47174-B - Bradford White


Bradford White MII Series Commercial Electric water heaters can be manufactured ... Tank. The wiring code at the end of the model number is used at the factory to facilitate ... 50(gal.)/189.3(liters). Press: Test 300(psi), Working 150(psi). Volts. 240 .... ECO. (High Limit). T'stat. When the thermostat calls for heat, contacts close.

COMMERCIAL ELECTRIC ENERGY SAVER WATER HEATER MII SERIES IMMERSION AND SURFACE MOUNTED THERMOSTAT MODELS

SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers)

Models Covered by This Manual: MII50(A)-*-**-(SF,CF,SCF)-*** MII80(A)-*-**-(SF,CF,SCF)-*** MII120(A)-*-**-(SF,CF,SCF)-*** *Denotes kW Rating **Denotes Warranty Years ***Denotes Wiring Code

Manual 238-47174-00B

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MII Series Commercial Electric Water Heaters

Table of Contents

Page

Service Procedure

Introduction ………………………………………………………………………. 2

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Tools……………………………………………………………………………… 2

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General Information ……………………………………………………………… 3

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Sequence of Operation …………………………………………………………… 10

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Troubleshooting …………………………………………………………………. 13

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Heating Element Testing …………….................................................................... 15

MCE-I

Line Voltage Testing………………...…………………………………………… 16

MCE-II

Fuse Testing…........................................................................................................ 17

MCE-III

High Limit (ECO) Testing (Surface Mounted Thermostats)……………………. 18

MCE-IV

High Limit (ECO) Testing (Surface Mounted Thermostats at 600V)……………. 19

MCE-V

High Limit (ECO) Testing (Contactor Models)…………………………………. 20

MCE-VI

Thermostat Operation Testing (Surface Mounted Thermostats).............................. 21

MCE-VII

Thermostat Operation Testing (Surface Mounted Thermostats at 600V)………… 22

MCE-VIII

Thermostat Operation Testing (Contactor Models)..................................................23

MCE-IX

Contactor Operation Testing……………………………………………………… 24

MCE-X

Thermostat Removal and Replacement (Surface Mounted Thermostats)………… 26

MCE-XI

Thermostat Removal and Replacement (Contactor Models)………………………27

MCE-XII

ECO Removal and Replacement (Contactor Models)……………………………..28

MCE-XIII

ECO Removal and Replacement (Surface Mounted Thermostats at 600V)……….29

MCE-XIV

Heating Element Removal and Replacement …………………………………….. 30

MCE-XV

Anode Inspection and Replacement ……………………………………………… 31

MCE-XVI

Generic Parts List ………………………………………………………………… 32

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Glossary of Terms……………………………………………………………….... 33

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Introduction

This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair of Bradford White Commercial Electric Water Heaters. The text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshooting procedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using the methods described in this service manual.

Tools

- Multi Meter. - 1-½” Deep Well Socket. - 1-1/16" Deep Well Socket. - ¼" Nut Driver.

- Phillips Head Screw Driver. - Common Screw driver. - Thermometer. - Drain Hose.

- Other Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers, Allen Wrench Set, Flash Light.

Page 2

2

GENERAL INFORMATION

Bradford White MII Series Commercial Electric water heaters can be manufactured with a choice between two different types of thermostat control options as follows: Surface Mounted Thermostats. Immersion Thermostat (contactor models). The model number is coded to identify the specific thermostat control system used for a particular unit. Below is typical model number and coded definitions:

MII50 12 3 SF 018 Wiring Code C-Contactor (Immersion Thermostat) CF-Contactor w/Fuse (Immersion Thermostat) S-Surface Thermostat SF-Surface Thermostat w/Fuse SC-Surface Thermostat (w/Contactors) SCF-Surface Thermostat w/Fuse (w/Contactors) Warranty kW Rating Tank The wiring code at the end of the model number is used at the factory to facilitate proper construction based on the electrical characteristics such as voltage, phase, kW rating and amp draw. In the field this information is determined from the heaters rating plate located on the front of the water heater.

Model Number

Electrical Characteristics

BRADFORD WHITE CORPORATION 200 LAFAYETTE ST. MIDDLEVILLE MI 49333 Model No: MII50123SF018 Serial No: ZB2564812 Cap. 50(gal.)/189.3(liters) Press: Test 300(psi), Working 150(psi)

Volts 240 Max Temp 180° Phase Three Amps 29 kW Each 4 Total kW 12 Wattage Rating Based Upon 60 Hz

3 Elements

Typical Rating Plate Located On Front Of Water Heater

Page 3

3

GENERAL INFORMATION

Contactor Models General Controls Layout Ground Lug Terminal Block

Upper Control Box

Fuse Block(s) Contactor(s) High Limit (ECO) Direct Immersion Bulb

Thermostat Direct Immersion Bulb

High Limit (ECO) Control Immersion Thermostat Control

Lower Control Box

Heating Elements

Surface Mounted Thermostat Models General Controls Layout Ground Lug Terminal Block

Upper Control Box

Fuse Block(s)

Surface Mounted Thermostats With ECO

Lower Control Box

Heating Elements

Page 4

4

GENERAL INFORMATION

600V Surface Thermostat (w/Contactors) Models General Controls Layout Terminal Block Ground Lug Upper Control Box

Contactor(s) High Limit (ECO) Control

Surface Thermostats

Lower Control Box Heating Elements

Page 5

5

GENERAL INFORMATION

Surface Mounted Thermostats Surface mounted thermostats are mounted into a bracket above each heating element. The bracket holds the thermostat against the side of the tank responding to tank surface temperatures to sense a call for heat, set point temperature and high limit (ECO) activation. As each element has a dedicated thermostat (for all models excluding 600V), it is possible to sequence the elements by varying the settings on the thermostats.

Manual ECO (high limit) Reset button

Surface Mount Combination Thermostat/ ECO (high limit) 89T Series

Temperature control Dial

Immersion Style Thermostat Control for Contactor Models The thermostat will complete control circuit voltage upon a call for heat. Likewise, the control will interrupt control circuit voltage when the water temperature is sufficient to satisfy the adjustable temperature limit of control.

Direct Immersion bulb

Immersion Style High Limit (ECO) Control for Contactor Models The high limit (ECO) control will interrupt control circuit voltage causing the heater to shut down when the high temperature limit of the control is reached (196°F±4°F). Once the cause for over heated water has been determined, The control must be manually reset to restore normal operation. Manual Reset Buttons

Direct Immersion bulb

Page 6

6

GENERAL INFORMATION

Surface Mounted Thermostats (w/Contactors) for 600V Models 600V models use contactors to deliver line voltage to the heating elements. However, rather than the immersion type high limit and thermostat devices, surface mounted thermostats are used to operate the control circuit of the water heater.

Surface Mounted Thermostat 59T Series

Temperature control Dial

Surface Mounted ECO (High Limit)

Manual Reset Button

Page 7

7

GENERAL INFORMATION

Contactor Contactor operation is achieved by energizing an operating coil in response to a call for heat from the immersion thermostat. Upon a call for heat, one or more contactors will energize all heating elements simultaneously. The operating coils are voltage specific, When contactor replacement is required be sure to order the proper operating coil base on the voltage rating found on the rating plate located on the front of the water heater.

Terminal connections of contactor operating coil.

Terminal connections to the fuse block and/or terminal block

Terminal connections to the heating elements

Direct Immersion “Screw-in” Type Heating Element

1-½” Hex Screw-in Flange

Terminal Block

0642 4500W 240V RC02404524

Zinc Plated Copper or Incoloy Sheath

Terminal Block Screw

Element Rating Ink Stamped on side of Terminal Block.

Page 8

8

GENERAL INFORMATION

Commonly Used Formulas (balanced 3 phase) Watts Amps = Volts x 1.732

(Single phase) Watts Amps = Volts

Common Service Wire Configurations

2

Ohms = Volts Watts

Watts = Amps x Volts

240V 1Ph BLACK Ungrounded

GREEN Grounding

RED Ungrounded

240

120 120

208 3Ph A

Neutral

240 3Ph

B

C

Neutral

A

120

480 3Ph/277 1Ph

B

C

208

RED

240

120 240 RED

C

277

208

BLACK

B 277

120 208

A

120

120 120

Neutral

RED

480

277

240

BLACK

480 RED

RED

480

BLACK

RED

Full Load Current Amps kW 6 9 12 13.5 15 18 24 27 30 36 45 54

208 Volt 1 Ph 3 Ph 28.8 16.6 43.2 25.0 57.6 33.3 64.9 37.5 72.1 41.6 86.5 50.0 115.4 66.7 129.8 75.0 144.2 83.3 173.0 100.0 216.3 125.0 259.6 150.0

240 Volt 1 Ph 3 Ph 25.0 14.4 37.2 21.6 50.0 28.9 56.2 32.5 62.5 36.1 75.0 43.4 100.0 57.8 112.5 65.0 125.0 72.2 150.0 86.7 187.5 108.3 225.0 130.0

277 Volt 1 Ph 21.6 32.4 43.3 48.7 54.1 64.0 86.6 97.4 108.3 129.9 162.4 194.9

380 Volt 3 Ph 9.1 13.6 18.2 20.5 22.7 27.3 36.4 41.0 45.6 54.7 68.4 82.0

415 Volt 3 Ph 8.3 12.5 16.7 18.8 20.9 25.0 33.4 37.5 41.7 50.1 62.6 75.1

480 Volt 1 Ph 3 Ph 12.5 7.2 18.7 10.8 25.0 14.4 28.1 16.2 31.2 18.0 37.5 21.6 50.0 28.9 56.2 32.5 62.5 36.1 75.0 43.3 93.7 54.1 112.5 65.0

600 Volt 3 Ph 5.8 8.7 11.5 13.0 14.4 17.3 23.1 26.0 28.9 34.6 43.3 52.0

Page 9

9

SEQUENCE OF OPERATION

MII Series Commercial Electric Water Heaters can use either immersion thermostat (contactor models) or surface mounted thermostats. Sequence of operation for each configuration is explained below. It would be impractical to show all wire diagrams applicable to both configurations. A “typical wiring diagram” is illustrated to aid in understanding the principles of the operating sequence. Immersion Thermostat (Contactor Models): Configured to use a single immersion thermostat to control one or more contactors to energize or de-energize all elements simultaneously. In addition, a separate high limit (ECO) control with manual reset is wired in series with the thermostat. Both controls use a direct immersion bulb inserted into the tank to sense water temperature. Immersion thermostat and high limit control are mounted to provide temperature adjustment and manual reset access from the exterior of the unit. Surface Mounted Thermostats: Surface mounted thermostats are mounted inside the lower control box, in a bracket above each heating element. The bracket holds the thermostat against the side of the tank responding to tank surface temperatures to sense a call for heat, set point temperature and high limit (ECO) activation. As each element is controlled by a dedicated thermostat, it is possible to sequence the elements by varying the settings on the thermostat. However, 600V models w/ surface mounted thermostats operate contactors in the same manner as an immersion thermostat model, only using surface thermostats to sense the call for heat. Line Voltage

Sequence of operation for each system is explained below.

Sequence of Operation: Immersion Thermostat (Contactor Models). The system has two distinct circuits.

Fuse Block

OR

Terminal Block

1. Power circuit (shown solid line). 2. Control Circuit (shown dotted line). 1

Line voltage is applied across terminals of fuse block or a terminal block. Line voltage continues down and connects to terminals L1, L2 & L3 of one or more contactors.

Contactor Coil

ECO (High Limit)

Contactor

A) Contactor is open (no call for heat), so there is no voltage across terminal T1, T2 & T3 of contactor. T’stat

B) The contactor is controlled by the control circuit consisting of the immersion thermostat, ECO (hi limit) and contactor coil.

2

3

4

5

When the thermostat calls for heat, contacts close inside the thermostat completing the circuit through the ECO and energizing the contactor coil. The energized contactor coil causes the contactor to close energizing the elements from terminals T1, T2 & T3 of the contactor. When the temperature setting of the thermostat is reached, the contacts in the thermostat open. This interrupts current flow through the control circuit deenergizing the contactor coil. The de-energized contactor coil causes the contactor to open, interrupting current flow through the elements. The heater is now in stand-by waiting for the next call for heat.

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10

Heating Elements

SEQUENCE OF OPERATION

Sequence of Operation: Surface Mounted Thermostats.

Line Voltage

1 Fuse Block

1

OR

Terminal Block

Line voltage is applied across terminals of fuse block or a terminal block. Line voltage continues down and connects to surface mounted thermostats at terminals L1 & L3.

2 2

ECO (high limit) in thermostat is closed, so there is line voltage present at terminal L4 of thermostats and to one side of each element.

ECO Closed

Power to one side of element

Surface Mounted Thermostat Heating Element

3

Water in tank is cold, so all thermostats are closed at terminal T2 (calling For heat). This completes the circuit and allows current to flow through heating elements.

Thermostat closed at terminal T2

3

4 4

As each thermostat is satisfied, it opens at terminal T2 interrupting current flow through the respective element. The system is now in stand-by mode, waiting for the next call for heat.

Thermostat open at terminal T2

Page 11

11

SEQUENCE OF OPERATION

Sequence of Operation: 600V Surface Mounted Thermostats (w/Contactors).

6 Element Configuration Shown (9 Elements Possible)

The system has two distinct circuits. 1. Power circuit - Line Voltage (600V) 2. Control Circuit - 120V 1

Line Voltage

Fuse Block Transformer 60VA

Line voltage is applied across terminals of fuse block or a terminal block. Line voltage continues down and connects to terminals L1, L2 & L3 of one or more contactors. A) Contactor is open (no call for heat), so there is no voltage across terminal T1, T2 & T3 of contactor. B) The contactor is controlled by the control circuit consisting of the surface mounted thermostat, ECO (hi limit) and contactor coil.

Contactor

2

3

4

5

6

When the thermostat calls for heat, contacts close inside the thermostat completing the circuit through the ECO and energizing the contactor coil. The energized contactor coil causes the contactor to close, energizing the elements from terminals T1, T2 & T3 of the contactor. When the temperature setting of the thermostat is reached, the contacts in the thermostat open. This interrupts current flow through the control circuit deenergizing the contactor coil.

High Limit

The de-energized contactor coil causes the contactor to open, interrupting current flow through the elements. The heater is now in stand-by waiting for the next call for heat. Notice in the wiring diagram at right that each row of elements is equipped with a surface mounted thermostat on the highest element in the row. These thermostats are individually wired in series to the contactor whose line voltage corresponds to the same row of elements. Each thermostat and contactor combination are wired to the high limit (ECO) device in parallel. This allows for each row of elements to be powered “ON” independent of the other element rows. However, the high limit (ECO) is wired in series so that voltage can be interrupted to the entire control circuit if the ECO senses that the tank water has become overheated.

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12

59T

59T

Heating Elements

TROUBLESHOOTING

Most common cause for improper electric water heater operation can be linked to heating element failure. When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot Water” It is always a good idea to check the heating elements first following the procedure on page 15. Common Heating Element Failures Are: 1. Dry Firing. Elements may be partially submerged in water or most likely, completely exposed with no water in the tank at all. In open air, an energized element (Dry Fired) will become completely inoperable within seconds. In some cases sediment or lime build up around an element can eventually cause an air pocket, resulting in a dry fired element. When element replacement is required, be sure tank is full of water prior to energizing the water heater. 2. Grounded Element. In most cases, an element with a short circuit to ground will cause the circuit breaker in the service panel to open or shut off. In some cases there may not be enough current draw for the circuit breaker to open. This will allow the heating element to be in continuous operation resulting in over heated water, limited only by the ECO or Energy Cut Off located in the thermostat circuit. Repeated actuation of the ECO usually is the result of a grounded heating element. 3. Sediment build up. Slow hot water recovery can usually be traced back to sediment or lime build up around heating element. Sediment build up can also over time cause a dry fired element. If a heating element is found to be inoperative, it must be replaced. Follow service procedure MCE-XV on page 30. The illustration below shows a common “Screw-In” type heating element identifying certain features commonly referred to throughout this manual.

1-½ Hex Screw-in Flange

Zinc Plated Copper or Incoloy Sheath

0642 4500W 240V RC02404524

Terminal Block

Terminal Block Screw

Element Rating Ink Stamped on side of Terminal Block.

Typical Direct Immersion “Screw-In” Type Heating Element

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TROUBLESHOOTING

Quick Step Plan to Hot Water 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Check all wire connections to insure they are snug and corrosion free.

WARNING High voltage exposure. Use caution when making voltage checks to avoid hazard to life or property.

3. Reset high limit (ECO) (page 18-20). 4. Check for inoperative heating element (page 15). 5. Check line voltage (pg 16), and internal fuses (page 17). 6. Refer to table below if items 1 through 5 above do not correct problem.

SYMPTOM

No Hot Water

PROBABLE CAUSE

CORRECTIVE ACTION

1. No power to heater. 2. Blown water heater fuses. 3. Loose wire connections. 4. Inoperative heating elements. 5. Inoperative thermostat(s). 6. Open ECO. 7. Inoperative contactor(s).

1. Check circuit breakers at service panel. 2. Check water heater fuses. 3. Check all wire connections. 4. Check heating element(s). 5. Check thermostat(s) operation. 6. Reset (check) ECO. 7. Check contactor operation.

2. MCE-III, Page 17 4. MCE-I, Page 15. 5. MCE-VII-IX, Page 21-23. 6. MCE-IV-VI, Page 18-20. 7. MCE-X, Page 24,25

Not Enough Hot Water or Continues Operation

1. Inoperative heating element. 2. Sediment or lime build up on element(s). 3. Thermostat(s) set to low. 4. Inoperative thermostat(s). 5. Inoperative contactor(s). 6. Loose wire connection. 7. High demand period. 8. Undersized heater. 9. Very cold inlet water to heater. 10. Plumbing connections reversed.

1. Check heating element(s). 2. Clean or replace heating element(s) 3. Increase thermostat setting. 4. Check thermostat(s). 5. Check contactor operation. 6. Check all wire connection. 7. Reduce demand. 8. Replace with larger heater. 9. Temper water to heater. 10. Correct plumbing connections.

1. MCE-I, Page 15. 2. MCE-XV, Page 30. 4. MCE-VII-IX, Page 21-23. 5. MCE-X, Page 24,25

Slow Hot Water Recovery

1. Sediment or lime build up on element(s). 2. Loose wire connections. 3. Inoperative thermostat(s). 4. Inoperative contactor(s). 5. Derated heating element installed.

1. Clean or replace heating elements. 2. Check all wire connections. 3. Check thermostat(s). 4. Check contactor operation. 5. Verify element voltage and wattage rating.

1. MCE-XV, Page 30. 3. MCE-VII-IX, Page 21-23. 4. MCE-X, Page 24-25 5. See page 8.

Over Heated Water

1. Surface thermostat(s) not flush with tank. 2. Grounded heating element(s). 3. Thermostat set to high. 4. Inoperative thermostat(s). 5. Inoperative ECO.

1. Check surface thermostat(s) mounting. 2. Check heating element(s). 3. Adjust thermostat(s) to desired setting. 4. Check thermostat(s). 5. Check ECO.

1. MCE-XI, Page 26. 2. MCE-I, Page 15. 4. MCE-VII-IX, Page 21-23. 5. MCE-IV-VI, Page 18-20.

1. Lime formation on elements. 2. High or low line voltage.

1. Clean or replace heating elements. 2. Verify line voltage to heater.

1. MCE-XV, Page 30. 2. MCE-II, Page 16.

1. Low line voltage. 2. Debris between contactor plates. 3. Incorrect or defective operating coil. 4. Loose wire connections.

1. Verify line voltage to heater 2. Replace contactor. 3. Replace contactor. 4. Check wire connections.

1. MCE-II, Page 16

Noisy (singing or hissing) Elements Noisy Contactor

Page 14

14

SERVICE PROCEDURE

SERVICE PROCEDURE MCE-I Heating Element Testing

Test for Open or Burned Out Element. 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Remove access cover from lower control box. Remove insulation from inside of control box. 3. Disconnect wires from heating element.

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

4. Set multi-meter to “ohms” setting. 5. Touch probes of multi-meter to screw terminals of heating element (see illustration 1). 6. Reading should be 12.8 ohms (±6%) for a 240 volt, 4500 watt element, see table below for other elements.

NOTE Disconnect element Wires

2

Ohms = Volts Watts

A reading outside the range using the formula above (±6%), indicates a bad element and the element must be replaced.

Ohms of electrical Resistance For commonly Used Elements

Element Screw Terminals

Illustration 1

Voltage Rating of Element

Element Wattage

208

240

480

2000 3000 4000 4500 5000 6000

21.6 14.4 10.8 9.6 8.7 7.2

28.8 19.2 14.4 12.8 11.5 9.6

115.2 76.8 57.6 51.2 46.1 38.4

Test For Grounded Heating Element (damaged heating element with short circuit to ground). 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Remove access cover from lower control box. Remove insulation from inside of control box.

NOTE Disconnect element Wires

3. Disconnect wires from heating element. Element Flange

4. Set multi-meter to “ohms” setting. 5. Touch one probe of multi-meter to either screw terminal of heating element and the other on the element flange (see illustration 2). There should be no reading on the ohm meter. Any reading indicates a grounded element and the element must be replaced. Repeat this step for the other screw terminal.

Element Screw Terminal

Illustration 2

Page 15

15

SERVICE PROCEDURE MCE-II Line Voltage Testing

DANGER High voltage exposure. To avoid hazard to life or property use extreme caution when making voltage checks .

Line Voltage Testing Line voltage (single phase or three phase) will connect to a terminal block or directly to a fuse block located inside control panel.

Determine heaters voltage and phase by referring to the rating plate located on the front of the heater. Apply the appropriate phase procedure below to determine if proper line voltage is present. Single Phase Line Voltage Testing 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open upper control panel door.

Line voltage from service panel connected to Terminal block of heater

Line voltage from service panel connected to Fuse block of heater

OR

3. Determine connection point for line voltage from service panel, terminal block or fuse block 4. Set multi-meter to volts AC. Be sure to scale meter for appropriate voltage. 5. Use caution and turn power “ON” to water heater. 6. Use caution and check voltage across top terminals where service voltage connects to water heater. (see illustration 3). A) Rated voltage IS present, power to the water heater is okay.

Check voltage across top terminals.

B) Rated voltage NOT present, Check service panel.

Illustration 3

Three Phase Line Voltage Testing 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Open upper control panel door. 3. Determine connection point for line voltage from service panel, terminal block or fuse block

Line voltage from service panel connected to Terminal block of heater

OR

Line voltage from service panel connected to Fuse block of heater

4. Set multi-meter to volts AC. Be sure to scale meter for appropriate voltage. 5. Use caution and turn power “ON” to water heater. 6. Use caution and check voltage across top terminals where service voltage connects to water heater. (see illustration 4). A) Rated voltage IS present, power to the water heater is okay.

Check voltage across top terminals.

B) Rated voltage NOT present, Check service panel.

Illustration 4

Page 16

16

SERVICE PROCEDURE MCE-III Fuse Testing

Fuse Testing

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

1. Turn “OFF” power to water heater. 2. Open upper control box to allow access to fuse block. 3. Locate fuse block and remove fuses. 4. Set multi-meter to the “Ohms” setting. 5. Check continuity across fuse (see illustration 5). A) Continuity IS present, fuse is okay. B) Continuity NOT present, Replace with new fuse

Illustration 5

Page 17

17

SERVICE PROCEDURE MCE-IV High Limit (ECO) Testing

DANGER High voltage exposure. To avoid hazard to life or property use extreme caution when making voltage checks .

High Limit Control (ECO) Testing for Surface Thermostat models (not including 600V)

1. This procedure assumes line voltage and fuses are in working order. 2. This procedure illustrates testing of just one surface thermostat. Repeat this procedure for all surface thermostats on the unit.

ECO reset button

3. Turn power “OFF” to water heater. 4. Remove lower control box cover and remove insulation from inside of control box. 5. Remove plastic cover from thermostat(s). 6. Turn power “ON” to water heater. 7. Check voltage across terminals L1 & L4 for all thermostats (see illustration 6). Illustration 6

A) Rated Voltage IS present, ECO is okay. B) Rated voltage NOT present, proceed to step 8.

8. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s). Turn power “ON” to water heater and recheck voltage across terminals L1 & L4 of thermostat(s). A) Rated voltage IS present, the ECO has previously opened indicating the water in the tank, at some point did overheat, Check the following: 1. Thermostat must be in full contact with tank. 2. Be sure heating element(s) is not shorted to ground (see page 15). 3. Proper thermostat operation (see page 21). B) Rated voltage NOT present, water in tank may be over heated. 1. If water is overheated, turn “OFF” power to water heater and flow water through tank to cool below set point of upper thermostat. Reset ECO and recheck voltage. 2. If water is cool, Replace thermostat(s).

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SERVICE PROCEDURE MCE-V High Limit (ECO) Testing

DANGER High voltage exposure. To avoid hazard to life or property use extreme caution when making voltage checks .

High Limit Control (ECO) Testing for 600V Surface Thermostat Models

1. This procedure assumes line voltage, transformer, fuses, and thermostat are in working order.

ECO reset button

2. Turn power “OFF” to water heater. 3. Remove lower control box cover and remove insulation from inside of control box. 4. Check for continuity across terminals 1 & 2. (see illustration 7) A) Continuity IS present, ECO is okay. B) Continuity NOT present, proceed to step 5. 5. Verify power to the water heater is “OFF”, firmly press the ECO reset button. Recheck continuity across terminals 1 & 2 (see illustration 7).

Illustration 7

A) Continuity IS present, the ECO has previously opened indicating the water in the tank, at some point did overheat, Check the following: 1. Thermostat must be in full contact with tank. 2. Be sure heating element(s) is not shorted to ground (see page 15). 3. Proper thermostat operation (see page 22). B) Continuity NOT present, water in tank may be over heated. 1. If water is overheated, verify that power to water heater is “OFF”. Flow water through the tank to cool below set point of upper thermostat. Reset ECO and recheck continuity. 2. If water is cool, Replace ECO (High Limit).

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19

SERVICE PROCEDURE MCE-VI High Limit (ECO) Testing High Limit Control (ECO) Testing for Contactor Models Switch Contacts: Normally closed. Open on rise @ 196°F ±4°F Manual Reset.

Observe heating cycle. Does switch open?

N

Is water temp over 196°F

Y

N Y

1. Determine if Hi-Limit has actuated. This can be done by simply depressing the reset buttons. If you hear and/or feel a small click, the switch has actuated. 2. Use caution and turn power on to water heater and observe heating cycle following the Hi-Limit Heating Cycle flow chart.

Is water temp over 196°F

Y

Switch OK

N Replace switch

High Limit Heating Cycle Flow Chart

High Limit Control Continuity Testing for Contactor Models 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Water temperature must be below 196°F ±4°F 3. Remove Hi-Limit switch from control panel. It is not necessary to remove immersion bulb from tank at this time. See general controls layout on page 4 for location.

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

4. Disconnect wire leads to Hi-Limit Control during this test. 5. Depress reset buttons to insure switch contacts are closed. 6. Set multi-meter to Ohms setting, Check continuity Thru circuit A & B as shown in the illustrations below. - Continuity IS present, Switch is okay. - Continuity NOT present, Replace switch.

NOTE Disconnect Wire Leads to Control

Circuit “A” Continuity Testing

Circuit “B” Continuity Testing

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20

SERVICE PROCEDURE MCE-VII Thermostat Testing

Surface Mounted Thermostat. Operation Testing (not including 600V models)

DANGER High voltage exposure. To avoid hazard to life or property, use extreme caution when making voltage checks .

Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. TURN OFF POWER TO WATER HEATER. 3. Remove access cover from lower control box. Remove insulation from inside of control box. Remove plastic cover from thermostat. 4. Turn power “ON” to water heater. 5. Set multi-meter to “Volts AC”. 6. Check across terminals L1 & L3 of thermostat (see illustration 8) A) Rated voltage NOT present, Check fuses and or line voltage. B) Rated voltage IS present, proceed to next step.

Illustration 8

Illustration 9

7. Check across terminals L4 and T2 of thermostat (see illustration 9). A) Rated voltage NOT present, Recheck ECO. If ECO is okay, replace thermostat. B) Rated voltage IS present, okay, thermostat is calling for heat, go to next step. 8. Check across element terminals (see illustration 10). A) Rated voltage NOT present, check wire connections from thermostat to element. B) Rated voltage IS present, Repeat element testing, see page 15.

Water Temperature In Tank Is Above Thermostat Setting. 1. This procedure assumes line voltage, ECO and elements are in working order. 2. Turn power “ON” to water heater.

Illustration 10

3. Set multi-meter to “Volts AC”. 4. See illustration 9 above, check across terminals L4 and T2 of thermostat. A) Rated voltage IS present, replace thermostat. B) Rated voltage NOT present, thermostat is okay. C) Lower than rated voltage IS present, recheck for grounded element (see page 15).

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SERVICE PROCEDURE MCE-VIII Thermostat Testing

600V Surface Mounted Thermostat Models. Operation Testing

DANGER High voltage exposure. To avoid hazard to life or property, use extreme caution when making voltage checks .

Water In Tank Is Cold With Power ON. 1. This procedure assumes line voltage, ECO, transformer thermostat, and elements are in working order. 2. TURN OFF POWER TO WATER HEATER. 3. Remove access cover from lower control box. Remove insulation from inside of control box.

4. Using a phillips head screw driver, disconnect the wire lead at terminal 2 of the thermostat. Only check one thermostat at a time to insure wires are correctly reinstalled upon completion. Mark wires if necessary for reinstallation. 5. Set multi-meter to check continuity. 6. Check continuity across terminals 1 & 2 of thermostat (see illustration 11). A) Continuity NOT present, replace thermostat. B) Continuity IS present, thermostat is okay.

Illustration 11

Water Temperature In Tank Is Above Thermostat Setting. 1. This procedure assumes line voltage, ECO, thermostat, transformer, and elements are in working order. 2. TURN OFF POWER TO WATER HEATER. 3. Remove access cover from lower control box. Remove insulation from inside of control box. 4. Using a phillips head screw driver, disconnect the wire lead at terminal 2 of the thermostat. Only check one thermostat at a time to insure wires are correctly reinstalled upon completion. Mark wires if necessary for reinstallation. 5. Set multi-meter to check continuity. 6. See illustration 11 above, check across terminals 1 & 2 of thermostat. A) Continuity IS present, replace thermostat. B) Continuity NOT present, thermostat is okay.

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SERVICE PROCEDURE MCE-IX Thermostat Testing

Immersion Thermostat Operation Testing

DANGER High voltage exposure. To avoid hazard to life or property use extreme caution when making voltage checks .

Thermostat Specification: Calibration: 184°F/176°F Max Differential: 6°F Operating Range 80 to 180°F

Providing the water temperature in tank is within the operating range of the thermostat, checking thermostat operation can be as simple as rotating the thermostat dial and listening to the contactor(s) to see if they respond to a call for heat. Use caution and turn Power “ON” and rotate the thermostat dial to call for heat. With water temperature below the thermostat setting, the contactor(s) close. With the contacts closed, use caution and check for rated voltage across lower terminals of contactor(s) (see illustration 12), If rated voltage is present, the thermostat is calling for heat. Rotate thermostat dial to the minimum setting. With water temperature above the thermostat setting the contactor(s) will open. With the contacts open, voltage should not be present at lower terminals of contactor(s). Follow the procedure below If preliminary testing above does not verify thermostat operation.

Check voltage across lower terminals of contactor(s)

Thermostat Control Continuity Testing.

L1

L2

L3

T1

T2

T3

Illustration 12

1. This procedure assumes line voltage, ECO and contactor(s) are in working order. 2. STOP, DANGER! Turn power “OFF” to water heater. 3. Remove lower control box cover and insulation. 4. Locate thermostat control (see general controls layout on page 4) and remove wire leads to control screw terminals. 5. Water temperature in tank must be within operating range of thermostat for this test. If above or below, it will be necessary to drain tank and remove thermostat immersion bulb from tank to warm or cool the bulb to be within operating range of thermostat. Thermostat Immersion Bulb

6. Set multi-meter to the “Ohms” setting. 7. Rotate thermostat dial to highest setting. 8. Check across screw terminals of control (see illustration 13).

Thermostat Dial

A) Continuity IS present, okay, Go to step 9. B) Continuity NOT present, replace thermostat. 9. Rotate thermostat dial to lowest setting. 10. Check across screw terminals of control (see illustration 13). A) Continuity NOT present, thermostat is okay, B) Continuity IS present, replace thermostat.

NOTE: Disconnect Wire Leads to Control Screw Terminals

Illustration 13

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SERVICE PROCEDURE MCE-X Contactor Testing

DANGER High voltage exposure. To avoid hazard to life or property, use extreme caution when making voltage checks .

Contactor Operation Testing

Noisy Contactor

Noisy or chattering contactor operation in most cases is due to voltage variations being supplied to the water heater. Extended periods of voltage variations will cause damage to the operating coil of the contactor causing noisy operation. Determine that service voltage to the unit meets the electrical requirements per the rating plate located on the front of the water heater. In addition, debris between the contact plates will cause noisy operation.

Contactor Operating Coils Contactor operation is achieved by energizing an operating coil in response to a call for heat from the thermostat. There are three different operating coils used depending on voltage rating of the water heater as follows: Description

Color Code

208/240 Volt Coil 277 Volt Coil 480 Volt Coil

Green Blue Black

All the coils have a color code for visual conformation. In addition, the 277 & 480 volt coils are labeled with voltage rating for proper identification. All contactors supplied for replacement are equipped with The 208/240 volt operating coil. By removing the rear mounting plate of the contactor, the operating coils can be changed based on desired service voltage. When contactor replacement is required be sure to order the proper operating coil base on the voltage rating found on the rating plate located on the front of the water heater.

Rear Mounting Plate

Operating Coil

Color Code Location

Identification Label Location

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SERVICE PROCEDURE MCE-X Contactor Testing

Contactor Operation Testing (continued) This procedure assumes control circuit is operating correctly. Providing the water temperature in tank is within the operating range of the thermostat, checking contactor operation can be as simple as rotating the thermostat dial and listening to the contactor(s) to see if they respond to a call for heat.

DANGER High voltage exposure. To avoid hazard to life or property, use extreme caution when making voltage checks .

1. Turn Power “ON” and rotate thermostat dial to the maximum setting, with water temperature in tank below the thermostat setting, the contactor(s) will close. With the contacts closed, check for line voltage across operating coil terminals (see illustration 14). A) Line voltage IS present, okay, go to step 2. B) Line voltage NOT present, verify control circuit operation. 2. Check for rated voltage across lower terminals of contactor(s) (see illustration 15). A) Rated voltage IS present, okay, go to step 3. B) Rated voltage NOT present, replace contactor. 3. Rotate thermostat dial to the minimum setting. With water temperature in tank above thermostat setting, the contactor(s) will open. With the contacts open, voltage should not be present at lower terminals of contactor(s). 4. Check for line voltage across operating coil terminals (see illustration 14).

Illustration 14

A) Line voltage IS present, verify control circuit operation. B) Line voltage NOT present, okay go to step 5. 5. Check for rated voltage across lower terminals of contactor(s) (see illustration 15). A) Rated voltage IS present, replace contactor. B) Rated voltage NOT present, contactor is okay.

Check voltage across lower terminals of contactor(s)

L1

L2

L3

T1

T2

T3

Illustration 15

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SERVICE PROCEDURE MCE-XI Thermostat Removal and Replacement

Surface Mounted Thermostat Removal 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Remove access cover from lower control box. Remove insulation from inside of control box. Remove plastic cover from thermostat.

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

3. Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connection to new thermostat. 4. Note thermostat temperature setting for proper setting of new thermostat. 5. Slide thermostat upwards and out of mounting bracket. Surface Mounted Thermostat Replacement 1. Use a stiff brush to remove any debris or loose scale from tank surface where new thermostat will be installed. 2. Slide new thermostat down into thermostat bracket until it snaps into place. IMPORTANT! Thermostat must set completely flat or flush to tank surface. An improperly installed thermostat will cause improper water heater operation. 3. Refer to the wire diagram located on the inside of the upper control box cover and re-connect wires to the thermostat. Be sure wire connections are snug and corrosion free. Do not over tighten, doing so may damage thermostat. 4. Set thermostat to the original thermostat setting found on the old thermostat. 5. Restore power to water heater and verify proper heater operation. Tank Surface Proper Thermostat mounting flush with tank surface Thermostat

Improper Thermostat mounting. Thermostat not flush with tank surface Thermostat mounting bracket

Front View Thermostat Mounting

Side View Proper Thermostat Mounting

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Side View Improper Thermostat Mounting

SERVICE PROCEDURE MCE-XII Thermostat Removal and Replacement

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

Immersion Thermostat Removal & Replacement 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the Immersion bulb location (see illustration 16 ). 3. Close drain spigot and remove hose. 4. Remove lower control box cover and insulation. 5. Locate thermostat inside lower control box mounted to the right side of the box, below the ECO control (see illustration 16). 6. Follow copper capillary tube from thermostat to the immersion bulb location and remove immersion bulb from tank, 11/16 wrench.

Immersion Thermostat Bulb Location

7. Remove (pull) thermostat control dial from stem of thermostat.

ECO Control

8. Remove the two thermostat mounting screw screws located under thermostat dial (see illustration 16).

Thermostat control Mounting Screws Located Under Thermostat Dial

Copper Capillary 9. Once thermostat is removed, disconnect Tube wire leads to the thermostat. NOTE: It may be necessary to identify wires for proper reconnection to new thermostat. Immersion

10. Refer to wiring diagram located on the inside of the upper control box cover and properly reconnect wire leads to new thermostat and remount control inside control box using screws from step 8.

Thermostat control

11. Replace control dial to stem of thermostat. 12. Loosen ferrule nut of immersion bulb. (see illustration 17) Immersion bulb

Illustration 16

Ferrule nut

Tank nut

Copper capillary tube

Illustration 17 13. Position tank nut at end of immersion bulb as shown in illustration 17. Insert immersion bulb into tank and tighten tank nut. 14. Gently pull copper capillary tube to insure the immersion bulb is in a horizontal position as shown in illustration 17 and tighten ferrule nut. 15. Resume water supply, fill tank and check for leaks. 16. Be sure tank is full or water and resume power supply to water heater. Verify proper thermostat operation.

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SERVICE PROCEDURE MCE-XIII Contactor Model High Limit (ECO) Control Removal and Replacement Contactor Model High Limit (ECO) Control Removal and Replacement 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the Immersion bulb location (see illustration 18).

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

3. Close drain spigot and remove hose. 4. Remove lower control box cover and insulation. 5. Locate ECO control inside lower control box mounted to the right side of the box, above the thermostat control (see illustration 18).

ECO Immersion Bulb the Location

6. Follow copper capillary tube from ECO control to immersion bulb location and remove immersion bulb from tank, 11/16 wrench. 7. Remove the two ECO control mounting screws located outside the lower control box.

ECO Control

Copper Capillary Tube

Thermostat Control

8. Once ECO control is removed, disconnect wire leads to the control. NOTE: It may be necessary to identify wires for proper reconnection to new control. 9. Refer to wiring diagram located on the inside of the upper control box cover and properly reconnect wire leads to new ECO control and remount control inside control box using screws from step 7. 10. Loosen ferrule nut of immersion bulb. (see illustration 19) Immersion bulb

Illustration 18

Ferrule nut

Tank nut

Copper capillary tube

Illustration 19 11. Position tank nut at end of immersion bulb as shown in illustration 19. Insert immersion bulb into tank and tighten tank nut. 12. Gently pull copper capillary tube to insure the immersion bulb is in a horizontal position as shown in illustration 19 and tighten ferrule nut. 13. Resume water supply, fill tank and check for leaks. 14. Be sure tank is full of water and resume power supply to water heater. Verify proper ECO operation.

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SERVICE PROCEDURE MCE-XIV 600V Model High Limit (ECO) Control Removal and Replacement DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

600V Surface Thermostat Model High Limit (ECO) Control Removal and Replacement 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Remove lower control box cover and insulation. 3. Locate high limit switch mounted to the tank above the element spuds (see illustration 20). 4. Disconnect wire leads to the high limit. NOTE: It may be necessary to identify wires for proper reconnection to new control. 5. Remove the two high limit mounting nuts holding the sensor to the tank. Take care not to damage the mounting studs. 6. Fasten the replacement high limit to the tank using the nuts from step 5. Take care not to damage the mounting studs. Refer to wiring diagram located on the inside of the upper control box cover and properly reconnect wire leads to new high limit.

High Limit Switch

7. Verify proper ECO operation. Mounting Stud

Illustration 20

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SERVICE PROCEDURE MCE-XV Heating Element Removal and Replacement

Heating Element Removal 1. STOP, DANGER! Turn power “OFF” to water heater. 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the Element(s). 3. Close drain spigot and remove hose. 4. Remove access cover from lower control box. Remove insulation from inside of control box. Remove plastic cover from thermostat. 5. Disconnect wires from element terminals.

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

6. Remove element from tank using 1-½” deep well socket or appropriate wrench. Unscrew element counter-clockwise to remove from tank. 7. Be sure to remove old element gasket from the tank. It is not recommended to be re-used. Heating Element Replacement 1. Check new element terminal block for proper electrical rating. NOTE: Some elements have dual ratings, be sure to check all surfaces of the element terminal block (see illustration below). 2. Apply new element gasket to the new element. Be sure gasket is seated flat against element flange without rolls or gaps (see illustration below). 3. Clean any debris from element fitting on tank. 4. Thread new element clockwise into tank. Tighten element using 1-½” deep well socket or appropriate wrench. Do not over tighten, over tightening may damage element gasket. 5. Reconnect wires to element, be sure connections are snug and corrosion free. Do not over tighten, doing so may damage terminal block. 6. Resume water supply to heater, be sure tank is full of water and check for leaks. 7. Re-install plastic thermostat protector(s). 8. Re-install insulation and control box cover. 9. To resume operation, BE SURE TANK IS FULL OF WATER and restore power to water heater. Verify proper heater operation. Element Rating. Example: (4500 Watt, 240 Volt) Date Code

0642 4500W 240V RC02404524

Element Flange Element Gasket Seated Flat Against Element Flange Without Rolls or Gaps

Terminal Block Manufacturer Identification

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SERVICE PROCEDURE MCE-XVI Anode Inspection and Replacement Anode Inspection and Replacement

DANGER High voltage exposure. To avoid hazard to Life or property, be sure power is turned OFF to water heater while performing this procedure.

WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 1. Turn power “OFF” to water heater. 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the anode locations at the top of the tank. 3. Close drain spigot and remove hose. 4. Remove the plastic anode access plugs at the anode locations. 5. Remove anode from the water heater (1-1/16" socket). 6. Visually Inspect anode. Anode should show signs of depletion, this is normal. If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended. 7. Upon completion of inspection or subsequent replacement, reinstall anode into heater. resume water supply, refill heater with water and check for leaks. 8. To resume operation, BE SURE HEATER IS FULL OF WATER and turn power “ON” to water heater.

Anode Rod Locations

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Generic Parts List

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Generic Parts List

Item 1 2 3 3A 4 5 5A 6 7 8 9 10 10A 11 11A 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25

Description Anode. Hot Water Outlet Nipple. T&P Nipple. T&P Coupling. T&P Relief Valve. High Limit Switch. Surface High Limit Switch. Hex Nut Lock Washer Screw High Limit Spacer. Cleanout O-Ring. Cleanout Gasket (ASME). Cleanout Cover. Cleanout Cover (ASME). Cleanout Cover Screw. Cleanout Cover Screw (ASME) Cleanout Access Cover. Brass Drain Valve. Escutcheon. Drain Extender. Thermostat Dial Screw. Immersion Thermostat. Heating Element. Surface thermostat Bracket. Surface Thermostat. Surface Thermostat Cover. Lower Control Box Cover. Heating Element Plug.

Item 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Description Heating Element Gasket. Cold Water Inlet Nipple. Plastic Snap Bushing. Lower Control Box. Upper Control Box. Terminal Block (Block A) Terminal Block End (used for block A). Terminal Block 2 pole. Terminal Block 3 Pole. Screw. Fuse Block 2 Pole Class G Fuse Block 3 Pole Class G Fuse Block 3 Pole Class J Contactor 3 Pole. Contactor 4 Pole. Screw. Contactor Coil Fuse Class G Fuse Class J Fuse Class J Ground Lug Small. Ground Lug Large. Screw. ¾ NPT Plug. Transformer - 120V

Glossary of Terms Term Voltage CurrentResistanceEnergyPower-

Definition Electrical potential Rate of voltage flow Ability of a device to dissipate power irreversibly Ability to do work Energy per unit of time

Unit of measure Volts Amperes (amp) Ohms kW/hr, Joule Watts, kW, VA

One kilowatt (1kW) = 1,000 Watts. = 3,412 BTU DC = Direct Current AC = Alternating Current Hz = Hertz

BTUH = British thermal units per hour PSI = Pounds per square inch GPM = Gallons per minute GPH = Gallons per hour ECO = Energy cut off NPT = National pipe thread ASME = American Society of Mechanical Engineers

°F = Degrees Fahrenheit °C = Degree Centigrade

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NOTES

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NOTES

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