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State Water Heaters RESIDENTIAL ELECTRIC WATER HEATER, Service Handbook

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RESIDENTIAL ELECTRIC WATER HEATER 

SERVICE HANDBOOK 

-------------------------------------------------------------------------------------------------------------------------------------------- 
Technical Training Department 

15 of 36 

Residential Electric Svc Handbook                      

Ashland City, Tennessee ©2004 

 

                                        STC082      

 
 

C2 CIRCUIT TESTING  

SINGLE ELEMENT, SINGLE THERMOSTAT CIRCUIT 

 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

COMPLAINT: 

POSSIBLE CAUSE 

REMEDY 

Power off 

Check fuse or circuit 
breaker. 

High Limit (ECO)  

Press red (reset) button (p.10)

NO HOT WATER 

Element Burned Out 

Continuity Check (p. 8) or 
amperage check ( 

Thermostat set above desired 
temperature 

Adjust thermostat (p.12) Hot 
setting is about 120°F. 

Element grounded 

Check for grounded element  
See diagram (p.9 & 10) 

WATER TOO HOT 

Thermostat stuck in call for 
heat.   

Replace thermostat. 

WATER NOT HOT ENOUGH 

Thermostat set at too low a 
temperature 

See temperature adjustment 
(p, 12) 

Missing or broken dip tube 

Check dip tube and replace if 
necessary 

REDUCED HOT WATER 
DELIVERY 

Sediment accumulation in the 
tank. 

Clean the tank.  Drain the tank 
or use a chemical de-liming 
agent. 

 

 

 

Summary of Contents for RESIDENTIAL ELECTRIC WATER HEATER

Page 1: ......

Page 2: ...g text and illustrations will provide you with a step by step procedure to verify proper installation operation and troubleshooting procedures Additional quick reference data is included to assist you in servicing this product The information contained in this handbook is designed to answer commonly faced situations encountered in the operation of the Residential Electric product line and is not m...

Page 3: ...nts are allowed to operate during this test Incoming cold water mixes the remaining stored water below this 25 degree limitation Energy Factor is an indicator of the combined thermal efficiency and standby efficiency of a water heater The higher the energy factor the more efficient the water heater will be Recovery rate is the amount of water that is heated to a set temperature per hour An example...

Page 4: ...ter amperage Water weighs 8 25 pounds per gallon at 120 F 49 C of Hot water Mixed temp Cold divided by Hot temp Cold This formula gives the number of gallons drawn from the water heater for each gallon delivered at a shower head or faucet If the shower head flow rate gallons per minute is known the draw efficiency and gallon capacity of the water heater may be used to calculate the length of the s...

Page 5: ...HUT OFF VALVE PRE PRESSURIZED TO EQUAL SUPPLY WATER PRESSURE DRAIN LINE HOT WATER TO FIXTURES ELECTRICAL JUNCTION BOX ADJACENT CONDUIT ENTRANCE RATING PLATE WITH MODEL AND SERIAL NUMBER TEMPERATURE AND PRESSURE RELIEF VALVE OPENING MAY BE ON SIDE OR TOP OF HEATER DO NOT REUSE OLD VALVE ACCESS PANELS WATER TEMPERATURE ADJUSTMENT IS BEHIND THESE PANELS RECOMMENDED SETTING IS 125 SEE MANUAL AND LABEL...

Page 6: ...e added to improve water flow for larger applications This balanced piping system is preferred instead of a series piping system where one water heater feeds heated water to the cold inlet of the second water heater A series arrangement does not deliver hot water as quickly or in as great an amount as a parallel piping arrangement Expansion tanks may be required by local code Water expands by abou...

Page 7: ... Svc Handbook Ashland City Tennessee 2004 STC082 CONSTRUCTION typical This portion of this manual applies to the Operation and Servicing of Residential Electric Tank Type Water Heaters The illustrations are for two element models but the information also applies to single element models Model and Rating Plate ...

Page 8: ...ater was ordered with a simultaneous wiring system If they operate at the same time amperage draw doubles wire gauge size increases fuse size increases and little is gained in heat recovery Residential Electric continued Since the element s heating area is totally immersed in the tank thermal efficiency is assumed to be 100 All of the heat generated by the element enters the water Watt Density the...

Page 9: ...r set to scale above expected indication Note Volts divided by Amps OHMS Example 240V 18 75 Amps 12 8 OHMS Continuity Check Same as above but with meter set to continuity scale If the meter has an audible indicator listen for sound Test probe on each terminal of an element Resistance of Element in Ohms 7 5 Rated Wattage Rated Voltage 600 750 1000 1250 1500 2000 2500 120 23 2 18 6 13 9 11 1 9 28 6 ...

Page 10: ... 3 Set the meter to the Ohms Continuity scale Check the meter by placing the ends of the probes against each other If the meter has an audible continuity check you should hear a sound when this check is done 4 Place one probe on an element terminal screw and the other on the tank Be sure to test both element screw terminals 5 If the meter has an audible continuity check and you hear the sound on e...

Page 11: ...plaint No hot water Check for proper voltage across ECO terminals 2 4 If voltage is not detected press the red reset button to activate power and re check Watts divided by volts Amps Example 4500W 240V 18 75 Amps Conditions Power on Thermostat is calling for heat water in tank is cold TEST CLAMP METER AROUND EACH WIRE TO THE ELEMENT S IF THE WATER HEATER HAS TWO ELEMENTS THE TOP THERMOSTAT MUST BE...

Page 12: ...ers could be used to conduct this test but be certain that possible amperage will not exceed the multi meter s limit Complaint A grounded element is suspected whenever the water temperature becomes excessively hot and or the end user must push the high limit reset to reactivate the heater Watts divided by volts Amps Conditions Power on Thermostat is satisfied TEST CLAMP METER AROUND EACH WIRE TO T...

Page 13: ...ric Svc Handbook Ashland City Tennessee 2004 STC082 FIELD WIRING L1 to Ground 120 Volts L2 to Ground 0 Volts L1 or L2 to Ground 120 Volts L1 to L2 240 Volts L1 to L2 480 Volts L2 to L3 480 Volts L1 to L3 480 Volts L1 L2 or L3 to Ground 277 Volts L1 to L2 277 Volts L1 to Ground 277 Volts L2 to Ground 0 Volts ...

Page 14: ... must be manually reset when the tank cools by pressing the red reset button Note If the thermostat is not flat against the tank or the insulation has been removed from the access area the thermostat may not read the tank temperature properly and may cause the ECO high limit reset button to trip or the T P valve to open as a result of high water temperature in the tank TEMPERATURE ADJUSTMENT All t...

Page 15: ...IRCUIT WIRING AND SEQUENCE OF OPERATION C 2 Circuit Standard on most single element water heaters Operation from a cold tank of water Single Element Single Thermostat Single High Limit WH9 6 Thermostat WIRING DIAGRAM Note If used on a normally two element heater controls will be located behind the upper service cover and the element behind the lower service cover ...

Page 16: ... Burned Out Continuity Check p 8 or amperage check Thermostat set above desired temperature Adjust thermostat p 12 Hot setting is about 120 F Element grounded Check for grounded element See diagram p 9 10 WATER TOO HOT Thermostat stuck in call for heat Replace thermostat WATER NOT HOT ENOUGH Thermostat set at too low a temperature See temperature adjustment p 12 Missing or broken dip tube Check di...

Page 17: ...Handbook Ashland City Tennessee 2004 STC082 A 6 CIRCUIT INTERLOCK OR NON SIMULTANEOUS COMPONENTS WIRING DIAGRAM A 6 Circuit 2 Elements 2 Thermostats 1 High Limit A 6 Circuit Standard on dual element water heaters non simultaneous interlocked operation UPPER THERMOSTAT WH10 7 LOWER THERMOSTAT WH9 2 A 6 WIRING CIRCUIT ...

Page 18: ...e tank is forced to the bottom by the dip tube The lower element is usually energized first on successive hot water draws as cold water enters the tank In most water heater applications the lower element and the lower thermostat do over 90 of the water heating job The upper element is only energized again when the entire tank is cold and the upper thermostat calls for heat If the upper element bur...

Page 19: ... Ashland City Tennessee 2004 STC082 A 9 OFF PEAK TIME CLOCK CIRCUIT 2 Elements 2 Thermostats 2 High Limits 3 Wire Three wire circuit for non simultaneous element operation and single phase power This circuit permits off peak meter usage or connection to a 3 phase supply circuit UPPER THERMOSTAT WH10 7 LOWER THERMOSTAT WH9 6 ...

Page 20: ...E HANDBOOK Technical Training Department 19 of 36 Residential Electric Svc Handbook Ashland City Tennessee 2004 STC082 Cold tank of water Single Electrical Service Single Phase SEQUENCE OF OPERATION OFF PEAK TIME CLOCK CIRCUIT COLD TANK START ...

Page 21: ... 4 6000 6000 N A N A 21 7 12 5 Formula L2 Amps wattage x 1 73 volts Wattage of total wattage UNBALANCED 3 PHASE LOAD Three phase power delivers power with 3 legs to the water heater The water heater must be specially wired to accept three phase power Since there are only two elements with two wire terminals each in the water heater power from a three leg power supply cannot be divided evenly One l...

Page 22: ...the red wire on upper thermostat terminal 4 in the diagram will be moved to upper ECO terminal 4 Warning Attempting an unauthorized field conversion will double the amperage draw and may overload the wiring to the water heater resulting in a fire hazard Warning Maximum amperage draw if wired for simultaneous operation is 48amps in accordance with the National Electrical Code Internal wiring may fu...

Page 23: ...least 15 F below the upper thermostat setting Power on Upper thermostat calling for heat Multi meter set to the proper AC voltage scale Test between upper high limit terminals 1 and 3 If then the proper voltage is not present disconnect Check the power from the breaker or fused disconnect the proper voltage is present Check the wiring in the water heater junction box and continue to the next step ...

Page 24: ...s present Continue to next step Test between lower high limit 2 and upper thermostat 4 If then proper voltage is not present Push lower high limit reset Check time clock or off peak meter pushing reset restored voltage Conduct lower element checks pushing reset did not restore voltage Replace lower high limit proper voltage is present Test between the terminals of the lower element If then proper ...

Page 25: ...put may create a safety hazard by overloading the water heater wiring or supply wiring or fusing Installing an element with a lower wattage or voltage rating will reduce performance Normally a residential electric water heater with two elements will have only one element operate at a time If the upper element or thermostat fails the customer will be out of hot water If the lower element or thermos...

Page 26: ...e bulletins and more are available on the website www statewaterheaters com This information is intended to supplement service and maintenance information found in the heater installation and operation manual Why water heaters leak information 26 Index of Technical Bulletins Water Hammer 27 Mineral Buildup 28 Aluminum Hydroxide 29 Discolored Water 30 Smelly Water 31 Chlorination Procedure 32 Not E...

Page 27: ...ge gouges appear in its surface WATER CONDITIONS WHAT WHY PREVENTION Hard Water Electric Water Heaters See above explanation Lime calcium forms on the electric elements Elements become excessively hot and may split Split elements often leak to the outside of the heater Inspect and clean elements as necessary Add a water softener Install elements resistant to failure due to Lime mineral build up Wa...

Page 28: ...re time is directly related to the intensity of the surge pressure EFFECTS The damage from water hammer can manifest itself in a number of ways The most common are Expanded Tank Shell This can be demonstrated by measuring the circumference at various locations along the shell Pressures in excess of the maximum design working pressure can cause permanent deformation of the shell Collapsed Flue Tube...

Page 29: ...en include a popping of water trapped under lime deposits or the sizzling of water trapped next to elements boiling it to steam THE FIX Treatment of a limed up water heater is relatively simple Since CaCO3 is a base the easiest way to dissolve it so it can be flushed from the heater is with an acid The most commonly used is phosphoric acid at a food grade level Two common treatments marketed by th...

Page 30: ... identifiable by weld bead on plug If the tank is new with lime build up to any degree 1 Turn off the heater 2 Drain the heater 3 Remove the anode 4 Add UN LIME to the tank 20 40 gallon models use 3 gallons of UN LIME 41 65 gallon models use 5 gallons of UN LIME 66 100 gallon models use 7 gallons of UN LIME On electric models be certain the lower element is immersed in solution 5 Heat the UN LIME ...

Page 31: ...ons even more favorable Soluble iron in the water provides food for the bacteria Rusty discolored water is the end result of the bacteria feeding process Water heaters and storage tanks usually require new anode rods as presence of iron bacteria contributes to premature anode failure The requirements for the bacteria to thrive are Elevated level of iron and manganese in the water Water with little...

Page 32: ...e tank c water with little or no dissolved oxygen d and temperatures below 138 F Items that can increase the potential for this bacteria are a water softeners b well water c and long periods of no water movement Other factors that may contribute to smelly water Chlorides of Magnesium and Calcium leave a bitter taste Chloride of Sodium produces a salty taste Sulfates 50 ppm give a medicinal taste C...

Page 33: ...r Purex for every 25 gallons of tank capacity STEP 7 Reinstall anode rod s after inspecting and replacing as needed STEP 8 Open cold water supply valve and refill the system Then draw the water to every hot water fixture until the smell of chlorine is detected Operate dish and clothes washers until a noticeable amount of the chlorine is detected as well All hot water lines must receive treatment S...

Page 34: ...the faucet nearest to the water heater time in seconds how long it takes to fill a 1 gallon bucket flow rate Gallon per minute gpm 60 seconds seconds to fill a 1 gallon bucket If the bucket fills in 10 sec 6 gpm 12 sec 5 gpm 15 sec 4 gpm 20 sec 3 gpm 24 sec 2 5 gpm STEP 2 Turn both upper and lower thermostat dials on the water heater to 130 F STEP 3 Run about 15 gallons of hot water from the neare...

Page 35: ...ves They serve a useful purpose Do not remove them The use of pressure reducing valves PRV is another cause PRVs are designed to conserve water and prolong fixture life Many PRVs also act as very effective check valves Again do not remove them Water softeners in the system may also act as a back flow prevention device TEST Follow these easy steps to diagnose thermal expansion Turn the heater therm...

Page 36: ...ollow the manufacturer s instructions for installing the expansion tank Run the thermal expansion check again The pressure should increase only slightly then hold steady throughout the recovery cycle The expanded water is flowing back from the heater and into the pressurized storage bladder of the expansion tank Air pressure will force this water out of the expansion tank into the supply once usag...

Page 37: ... the temperature is below its reset temperature The pressure rating on the relief valve should be the same or less than the certified working pressure of the tank generally 150 psi and be below the lowest pressure rating of any system components It is not acceptable to install a relief valve that exceeds the maximum working pressure of the water heater Once the pressure in the tank reaches the val...

Page 38: ...ers Telephone 1 800 821 2017 Fax number 800 644 9306 or visit our web site at www statewaterheaters com State water heater visit our web site or telephone the Technical Information Department at 1 800 365 0024 This Service Handbook was prepared by the Technical Training Department Ashland City TN For additional information or assistance in servicing your ...

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