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A.O. Smith Gold Xi and Gold Series Technical Documents

1. 37 Temperature Sensor Resistance Test 38 Temperature Sensor DC Voltage Test 39 ECO Continuity Test eee 39 ECO Voltage Test 40 ELECTRONIC CONTROLS ssssseeseeeeeennens 41 CCB Central Control 42 CCB Socket amp Wiring Terminal Identification 43 CCB Enable Disable Circuit s 45 Checking Power And Ground To The 46 User Interface Module 47 ELECTRONIC CONTROL SYSTEM 48 Control System 48 Control System 48 The Desktop Screen sessseeeeee 49 Status Icons o oet er tei eee 50 Operating 51 Control System 51 Temperatures 52 Temperature Settings 53 Heater Status Menu 54 Economy Mode Setup 55 Setpoint Adjustment Value 56 Time Clock Settings
2. 13 Checking Three Phase 14 Phase Conversions Surface Mount Control Models 15 Phase Conversions Electronic Control Models 16 UI E 17 Surface Mount Thermostats 18 Thermostat amp ECO 19 Heating Elements eese 20 Heating Element 20 Heating Element Amperage 23 Heating Element Voltage 24 Heating Element Resistance amp Ground Test 25 Replacing Heating Elements 26 Element Sensors neve ede entere tes 27 Element Sensor 28 CORnt aClOIS iiis Sek eve etc rbd 29 Contactor 30 Contactor Inspection esee 31 Contactor Coil Voltage At Contactor 32 Contactor Coil Voltage At 33 Transformers do id die it tht dee o 34 120 VAC Control Circuit Transformer Wiring 34 120 VAC Control Circuit Transformer Test 35 24 VAC Transformer 36 Immersion Temperature Probes
3. Servicing should only be performed by a Qualified Service Agent 38 OPERATION amp SERVICE Temperature Sensor DC Voltage Test 1 Ensure the main breaker or disconnect switch is turned on 2 Verify the CCB circuit board 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 46 3 Unplug the J5 plug from the CCB circuit board 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 fthe measured voltage is 5 VDC the temperature sensor is being 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 circuit board see page 42 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
4. YELLOW RED WIRES necessary changes WIRES WIRES Electronic Control Models Single Phase to Three Phase Power Distribution Block see Figure 2 on page 9 1 Disconnect blue wires from terminal L 1 Disconnect yellow wires from terminal L 2 L1 L2 L3 1 51 53 SSS SSS fe SN L2 L3 Connect all blue wires and yellow wires to terminal L 3 A nm Incoming power will be connected to terminals L 1 L 2 and L 3 Service Note Keep in mind when converting from single phase power to three phase power the current amperage will decrease significantly ensure breakers and fuses are not oversized before placing the water heater back in service Contact a Qualified Licensed electrician to make necessary changes ALL BLACK ALL ALL WIRES RED WIRES BLUE YELLOW WIRES Servicing should only be performed by a Qualified Service Agent 16 OPERATION amp SERVICE FUSES The water heaters covered in this manual have power circuit fuses to protect the heating element circuits Electronic Control models will have two additional 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 power circuit fuses MUST BE of the same value and type as the factory installed f
5. sseesssss 57 Daily Operating Mode Settings 58 Alarm Output Setup Menu ese 59 Display Settings Menu eeeem 60 Heater Information 61 Current Fault Alert Menu esee 62 Fault History Menu 62 Fault Occurrence Menu esee 62 Restore Factory Defaults 63 Factory Default User Settings 63 TROUBLESHOOTING sieneen 64 Common Service 64 Surface Mount Control 64 Electronic Control Models sese 65 Fault Conditions 1 1 65 Alert Conditions eessssssseeeeeennn 65 Resetting The Control System 65 Control System 65 UIM Display Is 65 UIM Is 66 Heating Cycle 66 Fault amp Alert Messages 67 No Current Detected 67 Temp
6. BANK 2 MIDDLE BANK 1 LOWER AN Heating Elements Power Connection Terminals 6 4 5 6 Heating Element Banks 4 5 ie Blk Blu Red Yel Red o m x Numbers Connections Wire Colors to Elements LEGEND Servicing should only be performed by a Qualified Service Agent 30 OPERATION amp SERVICE Contactor Inspection A thorough visual inspection of the contactors used on Electronic Control Models should be performed as part of any regular maintenance program and whenever the water heater is being serviced Refer to the listed Steps 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 power circuit fuse block and all wiring terminals on the contactors See Figure 2 on page 9 for the location of these components 3 Remove the top cover two small screws from the contactor Check for and remove 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 cha
7. 1 A O Inm O ON o cw Water heater may be undersized Check thermostat ECO controls on Surface Mount Control Models see pages 18 amp 19 Check Operating Set Point and Differential Set Points on Electronic Control Models see pages 52 amp 53 On Electronic Control Models ensure the water heater is not in the Economy Mode during peak demand periods and ensure the time is set correctly daylight savings etc see pages 55 58 Ensure the power supply matches the listed voltage on the water heater rating plate see pages 12 14 Check for water supply piping leak or restriction lime scale valve partially closed Check all fuses see page 17 Check heating elements pages 20 26 Check Contactors on Electronic Control Models see pages 29 33 Check both enable disable circuits at the CCB s J7 socket on Electronic Control Models If either both 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 the CCB Enable Disable Circuit s Test on page 45 and Heater Status Menu information on page 54 Water Heater Trips Breaker 1 2 3 4 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 Ensure the internal power supply phase wiring is configured correctly
8. press DOWN for more BACK Fault Occurrence Menu Fault Occurrence ECO No Current Detected Tank Temp Probe CCB Hardware Model Faults Servicing should only be performed by a Qualified Service Agent 62 ADVANCED 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 Main Menu Heater Information Current Fault 45 The Restore Factory Defaults menu will be displayed Fault History Fault Occurrence Restore Factory Defaults HELP been restored the Restore Factory Defaults menu From the Restore Factory Defaults menu press the Operational Button underneath YES The display will show text confirming the factory default settings have Press the Operational Button underneath BACK to exit Restore Factory Defaults Are you sure you want to restore the system to factory defaults Factory Default User Settings TEMPERATURES MENU DEFAULT SETTING ADJUSTABLE RANGE Operating Set Point 120 F 49 90 F to 190 F 32 C to
9. 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 to indicate which heating elements are being energized and which heating elements are not being energized The Status Icons are also capable of indicating when a heating element that should be energized is not drawing current amps See the Status Icons Table on page 50 The electronic control system displays a No Current Detected Alert message on the UIM see pages 47 49 if the control system does not sense current amperage from a heating element when expected IE a call for heat is active all contactor coils have been energized and the control system is not sensing current from one or more heating elements During Alert conditions the control system allows the water heater to continue heating other elements may still be working but prompts the user to have the water heater serviced Servicing should only be performed by a Qualified Service Agent 27 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 b
10. see pages 15 amp 16 Check for grounded heating elements see page 26 Check for pinched shorted wiring internal wiring or power supply wiring Contactor Chatter Condition contactors opening and closing rapidly 1 3 Ensure the 120 VAC Control Circuit Transformer is properly configured to match the power supply to the water heater on Electronic Control Models see page 34 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 32 SURFACE MOUNT CONTROL MODELS See the Common Service Problems above Servicing should only be performed by a Qualified Service Agent 64 TROUBLESHOOTING ELECTRONIC CONTROL MODELS The remainder of the Troubleshooting section covers Electronic Control Models only 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 control 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 operatio
11. meo eeo exo Heating elements icon for a water heater equipped with 3 Banks of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Open circles with an X represent heating elements the control system has energized that it IS NOT sensing electrical current from Heating elements icon for a water heater equipped with 3 Banks of heating elements In this example 2 Banks 6 elements have been energized and 3 elements have not The control system is sensing electrical current from 4 heating elements The control system is reporting that it is not sensing electrical current from 2 elements that it should be sensing current from The control system would declare an Alert Condition in this case m The control has detected declared a Fault Condition Fault message details can be viewed in the Current 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
12. rected after performing the procedures outlined here 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 problem with the temperature probe Call service professional Paul Stewart XXX XXX XXXX press DOWN for more BACK ADVANCED 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 42 44 Check the resistance of the temperature sensor inside the Immersion Temperature Probe see pages 37 39 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 after performing the procedures outlined here Servicing should only be performed by a Qualified Service Agent 68 TROUBLESHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR Energy Cut Out ECO Fault Condition The control syste
13. user interface module J12 Socket Heating Element Sensors Bank 1 J13 Socket Heating Element Sensors Bank 2 J14 Socket Heating Element Sensors Bank 3 J15 Socket Not Used J16 Socket Not Used J17 Wiring Terminals Not Used Servicing should only be performed by a Qualified Service Agent 44 ELECTRONIC CONTROLS CCB Enable Disable Circuit s Test The electronic control system includes two enable disable circuits see page 54 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 66 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 to J7 plug by an external supervisory control ensure that control s dry contacts are closed to enable heatin
14. 3M ScotchCode STD C Colored Wire Markers or equivalent Volt Ohm Multi Meter recommend Fieldpiece HS36 Fluke 187 UEI model DL289 or equivalent capable of measuring AC Voltage up to 600 VAC e DC Voltage up to 24 VDC Ohms up to 2 000 000 ohms AC amp meter recommend UEI model DL289 or equivalent capable of measuring AC amperage up to 400 amps Servicing should only be performed by a Qualified Service Agent 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 toll free phone number shown on 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 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 residentia
15. 88 Differential Settings 2 F 1 1 to 20 F 1 C to 11 Tank Probe Offset 0 0 C 5 F to 5 F 3 C to 3 C ECONOMY MODE SETUP MENU DEFAULT SETTING ADJUSTABLE RANGE 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 55 ALARM OUTPUT SETUP MENU DEFAULT SETTING ADJUSTABLE RANGE Alarm Output Function Disabled See page 59 Alarm SP 100 38 C 90 F to 190 F 32 C to 88 C DISPLAY SETTINGS MENU DEFAULT SETTING ADJUSTABLE RANGE Temperature Units Fahrenheit Fahrenheit or Celsius Backlight Delay 10 Seconds Always off on 10 30 60 Sec Contrast 30 20 to 100 Servicing should only be performed by a Qualified Service Agent 63 TROUBLESHOOTING TROUBLESHOOTING COMMON SERVICE PROBLEMS No Hot Water 1 m Hot water supply valve turned off Check power to the water heater see pages 12 14 Check thermostat ECO controls on Surface Mount Control Models see pages 18 amp 19 Check Operating Set Point and Differential Set Points on Electronic Control Models see pages 52 amp 53 Check all fuses see page 17 Check heating elements pages 20 26 Ensure both enable disable circuits at the CCB s J7 plug socket connection are closed circuits on Electronic Control Models See CCB Enable Disable Circuit s Test on page 45 Not Enough Hot Water
16. Alarm Output Settings Changing the user settings in this menu is done using the same methods outlined in Temperature Settings on page 53 Service Note Adjustable user settings in the Alarm Output Setup menu are unaffected by Restore Factory Defaults see page 63 Servicing should only be performed by a Qualified Service Agent 59 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 IE temperature units display to Celsius C or Backlight Delay 30s Fahrenheit F Backlight Delay Contrast Adjustable user setting that determines how long the UIM s LCD backlight remains illuminated after a key has been pressed CHANGE 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 53 Service Note Adjustable user settings in the Display Settings menu are unaffected by Restore Factory Defaults see page 63 Servicing should only be performed by a Qualified Service Agent 60 ELECTRONIC CONTROL SYSTEM HEATER INFORMATION MENU This menu displays non adjustable operational information Elapsed Time Top
17. Alert menu Servicing should only be performed by a Qualified Service Agent 50 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 Heating The control system is in the Heating Mode At least one bank of heating elements 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 system 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 Se
18. 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 49 ELECTRONIC CONTROL SYSTEM 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 see page 45 and the Heater Status Menu information on page 54 S The control system is in Heating Mode and has energized the electromagnetic contactor coils for at least one bank of heating elements This animated
19. 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 52 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 see UIM Navigation on page 48 Notice how the text above the Operational Buttons on the display changes as you navigate through the various menus and screens With Temperatures selected highlight in black in the Main Menu press the Operational Button underneath SELECT to enter the Temperatures Menu If Temperatures is not selected use the Up and Down buttons to select this menu item MODEL INFORMATION Tank Temperature 120 F Operating Set Point 120 Status Standby Friday 5 00 PM Normal Mode Main Menu Heater Status Economy Mode Setup Alarm O
20. J4 wiring terminals on the CCB see pages 42 and 43 for pinched or shorted wires repair or replace damaged wiring as necessary 3 Pole Contactor Side View Electromagnetic Contactor Coil Wiring Terminals 120 VAC Servicing should only be performed by a Qualified Service Agent 32 OPERATION amp SERVICE Contactor Coil Voltage At CCB This test procedure will measure contactor coil voltage where it originates at the J4 wiring terminals on the CCB See page 42 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 heat is active for all heating elements Raise the Operating Set Point in the Temperatures Menu to 140 F or higher Set all Heating Element Bank Differentials in the Temperatures Menu to 2 F see pages 52 and 53 3 Using 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 6 or 9 heating elements also check between the ground connection and the CCB s 44 OUT 2 wiring terminal and on water heaters equipped with 9 elements also check between ground and the CCB s J4 OUT 3 wiring terminal Measure and record voltage readings taken in this Step S
21. 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 Heating Element Ratings and Heating Element Configurations on page 21 and Replacing Heating Elements on page 26 When replacing fuses use an insulated fuse puller to remove and install fuses Always use the correct size for the circuit See the Replacement Fuses Service Note on page 17 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 rat
22. Of Menu Total accumulated time the control system VERUS EUN T MEM water heater has been energized Elapsed Time Total Heating Time 7 days 18 hrs 35 mins Total Heating Time Total accumulated time the control system i i 2 days 46 mi has been in the heating mode IE any heating Cycle Count 00000042 elements have been energized Bank 1 Cycles 00000035 Bank Cycles Bank 1 On Time Total accumulated count of heating cycles for each Bank of heating elements Bottom Of Menu Bank On Time Heater Information Total accumulated heating on time for each Bank 2 On Time Bank of heating elements 1 day 4hrs 44 mins Bank 3 Cycles 00000025 CCB Version Bank 3 On Time Software version for Central Control Board awe 39 wine CCB Version 0 00 UIM Version UIM Version 0 00 Software version for User Interface Module Servicing should only be performed by a Qualified Service Agent 61 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 Operational Button underneath SELECT to display the current Fault or Alert message If there is not a Fault or Alert condition currently active none is displayed to the right of this menu FAULT HISTORY MENU This menu displays non adjustable operational information The control system records and stores the last 9 Fault and Alert messages in chronologic
23. PM Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day 4 Servicing should only be performed by a Qualified Service Agent 56 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Time Clock Settings ACTION DISPLAY From the Desktop Screen navigate to the Economy Mode Setup menu see page 56 for instructions Economy ene Setup Setpoint Adjustment Use the Up Down buttons to select highlight in black 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 Normal All Day Normal All Day ka Use the Up Down buttons to select the Weekday setting Current Time Press the Operational Button underneath CHANGE to activate the adjustment mode for this setting CN Weekday J 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 AT Weekday Monday the adjustment mode is activated and how the current L lt Time 4 19 PM 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
24. Probe Open 68 Temp Probe Short ssssseeeeee 68 Energy Cut Out ECO sse 69 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 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 available copies can be obtained from the manufacturers web site or by calling the toll free phone number shown on the back cover of this Service Manual Review the Common Service Problems on page 64 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 diagnostic 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 t
25. VAC the CCB circuit board is receiving the correct power If the 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 e Check the J2 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 42 Check the 120 VAC Control Circuit Transformer to ensure it is wired correctly and outputting the correct voltage see pages 34 35 e Check the Control Circuit fuses see Figure 2 on page 9 for location and the Fuse test procedure on page 17 Ensure earth ground is supplied to the CCB With the J2 plug installed in the J2 socket on the CCB page 42 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 plug to make contact with the metal conductors inside If the measured voltage is approximately 120 VAC the CCB is properly grounded If the 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 are tight and making good contact Ensure the water heater is properly grounded Checking for Ground Servicing should only be performed
26. are available from the manufacturer voltage conversions are not covered in this manual Verifying the power supply is adequate is typical first step during most service diagnostic procedures The illustrations and instructions that follow outline how this is done using a standard AC volt meter see Tools Required on page 3 Service Warning Never touch any wiring inside the water heater until the main power supply to the water heater has been secured Secure power to the water heater by turning off the power supply breaker and or disconnect switch AND verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater s control panel Service Warning Zero or low voltage readings between internal wiring and or Power Distribution Block 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 L1HOT L2NEUTRAL GROUND L1 HOT L2 HOT GROUND L1 L2 L3 pe pe al 208 240 480 120 277 sel bees ese OSS SSS SSS Q Power Distribution Block e PS m 271 volts see Figures 1 amp 2 on pages 8 and 9 120 277 volts 277 Volt 10 Power 208 240 480 Volt 10 Power L1HOT L2 HOT L3 HOT GROUND 208 240 480 208 240 480 120 208 277 sg WORE LL IH PEL 2 ag 29240480 volts volts 208 240 480 Volt Power Servicing should only be performed by a Qual
27. converting these models to work with single and three phase power supplies Service Note 208 volt 54 KW models are 3 phase only and CAN NOT be converted to single phase All other models can be phase converted SECURE MAIN POWER SUPPLY TO THE WATER HEATER AT THE MAIN BREAKER OR DISCONNECT SWITCH FIRST Service Warning Never touch any wiring inside the water heater until the main power supply to the water heater has been turned off Verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater s control panel Electronic Control Models Three Phase to Single Phase Power Distribution Block see Figure 2 on page 9 Disconnect blue wires and yellow wires from terminal L 3 2 Connect all blue wires to terminal L 1 with black wires L1 L2 L3 3 MERE RON 28581 888 sess ess Connect all yellow wires to terminal L 2 with red wires 4 Incoming power will be connected to terminals L 1 and L 2 Service Note 208 volt 54 KW models are three phase only these models CAN NOT be converted to single phase Keep in mind when converting other models from three phase power to single phase power the current amperage will increase significantly ensure breakers fuses and wiring are properly sized to allow for the increased amperage before placing the water heater back in ES service Contact a Qualified Licensed electrician to make ALL
28. heating elements to ensure they are not grounded see page 26 first Replace any grounded elements If no elements are grounded replace the thermostat ECO control s that require frequent resetting STEP 6 CHECKING POWER TO THE CONTROL STEP 7 CHECKING POWER TO THE HEATING ELEMENT Servicing should only be performed by a Qualified Service Agent 19 OPERATION amp SERVICE HEATING ELEMENTS This section of the manual provides information on how to determine the actual voltage and wattage rating of a heating element along with tables showing heating element configurations heating element amperage and heating element resistance ohms This section also contains heating element test procedures to measure amperage voltage resistance and check for grounded elements These procedures are used to determine if a heating element is defective or working properly An AC amp meter AC volt meter and ohm meter are required see Tools Required on page 3 Heating Element Construction The water heater s covered in this manual use electric heating elements to heat water Heating elements convert electrical energy into heat energy Heating elements are constructed with metal tubing Inside the tube is a wire conductor surrounded by an insulating material The wire conductor inside the heating element has a relatively high resistance to the flow of electricity Heat is generated when the electricity voltage applied to the heating element begins to f
29. if any heating elements are not working properly 1 Secure power to the water heater at the main breaker or disconnect switch Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary Surface Mount Control Models raise the temperature settings to ensure a call heat is active for all heating elements Press the red reset button firmly on all thermostat ECO controls then raise the temperature setting on all thermostat ECO controls to 140 F or higher see page 18 Restore power to the water heater Electronic Control Models adjust the temperature settings to ensure a call heat is active for all heating elements Raise the Operating Set Point in the Temperatures Menu to 140 F or higher Set all Heating Element Bank Differentials in the Temperatures Menu to 2 F see pages 52 and 53 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 Measure and record the amperage at all heating elements by clamping the jaws of the meter around ONLY one of the wires to each heating element See the image below Heating element amp readings should be approximately the same for all heating elements The normal operating amps for all heating elements is provided in the Heating Element Amperage table on page 22 or it can be calculated using ohms law as explained on page 11 Service Note Check all power circuit wiring to the he
30. 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 E y m Servicing should only be performed by a Qualified Service Agent 39 OPERATION amp SERVICE ECO Voltage Test 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 46 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 42 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 plug to make contact with the metal conductor inside Touch the other volt meter probe to the ground wire connection on the water heater as shown in the Ground Connection image below The measured voltage should be approximately 120 VAC f the measured voltage is approximately 120 VAC proceed to Step 5 If the 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
31. on ohms law applied to single phase power The KW rating of individual heating elements is marked on the end of each element see page 21 Approximate current amps and resistance ohms for individual heating elements are provided in tables on page 22 See the water heater s rating label for the listed voltage phase power supply requirements total input KW and total full load amp draw of the water heater being serviced Calculating Amps Ohms Volts Watts Using a 240 volt electric water heater equipped with a 4500 watt heating element as an example Ohms Law can be used to determine 1 What the resistance of each heating element should be 240 volts 18 75 amps 12 8 ohms 2 What the correct amp reading should be 4500 watts 240 volts 18 75 amps 240 volts 12 8 ohms 18 75 amps 3 How many watts are being used how much heat is being generated 240 volts x 18 75 amps 4500 watts 4 5 KW 4 What the voltage is e 18 75 amps x 12 8 ohms 240 volts 4500 watts 18 75 amps 240 volts Servicing should only be performed by a Qualified Service Agent 11 OPERATION amp SERVICE SINGLE AND THREE PHASE POWER The water heaters covered in this manual can be field converted for a single or three phase power supply see pages 15 and 16 These water heaters can be factory ordered for standard North American power supplies 277 208 240 480 volt models 277 volt models are single phase only Voltage conversion kits with instructions
32. on the primary and secondary windings checked in Steps 3 and 4 above Primary Winding Voltage Test Secondary Winding Voltage Test Servicing should only be performed by a Qualified Service Agent 35 OPERATION amp SERVICE 24 VAC 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 see Figure 2 on page 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 42 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 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 than 120 VAC Checkthe J1 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 42 Check the 120 VAC Control Circuit Transformer to ensure it is wired correctly and outputting the correct voltage see pages 34 amp 35 Ensure there is 120 VAC being supplied to the CCB see page 46 Call the toll fre
33. the Economy Set Point The Tank Temperature 120 F Economy Set Point normal Operating Set Economy Set Point 100 F Point minus the programmed Setpoint Status Standby Adjustment value The Economy Set Point is Friday the water temperature the control system 5 00 maintains during programmed Economy e 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 Mon 5 00 PM Heater In Economy Mode No Seven Day 24 hr clock Use this menu item to Sun Economy Mode All 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 Wed Normal All Day the Desktop until the time day has been CHANGE 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 Seven daily sub menus are listed at the bottom of the Economy Mode Setup menu There are 3 Operating Modes in each sub menu Normal Operation All Day Economy Mode All Day and Normal Operation Between Only one Operating Mode can be active the fac
34. 1 and check all wiring and connections between the heating elements contactors fuses and the power distribution block Ensure all wiring and connections are tight and making good contact replace any wiring fuses contactors that are damaged or show signs of excessive wear Measuring resistance ohms on an electric heating element Touch the two ohm meter probes to the d terminals on the end of each heating element Servicing should only be performed by a Qualified Service Agent 25 OPERATION amp SERVICE Heating Element Ground Test 1 2 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 Figures 1 and 2 on pages 8 and 9 and at the two wiring terminals on the ends of all heating elements Disconnect both power wires from the terminals on the top of all heating elements to be tested 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 Touch one of the ohm meter probes to one of the two heating element wiring terminals and the other probe to a grounded surface on the water heater such as the water heater s storage tank use sand cloth if necessary to remove any coating that may prevent metal to metal contact or the water heater ground wire connection Check
35. Service Handbook a LN MODELS DRE 52 80 120 SERIES 100 amp DVE 52 80 120 SERIES 100 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS WATER HEATER CONSTRUCTION OPERATION amp SERVICE TROUBLESHOOTING 500 Tennessee Waltz Parkway Ashland City TN 37015 EN EN SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT PRINTED IN THE U S A 0908 315014 000 COMMERCIAL ELECTRIC WATER HEATER SERVICE MANUAL TABLE OF CONTENTS INTRODUGCTION titio ti terere eee i deceret 2 iir ecce rit ere ek tie 2 Service Warning esses 2 Tools Required eere 3 INSTALLATION 4 Closed Water Systems sse 4 Thermal Expansion eene 4 Electrical Requirements 5 PRE SERVICE CHECKS essere 6 Wiring Connections esseeeeeennenn 6 Service Precautions esee 5 WATER HEATER CONSTRUCTION 7 Surface Mount Control Models 8 Electronic Control 9 OPERATION amp SERVICE seen 10 Principles of 10 Single And Three Phase Power 12 Checking Single Phase
36. TES CHECK REPAIR Temp Probe Open Fault Condition The control system has detected an open circuit in 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 Fauk occurred 0 mins ago There is problem with the temperature probe Call service professional Paul Stewart XXX XXX XXXX press DOWN for more BACK ADVANCED Check the J5 plug socket connections 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 42 44 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 42 44 Check the resistance of the temperature sensor inside the Immersion Temperature Probe see pages 37 39 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
37. With the J5 plug installed in the J5 socket on the CCB page 42 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 plug to make contact with the metal conductor inside Touch the other volt meter probe to the ground wire connection on the water heater as shown in the Ground Connection image below The measured voltage should be approximately 120 VAC 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 f the measured voltage is zero volts or considerably less than 120 VAC perform the ECO Continuity Test on page 39 120 VAC To ECO 120 VAC From ECO Servicing should only be performed by a Qualified Service Agent 40 ELECTRONIC CONTROLS ELECTRONIC CONTROLS This section covers the electronic control system used on Electronic Control Models see Figure 1 on page 9 The control system includes a CCB Central Control Board and a UIM User Interface Module The CCB constantly monitors safely controls heating elements water temperature and other functions of the water heater Operational information is continuousl
38. ack 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 current has been sensed it DOES NOT indicate the amount or level of current is correct for a given heating element As explained on the previous page Element Sensors contain three individual current sensors The three sensors are installed just above the power circuit fuse blocks One heating element power wire is routed through a hole in one sensor The plug from each Element Sensor plugs into one of three sockets on the CCB The J12 J13 and J14 sockets are for heating element Banks 1 2 and 3 respectively 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 is defective the entire Element Sensor assembly must be replaced If current through a heating element has been verified with an AC amp meter see page 23 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 On models equipped with 2 or 3 Banks of heating elements secure power to the water heater and try switching Element Sensor plugs between the J12 J13 and J14 sockets to verify the Element Sensor is defective a No Current Detected Alert message and Status Icon indication s
39. age proceed to the Contactor Coil Voltage At CCB test on page 33 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 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 page 34 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 contactor coil and the J4 wiring terminals on the CCB see pages 42 and 43 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
40. al notification verification of various operational conditions such as fault conditions and heating mode status This relay can be used with building EMS Energy Management 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 and or verification of the enable disable circuits open closed status There are CHANGE BACK HELP two enable disable circuits available for Acn Qutsut Sine external supervisory control s at the J7 socket on the CCB see page 42 Enable disable circuit s status can be viewed in the ee Heater Status Menu see page 54 Temp Heater SP Used for external notification when current tank temperature drops below Operating Set Point CHANGE BACK Temp Alarm SP Used for external notification when current tank temperature drops below 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 Alarm SP 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
41. al 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 intermittent operational problems or when the customer has reset the control system prior to a service agent s arrival With a Fault or Alert item selected press the Operational Button underneath VIEW to display the details for the Fault or Alert message The Fault Alert message screen displays a brief description of the condition contact information and access to the Advanced service information sub menu FAULT OCCURRENCE MENU 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 Main Menu Current Fault Selected Main Menu Heater Information Current Fault 45 Fault History Fault Occurrence Restore Factory Defaults Fault History Menu Fault History 1 No Current Detected 40D 1 days 5 hrs 45 mins ago Energy Cut Out ECO A5 1 days 6 hrs 20 mins ago Temp Probe Short 45 2 days 1hrs 10 mins ago No Current Detected 40D 2 3 4 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
42. ating element s on any element drawing zero or low amps see the wiring diagram on the water heater On Electronic Control Models check the contactors on any heating element s drawing zero or low amps see pages 29 33 Perform the Heating Element Voltage and Heating Element Resistance amp Ground tests see pages 24 26 on any heating elements drawing zero amps or any heating element drawing less than normal operating amps If the measured amp draw on any element is considerably less or more than the normal operating amps ensure the voltage and KW rating of those heating elements is the correct value for the water heater being serviced see Heating Element Ratings and Heating Element Configurations on page 21 Measuring amperage on an electric heating element Make sure the jaws of the AC amp meter are clamped e around ONLY ONE WIRE to the heating element being tested Clamping around more than one wire often gives a false zero amp reading DO NOT TOUCH THE ENDS OF ANY HEATING ELMENTS WHILE PERFORMING THIS TEST Be extremely careful as there will be high voltage present at the wiring terminals on all heating elements during this test Servicing should only be performed by a Qualified Service Agent 23 OPERATION amp SERVICE Heating Element Voltage Test This test is typically performed after an amperage test see page 23 has determined one or more heating elements is not drawing correct amperage 1 Secure power to t
43. between the other heating element terminal and ground also see the image below If there is infinite resistance no continuity between both heating element wiring terminals and ground the heating element s is not grounded If there is any resistance measured there is continuity between either heating element wiring terminal and ground the heating element is defective and must be replaced Ensure the voltage and KW rating of the replacement heating element is the correct rating for the water heater being serviced see Heating Element Ratings and Heating Element Configurations on page 21 Checking an electric heating for any resistance or continuity to ground Touch one of the ohm meter pe E probes to one terminal on the end of a heating element and the other probe to a grounded surface on the water heater Replacing Heating Elements 1 2 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 Figures 1 and 2 on pages 8 and 9 and at the two wiring terminals on the ends of all heating elements Disconnect both power wires from the terminals on the top all heating elements being replaced Drain the water 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 man
44. by a Qualified Service Agent 46 ELECTRONIC CONTROLS UIM USER INTERFACE MODULE UIM Components 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 Notes Button Pad Ribbon Cable 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 F zx UIM Circuit Board K jel a J2 Socket NW JS Socket Burton Ped Communication tbommunication Ribbon Cable To Ensure Ribbon Cable Plug gl Button Pad is inserted exactly as shown o RIR RI RIA RIN i pow bs eS i Circuit Board Front Servicing should only be performed by a Qualified Service Agent 47 ELECTRONIC CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM CONTROL SYSTEM FEATURES Advanced Diagnostics Plain English text and animated icons display detailed
45. d in one or heating circuit s Note this is an alert The unit will continue to heat water in press DOWN for more BACK ADVANCED Ensure the power supply to the water heater matches the listed voltage on the water heater rating plate Ensure there is not a dead leg of power on 30 models see pages 12 14 Check power circuit fuses see page 17 Check heating elements see pages 20 26 Check contactors see pages 29 33 Check power circuit wiring to heating elements from Power Distribution Block to fuse blocks to contactors to heating elements see wiring dia gram on water heater and Contactor Configura tion illustration on page 30 Correct any mis wiring Repair or replace damaged wiring as necessary Check the Element Sensor J12 J13 J14 plug socket connections at the CCB for wear or dam age see page 28 Ensure they are mating properly and providing good contact See CCB illustration and socket identification on pages 42 44 for location Check Element Sensors see pages 27 amp 28 Replace any Element Sensors determined to be defective 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 67 TROUBLESHOOTING Fault amp Alert Messages DISPLAYED MESSAGE CONDITION INDICA
46. e technical support phone 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 42 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 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 than 24 VAC Checkthe J1 plug socket connections on the CCB for wear or damage Ensure they are mating properly and providing good contact see page 42 Check the wiring between pins 4 amp 5 of the J1 plug and the 24 VAC transformer see Figure 2 on page 9 for transformer location Ensure wiring is not pinched or shorted and continuous to the 24 VAC secondary winding repair or replace damaged wiring as necessary If 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 the
47. e 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 Electronic Control Models see Figure 2 on page 9 covered in this manual may experience erratic control operation if the water heater is not properly grounded 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 see pages 12 14 The electric water heater models covered by this manual are phase convertible see pages 15 and 16 Servicing should only be performed by a Qualified Service Agent 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 transformers and heating elements
48. ential 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset 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 3 6 or 9 heating elements Each group of 3 heating elements is one Bank of heating elements Heating elements are energized in Banks of 3 Each Bank of heating elements will have a Differential Setting associated with it Differential Settings are located in the Temperatures Menu There is a 1st Differential Setting on all models There will be one additional Differential Setting visible adjustable for each additional Bank of 3 heating elements Operating Sequence With an Operating Set Point of 120 F and all Differential settings at 2 F the On Off sequencing of heating element Banks would be as follows BANK NUMBER DIFFERENTIAL SETTING TURN ON TEMP TURN OFF TEMP Bank 1 2 F 118 F 120 F Bank 2 2 F 116 F 118 F Bank 3 2 F 114 F 116 F 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 0 F If the current Tank Temperature is sensed 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
49. ervice 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 If the measured voltage s were approximately 120 volts the CCB circuit board 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 Wiring Terminals Water Heater Ground and J4 OUT 1 Water Heater Ground Connection CCB s J4 OUT 1 Terminal Servicing should only be performed by a Qualified Service Agent 33 OPERATION amp SERVICE TRANSFORMERS This section of the manual provides information on how to test and ensure the multiple tap 120 VAC Control Circuit Transformer is wired properly on Electronic Control Models This section will also provide test procedures for the 24 VAC transformer used by the electronic control system see Figure 2 on page 9 for location of the transformers on these models Surface Mount Control Models are not equipped with transformers 120 VAC Control Circuit Transformer Wiring The 120 VAC Control Circuit transformer is a multiple or multi tap transformer that can accept 4 different input voltages to it s primary winding See Figure 2 on page 9 for location This transformer outputs 120 VAC power from it s secondary winding which powers
50. esent 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 the switch contacts in thermostats 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 is 10096 conclusive Servicing should only be performed by a Qualified Service Agent 17 OPERATION amp SERVICE SURFACE MOUNT THERMOSTATS The Surface Mount Control Model water heaters covered in this manual have separate thermostat ECO energy cut out combination controls mounted to the surface of the storage tank directly above the heating elements they control IE a water heater equipped with 9 heating elements will have 9 thermostat ECO controls These controls contain two bimetal thermal switches that react to heat sensed from the surface of the water heater s storage tank Thermostat The thermostat portion of these controls is an automatic SPST single pole single throw switch see the Internal Wiring illustration below As the tank water temperature rises and falls each individual thermostat will de energize contact opens and energize contact cl
51. ferent on Surface Mount Control see Figure 1 page 8 and Electronic Control see Figure 2 page 9 model water heaters Because of these differences there are two methods for field converting these models to work with single and three phase power supplies Service Note 208 volt 54 KW models are 3 phase only and CAN NOT be converted to single phase All other models can be phase converted SECURE MAIN POWER SUPPLY TO THE WATER HEATER AT THE MAIN BREAKER OR DISCONNECT SWITCH FIRST Service Warning Never touch any wiring inside the water heater until the main power supply to the water heater has been turned off Verify with a volt meter that all wiring has no voltage present before touching any wiring inside the water heater s control panel Surface Mount Control Models Power Distribution Block Three Phase to Single Phase see Figure 1 on page 8 1 Disconnect blue wires from terminal L 2 L1 L2 L3 WEN Eee ass Fase Ess SOS 2 Connect all blue wires to terminal L 1 with black wires 3 Disconnect all red wires from terminal 1 3 4 Connect all red wires to terminal L 2 with yellow wires 5 Incoming power will be connected to terminals L 1 and L 2 Service Note 208 volt 54 KW models are three phase only these models CAN NOT be converted to single phase Keep in mind when converting other models from three phase power to single phase power the current amperage will increase significantly fo ei Es e
52. g elements is terminated to prevent further heating operation Should the ECO activate the water temperature must drop below 140 F 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 38 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 also 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 49 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 page 32 and heating elements is terminated during lock out
53. g operation Check the supervisory control s settings programming to ensure it is not disabling heating operation during occupied normal demand periods 2 If the 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 circuit board see page 42 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 f the ohm meter shows no continuity open circuit between pins 1 amp 2 or between pins amp 4 of the J7 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 f the ohm meter shows continuity closed circuit between pins 1 amp 2 and between pins 3 amp 4 of the J7 plug end and heating operation will not activate with a cold tank of water call the toll free Technical Support phone number listed on the back cove
54. he water heater at the main breaker or disconnect switch Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary Surface Mount Control Models raise the temperature settings to ensure a call heat is active for all heating elements Press the red reset button firmly on all thermostat ECO controls then raise the temperature setting on all thermostat ECO controls to 140 F or higher see page 18 Restore power to the water heater Electronic Control Models adjust the temperature settings to ensure a call heat is active for all heating elements Raise the Operating Set Point in the Temperatures Menu to 140 F or higher Set all Heating Element Bank Differentials in the Temperatures Menu to 2 F see pages 52 and 53 Using an AC volt meter set the volt meter to an AC voltage range above the expected voltage 600 VAC or higher range initially Check voltage between the two terminals on the heating element see the image below Record the voltage at all heating elements Voltage should match the listed voltage on the water heater s rating label If the measured voltage is zero volts or is not the correct voltage check power to the water heater pages 12 14 check fuses page 17 Ensure heating element power circuit wiring is correct see wiring diagram on water heater Check thermostat ECO control s supplying power to the heating element on Surface Mount Control models see page 19 Check co
55. hecking Three Phase 3O Power A three phase power supply consists of three wires connected to the L1 L2 and L3 terminals of the Power Distribution Block All three wires are hot with voltage present Voltage Between Terminals Set the volt meter to an AC voltage range above the expected voltage 600 VAC or higher range initially Checking three phase 3O power requires that three voltage readings be taken between all possible parings of the terminals on the Power Distribution Block Carefully touch the two test probes between 1 L1and L2 terminals of the water heater s Power Distribution Block 2 L2and L3 terminals of the water heater s Power Distribution Block 3 L1and L3 terminals of the water heater s Power Distribution Block All three voltage readings should match the voltage listed on the water heater s rating label by 5 Voltage to Ground Check between each of the three terminals L1 L2 and L3 of the Power Distribution Block and the ground wire connection inside the water heater s control panel On some 208 volt power supplies each reading will be approximately 120 volts to ground 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 should be approximately 120 volts to ground On 480 power supplies each reading to ground should be approximately 277 volts Service Warning Zero or low
56. hould follow the defective Element Sensor and report a different heating element is not drawing current when current is expected CCB Element Sensor Sock V me z ets Heating Element Wire Routing Servicing should only be performed by a Qualified Service Agent 28 OPERATION amp SERVICE CONTACTORS This section of the manual provides information on how contactors used on Electronic Control Models are constructed how they work and how to test contactor operation see Figure 2 on page 9 for location of the contactors on these models Surface Mount Control Models are not equipped with contactors Contactor Construction How They Work Magnetic contactors are used on Electronic Control Models to energize and de energize the heating elements Power from the fuse blocks is supplied to the heating elements through three switches 3 poles inside the contactor 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 switches are closed by an electromagnetic coil inside the base of the contactor When a call for heat is activated the electronic 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
57. hrough 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 Call the toll free phone number listed on the back cover of this manual for technical assistance 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 plugs are not damaged or worn Also ensure plugs and sockets are mating properly and pro
58. 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 O O O Heating elements icon for a water heater equipped with 1 Bank of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Open circles represent heating elements the control system has not energized and is not sensing electrical current from Heating elements icon for a water heater equipped with 2 Banks of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Open circles represent heating elements the control system has not energized and is not sensing electrical current from Heating elements icon for a water heater equipped with 3 Banks of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Open circles represent heating elements the control system has not energized and is not sensing electrical current from Heating elements icon for a water heater equipped with 3 Banks of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Filled circles represent heating elements the control system has energized AND is sensing electrical current from eee OO SES ooo oo WEN eee
59. ified Service Agent 12 OPERATION amp SERVICE Checking Single Phase 16 Power A single phase power supply consists of two wires connected to the L1 and L2 terminals of the Power Distribution Block the L3 terminal is not used On a single phase 10 277 volt power supply one of the two wires is a neutral wire and does have voltage present On a single phase 10 277 volt power supply the hot wire should be connected to the L1 terminal and the neutral wire should be connected to the L2 terminal On 208 240 and 480 volt power supplies both wires connected to L1 and L2 are hot with voltage present Voltage Between Terminals 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 and carefully touch the two test probes to the L1 and L2 terminals of the water heater s Power Distribution Block The voltage readings should match the voltage listed on the water heater s rating label by 596 Voltage to Ground With the power supply to the water heater turned on check between the L1 terminal and the ground wire connection inside the water heater s control panel Check between L2 and ground in the same way On a 277 volt power supply only one of the two terminals should read 277 volts the neutral will read approximately zero volts On 208 240 volt power supplies each reading should be approximately 120 volts to ground On 480 volt power supp
60. 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 setting should now be displayed for Sun Normal Operation All Day e Economy Mode All Day 7 Normal Operation Between Sending Updates to CCB Setpoint Adjustment Current Time Heater In Economy Mode No Mon Normal All Day Tue Normal All Day Mon 5 00 PM 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 unde
61. ing label see pages 12 14 Ensure the internal power phase configuration matches the power supply to the water heater The water heaters covered by this manual are phase convertible see pages 15 and 16 Electronic Control Models covered by this manual are equipped with contactors and will 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 page 34 in this manual Service Note Contactor Chatter Incorrect supply voltage wiring to the multiple tap 120 VAC Control Circuit Transformer on Electronic Control Models 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 Ensure the primary winding of the multiple tap 120 VAC Control Circuit Transformer is wired to match the power supply voltage see pages 12 14 and page 34 Servicing should only be performed by a Qualified Service Agent WATER HEATER CONSTRUCTION WATER HEATER CONSTRUCTION There are two types of commercial electric water heaters covered in this manual See Figure 1
62. l 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 INSTALLATION CONSIDERATIONS ELECTRICAL REQUIREMENTS Grounding Review the electrical ground requirements given in the Instruction Manual that came with the water heater and ensure th
63. lies each reading to ground should be approximately 277 volts Service Warning Zero or low voltage readings between internal wiring and or Power Distribution Block 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 taken between L1 and L2 are more than 5 of the listed voltage on the water heater s rating label or if the readings to ground were far less at or near zero volts than expected check the fuses and 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 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 it back in service Contact the distributor and or manufacturer to determine if the water heater can be field converted and or replaced to match the power supply at the location L1HOT L2NEUTRAL GROUND L1 L2 L3 L1HOT L2 HOT GROUND i FINEN ANS e Power Distribution Block see Figures 1 amp 2 on pages 8 and 9 208 240 480 120 277 277 volts Ovolts Y volts volts li 277 volts 120 277 volts 277 Volt 10 Power 208 240 480 Volt 10 Power Servicing should only be performed by a Qualified Service Agent 13 OPERATION amp SERVICE C
64. low amperage and encounters the resistance ohms of the wire conductor inside Side View Wiring Terminals Heat element tube Top View encloses wire conductor and insulating material Internal View Heating Element Tube Wire conductor 9 inside tube Servicing should only be performed by a Qualified Service Agent 20 OPERATION amp SERVICE Heating Element Ratings Heating elements are labeled with their voltage and KW rating see image below The element shown here is a 6000 watt 6 KW 240 volt element Wattage and Voltage Ratings Note some heating elements are dual rated elements IE 208 240 volts Heating Element Configurations The table below shows how many heating elements are installed at the factory and the wattage of each heating element according to the rated voltage of the water heater The table below represents all available tank sizes 50 80 and 120 gallon models Service Note 208 volt 18 KW models are only available with six 3000 watt elements and 208 volt 36 KW models are only available with nine 4000 watt heating elements TOTAL HEATING NUMBER OF FACTORY INSTALLED WATER HEATER ELEMENT HEATING ELEMENTS INPUT KW 208 VAC 240 277 480 VAC Servicing should only be performed by a Qualified Service Agent 21 OPERATION amp SERVICE Heating Element Amperage This table shows the approximate amp draw for the various heating elements used First determine the actual
65. m has detected excessive water temperature inside the water heater The ECO high temperature limit switch activates at 202 F 94 C See ECO High Temperature Limit Switch description on page 37 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 Fauk occurred 0 mins ago Tank temperature is excessive The water heater has been disabled Call a service professional Paul Stewart press DOWN for more BACK ADVANCED Check the J5 plug socket connections 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 42 44 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 42 44 Check ECO continuity and for 120 VAC to and from the ECO see pages 37 40 Replace Immersion Temperature Probe if ECO switch contacts remain open at normal operating tem peratures Ensure the contactors are not stuck closed see page 31 Ensure the contactor coils a
66. ments from the factory HEATING ELEMENTS CANNOT BE ADDED TO A WATER HEATER Servicing should only be performed by a Qualified Service Agent 7 WATER HEATER CONSTRUCTION SURFACE MOUNT CONTROL MODELS WATER OUTLET T amp P VALVE POWER CIRCUIT FUSE BLOCKS L POWER DISTRIBUTION BLOCK THERMOSTAT ECO COMBINATION CONTROLS ASME PLATE IF APPLICABLE HEATING ELEMENTS PLUG DRAIN WATER INLET Figure 1 Servicing should only be performed by a Qualified Service Agent WATER HEATER CONSTRUCTION ELECTRONIC CONTROL MODELS WATER OUTLET UIM USER INTERFACE MODULE T amp P VALVE ON FRONT CABINET i st D L B 377 a a SU UNT POWER DISTRIBUTION 120V CONTROL CIRCUIT BLOCK TRANSFORMER 4 RAN CCB CIRCUIT BOARD d fuse e Central Control Board CONTROL CIRCUIT FUSE BLOCK IMMERSION TEMPERATURE PROBE also contains ECO high temp limit switch POWER CIRCUIT FUSE BLOCKS 2 per bank of heating elements HEATING ELEMENTS 3 BANK 3 CONTACTORS 2 per bank of heating elements HEATING ELEMENTS 3 BANK 2 ASME PLATE IF APPLICABLE HEATING ELEMENTS 3 BANK 1 DRAIN WATER INLET Figure 2 Servicing should o
67. mer 4 24 VAC out from transformer 5 24 VAC out from transformer J2 Socket 120 VAC Power Supply PIN DESCRIPTION 1 120 VAC hot 2 Earth Ground 3 120 VAC neutral J3 Wiring Terminals Alarm Output Relay see page 59 TERMINAL DESCRIPTION N O Dry Contact Output Normally Open Terminal Alarm Output Relay N C Dry Contact Output Normally Closed Terminal Alarm Output Relay COM Dry Contact Output Common Terminal Alarm Output Relay J4 Wiring Terminals Contactor Coils TERMINAL DESCRIPTION OUT 1 120 VAC hot to Heating Element Bank 1 Contactor Coils OUT 2 120 VAC hot to Heating Element Bank 2 Contactor Coils OUT 3 120 VAC hot to Heating Element Bank 3 Contactor Coils J5 Socket Immersi on Temperature Probe ECO PIN DESCRIPTION 1 ECO energy cut out 120 VAC hot out red wire 2 Temperature probe thermistor 45 0 VDC black wire 3 Temperature probe thermistor 5 0 VDC black wire 4 ECO energy cut out 120 VAC return red wire J6 Socket Not Used Servicing should only be performed by a Qualified Service Agent 43 ELECTRONIC CONTROLS J7 Socket Enable Disable Circuits 1 amp 2 see pages 45 amp 54 PIN DESCRIPTION 1 Enable Disable circuit 1 2 Enable Disable circuit 1 3 Enable Disable circuit 2 4 Enable Disable circuit 2 J8 Socket Not Used J9 Socket Not Used J10 Socket Not Used J11 Port Communication Port UIM Display
68. mine what the actual voltage and KW rating is for the heating elements in the water heater being serviced see Heating Element Ratings and Heating Element Configurations on page 21 Replace any elements that are not the proper rating for the water heater being serviced 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 Figures 1 and 2 on pages 8 and 9 and at the two wiring terminals on the ends of all heating elements Disconnect both power wires from the terminals on the top of all heating elements to be tested Using an ohm meter set the ohm meter to a range just above the expected ohms 200 ohm range initially Touch the ohm meter probes between the two terminals on each heating element see the image below Measure and record the resistance ohms at all heating elements being tested Compare the resistance value ohms measured to the values given in the Heating Element Resistance table on page 22 If the measured resistance ohms matches the values in the Heating Element Resistance table on page 22 the heating element resistance is correct If the resistance reading is infinite no continuity at all between the two terminals the heating element is defective and must be replaced During heating element replacement be sure to check fuses page 17 inspect contactors on Electronic Control Models see page 3
69. n that can be displayed on one screen of the LCD display Use the Up amp Down Buttons to navigate to the bottom of this menu Status Displays the current Operating State of the control system IE Heating Standby Fault Top Of Menu Heater Status Status etc see Table 2 on page 51 Element Banks On Element Banks On ECO Contact Closed Enable Disable 1 Closed Displays the current number of heating Enable Disable 2 Closed element Banks the control system has Element Bank 1 On energized Each Bank of elements contains 3 Element Bank 2 On heating elements ECO Contact Bottom Of Menu Heater Status Enable Disable 1 Displays the current state of the ECO high temperature limit switch contacts The ECO switch is located inside the immersion Enable Disable 2 Closed Temperature Probe two red wires neni Monk a Enable Disable 1 amp 2 Element Bank 2 On No Element Bank 3 On Displays the current state open or closed of Alarm Condition the two Enable Disable circuits J7 socket on Alarm Relay Output the CCB see page 42 provided for external supervisory controls such as building EMS Energy Management System Both of these Enable Disable circuits must be closed to enable heating operation If either Enable Disable circuit is open for any reason heating operation will be disabled There is a plug with two jumper wires installed from the factory in the CCB J7 socket to enable heating operation when exter
70. nal 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 only DO NOT apply any external voltage or connect any load IE relay coil to either circuit Element Bank On Displays the on off status of each Bank of heating elements Yes On No Off Alarm Condition Displays the status of the user definable Alarm Output function see page 59 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 x 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 54 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 low load or peak demand periods Setpoint Aditistment Desktop Screen During Economy Mode Adjustable user setting 2 F to 50 F factory MODEL INFORMATION default is 20 F the control system uses to calculate
71. nal 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 REEAIN UIM Display Is Blank e Check restore power supply to the water heater at Power Distribution Block see pages 12 14 UIM is not energized LCD display is blank Check control circuit transformer fuses see Fig ure 2 page 9 and checking fuses page 17 Possible Causes M e Check communication cable connections at UIM s J2 Socket page 47 and the CCB s J11 No power to water heater Port page 42 Blown control circuit transformer fuses 120 VAC power problems Install a new communication cable between 24 VAC power problems UIM s J2 Socket and the CCB s J11 Port use Defective transformer s standard Cat 5 network cable Wiring or plug socket connection problems UIM communication cable problems Closely inspect communication ports on CCB and UIM ensure they are mating properly and Important Service Reminder providing good contact pages 42 amp 47 Ensure 120 VAC power ground is supplied to When performing any troubleshooting steps outlined CCB s J2 Socket follow procedure on page 46 in this service manual always consider the wiring and connectors between components Perform close visual inspection of all wiring and connectors to a gi
72. nly be performed by a Qualified Service Agent OPERATION amp SERVICE OPERATION amp SERVICE This section of the manual will cover the principles of electricity single and three phase power fuses surface mount thermostat ECO combination controls 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 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 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 eleme
73. nsure breakers fuses and wiring are properly sized to allow for E the increased amperage before placing the water heater back BLUEIBLACK YELLOWIRED WIRES service Contact a Qualified Licensed electrician to make necessary changes Surface Mount Control Models Single Phase to Three Phase 1 Disconnect blue wires from terminal L 1 Power Distribution Block see Figure 1 on page 8 L1 L3 aea Disconnect red wires from terminal 1 2 2 3 Connect all blue wires to terminal L 2 with yellow wires 4 Connect red wires to terminal L 3 5 Incoming power will be connected to terminals L 1 L 2 and L 3 Service Note Keep in mind when converting from single phase Ses power to three phase power the current amperage will decrease SS SSS significantly ensure breakers and fuses are not oversized before ES placing the water heater back in service Contact a Qualified L2 L3 Licensed electrician to make necessary changes ALL BLACK BLUE YELLOW ALL RED WIRES WIRES WIRES Servicing should only be performed by a Qualified Service Agent 15 OPERATION amp SERVICE PHASE CONVERSIONS ELECTRONIC CONTROL MODELS Internal wiring connections between the Power Distribution Block and the heating elements is different on Surface Mount Control see Figure 1 page 8 and Electronic Control see Figure 2 page 9 model water heaters Because of these differences there are two methods for field
74. ntactors on Electronic Control Models see pages 29 33 Check all wiring and connections between the heating elements contactors fuses and the power distribution block Ensure all wiring and connections are tight and making good contact replace any wiring fuses and or contactors that are not working properly damaged or show signs of excessive wear Measuring voltage on an electric heating element Touch the two volt meter probes to the two RR terminals on the end of each heating element DO NOT TOUCH THE ENDS OF ANY HEATING ELMENTS WHILE PERFORMING THIS TEST Be extremely careful as there will be high voltage present at the wiring terminals on all heating elements during this test Servicing should only be performed by a Qualified Service Agent 24 OPERATION amp SERVICE Heating Element Resistance amp Ground Tests This is a two part test In the first part of this test the actual resistance ohms of each heating element is measured In the second part of this test each heating element 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 1 Deter
75. nts 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 voltage divided by the resistance The following equations further explain ohms law Ohms Law applied to SINGLE PHASE 15 power V Volts electrical pressure A Amps electrical flow current O Ohms resistance to electrical flow current W Watts rate or amount of electricity used V A 0 W V A V O A VxA W AxO V W A V Service Note Heating elements used on the water heaters covered by this manual are two wire single phase elements Though the power supply to the water heater may be three phase calculations to determine amperage and resistance for individual heating elements is based
76. on active Enable disable circuit s open Check for and correct any active Fault condition see Current Fault Menu page 62 Check enable disable circuits ensure both cir cuits are closed follow procedure outlined on page 45 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 66 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 47 of this manual DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR Current Detected Alert Condition The control system has not detected current in one or more heating element circuits when expected Possible Causes 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 Alert No Current Detected Alert ocourred 14 mins ago No current detecte
77. on page 8 and Figure 2 on page 9 SURFACE MOUNT CONTROL MODELS The first type of water heater covered in this manual is equipped with surface mount thermostat ECO controls Surface Mount Control Models There will be separate thermostat ECO energy cut out combination controls mounted to the surface of the storage tank directly above the heating elements they control IE a water heater equipped with 9 heating elements will have 9 combination thermostat ECO controls These combination thermostat ECO controls sense temperature directly from the surface of the storage tank Each combination control will have a temperature setting adjustment screw As the tank water temperature rises and falls each individual thermostat will de energize and energize one heating element according to it s temperature setting ELECTRONIC CONTROL MODELS The second type of water heater covered in this manual is equipped with an electronic control system Electronic Control Models 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 Banks of 3 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 clo
78. 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 Advanced Service menu displays a list of possible causes for current Fault and Alert conditions to aid in servicing See the Troubleshooting section pages 65 69 Economy Mode Operation 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 pages 55 58 Linear Sequencing First bank on is the last bank off Banks of heating elements 3 elements per bank are energized according to adjustable 1 to 20 differential set points for each bank see page 52 Helps reduce operating costs during low moderate loads CONTROL SYSTEM NAVIGATION The UIM User Interface Module is located on the front cabinet of the Electronic Control Model water heaters 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 H1 f ll fF Up amp Down Buttons eae 120 F Navigate Menu Items LI ae ee Adjust User Settings LCD Screen Information 3 Operational Buttons Display Area Wl Na
79. ore Factory Defaults This control system feature allows the user to restore control system user settings to 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 51 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 control 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 118 Operating Set Point 1st Differ
80. oses one heating element according to it s temperature setting The temperate setting is adjustable using the dial on the lower portion of the control The adjustable range is 120 F 49 C 180 F 82 C The factory default setting is 140 F 60 C ECO The ECO portion of these controls is a manual reset DPDT double pole double throw Switch see the Internal Wiring illustration below The ECO is a high temperature limit switch designed to protect against excessively high water temperatures that can be caused by defective thermostats and grounded heating elements The ECO temperature setting is non adjustable and fixed at 200 F 93 C If the ECO activates contacts open in response to abnormally high temperatures the contacts will not close automatically the ECO must be manually reset by pressing the red button on the top of the control The tank temperature must cool to approximately 120 F 49 C before the ECO can be reset When activated contacts open the ECO will interrupt all power supplied to the thermostat portion of the control and the heating element THERMOSTAT ECO FRONT VIEW THERMOSTAT ECO INTERNAL WIRING Power Supply to L1 and L3 Terminals ECO ECO Manual top of the Reset Button K E control ECO DPDT e ridi Contacts id M ontacts Thermostat Dial i Thermostat bottom of the 5 Thermostat SPST control Contacts om O E mw 120 m orf Heating Element Ser
81. ow from a grounded element through the water to the storage tank If the measured amps are considerably less than the values in the table above test those elements for grounding see page 25 Heating Element Resistance This table shows the approximate resistance in ohms for the various heating elements used First determine the actual rated wattage and voltage of the element being tested see Heating Element Ratings on page 21 Then follow the Measuring Resistance Test procedure on page 25 to measure the resistance of each heating element Compare the measured value 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 ELEMENT APPROXIMATE RESISTANCE OHMS WATTAGE 208 VAC 240 VAC 277 VAC 480 VAC 2000 2163 2880 3836 11520 1442 1920 2558 7680 3000 40 1082 1440 1918 5760 1280 1705 5120 5000 865 1152 1535 4608 6000 721 9 60 1279 3840 Servicing should only be performed by a Qualified Service Agent 22 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
82. 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 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 29 OPERATION amp SERVICE Contactor Configurations This illustration shows how contactors are configured and how they provide power to the heating elements on Electronic Control Model water heaters This is a redundant contactor configuration two contactors must close their contacts to energize any heating element Elements and Banks are numbered according to how the control system monitors them see Element Sensors pages 27 and 28 There are two contactors installed for each Bank IE the illustration shows a 9 element configuration a water heater factory equipped with 6 heating elements would have 4 contactors and a water heater with 3 elements would have 2 contactors Wiring is shown for the first two heating elements in Bank 1 only for simplicity BANK 1 LOWER BANK 2 MIDDLE BANK 3 UPPER 4 B E B Re B E Red i m Bik E B ES p Fod BANK 3 UPPER
83. r Distribution Block ensure wiring is correct and connections are tight and making good contact Check the control circuit fuses see Figure 2 on page 9 for location and the Fuse test procedure on page 17 Verify 120 VAC Control Circuit Transformer wiring is correct see page 34 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 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 at the main breaker or disconnect switch Disconnect all wiring to the transformer Using an ohm meter check for continuity between the terminals
84. r 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 45 ELECTRONIC CONTROLS Checking Power and Ground To The CCB The CCB circuit board is powered by the120 VAC Control Circuit Transformer see pages 34 35 at the J2 Socket pins 1 amp 3 see page 42 This procedure is performed to ensure the 120 VAC power is being supplied to the CCB 1 2 7 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 see Figure 2 on page 9 and pages 12 14 Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC Ensure 120 VAC power is supplied to the CCB With the J2 plug installed in the J2 socket on the CCB page 42 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 plug to make contact with the metal conductors inside Voltage should be approximately 120 VAC If the measured voltage is approximately 120
85. rated wattage and voltage of the element being tested see Heating Element Ratings on page 21 Then follow the Heating Element Amperage Test procedure on page 23 to measure amperage at each heating element Compare the measured value 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 ELEMENT APPROXIMATE CURRENT AMPS WATTAGE 208 VAC 240 VAC 277 VAC 480 VAC x 952 833 722 2404 2083 1805 6000 28 85 25 00 2166 1250 Service Note Correct Elements If the measured amp draw on any element is considerably less or more than the values given in the table above check the element rating to ensure it matches the water heater s factory configuration see Heating Element Ratings and Heating Element Configurations on page 21 All heating elements should have the same voltage and KW rating in a water heater If an element is not the correct rating for the water heater being serviced it must be replaced with a properly rated heating element Service Note Grounded Elements Grounded elements on Surface Mount Control Models Figure 1 page 8 can draw low amps because power is continuously present at one terminal on each element see the wiring diagram on page 18 Power from the thermostat s L4 terminal is always present at each element and can fl
86. re not being ener gized during standby mode see pages 32 amp 33 Check water system piping ensure heat is not being added to the water inside 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 69 NOTES NOTES NOTES 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
87. rneath 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 Monday cT Q Normal Operation Day Economy Mode All Day Normal Operation Between May Start C700 PM Stop 8 00 PM Monday A Normal Operation Day Economy Mode All Day Normal Operation Between M 7 3000 Stop 8 00 PM Sending Updates to CCB CHANGE BACK Setpoint Adjustment Current Time Mon 5 00 PM Heater In Economy Mode No Sun Economy Mode All Day Mon Normal 7 30 AM to 8 00 PM Normal All Day Servicing should only be performed by a Qualified Service Agent 58 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 42 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 extern
88. ry Winding X1 X2 120 VAC Servicing should only be performed by a Qualified Service Agent 34 OPERATION amp SERVICE 120 VAC Control 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 see Figure 2 on page 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 Voltage between these two terminals should match the water heater s power supply voltage at the Power Distribution Block 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 Check the wiring between the Control Circuit Transformer s primary winding and the Control Circuit Fuse Block see Figure 2 on page 9 for location ensure wiring is correct and connections are tight and making good contact e Check the wiring between the Control Circuit Fuse Block and the Powe
89. se which in turn supplies power to the heating elements HEATING ELEMENT CONFIGURATIONS Both types of water heaters covered in this manual are factory equipped with either 3 6 or 9 heating elements depending on how they were ordered from the factory see the Heating Element Configurations table on page 21 Each group of 3 heating elements physically installed in diagonal rows of 3 is referred to as a Bank of heating elements Bank 1 is the lowest group of 3 heating elements Bank 2 is the middle group of 3 heating elements and Bank 3 is the upper group of 3 heating elements See Figure 1 on page 8 and Figure 2 on page 9 Heating Element Voltage and KW Conversion Kits Voltage and heating element KW conversion kits are available for the water heaters covered in this manual Voltage and KW conversions are not covered in this manual Voltage and KW conversion kits with instructions are available from local distributors and can be ordered from the manufacturer s parts department by calling the toll free number listed on the back cover of this manual Have the complete model and serial number along with the listed voltage and input KW from the rating label of the water heater on hand before calling Service Note There are field conversion kits to increase decrease KW input and change voltage However conversion kits do not allow adding heating elements to a water heater Water heaters must remain as they were configured with 3 6 or 9 heating ele
90. the CCB circuit board and the contactor coils The input power wiring to the primary winding of this transformer must be configured to match the power supplied 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 circuit board The table and illustrations that follow show how to properly configure the input power wiring to the transformers primary winding 1 Only one wire need be changed on the transformer to change voltage Do not move or change the wire to the common H1 connection on the primary winding or either wire to the secondary winding X1 or X2 connections Remove the wire from the terminal marked H2 208 H3 240 H4 277 or H5 480 and attach it to the appropriate terminal that matches the water heater s power supply voltage 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 277 480 VAC H1 Common amp H5 480 H1 H2 H4 H5 N A Primary Winding g SH tH Impervi RAN A 3 LH E 100v 50 60H2 o amp amp x 800 664 4660 TEMP CL 105 x cw o v B100 0087 3 es QU 210845 x2 x1 CONTROL 7a 12 ee PSs PES PSs a 8100 0087 3 Seconda
91. 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 eli eril current time in the same way as outlined above KP rine When finished making changes press the Operational 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 The new settings should be displayed as the Current Time Economy Mode Setup Setpoint Adjustment 20 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 wy Servicing should only be performed by a Qualified Service Agent 57 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Daily Operating Mode Settings ACTION DISPLAY Economy Mode All 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 See Time Clock settings on page 57 for instructions on navigating to the Economy Mode Setup menu Economy Mode Setup Setpoint Adjustment Current Time Mon 5 00 PM Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Use the Up Down buttons to select highlight
92. the two outside pins red wires of the J5 plug end as shown in the Checking ECO Switch Continuity image below 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 continuity through the ECO present call the toll free Technical Support phone number listed on the back cover of this manual for further assistance f the ohm meter shows no continuity open circuit between the two outside pins red wires of the J5 plug end and the control system 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 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 F 94 C check contactors pages 29 32 to ensure they are not stuck closed and check for voltage at all heating elements page 24 during the standby mode Check water system piping ensure heat is not being added to the water inside the water heater being serviced 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
93. tion beginning on page 52 and Economy Mode Setup Menu section beginning on page 55 Status The Operating State of the control system is displayed beneath the Operating Set Point See Table 2 on page 51 Service Note The Desktop Screen MODEL INFORMATION displays text and animated icons that convey operational information Tank Temperature 118 F Review the Status Icons explanation Operating Set Point 120 F in Table 1 on page 50 and Contactor Status Heating Configurations on page 30 Learning Friday to use this real time visual display of 5 00 PM the operating sequence will help to Normal Mode quickly diagnose operational problems Status Icons Figure 5 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 page 57 has been initially set Day and Time are adjusted in the Economy Mode Setup menu 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 51 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
94. to prevent further heating operation If the control system locks out the condition that caused the lock out must be 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 37 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 circuit board see page 42 for location Using an ohm meter set the ohm meter range to a scale above 30 000 ohms initially 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 The resistance test indicates an open infinite resistance or a direct short no resistance circuit The nature of the service problem is temperature control and the resistance readings are considerably 25 or more different than the values in the table here at the given temperature Checking Temperature Sensor Resistance Temperature Sensor Resistance Data WATER TEMPERATURE REET ANCE Celsius Fahrenheit IN OHMS 3 40 26 435 21 70 11 974 38 100 5 862 49 120 3 780 55 130 3 066 60 140 2 503 71 160 1 698 82 180 1 177
95. tory default is Normal Operation All Day Normal Operation All Day When this operating mode is active the normal Operating Set Point Temperatures Menu page 52 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 start time and one stop time event per day Servicing should only be performed by a Qualified Service Agent 55 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Setpoint Adjustment Value ACTION DISPLAY From the Desktop screen press the Operational Button underneath MENU to enter the Main Menu see UIM Navigation on page 48 Notice how the text above the Operational Buttons on the display changes as you navigate through the various menus and screens MODEL INFORMATION Tank Temperature 120 F Operating Set Point 120 Status Standby Friday 5 00 PM Normal Mode 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 Set
96. transformer for pinched or shorted wires repair or replace damaged wiring as necessary Primary Winding Voltage Test Secondary Winding Voltage Test Servicing should only be performed by a Qualified Service Agent 36 OPERATION amp SERVICE IMMERSION TEMPERATURE PROBE This section of the manual provides information on how test the Immersion Temperature Probe on Electronic Control Models see Figure 2 on page 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 circuit board at the J5 socket See the CCB circuit board layout and identification illustration and tables on pages 42 44 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 49 Voltage to the contactor coils page 32 and heatin
97. tter see pages 6 amp 34 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 closed The switch contacts are not replaceable If the contacts show signs of excessive wear 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 Perform Close Visual Inspection Of Switch Contacts Servicing should only be performed by a Qualified Service Agent 31 OPERATION amp SERVICE Contactor Coil Voltage At Contactor This test procedure will measure contactor coil voltage at the contactor 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 heat is active for all heating elements Raise the Operating Set Point in the Temperatures Menu to 140 F or higher Set all Heating Element Bank Differentials in the Temperatures Menu to 2 F see pages 52 and 53 Using an AC volt meter set the volt meter to an AC voltage range just above 120 VAC Touch the two volt meter probes to the contactor coil wiring terminals at each contactor There should be approximately 120 volts present between the two terminals If there is no volt
98. tup Seven day 24 hour time clock with temperature set back capability to reduce operating costs during unoccupied or reduced demand periods Alarm Output Setup The control system s CCB Central Control Board see page 42 features on board SPDT single pole double throw relay contacts for building EMS Energy Management System 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 Heater Information 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 bank s cycle count and heating bank on time along with UIM and CCB software revisions can be viewed in this menu Current Fault Alert Displays any current Alert or Fault messages Fault History Fault Occurrence 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 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 Rest
99. ufacturers web site or by calling the toll free phone number on the back cover of this manual Remove install heating elements using a 1 1 2 six point socket Install a new heating element gasket with the new element Replacement elements and gaskets can be obtained from local distributors or by calling the toll free phone number on the back cover of this manual Servicing should only be performed by a Qualified Service Agent 26 OPERATION amp SERVICE ELEMENT SENSORS Electronic Control Models covered in this manual monitor all heating elements using Element Sensors Each Element Sensor monitors 3 heating elements There will be one Element Sensor for each Bank of heating elements See Figure 2 on page 9 and the illustration on page 30 Water heaters equipped with 3 heating elements will have 1 Element Sensor water heaters equipped with 6 elements will have 2 Element Sensors and water heaters equipped with 9 elements will have 3 Element Sensors Element Sensor Construction Element Sensors consists of 3 individual current sensors a 10 conductor plug and 9 wires that connect between the individual current sensors and the plug Each current sensor monitors one heating element Current sensors are enclosed in a black plastic housing that has a hole in the middle One power wire to each heating element is routed through the hole in one of the current sensors See the images below Element Sensor 10 Conductor Plug Element Sensor Functions
100. up menu Main Menu Temperatures Heater Status Economy Mode Setup Alarm Output Setup Display Settings Use the Up Down buttons to select highlight in black Setpoint Adjustment Press the Operational Button underneath CHANGE to activate the adjustment mode for the Setpoint Adjustment value Economy Mode Setup Setpoint Adjustment 40 Current Time Wed 4 19 PM Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day f 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 Economy Mode Setup Setpoint Adjustment 20 Current Time Wed 4 19 PM Heater In Economy Mode No Sun Normal All Day Mon Normal All Day Tue Normal All Day Wed Normal All Day f UPDATE CANCEL The new Setpoint Adjustment value should now be displayed as the current value Economy Mode Setup Setpoint Adjustment 20 Current Time Wed 4 19
101. uses Class G SC 30 Amp Time Delay Replacement 120 Volt Control Circuit Transformer fuses MUST BE of the same value and type as the factory installed fuses Class G SC 3 Amp Ohm Meter Method Secure power to the water heater at the main breaker or disconnect switch Remove each fuse to be tested with an insulated fuse puller Set the 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 If the fuse being tested shows a low resistance 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 an audible beep the fuse being tested is blown and must be replaced Ohm Meter Method Volt AA Y 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 thermostats contactors must be closed during this test Touch the two test probes to both ends of all fuses while still in their fuse blocks 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 pr
102. utput Setup Display Settings With the Operating Set Point selected highlight in black in the Temperatures Menu press the Operational Button underneath CHANGE to activate the adjustment mode for this menu item Temperatures Operating Set Point 120 F ist Differential 2 F 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset o F wi CHANGE BACK HELP Press the Up and Down buttons to adjust the Operating Set Point to the desired setting Press the Operational Button underneath UPDATE to confirm the new setting Press the Operational Button underneath CANCEL to discard the new setting and retain the previous setting The new Operating Set Point value should now be displayed as the current value NOTE Use this same procedure to adjust the Differential settings and the Tank Probe Offset in the Temperatures Menu This same procedure is used to change user settings in other control system menus Temperatures Operating Set Point 1st Differential 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset Temperatures Operating Set Point ist Differential 2nd Differential 3rd Differential Tank Temperature Tank Probe Offset CHANGE BACK HELP Servicing should only be performed by a Qualified Service Agent 53 ELECTRONIC CONTROL SYSTEM HEATER STATUS MENU This menu displays non adjustable operational information This menu contains more informatio
103. ven component before replacement Check J1 and J2 plug socket connections on the CCB ensure they are mating properly and providing good contact page 42 e Check 24 VAC transformer follow procedure Ensure wires were stripped before being crimped in outlined on page 36 a wire connector ensure wires are crimped tightly in Call the technical support phone number on the their connectors Ensure pins inside plugs sockets back cover of this manual for further assistance are not damaged or worn ensure plugs sockets are if the problem has not been corrected after per mating properly amp providing good contact forming the procedure outlined here Servicing should only be performed by a Qualified Service Agent 65 TROUBLESHOOTING Control System Unresponsive cont DISPLAYED MESSAGE CONDITION INDICATES CHECK REPAIR UIM is Inoperable UIM does not respond to any user input using the operational and or Up and Down buttons Ensure Ribbon Cable from the Button overlay is inserted correctly in UIM J3 Socket page 47 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 Heating Cycle Disabled Control System not activating call for heat with cold tank of water Thermometer Icon on Desktop Screen appears with diagonal line as shown here Possible Causes Fault conditi
104. vicing should only be performed by a Qualified Service Agent 18 OPERATION amp SERVICE Thermostat amp ECO Test oar cnm Secure power to the water heater at the main breaker or disconnect switch Ensure tank temperature is less than 100 F 38 C dump water to lower tank temperature if necessary Press the red reset button firmly on all thermostat ECO controls Raise the temperature setting on all thermostat ECO controls to 140 F or higher Restore power to the water heater With an AC volt meter check for voltage between the L1 and L3 terminals on the control see illustrations below Measured voltage should match the power supply to the water heater Service Note If the measured voltage is zero volts or not the correct voltage ensure heating element power circuit wiring is correct see wiring diagram on water heater check fuses page 17 and or restore power to the water heater see pages 12 14 With an AC volt meter check for voltage between the L4 and T2 terminals on the control see illustrations below if the measured voltage matches the power supply to the water heater the ECO is resetting properly If the measured voltage between L4 and T2 is low or not present the control is defective replace the control Service Note Grounded heating elements defective thermostats and or a defective ECOs can all cause frequent ECO activation If an ECO is being frequently reset on any of the thermostat ECO controls check all
105. viding 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 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 toll free phone number shown on 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 panels while servicing Insulated fuse puller s Adhesive numbered colored wire markers 3M ScotchCode SDRO 9 Numbered Wire Markers
106. vigate Menus Activate Adjustment Modes Update Cancel Changes Figure 4 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 depending 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 48 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 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 sec
107. voltage readings between internal wiring and or Power Distribution Block 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 taken between L1 L2 and L3 are more than 5 of the listed voltage on the water heater s rating label or if the readings to ground were far less at or near zero volts than expected check the fuses and 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 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 it back in service Contact the distributor and or manufacturer to determine if the water heater can be field converted and or replaced to match the power supply at the location L1HOT L2 HOT L3 HOT GROUND L1 L2 L3 FERE ee 208 240 480 M 208 240 480 120 208 277 SSS Less Sss TENES Power Distribution Block see Figures 1 amp 2 on pages 8 and 9 NL i FN volts 208 240 480 volts 208 240 480 Volt Power Servicing should only be performed by a Qualified Service Agent 14 OPERATION amp SERVICE PHASE CONVERSIONS SURFACE MOUNT CONTROL MODELS Internal wiring connections between the Power Distribution Block and the heating elements are dif
108. y reported to the user through text and icons on the liquid crystal display LCD portion of the UIM When there are operational problems Fault and Alert messages will also be displayed Users can navigate through multiple control system menus to view operational information and change user settings see the Electronic Control System section beginning on page 48 H etg ES 22 2 la gt Tank Temperature 116 F f o 5 Operating Set Point 120 foo c 1 dB UIM User Interface Module CCB Central Control Board Servicing should only be performed by a Qualified Service Agent 41 ELECTRONIC CONTROLS CCB CENTRAL CONTROL BOARD All wiring connections and sockets will be identified in the following pages The Troubleshooting section of this manual will refer to this illustration and information O S 5 4 3 2 c 0 didis 2 ees Lm d NO 16 lt 1 J5 K 9 9 9 9 2 1 N Servicing should only be performed by a Qualified Service Agent 42 ELECTRONIC CONTROLS CCB Socket amp Wiring Terminal Identification Refer to the illustration on page 42 for physical location of the sockets and wiring terminals J1 Socket Transformer PIN DESCRIPTION 1 120 VAC hot to transformer 2 Not used 3 120 VAC neutral to transfor

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