State Water Heaters ***120kW I Instruction Manual Download Page 1

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Instruction Manual

PRINTED 0612

196675-006

PLACE thEsE InstruCtIons AdjACEnt to hEAtEr And notIfy ownEr to kEEP for futurE rEfErEnCE.

CoMMErCIAL ELECtrIC wAtEr hEAtErs

Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.

InstALLAtIon - oPErAtIon - sErVICE

MAIntEnAnCE - LIMItEd wArrAnty

Low Lead Content

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Summary of Contents for ***120kW I

Page 1: ...t to heater and notify owner to keep for future reference COMMERCIAL ELECTRIC WATER HEATERS Thank you for buying this energy efficient water heater We appreciate your confidence in our products INSTALLATION OPERATION SERVICE MAINTENANCE LIMITED WARRANTY Low Lead Content OPTIONAL ...

Page 2: ... 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 DANGERindicatesanimminentlyhazardous situation which if not avoided will result in de...

Page 3: ...ly may also cause erratic control system operation on ELECTRONIC CONTROL models 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 th...

Page 4: ...nt 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 back cover of this manual 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 Carefu...

Page 5: ...7 246 221 201 184 170 158 Figured at 1 KW 3413 Btu 4 1 gallons at 100 F temperature rise To determine recovery rate per minute divide recovery rate per hour by 60 Table 2 Understanding Your Models Model Designator Sample 8254 I or S FEA X Y B Letter Designator 82 Gallon 310 31 Liters Capacity of unit 54 kW input of unit I Immersion Type Thermostats S Surface Mounted Thermostats F Unit is fused E 3...

Page 6: ...ational Sanitation Foundation NSF 5 requirements LISTED 22U1 No OF WATTS PHASE VOLTS AC ELEMENTS EACH RATED MEASURED WATTS COMMERCIAL STORAGE TANK WATER HEATER MODEL NUMBER SERIAL NUMBER ITEM ID PART NUMBER WATTS TOTAL CAPACITY US GAL STANDBY LOSS MAX WORKING PRESSURE Low Lead Content Low Lead Content ...

Page 7: ...7 FEATURES AND COMPONENTS ELECTRONIC CONTROL MODELS Figure 2 ...

Page 8: ...8 FEATURES AND COMPONENTS SURFACE MOUNT CONTROL MODELS Figure 3 ...

Page 9: ... tank or connections will not result in damage to the area adjacent to the heater or to lower floors of the structure Close to the point of major hot water usage and the power supply Hot water piping and branch circuit wiring should be as short as possible Insulate hot and cold water piping where heat loss and condensation may be a problem Heater construction permits installation maintenance and s...

Page 10: ...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 wa...

Page 11: ... 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 will not cause any bodily injury or prop...

Page 12: ... 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 Allowable Ampacities of Insulated Conductors Not more than three conductors in raceway cable or earth directly buried based on ambient temperature of 30 C 86...

Page 13: ... element current sensors for monitoring the power circuits Refer to the control circuit label on the water heater for details The CCB is powered by a small 120V 24V transformer The control circuit operates on 120V supplied by a larger 100VAtransformer Standard equipment includes control circuit fusing using two 3 amp class G fuses with 600 volt rating Do not substitute fuses of a different rating ...

Page 14: ...14 CCB CENTRAL CONTROL BOARD CONTROL CIRCUIT DIAGRAM ELECTRONIC CONTROL MODELS Figure 6 WIRING DIAGRAMS ...

Page 15: ...s the heater circuits and includes wiring diagrams All heater circuits are designed for 60 50 hertz alternating current The water heater circuit wiring is 12 AWG AWM or TEW type rated 600 volts 105 C Fusing consists of three 30 amp fuses for each contactor Fusing is an optional feature for Canadian models THREE ELEMENTS SINGLE AND THREE PHASE SIX ELEMENTS SINGLE AND THREE PHASE ...

Page 16: ...s to terminal L1 with black wires 3 Reconnect all yellow wires to terminal L2 with red wires 4 Connect incoming power to terminals L1 and L2 CONVERSION TO THREE PHASE When heater is shipped for connection to a single phase electrical service it may be connected to a three phase electrical service of the same voltage by 1 Disconnect blue wires from terminal L1 2 Disconnect yellow wires from termina...

Page 17: ...n page 8 The following describes the heater circuits and includes wiring diagrams All heater circuits are designed for 60 50 hertz alternating current The water heater circuit wiring is 12 AWG AWM or TEW type rated 600 volts 105 C Fusing consists of two 30 amp fuses for each element Fusing is an optional feature for Canadian models DIAGRAM 3 ...

Page 18: ...nnect all red wires to terminal L2 with yellow wires 5 Connect incoming power to terminals L1 and L2 CONVERSION TO THREE PHASE When heater is shipped for connection to a single phase electrical service it may be connected to a three phase electrical service of the same voltage by 1 Disconnect blue wires from terminal L1 2 Disconnect red wires from terminal L2 3 Connect all blue wires to terminal L...

Page 19: ... Models only 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 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 Dr...

Page 20: ... 94 C When the ECO switch contacts open activate the electronic control system locks out and displays a Fault message Voltage to the contactor coils and heating 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 su...

Page 21: ...adjustable 1 to 20 differential set points for each bank First bank on is the last bank off 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 actin...

Page 22: ...e control system has initiated heating operation 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 ...

Page 23: ...splayed in this menu Economy Mode Setup 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 features on board SPDT single pole double throw relay contacts for building EMS Energy Management System notification of operational conditions such as Fault ...

Page 24: ...ng 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 Temperature Settings The Operating Set Point and the Differential Settings are adjusted in the Temperatures Menu The following ...

Page 25: ...e 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 Alarm Output Setup Menu 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 is used for building EMS Energy ...

Page 26: ...ational Buttons on the display changes as you navigate through the various menus and screens 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 Setup menu Use the Up Down buttons to select highlight in black Setpoint Adjustment Press the Operational Button underneath CHANGE to ...

Page 27: ...nges to ACCEPT CANCEL when the adjustment mode is activated and how the current 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 the previous setting Use the Up Down and the CHANGE ACCEPT Operational Buttons to individual...

Page 28: ...e Up Down and CHANGE buttons to enter the Mon sub menu 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 ...

Page 29: ...en 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 ...

Page 30: ...ssages in chronological 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...

Page 31: ... Restore Factory Defaults menu 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 f...

Page 32: ...rom water system Check for any leaks and immediately correct any if found 7 Restart the water heater as directed in this manual See the Repair Parts Illustration for anode rod location FLUSHING the Water Heater 1 Turn off the electrical supply to the water heater at the breaker or disconnect switch 2 Ensure the cold water inlet valve is open 3 Open a nearby hot water faucet and let the water run u...

Page 33: ... not remove these types of scale which are occasionally encountered Call the toll free phone number on the back cover of this Instruction Manual to purchase UN LIME and heating element gaskets Other scale removal 1 Flush cleaned ends of elements with water when deliming or cleaning is completed 2 Remove sediment and scale from the tank bottom through the access provided by the element openings or ...

Page 34: ...s are normal however the tank bottom and elements should be cleaned See the Maintenance section of this manual 2 Some of the electrical components of the water heater make sounds which are normal Contactors will click or snap as the heater starts and stops Transformers and contacts often hum Water leakage is suspected Refer to Leakage Checkpoint on the following page 1 Check to see if the heater d...

Page 35: ...nters 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 Water on the side of the tank may be condensation due to the panel or insulation not being in place Water leaks at the elements may be due to 1 Defective elements which leak at terminals or through flange Replace element 2 Lo...

Page 36: ... any component in the system 3 Service valves are shown for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 1 UNIT LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICE...

Page 37: ...e Control should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 1 UNIT WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPE...

Page 38: ...ure Control should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 1 UNIT WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE T...

Page 39: ...n the system 3 Service valves are shown for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 2 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LO...

Page 40: ...d to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW ...

Page 41: ...red to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 2 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER F...

Page 42: ...alves are shown for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 3 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES...

Page 43: ...p between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 3 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNI...

Page 44: ...pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 3 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE ...

Page 45: ...vicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 4 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIRE...

Page 46: ...ter s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 4 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS S...

Page 47: ...eater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 4 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHO...

Page 48: ...2 Inlet and outlet size 1 1 2 THREE HEATERS Tank Capacity Gallons Part Number H W D A 52 9003430205 66 1 4 91 3 4 27 1 4 13 1 4 80 9003430205 70 1 2 95 1 4 31 1 4 9 3 4 120 9003430205 73 1 4 99 1 2 35 3 4 5 1 2 Inlet and outlet size 2 1 2 FOUR HEATERS Tank Capacity Gallons Part Number H W D A 52 9003431205 66 1 4 126 3 4 27 1 4 13 1 4 80 9003431205 70 1 2 130 1 4 31 1 4 9 3 4 120 9003431205 73 1 4...

Page 49: ...5721215 10 Nipple T P valve extension 9005717215 9005717215 9005717215 11A T P Valve 3 elements 9005715205 9005715205 9005715205 11B T P 6 or 9 elements 9005923205 9005923205 9005923205 12A Fuse Power Circuit not 54KW at 208V or not 575V 9005904215 9005904215 9005904215 12B Fuse Power Circuit for 54KW at 208V model 9006864015 9006864015 9006864015 12C Fuse Power Circuit for 575V models 9005893215 ...

Page 50: ...9205 5B Fuse Block Power Circuit for 54KW at 208V model 9005079205 9005079205 9005079205 5C Fuse Block Power Circuit for 575V models 9005007205 9005007205 9005007205 6 Element Gasket BOX OF 50 9000308005 9000308005 9000308005 7 Elements max 54KW 9 elements SEE CHART 8 Bracket T Stat 9003898215 9003898215 9003898215 9 Personal Protector 9003899015 9003899015 9003899015 10 Thermostat 9004533215 9004...

Page 51: ...51 NOTES ...

Page 52: ...52 ...

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