State Water Heaters RESIDENTIAL ELECTRIC WATER HEATER Service Handbook
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State Water Heaters RESIDENTIAL ELECTRIC WATER HEATER Service Handbook

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  • Page 2: Table Of Contents

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TABLE OF CONTENTS Page Page Introduction A-9 Off Peak Circuit......18 Certification and Approval…………………1 A-9 Circuit Sequence of Oper....19 Tools ............2 Three phase unbalanced circuit ..20 Terms, Definitions, Formulas..... 2 A-9 Circuit Testing ......21 Residential Electric Water Heaters Miscellaneous Information....24...

  • Page 3: Tools

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK GENERAL SECTION TOOLS REQUIRED: FOR SERVICING RESIDENTIAL ELECTRIC MODELS #2 Phillips screw driver • electrical multi-meter (volt/Ohm) • water pressure gauge (with a lazy hand) • thermometer • hose – to drain tank •...

  • Page 4: Residential Electric Water Heaters

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK GENERAL SECTION – cont’d. TERMS, DEFINITIONS, AND FORMULAS: Water Expands when it is heated. Volume increases about 2% from 40° to 140° F. Minerals and gases will separate from water as temperature increases Amperage (Amps) (1 phase) = Watts divided by Volts (Ohm’s Law) KW Required = (GPH X 8.25 X Temp.

  • Page 5: Installation

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK INSTALLATION - typical SOME MODELS MAY HAVE SIDE OR REAR CONNECTIONS COLD WATER TO FUSED INLET LINE ELECTRICAL TEMPERATURE AND SUPPLY PRESSURE RELIEF VALVE (BREAKER BOX) OPENING MAY BE ON SIDE OR TOP OF HEATER. DO...
  • Page 6 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK INSTALLATION - typical Parallel Piping arrangement for multiple water heaters ensures maximum hot water and efficient operation. This piping arrangement depends on dividing piping between water heaters evenly. It may be expanded for more than two water heaters.

  • Page 7: Construction

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK CONSTRUCTION - typical This portion of this manual applies to the Operation and Servicing of Residential Electric, Tank Type, Water Heaters. The illustrations are for two element models but the information also applies to single element models.
  • Page 8 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK Construction – cont’d. Heating element(s) This style water heater will have one or two electric, heating elements immersed in the tank. One element will always be located low in the tank; a second element is commonly located down about 1/3 of the tank height from the top of the tank.

  • Page 9: Element Test - Continuity

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK ELEMENT TEST – RESISTANCE/CONTINUITY OHMS Resistance Check** Disconnect wires from the element terminals. 12.8 NOTE: OHM readings may vary by up to 7.5% depending on the meter and the element. Always check meter for proper operation by touching probe ends together.
  • Page 10 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK GROUNDED ELEMENT TEST USING A MULTI-METER Check Continuity to the Tank Beep Note: An element’s resistance wire is insulated so current cannot reach the 00.0 outside of the element and come in contact with the water or the tank during normal operation.
  • Page 11 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK FAILED ELEMENT TEST - AMPERAGE METHOD Amperage Check: Measures the flow of current through a wire. Failed Element Test – using “clamp type” Amperage Meter. Many multi-meters could be used to conduct this test but be certain that possible amperage will not exceed the multi-meter’s limit.
  • Page 12 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK GROUNDED ELEMENT CHECK – AMPERAGE METHOD Amperage Check: Measures the flow of current through a wire. Grounded Element Test – using “clamp type” Amperage Meter. Many multi-meters could be used to conduct this test but be certain that possible amperage will not exceed the multi-meter’s limit.

  • Page 13: Field Wiring

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK FIELD WIRING L1 to Ground = 120 Volts L1 to L2 = 480 Volts L2 to Ground = 0 Volts L2 to L3 = 480 Volts L1 to L3 = 480 Volts L1, L2, or L3 to Ground...
  • Page 14 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK SURFACE MOUNTED THERMOSTAT (S) AND HIGH LIMIT (S) The thermostats and high limits are held against the side of the tank. As the tank surface heats or cools, a metal disc inside of the control expands or contracts to open or close electrical contacts in the controls.
  • Page 15 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK C-2 CIRCUIT WIRING AND SEQUENCE OF OPERATION C-2 Circuit – Standard on most single element water WIRING DIAGRAM heaters. Operation from a cold tank of water • Note: If used on a normally two element...

  • Page 16: Thermostats

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK C2 CIRCUIT TESTING SINGLE ELEMENT, SINGLE THERMOSTAT CIRCUIT COMPLAINT: POSSIBLE CAUSE REMEDY Check fuse or circuit Power off breaker. NO HOT WATER High Limit (ECO) Press red (reset) button (p.10) Continuity Check (p. 8) or...
  • Page 17 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK A – 6 CIRCUIT (INTERLOCK OR NON-SIMULTANEOUS) COMPONENTS WIRING DIAGRAM A-6 Circuit A-6 WIRING CIRCUIT • 2 Elements • 2 Thermostats • 1 High Limit A-6 Circuit - Standard on dual element water heaters non-...

  • Page 18: Sequence Of Operation

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK SEQUENCE OF OPERATION:A-6 CIRCUIT COLD TANK STARTUP Note: The operation sequence at right only applies to the initial cold tank start. On successive cycles cold water entering the tank is forced to the bottom by the dip tube.
  • Page 19 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK A-9 OFF PEAK/TIME CLOCK CIRCUIT • 2 Elements • 2 Thermostats • 2 High Limits • 3 Wire Three wire circuit for non-simultaneous element operation and single-phase power. This circuit permits off-peak meter usage or connection to a 3-phase supply circuit.
  • Page 20 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK SEQUENCE OF OPERATION: OFF-PEAK/TIME CLOCK CIRCUIT COLD TANK START Cold tank of water • Single Electrical Service • Single Phase -------------------------------------------------------------------------------------------------------------------------------------------- Technical Training Department 19 of 36 Residential Electric Svc Handbook Ashland City, Tennessee ©2004...

  • Page 21: Three Phase Unbalanced Circuit

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK THREE-PHASE UN-BALANCED CIRCUIT Note: For simplicity, the thermostats are not shown. UNBALANCED 3 PHASE LOAD Three phase power delivers power with 3 legs to the water heater. The water heater must be specially wired to accept three phase power.
  • Page 22 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TESTING THE A-9 OFF-PEAK / TIME CLOCK CIRCUIT OPTIONAL UNBALANCED 3-PHASE CIRCUIT A-9 Circuit: Two elements Two thermostats Two high limits 3 wires Note: The standard A-9 circuit is designed as an interlock circuit –...
  • Page 23 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TESTING THE A-9 OFF-PEAK / TIME CLOCK CIRCUIT Connection to an off-peak clock interrupts power to the lower thermostat and heating element during the designated time period but does not interrupt power to the upper thermostat.
  • Page 24 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TESTING THE A-9 OFF-PEAK / TIME CLOCK CIRCUIT Complaint: Lack of Hot Water Test Condition: Upper thermostat satisfied Test between upper high limit 4 and upper thermostat 4 If … … then proper voltage is not present Replace upper thermostat.
  • Page 25 • Normally, a residential electric water heater with two elements will have only one element operate at a time. If the upper element or thermostat fails, the customer will be out of hot water. If the lower element or thermostat fails, the customer should still have 1/3 of the tank with hot water.
  • Page 26 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK SERVICE BULLETINS The following are bulletins designed to help service the standard, residential gas and electric model water heaters. These bulletins and more are available on the website www.statewaterheaters.com. This information is intended to supplement service and maintenance information found in the heater installation and operation manual.
  • Page 27 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK WHY WATER HEATER TANKS LEAK WHAT PREVENTION Water Water expands when it is heated A Temperature and Pressure Relief Valve Pressure (Thermal Expansion). Water limits pressure to a maximum. cannot be compressed. Adding a Thermal Expansion Tank limits Excessive Pressure in the tank pressure to near supply water pressure.

  • Page 28: Water Hammer

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 11 WATER HAMMER Water hammer is the destructive forces, pounding noises and vibration in a piping GENERAL system when water flowing through a pipeline is stopped abruptly. When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief.

  • Page 29: Mineral Buildup

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 13 MINERAL BUILD-UP SYMPTOMS • • • Rumbling Crackling Popping With the advent of high input and larger storage tanks in both commercial and CAUSE residential heaters, deliming has become a necessity of modern maintenance. Lime (CaCO ), is the most notable factor when discussing water hardness.

  • Page 30: Aluminum Hydroxide

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 14 ALUMINUM HYDROXIDE “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than SYMPTOMS six months). In a few isolated parts of the United States where the water supply has a relatively high pH (8+),...

  • Page 31: Discolored Water

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 21 DISCOLORED WATER Rusty, brown, black, or yellow water appearing in the hot water. SYMPTOMS Complaints of discolored water are commonly blamed on water heaters and CAUSE storage tanks, but in fact, it is a rare occurrence for today’s high quality glass lined tanks to have a lining failure significant enough to allow water to contact enough bare metal to discolor the contents of even a small tank.

  • Page 32: Smelly Water

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 22 SMELLY WATER The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, CAUSE scientifically termed Divibrio Sulfurcans. This bacteria often enters the water system through construction or a break in ground piping. The bacteria create the energy it...

  • Page 33: Chlorination Procedure

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 23 CHLORINATION PROCEDURE PROCEDURE Please read the steps of the chlorination procedure prior to beginning. If you feel uncomfortable performing any of these steps, contact a service person to perform this procedure for you.

  • Page 34: Not Enough Hot Water - Electric

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 36 NOT ENOUGH HOT WATER - ELECTRIC Not enough hot water complaints are becoming more frequent in the water heater CAUSE industry. This increase was triggered when changes required by our regulatory agencies were implemented.

  • Page 35: Thermal Expansion

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 45 THERMAL EXPANSION • Effects are only noticeable after hot water use followed by periods of no water use. SYMPTOMS • Relief valve drips during any recovery cycle when no hot or cold water is used.
  • Page 36 RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK The ideal fix involves the use of a pressure reducing valve if supply pressures are THE FIX above 60 to 70 psi, and a properly sized expansion tank. The PRV reduces supply pressures to 40 to 60 psi allowing an economically priced and sized expansion tank to be used.

  • Page 37: Leaking Temperature And Pressure Relief Valve

    RESIDENTIAL ELECTRIC WATER HEATER SERVICE HANDBOOK TECHNICAL BULLETIN BULLETIN 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE • Water seeping around the relief valve tank connection SYMPTOMS • Leakage at the threaded portion of the relief valve connection • Intermittent weeping and/or dribbling from the relief valve •...
  • Page 38 To order additional copies of this Service Handbook and to view other service and presentation literature and CDs that are available from State Water Heaters: Telephone 1-800-821-2017, Fax number 800-644-9306 or visit our web site at www.statewaterheaters.com For additional information or assistance in servicing your...

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Standard residential electric water heater

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