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WATER HEATER CONSTRUCTION

Servicing should only be performed by a Qualified Service Agent

5 - 20 GALLON MODELS

Figure 1

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Страница 1: ...d Service Agent COMMERCIAL ELECTRIC WATER HEATERS MODELS DSE 5 THRU DSE 120 SERIES 100 and 102 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS WATER HEATER CONSTRUCTION OPERATION SERVICE TROUBLESHOOTIN...

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Страница 3: ...ircuit Transformer Test 41 24 VAC Transformer Test 42 Immersion Temperature Probe 43 Temperature Sensor Resistance Test 44 Temperature Sensor DC Voltage Test 45 ECO Continuity Test 45 ECO Voltage Test...

Страница 4: ...epresentative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that...

Страница 5: ...pies can be obtained from the manufacturers web site or by calling the technical support phone number shown on the water heater labeling and the back cover of this Service Manual TOOLS REQUIRED Instru...

Страница 6: ...be a closed system 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 pr...

Страница 7: ...n this manual are equipped with electronic controls that may experience erratic operation if the water heater is not properly grounded These water heaters are also equipped with a LWCO low water cut o...

Страница 8: ...size for the circuit See the Instruction Manual that came with the water heater for fuse size requirements See page 15 in this manual 5 Using an AC volt meter measure the branch circuit power supply v...

Страница 9: ...r to close which in turn supplies power to the heating elements see pages 34 38 Heating Element Configurations Depending on tank size and how they were ordered from the factory the water heaters cover...

Страница 10: ...WATER HEATER CONSTRUCTION Servicing should only be performed by a Qualified Service Agent 8 5 20 GALLON MODELS Figure 1...

Страница 11: ...Servicing should only be performed by a Qualified Service Agent 9 WATER HEATER CONSTRUCTION 30 120 GALLON MODELS Figure 2...

Страница 12: ...mine 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 flow of electric...

Страница 13: ...ions further explain ohms law V Volts electrical pressure A Amps electrical flow current O Ohms resistance to electrical flow current W Watts rate or amount of electricity used Ohms Law applied to sin...

Страница 14: ...or less are convertible as single or three phase and include jumpers to make the conversion 208 240 VAC models factory configured as single phase with over 24KW can be converted to three phase but jum...

Страница 15: ...of the 4 poles of the contactor and ground On 208 240 volt power supplies each reading to ground should be approximately 120 volts On 480 volt power supplies each reading to ground should be approxima...

Страница 16: ...wer supplies each reading to ground will be approximately 120 volts Some 208 volt models will have a stinger leg with one of the three readings to ground measuring 208 volts 208 volt stinger legs shou...

Страница 17: ...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 being tested...

Страница 18: ...inside See Principles of Electricity on page 10 There are two types of heating elements installed in the water heaters covered in this manual one type has six wire leads and the other has three wire l...

Страница 19: ...r only Each heating element has 3 loops each loop is a resistive circuit see Heating Element Construction on page 16 Six wire heating elements have a wire lead connected to both ends of the three loop...

Страница 20: ...section of this manual pages 34 38 Heating Element Flange End View Two ends of loop 1 Two ends of loop 2 Two ends of loop 3 Connection Diagram Wiring Diagram 3 Pole Contactor Three loops of one heati...

Страница 21: ...pply See the Contactors section of this manual pages 34 38 Heating Element Flange End View Two ends of loop 1 Two ends of loop 2 Two ends of loop 3 Connection Diagram Wiring Diagram 4 Pole Contactor T...

Страница 22: ...connected to a three phase power supply See the Contactors section of this manual pages 34 38 Heating Element Flange End View Two ends of loop 1 Two ends of loop 2 Two ends of loop 3 Connection Diagra...

Страница 23: ...onnected to a three phase power supply See the Contactors section of this manual pages 34 38 Heating Element Flange End View Two ends of loop 1 Two ends of loop 2 Two ends of loop 3 Connection Diagram...

Страница 24: ...rs connected to a three phase power supply See the Contactors section of this manual pages 34 38 Heating Element Flange End View Two ends of loop 1 Two ends of loop 2 Two ends of loop 3 Connection Dia...

Страница 25: ...element voltage and KW ratings other than what is shown in this table Always check the water heater s rating label to see how the water heater was configured at the factory Service Note Models at 54...

Страница 26: ...ng element First determine the actual rated wattage and voltage of the element being tested see page 23 Then follow the Heating Element Amperage test procedure on page 25 to measure amperage through e...

Страница 27: ...amp draw of the same loop more than once See the connection wiring diagram on pages 18 21 that corresponds to the power supply phase and type of contactor s installed on the water heater being service...

Страница 28: ...h a 3 pole or 4 pole contactor s see page 35 3 Determine if the water heater is equipped with six or three wire heating elements see page 17 4 Locate the heating element connection wiring diagram that...

Страница 29: ...is procedure at each contactor s for other heating elements being tested D Three Phase Power 4 Pole Contactor Six Wire Element see diagrams page 21 1 Measure and record voltage to the 1 heating elemen...

Страница 30: ...ire heating element First determine the actual rated wattage and voltage of the element being tested see page 23 Then follow the Measuring Resistance test procedure on page 29 to measure the resistanc...

Страница 31: ...ich heating element loops see pages 16 17 connect to which terminals on the contactor s Use wire markers see Tools Required page 3 to label contactor terminals and or the wiring leads of the heating e...

Страница 32: ...for continuity ohms resistance between all six wire ends from each loop on the heating element and the ground wire connection to the water heater six continuity readings See pages 16 17 and the illus...

Страница 33: ...he new element is properly wired 6 Install the new heating element and a new element gasket Install tighten four heating element flange bolts Replacement elements and gaskets can be obtained from loca...

Страница 34: ...trol system provides valuable operational and diagnostic information to aid in servicing The electronic control system displays animated Status Icons on the UIM s User Interface Module LCD display to...

Страница 35: ...J14 J15 and J16 sockets are for heating elements 1 5 respectively depending on how many elements are installed in the water heater See the images below Service Note The Element Sensors cannot be servi...

Страница 36: ...e spring tension forces or holds the switch contacts in their normally open state The contactor s switch contacts are closed by an electromagnetic coil located inside the base of the contactor When a...

Страница 37: ...ng element connection wiring diagrams for these standard configurations on pages 18 22 Also see the Heating Element Construction and Heating Element Wiring information on pages 16 17 The illustrations...

Страница 38: ...e the contactor to malfunction 5 Physically test the mechanical spring action of the contactor by depressing the contactor mechanism If the action is not smooth and or sticks replace the contactor 6 P...

Страница 39: ...volts and or the contactors chatter open and close rapidly ensure the Control Circuit Transformer is wired correctly see pages 39 40 If the measured voltage is approximately 120 volts the contactor sh...

Страница 40: ...CCB s J4 OUT 1 wiring terminal See the images below On water heaters equipped with more heating elements also check between the ground connection and the CCB J4 OUT 2 J4 OUT 3 J17 OUT 4 and J17 OUT 5...

Страница 41: ...imary winding of this transformer must be configured to match the power supply voltage to the water heater Incorrect wiring can cause output voltage from the transformer s secondary winding to be too...

Страница 42: ...instructions below show how to properly configure the input power wiring to the transformers primary winding Service Note The 380 Volt H2 tap is used for international applications Ensure you do not c...

Страница 43: ...correct and connections are tight and making good contact Check the wiring between the Control Circuit Fuses and the Power Distribution Block or contactor on single element models ensure wiring is co...

Страница 44: ...mber on the back cover 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 Secon...

Страница 45: ...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 control system Temperature Sensor The temperature sen...

Страница 46: ...he 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 inf...

Страница 47: ...Checking ECO Switch Continuity image below If the ohm meter shows continuity closed circuit between the two outside pins red wires of the J5 plug end the ECO switch has reset properly If the control s...

Страница 48: ...considerably 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...

Страница 49: ...tem will declare a LWCO Fault condition and lock out see page 79 Voltage to the contactor coils pages 37 38 and heating elements is terminated to prevent further heating operation Inspection and Clean...

Страница 50: ...current interrupts the electrical flow of the corrosion process which in turn reduces corrosion The control system adjusts and monitors current flow thorough the anode If there is an operational prob...

Страница 51: ...dule and a Button Pad Overlay The control system constantly monitors and safely controls heating elements water temperature and other functions of the water heater Information is continuously reported...

Страница 52: ...OPERATION SERVICE Servicing should only be performed by a Qualified Service Agent 50 CCB Central Control Board...

Страница 53: ...nsformer 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 Dry Cont...

Страница 54: ...14 Socket Heating Element 3 Sensors J15 Socket Heating Element 4 Sensors J16 Socket Heating Element 5 Sensors J17 Wiring Terminals Contactor Coils PIN DESCRIPTION 1 Enable Disable circuit 1 2 Enable D...

Страница 55: ...jumper 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 co...

Страница 56: ...is zero 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 m...

Страница 57: ...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 UIM or Button Pad Over...

Страница 58: ...n models equipped with more than one heating element First On First Off cycling of heating elements the first heating element energized at the beginning of a heating cycle is the first element de ener...

Страница 59: ...UIM User Interface Module is located on the front cabinet of the water heater All operational information and user settings are displayed and accessed using the UIM The UIM includes five snap acting...

Страница 60: ...clock has been initially set Day and Time are adjusted in the Economy Mode Setup menu see page 66 The current Operating Mode either Normal Mode or Economy Mode is displayed beneath the day and time Me...

Страница 61: ...urrent flow from Heating element icon for a water heater equipped with 3 heating elements Each circle represents one element Filled circles represent elements the control system has energized and IS s...

Страница 62: ...demand periods Alarm Output Setup The control system s CCB Central Control Board see page 50 features on board SPDT single pole double throw relay contacts for building EMS Energy Management System no...

Страница 63: ...Operating Sequence On a water heater equipped with 3 heating elements with an Operating Set Point of 120 F and all Differential settings at 2 F the On Off sequencing of heating elements would be as f...

Страница 64: ...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...

Страница 65: ...n the CCB J7 socket to enable heating operation when external controls are not in use Service Note If a supervisory control s is used to enable disable heating operation install field wiring between t...

Страница 66: ...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 Daily Operating Mode...

Страница 67: ...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...

Страница 68: ...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...

Страница 69: ...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...

Страница 70: ...d for notification or verification of the enable disable circuits open closed status There are two enable disable circuits available for external supervisory control s at the J7 socket on the CCB see...

Страница 71: ...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...

Страница 72: ...ized Total Heating Time Total accumulated time the control system has been in the heating mode IE any heating element s has been energized Element Cycles Total accumulated count of heating cycles for...

Страница 73: ...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...

Страница 74: ...al Button underneath 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 TE...

Страница 75: ...ages 12 14 6 Check hot water supply piping for leaks or restrictions lime scale valve partially closed 7 Check all fuses see page 15 8 Check heating elements pages 23 30 9 Check Contactors on see page...

Страница 76: ...r When performing any troubleshooting steps outlined in this service manual always consider the wiring and connectors between components Perform a close visual inspection of all wiring and connectors...

Страница 77: ...as 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 see pa...

Страница 78: ...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 fuses see page 15 Check heating...

Страница 79: ...erature sensor inside the Immersion Temperature Probe see pages 43 45 Replace the Immersion Temper ature Probe if measured resistance is above 56 000 ohms Call the toll free technical support phone nu...

Страница 80: ...ation and socket identification on pages 50 52 Replace damaged plug connectors wiring harness as necessary Check for pinched or broken wiring between the Immersion Temperature Probe and the J5 plug so...

Страница 81: ...n page 5 in this man ual Ensure the CCB is properly grounded see the Checking Power And Ground To The CCB tests on page 54 Ensure the ground wire leading from pin 2 of the J2 plug on the CCB page 50 i...

Страница 82: ...ter heater and Grounding instructions on page 5 in this man ual Ensure the CCB is properly grounded see the Checking Power And Ground To The CCB tests on page 54 Ensure the ground wire leading from pi...

Страница 83: ......

Страница 84: ...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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