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AHRI 105, Installation And Operating Instruction

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AHRI 105 Installation And Operating Instruction Download Page 35

35

condition

cause

ReMedy

no hot water.

 
 
 
 
 
 

Dry-fired element.

Replace with new element.

Main power supply is “OFF”.

Turn “ON” main power supply.

Burnt fuse.

Replace with new fuse.

Circuit breaker has tripped.

Reset circuit breaker.

High limit reset control has tripped.

Reset high limit control by pushing 
the reset button.

Circuit breaker is defective.

Replace with new circuit breaker.

Defective thermostat.

Replace with new thermostat.

Defective element.

Replace with new element.

not enough hot water.
 
 
 
 
 
 
 
 
 
 
 

Water heater is undersized.

Install size of water heater that meets demand.

High hot water demand.

Increase the temperature of the thermostat.

Very cold water supply.

Increase the temperature of the thermostat.

Wrong piping connections.

Correct piping.

Sediment or lime accumulation at bottom

of water heater.

Drain water heater. Check to see if water treatment

is necessary.

Hot water plumbing system leaks.

Check hot water plumbing system for leaks and repair.

Thermostat adjusted too low.

Increase the temperature of the thermostat.

Defective thermostat.

Replace with new thermostat.

Defective element.

Replace with new element. 

Long runs or exposed piping.

Insulate piping.

Hot water piping on outside wall.

Insulate piping.

boiling hot water.
 
 
 
 

Thermostat temperature set too high.

Lower the temperature on the thermostat.

Thermostat not in contact with water heater. Position properly. Be sure insulation is not 

interfering with thermostat.

Element attacked by CO

2

.

Replace with new element.

Defective thermostat.

Replace with new thermostat.

continuous operation.
 
 
 
 
 

Water heater is undersized.

Install size of water heater that meets demand.

Element wattage too small.

See 

Conversion Guide.

Thermostat not in contact with water heater. Position properly. Be sure insulation is not 

interfering with thermostat.

Thermostat temperature set too low.

Increase the temperature of the thermostat.

Defective thermostat.

Replace with new thermostat.

Defective high limit reset control.

Replace with new high limit reset control.

element failure.
 
 
 
 

Wiring connections are wrong.

see figures 11 to 24 for correct wiring.

Wiring connections are loose.

Locate, clean carefully, reconnect properly.

Lightning/Power surge.

Inspect/replace fuse, element, and thermostat.

High voltage.

Check with electrical utility and correct.

Short circuit.

Locate short circuit and repair.

thermostat failure.
 
 
 
 

No power.

Inspect fuse/circuit breaker, replace/reset.

Loose wiring connection.

Locate, clean carefully, reconnect properly.

Lightning/Power surge.

Inspect/replace fuse, element, and thermostat.

Low/High voltage.

Check with electrical utility and correct.

Short circuit.

Locate short circuit and repair.

blown fuse/circuit breaker.
 
 
 
 
 

Wiring connections are wrong.

see figures 11 to 24 for correct wiring.

Wiring connections are loose.

Locate, clean carefully, reconnect properly.

Lightning/Power surge.

Inspect/replace fuse, element, and thermostat.

High voltage.

Check with electrical utility and correct.

Short circuit.

Locate short circuit and repair.

Power supply wiring undersized.

see table 1 and consult electrical code for correct wire size.

fuse burns instantly.

Short-circuit.

Locate short circuit and repair.

fuse burns often.
 

Fuse contacts oxidized or fuse not screwed 

in tight enough.

Clean contacts and tighten fuse.

Power supply wiring is undersized.

see table 1 and consult electrical code for correct wire size.

TROUBLESHOOTING GUIDE

condition

cause

ReMedy

smoking wiring.
 
 

Lightning/Power surge.

Inspect/replace fuse, element, and thermostat.

Low/High voltage.

Check with electrical utility and correct.

Power supply wiring undersized.

see table 1 and consult electrical code for correct wire size.

service wires charred or hot.
 
 
 
 
 

Wiring connections are wrong.

see figures 11 to 24 for correct wiring.

Water heater not properly grounded.

Properly ground the water heater.

Lightning/Power surge.

Inspect/replace fuse, element, and thermostat.

High voltage.

Check with electrical utility and correct.

Short circuit.

Locate short circuit and repair.

Power supply wiring undersized.

see table 1 and consult electrical code for correct wire size.

drain valve leaks.
 

Drain valve is open.

Close the drain valve.

Defective drain valve.

Replace with new drain valve.

water drips from the 
relief valve.

Excessive water pressure.

Install a pressure-reducing valve.

Thermal expansion in a closed water

system.

Install a suitable expansion tank on the cold water 

supply line.

Improperly seated relief valve.

Check relief valve works properly and replace, if neces-
sary.

Defective thermostat.

Replace with new thermostat.

Defective relief valve.

Replace with new relief valve.

water on the floor/drain pan.
 
 

Water discharge from the relief valve.

see 

Pressure build-up in a water system.

Element leaks.

Replace with new element and gasket.

Water heater leaks.

Replace with new water heater.

wet insulation.
 
 

Leaking plumbing connections.

Locate leak and repair.

Leaking around heating element.

Tighten, clean, and smooth face of tank flange and replace 
element gasket.

Water discharge from the relief valve.

see 

Pressure build-up in a water system.

singing element.

Build up of mineral deposits on element.

Clean element, replace with new element if necessary.

singing thermostat.
 

Thermostat not flush with tank.

Install thermostat properly.

Wiring connections are loose.

Locate, clean carefully, reconnect properly.

traces of rust in the hot water. Anode rods has been eaten away.

Replace new anode rods.

Rusty water.

Water corrosion.

Replace with new water heater.

Rotten egg smell.

High sulfate or mineral content in water.

Change magnesium anodes to an aluminum anodes and 

bleach water heater.

tank bulged.
 
 

No relief valve installed.

Install proper relief valve.

Excessive water pressure.

Install a pressure-reducing valve.

Thermal expansion in a closed water 

system.

Install a suitable expansion tank on the cold water supply

line.

Summary of Contents for 105

Page 1: ...he water heater rating plate DO NOT CONNECT the power supply wiring to anywhere other than the power distribution block in elec trical junction box of the water heater DO NOT TURN ON the power to the water heater unless it is completely filled with water DO NOT DRAIN the water heater unless the power to the water heater has been turned OFF DO NOT STORE or use gasoline or other flammable vapours an...

Page 2: ...rts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING Serious injury or death can occur if you do not follow the instructions immediately Serious injury or death can occur if you do not follow the instructions Before proceeding with the installation instructions 1 Inspect the water heater and ...

Page 3: ... are twelve 12 inches 30 5 cm from the top and thirty 30 inches 76 2 cm in front of the unit Sooner or later all water heaters leak The manufacturer based on national building codes has given the necessary advice to prevent damage to the building Under no cir cumstances is the manufacturer to be held liable for any water damage in connection with this water heater Should this water heater be insta...

Page 4: ... Canada and ANSI Z21 22 in the United States is supplied with the water heater and MUST BE installed by the installer The relief valve should never be plugged or removed from the opening marked for it on the water heater If this relief valve should need to be replaced use only a new tempera ture and pressure relief valve Never install an old or existing relief valve as it may be damaged or inadequ...

Page 5: ...ied service technician must be called to have the system checked and the problem corrected Filling the Water Heater DANGER WARNING CAUTION AVERTISSEMENT ATTENTION NEVER operate the water heater unless it is completely filled with water Failure to follow this instruction can result in premature failure of the water heater and its component parts that is not covered by the warranty Check that all of...

Page 6: ...net d arrêt manuel Figure 6 All Bronze Circulating Pump Thermometer Check Valve Tank Temperature Control ONE TEMPERATURE ONE WATER HEATER STORAGE TANK FORCED CIRCULATION WITHOUT BUILDING RECIRCULATION HOT WATER OUTLET COLD WATER INLET Manual shut Off Valve Temperature and Pressure Relief Valve Overflue Tube Flow Regulating Plug Cock Thermal Expansion Tank Union Union Union Union Union Pompe circul...

Page 7: ...Valve Tank Temperature control HOT WATER OUTLET Thermometer Thermal Expansion Tank COLD WATER SUPPLY Thermometer TWO HEATERS WITH STORAGE TANK WITH OR WITHOUT BUILDING CIRCULATION Temperature and Pressure Relief Valve Overflue Tube Manual shut off Valve Union NOTE Must Be Identical Size Water Heaters Union Union Union Union Union Union RÉSERVOIR D ENTREPOSAGE CHAUFFE EAU 2 CHAUFFE EAU 1 Pompe circ...

Page 8: ...ON STORAGE TANK HEATER 1 HEATER 2 HEATER 3 HOT WATER OUTLET COLD WATER SUPPLY Temperature and Pressure Relief Valve Overflue Tube Union Manual shut Off Valve NOTE Must Be Identical Size Water Heaters Union Union Union Union Union Union Union Union Robinet régulateur de débit Réservoir d expansion thermique Thermomètre Clapet de retenue Pompe circulatrice en bronze Contrôle de température de la cuv...

Page 9: ...ltage on the rating plate of the water heater 480V 277V 240V 208V 0V PRIMARY X1 X2 0V 120V Figure 10B Figure 10A POWER DISTRIBUTION BLOCK GROUND HIGH LIMIT SWITCH THERMOSTAT THERMOSTAT ELEMENT ELEMENT RED RED RED BLACK BLACK BLACK BLACK Figure 11 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial electric water heater models 105 108 112 with 2 elements PRIMARY 600V 240V PRIMAIRE...

Page 10: ...OSTAT ELEMENT THERMOSTAT ELEMENT HIGH LIMIT SWITCH Ancien Nom Commer_Wiring_05 Nouveau Nom DF Comm 50 80 120G 4Ele RED RED RED RED RED RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK Figure 12 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial electric water heater models 105 108 112 with 4 elements ...

Page 11: ...SFORMER FUSES 30 AMP CLASS G CANADIAN MODELS OPTIONAL CONTROL TRANSFORMER 480V 0V 120V 277V 240V 208V 0V FUSES 3 AMP CLASS G RED BLACK BLACK BLUE BLACK BLACK BLACK RED RED YELLOW BLUE BLUE BLACK BLACK RED RED BLACK RED BLACK BLACK RED RED BLACK RED RED BLACK BLACK RED BLUE RED RED BLACK BLACK INSTALLATION INSTRUCTIONS Figure 13 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial ...

Page 12: ...12 INSTALLATION INSTRUCTIONS Figure 14 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial electric water heater models 105 108 with 6 elements ...

Page 13: ... BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK BLACK BLACK RED RED YELLOW RED RED YELLOW RED RED YELLOW BLUE BLACK BLACK BLUE BLACK BLACK BLUE RED RED RED BLACK BLACK BLACK RED RED RED BLACK BLACK BLACK RED RED RED BLACK BLACK BLACK RED RED RED BLACK BLACK BLACK RED RED RED BLACK BLACK BLACK RED RED RED BLACK BLACK BLACK INSTALLATION INSTRUCTIONS Figure 15 208 Volts 240 Volts 2...

Page 14: ...V 277V 240V 208V 0V 0V CONTROL TRANSFORMER POWER DISTRIBUTION BLOCK 1 PHASE RED RED YELLOW BLACK RED BLACK BLACK BLUE RED RED BLACK BLACK RED BLACK RED RED BLACK BLACK RED BLACK BLUE BLUE BLACK BLACK BLACK RED BLACK RED INSTALLATION INSTRUCTIONS Figure 16 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial electric water heater models 112 with 3 elements ...

Page 15: ...STRIBUTION BLOCK 1 PHASE BLACK BLACK RED RED BLACK BLACK BLACK BLACK RED RED RED YELLOW BLACK BLACK BLUE RED RED YELLOW BLACK BLACK BLUE RED RED RED BLACK BLACK RED BLACK RED RED BLACK BLACK BLACK RED BLACK RED RED BLACK BLACK RED BLACK RED RED BLACK BLACK RED BLACK BLUE BLUE BLACK RED RED Figure 17 INSTALLATION INSTRUCTIONS 208 Volts 240 Volts 277 Volts 480 Volts Wiring diagram for commercial ele...

Page 16: ...0G 9Ele RED BLACK BLACK BLACK BLACK BLACK BLACK RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE BLUE RED YELLOW YELLOW RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED YELLOW RED RED BLACK YELLOW YELLOW RED RED RED BLACK Figure 18 ...

Page 17: ...TION HIGH LIMIT SWITCH THERMOSTAT TO CONTACTOR TO CONTACTOR FROM CURRENT TRANSFORMER POWER DISTRIBUTION BLOCK BLACK RED BLUE RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLUE Ancien Nom Commer_50 80_102 Nouveau Nom DF Comm 50 80 600V 3Ele RED BLACK BLACK RED BLUE 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 105 108 with 3 elements Canadian model only ...

Page 18: ...ROUND ELEMENTS ELEMENTS CONTACTORS BLACK RED RED RED RED BLUE BLACK BLACK BLACK BLACK RED RED RED RED RED RED RED BLACK RED BLACK RED Ancien Nom Commer_50 80_101 Nouveau Nom DF Comm 50 80 600V 6Ele THERMOSTAT BLUE 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 105 108 with 6 elements Canadian model only ...

Page 19: ...LEMENTS ELEMENTS ELEMENTS CONTACTORS POWER DISTRIBUTION BLOCK RED BLACK RED RED RED RED BLACK RED BLACK RED RED RED RED BLUE BLUE BLUE BLACK BLACK BLACK BLACK RED RED RED BLACK RED RED RED RED RED RED BLACK 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 105 108 with 9 elements Canadian model only ...

Page 20: ...SES 3 AMP CLASS G CONTROL TRANSFORMER THERMOSTAT ELEMENTS CONTACTOR POWER DISTRIBUTION BLOCK RED RED RED RED BLUE RED RED RED BLACK BLACK BLACK BLUE BLACK BLACK 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 112 with 3 elements Canadian model only ...

Page 21: ...GROUND THERMOSTAT THERMOSTAT CONTACTORS ELEMENTS ELEMENTS POWER DISTRIBUTION BLOCK BLACK RED BLACK BLACK BLACK BLUE RED RED RED BLACK RED BLACK BLUE RED RED RED RED RED RED BLUE RED BLACK RED 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 112 with 6 elements Canadian model only ...

Page 22: ...EMENTS ELEMENTS ELEMENTS CONTACTORS POWER DISTRIBUTION BLOCK RED BLACK 600V 240V RED RED RED RED BLACK RED BLACK BLACK BLACK BLACK BLUE BLUE BLUE BLUE RED RED RED RED BLACK BLACK BLACK YELLOW RED RED RED RED RED RED RED RED 600 Volts 3 Phases Wiring diagram for commercial electric water heater models 112 with 9 elements Canadian model only ...

Page 23: ...ing power to terminal block L1 and L2 Surface mount thermostat Single phase to three 3 phases See Figure 26 Figure 26 BLACK RED BLUE YELLOW Single Phase L1 L2 Power distribution block 1 Disconnect all blue from terminal L1 on the distribution block 2 Disconnect all yellow wires from terminal L2 3 Reconnect all blue and yellow wires to terminal L3 4 Connect incoming power to terminal block L1 L2 an...

Page 24: ...f elements in the water heater to be converted 4th digit of model number on the rating plate see page 23 2 Find the Desired total input kW in Table 2 that matches the number of elements 3 Then move across the Table 2 on the same row to the Desired Voltage column The appropriate Conversion Kit part number will be the one where the Desired total input row intersects the Desired Voltage column DANGER...

Page 25: ...TISSEMENT ATTENTION DO NOT turn ON the power to this water heater if It is not completely filled with water The power supply voltage does not match the voltage listed on the rating plate Gasoline or other flammable vapours and liquids have been stored in the vicinity of the water heater Failure to follow these instructions can result in property dam age personal injury or death Do not open the ele...

Page 26: ...he red reset button on the high limit switch 4 Replace the insulation and close the element access panel before turning ON the power to the water heater Water Temperature Regulation The higher the setting the greater the risk of scalding Hot water can cause third degree burns in less than one 1 second at 160 F 71 C in five 5 seconds at 140 F 60 C and in thirty 30 seconds at 130 F 54 C In household...

Page 27: ... 11 to 24 7 Set the thermostat to the desired temperature see Water Temperature Regulation page 26 8 Replace the insulation and close the element access panel before turning ON the power to the water heater Temperature and Pressure Relief Valve Manually operate the temperature and pressure relief valve at least once a year standing clear of the outlet to avoid being burned Lift and release the ope...

Page 28: ...ing it back in operation Make sure that the water heater is completely full of water and that the cold water supply manual shut off valve is open before turning ON the power to the water heater Getting Service for your Water Heater If you are having problems with your water heater follow these three easy steps 1 Read the Troubleshooting Guide contained in this manual see Page 34 It lists the most ...

Page 29: ...t All 10 99000061 A Jacket door All 11 25004111 A Clean out cover All 12 GA1N1110 Clean out gasket All 13 DV3Z0070 Brass drain valve All 14 16001402 A Inlet nipple 1 X 4 All 15 56000018 A Lower thermostat All 16 SV0N3020 T P relief valve All 17 16000015 A Relief nipple X 3 All Illustration shows Model 108 with 4 elements Part Watts Volts 9AG30 80 3 000W 208V 9AG40 80 4 000W 9AG45 80 4 500W 9AG50 8...

Page 30: ...n thermostat high limit All except 1053 1083 56000022 A High limit 1053 1083 14 GA1N1110 Clean out gasket All 15 25004111 A Clean out cover All 16 99000061 A Jacket door All 17 18G0001 Thermostat bracket All 18 DV3Z0070 Brass drain valve All 19 56000018 A Lower thermostat 1053 1083 20 16001402 A Inlet nipple 1 X 4 All 21 SV0N3020 T P relief valve All 22 16000015 A Relief nipple X 3 All 23 44000004...

Page 31: ...All 10 25004111 A Clean out cover All 11 GA1N1110 Clean out gasket All 12 99000061 A Jacket door All 13 DV3Z0070 Brass drain valve All 14 16001402 A Inlet nipple 1 X 4 All 15 56000018 A Lower thermostat All except 1123 16 56000018 A Middle thermostat 1129 only 17 18G0001 Thermostat bracket All 18 56000016 A Combination thermostat high limit 1126 1129 top 1123 bottom 19 S E E ELE M ENT TABLE B E LO...

Page 32: ...0003 A Fuses 3 amps Class G All 6 32000006 A Terminal block three phases All 7 CM586000 Contactors HCC 3XU02CY All 8 99001204 A Twist lock flange with screws All 9 18G0002 Square flange element gasket All 10 S E E ELE M ENT TABLE B E LO W 11 56000016 A Combination thermostat high limit All except 1053 1083 56000022 A High limit 1053 1083 12 GA1N1110 Clean out gasket All 13 25004111 A Clean out cov...

Page 33: ...All 11 DV3Z0070 Brass drain valve All 12 16001402 A Inlet nipple 1 X 4 All 13 56000018 A Lower thermostat All except 1123 14 56000018 A Middle thermostat 1129 only 15 18G0001 Thermostat bracket All 16 56000016 A Combination thermostat high limit 1126 1129 top 1123 bottom 17 S E E ELE M ENT TABLE B E LO W 18 18G0002 Square flange element gasket All 19 990012040A Twist Lock flange with screws All 20...

Page 34: ... undersized Install size of water heater that meets demand Element wattage too small See Conversion Guide Thermostat not in contact with water heater Position properly Be sure insulation is not interfering with thermostat Thermostat temperature set too low Increase the temperature of the thermostat Defective thermostat Replace with new thermostat Defective high limit reset control Replace with new...

Page 35: ...ective thermostat Replace with new thermostat Defective relief valve Replace with new relief valve Water on the floor drain pan Water discharge from the relief valve See Pressure build up in a water system Element leaks Replace with new element and gasket Water heater leaks Replace with new water heater Wet insulation Leaking plumbing connections Locate leak and repair Leaking around heating eleme...

Page 36: ... the tank at all times All anodes must be checked at least once every two years replaced if necessary 8 To any damages or failure caused by having affixed to the heater any non factory made or factory approved replacement part s such as elements controls relief valves etc 9 To any damage caused by not having the water heater installed adjacent to a free flowing drain in the event of water leakage ...

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