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500 Tennessee Waltz Parkway Ashland City, TN 37015 Instruction Manual PRINTED 0713 327368-000 PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE. Thank you for buying this energy efficient water heater. We appreciate your confidence in our products. Saudi Arabia and Kuwait Manual INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY RESIDENTIAL ELECTRIC WATER HEATERS
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Page 1: RESIDENTIAL ELECTRIC WATER HEATERS1 500 Tennessee Waltz Parkway Ashland City, TN 37015 Instruction Manual PRINTED 0713 327368-000 PLACE THESE INSTRUCTIONS ADJACENT TO HEATER …

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500 Tennessee Waltz ParkwayAshland City, TN 37015

Instruction Manual

PRINTED 0713 327368-000

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Thank you for buying this energy efficient water heater. We appreciate your confidence in our products.

Saudi Arabia and Kuwait ManualINSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY

RESIDENTIAL ELECTRIC WATER HEATERS

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SAFE INSTALLATION, USE, AND SERVICEThe proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

IMPORTANT DEFINITIONS

• Qualifi ed Installer or Service Agency:

Installation and service of this water heater requires ability equivalent to that of a Qualifi ed Agency (as defi ned by ANSI below) in the fi eld involved. Installation skills such as plumbing, electrical supply are required in addition to electrical testing skills when performing service.

• ANSI Z223.1 2006 Sec. 3.3.83:

“Qualifi ed Agency” - “Any individual, fi rm, corporation or company that either in person or through a representative 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 is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

DANGER

WARNING

CAUTION

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

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GENERAL SAFETY INFORMATIONPRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system which has been under water.If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency.1. External fire.2. Damage.3. Firing without water.This appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to insure they do not play with the appliance.

GROUNDING INSTRUCTIONSThis water heater must be grounded in accordance with the National Electrical Code and/or Local/National codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation on ELECTRONIC CONTROL models.This water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor

must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater.

HYDROGEN GAS (FLAMMABLE)

Hydrogen gas can be produced in a hot water system served by this heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely fl ammable. To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to fl ow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

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Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Installation and service of this water heater requires ability equivalent to that of a licensed tradesman or qualifi ed agency (page 2) in the fi eld involved. Plumbing and electrical work are required.

Abbreviations Found In This Instruction Manual:• ANSI - American National Standards Institute• ASME - American Society of Mechanical Engineers• NEC - National Electrical Code• NFPA - National Fire Protection Association• UL - Underwriters Laboratory

PREPARING FOR THE INSTALLATION1. Read the “General Safety Information” section of this

manual fi rst and then the entire manual carefully. If you don’t follow the safety rules, the water heater may not operate safely. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of the electric water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

The model and rating plates on page 5 interprets certain markings into useful information. Both of these references should be used to identify the heater, its components and optional equipment.

2. The installation must conform with these instructions and the Local/National code authority having jurisdiction and the requirements of the power company. In the absence of Local/National codes, the installation must comply with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National Electrical Code may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical Code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. Qualified Installer must install an all pole, full disconnect switch, per the Local/National code.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number listed on the back cover of this manual for technical assistance.

A sample rat ing plate is shown on page 5 of this manual. In order to expedite your request, please have full model and serial number available for the technician.

4. Carefully plan your intended placement of the water heater. Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

Installation and service of this water heater requires ability equivalent to that of a licensed tradesman or qualified agency (page 2) in the f ield involved. Plumbing and electrical work are required.

TABLE OF CONTENTS

INTRODUCTION

SAFE INSTALLATION, USE, AND SERVICE ..................................... 2GENERAL SAFETY INFORMATION ................................................... 3 Precautions .................................................................................... 3 Hydrogen Gas (Flammable) .......................................................... 3INTRODUCTION .................................................................................. 4 Preparing for the Installation ........................................................ 4MODEL AND RATING ......................................................................... 5FEATURES AND COMPONENTS ....................................................... 6 Electronic Control Models ............................................................ 6LOCATING THE NEW WATER HEATER ............................................ 7 Facts to Consider About the Location ......................................... 7 Clearances ...................................................................................... 7USER INFORMATION ......................................................................... 7 Thermostat Settings-Surface Mount Controls ............................ 7USER CARE ........................................................................................ 7 Draining the Water Heater .......................................................... 7-8 Filling the Water Heater ................................................................. 8INSTALLATION .................................................................................... 9 Required Ability ................................................................................ 9 General ............................................................................................ 9 Contaminated Water ........................................................................ 9 Circulating Pump .............................................................................. 9 Insulation Blankets ........................................................................... 9 Temperature-Pressure Relief Valve ............................................ 9-10

Closed Water Systems ................................................................... 10 Thermal Expansion ........................................................................ 10ELECTRICAL ......................................................................................11 General ...........................................................................................11 Branch Circuit .................................................................................11 Calculating Amperage/Overcurrent Protection ................................11WIRING DIAGRAMS .......................................................................... 12OPERATION ....................................................................................... 13 General .......................................................................................... 13 Filling the Water Heater ................................................................. 13 Initial Start Up ................................................................................ 13 Draining the Water Heater ............................................................. 13TEMPERATURE REGULATION ........................................................ 14 Temperature Adjustment ................................................................ 14MAINTENANCE ................................................................................. 15 General .......................................................................................... 15 Anode Rod Inspection .................................................................... 15TROUBLESHOOTING CHECKLIST .................................................. 16 Checklist ........................................................................................ 16 Leakage Checkpoints .................................................................... 17WARRANTY .................................................................................. 18-19 Repair Parts List ....................................................................... 20-21NOTES .......................................................................................... 22-24

Note:USER/OWNER (BOLD TEXT)QUALIFIED INSTALLER/SERVICE AGENCY ONLY (STANDARD TEXT).

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RESIDENTIAL STORAGETANK WATER HEATER

IPX1

MODEL NUMBER SERIAL NUMBER ITEM ID / PART NUMBER

MAXIMUMPh V Hz No. of W (WATTS) WORKING PRESSURE

(PHASE) (VOLTS) (HERTZ) ELEMENTS EACH TOTAL PSI kPa

CAPACITY US GAL l (LITERS)

MODEL AND RATING

RATING PLATE

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FEATURES AND COMPONENTS

FIGURE 1

This page shows typical water heater installations by model designations.

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FACTS TO CONSIDER ABOUT THE LOCATION

The water heater should be located as close as possible to/or centralized to the water piping system. The water heater should be located in an area not subject to freezing temperatures.

The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower fl oors of the structure.

When such locations cannot be avoided, a suitable drain pan should be installed by a qualifi ed installer, under the heater.

Such pans should be at least two 2” (5.1 cm) deep, have a minimum length and width of at least 2” (5.1 cm) greater than the diameter of the heater and should be piped to an adequate drain.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a

LOCATING THE NEW WATER HEATER

USER CARE

USER INFORMATION

piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or turn off incoming water to water heater when leakage is detected.

• Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water pressure differential between the cold water and how water pipes connected to the water heater.

CLEARANCESA minimum clearance of 4” (10.2 cm) must be allowed for access to replaceable parts such as thermostats, drain valve and relief valve.Adequate clearance for servicing this water heater should be considered before installation, such as changing the anodes, etc.

FLOOD WARNINGIF THE HEATER BECOMES IMMERSED IN WATER UP TO OR ABOVE THE LEVEL OF THE BOTTOM OF THE ELEMENT DOORS, THE HEATER SHOULD BE EXAMINED BY A COMPETENT SERVICE PERSON BEFORE IT IS PLACED IN OPERATION.

Water may drip from the discharge pipe of the pressure relief device and this pipe must be left open to the atmosphere.The pressure relief device must be operated at least once a year to insure proper operation, verify that it is not blocked and to remove lime deposits. This is to be done by a Qualified Service Agent as a part of the regular maintenance.

THERMOSTAT SETTINGS-SURFACE MOUNT CONTROLS Adjustment of temperature controls on surface mounted controls is to be performed by a qualifi ed service agent at initial start-up.

DRAINING THE WATER HEATERThe water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater.

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1. Turn off the electrical disconnect switch.2. Open a hot water valve until the water is cool, then close the

supply water inlet valve to heater.3. Attach hose to outlet opening of drain valve and direct end

to drain.4. Open the heater drain valve.5. If the heater is being drained for an extended shutdown, it

is suggested the drain valve be left open during this period. The hose may be removed.

Follow FILLING instructions when restoring hot water service.

FILLING THE WATER HEATER

1. Turn off the electrical disconnect switch.2. Close the water heater drain valve.3. Open a nearby hot water faucet to permit the air in the system

to escape.4. Fully open the cold water inlet pipe valve allowing the heater

and piping to be fi lled.5. Close the hot water faucet as the water starts to f low.

The heater is now ready for STARTUP and TEMPERATURE REGULATION.

THE FOLLOWING PAGES ARE FOR INSTALLATION, SERVICE/MAINTENANCE AND

TROUBLESHOOTING.THESE INSTRUCTIONS ARE TO BE USED AND PERFORMED BY A QUALIFIED INSTALLER OR

SERVICE AGENCY ONLY.

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INSTALLATION

In order to avoid a hazard due to inadvertent resetting of the thermal cutout, this appliance must not be supplied through an external switching device, such as a timer, or connected to a circuit that is regularly switched on and off by the utility.

CAUTION

REQUIRED ABILITYInstallation and service of this water heater requires ability equivalent to that of a qualifi ed installer or service agency (page 2) in the fi eld involved. Plumbing and electrical work is required.

GENERALThe installation must conform with these instructions and the Local/National code authority having jurisdiction and the requirements of the power company. In the absence of Local/National codes, the installation must comply with the latest editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1. The National Electrical Code may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. The Canadian Electrical Code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

Do NOT test the electrical system before the heater is fi lled with water, follow the START UP procedure in the OPERATION section of this manual.

The principal components of the heater are identifi ed in the Features and Components illustrations on page 6.

MIXING VALVE USAGE: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infi rm, or physically/developmentally disabled. If anyone using hot water in your home fi ts into one of these groups or if there is a Local/National code or state law requiring a maximum water temperature at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfi es your hot water needs, a means such as a MIXING VALVE, should be used at the hot water taps used by these people or at the water heater.

MIXING VALVES for reducing point of use temperature are available and are to be set at a maximum of 125 degree F (52°C). Consult a qualifi ed installer or service agency. Follow all manufacturer’s Instructions for installation of these valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

CONTAMINATED WATERThis water heater shall not be connected to any heating system(s) or component(s) used with a non-potable water heating appliance.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

CIRCULATING PUMPField installed circulating pumps should be of all bronze construction.

INSULATION BLANKETSInsulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the EPACT and ASHRAE/IES 90.1 standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death.

• Do not cover the temperature and pressure relief (T & P) valve with an insulation blanket.• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.• Do obtain new warning and instruction labels for placement on the blanket directly over the existing labels.

TEMPERATURE-PRESSURE RELIEF VALVE

This water heater is provided with a properly rated/sized and certifi ed combination temperature - pressure relief valve by the

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manufacturer. The valve is certifi ed by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.

If replaced, the new valve must meet the requirements of Local/National codes, but not less than a combination temperature and pressure relief valve rated/sized and certifi ed as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or KW input rate as shown on the water heater’s model rating plate.

For safe operation of the water heater, the temperature and pressure relief valve must not be removed from its designated opening nor plugged. The temperature-pressure relief valve must be installed directly into the fi tting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit only within 6 inches (15.2 cm) above, or at any distance below the structural fl oor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.

No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water fl ow may cause property damage.

The Discharge Pipe:• Shall not be smaller in size than the outlet pipe size of the valve, or

have any reducing couplings or other restrictions.• Shall not be plugged or blocked.• Shall be of material listed for hot water distribution.• Shall be installed so as to allow complete drainage of both the

temperature-pressure relief valve and the discharge pipe.• Must terminate a maximum of 6" (15.2 cm) above a fl oor drain or

external to the building. In cold climates, it is recommended that the

discharge pipe be terminated at an adequate drain inside the building.• Shall not have any valve or other obstruction between the relief

valve and the drain.

The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged can cause bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the temperature-pressure relief valve with a properly rated/sized new one.

If you do not understand these instructions or have any questions regarding the temperature-pressure relief valve call the toll free number listed on the back cover of this manual for technical assistance.

CLOSED WATER SYSTEMSWater supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back fl ow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSIONAs water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion.

A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.

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ELECTRICAL

GENERALInstallation must conform with these instructions and Local/National code authority having jurisdiction and requirements of the power company. In the absence of Local/National codes, the installation must comply with current editions of the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1.

An electrical ground is required to reduce risk of electrical shock or possible electrocution. The water heater should be connected to a separate grounded branch circuit with over-current protection and an all pole, full disconnect switch. The water heater should be grounded in accordance with Local/National codes.

Voltage applied to the heater should not vary more than +5% to -10% of the model and rating plate marking for satisfactory operation.

DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON BEFORE THE HEATER TANK IS FILLED WITH WATER. DOING SO WILL CAUSE THE HEATING ELEMENTS TO BURN OUT AND VOID WARRANTY.

The factory wiring is attached to a terminal block within the external junction box unit. The branch circuit is connected to the terminal block within this junction box. The water heater should be connected to a separate, grounded, branch circuit with overcurrent protection and disconnect switch. The water heater should be grounded in accordance with Local/National codes.

BRANCH CIRCUITThe branch circuit wire size should be established through reference to the current edition of NFPA-70, the National Electrical Code or other locally approved source in conjunction with the heater amperage rating. For convenience, portions of the wire size tables from the Code are reproduced here. The branch circuit should be sized at 125 percent of the heater rating and further increase wire size as necessary to compensate for voltage drop in long runs.

CALCULATING AMPERAGE/OVERCURRENT PROTECTION The rating of the overcurrent protection should be computed on the basis of 125 percent of the total connected load amperage. Where the standard ratings and settings do not correspond with this computation, the next higher standard rating or setting should be selected.Portion of Table 310-16 (NFPA-70) follows:Allowable Ampacities of Insulated Copper Conductors. Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F).These ampacities relate only to conductors described in Table 310-13 in Code.For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code.For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code.

TABLE 1

Size Temperature Rating of ConductorSee Table 310-13 in Code

AMGMCM

60°C(140°F)

75°C(167°F)

Types:RUW, (14-2), T, TW, UF

Types:RH, RHW, RUH, (14-2),

THW, THWN, XHHW, USE181614

- - -- - -15

- - -- - -15

12108

203040

203045

643

557080

6585100

Portion of Table 310-18 follows:Allowable Ampacities of Insulated Aluminum and Copper -Clad Aluminum Conductors.Not more than three conductors in Raceway or Cable or Direct Burial (Based on Ambient Temperature of 30° C, 86° F. These ampacities relate only to conductors described in Table 310-13 in Code.For ambient temperatures over 30° C (86° F), see Correction Factors, Note 13 in Code.

TABLE 2

Size Temperature Rating of ConductorSee Table 310-13 in Code

AMGMCM

60°C(140°F)

75°C(167°F)

Types:RUW, (12-2), T, TW, UF

Types:RH, RHW, RUH, (12-2),

THW, THWN, XHHW, USE1210

1525

1525

86

3040

4050

43

5565

6575

21

7585

90100

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WIRING DIAGRAMS

FIGURE 2

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INITIAL START UPThe following checks should be made by the installer when the heater is placed into operation for the fi rst time.1. Turn off the electrical disconnect switch.2. Open the front panel or top access cover, check all water and

electrical connections for tightness. Also check connections on top and or sides of heater. Repair water leaks and tighten electrical connections as necessary.

3. Depress the red manual reset button on each Thermostat/ECO combination control. (See Figure 4)

4. Turn on the electrical disconnect switch.5. Observe the operation of the electrical components during the fi rst

heating cycle. Use care as the electrical circuits are energized.6. Close the front panel or top access cover.

Temperature control and contactor operation should be checked by allowing heater to come up to temperature and shut off automatically. Use care as the electrical circuits are energized.

DRAINING THE WATER HEATERThe water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the heater.1. Turn off the electrical disconnect switch.2. Open a hot water valve until the water is cool, then close the

supply water inlet valve to heater.3. Attach hose to outlet opening of drain valve and direct end to drain.4. Open a nearby hot water faucet and the heater drain valve.5. If the heater is being drained for an extended shutdown, it is

suggested the drain valve be left open during this period. The hose may be removed.

Follow FILLING instructions when restoring hot water service.

INSTALLATION

OPERATIONGENERALRefer to the Features and Components section of this manual (page 6) for the location of components mentioned in the instructions that follow.

NEVER turn on power to the water heater without being certain the water heater is fi lled with water and a temperature and pressure relief valve is installed in the relief valve opening.

DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS FILLED WITH WATER. FOLLOW FILLING AND START-UP INSTRUCTIONS IN OPERATION SECTION.

FILLING THE WATER HEATER

1. Turn off the electrical disconnect switch.

2. Close the water heater drain valve.

3. Open a nearby hot water faucet to permit the air in the system to escape.

4. Fully open the cold water inlet pipe valve allowing the heater and piping to be fi lled.

5. Close the hot water faucet as water starts to flow. The heater is now ready for STARTUP and TEMPERATURE REGULATION.

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THE WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER AT TEMPERATURES DESIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALDS RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND TIME OF EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN , AGED OR DISABLED PERSONS INCREASES THE HAZARD TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.

It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature thermostats (See Figure 4) be set for the lowest temperature which satisfi es your hot water needs. This will also provide the most energy effi cient operation of the water heater.

Figure 3 shows the approximate time-to-burn relationship for normal adult skin. The thermostats on your water heater have a linear relationship between degrees of angular rotation and the corresponding change in temperature. Thus rotating the temperature adjustment indicator 30 angular degrees will result in a 10 degree Fahrenheit change in water temperature.

Water Temperature°F (°C)

Time for 1st Degree Burn(Less Severe Burns)

Time for Permanent Burns2nd & 3rd Degree

(Most Severe Burns)110 (43) (normal shower temp.)116 (47) (pain threshold)116 (47) 35 minutes 45 minutes122 (50) 1 minute 5 minutes131 (55) 5 seconds 25 seconds140 (60) 2 seconds 5 seconds149 (65) 1 second 2 seconds154 (68) instantaneous 1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

FIGURE 3

TEMPERATURE ADJUSTMENTThe water temperature is controlled by surface mounted thermostats with ECO high limit. There is one mounted fi rmly against the tank directly above each element. The thermostats of P-4 circuit are adjustable from approximately 110°F (43°C) (lowest setting) to 150°F (66°C) (highest setting). The thermostats of A-6 circuit are adjustable from approximately 110°F (43°C) (lowest setting) to 150°F (66°C) (highest setting). The thermostat of C-2 circuit is adjustable from approximately 110°F (43°C) to 170°F (77°C). The over temperature device (ECO high limit) attached to each thermostat has a manual reset.

FIGURE 4

NOTE: It is not necessary to adjust the upper thermostat for a dual element unit. However, if it is adjusted above the factory set point 120°F (49°C) it is recommended that it not be set higher than the lower thermostat setting.

To change the temperature setting:

1. DANGER: Turn off the heater electrical supply. Do not attempt to adjust thermostat with power on.

2. Open the junction box door (for upper thermostat of dual element water heater only) and/or remove the (lower) thermostat access panel. Do not remove the plastic personnel protectors covering the thermostats. The thermostat is factory pre-set at 120°F (49°C).

3. Using a fl at tip screwdriver, rotate the adjusting knob to the desired temperature setting.

4. Replace the covers and access panels, and turn on heater electrical supply.

TEMPERATURE REGULATION

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GENERAL

Periodically the drain valve should be opened and the water allowed to run until it flows clean. This will help to prevent sediment buildup in the tank bottom.

Periodically check the temperature and pressure relief valve to ensure that it is in operating condition. Lift the lever at the top of the valve several times until the valve seats properly and operates freely.

Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale from the heating element.

The heater tank is equipped with an anode rod to aid in corrosion control.

ANODE ROD INSPECTION

The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifi ces itself to protect the tank. Instead of corroding tank, water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition.

Anode deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by a qualifi ed technician, and at a minimum should be checked annually after the warranty period.

Artifi cially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions.

The use of a water softener may decrease the life of the water heater tank.

The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement.

NOTE: Artifi cially softened water requires the anode rod to be inspected annually.

MAINTENANCE

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TROUBLESHOOTING CHECKLISTCHECKLISTBefore calling for service, check the following points to see if the cause of trouble can be identifi ed and corrected.

Reviewing this checklist may eliminate the need of a service call and quickly restore hot water service. See Figure 1 on page 7 in this manual to identify and locate water heater components.

NOT ENOUGH OR NO HOT WATER1. Be certain the electrical disconnect switch serving the water heater

is in the ON position.

2. Check the fuses.

• The electrical disconnect switch usually contains fuses.

3. If the water was excessively hot, and is now cold, the high limit switch may have activated.

• See the Temperature Regulation section of this manual for more information on how to reset the ECO high limit controls.

4. The capacity of the heater may have been exceeded by a large demand for hot water.

• Large demands require a recovery period to restore water temperature.

5. Cooler incoming water temperature will lengthen the time required to heat water to the desired temperature.

6. Look for hot water leakage.

7. Sediment or pipe scale may be affecting water heater operation.

ABNORMAL SOUNDS1. Sediment or lime scale accumulations on the elements causes

sizzling and hissing noises when the heater is operating.

• The sounds are normal, however, the tank bottom and elements should be cleaned. See the Maintenance section of this manual.

WATER LEAKAGE IS SUSPECTEDRefer to Leakage Checkpoint on the following page 17.

1. Check to see if the heater drain valve is tightly closed.

2. If the outlet of the relief valve is leaking it may represent:

• Excessive water temperature.

• Faulty relief valve.

• Excessive water pressure.

3. Excessive water pressure is the most common cause of relief valve leakage. It is often caused by a “closed system”. See “Closed Water Systems” and “Thermal Expansion” in the Installation section of this manual for more information.

4. Examine the area around the element for gasket leakage.

• Tighten the elements or, if necessary, follow the WATER AND LIME SCALE REMOVAL procedure to replace the gaskets.

IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF MALFUNCTION

1. Turn the power supply to the water heater off.

2. Close the supply water inlet valve to the heater.

3. Contact a Qualifi ed Service Agency in your area. Call the toll free phone number on the back cover of this Instruction Manual for assistance in locating a service agency in your area.

REPLACEMENT PARTSCall the toll free phone number on the back cover of this Instruction Manual for assistance in locating replacement parts.. When ordering parts, specify complete model no., serial no., (see rating plate), quantity and name of part desired. Standard hardware items should be purchased locally.

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LEAKAGE CHECKPOINTSInstructions: Use this illustration as a guide when checking for sources of water leakage. You or your dealer may be able to correct what appears to be a problem. NOTE: Cover and Insulation shown removed to reveal tank top.

Relief Valve To Open Drain

Condensation and dripping may appear on pipes when cold water temperature is low. Pipe fi tting may be leaking.

Relief valve operation and leakage may be due to water expansion during heating cycle or foreign material on seat of valve. If the valve is not piped to an open drain the released water could be mistaken for a leaking heater. To check where threaded material between jacket opening and swab spud area. Remove valve* if indicated and repair with pipe joint compound.

Water on the side of the tank may be condensation due to the panel or insulation not being in place.

Drain valve leakage could be from the valve itself.* To check for leakage where threaded portion enters tank, insert Q-tip or similar absorbent material between jacket opening and valve to swab spud area. Remove valve* if leak is indicated and repair with pipe joint compound.*Contact your dealer as it is necessary to shut off electricity and drain tank to perform procedure.

Water leaks at the elements may be due to:1. Defective element which leaks at

terminals or thru flange. Replace element*.

2. Loose element/gasket leak: (a) Screw-in type: tighten with 1-1/2”

socket wrench. If leak continues, remove element*, discard gasket and clean thread areas.Apply nonhardening Permatex Number 2 to thread areas, install new gasket and screw element into fi tting until it seats. Tighten 1/2 to 3/4 turn with wrench.

(b) Flange type: tighten screw with wrench. If leak continues remove element* and discard gasket. Clean gasket seating areas and re-install element with new gasket. A new element may be required where threads have become rusted or damaged, preventing tightening.

All water which appears at the water heater bottom or on the surrounding fl oor may be caused by condensation, loose connections or relief valve operation and leakage. Do not replace the water heater until full inspection of all potential leak points is made and corrective steps taken to stop the leak. Leakage from other appliances, water lines or ground (see page 16) should also be suspected until proven otherwise.

Anode Rod (Some Models)

Where possible remove or lift top cover to examine threads of fi ttings installed into tank for evidence of leakage. Correct fi tting leaks as necessary.

To Open Drain

FIGURE 5

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RESIDENTIAL ELECTRIC WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY. In accordance with the warranty terms and conditions specifi ed below.

A. O. Smith Corporation (the warrantor) will furnish the ORIGINAL OWNER, 1) a replacement A. O. Smith water heater of equivalent size and current model if the glasslined tank in this water heater leaks and, 2) a replacement part for any component part which fails. Sacrifi cial anode rods areconsumable maintenance parts and are excluded fromwarranty coverage.

THE A. O. SMITH WATER HEATERS REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY. The warranty period will be determined by the original date of purchase of the water heater, or in the absence of a Bill of Sale verifying said date, from the date of manufacture indicated on rating plate affi xed to this water heater. This warranty is not transferrable and applies to models listed below:

When the water heater has been used for other than single family residential application;

1. The tank warranty shall be reduced to 1 year for 6 year models and to 3 years for 10 year models.

2. The parts warranty shall be reduced to 1 year for all models.

CONDITIONS AND EXCEPTIONS

This warranty shall apply only when the water heater is installed and operated in accordance with 1) all local fi re codes and plumbing codes, ordinances and regulations, 2) the printed instructions provided with it, 3) good industry practices, and 4) proper safety practices such as but not limited to a properly sized drain pan if installed in an area where leakage from the tank or its connections would result in damage to the area adjacent to the heater. In addition, a new temperature and pressure relief valve, certifi ed by the Canadian Gas Association must have been properly installed and piped to the nearest drain.

This warranty shall apply only when the heater is:• owned by the original purchaser;• installed for indoor operation only;• used at temperatures not exceeding the maximum calibrated setting of its thermostat;• used at water pressure not exceeding the working pressure shown on the heater;• fi lled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;• used in a non-corrosive and non-contaminated atmosphere;• used with factory approved anode(s) installed;• in its original installation location;• in the United States, its territories or possessions,

and Canada;• sized in accordance with proper sizing techniques for residential water heaters;• bearing a rating plate which has not been altered, defaced or removed except as required by the warrantor;• used in an open system or in a closed system with a properly sized and installed thermal expansion tank;• connected to the proper voltage or:• operated at the factory rated input;• installed with no attempted, nor actual modifi cation or alteration of the water heater’s design in any way, including but not limited to, the attachment of non- company approved appliances or equipment, including any additional aftermarket equipment introduced into the sealed system.

Any accident to the water heater or any part thereof (including freezing, fi re, fl oods, or lightning), any misuse, abuse or alteration of it, any operation of it in a modifi ed form, any operation of the water heater on desalinated (deionized) water, or any damage caused by attempts to repair tank leaks or parts, will void this warranty. This warranty does not cover water heaters replaced for cosmetic reasons or for reasons of noise, taste, odor, discolored and/or rusty water. This warranty does not apply to water heaters used to heat pools, whirlpools or hot tubs or used for space heating where its sizing does not conform with specifi cations of the heating component manufacturer.

This warranty gives you specifi c legal rights, and you may have other rights which vary under the laws of each state. If any provision of this warranty is prohibited or invalid under applicable state law, that provision shall be ineffective to the extent of the prohibition or invalidity without invalidating the remainder of the affected provision or the other provisions of this warranty.

MODELS Tank PartsDEL 6-year 6-yearPCT 10-year 6-yearE C RT, E C T, E C S , E C L , EJC, EJCT, ECJ, ECLN, ECJN, EJCS

6-year 6-year

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SERVICE AND LABOR RESPONSIBILITY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS. Such costs may include but are not limited to:

a. Labor charges for service, removal, or reinstallation of the water heater or part thereof.

b. Shipping and delivery charges for forwarding the new water heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor.

c. All cost necessary or incidental for handling and administrative charges, and for any materials and/or permits required for installation of the replacement heater or part.

LIMITATION ON IMPLIED WARRANTIES

Impl ied warrant ies, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

CLAIM PROCEDURE

Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is not practical, the owner should contact: A.O. Smith Corporation, 500 Tennessee Waltz Parkway, Ashland City, TN 37015. Phone: 1.800.323.2636 or visit our website: www.hotwater.com.

For Canadian customers contact: A.O. Smith Enterprises LTD., P.O. Box 310, 768 Erie Street, Stratford, Ontario N5A6T3 or phone: 1.800.265.8520

Replacement Parts may be ordered through authorized servicers or distributors. Refer to your local Yellow Pages for where to call or contact A.O. Smith Corporation, 500 Tennessee Waltz Parkway, Ashland City, TN 37015. Phone: 1.800.433.2545 or visit our website at: www.hotwater.com/parts.

The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.Dealer replacements are made subject to in-warranty validation by warrantor.

PROOF OF PURCHASE AND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWNER. THIS FORM DOES NOT CONSTITUTE PROOF OF PURCHASE OR PROOF OF INSTALLATION.

DISCLAIMERS

NO EXPRESSED WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty, the Owner will be furnished with the closest comparable water heater meeting the then current governmental regulations and industry standards. A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards. The limitedwarranty is voided if the maintenance procedures listed inthe owner’s instruction manual are not followed.

IMPORTANT INFORMATION Model Number ________________________________ Serial Number ________________________________

INSTALLATION INFORMATION

Date Installed _______________________________

Company’s Name _____________________________

Street or P.O. Box ____________________________

City, State, and Zip Code ________________________

Phone Number ________________________________ Plumber’s Name ______________________________

www.hotwater.com

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Key No. Part Description1 Temperature-Pressure Relief Valve

2 Secondary Anode Rod/Nipple w/Heat Trap*

3 Element w/Gasket

4 Element Gasket

5 Lower Outer Door

6 Terminal Cover (Double Element)

7 Upper Thermostat w/Hi Limit

8 Terminal Cover

9 Lower Thermostat

10 Terminal Cover

11 Lower Thermostat

12 Thermostat Bracket (ea).

13 Drain Valve

14 Primary Anode

15 Dip Tube

16 Nipple w/Heat Traps*

17 Upper Outer Door

18 Base Pan w/Side Drain

19 Pipe Insulation*

20 T & P Insulation

** Instruction Manual

* If Applicable** Not Illustrated

LOWBOY AND UPRIGHT ELECTRIC MODELS (Single and Dual Element)

Now that you have purchased this water heater, should a need ever exist for repair parts or service, simply contact the company it was purchased from or direct from the manufacturer listed on the rating plate on the water heater.

Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly.

The model number of your Water Heater will be found on the rating plated located above the lower access panel.

Be sure to provide all pertinent facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:

• MODEL NUMBER • VOLTAGE AND ELEMENT WATTAGE • SERIAL NUMBER • PART DESCRIPTION

REPAIR PARTS LIST

FIGURE 6

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* If Applicable ** Not Illustrated

Key No. Part Description1 Temperature-Pressure Relief Valve

2 Outlet Nipple Assembly

3 Inlet Nipple

4 Junction Box Cover

5 Upper and Lower Element

6 Element Gasket

7 Thermostat Bracket (ea.)

8 Lower Thermostat

9 Terminal Cover

10 Lower Thermostat w/Hi Limit

11 Terminal Cover

12 Lower Outer Door

13 Upper Outer Door

14 Upper Thermostat w/Hi/Limit

15 Anode Rod

16 Drain Valve

17 Base Pan w/Side Drain

18 Conduit Bracket

19 Pipe Insulation*

20 T & P Insulation*

21 Dip Tube

22 Plug

** Instruction Manual

COMPACT ELECTRIC MODELS

FIGURE 7

REPAIR PARTS LIST

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NOTES

Page 23: RESIDENTIAL ELECTRIC WATER HEATERS1 500 Tennessee Waltz Parkway Ashland City, TN 37015 Instruction Manual PRINTED 0713 327368-000 PLACE THESE INSTRUCTIONS ADJACENT TO HEATER …

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NOTES

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www.hotwater.com500 Tennessee Waltz Parkway, Ashland City, TN 37015

Tech Support: 800-527-1953Parts: 800-433-2545

Copyright © 2013 A. O. Smith Water Heater Corporation , All rights reserved.

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25

www.hotwater.com500 Tennessee Waltz Parkway, Ashland City, TN 37015

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