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Manual 238-51544-00A

REV 08/18

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

Residential:

RE1 & RE3 Upright Models.

RE1 & RE2 Lowboy Models.

RE1 Utility Models.

RE1 Wall Hung Models.

Light Duty:

LE Upright Models.

LE Utility Models.

LE Lowboy.

LE Wall Hung.

Residential & Light Duty

Commercial Electric Water Heaters

Summary of Contents for ElectriFLEX LD LE Series

Page 1: ...ons for Service To be performed ONLY by qualified service providers Models Covered by This Manual Residential RE1 RE3 Upright Models RE1 RE2 Lowboy Models RE1 Utility Models RE1 Wall Hung Models Light Duty LE Upright Models LE Utility Models LE Lowboy LE Wall Hung Residential Light Duty Commercial Electric Water Heaters ...

Page 2: ...e Double Element Simultaneous 3 Phase Thermostat Removal and Replacement Heating Element Removal and Replacement DipTube and Anode Inspection and Replacement Generic Parts List Page 2 This service manual is designed to aid service and maintenance professionals on the function proper diagnosis and repair of Bradford White residential electric and light duty commercial electric water heaters The tex...

Page 3: ...8 208 208 277 A B C Neutral RED BLACK RED 277 277 480 480 480 120 A B C Neutral RED BLACK RED 120 120 240 240 240 Amps for single phase units Example 4500W 240V 18 75A Watts Volts Amps for balanced 3 phase units Example 4500W 240V x 1 732 10 82A Watts Volts x 1 732 Watts Example 18 75A x 240V 4500W Ohms Example 240V 4500W 12 8 Ohms Volts Watts 2 Commonly Used Formulas Page 3 Amps x Volts 2 ...

Page 4: ... Operation Residential High Efficiency Upright RE2 Series Simultaneous Operation Residential Electric Lowboy RE2 Series Simultaneous Operation Light Duty Commercial Electric LE Series Non Simultaneous Operation Light Duty Commercial Electric LE Series Simultaneous Operation Maximum Wattage Element Upper Lower Voltage 3 000 1 500 1 500 120 10 000 5 000 5 000 208 11 000 5 500 5 500 240 12 000 6 000 ...

Page 5: ...he thermostat against the side of the tank Surface mounted thermostats respond to tank surface temperatures to sense a call for heat set point temperature settings and high limit ECO activation It is important that the entire back surface of the thermostat is in full contact or flush with the tank Improperly mounted thermostat will lead to improper water heater operation 1 Hex Screw in Flange Term...

Page 6: ...s Operation 3 phase Sequence of Operation Single Element Operation Line voltage is applied across terminals L1 L3 of the thermostat ECO is closed so there is voltage at terminal L4 and to one side of the element 1 2 When the thermostat is satisfied it opens at terminal T2 interrupting current flow through the element System is now in stand by mode waiting for the next call for heat 3 1 ECO Closed ...

Page 7: ...ents Tank is cold Therefore the thermostats are closed at terminals T2 2 calling for heat The circuit is complete through the upper thermostat only allowing current to flow through upper element 1 2 1 2 ECO Closed Thermostat closed at terminal T2 When the upper thermostat is satisfied it opens at terminal T2 interrupting current flow through the upper element Terminal T4 closes allowing voltage to...

Page 8: ...als L1 L3 of the upper thermostat ECO in both upper and lower thermostat is closed so there is voltage at terminal L4 of each thermostat and to one side of the upper and lower elements Tank is cold therefore both thermostats are closed at terminal T2 calling for heat This completes the circuit through the thermostats and allows current to flow through the elements 1 2 Circuit one Circuit two 1 ECO...

Page 9: ... flow through lower element When the lower thermostat is satisfied it opens at terminal T2 interrupting the current flow through the lower element The system is now in stand by mode waiting for the next call for heat 3 4 The lower thermostat element combination will generally cycle on and off more often than the upper In some cases such as a cold tank or in high demand periods the upper thermostat...

Page 10: ...2 calling for heat This completes the circuit through the thermostats and allows current to flow through the elements 1 2 Sequence of Operation Double Element Simultaneous Operation 3 Phase When either thermostat is satisfied it will open at terminal T2 interrupting current flow through the corresponding element As both thermostats satisfy the system will be in stand by mode waiting for the next c...

Page 11: ... When upper thermostat is satisfied it opens at terminal T2 interrupting current flow through upper element and closes at terminal T4 allowing voltage to pass to one side of the lower element This completes the circuit through the lower thermostat and off peak meter allowing current flow through lower element 3 When the lower thermostat is satisfied it opens at terminal T2 interrupting current flo...

Page 12: ...ment An element with a short circuit to ground will in most cases cause the circuit breaker in the service panel to open or shut off In some cases there may not be enough current draw for the circuit breaker to open This will allow the heating element to be in continuous operation resulting in over heated water limited only by the ECO or Energy Cut Out Repeated actuation of the ECO is usually the ...

Page 13: ...2 Check all wire connections 3 Check thermostat s replace as needed 4 Check terminal block of element for proper voltage and wattage rating 1 Position thermostat flush with tank surface 2 Check heating element s Replace as needed 3 Adjust thermostat s to desired setting 4 Check thermostat s replace as needed 5 Check ECO replace thermostat as needed 6 Replace with larger heater SERVICE PROCEDURE 3 ...

Page 14: ...ee Figure 3 A Rated Voltage IS present ECO is okay B Rated voltage NOT present proceed to step 2 2 Turn power OFF to water heater and firmly press ECO reset button on thermostat s Turn power ON and recheck voltage across terminals L1 L4 of upper thermostat see Figure 3 A Rated voltage IS present the ECO has previously opened indicating the water in the tank at some point did overheat check the fol...

Page 15: ... voltage exposure Be sure power is turned OFF to water heater prior to performing this procedure Testing For Heating Element Short Circuit To Ground Step 1 TURN OFF POWER TO WATER HEATER Step 2 Remove access cover s from front of water heater Remove insulation and plastic cover from thermostat Step 3 Disconnect wires from heating element s Step 4 Set multi meter to ohms setting Step 5 Touch one pr...

Page 16: ... to next step 5 Check across element terminals see Figure 7 A Rated voltage NOT present check wire connections from thermostat to element B Rated voltage IS present Repeat element testing see page 15 Figure 7 Water Temperature In Tank Is Above Thermostat Setting 1 This procedure assumes line voltage ECO and elements are in working order 2 Turn power ON to water heater 3 Set multi meter to Volts AC...

Page 17: ...ater 1 This procedure assumes line voltage ECO and elements are in working order 2 Turn power ON to water heater and set multi meter to Volts AC 3 Adjust temperature setting of upper thermostat to the highest setting Water temperature in tank must be below thermostat setting for this test 4 See Figure 8 above check voltage across terminals L4 and T2 of upper thermostat A Rated voltage IS present o...

Page 18: ...e sure thermostats are reset to their original temperature settings as found prior to thermostat testing Page 18 SERVICE PROCEDURE RE III Residential Thermostat Testing Water Temperature In Tank Is Above Thermostat Setting 1 This procedure assumes Line voltage ECO and elements are in working order 2 Adjust upper and lower thermostats to the lowest setting 3 Turn power ON to water heater and set mu...

Page 19: ...Water 1 This procedure assumes line voltage ECO and elements are in working order 2 Turn power ON to water heater and set multi meter to Volts AC 3 Adjust temperature setting of upper thermostat to the highest setting Water temperature in tank must be below thermostat setting for this test 4 See Figure 13 above check voltage across terminals L4 T2 of upper thermostat A Rated voltage IS present oka...

Page 20: ... injury during this procedure WARNING Be sure thermostats are reset to their original temperature settings as found prior to thermostat testing Page 20 SERVICE PROCEDURE RE III Residential Thermostat Testing Water Temperature In Tank Is Above Thermostat Setting 1 This procedure assumes line voltage ECO and elements are in working order 2 Adjust upper and lower thermostats to the lowest setting 3 T...

Page 21: ...testing see page 15 6 Check across terminals L1 L3 of lower thermostat see Figure 20 A Rated voltage NOT present check wire connections from upper to lower thermostats B Rated voltage IS present okay go to step 7 7 Check across terminals L4 and T2 of lower thermostat see Figure 21 A Rated voltage NOT present recheck ECO see page 14 If ECO is okay replace thermostat B Rated voltage IS present proce...

Page 22: ...eplace upper thermostat B Rated voltage NOT present upper thermostat is okay Go to step 6 below C Lower than rated voltage IS present recheck for grounded upper element see page 15 6 Check across terminals L4 and T2 of lower thermostat see Figure 23 A Rated voltage IS present replace lower thermostat B Rated voltage NOT present lower thermostat is okay C Lower than rated voltage IS present recheck...

Page 23: ...not interrupted line voltage 2 Turn power ON to water heater and set multi meter to Volts AC 3 Adjust temperature setting of upper lower thermostat to the highest setting Water temperature in tank must be below thermostat setting for this test 4 See Figure 24 above Check voltage across terminals L4 T2 of upper thermostat A Rated voltage IS present okay upper thermostat is calling for heat Go to st...

Page 24: ...rmostat Setting 1 This procedure assumes line voltage ECO and elements are in working order 2 Adjust upper and lower thermostats to the lowest setting 3 Turn power ON to water heater and set multi meter to Volts AC 4 Check across terminals L4 and T2 of upper thermostat see Figure 24 on page 23 A Rated voltage IS present replace upper thermostat B Rated voltage NOT present upper thermostat is okay ...

Page 25: ... testing see page 15 Figure 29 Figure 30 Tank Does Not Deliver Enough Hot Water 1 This procedure assumes line voltage ECO and elements are in working order 2 Turn power ON to water heater and set multi meter to Volts AC 3 Adjust temperature setting of upper lower thermostat to the highest setting Water temperature in tank must be below thermostat setting for this test 4 See Figure 29 above Check v...

Page 26: ...prior to thermostat testing Figure 34 Water Temperature In Tank Is Above Thermostat Setting 1 This procedure assumes line voltage ECO and elements are in working order 2 Adjust upper and lower thermostat to the lowest setting 3 Turn power ON to water heater and Set multi meter to Volts AC 4 See Figure 32 above Check across terminal L3 of upper thermostat T2 of lower thermostat A Rated voltage IS p...

Page 27: ...rminals see Figure 36 A Rated voltage NOT present check wire connections from thermostat to upper element B Rated voltage IS present repeat element testing see page 15 7 Check across terminal L3 of upper thermostat and T2 of lower thermostat see Figure 37 A Rated voltage NOT present check ECO see page 14 wire connections at upper lower thermostats If okay replace lower thermostat B Rated voltage I...

Page 28: ...ls L4 and T2 of upper thermostat see Figure 39 A Rated voltage IS present replace upper thermostat B Rated voltage NOT present upper thermostat is okay Go to step 6 below C Lower than rated voltage IS present recheck for grounded upper element see page 15 6 Check across terminal L3 of upper thermostat and T2 of lower thermostat see Figure 40 A Rated voltage IS present replace lower thermostat B Ra...

Page 29: ... Hot Water 1 This procedure assumes line voltage ECO and elements are in working order 2 Turn power ON to water heater and set multi meter to Volts AC 3 Adjust temperature setting of upper lower thermostat to the highest setting Water temperature in tank must be below thermostat setting for this test 4 See Figure 41 above Check voltage across terminals L4 T2 of upper thermostat A Rated voltage IS ...

Page 30: ...found prior to thermostat testing Water Temperature In Tank Is Above Thermostat Setting 1 This procedure assumes line voltage ECO and elements are in working order 2 Adjust upper and lower thermostat to the lowest setting 3 Turn power ON to water heater and Set multi meter to Volts AC 4 See Figure 44 above Check across terminal L1 of upper thermostat T2 of lower thermostat A Rated voltage IS prese...

Page 31: ...cross upper element terminals see Figure 48 A Rated voltage NOT present check wire connections from thermostat to upper element B Rated voltage IS present repeat element testing see page 15 7 Check across terminal L4 of lower thermostat and T2 of lower thermostat see Figure 49 A Rated voltage NOT present check ECO see page 14 wire connections at upper lower thermostats If okay replace lower thermo...

Page 32: ...Turn power ON to water heater 4 Set multi meter to Volts AC 5 Check across terminals L4 and T2 of upper thermostat see Figure 51 A Rated voltage IS present replace upper thermostat B Rated voltage NOT present upper thermostat is okay Go to step 6 below C Lower than rated voltage IS present recheck for grounded upper element see page 15 6 Check across terminals L4 T2 of lower thermostat see Figure ...

Page 33: ...new thermostat down into thermostat bracket until it snaps into place IMPORTANT Thermostat must sit completely flat or flush to tank surface An improperly installed thermostat will cause improper water heater operation 3 Refer to the wire diagram located on the inside of the access cover and reconnect wires to the thermostat Be sure wire connections are snug and corrosion free Do not over tighten ...

Page 34: ...l block see illustration below 2 Apply new element gasket to the new element Be sure gasket is seated flat against element flange without rolls or gaps see illustration below 3 Clean any debris from element fitting on tank Lubricate element threads as needed with thread lubricant 4 Thread new element clockwise into tank Tighten element using 1 deep well socket or appropriate wrench Do not over tig...

Page 35: ...R and turn power ON to water heater Diptube Inspection and Replacement WARNING Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury SERVICE PROCEDURE RE VII Dip Tube and Anode Inspection and Replacement Anode Inspection and Replacement Step 1 Turn power OFF to water heater Step 2 Turn off cold water...

Page 36: ...r 6 Heat Trap Insert Inlet 7 Cold Water Inlet Diptube 8 Upper Thermostat Protector 9 Upper Thermostat 10 Thermostat Mounting Bracket 11 Heating Element 12 Element Gasket 13 Access Cover 14 Lower Thermostat Protector 15 Lower Thermostat 59T 16 Brass Drain Valve 17 Thermostat w High Limit 59T 66T 18 ASSE Approved Mixing Device 19 Kit Heat Trap ...

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