tools Required page 3 Service Note Replacement Fuses Replacement fuses MUST BE of the same value and type as the factory installed fuses call the toll free technical support or parts department phone number on the back cover of this manual for further assistance Ohm Meter Method Secure power to the water heater at the main breaker or disconnect switch 2 Remove each fuse to be tested with an insulated fuse puller 3 Setthe Ohm meter to it s lowest resistance range 200 or to an audible beep continuity test setting if SO equipped 4 Touch the meter probes to both ends of each fuse simultaneously 5 If the fuse being tested shows a low resistance lt 1 ohms or the continuity test feature sounds an audible beep the fuse being tested is good and can be re installed 6 Ifthe fuse being tested shows infinite resistance open circuit or the continuity test feature does not sound
7. 50 52 Check ECO continuity and for 120 VAC to and from the ECO see pages 45 amp 46 Replace Immersion Temperature Probe if ECO switch contacts remain open at normal operating tem peratures Ensure the contactors are not stuck closed see page 36 Ensure the contactor coils are not being ener gized during standby mode see pages 37 amp 38 Check water system piping ensure heat is not being added to the water heater being serviced by any other heating appliances or heat sources Call the toll free technical support phone num ber on the back cover of this manual for further assistance if the problem has not been cor rected after performing the procedures outlined here Servicing should only be performed by a Qualified Service Agent 78 TROUBLESHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR Fault Ensure the water heater is full of water Follow Fault Condition the filling instructions in the maintenance sec tion of Instruction Manual that came with the The control system has detected a low water water heater condition in the water heater s storage tank see Ensure the water heater is properly grounded page 47 see grounding instructions in the Instruction Manual that came with the water heater and Possible Causes Grounding instructions on page 5 in this man No water or low water in tank ual Water heater CCB not properly grounded Plug socket
8. 60 C before the control system can be reset Once the water temperature has cooled below this point the power supply to the water heater must be turned off and on again to reset the control system Temperature Sensor The temperature sensor located inside the Immersion Temperature Probe is a thermistor two black wires Thermistors are thermally sensitive resistors As the water temperature rises the resistance in ohms of the sensor will decrease as the temperature falls the resistance will increase see the Temperature Sensor Resistance Data table on page 44 The control system interprets the changes in resistance as changes in water temperature The control system constantly monitors the temperature sensor thermistor for temperature The control system is programmed to declare a Fault condition if the resistance of the temperature sensor drops below 390 ohms shorted or above 56 000 ohms open If the resistance of the temperature sensor is below 390 ohms the control system will lock out and display a Temp Probe Short Fault message on the UIM page 58 If the resistance of the temperature sensor is above 56 000 ohms the control system will lock out and display a Temp Probe Open Fault message on the UIM Voltage to the contactor coils see pages 3 amp 38 and heating elements is terminated during lock out to prevent further heating operation If the control system locks out the condition that caused the lock out must be
9. D d 1 ME STANDARD 3 MN ANODE ROD GROUND LUG ground wire connection POWER DISTRIBUTION BLOCK only when there is more than one contactor POWER CIRCUIT FUSES optional CONTROL ince CIRCUIT UIM user interface module T FUSES CCB CIRCUIT BOARD 120V Central Control Board CONTROL CIRCUIT TRANSFORMER CONTACTOR s IMMERSION TEMPERATURE PROBE also contains ECO ON OFF SWITCH high temp limit switch Pilot Switch LWCO PROBE 24V TRANSFORMER low water cut off DRAIN HINGED ACCESS DOOR HEATING ELEMENT s COLD WATER INLET POWERED ANODE ROD Figure 2 Servicing should only be performed by a Qualified Service Agent 9 OPERATION amp SERVICE OPERATION amp SERVICE This section of the manual will cover principles of electricity single and three phase power fuses heating element construction amp operation heating element sensors contactors common service procedures and more Information and service procedures presented in this section will be referenced in the troubleshooting sections at the end of this manual PRINCIPLES OF ELECTRICITY Voltage The unit of measurement used to quantify electrical pressure or the force that causes electrical energy to flow is the volt or voltage Volt meters are used to determine if there is an adequate supply of electricity or voltage to a heating element Amperage The unit of measurement used to quantify the
10. Distribution Block or contactor on single element models ensure wiring is correct and connections are tight and making good contact Verify 120 VAC Control Circuit Transformer wiring is correct see pages 39 amp 40 Check Secondary Winding Voltage Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC Touch the two volt meter probes between the Control Circuit Transformer s secondary winding X1 and X2 terminals as shown in the Secondary Winding Voltage Test image below There should be approximately 120 VAC present between these two terminals If the voltage measured is approximately 120 VAC the Control Circuit Transformer is operating properly If the voltage measured is zero volts or considerably less or more 10 than 120 VAC AND all Steps above have been completed and the results were successful replace the Control Circuit Transformer When replacing the Control Circuit Transformer check all wiring to and from the transformer for pinched or shorted wires repair or replace damaged wiring as necessary Service Note A continuity test can also be performed on the Control Circuit Transformer primary and secondary windings to determine if either winding is an open circuit Secure power to the water heater Disconnect all wiring to the transformer Using an ohm meter check for continuity between the terminals on the primary and secondary windings checked in Steps 3 and 4 above Primary Winding Voltage Tes
11. J14 Socket Heating Element 3 Sensors J15 Socket Heating Element 4 Sensors J16 Socket Heating Element 5 Sensors J17 Wiring Terminals Contactor Coils TERMINAL DESCRIPTION OUT 4 120 VAC hot to Heating Element 4 Contactor Coil if so equipped OUT 5 120 VAC hot to Heating Element 5 Contactor Coil if so equipped Servicing should only be performed by a Qualified Service Agent 52 OPERATION amp SERVICE CCB Enable Disable Circuit s Test The electronic control system includes two enable disable circuits see page 63 for use with field installed supervisory controls such as building EMS Energy Management System These two circuits are located at the CCB s four pin J7 Socket Both of these Enable Disable circuits must be closed to enable heating operation If either circuit is open for any reason heating operation will be disabled even though the tank temperature may be well below the Operating Set Point see Heating Cycle Disabled on page 75 There is a plug with two jumper wires installed from the factory in the CCB J7 socket to enable heating operation when external controls are not in use If the plug is not present or if one of the two jumper wires fails to close either enable disable circuit heating operation will be disabled A simple continuity check is performed on the J7 Plug end to ensure heating should not be disabled as follows 1 If either enable disable circuit is in use external wiring connected J7 plug
12. Phase Power Three Phase Power Only Metal bar that joins or splices together one end of each loop Six wiring leads one at both ends POBRE COR Three wiring leads one at one end of each loop Six wiring leads Metal bar that joins or splices together one end of each loop Servicing should only be performed by a Qualified Service Agent 17 OPERATION amp SERVICE Single Phase Wiring 3 Pole Contactor The illustrations below show how six wire heating elements page 17 are wired to 3 pole contactors on water heaters connected to a single phase power supply See the Contactors section of this manual pages 34 38 Connection Diagram Wiring Diagram L1 L2 L1 L2 OA Heating Element Flange End View Three loops of one heating element Single phase 10 power supply Note middle pole of the three pole contactor is not used on models configured for single phase 10 power 3 Pole Contactor Note these two lines exiting the bottom of the contactor represent six wiring leads from a heating element as shown in the connection diagram on the left Two ends Two ends Two ends ofloop1 ofloop2 ofloop3 Servicing should only be performed by a Qualified Service Agent 18 OPERATION amp SERVICE Single Phase Wiring 4 Pole Contactor The illustrations below show how six wire heating elements page 17 are wired to 4 pole contactors on water heaters connected to a s
13. Wiring 39 amp 40 120 VAC Control Circuit Transformer Test 41 24 VAC Transformer 42 Immersion Temperature Probe 43 Temperature Sensor Resistance Test 44 Temperature Sensor DC Voltage Test 45 ECO Continuity oe eta eoe cete ca 45 ECO Voltage Tesisin nonen 46 LWCO Low Water Cut 47 Powered Anode Rod 48 Electronio Controls e de 49 CCB Central Control 50 CCB Socket amp Wiring Terminal Identification 51 CCB Enable Disable Circuit s Test 53 Checking Power And Ground To 54 UIM User Interface Module 55 ELECTRONIC CONTROL SYSTEM 56 Heating Element Operation 56 Control System 57 Control System Navigation 57 The Desktop 58 LEIS ICOMS 2 59 Operating ona eese 60 Control System 22222 60 Temperatures eae
14. after performing the procedures outlined here Servicing should only be performed by a Qualified Service Agent 77 TROUBLESHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICATES Energy Cut Out ECO Fault Condition The control system has detected excessive water temperature inside the water heater The ECO high temperature limit switch activates at 202 F 94 C oee ECO High Temperature Limit Switch description on page 43 Possible Causes Plug socket connection problems Wiring connection problems Contactor s stuck closed Contactor coils being energized in standby mode Defective Immersion Temperature Probe Water piping problems Energy Cut Out ECO Fault occurred 0 mins ago Tank temperature is excessive The water heater has been disabled Call a service professional Paul Stewart XXX press DOWN for more BACK ADVANCED CHECK REPAIR Check the J5 plug socket connection at the CCB ensure they are mating properly and pro viding good contact Check the pins inside the J5 plug socket for wear or damage See CCB illustration and socket identification on pages 50 52 Replace damaged plug connectors wiring harness as necessary Check for pinched or broken wiring between the Immersion Temperature Probe and the J5 plug socket connection on the CCB repair or replace damaged wiring as necessary See CCB illustration and socket identification on pages
15. back cover of this manual for further assistance if the problem has not been cor rected after performing the procedures outlined here Servicing should only be performed by a Qualified Service Agent 76 TROUBLESHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR Temp Probe Open Fault Condition The control system has detected an open circuit from the temperature sensor The control system will declare this Fault condition if it senses a resistance above 56 000 ohms from the temperature sensor Possible Causes Plug socket connection problems Wiring connection problems Defective Immersion Temperature Probe Temp Probe Open Fault occurred 0 mins ago There is problem with the ab NN temperature probe Call a service professional Paul Stewart XXX XXX press DOWN far more ka ACK ADVANCED _ Temp Probe Short Fault Condition The control system has detected a shorted circuit in the temperature sensor The control system will declare this Fault condition if it senses a resistance below 390 ohms from the temperature sensor Possible Causes Shorted wiring Defective Immersion Temperature Probe Temp Probe Short Fault occurred 14 mins ago There is a problem with the temperature probe Call a service professional Paul Stewart XXX XXX XXXX press DOWN for more BACK ADVANCED Check the J5 plug socket connections at th
16. by an external supervisory control ensure that control s dry contacts are closed to enable heating operation Check the supervisory control s settings programming to ensure it is not disabling heating operation during occupied peak demand periods 2 Ifthe J7 plug is missing or jumper wires are not installed in the J7 plug call the toll free Technical Support phone number listed on the back cover of this manual for further assistance 3 If there are no external supervisory controls wired to the J7 plug Secure power to the water heater Unplug the J7 plug from the CCB see page 50 for location 4 Using an ohm meter set the Ohm meter to it s lowest resistance range 200 or to an audible beep continuity test setting if so equipped 5 Touch the ohm meter probes between pins 1 amp 2 first and then between pins amp 4 of the J7 plug end as shown in the images below There should be continuity present in both tests e f the ohm meter shows no continuity open circuit between pins 1 amp 2 or between pins 3 amp 4 of the 47 plug end ensure the two jumper wires are properly installed in the plug end and are not broken Ensure the J7 plug socket connection is mating properly and providing good contact Repair replace damaged plug connectors wiring as necessary e f the ohm meter shows continuity closed circuit between pins 1 amp 2 and between pins amp 4 of the J7 plug end and heating operation will not activate with a cold tank
17. cannot be converted to single phase No 480 VAC models are phase convertible Heating element voltage and KW conversions are not permitted on any models Verifying the power supply is correct is typical first step during most service procedures The illustrations and instructions on the following pages will outline how this is done L1 HOT L2 NEUTRAL GROUND L1 HOT L2 HOT GROUND M ake SSS SSS SSS pol ell ol Power Distribution Block a 2208 240 480 120 277 277 volts 7 0 volts EL h 4 Models with more than one heating element only PASE LU 377 volta See Figures 1 amp 2 on pages 8 and 9 490 277 volta 277 Volt 10 Power 208 240 480 Volt 10 Power L1 HOT L2 HOT L3 HOT GROUND 208 240 480 7 120 208 277 ARMS S F P 2 208 240 480 volts 208 240 480 Volt 30 Power Servicing should only be performed by a Qualified Service Agent 12 Measure power supply voltage to water heater on single element models at upper terminals of the contactor OPERATION amp SERVICE Checking Single Phase 10 Power A single phase power supply will be connected to the L1 and L2 terminals of the Power Distribution Block or directly to the contactor on models equipped with a single element On 208 240 480 volt power supplies both wires are hot with voltage present On 277 volt power supply one of the two wires is a neutral and does not have any voltage presen
18. factory there will be two types of contactors used 3 pole and 4 pole contactors The illustrations below show the five standard contactor configurations There are more detailed heating element connection wiring diagrams for these standard configurations on pages 18 22 Also see the Heating Element Construction and Heating Element Wiring information on pages 16 17 The illustrations below show standard configurations The water heaters covered by this manual can be custom ordered and may have configurations other than what is shown in this manual Always refer to the wiring diagram on the water heater Three Phase 30 Power 3 Pole Contactor 3 Pole Contactor 4 Pole Contactor L 1 LZ L3 L1 LZ L3 L1 2 L3 Single Phase 10 Power 3 Pole Contactor 4 Pole Contactor L1 LZ L1 Lz Servicing should only be performed by a Qualified Service Agent OPERATION amp SERVICE Contactor Inspection A thorough visual inspection of the contactors should be performed as part of any regular maintenance program and whenever the water heater is being serviced Refer to the listed oteps and images below for this procedure 1 Secure power to the water heater at the main breaker or disconnect switch 2 Verify with an AC volt meter that there is not any voltage present at the Power Distribution Block see Figure 2 on page 9 or the contactor on single element models 3 Remove the top cover two small screws from the contactor Check for and re
19. of water call the toll free Technical Support phone number listed on the back cover of this manual for further assistance Service Note If a supervisory control s is used to enable disable heating operation install field wiring between the J7 socket on the CCB and a set of dry contacts on the external control per all applicable building codes This is a switching circuit only DO NOT apply any external voltage or connect any load IE relay coil to either circuit Servicing should only be performed by a Qualified Service Agent 53 OPERATION amp SERVICE Checking Power and Ground To The CCB The CCB is powered by the120 VAC Control Circuit Transformer see pages 39 41 at the J2 Socket pins 1 amp 3 see page 50 This procedure is performed to ensure the 120 VAC power is being supplied to the CCB 1 Ensure the main breaker or disconnect switch is turned on 2 Verify with an AC volt meter that proper voltage is present at the Power Distribution Block or the contactor on single element models see Figures 1 and 2 on pages 8 amp 9 and pages 12 14 Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC 4 Ensure 120 VAC power is supplied to the CCB With the J2 plug installed in the J2 socket on the CCB page 50 insert the two volt meter probes into pins 1 amp 3 of J2 plug as shown in the Checking for 120 VAC image below Volt meter probes may have to be pressed firmly into the plug to make
20. rate at which electrical current is flowing is the ampere or amp Amp meters are used to determine if a heating element is working if there is adequate current flowing through the heating element Ohms The unit of measurement used to quantify the opposition or resistance to the flow of electricity is the ohm As resistance ohms in an electrical circuit increases current amperage will decrease and as resistance decreases current will increase Ohm meters are used for measuring the resistance of heating elements for open circuit continuity tests on heating elements and for shorted to ground continuity tests on heating elements Service Note Volt ohm and amp meter test instruments are necessary to perform the service and diagnostic procedures outlined in this manual see Tools Required on page 3 Wattage The unit of measurement used to quantify the rate or amount of electrical energy being used is the watt One thousand watts is referred to as one kilowatt Heating elements are rated in kilowatts expressed as KW The higher the kilowatt rating of a heating element the more power it will use and the more heat it will generate One kilowatt generates 3412 Btu of heat Servicing should only be performed by a Qualified Service Agent 10 OPERATION amp SERVICE Ohms Law A law that explains the relationship between voltage current and resistance The law states that the electric current flowing through a conductor is equal to the vo
21. see pages 76 80 An Advanced Service menu displays a list of possible causes for current Fault and Alert conditions to aid in servicing Economy Mode Operation The control system automatically lowers the Operating Set Point by a programmed value during user defined time periods Helps reduce operating costs during unoccupied or peak demand periods See Economy Mode Setup Menu on pages 64 67 CONTROL SYSTEM NAVIGATION The User Interface Module is located on the front cabinet of the water heater All operational information and user settings are displayed and accessed using the UIM The UIM includes five snap acting momentary user input buttons an Up Down and 3 Operational Buttons UIM User Interface Module Tank Temperature 114 F Operating Set Point 120 jut aun Up amp Down Buttons Navigate Menu Items Lt Friday Adjust User Settings LCD Screen W 1 n Information Display Area 3 Operational Buttons Navigate Menus Activate Adjustment Modes Update Cancel Changes Figure 6 Up amp Down Buttons Used to navigate up and down and to select highlight menu items Also used to adjust or change increase decrease on off set time various user settings Operational Buttons The 3 Operational Buttons are multifunctional Their current function is defined by the text that appears directly above each button on the LCD screen The function will change depe
22. 61 Temperature Settings 62 Heater Status Menu eese ence 63 Economy Mode Setup 64 Setpoint Adjustment Value 65 Time Clock Setlings ioo nens 66 Daily Operating Mode Settings 67 Alarm Output Setup 68 Display Settings 69 Heater Information 70 Current Fault Alert 442 71 Fault ple AR IU 71 Fault Occurrence Merll x cato osea 71 Restore Factory Defaults 72 TROUBLESHOOTING 73 Common Service 73 Control System Diagnostics 74 Fault Conditions t tease 74 Alert CoOndillOriSsess aces ee 74 Resetting The Control System 74 Control System Unresponsive 74 UIM Bisplay IS Blank ei rone 74 HIM IS MoOperabl E su iit eo 75 Heating Cycle Disabled 75 Fault amp Alert Messages
23. Contactor The illustrations below show how six wire heating elements page 17 are wired to 4 pole contactors on water heaters connected to a three phase power supply See the Contactors section of this manual pages 34 38 Connection Diagram Wiring Diagram L1 L2 L3 L1 L2 L3 Three phase 30 power supply Models configured for three phase power 30 and equipped with 4 pole contactors will have a jumper wire between the 2nd and 3rd poles of the contactor 4 Pole Contactor Heating Element Flange End View Three loops of one heating element Two ends Two ends Two ends ofloop 1 ofloop2 ofloop3 Servicing should only be performed by a Qualified Service Agent 21 OPERATION amp SERVICE Three Phase Y Configuration 3 Pole Contactor The illustrations below show how three wire Y configured heating elements page 17 are wired to 3 pole contactors on water heaters connected to a three phase power supply See the Contactors section of this manual pages 34 38 Connection Diagram Wiring Diagram L1 12 Ls Li L2 Ls Three phase 30 power supply 3 Pole Contactor Metal bar that joins or splices together one end of each loop of one heating element Wiring leads from heating Hb Metal bar that joins or splices together one end of each loop Two ends Twoends Two ends of loop 1 ofloop2 ofloops3 Servicing should only be performed by a Qualified Service Agent 22 OPE
24. DISPLAY From the Desktop Screen navigate to the Economy Mode Setup menu see page 65 for instructions Economy Mode Setup mu Setpoint Adjustment 20 Use the Up Down buttons to select highlight in black Current Time Wed 4 19 PM Current Time sub menu Press the Operational Button Heater In Economy Mode No underneath CHANGE to enter the Current Time sub Sun Normal All Day menu Mon Normal All Day Tue Normal All Day Wed Normal All Day Use the Up Down buttons to select the Weekday Current Time Press the Operational Button underneath CHANGE to ATs Weekday activate the adjustment mode for this setting 3 Time 4 19 PM Press the Up and Down buttons to adjust the Weekday setting to the current day Notice how the text above the Operational Buttons on Current Time the display changes to ACCEPT amp CANCEL when VCI Weekday Monday the adjustment mode is activated and how the current A A 4 19 setting is outlined rather than highlighted in black Press the Operational Button underneath ACCEPT to enter and confirm the new setting Pressing the Operational Button underneath CANCEL would discard the new setting and retain the previous setting Use the Up Down and the CHANGE ACCEPT Operational Buttons to individually select and change the Current Time remaining time settings Hour Minutes AM PM to the am s dno ee current time in the same way as outlined ab
25. M User Interface Module and a Button Pad Overlay The control system constantly monitors and safely controls heating elements water temperature and other functions of the water heater Information is continuously reported to the user through text and icons on the liquid crystal display LCD portion of the UIM Users can navigate through multiple control system menus to view operational information and change user settings CCB Central Control Board Tank Temperature 114 F Operating Set Point 120 F Sue F tA 2 UIM User Interface Module Servicing should only be performed by a Qualified Service Agent OPERATION amp SERVICE CCB Central Control Board 2 1 J6 O Servicing should only be performed by a Qualified Service Agent 50 OPERATION amp SERVICE CCB Socket amp Wiring Terminal Identification Refer to the illustration on page 50 for physical location of the sockets and wiring terminals J1 Socket Transformer DESCRIPTION 120 VAC hot to transformer Not used 1 2 JjNtued o 45 120 VAC neutral to transformer 4 24 out from transformer 0000000000000 24 VAC out from transformer 24 VAC out from transformer J2 Socket 120 VAC Power Supply DESCRIPTION 1 120 VAC hot 2 Earth Ground 120 VAC neutral J3 Wiring Terminals Alarm Output Relay see page 68 TERMINAL DESCRIPTION Dry Contact Output Normally Ope
26. P Servicing should only be performed by a Qualified Service Agent ELECTRONIC CONTROL SYSTEM RESTORE FACTORY DEFAULTS MENU This control system menu allows the user to restore most of the control system s user settings to their factory default settings User settings in the Alarm Output Setup and Display Settings menus are unaffected by executing Restore Factory Defaults Restore Factory Defaults ACTION DISPLAY From the Main Menu use the Up Down buttons to select highlight in black the Restore Factory Defaults menu Press the Operational Button underneath SELECT Heater Information The Restore Factory Defaults menu will be displayed Current Fault 45 Fault History Fault Occurrence Restore Factor oou From the Restore Factory Defaults menu press the eS Operational Button underneath YES The display will Restore Factory Defaults show text confirming the factory default settings have been restored i Are you sure you want to i ti dont system to factory Press the Operational Button underneath BACK to exit diee the Restore Factory Defaults menu Factory Default User Settings 120 F 49 C 90 F to 190 F 32 C to 88 C Setpoint Adjustment 20 F 11 C 2 F to 50 F 1 C to 28 C Daily Operating Mode Normal Operation All Day See page 64 Alarm SP 100 38 C 90 F to 190 F 32 C to 88 C Servicing should only be performed by a Qualified Service Agent 72 TROUBLESHOOTING
27. RATION amp SERVICE Heating Element Ratings There are six standard heating element KW ratings used 3 6 9 Heating Element Flange 12 15 and 18KW Heating element flanges are stamped with the part number voltage and KW rating see the illustration to the right Heating Element Configurations The table below shows standard heating element configurations used Keep in mind the water heaters covered by this service manual ue can be custom ordered with heating element voltage and KW ratings om E s other than what is shown in this table Always check the water heater s rating label to see how the water heater was configured at the factory J m a 7 12 i Service Note Models at 54 KW and above are not available in 208 single phase 10 configurations Also notice that some 208 volt models will contain additional elements STANDARD NUMBER KW INPUT OF ELEMENTS RATINGS AND WATTAGE 3 1 300 6 1 6000 9 1 900 1 18 000 2 9 000 5 18 000 208 Volt models use one additional element Only Available in 50 gallon models or larger Servicing should only be performed by a Qualified Service Agent OPERATION amp SERVICE Heating Element Amperage Six Wire Elements The table below shows the approximate amp draw through each loop see page 17 of a six wire heating element First determine the actual rated wattage and voltage of the element being tested see page 23 The
28. S O CH LOO ELEMENT WATTAGE PER LOOP 59a vac 240 VAC 277 VAC 480 VAC 300 100 436 57 60 7673 23040 11520 6 000 2000 2163 2880 23836 _ 9 000 8000 1442 1920 2558 76 80 12 00 4 000 1082 1440 1918 57 60 5000 46 08 15000 865 1152 1535 18 000 6000 727 960 1279 3840 Heating Element Resistance Three Wire Y Configured Elements This table shows the approximate resistance in ohms between each wiring lead and the metal shorting bar on the element flange see page 17 in a three wire heating element First determine the actual rated wattage and voltage of the element being tested see page 23 Then follow the Measuring Resistance test procedure on page 29 to measure the resistance between each wiring lead and shorting bar on the element being tested The 3 ohm readings should be approximately the same Compare the measured resistance to the values in the table below Keep in mind there will be some variance between measured values and the values in this table due to fluctuations in temperature and the calibration of test instruments being used 3 WIRE Y CONFIGURED ELEMENT TABLE APPROXIMATE OHMS BETWEEN EACH TOTAL WIRE END AND THE METAL SHORTING BAR ELEMENT WATTAGE 208 VAC 240 VAC 480 VAC Servicing should only be performed by a Qualified Service Agent 28 OPERATION amp SERVICE Heating Element Resistance amp Ground Tests This is a two par
29. SHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR No Anode Current Ensure the water heater is full of water Follow Low Anode Protection the filling instructions in the maintenance sec Anode Voltage tion of Instruction Manual that came with the Alert Condition Water eater Ensure the water heater is properly grounded The control system has detected one of three see grounding instructions in the Instruction potential problems with the powered anode rod on Manual that came with the water heater and models so equipped see page 48 Grounding instructions on page 5 in this man ual Possible Causes Ensure the CCB is properly grounded see the No water or low water in tank Checking Power And Ground To The CCB tests Water heater CCB not properly grounded on page 54 Ensure the ground wire leading Plug socket wiring connection problems from pin 2 of the J2 plug on the CCB page 50 Powered anode rod wiring shorted to ground is securely connected to ground and the wire Heavy calcium lime accumulation on anode was properly stripped and crimped in it s con Defective powered anode rod nector Check the J10 plug socket connection at the Alert CCB ensure they are mating properly and pro No Anode Current viding good contact See CCB illustration and Alert occurred 14 mins ago socket identification on pages 50 52 The p de s a t gus d Apis i Check for pinched broken sh
30. Service Handbook VIVE XN CEs MODELS DSE 5 THRU DSE 120 ih AC m SERIES 100 and 102 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS WATER HEATER CONSTRUCTION OPERATION amp SERVICE TROUBLESHOOTING 500 Tennessee Waltz Parkway Ashland City TN 37015 d Smith F SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT PRINTED IN THE U S A 1008 198335 000 COMMERCIAL ELECTRIC WATER HEATER SERVICE MANUAL TABLE OF CONTENTS INTRODUCTION 2 Qual IONS 2 Service Warming m E 2 TOIS INSTALLATION 4 Closed Water Systems 4 Thermal EXPANSION yee ditas ius 4 Electrical 5 PRE SERVICE CGHEGISS Liege tU 6 Service 5 WATER HEATER CONSTRUCTION 7 5 20 Gallon 15 8 30 5 120 Gallon Models ret lr 9 OPERATION amp SERVIC E ariadna 10 PrNCIDIES OF E 10 Single And Three Phase Power 12 Checking Single Phase
31. Setpoint Status Standby Adjustment value The Economy Set Point is Friday the water temperature the control system 5 00 PM maintains during programmed Economy D C Economy Mode Mode time periods Economy Set Point is displayed instead of Operating Set Point and Economy Mode appears beneath the current time on the Desktop Screen during Economy Mode time periods Setpoint Adjustment Current Time Current Time Heater In Economy Mode No Seven Day 24 hr clock Use this menu item to Sun Economy Mode Day set the current time and day of the week Normal 7 30 AM to 8 00 PM Current day and time are not set from the Tue Normal All Day factory Clock Not Set will be displayed on Normal All Day the Desktop until the time day has been initially set Note the time will not self adjust for Daylight Savings time Heater In Economy Mode Displays whether the control system is currently operating in Economy Mode or not Daily Operating Mode Sun Mon Tue Wed Thu Fri Sat oeven daily sub menus are listed at the bottom of the Economy Mode Setup menu There are 3 Operating Modes available in each daily sub menu Normal Operation All Day Economy Mode All Day and Normal Operation Between Only one Operating Mode can be active at a time the factory default is Normal Operation Day Normal Operation All Day When this operating mode is active the normal Operating Set Point Te
32. TEM Table 1 Status Icons ICON DESCRIPTION Water temperature in the tank has fallen Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the immersion Temperature Probe Water temperature in the tank has reached the Operating Set Point Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the immersion Temperature Probe The control is unable to initiate a heating cycle This will happen whenever a Fault condition is detected by the control system or when either of the two Enable Disable circuits are open circuits For more information on Enable Disable circuits review the Heater Status Menu information on page 63 The control system is in Heating Mode and has energized the electromagnetic contactor coils for at least one heating element This animated icon DOES NOT indicate current has been sensed from the heating elements only that there is a call for heat present and the control system has initiated heating element operation Heating element icon for a water heater equipped with 1 heating element Open circles represent elements the control system has not energized and IS NOT sensing electrical current flow from Heating element icon for a water heater equipped with 2 heating elements Each circle represents one element Open circles represent elements the control system has not en
33. TROUBLESHOOTING COMMON SERVICE PROBLEMS No Hot Water 1 Oo oF W DP Hot water supply valve to fixtures turned off cold water supply valve to water heater turned off Check power to the water heater see pages 12 14 Check Operating Set Point and Differential Set Points see pages 61 amp 62 Check all fuses see page 15 Check heating elements pages 23 30 Ensure both enable disable circuits at the CCB s J7 plug socket connection are closed circuits See CCB Enable Disable Circuit s Test on page 53 and Heater Status Menu information on page 63 Not Enough Hot Water 1 2 3 O N O Water heater may be undersized Check Operating Set Point and Differential Set Points see pages 61 amp 62 Ensure the time is set correctly daylight savings etc and ensure the water heater is not in the Economy Mode during peak demand periods see pages 64 67 Check power to the water heater see pages 12 14 ensure there is not a dead leg on water heaters configured for three phase 30 power Ensure the power supply to the water heater matches the listed voltage on the water heater rating plate see pages 12 14 Check hot water supply piping for leaks or restrictions lime scale valve partially closed Check all fuses see page 15 Check heating elements pages 23 30 Check Contactors on see pages 34 38 Ensure both enable disable circuits at the CCB s J7 socket are closed circuits If either bot
34. Wire Element see diagrams page 18 1 Measure and record voltage to all three heating element loops between the first and third lower terminals of the contactor L1 amp L2 Note All three element loops are wired to the first and third lower terminals on the contactor Repeat this procedure at each contactor s for other heating elements being tested B Single Phase Power 4 Pole Contactor Six Wire Element see diagrams page 19 1 Measure and record voltage to the 1 heating element loop between the first and second lower terminals of the contactor L1 amp L2 2 Measure and record voltage to the 2 heating element loop between the first and fourth lower terminals of the contactor L1 amp L2 3 Measure and record voltage to the heating element loop between the third and fourth lower terminals of the contactor L1 amp L2 Note All three voltage readings should be approximately the same Repeat this procedure at each contactor s for other heating elements being tested D Three Phase Power 3 Pole Contactor Six Wire Element see diagrams page 20 1 Measure and record voltage to the 1 heating element loop between the first and second lower terminals of the contactor L1 amp L2 2 Measure and record voltage to the 2 heating element loop between the first and third lower terminals of the contactor L1 amp L3 3 Measure and record voltage to the heating element loop between the second and third lower termina
35. ages Fault History Retains 9 event history of Fault Alert messages with time stamp The Fault History is useful when dealing with intermittent operational problems or when the customer has reset the control system prior to a service agent s arrival Fault Occurrence Total accumulated number each individual Fault condition has occurred is displayed in this menu This running total of Fault Occurrences can be useful in determining which if any operational problems have been persistent Restore Factory This control system feature allows the user to restore control system user settings to Defaults their factory default settings Alarm Output Setup and Display Settings menu items ARE NOT changed when factory defaults are restored Help Menu Accessible by pressing the corresponding Operational Button from most menus and screen displays This menu provides access to instructions and explanations for user settings Operating States Status Icons manufacturer s web address technical support phone number and service agent contact information T This table shows a list of the control system menus These menus will be explained in greater detail in the pages that follow Servicing should only be performed by a Qualified Service Agent 60 ELECTRONIC CONTROL SYSTEM TEMPERATURES MENU Operating Set Point Temperatures User adjustable setting 90 F to 190 F range factory default is 120 F When the water temperature sensed by the contro
36. an audible beep the fuse being tested is blown and must be replaced Ohm Meter Method Volt Method J T Volt Meter Method Fuses can also be checked using an AC volt meter The power supply must be turned on and a call for heat must be active all contactors must be closed during this test Touch the two test probes to both ends of each fuse while still in the fuse blocks A high voltage at or above 120 VAC reading indicates the fuse is blown Azero volt reading generally indicates the fuse is good Next check for voltage between each end of the fuse and ground to ensure voltage is present at both ends of the fuse If no voltage is present between either end of the fuse and ground the test has not been conclusive secure power to the water heater and perform the ohm meter test method described above The voltage test method is a good way to quickly identify fuses that are blown but it is not always conclusive due to the dependence on power being present at both ends of the fuse all contactors being closed and correct wiring Keep this in mind as there may be times when a fuse that is blown tests good due to one of these dependencies not being met The ohm meter method described above may be more time consuming but it is 10096 conclusive Servicing should only be performed by a Qualified Service Agent 15 OPERATION amp SERVICE HEATING ELEMENTS Heating Element Construction The water heaters covered in this manual use el
37. been in the heating mode IE any heating element s has been energized Element Cycles Total accumulated count of heating cycles for each heating element Element On Time Total accumulated heating on time for each heating element CCB Version Software version for Central Control Board see page 50 UIM Version Software version for User Interface Module see page 55 Top Of Menu Heater Information Elapsed Time 7 days 18 hrs 35 mins Total Heating Time 2 days 46 mins 00000042 00000035 Cycle Count Element 1 Cycles Element 1 On Time Bottom Of Menu Heater Information Element 2 On Time 1day 4hrs 44 mins Element 3 Cycles 00000025 Element 3 On Time 8 hrs 30 mins CCB Version UIM Version Servicing should only be performed by a Qualified Service Agent 70 ELECTRONIC CONTROL SYSTEM CURRENT FAULT ALERT MENU This menu displays non adjustable operational information With the Fault History _ sub menu selected in Main Menu press the Main Menu Operational Button underneath SELECT to Heater Information display the current Fault or Alert message If there is not a Fault or Alert condition currently Current Fault active none is displayed to the right of this Fault History menu Fault Occurrence FAULT HISTORY MENU Restore ial be Defaults This menu displays non adjustable operational information The control system records and stores the last 9 Fault and Alert messa
38. contact with the metal conductors inside Voltage should be approximately 120 VAC 5 Ifthe measured voltage is approximately 120 VAC the CCB is receiving the correct power 6 Ifthe measured voltage is zero volts or considerably less than 120 VAC Checkthe 120 VAC wiring between the CCB J2 socket and the 120 VAC Control Circuit Transformer ensure wiring is correct and connections are tight and making good contact Check the J2 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 50 Check the 120 VAC Control Circuit Transformer to ensure it is wired correctly and outputting the correct voltage see pages 39 41 Check the Control Circuit fuses see Figures 1 and 2 on pages 8 amp 9 for location and the Fuse test procedure on page 15 7 Ensure earth ground is supplied to the CCB With the J2 plug installed in the J2 socket on the page 50 insert the two volt meter probes into pins 1 amp 2 of the J2 plug as shown in the Checking for Ground image below Volt meter probes may have to be pressed firmly into the plug to make contact with the metal conductors inside If the measured voltage is approximately 120 VAC the CCB is properly grounded 8 Ifthe measured voltage is zero volts or considerably less than 120 VAC Check the ground wiring between the CCB J2 socket and the water heater s ground connection ensure wiring is correct and connections ar
39. corrected before the control system can be reset by cycling power off and on again Servicing should only be performed by a Qualified Service Agent OPERATION amp SERVICE Temperature Sensor Resistance Test Secure power to the water heater at the main breaker or disconnect switch Unplug the J5 plug from the CCB see page 50 for location Using an ohm meter set the ohm meter range to a scale above 30 000 ohms initially A U N Touch the ohm meter probes between the two middle pins black wires of the J5 plug end as shown in the image below Compare the measured resistance value ohms to the values given in the resistance data table below Temperature probes are very reliable and should only be replaced when e The resistance test indicates an open infinite resistance or a direct short no resistance circuit e The nature of the service problem is temperature control and the resistance readings are considerably 25 different than the values in the table here at the given temperature Checking Temperature Sensor Resistance Temperature Sensor Resistance Data WATER TEMPERATURE RESISTANCE in Servicing should only be performed by a Qualified Service Agent 44 OPERATION amp SERVICE Temperature Sensor DC Voltage Test 1 Ensure the main breaker or disconnect switch is turned on 2 Verify the CCB has the correct input voltage at the J2 socket and is properly grounded perform the Check
40. cts open and close rapidly and may permanently damage the contactors and or the CCB The instructions below show how to properly configure the input power wiring to the transformers primary winding Service Note The 380 Volt H2 tap is used for international applications Ensure you do not connect the second wire to the H2 tap for standard 480 volt applications 1 Determine power supply voltage to the water heater see pages 12 14 Ensure the power supply wiring to the 120 VAC transformer s primary winding are connected to the proper terminals as shown in the table below 2 Only one wire needs to be moved on the transformer s primary winding terminals to configure for a different voltage Do not move or change the wire connected to the H1 terminal on the primary winding Do not move or change either wire at the secondary winding X1 or X2 connections WATER HEATER POWER SUPPLY VOLTAGE PRIMARY WINDING CONNECTIONS 380 VAC H1 Common amp H2 380 480 VAC H1 Common amp H3 480 Primary Winding H1 H3 9070775024175 SEC V Haf H1 H2 1 2 120 teint ee H1 H3 480 Hz 9050 HE TT WESA im siasa on S per ri LL 0 075 awa xal 0830 ma 1 CLASS CLASE CLASSE 105 C 39077 549 53 Secondary Winding Servicing should only be performed by a Qualified Service Agent 40 OPERATION amp SERVICE 120 VAC Contr
41. defective the entire assembly must be replaced If the correct amperage through a heating element loop has been verified with an AC amp meter see page 25 and the current sensor for that element does not activate and send a signal to the CCB Ensure the Element Sensor plug and socket connection is making good contact e On models equipped with more than one heating element secure power to the water heater and try switching Element Sensor plugs between the J12 J13 J14 J15 and J16 sockets to verify the Element Sensor is defective a Current Detected Alert message and Status lcon indication should follow the defective Element Sensor and report a different heating element loop is not drawing current when current is expected deis Element Sensor sockets Element Sensor amp Element Wire Routing Individual Current Sensors To J12 J16 Sockets To J12 J16 Sockets Servicing should only be performed by a Qualified Service Agent 33 OPERATION amp SERVICE CONTACTORS This section of the manual provides information on how contactors are constructed how they work and how to test contactor operation see pages 8 amp 9 for location Contactor Construction How They Work Magnetic contactors are used to energize and de energize the heating elements The water heaters covered in this manual are equipped with either 3 pole or 4 pole contactors the illustrations below show a 3 pole contactor see Contactor Configuration
42. e CCB ensure they are mating properly and pro viding good contact Check the pins inside the J5 plug socket for wear or damage See CCB illustration and socket identification on pages 50 52 Replace damaged plug connectors wiring harness as necessary Check for pinched or broken wiring between the Immersion Temperature Probe and the J5 plug Socket connection on the CCB repair or replace damaged wiring as necessary See CCB illustration and socket identification on pages 50 52 Check the resistance of the temperature sensor inside the Immersion Temperature Probe see pages 43 45 Replace the Immersion Temper ature Probe if measured resistance is above 56 000 ohms Call the toll free technical support phone num ber on the back cover of this manual for further assistance if the problem has not been cor rected after performing the procedures outlined here Check for pinched or shorted wires between the J5 plug socket connection on the CCB and the Immersion Temperature Probe repair or replace damaged wiring as necessary See CCB illustration and socket identification on pages 50 52 Check the resistance of the temperature sensor inside the Immersion Temperature Probe see pages 43 45 Replace the Immersion Temper ature Probe if measured resistance is below 390 ohms Call the toll free technical support phone num ber on the back cover of this manual for further assistance if the problem has not been cor rected
43. e tight and making good contact e Ensure the water heater is properly grounded Checking for 120 VAC Checking for Ground Servicing should only be performed by a Qualified Service Agent 54 OPERATION amp SERVICE UIM User Interface Module The UIM s major components include a Circuit Board with LCD display and a Button Pad Overlay which contains the five user input buttons Service Note The Ribbon Cable that connects the Button Pad Overlay to the UIM Circuit Board must be plugged in exactly as shown in the images below with the metal crimp connections visible on the plug end and the UIM Circuit Board back facing out There are six pins on this Ribbon cable socket Ensure all six pins are inserted into the Ribbon Cable plug whenever removing or installing the UIM or Button Pad Overlay Failure to connect this Ribbon cable exactly as shown when servicing will render the User Input Buttons inoperable This should be checked whenever the nature of the service complaint is an inoperable or unresponsive controller or UIM Button Pad Overlay di o UIM Circuit Board Backi e E J2 eR CCB ce Af 2 ll Communication iB mor t EUA ie Servicing should only be performed by a Qualified Service Agent 55 ELECTRONIC CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM HEATING ELEMENT OPERATION Depending on tank size and how they were ordered from the factory the water heaters covered in this manual may be equ
44. e values in this table due to fluctuations in voltage temperature and the calibration of test instruments being used 3 WIRE Y CONFIGURED ELEMENT TABLE TOTAL APPROXIMATE AMPS THROUGH EACH WIRE ELEMENT WATTAGE 208 VAC 240 VAC 480 VAC Servicing should only be performed by a Qualified Service Agent 24 OPERATION amp SERVICE Heating Element Amperage Test This test should be considered as a first diagnostic procedure for the common service complaints of no hot water or not enough hot water The heating element amperage test shown on this page is the best procedure to quickly determine which if any heating elements are not working properly 1 2 Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary Adjust the temperature settings to ensure a call for heat is active for all heating elements Raise the Operating Set Point to 140 F or higher Set all Differentials at 2 F see pages 61 and 62 Using a clamp style AC amp meter set the amp meter to an AC amperage range just above the expected amperage 100 AC amp range initially The normal operating amps for all standard heating elements loops is provided in the tables on page 24 or it can be calculated using ohms law as explained on page 11 Follow the procedure below that corresponds to the type six or three wire element of heating element being tested see explanation on pages 16 amp 17 When measuring amperage clamp the jaw
45. ectric heating elements to heat water Heating elements convert electrical energy into heat energy Heating elements are constructed using 3 tubes formed into U shaped loops The two ends of each loop are permanently fitted into the element flange Inside each loop is a wire conductor a resistive electrical circuit surrounded by an insulating material These wire conductors pose a relatively high resistance to the flow of electricity Heat is generated when the electricity voltage applied to the element begins to flow amperage and encounters the resistance ohms of the wire conductors inside See Principles of Electricity on page 10 There are two types of heating elements installed in the water heaters covered in this manual one type has six wire leads and the other has three wire leads Heating elements with six wire leads are installed on water heaters configured for single phase and three phase power Heating elements with three wire leads Y configured are installed on water heaters configured for three phase power only See Single And Three Phase Power on page 12 and Heating Element Wiring section between pages 17 22 fi Heating Element Flange Three U shaped loops enclose wire conductors that are surrounded by an insulating material Six or Three Wire Leads Top View Heating Element Flange End View Side View Internal View U Shaped Loop VAAAAAAAAAAAAAAAAAAAAAAAAAY un Au 5 C E un Fe
46. ement System and other external supervisory controls Output Function Alarm Output Setup Adjustable user setting Available options for the Alarm Output Function setting are Alarm SP Heating Mode Used for heating mode on off status notification Enable Disable Closed Used for notification or verification of the enable disable circuits open closed status There are two enable disable circuits available for external supervisory control s at the J7 socket on the CCB see page 50 Enable disable circuit s status can be viewed in the Heater Status Menu see page 63 Alarm SP Temp Heater SP Used for external notification when current tank temperature drops below Operating Set Point Temp Alarm SP Used for external notification when current tank temperature drops below the programmable Alarm SP Fault or Alert Used for external notification whenever a Fault or Alert condition is active Fault Used for notification whenever a Fault condition is active Disabled Disables the Alarm Relay Output Function this is the factory default setting Alarm SP Alarm Set Point Adjustable user setting 90 F to 190 F the control system uses for the Temp Alarm SP function described above This setting has no effect with any other Alarm Output functions Alarm Output Settings Changing the user settings in this menu is done using the same method outlined in Temperature Settings on page 62 Service Note Ad
47. ensed from the immersion Temperature Probe at 120 F and the offset is adjusted to 5 F the control system would calibrate or offset the Tank Temperature to 115 F Heating cycles would then start stop based on the calibrated Tank Temperature Used to calibrate for slight differences in control system temperature sensing This can improve the precision of temperature control in the storage tank and at points of use This feature can also be used to compensate for building recirculation loops hot water returning to the storage tank that may cause the heating cycle to terminate prematurely Servicing should only be performed by a Qualified Service Agent 61 ELECTRONIC CONTROL SYSTEM Temperature Settings The Operating Set Point and the Differential Settings are adjusted in the Temperatures Menu The following instructions explain how to adjust these user settings and navigate the control system menus ACTION DISPLAY From the Desktop Screen press the Operational Button underneath MENU to enter the Main Menu MODEL INFORMATION see UIM Navigation on page 57 Tank Temperature 1209 Operating Set Point 1209 Notice how the text above the Operational Buttons on Status Standby the display changes as you navigate through the various Friday menus and screens Mo 5 00 PM Normal Mode With Temperatures selected highlight in black in the Main Menu press the Operational Button underneath Main Menu SELECT to enter the Te
48. er will cause low high output voltage from the transformer This can cause contactors to open and close their contacts rapidly contactor chatter and result in permanent damage to the contactors See pages 39 amp 40 Servicing should only be performed by a Qualified Service Agent 6 WATER HEATER CONSTRUCTION WATER HEATER CONSTRUCTION Electronic Controls The water heaters covered in this Service Manual are equipped with an electronic control system see page 56 The control system senses temperature electrically from an Immersion Temperature Probe The probe is installed in a threaded opening in the storage tank wet well and senses water temperature directly As the stored water temperature rises and falls the control system de energizes and energizes heating elements indirectly using electromagnetic contactors The control system energizes the electromagnetic contactor s 120 VAC coil causing the switch contacts of the contactor to close which in turn supplies power to the heating elements see pages 34 38 Heating Element Configurations Depending on tank size and how they were ordered from the factory the water heaters covered in this Service Manual may be equipped with 1 to 5 electric heating elements Total input KW ranges from 3KW to 90KW The water heaters covered in this manual available in storage tanks sizes from 5 to 120 gallons Power Conversions Other than power supply phase conversions on some models the wate
49. ergized and IS NOT sensing electrical current flow from Filled circles represent elements the control system has energized and 15 sensing electrical current flow from Heating element icon for a water heater equipped with 3 heating elements Each circle represents one element Filled circles represent elements the control system has energized and 15 sensing electrical current flow from Heating element icon for a water heater equipped with 4 heating elements Each circle represents one element Open circles with an X represent elements the control system has energized that it IS NOT sensing electrical current flow from Heating element icon for a water heater equipped with 5 heating elements Each circle represents one element Open circles represent elements the control system has not energized and IS NOT sensing electrical current flow from Filled circles represent elements the control system has energized and 15 sensing electrical current flow from Heating element icon for a water heater equipped with 5 heating elements In this example 4 elements have been energized and 1 element has not The control system IS sensing electrical current flow from 2 elements The control system IS NOT sensing electrical current flow from 2 elements that it should The control system would declare an Alert Condition in this case but would continue to operate The control has detected declared a Fault Condition Fault message details can be viewed in the Curren
50. g use this real time visual display of the Friday operating sequence will help to 5 00 PM quickly and accurately diagnose Normal Mode operational problems HELP Status Icons Figure 7 Day Time Operating Mode The current time and day are also displayed on the Desktop Screen Clock Not Set will be displayed until the time clock has been initially set Day and Time are adjusted in the Economy Mode Setup menu see page 66 The current Operating Mode either Normal Mode or Economy Mode is displayed beneath the day and time Menu The left Operational Button is pressed to enter the Main Menu where all control system menus are accessed See Table 3 on page 60 for a list of control system menus Help The right Operational Button is pressed to access instructions and explanations for user settings Operating States Status Icons manufacturer s web address technical support phone number and service agent contact information Discreet Menu Contact Information From the Desktop Screen press and hold down the middle unmarked Operational Button for 30 seconds and then release it This will launch a discreet menu where personalized contact information can be entered Installing contractors and or service agents can enter their company name and telephone number This contact information will be displayed with all Fault and Alert messages Servicing should only be performed by a Qualified Service Agent 58 ELECTRONIC CONTROL SYS
51. ges in chronological order in this menu The most recent will be at the top of the list A time stamp is displayed below each listed Fault and Alert message showing when the Fault or Alert condition occurred The Fault History is useful when dealing with 2 Gage ihr 10 mi ego i No Current Detected 400 intermittent operational problems or when the customer has reset the control system prior to a service agent s arrival Main Menu Current Fault Selected No Current Detected 40D 1 days 5 hrs 45 mins ago Energy Cut Out ECO A5 Current History Fault Message Temp Probe Short Fault occurred 14 mins ago With a Fault or Alert item selected press the Operational Button underneath VIEW to display the details for the Fault or Alert There is a problem with the message The Fault Alert message screen temperature probe displays a brief description of the condition contact information and access to the Paul Stewart Advanced Service information sub menu XXX XXX XKXX FAULT OCCURRENCE MENU Lind LLL Lassen BACK ADVANCED Total accumulated number each individual Fault condition has occurred is displayed in Fault Occurrence Menu this menu This running total of Fault Occurrences can be useful in determining which if any operational problems have been persistent LWCO Fault Occurrence Tank Temp Probe Powered Anode Fail CCB Hardware Model Faults HEL
52. h circuits are being used by a supervisory control s check that control s settings to ensure it is not disabling heating operation during occupied normal demand periods See CCB Enable Disable Circuit s Test on page 53 and Heater Status Menu information on page 63 Water Heater Trips Breaker 1 2 3 Ensure the power supply breaker fusing to the water heater meets the minimum required fuse wire breaker sizing See the listed voltage and amperage on the water heater rating plate see pages 12 14 Check for grounded heating elements see page 30 Check for pinched shorted wiring internal wiring or power supply wiring Contactor Chatter Condition contactors opening and closing rapidly 1 Ensure the 120 VAC Control Circuit Transformer is properly configured to match the power supply to the water heater see pages 39 amp 40 Ensure the power supply to the water heater matches the listed voltage on the water heater rating plate see pages 12 14 Ensure wiring connections at 120 VAC contactor coil s are secure and in good condition see page 37 Servicing should only be performed by a Qualified Service Agent 73 TROUBLESHOOTING CONTROL SYSTEM DIAGNOSTICS Fault Conditions When the control system declares a Fault condition it will display a Fault message on the UIM and lock out Voltage to the contactor coils and heating elements is terminated to prevent further heating operation Alert Conditions When the c
53. he water level in the water heater remains at or above the level of the probe current will flow from the probe end through the water to the water heater s storage tank which is grounded If the water level drops below the LWCO probe the control system will declare a LWCO Fault condition and lock out see page 79 Voltage to the contactor coils pages 37 amp 38 and heating elements is terminated to prevent further heating operation Inspection and Cleaning Over time calcium and lime deposits will adhere to the end of the LWCO probe depending on water hardness water usage and water temperature Heavy calcium lime accumulation will diminish the current flow through the probe and cause LWCO Fault conditions Inspection and cleaning of the LWCO should be performed periodically and any time the control system declares a LWCO Fault condition 1 Secure power to the water heater follow the draining instructions in the maintenance section of the Instruction Manual that came with the water heater to drain the tank 2 Disconnect wiring to the LWCO probe and remove it from the water heater 3 Closely inspect the LWCO for any damage or cracks in the ceramic insulator replace the LWCO probe if any cracks or damage is noticed 4 Clean any calcium lime deposits from the probe end by gently scraping and using steel wool Reinstall the LWCO probe reconnect wiring to the probe 5 Follow the filling instructions in the maintenance section of the Instruc
54. heater follow the draining instructions in the Maintenance Section of Instruction Manual that came with the water heater If the Instruction Manual is not available copies can be obtained from the manufacturers web site or by calling the toll free phone number on the back cover of this manual Remove the four heating element flange bolts and remove the heating element s being replaced leave wiring leads connected to the contactor s Disconnect all wiring leads from the old heating element at the contactor s Pay close attention to wiring leads and which heating element loops see pages 16 amp 17 connect to which terminals on the contactor s Use wire markers see Tools Required page 3 to label contactor terminals and or the wiring leads of the heating element to ensure the new element is properly wired Install the new heating element and a new element gasket Install tighten four heating element flange bolts Replacement elements and gaskets be obtained from local distributors or by calling the toll free phone number on the back cover of this manual Connect the new heating element wiring leads to the contactor s according to the wiring diagram on the water heater and the wire marker labels attached in Step 5 above Securely tighten wiring leads at contactor s Heating elements sometimes fail due to problems with wiring or other water heater components Be sure to check fuses page 15 inspect contactors page 36 and check al
55. heating element loops at the lower terminals of the contactors oix Wire Element Flange Six Wire Element Three Wire Element Three Wire Element Flange Voltage Test Procedure Determine power supply phase voltage to the water heater see the water heater s rating label Determine if the water heater is equipped with a 3 pole or 4 pole contactor s see page 35 Determine if the water heater is equipped with six or three wire heating elements see page 17 U N Locate the heating element connection wiring diagram that corresponds to the power supply phase type of contactor and type of element s determined in Steps 1 3 above See pages 18 22 Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary 6 Adjust the temperature settings to ensure a call for heat is active for all heating elements Raise the Operating Set Point to 140 F or higher Set all Differentials at 2 F see pages 61 and 62 7 Setthe AC volt meter to a range above the expected voltage 600 VAC or higher range initially 8 Follow the instruction from the list on page 27 that corresponds with the power supply phase type of contactor s and type of heating element s on the water heater being serviced as determined in Steps 1 3 above Servicing should only be performed by a Qualified Service Agent 26 OPERATION amp SERVICE Heating Element Voltage Test cont A Single Phase Power 3 Pole Contactor Six
56. information on how to check wiring and test the multiple tap 120 VAC Control Circuit Transformer and the 24 VAC transformer see Figures 1 and 2 on pages 8 amp 9 for location of the transformers Service Note There are two different 120 VAC transformers used on the water heaters covered in this manual One is used on water heaters factory configured for 208 240 277 volts The other is used on 380 480 volt models Both are multi tap transformers and primary winding wiring configuration is similar 120 VAC Transformer Wiring 208 240 277 Volt Models This is a multiple or multi tap transformer that can accept different input voltages to it s primary winding This transformer outputs 120 VAC power from it s secondary winding which powers the CCB page 50 and the contactor coils The input power wiring to the primary winding of this transformer must be configured to match the power supply voltage to the water heater Incorrect wiring can cause output voltage from the transformer s secondary winding to be too low or too high This can cause contactor chatter contacts open and close rapidly and may permanently damage the contactors and or the CCB The instructions below show how to properly configure the input power wiring to the transformers primary winding 1 Determine power supply voltage to the water heater see pages 12 14 Ensure the power supply wiring to the 120 VAC transformer s primary winding are connected to the proper termina
57. ing Power and Ground To tests on page 54 3 Unplug the J5 plug from the CCB note the control system will lock out and display Temp Probe Open Fault message on the UIM when the J5 plug is removed cycle power off and reinstall J5 plug when tests are complete Using a DC direct current volt meter check for DC voltage between pins 2 amp 3 of the J5 socket as shown in the DC Voltage To Temperature Sensor image below e f the measured voltage is 5 VDC the sensor is powered correctly If there is not 5 VDC call the toll free Technical Support phone number listed on the back cover of this manual for further assistance ECO Continuity Test 1 Secure power to the water heater at the main breaker or disconnect switch 2 Unplug the J5 plug from the CCB see page 50 for location 3 Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary 4 Using an ohm meter set the Ohm meter to it s lowest resistance range 200 or to an audible beep continuity test setting if so equipped 5 Touch the ohm meter probes between the two outside pins red wires of the J5 plug end as shown in the Checking ECO Switch Continuity image below e f the ohm meter shows continuity closed circuit between the two outside pins red wires of the J5 plug end the ECO switch has reset properly If the control system continues to lock out displaying the Energy Cut Out ECO Fault message with cont
58. ing an AC volt meter set the volt meter to an AC voltage range just above 120 VAC Touch one of the two volt meter probes to the ground wire connection on the water heater Touch the other volt meter probe to the CCB s J4 OUT 1 wiring terminal See the images below On water heaters equipped with more heating elements also check between the ground connection and the CCB J4 OUT 2 J4 OUT 3 J17 OUT 4 and J17 OUT 5 wiring terminals to ensure the CCB is sending 120 VAC to the other contactor coils Measure and record voltage output for all contactors at the CCB up to 5 voltage readings on models so equipped Service Warning Be extremely careful when performing this test procedure there will be high voltage present at many terminals and wiring connections in the surrounding area 5 Ifthe measured voltage s were approximately 120 volts the CCB is operating properly 6 Ifthe measured voltage s were zero or considerably less than 120 volts call the toll free Technical Support phone number listed on the back cover of this manual for further assistance Checking Contactor Coil Voltage at the CCB s J4 amp J17 Wiring Terminals CCB J4 amp J17 Wiring Terminals CCB s J4 OUT 1 Terminal Water Heater Ground Connection L IN IT I Ea T T i E IT l Servicing should only be performed by a Qualified Service Agent 38 OPERATION amp SERVICE TRANSFORMERS This section of the manual provides
59. ingle phase power supply See the Contactors section of this manual pages 34 38 Connection Diagram Wiring Diagram L1 L2 L1 L2 Models configured for K single phase power 10 and equipped with 4 pole contactors will have two jumper wires One between the 1st and 3rd poles of the contactor and one between the 2nd and 4th poles of the contactor a Single phase 10 power supply 4 Pole Contactor Heating Element Flange End View Three loops of one heating element lt Two ends Two ends Two ends ofloop1 ofloop2 ofloops3 Servicing should only be performed by a Qualified Service Agent 19 OPERATION amp SERVICE Three Phase Delta Wiring 3 Pole Contactor The illustrations below show how six wire heating elements page 17 are wired to 3 pole contactors on water heaters connected to a three phase power supply See the Contactors section of this manual pages 34 38 Connection Diagram Wiring Diagram L1 12 L3 L1 L2 L3 Three phase 30 power supply 3 Pole Contactor Note each line from the bottom of the contactor represents two wiring leads from a heating element as shown in the connection diagram on the left Three loops of one heating element Two ends Two ends Two ends ofloop1 ofloop2 ofloop3 Servicing should only be performed by a Qualified Service Agent 20 OPERATION amp SERVICE Three Phase Delta Wiring 4 Pole
60. inuity through the ECO present call the toll free Technical Support phone number listed on the back cover of this manual for further assistance e f the ohm meter shows no continuity open circuit between the two outside pins red wires of the J5 plug end and the tank temperature is known to be at or below 100 F 38 C replace the Immersion Temperature Probe Secure power to the water heater and drain the water heater before replacing the probe follow the draining and filling instructions in the maintenance section of the Instruction Manual that came with the water heater e f the control system continues to lock out displaying the Energy Cut Out ECO Fault message and the water temperature inside the water heater is becoming excessive at or above 202 94 check contactors pages 34 38 to ensure they are not stuck closed and check for voltage at all heating elements page 26 during standby mode Check water system piping ensure heat is not being added by any other heating appliances or heat sources If all these tests have been performed and the control system continues to lock out displaying the Energy Cut Out ECO Fault message call the toll free Technical Support phone number listed on the back cover of this manual for further assistance DC Voltage To Temperature Sensor Checking ECO Switch Continuity Servicing should only be performed by a Qualified Service Agent 45 OPERATION amp SERVICE ECO Voltage Test
61. ipped with 1 to 5 electric heating elements See Heating Element Construction on page 16 The illustration here shows how the heating elements are numbered and initially cycled on by the control system top to bottom The illustration also shows how the openings for each heating element are physically arranged on a water heater equipped with 5 heating elements Control Options The water heaters covered in this manual are factory ordered with 1 of 3 different heating element control options as follows Standard On Off Control This is the only configuration available on models equipped with a single heating element and the standard configuration on models equipped with more than one element All elements are cycled on simultaneously with each call for heat however there is a one second delay between elements being energized to reduce starting current All elements are cycled off at the same time at the end of each heating cycle Optional Modulation Sequencing Available on models equipped with more than one heating element First On First Off cycling of heating elements the first heating element energized at the beginning of a heating cycle is the first element de energized at the end of the heating cycle Elements are energized and de energized according to adjustable 1 to 20 F Differential set points for each element see page 61 Element Rotation the first element energized is rotated with each successive heating cycle Successive hea
62. justable user settings in the Alarm Output Setup menu are unaffected by Restore Factory Defaults see page 72 Servicing should only be performed by a Qualified Service Agent 68 ELECTRONIC CONTROL SYSTEM DISPLAY SETTINGS MENU Permits user to set display options for viewing information on the UIM s LCD screen Temperature Units Display Settings Adjustable user setting that changes Temperature Units F temperature units display to Celsius C or Fahrenheit F 4 Backlight Delay Contrast 20 Adjustable user setting that determines how long the UIM s LCD backlight remains illuminated after a key has been pressed L CHANGE BACK Available settings are Always Off 10 30 or 60 seconds and Always On Contrast Adjustable user setting to adjust the UIM s LCD screen contrast between text and background Display Settings Changing the user settings in this menu is done using the same methods outlined in Temperature Settings on page 62 Service Note Adjustable user settings in the Display Settings menu are unaffected by Restore Factory Defaults see page 72 Servicing should only be performed by a Qualified Service Agent ELECTRONIC CONTROL SYSTEM HEATER INFORMATION MENU This menu displays non adjustable operational information Elapsed Time Total accumulated time the control system water heater has been energized Total Heating Time Total accumulated time the control system has
63. l system from the immersion Temperature Probe reaches the Operating Set Point the control system will end the heating cycle A call for heat will be activated again when the water temperature drops below the Operating Set Point minus the 1st Differential Setting Example Operating Set Point is 120 F the 1st Differential Setting is 2 F factory default A call for heat will be activated when the sensed water temperature drops to 118 F Operating Set Point ist Differential 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset CHANGE Differential Settings Adjustable user setting s 1 F to 20 range factory default is 2 F The water heaters covered in this manual will have between 1 and 5 heating elements There is at least one Differential Setting on all models There will be additional Differential Settings for each additional heating element installed Operating Sequence On a water heater equipped with 3 heating elements with an Operating Set Point of 120 F and all Differential settings at 2 F the On Off sequencing of heating elements would be as follows ELEMENT NUMBER DIFFERENTIAL SETTING TURN ON TEMP TURN OFF TEMP Tank Temperature Non adjustable information display Current water temperature as sensed by the control system from the immersion Temperature Probe Tank Probe Offset User adjustable setting 5 F to 5 F range factory default is O F If the current Tank Temperature is s
64. l wiring and connections between the heating elements contactors fuses and the power distribution block Ensure all wiring is correct see the wiring diagram on the water heater Ensure all connections are tight and making good contact replace any wiring fuses contactors that are damaged or show signs of excessive wear Close the water heater drain valve and follow the filling instructions in the Maintenance Section of Instruction Manual that came with the water heater Double check all heating element flange bolts to ensure they are properly tightened and check all heating element wiring to ensure it is properly connected and tightened Restore power to the water heater and place the water heater back in service Check amp draw at all heating elements with a 100 call for heat active See page 25 Servicing should only be performed by a Qualified Service Agent 31 OPERATION amp SERVICE ELEMENT SENSORS The water heaters covered in this manual monitor heating elements using Element Sensors Each Element Sensor monitors all the three loops of a heating element see pages 16 amp 17 There will be one Element Sensor for each heating element IE water heaters equipped with 5 heating elements will have 5 Element Sensors Element Sensor Construction Element Sensors are an assembly that consists of 3 individual current sensors a 10 conductor plug and 9 wires that connect between the individual current sensors and the plug Each curren
65. ller to remove and install fuses Always use the correct size for the circuit See the Instruction Manual that came with the water heater for fuse size requirements See page 15 in this manual Using an AC volt meter measure the branch circuit power supply voltage to the water heater Ensure the measured voltage of the branch circuit supplying power to the water heater matches the water heater s rating label see pages 12 14 Ensure the phase of the branch circuit supplying power to the water heater matches the water heater s rating label Some water heater models covered by this Service Manual are phase convertible Some models are not phase convertible See the Instruction Manual that came with the water heater for more information on phase conversions The water heaters covered by this manual have a multi tap control circuit transformer This is a step down transformer that outputs 120 VAC secondary winding which is used to power the electronic control system and energize the contactor coils The transformer can accommodate different power supply voltages and has multiple input voltage connections or taps Ensure the input supply voltage primary winding wiring to the transformer is connected properly See the Instruction Manual that came with the water heater and pages 39 amp 40 in this manual for more information Service Note Contactor Chatter Incorrect supply voltage wiring to the multiple tap 120 VAC Control Circuit Transform
66. ls as shown in the table below 2 Only one wire needs to be moved on the transformer s primary winding terminals to configure for a different voltage Do not move or change the wire connected to the H1 terminal on the primary winding Do not move or change either wire at the secondary winding X1 or X2 connections WATER HEATER POWER SUPPLY VOLTAGE PRIMARY WINDING CONNECTIONS 208 VAC H1 Common amp H2 208 240 VAC H1 Common amp H3 240 277 VAC H1 Common amp H4 277 H1 H2 H3 H4 Primary Winding H1 H2 H3 SOTOTTSO24174R1 190 220 54 ULI CSA EN 61558 re Ha HIH Hi H3 i S Im 00 5 0 075 j 1 j oso 219 2 A1 CLASSICLASE CLASSE 105 39077 549 54 x2 Cag 120 VAC AB X1 X2 Secondary Winding g Servicing should only be performed by a Qualified Service Agent 39 OPERATION amp SERVICE 120 VAC Transformer Wiring 480 Volt Models This is a multiple or multi tap transformer that can accept 2 different input voltages to it s primary winding This transformer outputs 120 VAC power from it s secondary winding which powers the CCB page 50 and the contactor coils The input power wiring to the primary winding of this transformer must be configured to match the power supply voltage to the water heater Incorrect wiring can cause output voltage from the transformer s secondary winding to be too low or too high This can cause contactor chatter conta
67. ls of the contactor L2 amp L3 Note All three voltage readings should be approximately the same Repeat this procedure at each contactor s for other heating elements being tested D Three Phase Power 4 Pole Contactor Six Wire Element see diagrams page 21 1 Measure and record voltage to the 1 heating element loop between the first and second lower terminals of the contactor L1 amp L2 2 Measure and record voltage to the 2 heating element loop between the first and fourth lower terminals of the contactor L1 amp L3 3 Measure and record voltage to the heating element loop between the third and fourth lower terminals of the contactor L2 amp L3 Note All three voltage readings should be approximately the same Repeat this procedure at each contactor s for other heating elements being tested D Three Phase Power 3 Pole Contactor Three Wire Element see diagrams page 22 1 Measure and record voltage between the first amp second lower terminals of the contactor L1 amp L2 2 Measure and record voltage between the first amp third lower terminals of the contactor L1 amp L3 3 Measure and record voltage between the second amp third lower terminals of the contactor L2 amp L3 Note All three voltage readings should be approximately the same Repeat this procedure at each contactor s for other heating elements being tested Service Notes If the voltage is low or not present in any of the tests above check power
68. ltage divided by the resistance following equations further explain ohms law V Volts electrical pressure A Amps electrical flow current O Ohms resistance to electrical flow current W Watts rate or amount of electricity used Ohms Law applied to single phase power each loop of a six wire element Ohms Law applied to three phase power each wiring lead to a three wire element 0 577 xW V 2A VXxAx1 732W Service Note See Heating Element Ratings on page 23 to determine the voltage and KW rating of a heating element Servicing should only be performed by a Qualified Service Agent OPERATION amp SERVICE SINGLE AND THREE PHASE POWER These water heaters can be factory ordered for standard 277 208 240 480 volt power 277 volt models are single phase only other voltages may be single or three phase Field Conversions some water heaters may be converted for single or three phase power within the guidelines listed below Follow the phase conversion instructions provided in the Instruction manual that came with the water heater Voltage KW conversions ARE NOT permitted e 208 240 VAC models factory configured 24KW or less are convertible as single or three phase and include jumpers to make the conversion 208 240 VAC models factory configured as single phase with over 24KW can be converted to three phase but jumpers are not provided e 208 240 VAC models factory configured as three phase with over 24KW
69. move any debris from the area surrounding the switch contacts IE ants will occasionally infest the switch contacts and eventually cause the contactor to malfunction 5 Physically test the mechanical spring action of the contactor by depressing the contactor mechanism If the action is not smooth and or sticks replace the contactor 6 Perform a close visual inspection of the switch contacts The contacts are silver plated and should be smooth Contactor chatter see page 6 voltage spikes arcing excessive current along with normal wear and tear can cause the normally smooth surface of the contacts to become burnt pitted and damaged In extreme cases the contacts can weld together and permanently close the contacts The switch contacts are not replaceable If the contacts show signs of excessive wear or damage replace the contactor 7 Replace the top cover on all contactors when inspection is complete Top View Cover Plate On Side View Cover Plate Removed Physically Operate Mechanical Spring Action Of Contactor Press Down Here 3 Pole Contactor 4 Pole Contactor Perform Close Visual Inspection Of Switch Contacts SN3mJIS Servicing should only be performed by a Qualified Service Agent 36 OPERATION amp SERVICE Contactor Coil Voltage Test At Contactor This test procedure will measure contactor coil voltage at the contactor Ensure tank temperature is less than 100 F 38 C dump water t
70. mperatures Menu page 61 is used for the entire day Economy Mode All Day When this operating mode is active the Economy Set Point is used for the entire day Economy Set Point normal Operating Set Point minus the programmed Setpoint Adjustment value Normal Operation Between When this operating mode is active there will also be start and stop times to program The normal Operating Set Point is used between the programmed start and stop times and the Economy Set Point will be in effect during the rest of the day There is one programmable start and stop time event per day Servicing should only be performed by a Qualified Service Agent 64 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Setpoint Adjustment Value ACTION From the Desktop screen press the Operational Button underneath MENU to enter the Main Menu DISPLAY MODEL INFORMATION Tank Temperature 120 F Operating Set Point 120 F Notice how the text above the Operational Buttons on Status Standby the display changes as you navigate through the various Friday menus and screens 5 00 PM Us Normal Mode see UIM Navigation on page 57 Use the Up Down buttons to select highlight in black the Economy Mode Setup menu from the Main Menu Press the Operational Button underneath SELECT to enter the Economy Mode Setup menu Main Menu Temperatures Heater Status Economy Mode Setup Alarm Output Setup Display Settings SELECT Use the Up Down button
71. mperatures Menu Ill Temperatures If Temperatures is not selected use the Up and Down Heater Status buttons to select this menu item Economy Mode Setup Alarm Output Setup Display Settings With the Operating Set Point selected highlight in black the Temperatures Menu press the Operational Button Temperatures underneath CHANGE to activate the adjustment mode for this menu item 1st Differential 29F al ENS 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset CHANGE BACK Press the Up and Down buttons to adjust the Operating Set Point to the desired setting Temperatures Press the Operational Button underneath UPDATE to a confirm the new setting Press the Operational Button underneath CANCEL to discard the new setting and 3rd Differential retain the previous setting Tank Temperatura The new Operating Set Point value should now be Se displayed as the current value NOTE Use this same procedure to adjust the Differential settings and the Tank Probe Offset in the Temperatures Menu ist Differential 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset CHANGE This same procedure is used to change user settings in other control system menus Servicing should only be performed by a Qualified Service Agent 62 ELECTRONIC CONTROL SYSTEM HEATER STATUS MENU This menu displays non adjustable operati
72. n Terminal Alarm Output Relay Dry Contact Output Normally Closed Terminal Alarm Output Relay Dry Contact Output Common Terminal Alarm Output Relay J4 Wiring Terminals Contactor Coils TERMINAL DESCRIPTION OUT 1 120 VAC hot to Heating Element 1 Contactor Coil OUT2 120 VAC hot to Heating Element 2 Contactor Coil if so equipped OUT 3 120 VAC hot to Heating Element 3 Contactor Coil if so equipped J5 Socket Immersion Temperature Probe ECO PIN DESCRIPTION ECO energy cut out 120 VAC hot out red wire Temperature probe thermistor 5 0 VDC black wire 2 3 Temperature probe thermistor 5 0 VDC black wire ECO energy cut out 120 VAC return red wire J6 Socket Not Used Servicing should only be performed by a Qualified Service Agent 51 OPERATION amp SERVICE J7 Socket Enable Disable Circuits 1 amp 2 see pages 53 amp 63 DESCRIPTION Enable Disable circuit 1 Enable Disable circuit 1 2 jJEmableDisablecrcut 0 000 Enable Disable circuit 2 Enable Disable circuit 2 J8 Socket Not Used J9 Socket Not Used J10 Socket LWCO amp Powered Anode Rod DESCRIPTION Not Used Not Used LWCO Low Water Cut Off Input J11 Port Communication Port UIM Display user interface module l eee A e i 1 Powered Anode Rod Output on models so equipped 3 NetUsed a J12 Socket Heating Element 1 Sensors J13 Socket Heating Element 2 Sensors
73. n follow the Heating Element Amperage Test procedure on page 25 to measure amperage through each loop of the six wire heating element being tested The 3 amp readings one for each loop should be approximately the same Compare the measured values to the values in the table below Keep in mind there may be some variance between measured values and the values in this table due to fluctuations in voltage temperature and the calibration of test instruments being used SIX WIRE ELEMENT TABLE TOTAL WATTAGE APPROXIMATE AMPS THROUGH EACH LOOP PER LOOP 208 VAC 240 VAC 277 480 VAC 300 100 48 417 361 208 __ ELEMENT WATTAGE 6 000 2000 9692 833 722 417 9 000 8000 1442 1250 1083 625 12 000 4 000 1923 16 67 15 000 500 2404 2083 1805 18 000 6 000 28 85 m EE T NM NN Heating Element Amperage Three Wire Y Configured Elements The table below shows the approximate amp draw through each wire see page 17 of a three wire heating element First determine the actual rated wattage and voltage of the element being tested see page 23 Then follow the Heating Element Amperage test procedure on page 25 to measure amperage through each wire of the three wire heating element being tested The 3 amp readings should be approximately the same Compare the measured values to the values in the table below Keep in mind there may be some variance between measured values and th
74. nd must be replaced see page 31 6 Wire Element Resistance Test oee additional images illustrations and information in the Heating Element Construction and the Six and Three Wire Heating Elements Servicing should only be performed by a Qualified Service Agent 29 OPERATION amp SERVICE Heating Element Ground Test 1 Secure power to the water heater at the main breaker or disconnect switch 2 Verify with an AC volt meter that there is not any voltage present at the Power Distribution Block see Figure 2 on page 9 or the contactor on single element models 3 Disconnect and label the power wires from the contactor s to all elements being tested Pay close attention to wiring and which heating element loops see pages 16 amp 17 connect to which terminals on the contactor s Use wire markers see Tools Required page 3 to label contactor terminals and or the wiring leads of the heating element to ensure they are reconnected properly when finished 4 Using an ohm meter set the ohm meter to one of it s lowest resistance ranges 200 ohms or less initially An audible beep continuity test setting can also be used on ohm meters so equipped Six Wire Elements Test for continuity ohms resistance between all six wire ends from each loop on the heating element and the ground wire connection to the water heater six continuity readings See pages 16 amp 17 and the illustrations below There should not be any continuity be
75. nding on what menu is currently displayed or what menu item is selected When no text appears on the LCD screen above an Operational Button there is no function assigned Servicing should only be performed by a Qualified Service Agent 57 ELECTRONIC CONTROL SYSTEM THE DESKTOP SCREEN The illustration below shows the control system Desktop Screen This is the default screen If there are no active Fault or Alert conditions and no user input for approximately 10 minutes the control system will return to this screen automatically Model Information Model information and menu titles are shown in the black bar at the top of the Desktop Screen Tank Temperature Current water temperature as sensed from the immersion Temperature Probe see page 43 Operating Set Point Temperature at which the control system will maintain tank water temperature in the Normal Mode This line of text will read Economy Set Point whenever the control system is operating in the Economy Mode See Temperatures Menu on page 61 and Economy Mode Setup Menu on pages 64 67 Status The Operating State of the control system is displayed beneath the Operating Set Point See Table 2 on page 60 Service Note The Desktop Screen displays text and animated icons that z convey operational information Tank Temperature 114 F Review the Status Icons explanation Operating Set Point 1209 MODEL INFORMATION in Table 1 on page 59 Learning to Status Heatin
76. nels while servicing Insulated fuse puller s Adhesive numbered colored wire markers Scotch Code SDRO 9 Numbered Wire Markers 3M Scotch Code STD C Colored Wire Markers or equivalent Volt Ohm Multi Meter recommend Fieldpiece HS36 Fluke 187 UEI model DL289 or equivalent capable of measuring e AC Voltage up to 600 VAC e DC Voltage up to 24 VDC e Ohms up to 2 000 000 ohms AC amp meter recommend UEI model DL289 or equivalent capable of measuring e AC amperage up 400 amps Servicing should only be performed by a Qualified Service Agent 3 INSTALLATION CONSIDERATIONS INSTALLATION CONSIDERATIONS Installation information given in this Service Manual IS NOT a complete installation instruction Installation information covered in this Service Manual has a limited focus as it applies to servicing This Service Manual does not replace or supersede the Instruction Manual that came with the water heater Always refer to the Instruction Manual that came with the water heater for complete installation instructions If the instruction Manual that came with the water heater is not on hand copies can be obtained from the manufacturers web site or by calling the technical support phone number shown on the water heater labeling and the back cover of this Service Manual CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices
77. node If there is an operational problem the control system will declare an Alert condition see page 80 Inspection and Cleaning Over time calcium and lime deposits may adhere to the end of the anode rod depending on water hardness water usage and water temperature Heavy calcium lime accumulation will diminish the current flow through the anode rod and may cause anode rod Alert conditions Powered anode rods should be inspected cleaned periodically or anytime the control system declares a powered anode Alert condition see page 80 1 Secure power to the water heater follow the draining instructions in the maintenance section of the Instruction Manual that came with the water heater to drain the tank 2 Disconnect wiring to the powered anode rod and remove it from the water heater Closely inspect the powered anode for any damage replace the anode if damaged Clean any calcium lime deposits from the powered anode by gently scraping and using steel wool Reinstall the powered anode and reconnect the wiring 5 Follow the filling instructions in the maintenance section of the Instruction Manual that came with the water heater Restore power and place the water heater back in service Servicing should only be performed by a Qualified Service Agent 48 OPERATION amp SERVICE ELECTRONIC CONTROLS Introduction This section of the manual covers the electronic controls The control system includes a CCB Central Control Board a UI
78. nt Adjustment Current Time 5 00 PM Heater In Economy Mode Sun Economy Mode All Day Normal All Day Tue Normal All Day Wed Q Normal Operation Day Economy Mode All Day Normal Operation Between Start F PM Stop B 00 PM ACCEPT CANCEL Monday AUT Q Normal Operation Day 23 Economy Mode All Day j i J Normal Operation Between A Start 7 30 FTT Step 00 PH Sending Updates ta CCB Economy Mode Setup Setpoint Adjustment Current Time Man 5 00 PH Heater In Economy Mode No Sun Economy Mode All Day Man Hanmal 7 30 AM to 8 00 PM Tue Normal All Day Ve d Servicing should only be performed by a Qualified Service Agent 67 ELECTRONIC CONTROL SYSTEM ALARM OUTPUT SETUP MENU Permits user to set the condition from a list of options for when the CCB s integral alarm output relay will be energized Alarm relay connections common normally open normally closed are located on the J3 terminal strip on the CCB see page 50 Alarm output relay contacts are capable of switching 1 amp maximum at 120 VAC The alarm relay operates in the background according to the settings in this menu and is not capable of disabling water heater operation The alarm relay is used for external notification verification of various operational conditions such as Fault conditions and heating mode status This relay can be used with building EMS Energy Manag
79. number on the back cover of this manual for further assistance if all the procedures above have been performed and 120 VAC is still not present at pins 1 amp 3 of the J1 socket plug on the CCB Check Secondary Winding Voltage Using an AC volt meter set the volt meter to an AC voltage range just above 24 VAC With the J1 plug installed in the J1 socket on the CCB page 50 insert the two volt meter probes into pins 4 amp 5 of the J1 plug as shown in the Secondary Winding Voltage Test image below Volt meter probes may have to be pressed firmly into the plug to make contact with the metal conductors inside Voltage should be approximately 24 VAC If the voltage measured is approximately 24 VAC the transformer is operating properly If the voltage measured is zero volts or considerably less or more 5 expected than 24 VAC Check the J1 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 50 Check all wiring four wires between the J1 plug and the 24 VAC transformer see Figures 1 amp 2 on pages 8 amp 9 for location Ensure wiring is not pinched or shorted and continuous to the 24 VAC secondary winding repair or replace damaged wiring as necessary e f all the above procedures have been performed and there is still not 24 VAC present at pins 4 amp 5 of the J1 plug replace the 24 VAC transformer When replacing the transformer check all wiring to and from
80. o lower tank temperature if necessary 2 Adjust the temperature settings to ensure a call for heat is active for all heating elements Raise the Operating Set Point to 140 F or higher Set all Differentials at 2 F see pages 61 and 62 Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC 4 Touch the two volt meter probes to the contactor coil wiring terminals on the contactor Repeat this procedure at each contactor being tested There should be approximately 120 volts present between the two terminals Service Warning Be extremely careful when performing this test procedure volt meter probes are routed between wires in tight proximity there will be high voltage present at all terminals and wiring to the contactors If there is no voltage present proceed to the Contactor Coil Voltage At CCB test on page 38 If the measured voltage is considerably less than 120 volts and or the contactors chatter open and close rapidly ensure the Control Circuit Transformer is wired correctly see pages 39 amp 40 If the measured voltage is approximately 120 volts the contactor should close it s switch contacts If the contacts are closed the contactor coil is operating properly If the measured voltage is approximately 120 volts and the contactor s switch contacts do not close the contactor is defective and must be replaced When replacing a contactor that has failed in this way check all wiring between the c
81. ol Circuit Transformer Test 1 2 Ensure the main breaker or disconnect switch is turned on Verify with an AC volt meter that proper voltage is present at the Power Distribution Block or the contactor on single element models see Figures 1 and 2 on pages 8 amp 9 and pages 12 14 Check Primary Winding Voltage Using an AC volt meter set the volt meter to an AC voltage range above the expected voltage 600 VAC or higher range initially Touch the two volt meter probes between the control circuit transformer s primary winding H1 common terminal and the other primary winding terminal with a power wired connected to it as shown in the Primary Winding Voltage Test image below see pages 39 amp 40 Voltage between these two terminals should match the water heater s power supply voltage If the voltage at the primary winding terminals of the transformer matches the water heater s power supply voltage the primary winding is being powered correctly If the voltage measured is zero volts or considerably less or more than the water heater s power supply voltage e Check the control circuit fuses see the Fuse test procedure on page 15 e Check the wiring between the 120 VAC Control Circuit Transformer s primary winding and the Control Circuit Fuses see Figures 1 and 2 on pages 8 amp 9 for location ensure wiring is correct and connections are tight and making good contact Check the wiring between the Control Circuit Fuses and the Power
82. onal information Use the Up amp Down Buttons to navigate to the bottom and top of this menu Status Top Of Menu Displays the current Operating State of the Heater Status control system IE Heating Standby Fault Status Heating Elements On Elements On 1 ECO Contact Closed Displays the number of heating elements the Enable Disable 1 Closed control system has energized Enable Disable 2 Closed ECO Contact Element 1 On Element 2 On Displays the current state of the ECO high temperature limit switch contacts Enable Disable 1 amp 2 Bottom Of Menu Heater Stat Displays the current state open or closed of ee the two Enable Disable circuits J7 socket on Enable Disable 2 the CCB see page 52 provided for external supervisory controls such as building EMS ria sube m pai I 30 Energy Management System Both of these d Enable Disable circuits must be closed to Alarm Condition enable heating operation If either circuitis Alarm Relay Output open heating will be disabled A plug with A two jumper wires is installed from the factory in the CCB J7 socket to enable heating operation when external controls are not in use Service Note If a supervisory control s is used to enable disable heating operation install field wiring between the J7 socket on the CCB and a set of dry contacts on the external control per all applicable building codes This is a switching circuit
83. only DO NOT apply any external voltage or connect any load IE relay coil to either circuit Element On Displays the on off status of each heating element Yes On No Off Tank Full Displays the status of the LWCO Low Water Cut Off device Yes water level is at or above the LWCO probe No water level is low see page 47 Alarm Condition Displays the status of the user definable Alarm Output function see page 68 Yes alarm condition has been met No alarm condition has not been met Alarm Relay Output Displays the state of the normally open contacts of the Alarm Output relay This relay J3 contacts on the CCB see page 50 is used for building EMS Energy Management System notification of operational conditions such as Fault conditions and heating mode status Servicing should only be performed by a Qualified Service Agent 63 ELECTRONIC CONTROL SYSTEM ECONOMY MODE SETUP MENU This menu contains settings used to establish an Economy Set Point and Economy Mode operating periods This control system feature can help reduce operating costs during unoccupied or low demand periods Setpoint Adjustment Desktop Screen During Economy Mode Adjustable user setting 2 F to 50 F factory default is 20 F the control system uses to MODEL INFORMATION calculate the Economy Set Point The Tank Temperature 120 F Economy Set Point normal Operating Set Economy Set Point 100 F Point minus the programmed
84. ontactor coil and the J4 or J17 wiring terminals on the CCB see pages 50 52 for pinched or shorted wires repair or replace damaged wiring as necessary Service Note A continuity test can also be performed on contactor coils to determine if the failure is due to an open coil winding Secure power to the water heater at the main breaker or disconnect switch disconnect both wires to the contactor coil and check for continuity between the two terminals using an ohm meter If a contactor has an open coil the contactor must be replaced Check all wiring between the contactor coil and the J4 or J17 wiring terminals on the CCB see pages 50 52 for pinched or shorted wires repair or replace damaged wiring as necessary 4 Pole Contactor Side View 3 Pole Contactor Side View Electromagnetic Contactor Coil Wiring Terminals 120 VAC Servicing should only be performed by a Qualified Service Agent 37 OPERATION amp SERVICE Contactor Coil Voltage Test At CCB This test procedure will measure contactor coil voltage where it originates at the J4 amp J17 wiring terminals on the CCB See page 50 for the CCB s J4 wiring terminal location 1 Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary 2 Adjust the temperature settings to ensure a call for heat is active for all heating elements Raise the Operating Set Point to 140 F or higher Set all Differentials at 2 F see pages 61 and 62 3 Us
85. ontrol system declares an Alert condition it will continue heating but will display an Alert message on the UIM notifying the user that the water heater requires servicing Resetting Control System Turn the power supply to the water heater off for approximately 20 seconds and then back on If the operational problem that caused the control system to declare a Fault or Alert condition has not been corrected the control system will continue to display the Alert or Fault message and lock out CONTROL SYSTEM UNRESPONSIVE DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR UIM Display Is Blank UIM is not energized LCD display is blank Possible Causes No power to water heater Blown control circuit transformer fuses 120 VAC power problems 24 VAC power problems Defective transformer s Wiring or plug socket connection problems UIM communication cable problems Important Service Reminder When performing any troubleshooting steps outlined in this service manual always consider the wiring and connectors between components Perform a close visual inspection of all wiring and connectors to a given component before replacement Ensure wires were stripped before being crimped in a wire connector ensure wires are crimped tightly in their connectors Ensure pins inside plugs sockets are not damaged or worn ensure plugs sockets are mating properly amp providing good contact Check restore power supply to the water heater at Po
86. ontrol system has not detected current in one power on 30 models see pages 12 14 or more heating elements when expected Check power circuit fuses see page 15 Possible Causes Check heating elements see pages 23 30 Check contactors see pages 34 38 Power supply problem dead leg on 3 phase supply Blown power circuit fuses Defective heating element s Defective contactor s Plug socket connection problems Defective Element Sensor Wiring connection problems Check power circuit wiring to heating elements from Power Distribution Block or contactor on single element models to fuse blocks to con tactors to heating elements see wiring dia gram on water heater and Contactor Configuration illustrations on page 35 Correct any mis wiring Repair or replace damaged wir ing as necessary _ Check the Element Sensor J12 J13 J14 J15 No Current Detected and J16 plug socket connections at the CCB for Mert occured 14 mins ago wear or damage see page 33 Ensure they are d T E E mating properly and providing good contact oee CCB illustration and socket identification on pages 50 52 for location Note this is alert The unit a E URN ter water in Check Element Sensors see pages 32 amp 33 res ar Replace any Element Sensors determined to be defective CK ADVANCED Call the toll free technical support phone num ber on the
87. orted wiring between the Powered Anode Rod and the J10 Hote this is an alert The uait plug socket connection on the CCB repair or will continue to heat water in replace damaged wiring as necessary See UE ORT NIE CCB illustration and socket identification on BACK A pages 50 52 ees Remove the powered anode and inspect for icu damage and or heavy calcium lime accumula Low Anode Protection 1 tion clean and or replace anode as necessary Alert occumed 14 mins a dnd see page 48 The power anodes are providing lower than anticipated protection Call the toll free technical support phone num ber on the back cover of this manual for further Note this is an alert The unit assistance if the problem has not been cor will continue to heat water in press DOWN for more rected after performing the procedures outlined BACK Alert No Anode Voltage Aleit occumed 14 mins ago P SS NN No voltage detected from power anode s Note this is an alert The unit will continue to heat water in ka press DOWN for more BACK ADVANCED Servicing should only be performed by a Qualified Service Agent 80 fe Smith 500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com
88. ove E 23 tin DUNS When finished making changes press the Operational Lv Button underneath BACK to confirm all new settings and update the control system The display will Sending Updates to automatically return to the Economy Mode Setup menu CHANGE The new settings should be displayed as the Current Time Economy Mode Setup Setpoint Adjustment 20 L Current Time Mon 5 00 PM Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day Servicing should only be performed by a Qualified Service Agent 66 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Daily Operating Mode Settings ACTION DISPLAY Economy Mode Day From the Economy Mode Setup menu use the Up Down buttons to select highlight in black the Daily sub menu for Sun Press the Operational Button underneath CHANGE to enter this menu oee Time Clock settings on page 66 for instructions on navigating to the Economy Mode Setup menu Use the Up Down buttons to select highlight in black the Economy Mode All Day setting Press the Operational Button underneath SELECT to change from the factory default Normal Operation All Day setting to the Economy Mode All Day setting Press the Operational Button underneath BACK to confirm the new setting and update the control system You will be returned to the Economy Mode Setup menu The new se
89. plugs are not damaged or worn Also ensure plugs and sockets are mating properly and providing good contact Failure to perform this critical step or failing to perform this step thoroughly often results in needless down time unnecessary parts replacement and customer dissatisfaction Servicing should only be performed by a Qualified Service Agent 2 INTRODUCTION INSTRUCTION MANUAL Have a copy of the Instruction Manual that came with the water heater on hand for the correct model water heater you are working with before servicing Installation information given in this Service Manual IS NOT a complete installation instruction Installation information covered in this Service Manual has a limited focus as it applies to servicing This Service Manual does not replace or supersede the Instruction Manual that came with the water heater Always refer to the Instruction Manual that came with the water heater for complete installation instructions If the Instruction Manual is not on hand copies can be obtained from the manufacturers web site or by calling the technical support phone number shown on the water heater labeling and the back cover of this Service Manual TOOLS REQUIRED Instruction Manual that came with the water heater All tools common to installation and service of commercial water heaters such as hand tools torch pipe wrenches etc Electrical switch lock out device used to secure disconnect switches breaker pa
90. pts the user to have the water heater serviced Servicing should only be performed by a Qualified Service Agent 32 OPERATION amp SERVICE Element Sensor Operation When current amperage flows through a wire in an electrical circuit a magnetic field is developed that radiates out from the wire The individual current sensors detect this magnetic field When current flows in a wire routed through the hole in one of the individual current sensors the sensor is activated and sends a signal back to the CCB confirming the presence of current The current sensors require approximately 3 AC amps minimum to activate An active signal from a current sensor only indicates the minimum current has been sensed it DOES NOT indicate the amount or level of current is correct for a given heating element loop As explained on the previous page Element Sensors are an assembly that contain three individual current sensors The three current sensors are installed so that one wire from each loop of each element passes through the hole in a sensor The plug from each Element Sensor assembly plugs into one of five sockets on the CCB The J12 J13 J14 J15 and J16 sockets are for heating elements 1 5 respectively depending on how many elements are installed in the water heater See the images below Service Note The Element Sensors cannot be serviced in the field If it is determined one of the three individual current sensors in an Element Sensor assembly is
91. r heaters covered in this Service Manual cannot be field converted Voltage and KW conversions ARE NOT permitted See the Instruction Manual that came with the water heater for more information If the Instruction Manual is not available copies can be obtained from the manufacturers web site or by calling the technical support phone number shown on the water heater labeling and the back cover of this Service Manual Servicing should only be performed by a Qualified Service Agent 7 WATER HEATER CONSTRUCTION 5 20 GALLON MODELS HOT WATER TEMPERATURE amp PRESSURE UIM user interface module OUTLET RELIEF VALVE Front of hinged access door f ad 3 4 NPT OPENING i s 1 Hm a Uu i 24 V TRANSFORMER RE UIM user interface module Fuss 120V CONTROL CIRCUIT TRANSFORMER ON OFF SWITCH Pilot Switch COLD WATER INLET HEATING ELEMENT HINGED ACCESS DOOR CCB CIRCUIT BOARD Central Control Board JACKET REMOVED IMMERSION LWCO PROBE J TEMPERATURE also contains ECO high temp limit switch POWERED HEATING ELEMENT ANODE ROD Figure 1 Servicing should only be performed by a Qualified Service Agent WATER HEATER CONSTRUCTION 30 120 GALLON MODELS HOT WATER OUTLET TEMPERATURE amp PRESSURE UIM user interface module me VALVE Front of hinged access door TOP COVER PLUGS 3 4 m f p 2
92. r models covered by this Service Manual are phase convertible Voltage and KW conversions ARE NOT permitted Servicing should only be performed by a Qualified Service Agent 5 PRE SERVICE CHECKS PRE SERVICE CHECKS WIRING CONNECTIONS With the power supply to the water heater turned off ensure the wiring connections are properly tightened to all components including high voltage terminal blocks fuse blocks contactors and transformers Loose connections at any connection point will cause increased amperage and excessive heat which can damage wiring and components Whenever worn or damaged wiring and components must be replaced ensure all wiring connections are properly tightened before putting the water heater back in service SERVICE PRECAUTIONS 1 DO NOT energize the branch circuit supplying power to the water heater or test the water heater electrical system before the water heater is completely filled with water Read the start up procedures in the Instruction Manual that came with the water heater Be sure to turn off power and use a lock out device at the branch circuit power supply disconnect switch or breaker when servicing the electrical system of the water heater Never touch electrical components with wet hands or when standing in water When replacing heating elements ensure they are rated at the correct voltage and KW for the water heater being serviced see pages 23 and 31 When replacing fuses use an insulated fuse pu
93. s not been corrected after per forming the procedure outlined here Heating Cycle Disabled Check for and correct any active Fault condition see Current Fault Menu page 71 Control System not activating call Check enable disable circuits ensure both cir for heat with cold tank of water Ne cuits are closed follow procedure outlined on Thermometer Icon on Desktop 53 ocreen see page 58 appears with diagonal line as shown here Call the technical support phone number on the back cover of this manual for further assistance if the problem has not been corrected after per forming the procedure outlined here Possible Causes Fault condition active Enable disable circuit s open Servicing should only be performed by a Qualified Service Agent 75 TROUBLESHOOTING FAULT AND ALERT MESSAGES Troubleshooting procedures for the most common Fault and Alert messages are covered in this section In the tables that follow the first column shows the Fault or Alert message as displayed by the UIM along with an explanation The second column details things to check or repair and references test procedures detailed in the Operation and Service section pages 10 55 of this manual DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR Current Detected Ensure the power supply to the water heater Alert Condition matches the listed voltage on the water heater rating plate Ensure there is not a dead leg of The c
94. s of the amp meter around ONLY ONE WIRE at a time Six Wire Elements Measure and record amperage by clamping the jaws of the amp meter around one wire from each of the three element loops on the heating element being tested three amp readings Ensure you are not measuring the amp draw of the same loop more than once See the connection wiring diagram on pages 18 21 that corresponds to the power supply phase and type of contactor s installed on the water heater being serviced The three amp readings should be approximately the same Three Wire Elements Measure and record amperage by clamping the jaws of the amp meter around each of the three heating element wires three amp readings See the connection wiring diagrams on page 22 The three amp readings should be approximately the same Service Notes If the measured amps on any heating element loop wire is zero amps perform the Heating Element Voltage test page 26 and the Heating Element Resistance amp Ground tests pages 29 30 If the measured amps on any heating element loop wire is considerably less or more 20 than the normal operating amps shown in the tables on page 24 ensure the voltage and KW rating of those heating elements are the correct ratings for the water heater being serviced see the rating label on the water heater and Heating Element Ratings on page 23 If the heating element voltage and KW ratings are correct perform the Heating Element Resistance amp Ground tes
95. s on page 35 to view 4 pole contactor illustrations Power is supplied to the heating elements through three or four switches 3 pole and 4 pole contactors inside the contactor s Springs located inside the contactor hold the switch contacts open the springs are compressed and the spring tension forces or holds the switch contacts in their normally open state The contactor s switch contacts are closed by an electromagnetic coil located inside the base of the contactor When a call for heat is activated the control system sends 120 volts to the contactor s electromagnetic coil As current runs through the coil it becomes magnetized and overcomes the spring tension holding the switch contacts open The switch contacts then close which in turn sends power to the heating elements When the call for heat is satisfied the control system de energizes the contactor coil and spring tension returns the contacts to their normally open position 3 Pole Contactor Side View 3 Pole Contactor Internal Wiring 3 Normally Open Switch Contacts Heating Element Power Circuit Wiring Terminals Electromagnetic Electromagnetic Contactor Coil Contactor Coil Wiring Terminals 120 VAC Contactor Springs Hold Contacts Open When Electromagnetic Coil Is Not Energized Servicing should only be performed by a Qualified Service Agent 34 OPERATION amp SERVICE Contactor Configurations Depending on how the water heater was configured in the
96. s to select highlight in black Setpoint Adjustment Press the Operational Button underneath CHANGE to activate the adjustment mode for the Setpoint Adjustment value Current Time Heater In Economy Mode Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day Use the Up Down buttons to change the Setpoint Adjustment to the desired value The Setpoint Adjustment value is adjustable from 2 F to 50 F The factory default is 20 F Notice how the text above the Operational Buttons on the display changes to UPDATE amp CANCEL when the adjustment mode is activated and how the current value is outlined rather than highlighted in black Press the Operational Button underneath UPDATE to enter and confirm the new value Pressing the Operational Button underneath CANCEL would discard the new value and retain the previous value The new Setpoint Adjustment value should now be displayed as the current value Economy Mode Setup Current Time Wed 4 19 Heater In Economy Mode No Sun Normal All Day Normal All Day Tue Normal All Day Normal All Day Economy Mode Setup Setpoint Adjustment 20 Current Time Wed 4 19 Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day Servicing should only be performed by a Qualified Service Agent 65 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Time Clock Settings ACTION
97. stic and 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 SERVICE WARNING If you are not qualified as defined by ANSI above and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the service diagnostic or troubleshooting procedures described in this manual If you do not understand the instructions given in this manual or do not feel confident in your abilities to perform a given task do not attempt to perform any procedures outlined in this manual IMPORTANT SERVICE REMINDER When performing any troubleshooting step outlined in this manual always consider the wiring and connectors between components Perform a close visual inspection of all wiring and connectors to and from a given component before replacement Ensure wires were stripped before being crimped in a wire connector Ensure wires are crimped tightly in their connectors Ensure connection pins in sockets and
98. such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system Virtually all commercial and most residential water supply systems are closed systems today Closed water systems will experience thermal expansion which if not controlled with a properly installed and sized thermal expansion tank can cause premature failure leakage of the water heater Water heater failure leakage on closed systems where there is not a thermal expansion tank installed is not covered under the limited warranty 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 A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Servicing should only be performed by a Qualified Service Agent
99. sured voltage should be approximately 120 VAC e f the measured voltage is approximately 120 VAC the ECO switch is closed the control system should not be declaring an ECO Fault condition If the control system continues to lock out displaying the Energy Cut Out ECO Fault message in this condition call the toll free Technical Support phone number listed on the back cover of this manual for further assistance e f the measured voltage is zero volts or considerably less than 120 VAC perform the ECO Continuity Test on page 45 120 VAC To ECO 120 VAC From ECO Servicing should only be performed by a Qualified Service Agent 46 OPERATION amp SERVICE LWCO LOW WATER CUT OFF The water heaters covered in this manual are equipped with a LWCO low water cut off safety device The control system monitors a LWCO probe see the images below constantly to ensure the water level inside the water heater remains at or above the level where the probe is installed The LWCO probe is installed in a threaded fitting in the water heater s storage tank See Figures 1 amp 2 on pages 8 amp 9 for location The LWCO probe is wired to the CCB s J10 plug see pages 50 52 for location and identification LWCO Operation When the water heater is properly filled with water the end of the LWCO probe is in direct contact with the water The emits a low voltage to the LWCO probe and monitors electrical current flowing through the probe If t
100. t Check power supply voltage as follows 1 With the power supply to the water heater turned on set the volt meter to an AC voltage range above the expected voltage 600 VAC or higher range initially 2 Measure and record voltage between the L1 amp L2 terminals at the water heater s Power Distribution Block or at the contactor on a single element model Models equipped with a single element and a 4 pole contactor will require two voltage readings one voltage reading between the first and second terminals of the contactor and a second voltage reading between the third and fourth terminals of the contactor 3 Measure and record the voltage between the L1 terminal and the ground wire connection to the water heater Check between L2 and ground in the same way Note models equipped with a single element and a 4 pole contactor will require four voltage readings between the each of the 4 poles of the contactor and ground On 208 240 volt power supplies each reading to ground should be approximately 120 volts On 480 volt power supplies each reading to ground should be approximately 277 volts On 277 volt power one of the wires is a neutral wire and will normally read approximately zero volts to ground Service Warning Zero volt readings between terminals and ground can be due to an inadequate earth ground TREAT ALL WIRES AS BEING HOT until it has been determined there is no voltage present If the voltage readings between terminals step 2 or the
101. t Fault menu Heating operation is discontinued locked out until the condition that caused the Fault is corrected Power to the water heater must be cycled off and on to reset the control system Note cycling power will not reset the control system if the condition that caused the Fault has not been corrected The control has detected declared an Alert Condition The water heater will continue to operate during an Alert Condition but there is an operational condition that requires the attention of a Qualified Service Agent Alert message details can be viewed in the Current Alert menu Servicing should only be performed by a Qualified Service Agent 59 ELECTRONIC CONTROL SYSTEM Table 2 Operating States STATE DESCRIPTION Standby The water heater is not in an active heating cycle This usually indicates the temperature in the tank has reached the Operating Set Point and the control system has terminated the heating cycle a SEN control system is in the Heating Mode At least one heating element has been energized Alert The control system has detected declared an Alert Condition The controls system will continue heating operation However a Qualified Service Agent should be contacted to check service the water heater Fault The control system has detected declared a Fault Condition The control system will discontinue heating operation and lock out Power to the water heater must be cycled off and on to reset the control sys
102. t Secondary Winding Voltage Test Servicing should only be performed by a Qualified Service Agent 41 OPERATION amp SERVICE 24 VAC Transformer Test 1 2 3 Ensure the main breaker or disconnect switch is turned on Verify with an AC volt meter that proper voltage is present at the Power Distribution Block or the contactor on single element models see Figures 1 and 2 on pages 8 amp 9 and pages 12 14 Check Primary Winding Voltage Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC With the J1 plug installed in the J1 socket on the CCB page 50 insert the two volt meter probes into pins 1 amp 3 of the J1 plug as shown in the Primary Winding Voltage Test image below Volt meter probes may have to be pressed firmly into the plug to make contact with the metal conductors inside Voltage should be approximately 120 VAC If the voltage measured is approximately 120 VAC the primary winding is being powered correctly If the voltage measured is zero volts or considerably less or more 1096 than 120 VAC e Check the J1 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 50 Check the 120 VAC Control Circuit Transformer to ensure it is wired correctly and outputting the correct voltage see pages 39 41 Ensure there is 120 VAC being supplied to the CCB see page 54 Call the toll free technical support phone
103. t loops see pages 16 amp 17 connect to which terminals on the contactor s Use wire markers see Tools Required page 3 to label contactor terminals and or the wiring leads of the heating element to ensure they are reconnected properly when finished Using an ohm meter set the ohm meter to a range just above the expected ohms 200 ohm range initially Six Wire Elements Measure and record the resistance ohms between the two wire ends from each loop on the heating element three ohm readings Note the pattern the three loops form on the heating element flange on a six wire element as shown in the illustrations on pages 16 and 17 Ensure you are not measuring the resistance of the same loop more than once Ensure you are not measuring resistance between wires from two separate loops The three ohm readings should be approximately the same Three Wire Elements Measure and record the resistance ohms between each wire end of the heating element and the metal bar that shorts spices together one end of each heating element loop on a three wire element three ohm readings See the illustrations on pages 16 and 17 The three ohm readings should be approximately the same Compare the measured ohms values to the values given in the Heating Element Resistance tables on page 28 for the correct type six or three wire element being tested If the resistance reading for any element loop is infinite no continuity the heating element is defective a
104. t sensor monitors one loop on a heating element Current sensors are enclosed in a black plastic housing that has a hole in the middle One of the power wires to each heating element loop is routed through the hole in one of the current sensors See the images below Element Sensor 10 Conductor Plug Element Sensor Functions Working with the Element Sensors the electronic control system provides valuable operational and diagnostic information to aid in servicing The electronic control system displays animated Status Icons on the UIM s User Interface Module LCD display to indicate which heating elements are being energized and which heating elements are not being energized The Status Icons will also indicate when heating element that has been commanded on energized by the control system is not drawing current amps See the Desktop Screen on page 58 and the Status Icons Table on page 59 The electronic control system displays a No Current Detected Alert message on the UIM see pages 55 58 and 76 if the control system does not sense current amperage from a heating element when expected IE a call for heat is active the control system has commanded all heating elements on all contactor coils have been energized and the control system is not sensing current from one or more heating element loops During Alert conditions the control system allows the water heater to continue heating other elements may still be working but prom
105. t test In the first test the actual resistance ohms of each heating element loop is measured In the second part of this test each heating element loop is tested for any continuity to ground to ensure the heating element is not shorted to ground These tests should be considered as third and fourth diagnostic procedures to be performed whenever the results from the Heating Element Amperage Test showed a heating element was not drawing the correct amps AND the results from the Heating Element Voltage Test showed the element had the proper voltage applied Measuring Resistance 3 Wire Element Resistance Test 1 sections on pages 16 and 17 Determine what the actual voltage and KW rating is for the heating elements in the water heater being serviced see Heating Element Ratings on page 23 Ensure the voltage and KW rating of those heating elements are the correct ratings for the water heater being serviced see the rating label on the water heater Replace any elements that are not the proper rating for the water heater being serviced before proceeding Secure power to the water heater at the main breaker or disconnect switch Verify with an AC volt meter that there is not any voltage present at the Power Distribution Block see Figure 2 on page 9 or the contactor on single element models Disconnect and label the power wires from the contactor s to all elements being tested Pay close attention to wiring and which heating elemen
106. tem Note cycling power will not reset the control system until the condition that caused the Fault has been corrected Table 3 Control System Menus MENUS DESCRIPTION Temperatures Most commonly accessed menu Operating Set Point Differential settings Tank Temperature and Tank Probe Offset are located in this menu Heater Status Current Operating State Mode heating standby etc and status open closed on off yes no of monitored water heater functions and components are displayed in this menu Economy Mode oeven day 24 hour time clock with temperature set back capability to reduce operating oetup costs during unoccupied or reduced demand periods Alarm Output Setup The control system s CCB Central Control Board see page 50 features on board SPDT single pole double throw relay contacts for building EMS Energy Management oystem notification of operational conditions such as Fault Conditions and heating mode status This menu features a list of user definable conditions for relay activation Display Settings Temperature units F or C appearance brightness contrast and backlight delay user adjustable settings are located in this menu Elapsed time of operation total heating cycle time heating cycle count heating element s cycle count and on time along with UIM and CCB software revisions can be Heater Information viewed in this menu Current Fault Alert Displays any current Alert or Fault mess
107. the transformer for pinched or shorted wires repair or replace damaged wiring as necessary Servicing should only be performed by a Qualified Service Agent 42 OPERATION amp SERVICE IMMERSION TEMPERATURE PROBE This section of the manual provides information on how test the Immersion Temperature Probe see Figures 1 amp 2 on pages 8 amp 9 for location The Immersion Temperature Probe contains the ECO energy cut out and a Temperature Sensor The Immersion Temperature Probe plugs into the CCB at the J5 socket see pages 50 52 for location ECO High Temperature Limit Switch The ECO energy cut out is a high temperature limit switch designed to protect against excessively high water temperatures inside the water heater The ECO is a normally closed switch located inside the Immersion Temperature Probe two red wires The ECO temperature setting is non adjustable the contacts open at 202 F 94 C and will close at approximately 140 F 60 C Immersion Temperature Probe The control system constantly monitors the state of the ECO switch contacts If the ECO activates contacts open due to abnormally high water temperature the control system will lock out and display a Energy Cut Out ECO Fault message on the UIM page 78 Voltage to the contactor coils pages 37 amp 38 and heating elements is terminated to prevent further heating operation Should the ECO activate the water temperature must drop below 140 F
108. ting cycles would progress as follows on a model equipped with 3 heating elements First heating cycle Elements come on 1 2 3 and cycle off 1 2 3 e Second heating cycle Elements come on 2 3 1 and cycle off 2 3 1 e Third heating cycle Elements come on 3 1 2 and cycle off 3 1 2 Fourth heating cycle pattern repeats same as first Optional Linear Sequencing Available on models equipped with more than one heating element Operation is the same as Modulation Sequencing described above except that the First heating element energized will be the Last element de energized during operation IE First On Last Off cycling of heating elements Successive heating cycles would progress as follows on a model equipped with 3 heating elements First heating cycle Elements come on 1 2 3 and cycle off 3 2 1 e Second heating cycle Elements come on 2 3 1 and cycle off 1 3 2 e Third heating cycle Elements come on 3 1 2 and cycle off 2 1 3 Fourth heating cycle pattern repeats same as first Servicing should only be performed by a Qualified Service Agent 56 ELECTRONIC CONTROL SYSTEM CONTROL SYSTEM FEATURES Advanced Diagnostics Plain English text and animated icons display detailed operational and diagnostic information LCD screen on the front of the water heater displays the Sequence of Operation in real time Fault or Alert messages are displayed when operational problems occur
109. tion Manual that came with the water heater Restore power and place the water heater back in service Servicing should only be performed by a Qualified Service Agent 47 OPERATION amp SERVICE POWERED ANODE ROD All of the water heaters covered in this manual are equipped with a standard anode rod some of the water heaters covered in this manual are also equipped with a powered anode rod See pages 8 amp 9 for location Both types of anode rods are designed to reduce tank corrosion rusting that naturally occurs when water comes into contact with steel See the maintenance section of the Instruction Manual that came with the water heater for standard anode rod maintenance procedures Rust amp Corrosion Rusting amp corrosion of steel is an electrochemical process electrical current flows between the exposed steel of the storage tank and the water inside All tanks are glass lined but there will be exposed areas around spuds threaded fittings where glass coating is not possible Powered Anode Rod Operation A powered anode rod see images below is installed into a threaded fitting in the water heater s storage tank DC current flows from the CCB s J10 socket page 50 to the powered anode and through the water to the water heater s storage tank which is grounded The DC current interrupts the electrical flow of the corrosion process which in turn reduces corrosion The control system adjusts and monitors current flow thorough the a
110. to the water heater pages 12 14 Check fuses page 15 Ensure heating element power circuit wiring is correct see wiring diagram on water heater ensure all wiring and connections are tight and making good contact Check contactors see pages 34 38 If the measured voltage is a standard voltage 277 208 240 480 but does not match the listed voltage on the water heater s rating label secure power to the water heater DO NOT place the water heater back in service Call the toll free Technical Support phone number listed on the back cover of this manual for further assistance Servicing should only be performed by a Qualified Service Agent 27 OPERATION amp SERVICE Heating Element Resistance Six Wire Elements This table shows the approximate resistance in ohms of each loop see page 17 in a six wire heating element First determine the actual rated wattage and voltage of the element being tested see page 23 Then follow the Measuring Resistance test procedure on page 29 to measure the resistance of each loop of the six wire element being tested The 3 ohm readings one for each loop should be approximately the same Compare the measured resistance to the values in the table below Keep in mind there will be some variance between measured values and the values in this table due to fluctuations in temperature and the calibration of test instruments being used SIX WIRE ELEMENT TABLE APPROXIMATE OHMS OF EACH LOOP TOTAL WATTAGE O OHM
111. ts on pages 29 30 If the element voltage and KW ratings do not match the rating label call the toll free Technical Support phone number listed on the back cover of this manual for further assistance Three Wire Element Being Tested Measuring amperage on an electric heating element Make sure the jaws of the AC amp meter are clamped around ONLY ONE WIRE from each heating element at a time Take 3 amp readings one for each heating element loop wire The three readings should be approximately the same Servicing should only be performed by a Qualified Service Agent 25 OPERATION amp SERVICE Heating Element Voltage Test This test is typically performed after an amperage test page 25 has determined one or more heating elements or heating element loops is not drawing the correct amperage There are five standard element contactor wiring configurations for the water heaters covered by this manual see pages 18 22 This is due to differences in power supply phase type of contactor s installed and the type of heating elements installed Because of these differences there will be five different methods to measure voltage to the heating elements Voltage to the heating elements is always measured at the lower output terminals poles of each contactor The measured voltage should always match the listed voltage on the water heater s rating label Single Phase 10 Power Three Phase 3O Power L1 L2 Measure voltage to
112. tting should now be displayed for Sun Normal Operation Between From the Economy Mode Setup menu Use the Up Down and CHANGE buttons to enter the Mon sub menu as described above Use the Up Down buttons to select highlight in black the Normal Operation Between setting Press the Operational Button underneath SELECT to change the operating mode for Monday to Normal Operation Between Note that when this setting is selected Start and Stop time user settings appear on the display Use the Up Down buttons to navigate between the Start and Stop time Hour Minutes and AM PM settings With each item selected press the Operational Button underneath CHANGE to activate the adjustment mode for each setting Use the Up Down buttons to change the value to the desired setting Press the Operational Button underneath ACCEPT to enter the new setting or CANCEL to discard the new setting and retain the previous setting Press the Operational Button underneath BACK when finished to confirm the new settings and update the control system The display will return to the Economy Mode Setup menu with the new settings shown for Mon Economy Mode Setup Setpoint Adjustment 20 Current Time Man 5 00 PH i Heater In Economy Mode Mo Normal All Day Mon Normal All Day Tue Normal All Day Sunday Q Normal Operation Day H E gt EE a C Normal Operation Between Sending Updates Setpoi
113. tween any wire and ground Three Wire Elements Test for continuity ohms resistance between all three wire ends of the heating element and the ground wire connection to the water heater three continuity readings See pages 16 amp 17 and the illustrations below There should not be any continuity between any wire and ground The resistance in these tests should be infinite no continuity to ground If there is any resistance or continuity measured between any element wire end and ground the heating element is shorted to ground and must be replaced see page 31 Checking a heating element for any resistance or continuity to ground Touch one of the ohm meter probes to one wiring lead from a heating element and the other probe to a grounded surface on the water heater Take additional continuity to ground readings for all wiring leads on a heating element Testing a 3 Wire Element Testing a 6 Wire Element Servicing should only be performed by a Qualified Service Agent 30 OPERATION amp SERVICE Replacing Heating Elements 1 2 10 11 Secure power to the water heater at the main breaker or disconnect switch Verify with an AC volt meter that there is not any voltage present at the Power Distribution Block and contactors inside the water heater see Figures 1 and 2 on pages 8 and 9 for location and pages 12 14 for power supply test procedures Close the cold water supply valve to the water heater and drain the water
114. voltage between any of the terminals and ground step 3 was less than expected 95 expected check the power supply to the water heater Contact a Qualified Licensed electrician to restore power If the voltage readings taken in otep 2 above are a standard voltage 277 208 240 480 but do not match the listed voltage on the water heater s rating label secure power to the water heater DO NOT place the water heater back in service Call the toll free Technical Support phone number listed on the back cover of this manual for further assistance L1HOT L2 HOT GROUND Measure power supply L1HOT L2 NEUTRAL GROUND voltage to water heater on models with more 1 than one element at the Power Distribution Block L1 L2 prre E sss 6ee eee Seg SSS ess volts volts 208 240 480 120 277 SUE Power Distribution Block T 277volts Qvolts p 4 5 4 Pole Contactor 3 Pole Contactor L1 L 277 volts L1 L2 277 Volt 10 Power 120 277 volts 208 240 480 Volt 10 Power Measure power supply to heating elements on all models at the lower terminals of the contactor s Servicing should only be performed by a Qualified Service Agent 13 OPERATION amp SERVICE Checking Three Phase 3O Power A three phase power supply will be connected to the L1 L2 and L3 terminals of the Power Distribution Block or directly to the contactor on models equipped with a single element All three wires are hot
115. wer Distribution Block see pages 12 14 Check control circuit transformer fuses see Fig ure 2 page 9 and checking fuses page 15 Check communication cable connections at UIM s J2 Socket page 55 and the CCB s J11 Port page 50 Install a new communication cable between UIM s J2 Socket and the CCB s J11 Port use standard Cat 5 network cable Closely inspect communication ports on the CCB and UIM to ensure they are mating prop erly and providing good contact pages 50 amp 55 Ensure 120 VAC power ground is supplied to CCB s J2 Socket follow procedure on page 54 Check J1 and J2 plug socket connections on the CCB ensure they are mating properly and providing good contact page 50 Check 24 VAC transformer follow procedure outlined on page 42 Call the technical support phone number on the back cover of this manual for further assistance if the problem has not been corrected after per forming the procedure outlined here Servicing should only be performed by a Qualified Service Agent 74 TROUBLESHOOTING Control System Unresponsive cont DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR UIM is Inoperable Ensure Ribbon Cable from the Button overlay is inserted correctly in UIM J3 Socket page 55 UIM does not respond to any user input using the Call the technical support phone number on the operational and or Up and Down buttons back cover of this manual for further assistance if the problem ha
116. wiring connection problems LWCO probe wiring shorted to ground Heavy calcium lime accumulation on LWCO probe Ensure the CCB is properly grounded see the Checking Power And Ground To The CCB tests on page 54 Ensure the ground wire leading Defective LWCO probe from pin 2 of the J2 plug on the CCB page 50 is securely connected to ground and the wire was properly stripped and crimped in it s con LWCO Fault nector Fault occurred 14 mins ago Check the J10 plug socket connection at the The en ee cut off zm CCB ensure they are mating properly and pro viding good contact See illustration Call a service professional socket identification on pages 50 52 Paul Stewart XXX XXX XXXX Check for pinched broken shorted wiring press DOWN for between the LWCO probe and the J10 plug BACK ADVANCED socket connection on the CCB repair or replace damaged wiring as necessary See CCB illustration and socket identification on pages 50 52 Remove the LWCO probe and inspect for dam age and or heavy calcium lime accumulation clean and or replace the LWCO probe as neces sary see page 47 Call the toll free technical support phone num ber on the back cover of this manual for further assistance if the problem has not been cor rected after performing the procedures outlined here Servicing should only be performed by a Qualified Service Agent 79 TROUBLE
117. with voltage present Check power supply voltage as follows 1 With the power supply to the water heater turned on set the volt meter to an AC voltage range above the expected voltage 600 VAC or higher range initially Measure and record the voltage at the water heater s Power Distribution Block or at the contactor on single element models Measure voltage between L1 amp L2 L2 amp L3 and L1 amp L3 terminals This will be three voltage readings at a Power Distribution Block or a 3 pole contactor Models equipped with a single heating element and a 4 pole contactor will require taking the voltage readings between the L1 amp L2 and L2 amp L3 terminals twice since there are two L2 terminals on the contactor total of 4 voltage readings All voltage readings should be approximately the same Measure and record the voltage between the L1 terminal and the ground wire connection to the water heater Check between L2 and ground and L3 and ground in the same way Note models equipped with a single element and a 4 pole contactor will require four voltage readings between the each of the 4 poles of the contactor and ground On some 208 volt power supplies each reading to ground will be approximately 120 volts Some 208 volt models will have a stinger leg with one of the three readings to ground measuring 208 volts 208 volt stinger legs should be connected to L2 On 240 volt power supplies each reading to ground should be approximatel
118. y 120 volts On 480 volt power supplies each reading to ground should be approximately 277 volts Service Warning Zero volt readings between terminals and ground can be due to an inadequate earth ground TREAT ALL WIRES AS BEING HOT until it has been determined there is no voltage present If the voltage readings between terminals step 2 or the voltage between any of the terminals and ground step 3 was less than expected 9596 expected check power supply fuses the breaker and or disconnect switch supplying power to the water heater Contact a Qualified Licensed electrician to restore power If the voltage readings taken in Step 2 above are a standard voltage 208 240 480 but do not match the listed voltage on the water heater s rating label secure power to the water heater DO NOT place the water heater back in service Call the toll free Technical Support phone number listed on the back cover of this manual for further assistance L1 HOT on models with more E than one element at the 208 240 480 L2 HOT L3 HOT GROUND L1 L2 L3 Measure power supply voltage to water heater Power Distribution Block 88s SSS ess Power Distribution Block Measure power supply voltage to water heater 4 Pole Contactor 208 240 480 M 120 208 277 on single element models L1 L2 L3 contactor 208 240 480 volts L1 12 13 E 208 240 480 Volt 30 Power Measure power supply to heating elements on

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