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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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11 ELECTRICAL GENERAL 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 current editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. An electrical ground is required to reduce risk of electrical shock or possible electrocution. The water heater should be connected to a separate grounded branch circuit with over-current protection and disconnect switch. The water heater should be grounded in accordance with national and local codes. Voltage applied to the heater should not vary more than +5% to -10% of the model and rating plate marking for satisfactory operation. DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON BEFORE THE HEATER TANK IS FILLED WITH WATER. DOING SO WILL CAUSE THE HEATING ELEMENTS TO BURN OUT AND VOID WARRANTY. The factory wiring is attached to a terminal block within the external junction box unit. The branch circuit is connected to the terminal block within this junction box. The water heater should be connected to a separate, grounded, branch circuit with overcurrent protection and disconnect switch. The water heater should be grounded in accordance with national and local codes. BRANCH CIRCUIT The branch circuit wire size should be established through reference to the current edition of NFPA-70, the National Electrical Code or other locally approved source in conjunction with the heater amperage rating. For convenience, portions of the wire size tables from the Code are reproduced here. The branch circuit should be sized at 125 percent of the heater rating and further increase wire size as necessary to compensate for voltage drop in long runs. CALCULATING AMPERAGE/OVERCURRENT PROTECTION The heaters come from the factory in two configurations: 1. Two wire C-2 circuit for single element heater equipped with a high limit control, single phase power input. 2. Four wire A-8 circuit for dual element heater equipped with two high limit controls, single phase or three phase power input. The heater with dual elements is factory wired for connection to a three wire, three-phase delta branch circuit, non-simultaneous operation. In addition a ground conductor is required. Element connection is for non-simultaneous operation. This means only one element at a time operates. The wiring diagram, on page 12, shows the heater may be field converted to simultaneous element operation by moving the red wire on “J” terminal to L1. It is then possible for both elements to operate at once as determined by the thermostats. Regardless of element connection the heater operates in an “unbalanced” fashion. The heater may be field converted to single-phase operation by moving the wire on L3 of the terminal block to L2. L3 is not used, see page 12. The heater, now in single-phase non-simultaneous operation, may be field-converted to single phase simultaneous operation by moving the red wire on terminal “J” to L1, see page 12. This is an example of calculating heater amperage for both types of element operation. From this, the branch circuit conductor and overcurrent protection sizing can be established. The example is of a three-phase 240 volt unit with two, 6 kw e l e m e n t s . T h e n o t a t i o n s a r e f o r u n i t s fi e l d c o n v e r t e d t o s i n g l e - p h a s e . Check the heater model and rating plate for actual specifications and substitute those values in the following. TABLE 3 Non-simultaneous: (as factory wired) Simultaneous: (Field conversion) 3000 : 240 = 12.5 amps* 3000 : 240 = 12.5 amps* 12.5 x 1.73 = 21.6 amps *NOTE: as a single-phase non- simultaneous unit. *NOTE: as a single-phase simultaneous unit the total is: 12.5 x 2 = 25 amps The rating of the overcurrent protection should be computed on the b a s i s o f 12 5 p e r c e n t o f t h e t o t a l c o n n e c t e d l o a d a m p e r a g e . W h e r e t h e standard ratings and settings do not correspond with this computation, the next higher standard rating or setting should be selected. Portion of Table 310-16 (NFPA-70) follows: Allowable Ampacities of Insulated Copper Conductors. Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F). These ampacities relate only to conductors described in Table 310 -13 in Code. For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code. For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code. TABLE 4 Size Temperature Rating of Conductor See Table 310-13 in Code AMG MCM 60°C (140°F) 75°C (167°F) Types: RUW, (14-2), T, TW, UF Types: RH, RHW, RUH, (14-2), THW, THWN, XHHW, USE 18 16 14 - - - - - - 15 - - - - - - 15 12 10 8 20 30 40 20 30 45 6 4 3 55 70 80 65 85 100 Portion of Table 310-18 follows: Allowable Ampacities of Insulated Aluminum and Copper -Clad Aluminum Conductors. Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F. These ampacities relate only to conductors described in Table 310-13 in Code. For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code. TABLE 5 Size Temperature Rating of Conductor See Table 310-13 in Code AMG MCM 60°C (140°F) 75°C (167°F) Types: RUW, (12-2), T, TW, UF Types: RH, RHW, RUH, (12-2), THW, THWN, XHHW, USE 12 10 15 25 15 25 8 6 30 40 40 50 4 3 55 65 65 75 2 1 75 85 90 100
12 FIGURE 3 WIRING DIAGRAMS C-2 CIRCUIT FOR Lowboy 6/10/15/20 HEATERS EQUIPPED WITH HIGH LIMIT CONTROL A-8 CIRCUIT FOR DUAL ELEMENT HEATER FACTORY WIRED ---------- FIELD WIRING † WHITE FOR 120V & 277V
13 OPERATION GENERAL Refer to the Features and Components section of this manual (page 7) for the location of components mentioned in the instructions that follow. NEVER turn on power to the water heater without being certain the water heater is filled with water and a temperature and pressure relief valve is installed in the relief valve opening. DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS FILLED WITH WATER. FOLLOW FILLING AND START-UP INSTRUCTIONS IN OPERATION SECTION. FILLING THE WATER HEATER 1. Turn off the electrical disconnect switch. 2. Close the water heater drain valve. 3. Open a nearby hot water faucet to permit the air in the system to escape. 4. Fully open the cold water inlet pipe valve allowing the heater and piping to be filled. 5. Close the hot water faucet as water starts to flow. The heater is now ready for STARTUP and TEMPERATURE REGULATION. INITIAL START UP The following checks should be made by the installer when the heater is placed into operation for the first time. 1. Turn off the electrical disconnect switch. 2. Open the front panel or top access cover, check all water and electrical connections for tightness. Also check connections on top and or sides of heater. Repair water leaks and tighten electrical connections as necessary. 3. Depress the red manual reset button on each Thermostat/ECO combination control. (See Figure 5, Figure 6, Figure 7, or Figure 8) 4. Turn on the electrical disconnect switch. 5. Observe the operation of the electrical components during the first heating cycle. Use care as the electrical circuits are energized. 6. Close the front panel or top access cover. Temperature control and contactor operation should be checked by allowing heater to come up to temperature and shut off automatically. Use care as the electrical circuits are energized. DRAINING THE WATER HEATER The water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater. 1. Turn off the electrical disconnect switch. 2. Open a hot water valve until the water is cool, then close the supply water inlet valve to heater. 3. Attach hose to outlet opening of drain valve and direct end to drain. 4. Open a nearby hot water faucet and the heater drain valve. 5. If the heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this period. The hose may be removed. Follow FILLING instructions when restoring hot water service. INSTALLATION
14 THE WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER AT TEMPERATURES DESIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALDS RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND TIME OF EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN , AGED OR DISABLED PERSONS INCREASES THE HAZARD TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER. It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature thermostats (See Figure 4) be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater. Figure 4 shows the approximate time-to-burn relationship for normal adult skin. The thermostats on your water heater have a linear relationship between degrees of angular rotation and the corresponding change in temperature. Thus rotating the temperature adjustment indicator 30 angular degrees will result in a 10 degree Fahrenheit change in water temperature. Water Temperature °F (°C) Time for 1st Degree Burn (Less Severe Burns) Time for Permanent Burns 2nd & 3rd Degree (Most Severe Burns) 110 (43) (normal shower temp.) 116 (47) (pain threshold) 116 (47) 35 minutes 45 minutes 122 (50) 1 minute 5 minutes 131 (55) 5 seconds 25 seconds 140 (60) 2 seconds 5 seconds 149 (65) 1 second 2 seconds 154 (68) instantaneous 1 second (U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978) FIGURE 4 TEMPERATURE ADJUSTMENT The water heater is supplied with thermostats that may come from different manufactures and have different temperature indications as described below. APCOM THERMOSTATS A-8 Circuit thermostats have three designated set points; LO, MED and HI. (See Figure 5).The approximate equivalent temperatures for these three settings are: LO = 140°F (60°C), MED = 160°F (71°C) and HI = 181°F (83°C). These thermostats are set from the factory at the LO 140°F (60°C) setting. The over temperature device (ECO high limit) attached to each thermostat has a manual reset. The C-2 circuit thermostat is adjustable from approximately 130°F (54°C) to 170°F (77°C) (See Figure 6). These thermostats are set from the factory at approximately the 140°F (60°C) setting. The over temperature device (ECO high limit) attached to each thermostat has a manual reset. 30A 120-250 VAC 22A 277 VAC 12.5A 480-600VAC125 VA.PT.DTY. 120-480 VAC MODELWH10C MED 40A 120-277 VAC 25A.480-600 VAC 125VA.PT.DTY. 120-480 VAC APCOM INC FIGURE 5 FIGURE 6 THERMODISC THERMOSTATS A-8 circuit thermostats are adjustable from approximately 120°F (49°C) (lowest setting) to 181°F (83°C) (highest setting) (See Figure 7). T h e C - 2 c i r c u i t t h e r m o s t a t i s a d j u s t a b l e f r o m a p p r o x i m a t e l y 110 ° F (43°C) to 170°F (77°C) (See Figure 8). These thermostats are set from the factory at approximately the 140°F (60°C) setting. The over temperature device (ECO high limit) attached to each thermostat has a manual reset. L1 L3 L4 T2 T4 L2 T1 THERM O DISC89T RESETRESET 181°F120°F 140°F L1 L3 L4 T2 T4 L2 T1 THERM-O-DISC RESET 170°F 140°F 110°F RESET FIGURE 7 FIGURE 8 NOTE: It is not necessary to adjust the upper thermostat for a dual element unit. However, if it is adjusted above the factory set point 140°F (60°C) it is recommended that it not be set higher than the lower thermostat setting. To change the temperature setting: 1. DANGER: Turn off the heater electrical supply. Do not attempt to adjust thermostat with power on. 2. Open the junction box door (for upper thermostat of dual element water heater only) and/or remove the (lower) thermostat access panel. Do not remove the plastic personnel protectors covering the thermostats. The thermostat is factory pre-set at 140°F (60°C). 3. Using a flat tip screwdriver, rotate the adjusting knob to the desired temperature setting. 4. Replace the covers and access panels, and turn on heater electrical supply. TEMPERATURE REGULATION
15 GENERAL Periodically the drain valve should be opened and the water allowed to run until it flows clean. This will help to prevent sediment buildup in the tank bottom. Periodically check the temperature and pressure relief valve to ensure that it is in operating condition. Lift the lever at the top of the valve several times until the valve seats properly and operates freely. Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale from the heating element. The heater tank is equipped with an anode rod to aid in corrosion control. ANODE ROD INSPECTION The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifices itself to protect the tank. Instead of corroding tank, water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition. Anode deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by a qualified technician, and at a minimum should be checked annually after the warranty period. Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. The use of a water softener may decrease the life of the water heater tank. The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. NOTE: Artificially softened water requires the anode rod to be inspected annually. MAINTENANCE
16 TROUBLESHOOTING CHECKLIST CHECKLIST Before calling for service, check the following points to see if the cause of trouble can be identified and corrected. Reviewing this checklist may eliminate the need of a service call and quickly restore hot water service. See Figure 2 on page 7 in this manual to identify and locate water heater components. NOT ENOUGH OR NO HOT WATER 1. Be certain the electrical disconnect switch serving the water heater is in the ON position. 2. Check the fuses. • The electrical disconnect switch usually contains fuses. 3. If the water was excessively hot, and is now cold, the high limit switch may have activated. • See the Temperature Regulation section of this manual for more information on how to reset the ECO high limit controls. 4. The capacity of the heater may have been exceeded by a large demand for hot water. • Large demands require a recovery period to restore water temperature. 5. Cooler incoming water temperature will lengthen the time required to heat water to the desired temperature. 6. Look for hot water leakage. 7. Sediment or pipe scale may be affecting water heater operation. ABNORMAL SOUNDS 1. Sediment or lime scale accumulations on the elements causes sizzling and hissing noises when the heater is operating. • The sounds are normal, however, the tank bottom and elements should be cleaned. See the Maintenance section of this manual. WATER LEAKAGE IS SUSPECTED Refer to Leakage Checkpoint on the following page 17. 1. Check to see if the heater drain valve is tightly closed. 2. If the outlet of the relief valve is leaking it may represent: • Excessive water temperature. • Faulty relief valve. • Excessive water pressure. 3. Excessive water pressure is the most common cause of relief valve leakage. It is often caused by a “closed system”. See “Closed Water Systems” and “Thermal Expansion” in the Installation section of this manual for more information. 4. Examine the area around the element for gasket leakage. • Tighten the elements or, if necessary, replace the gaskets. IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF MALFUNCTION 1. Turn the power supply to the water heater off. 2. Close the supply water inlet valve to the heater. 3. Contact a Qualified Service Agency in your area. Call the toll free phone number on the water heater label for assistance in locating a service agency in your area. REPLACEMENT PARTS For replacement parts shown in this manual please contact the company it was purchased from or direct from the manufacturer listed on the rating plate on the water heater.
17 LEAKAGE CHECKPOINTS Instructions: Use this illustration as a guide when checking for sources of water leakage. You or your dealer may be able to correct what appears to be a problem. NOTE: Cover and Insulation shown removed to reveal tank top. Relief Valve To Open Drain Condensation and dripping may appear on pipes when cold water temperature is low. Pipe fitting may be leaking. Relief valve operation and leakage may be due to water expansion during heating cycle or foreign material on seat of valve. If the valve is not piped to an open drain the released water could be mistaken for a leaking heater. To check where threaded material between jacket opening and swab spud area. Remove valve* if indicated and repair with pipe joint compound. Water on the side of the tank may be condensation due to the panel or insulation not being in place. Drain valve leakage could be from the valve itself.* To check for leakage where threaded portion enters tank, insert Q-tip or similar absorbent material between jacket opening and valve to swab spud area. Remove valve* if leak is indicated and repair with pipe joint compound. *Contact your dealer as it is necessary to shut off electricity and drain tank to perform procedure. Water leaks at the elements may be due to: 1. Defective element which leaks at terminals or thru flange. Replace element*. 2. Loose element/gasket leak: (a) Screw-in type: tighten with 1-1/2” socket wrench. If leak continues, remove element*, discard gasket and clean thread areas.Apply nonhardening Permatex Number 2 to thread areas, install new gasket and screw element into fitting until it seats. Tighten 1/2 to 3/4 turn with wrench. (b) Flange type: tighten screw with wrench. If leak continues remove element* and discard gasket. Clean gasket seating areas and re-install element with new gasket. A new element may be required where threads have become rusted or damaged, preventing tightening. All water which appears at the water h e a t e r b o t t o m o r o n t h e s u r r o u n d i n g fl o o r may be caused by condensation, loose connections or relief valve operation and leakage. Do not replace the water heater until full inspection of all potential leak points is made and corrective steps taken to stop the leak. Leakage from other appliances, water lines or ground (see page 16) should also be suspected until proven otherwise. Anode Rod (Some Models) Where possible remove or lift top cover to examine threads of fittings installed into tank for evidence of leakage. Correct fitting leaks as necessary. To Open Drain FIGURE 9
18 EFFECTIVE For 3 Years, in the event of a tank leak, we will repair or, at our discretion, replace the defective water heater. For 1 Year, in the event of part failure, we will repair or, at our discretion, replace the defective part. We warrant this product against defects in materials or workmanship as described in this document if installed within the United States or Canada and provided the product remains at its original place of installation. Warranty coverage begins the date of installation OR the date of manufacture if installation cannot be verified. WHAT'S COVERED Subject to these terms, in the event of defect in materials and/ or workmanship resulting in a tank leak during the first three years, we will: • Replace the water heater should the tank leak. Subject to these terms, in the event of a defect in materials and/or workmanship appearing during the first year, we will: • Repair or, at our discretion, replace any part of the water heater covered under this limited warranty excluding parts subject to normal maintenance (Example: non-electronic anode rod, filter, etc) Service/labor, shipping, delivery, installation, handling or any other costs are not covered at any time under this warranty. Any replacement part or product will be warranted only for the unexpired portion of the original water heater’s limited warranty period. If an identical model is no longer available due to a change in law, regulation, or standard, we will replace the product with one having comparable capacity and input. In these instances, the owner will have the option of paying the difference between what was paid for the original model and the new model with the additional features, or receiving a refund of the portion of the purchase price, on a pro-rata basis allocable to the unexpired portion of the warranty. WHAT'S NOT COVERED • Problems caused by improper: gas supply line sizing, gas type, venting, connections, combustion air, voltage, wiring, or fusing • Failure to follow applicable codes • Failure to follow printed instructions • Abuse, misuse, accident, fire, flood, Acts of God • Improper installation, sizing, delivery, or maintenance • Claims related to rust, noise, smell, or taste of water • Failure to conduct authorized factory start up if required • Alterations to the water heater • Non-outdoor heaters installed outdoors • Damages due to a failure to allow for thermal expansion • Heat exchanger failure due to lack of adequate / proper supply of water • Heaters moved from their original location • Service trips to explain proper installation, use, or maintenance of the product/unit or to describe compliance requirements under applicable codes and regulations • Charges related to accessing your heater including but not limited to door/wall removal, equipment rental, etc. • Replacement parts after expiration of this warranty LIMITATIONS NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY, THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY. ALL OTHER WARRANTIES INCLUDING A WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE PURCHASE PRICE PAID WHETHER BASED ON CONTRACT, TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY. SERVICE INQUIRIES: For service inquiries call the telephone number listed below. Be prepared to provide the following information: name, address, and telephone number; the model and serial number of the water heater; proof of installation; and a clear description of the problem. For your records, fill in the product: Serial: ___________________ Model: ___________________ U.S. Customers: Canadian Customers: A. O. Smith Corporation P. O. Box 310 – 768 Erie Street 500 Tennessee Waltz Parkway Stratford (Ontario) N5A 6T3 Ashland City, Tennessee 37015 800-265-8520 800-527-1953 COMMERCIAL WATER HEATER LIMITED WARRANTY
20 REPAIR PARTS LIST Now that you have purchased this water heater, should a need ever exist for repair parts or service, simply contact the company it was purchased from or direct from the manufacturer listed on the rating plate on the water heater. Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly. The model number of your Water Heater will be found on the rating plated located above the lower access panel.Be sure to provide all pertinent facts when you call or visit. WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION: • MODEL NUMBER • VOLTAGE AND ELEMENT WATTAGE • SERIAL NUMBER • PART DESCRIPTION Lowboy 6, 10, 15, 20 Series 102 (refer to repair parts table). DRAIN VALVE (not supplied with heater) FIGURE 10