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American Water Heater Commercial Light Duty Electric Water Heaters Lowboy Standard and Upright Series User Manual
American Water Heater Commercial Light Duty Electric Water Heaters Lowboy Standard and Upright Series User Manual
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1 Instruction Manual PRINTED 1215 323289-005 PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE. COMMERCIAL LIGHT DUTY ELECTRIC WATER HEATERS Thank you for buying this energy efficient water heater. We appreciate your confidence in our products. Lowboy 6/10/15/20 Models Series 102 Lowboy 30/40/50 Models Series 110 Tall 30/40/50/66/80/120 Models Series 110 INSTALLATION - OPERATION - SERVICE - MAINTENANCE
2 SAFE INSTALLATION, USE, AND SERVICE The proper installation, use and servicing of this water heater is extre\ mely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages \ and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others \ who install, use, or service this water heater. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. IMPORTANT DEFINITIONS • Qualified Installer or Service Agency: Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, electrical supply are required in addition to electrical testing skills when performing service. • ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.” DANGER WARNING CAUTION DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury. CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage. CAUTION All safety messages will generally tell you about the type of hazard, what can happen if you do n\ ot follow the safety message, and how to avoid the risk of injury.
3 GENERAL SAFETY INFORMATION When servicing this unit, verify the power to the unit is turned off pri\ or to opening the control cabinet door. PRECAUTIONS DO NOT USE THIS WATER HE ATER IF ANY PART HAS BEEN E X P O S E D T O F LO O D I N G O R W AT E R D A M A G E . I m m e d i a t e l y call a qualified service technician to inspect the water heater and to replace any part of the control system which has been under water. If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified ser vice technician. 1. External fire. 2. Damage. 3. Firing without water. GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater. HYDROGEN GAS (FLAMMABLE) Hydrogen gas can be produced in a hot water system served by this heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN. Improper installation, use and service may result in property damage. CAUT ION Do not operate water heater if any part has been exposed to flooding or water damage . Inspect anode rods regularly, replace when significantly depleted. Install in location with drainage. Fill tank with water before operation. Properly sized thermal expansion tanks are required on all closed water systems. Refer to this manual for installation and service.
4 Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations Found In This Instruction Manual: • ANSI - American National Standards Institute • AHRI - Air-Conditioning, Heating and Refrigeration Institute • NEC - National Electrical Code • NFPA - National Fire Protection Association • UL - Underwriters Laboratory PREPARING FOR THE INSTALLATION 1. Read the “General Safety Information” section of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater may not operate safely. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. This manual contains instructions for the installation, operation, and maintenance of the electric water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER. Be sure to turn off power when working on or near the electrical system of the heater. Never touch electrical components with wet hands or when standing in water. When replacing fuses always use the correct size for the circuit, see page 12. The model and rating plates on page 6 interprets certain markings into useful information. Both of these references should be used to identify the heater, its components and optional equipment. 2. The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company. In the absence of local codes, the installation must comply with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National Electrical Code may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical Code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. 3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number listed on the water heater label for technical assistance. A sample rating plate is shown on page 6 of this manual. In order to expedite your request, please have full model and serial number available for the technician. 4. Carefully plan your intended placement of the water heater. Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual. Installation and service of this water heater requires ability equivalent to that of a licensed tradesman or qualified agency (page 2) in the field involved. Plumbing and electrical work are required. TABLE OF CONTENTS INTRODUCTION SAFE INSTALLATION, USE, AND SERVICE .......................................2 GENERAL SAFETY INFORMATION ....................................................3 Precautions .................................................................................. 3 Hydrogen Gas (Flammable) ......................................................... 3 INTRODUCTION .................................................................................. 4 Preparing for the Installation ........................................................ 4 DIMENSIONS AND CAPACITIES DATA .............................................. 5 APPROVALS ........................................................................................ 6 MODEL AND RATING .......................................................................... 6 FEATURES AND COMPONENTS ....................................................... 7 LOCATING THE NEW WATER HEATER .............................................8 Facts to Consider About the Location .......................................... 8 Clearances ................................................................................... 8 INSTALLATION .................................................................................... 9 Required Ability ............................................................................ 9 General ......................................................................................... 9 Contaminated Water ..................................................................... 9 Circulating Pump .......................................................................... 9 Insulation Blankets ....................................................................... 9 Temperature-Pressure Relief Valve ..............................................9 Closed Water Systems ............................................................... 10Thermal Expansion .................................................................... 10 ELECTRICAL ...................................................................................... 11 General ........................................................................................ 11 Branch Circuit .............................................................................. 11 Calculating Amperage/Overcurrent Protection ............................ 11 WIRING DIAGRAMS .......................................................................... 12 OPERATION ....................................................................................... 13 General ....................................................................................... 13 Filling the Water Heater .............................................................. 13 Initial Start Up ............................................................................. 13 Draining the Water Heater .......................................................... 13 TEMPERATURE REGULATION ........................................................ 14 Temperature Adjustment ............................................................ 14 MAINTENANCE ................................................................................. 15 General ....................................................................................... 15 Anode Rod Inspection ................................................................ 15 TROUBLESHOOTING CHECKLIST .................................................. 16 Checklist ..................................................................................... 16 Leakage Checkpoints ................................................................. 17 NOTES ............................................................................................... 18 Repair Parts List ......................................................................... 20
5 DIMENSIONS AND CAPACITIES DATA TABLE 2 - RECOVERY CAPACITIES Element Wattage (Upper/Lower) INPUT KW U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED F° 36F° 40F°54F°60F° 72F° 80F° 90F°100F° 108F°120F°126F° C° 20C° 22.2C° 30C°33.3C° 40C° 44.4C° 50C°55.5C° 60C°66.6C° 70C° NON-SIMULTANEOUS /1500 GPH17151110 8 8 76 655 1.5 LPH 64584338 32 29 2623 211918 /2000 GPH23201514 11 10 98 876 2.0 LPH 85775751 43 38 3431 282624 /2500 GPH28251917 14 13 1110 988 2.5 LPH107 967164 53 48 4338 363230 3000/3000 GPH34302320 17 15 1412 111010 3.0 LPH12811 5 8577 64 58 5146 433837 4000/4000 GPH45413027 23 20 1816 151413 4.0 LPH17015311 4102 85 77 6861 575149 4500/4500 GPH51463430 25 23 2018 171514 4.5 LPH19217312811 5 96 86 7769 645855 5000/5000 GPH56513834 28 25 2320 191716 5.0 LPH213192142128 107 968577 716461 6000/6000 GPH68614541 34 30 2724 232019 6.0 LPH256230170153 128 11 5 10292857773 SIMULTANEOUS OPERATION 3000/3000 GPH68614541 34 30 2724 232019 6 LPH 256230170153 128 11 5 10292857773 4000/4000 GPH90816054 45 41 3632 302726 8 LPH 341307227205 170 153 136123 11 410297 4500/4500 GPH101 916861 51 46 4136 343029 9 LPH 384345256230 192 173 153138 12811 511 0 5000/5000 GPH11 3101 7568 56 51 4541 383432 10 LPH 426384284256 213 192 170153 142128122 6000/6000 GPH135122 9081 68 61 5449 454139 12 LPH 5 11460341307 256 230 205184 170153146 Recovery capacities at 100° F rise equal: for non-simultaneous element operation = 4.1 gal. x KW of one element; for simultaneous element operation = 4.1 gal. x 2/3 KW of both elements. For other rises multiply element KW as previously explained by 410 and divide by temperature rise. Full load current for single phase = total watts : voltage. TABLE 1 - ROUGH-IN DIMENSIONS Models Dimensions No. of Elements Tank Capacity AB CDApprox. Shipping Weight US Gals. Litresinches mminches mminches mminches mmLbs.Kg. Lowboy-6 162315 1/2 39414 1/4 36211279 --3515.9 Lowboy-10 110 3818 1/4 4641845712 1/2 318 --5424.5 Lowboy-15 115 5726660 1845720 1/2 521 --5826.3 Lowboy-20 120 7622 1/4 56521 3/4 55215 3/8 391 --7333.1 Lowboy-30 230 11 430 7/8 78421 3/4 55224 1/8 613 8203 10045.4 Lowboy-40 24015132 1/4 8192461025 9/16 6498203 12556.7 Lowboy-50 25018932 1/4 81926 1/2 67325 1/8 6388203 16675.3 Tall-30 230 11 434 1/2 87620 1/2 521 --8203 9844.5 Tall-40 24015145 1/8 114620 1/2 521--8203 11 351.3 Tall-52 25018954 7/8 139420 1/2 521 --8203 13159.4 Tall-66 26625060 3/4 154321 3/4 552 --8203 17679.8 Tall-80 28030359 3/8 1508 24610 --8203 2 1195.7 Tall-120 211 9 45062 7/16 158629 3/8 746 --8203 326147.9 FIGURE 1
6 APPROVALS MODEL AND RATING Lowboy-30/40/50 & Tall-30/40/52/66/80/120Lowboy-6/10/15/20 All models are listed by Underwriters Laboratories Inc.
7 FEATURES AND COMPONENTS FIGURE 2 This page shows typical water heater installations by model designations. † OVER CURRENT PROTECTION MUST BE SUPPLIED IN WATER HEATER CIRCUIT. CONSULT LOCAL CODE OR CURRENT EDITION OF NEC FOR PROPER INSTALLATION. * INSTALL IN ACCORDANCE WITH ALL LOCAL CODES. INSTALL VACUUM RELIEF IN COLD WATER INLET LINE AS REQUIRED BY LOCAL CODES. INSTALL SUITABLE DRAIN PANS UNDER WATER HEATERS TO PREVENT DAMAGE DUE TO LEAKAGE. REFER TO WATER HEATER LOCATION ON PAGE 8. INSTALL THERMAL EXPANSION TANK IF THE WATER HEATER IS INSTALLED INTO A CLOSED WATER SYSTEM. SEE CLOSED WATER SYSTEMS ON PAGE 10. Lowboy 30/40/50 & All Tall Water Heaters Lowboy 6/10/15/20
8 FACTS TO CONSIDER ABOUT THE LOCATION The water heater should be located as close as possible to/or centralized to the water piping system. The water heater should be located in an area not subject to freezing temperatures. The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan should be installed under the heater. Such pans should be at least two inches deep, have a minimum length and width of at least two inches greater than the diameter of the heater and should be piped to an adequate drain. Drain pans suitable for these water heaters are available from your distributor, dealer or manufacturer listed on the rating plate. LOCATING THE NEW WATER HEATER Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain p a n . T h e s e d e v i c e s a r e a v a i l a b l e f r o m s o m e p l u m b i n g s u p p l y wholesalers and retailers, and detect and react to leakage in various ways: • Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected. • Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan. • Water supply shut-off devices that activate based on the water pressure differential between the cold water and how water pipes connected to the water heater. • Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply. CLEARANCES A minimum clearance of 4” must be allowed for access to replaceable parts such as thermostats, drain valve and relief valve. Adequate clearance for servicing this water heater should be considered before installation, such as changing the anodes, etc.
9 INSTALLATION REQUIRED ABILITY Installation and service of this water heater requires ability equivalent to that of a qualified installer or service agency (page 2) in the field involved. Plumbing and electrical work is required. GENERAL The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power c o m p a n y. I n t h e a b s e n c e o f l o c a l c o d e s , t h e i n s t a l l a t i o n m u s t c o m p l y with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National Electrical Code may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical Code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. Do NOT test electrical system before heater is filled with water, follow the START UP procedure in the OPERATION section of this manual. The principal components of the heater are identified in the Features and Components illustrations on page 7. MIXING VALVE USAGE: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/developmentally disabled. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a maximum water temperature at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a MIXING VALVE should be used at the hot water taps used by these people or at the water heater. MIXING VALVES f o r r e d u c i n g p o i n t o f u s e t e m p e r a t u r e a r e a v a i l a b l e and are to be set at a maximum of 120 degree F. Consult a qualified installer or service agency. Follow all manufacturer’s Instructions for installation of these valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual. CONTAMINATED WATER This water heater shall not be connected to any heating system(s) or component(s) used with a non-potable water heating appliance. Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system. CIRCULATING PUMP Field installed circulating pumps should be of all bronze construction. INSULATION BLANKETS Insulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the EPACT and ASHRAE/ IES 90.1 standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death. • Do not cover the temperature and pressure relief (T & P) valve with an insulation blanket. • Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference. • Do obtain new warning and instruction labels for placement on the blanket directly over the existing labels. TEMPERATURE-PRESSURE RELIEF VALVE This water heater is provided with a properly rated/sized and certified combination temperature - pressure relief valve by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME. If replaced, the new valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve rated/sized and certified as indicated in the above
10 paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (15 0 psi = 1,035 kPa) and a discharge c apacit y not less than the water heater Btu/hr or KW input rate as shown on the water heater’s model rating plate. For safe operation of the water heater, the temperature and pressure relief valve must not be removed from its designated opening nor plugged. The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit only within 6 inches (15.2 cm) above, or at any distance below the structural floor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve. No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage. The Discharge Pipe: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • Shall not be plugged or blocked. • Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve and the discharge pipe. • Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building. • Shall not have any valve or other obstruction between the relief valve and the drain. The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged can cause bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the temperature-pressure relief valve with a properly rated/sized new one. If you do not understand these instructions or have any questions regarding the temperature-pressure relief valve call the toll free number listed on the water heater label for technical assistance. CLOSED WATER SYSTEMS Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. THERMAL EXPANSION As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.