American Water Heater COMMERCIAL ELECTRIC WATER HEATERS manual

1 Service Handbook PRINTED IN THE U . S .A 1008 3 1 50 16-000 SERVICING SHOULD ONL Y BE PERFORMED BY A QUALIFIED SER VICE AGENT . COMMERCIAL ELECTRIC W A TER HEA TERS MODEL S STCE3-52/80/1 19 & ITCE3-52/80/1 19 INST ALLA TION CONSIDERA TIONS - PRE SERVICE CHECKS - W A TER HEA TER CONSTRUCTION - OPERA TION & SERVICE - TROUBLESHOOTING T echni[...]

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COMMERCIAL ELECTRIC W ATER HEATER SERVICE MANUAL T ABLE OF CONTENT S INTRODUCTION ............. .................................................. ........ 2 Qualifications ...... ................. .............. .............. .............. ..... 2 Service W arning ............. .............. ................ .............. ........ 2 T ools Req[...]

INTRODUCTION Servicing sh ould only be performe d by a Qualified Service Agent 2 INTRODUCTION This Service Manual is designed to be an ai d in servicing and troubleshooting the commercial electric water heater models listed on the cover .T he instructions, illustrations and procedures contained in th is manual are used to veri fy proper operation a[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 3 INTRODUCTION INSTRUCTION MANUAL Have a copy of the Instructi on Manual that came with the water heat er on hand for the correct model water heat er you are working wi th before servicing. Installation information gi ven in this Service Manual IS NOT a complete inst allation instruc[...]

INSTALLATION CONSIDERATIONS Servicing sh ould only be performe d by a Qualified Service Agent 4 INST ALLATION CONSIDERATIONS Installation inform ation given in th is Service Manual IS NOT a complete installation instruction. Installation inform ation covered in this Service Manual has a limited focus as it applies to servicing. This Service Manual [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 5 INSTALLATION CONSIDERATIONS ELECTRICAL REQUIREMENT S Grounding Review the electrical ground requirements given in the Inst ruction Manual th at came with the water heater and ensure the water heater has been properly grounded. The water heater must be grounded in accordance with th[...]

PRE SERVICE CHECKS Servicing sh ould only be performe d by a Qualified Service Agent 6 PRE SERVICE CHECKS WIRING CONNECTIONS With the power supply to t he water heater turned off ensur e the wiring co nnections are properly tightened to all com ponents including: high volt age term inal blocks, fuse blocks, contactors, transforme rs and heating ele[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 7 W ATER HEATER CONSTRUCTION W ATER HEATER CONSTRUCTION There are two types of commerci al electric water heaters cover ed in this manual . See Figure 1 on page 8 and Fi gure 2 on page 9. SURFACE MOUNT CONTROL MODELS The first type of water heat er covered in this manual is equipped [...]

W ATER HEATER CONSTRUCTION Servicing sh ould only be performe d by a Qualified Service Agent 8 SURFACE MOUNT CONTROL MODELS Figure 1[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 9 W ATER HEATER CONSTRUCTION ELECTRONIC CONTROL MODELS Figure 2[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 10 OPERATION & SERVICE This section of the manual will cover the princi ples of electricity , single a nd three phase power , fuses, surface mount thermostat/ECO combination controls, heating element construction & operation, heating element sensors, c[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 11 OPERATION & SERVICE Ohms Law A law that explains the relationship between voltage, current and resist ance. The law states that the electric curr ent flowing through a co nductor is equal to t he voltage divided by the resistance. The following equat ions further explain ohms [...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 12 SINGLE AND THREE PHASE POWER The water heaters covered in this manual can be field converted for a single or three phase power supply - see pages 15 and 16. Thes e water heaters can be factory ordered for standard North American power s upplies; 277/208/240[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 13 OPERATION & SERVICE Checking Single Phase (1Ø) Power A single phase power su pply consists of two wires connec ted to the L1 and L2 terminals of the Power Distribution Block, t he L3 terminal is not used. On a single phase (1Ø) 277 volt power supply one of the two wi res is [...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 14 Checking Three Phase (3Ø) Power A three phase power supply consis ts of three wires connected to the L1, L2 and L3 terminals of the Power Distribution Bl ock. All three wires are “hot” with voltage present. V olt age Between T erminals: Set the volt me[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 15 OPERATION & SERVICE PHASE CONVERSIONS - SURF ACE MOUNT CONTROL MODELS Internal wiring connections bet ween the Power Distribution Bl ock and the heating elements are different on Surface Mount Control (see Figure 1 p age 8) and Electronic Control (see Figure 2 page 9) model wa[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 16 PHASE CONVERSIONS - ELEC TRONIC CONTROL MODELS Internal wiring connections bet ween the Power Distribution Bl ock and the heating elements is different on Surface Mount Control (see Figure 1 p age 8) and Electronic Control (see Figure 2 page 9) model water [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 17 OPERATION & SERVICE FUSES The water heaters covered in this manual have power circui t fuses to protect the heating element circuits. Electronic C ontrol models will have two additional fuses to protect the primary winding of the 120 V olt Control Circuit T ransformer . S ee F[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 18 SURFACE MOUNT THERMOST AT S The Surface Mount Control Model water heaters covered in this manual have “separate” thermostat/ECO (energy cut out) combination c ontrols mounted to the surface of the storage tank directly above the heating element s they c[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 19 OPERATION & SERVICE Thermost at & ECO T est 1 Secure power to the water heater at the main breaker or disconnect switch. 2 Ensure tank temper ature is less than 100°F/38°C - dum p water to lo wer tank temperatur e if necessary . 3 Press the red reset button firmly on all[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 20 HEATING ELEMENT S This section of the m anual provides informatio n on how to determine the actual voltage and wattage rating of a heating element along with t ables showing heating element configurations, heating element amperage and heating el ement resis[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 21 OPERATION & SERVICE Heating Element Ratings Heating elements are labeled with their vo lt age and KW rating - see image below . The element shown here is a 6000 watt (6 KW) 240 volt element. Heating Element Configurations The table below shows how ma ny heating element s are i[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 22 Heating Element Amperage This table shows the approximat e amp draw for the various heating el ement s used. First determine the actual rated wattage and volt age of the element being tested - see Heating Element Ratings on page 21. Then follow t he Heating[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 23 OPERATION & SERVICE Heating Element Amperage T est This test should be consi dered as a first diagnostic proc edure for the common service complaints of no hot water or not enough hot water . The heating element amperage test shown on this page is the be st procedure to quickl[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 24 Heating Element V olt age T est This test is typically perform ed after an amperage test (see p age 23) has determined one or more heating elements is not drawing corr ect amperage. 1 Secure power to the water heater at th e main breaker or disconnect switc[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 25 OPERATION & SERVICE Heating Element Resist ance & Ground T ests This is a two part test. In t he first part of this test the actual resist ance (ohms) of each heating element is measur ed. In the second part of this test each heating el ement is tested for any continuity t[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 26 Heating Element Ground T est 1 Secure power to the water heater at th e main breaker or disconnect switch . 2 V erify with an AC volt meter that there is not any voltage present at the Power Distribution Blo ck (see Figures 1 and 2 on page s 8 and 9) and at[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 27 OPERATION & SERVICE ELEMENT SENSORS Electronic Control Models covered in this manual monitor all h eating elements using Element Sensors. Each Elem ent Sensor monitors 3 heat ing elements. There will be one Element Sensor for each B ank of heating elements. See Figure 2 on p a[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 28 Element Sensor Operation When current (amperag e) flows through a wire in an elec trical circuit a magnetic field is developed that radiates out from the wire. The individual current sensors detect this magnetic field. When current fl ows in a wire routed t[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 29 OPERATION & SERVICE CONT ACTORS This section of the manual provides information on how contactors used on Electronic Control Models are constructed, how they work and how to test contactor operation - see Figure 2 on page 9 for location of the cont actors on these models. Surf[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 30 Cont actor Configurations This illustration shows how contactors are configured and how they provide power to the heating elements on Electronic C ontrol Model water heaters, Th is is a redundant cont actor configuration - two contactors must close their co[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 31 OPERATION & SERVICE Cont actor Inspection A thorough visual inspecti on of the contactors used on Electronic Control Models should be performed as part of any regular maintenance program and whenever the water heater is being serviced. Refer to the listed S t eps and images be[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 32 Cont actor Coil V olt age - At Cont actor This test procedure will measure contactor coil vo lt age at the contactor . 1 Ensure tank temper ature is less than 100°F/38°C - dump wa ter to lo wer tank temperatur e if necessary . 2 Adjust the tem perature se[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 33 OPERATION & SERVICE Cont actor Coil V oltage - At CCB This test procedure will measure contactor coil vo lt age where it originat es at the J4 wiring terminals on the CCB. See page 42 for the CCB’ s J4 wiring terminal location. 1 Ensure tank temper ature is less than 100°F/[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 34 TR A N S F O R M E R S This section of the manual prov ides information on how to te st and ensure the multiple tap 120 V AC Control Circuit T ransform er is wired properly on Electr onic Control Models. This section will also provide test procedures for th[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 35 OPERATION & SERVICE 120 V AC Control Circuit T ransformer T est 1 Ensure the main breaker or disco nnect switch is turned on. 2 V erify with an AC volt meter that proper voltag e is present at the Power Distribution Block (see Figure 2 on page 9 an d pages 12 - 14). 3 Check Pr[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 36 24 V AC T ransformer T est 1 Ensure the main breaker or disco nnect switch is turned on. 2 V erify with an AC volt meter that proper voltag e is present at the Power Distribution Block (see Figure 2 on page 9 an d pages 12-14). 3 Check Primary W inding V ol[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 37 OPERATION & SERVICE IMMERSION T E MP ERATURE PROBE This section of t he manual provides information on how te st the Immersion T emperature Probe on Electronic Control Models - see Figure 2 on page 9 for location. The Imme rsion T emperature Probe contains the ECO (energy cut [...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 38 T emperature Sensor Resist ance T est 1 Secure power to the water heater at th e main breaker or disconnect switch . 2 Unplug the J5 plug from the CCB circuit board - see p age 42 for location. 3 Using an ohm meter: set the ohm meter rang e to a scale above[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 39 OPERATION & SERVICE T emperature Sensor DC V olt age T est 1 Ensure the main breaker or disco nnect switch is turned on. 2 V erify the CCB circuit board h as the correct input volt age at the J2 socket and is prop erly grounded - perform the “Checking Power and Ground T o Th[...]

OPERATION & SERVICE Servicing sh ould only be performe d by a Qualified Service Agent 40 ECO V olt age T est 1 Ensure the main breaker or disco nnect switch is turned on. 2 V erify the CCB has the correct input voltage at the J2 socket and is prop erly grounded - perfo rm the Checking Power and Grou nd T o The CCB tests on p age 46. 3 Using an [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 41 ELECTRONIC CONTROLS ELECTRONIC CONTROLS This section covers the elec tronic control system used on El ectronic Control Models - see Figure 1 on page 9. The c ontrol system includes a CCB (Central Control Board) and a UIM (User Interface Module). The CCB constantly monitors safely [...]

ELECTRONIC CONTROLS Servicing sh ould only be performe d by a Qualified Service Agent 42 CCB - CENTRAL CONTROL BOARD All wiring connections and so ckets will be identified in the following p ages. The T roubleshooting section of th is manual will refer to this illustration and information.[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 43 ELECTRONIC CONTROLS CCB Socket & Wiring T erminal Identification Refer to the illustration on pa ge 42 for physical location of the sockets and wiring terminals. J1 Socket - T ransformer J2 Socket - 120 V AC Power Supply J3 Wiring T erminals - Alarm Output Relay (see p age 59)[...]

ELECTRONIC CONTROLS Servicing sh ould only be performe d by a Qualified Service Agent 44 J7 Socket - Enable / Disable Circ uits 1 & 2 (see p ages 45 & 54) J8 Socket - Not Used J9 Socket - Not Used J10 Socket - Not Used J1 1 Port - Communication Port - UIM Display (user interface module) J12 Socket - Heating El ement Sensors Bank 1 J13 Socke[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 45 ELECTRONIC CONTROLS CCB Enable/Disable Circuit(s) T es t The electronic control system incl udes two enable/disabl e circuits (see p age 54) for use with field installed supervisory co ntrols such as building EM S (Energy Managem ent System). These two circuits are located at the [...]

ELECTRONIC CONTROLS Servicing sh ould only be performe d by a Qualified Service Agent 46 Checking Power a nd Ground T o The CCB The CCB circuit board is powered by the120 V AC Control Circuit T ransformer (see pages 34-35) at the J2 Socket, pins 1 & 3 (see page 42). This proced ure is performed to ensure the 120 V AC power is being supplied to [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 47 ELECTRONIC CONTROLS UIM - USER INTERFACE MODULE UIM Component s The UIM’s major component s incl ude a Circuit Board with LC D display and a Button Pad Overlay which contains the five user input buttons. Service Notes - Butt on Pad Ribbon Cable The Ribbon Cable that co nnects th[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 48 ELECTRONIC CONTROL SYSTEM CONTROL SYSTEM FEATURES Advanced Diagnostics: Plain English text an d animated icons display detailed operational and diagnostic informat ion. LCD screen on th e front of the wate r heater displays the Sequence of Operation in re[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 49 ELECTRONIC CONTROL SYSTEM THE DESKTOP SCREEN The illustration below shows the control system “Desktop Sc reen.” This is the default screen. If there are no active Fault or Alert conditions and no user input for approximately 10 minutes the control syst em will return to th is [...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 50 T able 1 St atus Icons ICON DESCRIPTION W ater temperature in the tank h as fallen. Sha ded area of the animated thermometer icon will rise and fall in response to water temperature in the stor age tank as sensed from the immersion T emperature Probe . W [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 51 ELECTRONIC CONTROL SYSTEM T able 2 - Operating St ates T able 3 - Control System Menus STAT E DESCRIPTION S tandby The water he ater is not in an activ e heating cycle. This u sually indicates the temperature in the tank has reached th e Operating Set Point and the control system [...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 52 T EMPERATURES MENU Operating Set Point User adjustable setti ng 90°F to 190°F range; factory default is 120°F . When the water temperature sensed by the control system from the immersion T emperature Probe reaches the Operating Set Point the control sy[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 53 ELECTRONIC CONTROL SYSTEM T emperature Settings The Operating Set Point and the Differential Settings are adj usted in the T emperatures Menu. The following instructions explain how to adjust these user settings and navigate the control system menus. ACTION DISPLAY From the Deskto[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 54 HEATER ST ATUS MENU This menu displays non adjust able operational information. This menu contains more information that can be displayed on one screen of the LCD display . Use the Up & Down Buttons to navigate to t he bottom of this menu. Statu s Dis[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 55 ELECTRONIC CONTROL SYSTEM ECONOMY MODE SETUP MENU This menu contains settings used to est ablis h an “Economy Set Point” and “Economy Mode” operating periods. This control system featur e can help reduce o perating costs during unoccupied, low load, or peak demand periods.[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 56 Economy Mode Settings Setpoint Adjustment V alue ACTION DISPLAY From the Desktop screen, press the Op erational Button underneath “MENU” to en ter the Main Menu. (see UIM Navigation on p age 48) Notice how the text above the Oper ational Buttons on th[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 57 ELECTRONIC CONTROL SYSTEM Economy Mode Settings Time Clock Settings ACTION DISPLAY From the Desktop Screen navigate to the Eco nomy Mode Setup menu - see p age 56 for instructions. Use the Up/ Down buttons to se lect (highlight in black) Current T ime sub menu. Press the Operation[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 58 Economy Mode Settings Daily Operating Mode Settings ACTION DISPLAY Economy Mode All Day : From the Economy Mode Setup me nu use the Up/Down buttons to select (highlight in black) the Daily sub menu for “Sun.” Press the Operational Button underne ath ?[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 59 ELECTRONIC CONTROL SYSTEM ALARM OUTPUT SETUP MENU Permits user to set the condition (from a list of options) for when the CCB’ s integral alarm output relay will be energized. Al arm relay connections (common, normally open, normally closed) are located on t he J3 terminal strip[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 60 DISPLAY SETTINGS MENU Permits user to set display options for viewing information on the UIM’ s LCD screen. T emperature Unit s Adjustable user setting that changes temperature units displa y to Celsius °C or Fahrenheit °F . Backlight Delay Adjustable[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 61 ELECTRONIC CONTROL SYSTEM HEATER INFORMATION MENU This menu displays non adjust able operational information. Elap sed Time T otal accumulated time the control system (water heater) has been energized. T ot al Heating Time T otal accumulated time the control system has been in the[...]

ELECTRONIC CONTROL SYSTEM Servicing sh ould only be performe d by a Qualified Service Agent 62 CURRENT FAULT / ALERT MENU This menu displa ys non adjustable operational information. With the Fault History sub menu selected in Main Menu; press the Operational Button underneath “SELECT” to display the current Faul t or Alert message. If there is [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 63 RESTORE FACTORY DEFAULT S MENU This control system menu allows the user to restore most of the control system’s user settings to their factory defau lt settings. User settings in the Al arm Output Setup and Display Settings menus are unaffected by executing Restore Factory Defau[...]

T ROUBLESHOOTING Servicing sh ould only be performe d by a Qualified Service Agent 64 T ROUBLESHOOTING COMMON SERVICE PROBLEMS No Hot W ate r 1 Hot water supply valve turned off. 2 Check power to the water h eater - see page s 12 - 14. 3 Check thermost at/ECO controls on Surface Mo unt Control Models - see p ages 18 & 19. 4 Check Operating Set [...]

Servicing shou ld only be performed by a Qualified Service Ag ent 65 T ROUBLESHOOTING ELECTRONIC CONTROL MODELS The remainder of the T roubleshooting section covers El ectronic Control Models only . Fault Conditions When the control system declare s a Fault condition it will display a Fault message on the UIM and lock out. V olt age to the contacto[...]

T ROUBLESHOOTING Servicing sh ould only be performe d by a Qualified Service Agent 66 Control System Unresponsive (cont) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/RE P AIR UIM is Inoperable UIM does not respond to any user input using the operational and/or Up and Down buttons. • Ensure Ribbon Cab le from the Button ov erlay is inserted correct[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 67 T ROUBLESHOOTING FAULT AND AL ERT MESSAGES T roubleshooting procedures for the most common F ault and Al ert messages are covered in this section. In the tables that follow the first colu mn shows the Fault or Alert message as displayed by the UIM along with an explanation. The se[...]

T ROUBLESHOOTING Servicing sh ould only be performe d by a Qualified Service Agent 68 Fault & Alert Messages DISPLAYED MESSAGE CONDITION/INDICATES CHECK/RE P AIR “T emp Probe Open” (Fault Condition) The control system has detected an open circuit in the temperature sensor . The control system will declare this fault condition if it senses a[...]

Servicing shou ld only be performed by a Qualified Service Ag ent 69 T ROUBLESHOOTING Fault & Alert Messages DISPLAYED MESSAGE CONDITION/INDICATES CHECK/RE P AIR “Energy Cut Out (ECO)” (Fault Condition) The control system has detect ed exce ssive water temperature inside the water heater . The ECO high temperature limit switch activates at [...]

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