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A.O. Smith DURA-Power DRE-52, Service Handbook

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Service Handbook

PRINTED IN THE U.S.A 0908 

315014-000

Servicing SHould only be performed by a Qualified Service agent.

commercial electric Water HeaterS 

modelS dre-52/80/120 SerieS 100

& dve-52/80/120 SerieS 100

inStallation conSiderationS - pre Service 

cHecKS - Water Heater conStruction - 

operation & Service - troubleSHooting

500 Tennessee Waltz Parkway

Ashland City, TN 37015

http://waterheatertimer.org/How-to-wire-water-heater-thermostats.html

http://waterheatertimer.org/3-phase-water-heater.html

Summary of Contents for DURA-Power DRE-52

Page 1: ...R HEATERS MODELS DRE 52 80 120 SERIES 100 DVE 52 80 120 SERIES 100 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS WATER HEATER CONSTRUCTION OPERATION SERVICE TROUBLESHOOTING 500 Tennessee Waltz Parkwa...

Page 2: ......

Page 3: ...ormer Test 35 24 VAC Transformer Test 36 Immersion Temperature Probes 37 Temperature Sensor Resistance Test 38 Temperature Sensor DC Voltage Test 39 ECO Continuity Test 39 ECO Voltage Test 40 ELECTRON...

Page 4: ...le 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 familia...

Page 5: ...al 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...

Page 6: ...Virtually all commercial and most residential water supply systems are closed systems today Closed water systems will experience thermal expansion which if not controlled with a properly installed an...

Page 7: ...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 err...

Page 8: ...eplacing 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 5 Using an AC volt...

Page 9: ...ndirectly using electromagnetic contactors The control system energizes the electromagnetic contactor s 120 VAC coil causing the switch contacts of the contactor to close which in turn supplies power...

Page 10: ...WATER HEATER CONSTRUCTION Servicing should only be performed by a Qualified Service Agent 8 SURFACE MOUNT CONTROL MODELS Figure 1...

Page 11: ...Servicing should only be performed by a Qualified Service Agent 9 WATER HEATER CONSTRUCTION ELECTRONIC CONTROL MODELS Figure 2...

Page 12: ...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 fl...

Page 13: ...ms 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 e...

Page 14: ...ructions 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...

Page 15: ...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...

Page 16: ...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 shoul...

Page 17: ...res 3 Disconnect all red wires from terminal l 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 model...

Page 18: ...t all blue wires to terminal L 1 with black wires 3 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 mode...

Page 19: ...beep the fuse being tested is good and can be re installed 6 If the fuse being tested shows infinite resistance open circuit or the continuity test feature does not sound an audible beep the fuse bei...

Page 20: ...the dial on the lower portion of the control The adjustable range is 120 F 49 C to 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 do...

Page 21: ...t 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 7 With an AC volt meter check for voltage between the L4 and T2 term...

Page 22: ...eter 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...

Page 23: ...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 ava...

Page 24: ...ge 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...

Page 25: ...g 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 elem...

Page 26: ...range above the expected voltage 600 VAC or higher range initially 7 Check voltage between the two terminals on the heating element see the image below Record the voltage at all heating elements Volt...

Page 27: ...pages 8 and 9 and at the two wiring terminals on the ends of all heating elements 4 Disconnect both power wires from the terminals on the top of all heating elements to be tested 5 Using an ohm meter...

Page 28: ...er 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 wa...

Page 29: ...through the hole in one of the current sensors See the images below Element Sensor Functions Working with the Element Sensors the electronic control system provides valuable operational and diagnosti...

Page 30: ...rom 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 Sensor...

Page 31: ...he 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...

Page 32: ...re 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 wit...

Page 33: ...witch 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...

Page 34: ...ably less than 120 volts and or the contactors chatter open and close rapidly ensure the Control Circuit Transformer is wired correctly see page 34 6 If the measured voltage is approximately 120 volts...

Page 35: ...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 t...

Page 36: ...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...

Page 37: ...and the Power 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 proce...

Page 38: ...of this manual for further assistance if all the procedures above have been performed and 120 VAC is still not present at pins 1 3 of the J1 socket plug on the CCB 4 Check Secondary Winding Voltage U...

Page 39: ...op 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 cont...

Page 40: ...e 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...

Page 41: ...tside pins red wires of the J5 plug end as shown in the Checking ECO Switch Continuity image below If the ohm meter shows continuity closed circuit between the two outside pins red wires of the J5 plu...

Page 42: ...bly 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 5 Check for 120 V...

Page 43: ...y controls heating elements water temperature and other functions of the water heater Operational information is continuously reported to the user through text and icons on the liquid crystal display...

Page 44: ...y be performed by a Qualified Service Agent 42 CCB CENTRAL CONTROL BOARD All wiring connections and sockets will be identified in the following pages The Troubleshooting section of this manual will re...

Page 45: ...rom transformer 5 24 VAC out from transformer PIN DESCRIPTION 1 120 VAC hot 2 Earth Ground 3 120 VAC neutral TERMINAL DESCRIPTION N O Dry Contact Output Normally Open Terminal Alarm Output Relay N C D...

Page 46: ...Not Used J11 Port Communication Port UIM Display 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...

Page 47: ...r 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 control...

Page 48: ...ro volts or considerably less than 120 VAC Check the 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...

Page 49: ...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 U...

Page 50: ...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 C...

Page 51: ...lock 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 Th...

Page 52: ...lements 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 e...

Page 53: ...nd 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 notifi...

Page 54: ...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...

Page 55: ...utton underneath SELECT to enter the Temperatures Menu If Temperatures is not selected use the Up and Down buttons to select this menu item With the Operating Set Point selected highlight in black in...

Page 56: ...e 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...

Page 57: ...e time day has been initially set Note the time will not self adjust for Daylight Savings time Heater In Economy Mode Displays whether the control system is currently operating in Economy Mode or not...

Page 58: ...buttons to select highlight in black Setpoint Adjustment Press the Operational Button underneath CHANGE to activate the adjustment mode for the Setpoint Adjustment value Use the Up Down buttons to cha...

Page 59: ...w the text above the Operational Buttons on the display changes to ACCEPT CANCEL when the adjustment mode is activated and how the current setting is outlined rather than highlighted in black Press th...

Page 60: ...ed for Sun Normal Operation Between From the Economy Mode Setup menu Use the Up Down and CHANGE buttons to enter the Mon sub menu as described above Use the Up Down buttons to select highlight in blac...

Page 61: ...Enable Disable Closed Used for notification and or verification of the enable disable circuits open closed status There are two enable disable circuits available for external supervisory control s at...

Page 62: ...user setting that determines how long the UIM s LCD backlight remains illuminated after a key has been pressed Available settings are Always Off 10 30 or 60 seconds and Always On Contrast Adjustable...

Page 63: ...energized Total Heating Time Total accumulated time the control system has been in the heating mode IE any heating elements have been energized Bank Cycles Total accumulated count of heating cycles f...

Page 64: ...low 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 rese...

Page 65: ...erneath YES The display will show text confirming the factory default settings have been restored Press the Operational Button underneath BACK to exit the Restore Factory Defaults menu TEMPERATURES ME...

Page 66: ...Check all fuses see page 17 8 Check heating elements pages 20 26 9 Check Contactors on Electronic Control Models see pages 29 33 10 Check both enable disable circuits at the CCB s J7 socket on Electro...

Page 67: ...tion cable problems Important Service Reminder When performing any troubleshooting steps outlined in this service manual always consider the wiring and connectors between components Perform a close vi...

Page 68: ...blem 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...

Page 69: ...lems 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 3 models see pages 12 14 Check power circuit fus...

Page 70: ...rature 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...

Page 71: ...d 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 con...

Page 72: ...NOTES...

Page 73: ...NOTES...

Page 74: ...NOTES...

Page 75: ......

Page 76: ...2 500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com...

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