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RESIDENTIAL GAS AND ELECTRIC WATER HEATER

SERVICE HANDBOOK

A.O. Smith Water Products Company

Training Department

2002

Ashland City, Tennessee

Residential Electric – continued

Three Phase – Unbalanced Circuit

Note:

Residential heaters may or may not offer the ability to wire elements for simultaneous

operation. If they are wired for non-simultaneous operation, amperage will be as if wired single
phase.

SIMULTANEOUS DUAL ELEMENTS

(both elements ‘on’ when entire tank is cold)

Element
Wattage

Upper/Lower

Full Load Current in Amperes

Connected to Three Phase Power

(Terminal L2/ Terminals L1 & L3

208V

240V

480V

3000/3000 25.0/14.4

21.7/12.5 10.8/6.3

4000/4000 33.3/19.2

28.9/16.7 14.4/8.3

4500/4500 37.5/21.6

32.5/18.8 16.2/9.4

5000/5000 N/A

36.1/20.8

18.0/10.4

6000/6000 N/A N/A

21.7/12.5

3 Supply Wires

6 Element Wires

3 Supply Wires

4 Element Wires

(See A-7 Circuit)

Содержание TC-049-R2

Страница 1: ...a thermocouple as their electrical source The second portion of this Handbook addresses service issues of Residential Electric Water Heaters having one or two heating elements and common wiring config...

Страница 2: ...TRIC HANDBOOK INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting A O Smith Residential Gas and Electric water heaters in the field No duplication or reproduction of...

Страница 3: ...et of marked drill bits electrical multimeter gas pressure gauge or monometer water pressure gauge thermometer tubing cutter if pilot tube is to be replaced hose to drain tank container to measure gal...

Страница 4: ...erature rise Thermal efficiency is approximately the amount of generated BTU British Thermal Units which enters the water A percentage of the total BTU passes out through the vent piping Temperature r...

Страница 5: ...olumn X 036091 PSI Inches of Water Column X 073483 Inches of Mercury Hg Centimeters Inches X 2 54 MM millimeters Inches X 25 4 Meters Inches X 0254 Doubling the diameter of a pipe will increase its fl...

Страница 6: ...Pressurize to Equal Supply Water Pressure Water Shut Off Valve Temperature and pressure relief valve tube piped to within 6 of drain Thermostat Recommending setting of 125 F Safety Pan Piped to Drain...

Страница 7: ...ank Type Water Heaters which are vented atmospherically and use a thermocouple as their electrical source Construction See also General section of this manual Control There is one control on this styl...

Страница 8: ...s gas The main flame burns until the tank reaches set temperature then the thermostat interrupts this main gas flow AFTER HAVING CONFIRMED THAT THE WATER HEATER HAS BEEN INSTALLED PER THE INSTALLATION...

Страница 9: ...ound the probe cools and heats As the rod expands it pushes against a lever actuated gas valve If the regulator is pushed sufficiently gas flow is interrupted to the main burner Adjusting the temperat...

Страница 10: ...is is approximately 120 degrees F the heater may shut off at 110 to 130 F The heater will consistently shut off at this same temperature For this same reason water temperature may drop 15 25 F around...

Страница 11: ...ucts Do not forget that your gas or oil furnace and gas clothes dryer also require a like amount of air When calculating air supply provisions also consider the presence of whole house exhaust fans or...

Страница 12: ...moke source to verify Manifold Gas Pressure Test Gas pressure checks are done with flowing gas Supply gas pressure checks are taken ahead of the gas control and as close to the heater as possible Pilo...

Страница 13: ...its own electrical generating system When two dissimilar metals are joined together and this joint is heated a small electrical current will be produced A thermocouple uses this science Thermocouple...

Страница 14: ...mocouple cools If then internal safety does not activate between 1 and 3 MV you will hear a click inside the valve replace the control valve internal safety does activate between 1 and 3 MV valve is w...

Страница 15: ...here are small black or red granules on the main burner or top of the heater or corroded jacket or vent piping is noted If then any of the above conditions exist raise the supply air temperature or in...

Страница 16: ...uildup Aluminum Hydroxide Condensation Discolored Water Smelly Water Chlorination Process Lack of hot water Thermal Expansion Temperature and Pressure Relief Valve Operation Parts Replacement The part...

Страница 17: ...RESSURE 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...

Страница 18: ...IAL ELECTRIC WATER HEATERS 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 infor...

Страница 19: ...U Recovery Rate KW X 3413 divided by Temp Rise X 8 25 Rise F KW X 3413 divided by GPH X 8 25 Supply electrical fusing or breakers should be sized at least 125 of expected heater amperage Water weighs...

Страница 20: ...ed enter the water Watt Density the density of the wattage output of the element compared to the surface area of the element i e High Watt Density Element will have the most wattage per square inch of...

Страница 21: ...dels Newer Models 1 Location Temperature Range F 2 59T Style 4100 A 6 A 7 X A 6 Upper Tank 110 170 2 59T Style 4000 A 6 A 7 C 2 X X Lower Tank 110 170 3 89T33 A 6 X Upper Tank 90 150 3 89T13 C 2 A 7 X...

Страница 22: ...that the water heater has been installed per the installation manual instructions C 2 Circuit Single element Single thermostat Single High Limit C 2 Circuit Prior to 1996 Power Enters High Limit 1 an...

Страница 23: ...le Element Single Thermostat Single High Limit Operation from a cold tank of water WIRING DIAGRAM Note If used on a normally two element heater controls will be located behind the upper service cover...

Страница 24: ...wer Interrupted to Upper Element Upper Thermostat 1 2 Open Switch Power to Lower Thermostat Upper Thermostat 1 4 Closed Lower Thermostat Contacts Open Through High Limit Lower Thermostat Contacts Clos...

Страница 25: ...ed operation Operation From cold tank of water A 6 Circuit Post 1995 Power Enters High Limit Through High Limit Upper Thermostat L1 T4 Contacts Open L1 T2 Contacts Closed Power to Upper Element Elemen...

Страница 26: ...ts 2 Thermostats 2 High Limits 4 wire Some electrical utilities give discounts if electricity is used during Off Peak times of the day This circuit allows use of an Off Peak meter which interrupts pow...

Страница 27: ...d Terminal 3 Of Upper Thermostat Upper High Limit 1 2 Is Closed Upper Thermostat 3 4 Is Open Upper Thermostat 1 2 Is Closed Upper Element Is On No Power To Lower High Limit Term 1 Top 1 3 Of Tank Is H...

Страница 28: ...nessee 27 Residential Electric continued A 7 Circuit 2 Elements 2 Thermostats 2 High Limits 4 Wire WIRING DIAGRAM A 7 Post 1995 Four wire circuit for non simultaneous element operation This circuit pe...

Страница 29: ...mostat 3 Upper High Limit 1 2 is Closed Upper Thermostat 3 4 is Open Upper Thermostat 1 2 is Closed Upper Element is On No Power to Lower High Limit Terminal 1 Top 1 3 of Tank is Heated Upper Thermost...

Страница 30: ...the A O Smith residential electric water heaters meet this code The American Society of Heating Refrigeration and Air Conditioning Engineer ASHRAE guidelines follow the National Appliance Energy Conse...

Страница 31: ...r non simultaneous operation amperage will be as if wired single phase SIMULTANEOUS DUAL ELEMENTS both elements on when entire tank is cold Element Wattage Upper Lower Full Load Current in Amperes Con...

Страница 32: ...res Power to the water heater is OFF Multimeter set to OHMS scale testing Black lead Common port Red lead in or OHMS port Dial indicator set to scale above expected indication Note Volts divided by am...

Страница 33: ...k circuit breaker fused disconnect check wire connections in heater junction box check position of heater ON OFF switch if applicable rated voltage is present continue to next step Test voltage betwee...

Страница 34: ...rated voltage is not present check wiring from control rated voltage is present repeat Ohms resistance test of element check for water leaks in piping or fixtures Complaint Water Too Hot Conditions T...

Страница 35: ...ut be certain that possible amperage will not exceed the multimeter s limit Complaint A grounded element is suspected whenever the water temperature becomes excessively hot and or the end user must pu...

Страница 36: ...nditions This test uses the multimeter s battery as the electrical supply Power to the water heater is OFF Multimeter set to OHMS scale testing Black lead Common port Red lead in or OHMS port Dial ind...

Страница 37: ...the meter to a scale below the voltage expected Complaint No hot water Test Conditions Tank is full of cold water Power is on to the heater Voltage Check Test between 1 and 3 or L1 and L3 If then cor...

Страница 38: ...nt Lack of Hot Water Conditions Upper thermostat satisfied Lower portion of tank still calling for heat Test between high limit 4 and thermostat 4 and L4 and T4 If then correct supply voltage is prese...

Страница 39: ...e water temperature becomes excessively hot and or the end user must push the high limit reset to reactivate the heater Amperage measures the flow of current through a wire Watts divided by volts Amps...

Страница 40: ...iring may be a See Pages 25 and 27 1 three wire 3 phase circuit 2 two wire single phase circuit or 3 connection to an off peak meter or time clock This third wiring system interrupts power to the lowe...

Страница 41: ...ocedure Power to the water heater is OFF Multimeter set to OHMS scale testing Black lead Common port Red lead in or OHMS port Dial indicator set to scale above expected indication Note Volts divided b...

Страница 42: ...eck power from the breaker fused disconnect the proper voltage is present check wiring in heater junction box continue to next step Test between upper high limit terminals 2 and 4 If then the proper v...

Страница 43: ...oltage is present continue to next step Test between lower high limit terminal 1 and 3 or L1 and L3 If then proper voltage is not present check wiring to upper thermostat and heater junction box check...

Страница 44: ...ower thermostat setting Test between lower high limit 4 and lower thermostat 2 or lower high limit L4 and lower thermostat T2 If then proper voltage is not present check jumper between lower high limi...

Страница 45: ...uspected whenever the water temperature becomes excessively hot and or the end user must push the high limit reset to reactivate the heater Amperage measures the flow of current through a wire Watts d...

Страница 46: ...e upper element and thermostat For this reason the lower element will normally accumulate lime faster and fail more often than the upper element Lower thermostats will fail more often than upper therm...

Страница 47: ...e are available on the A O Smith website www hotwater com This information is intended to supplement service and maintenance information found in the heater installation and operation manual Why water...

Страница 48: ...er temperature drop during usage Store water at a higher temperature install a mixing valve to reduce danger of scalding Contaminated Air Bleaches floor waxes detergents salt and many other household...

Страница 49: ...5 grains hardness 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 ou...

Страница 50: ...s 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...

Страница 51: ...rs Symptoms often 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 heater is relatively simp...

Страница 52: ...e 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...

Страница 53: ...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 ano...

Страница 54: ...vel of sulfur in the water b activated hydrogen from cathodic reactions within the tank c water with little or no dissolved oxygen d and temperatures below 138 F Items that can increase the potential...

Страница 55: ...el in the anode opening add one gallon of household chlorine bleach e g Clorox or Purex for every 25 gallons of tank capacity STEP 7 Reinstall anode rod s after inspecting and replacing as needed STEP...

Страница 56: ...you STEP 1 At 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 bu...

Страница 57: ...t 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 g...

Страница 58: ...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 effectiv...

Страница 59: ...e manufacturers 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 expan...

Страница 60: ...erature 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 pres...

Страница 61: ...7 1953 Website www hotwater com For every technical problem there is a solution A O Smith Water Products Company proudly introduces our service handbooks and product training CDs To place an order cal...

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