COMMERCIAL ELECTRIC WATER HEATER
SERVICE MANUAL
TABLE OF CONTENTS
INTRODUCTION .......................................................................2
Qualifications......................................................................2
Service Warning .................................................................2
Tools Required....................................................................3
INSTALLATION CONSIDERATIONS........................................4
Closed Water Systems .......................................................4
Thermal Expansion.............................................................4
Electrical Requirements......................................................5
PRE SERVICE CHECKS...........................................................6
Service Precautions............................................................5
WATER HEATER CONSTRUCTION ........................................7
5 - 20 Gallon Models ..........................................................8
30 - 120 Gallon Models ......................................................9
OPERATION & SERVICE........................................................10
Principles of Electricity......................................................10
Single And Three Phase Power .......................................12
Checking Single Phase Power..................................13
Checking Three Phase Power...................................14
Fuses................................................................................15
Heating Elements ............................................................ 16
Heating Element Construction...................................16
Six and Three Wire Heating Elements ......................17
Single Phase Element Wiring.............................18 - 19
Three Phase Element Wiring..............................20 - 22
Heating Element Ratings & Configurations...............23
Heating Element Amperage Tables...........................24
Heating Element Amperage Test...............................25
Heating Element Voltage Test ...................................26
Heating Element Resistance Tables..........................28
Heating Element Resistance Test..............................29
Heating Element Ground Test ...................................30
Replacing Heating Elements.....................................31
Heating Element Sensors.................................................32
Element Sensor Operation........................................33
Contactors ........................................................................34
Contactor Configurations...........................................35
Contactor Inspection..................................................36
Contactor Coil Voltage - At Contactor........................37
Contactor Coil Voltage - At CCB................................38
Transformers ....................................................................39
120 VAC Control Circuit Transformer Wiring.... 39 & 40
120 VAC Control Circuit Transformer Test.................41
24 VAC Transformer Test ..........................................42
Immersion Temperature Probe .........................................43
Temperature Sensor Resistance Test........................44
Temperature Sensor DC Voltage Test .......................45
ECO Continuity Test..................................................45
ECO Voltage Test ......................................................46
LWCO (Low Water Cut Off) ..............................................47
Powered Anode Rod ........................................................48
Electronic Controls ...........................................................49
CCB - Central Control Board.....................................50
CCB Socket & Wiring Terminal Identification ............51
CCB Enable Disable Circuit(s) Test...........................53
Checking Power And Ground To The CCB ...............54
UIM - User Interface Module.....................................55
ELECTRONIC CONTROL SYSTEM .......................................56
Heating Element Operation..............................................56
Control System Features..................................................57
Control System Navigation...............................................57
The Desktop Screen.........................................................58
Status Icons...............................................................59
Operating States........................................................60
Control System Menus..............................................60
Temperatures Menu..........................................................61
Temperature Settings ................................................62
Heater Status Menu..........................................................63
Economy Mode Setup Menu ............................................64
Setpoint Adjustment Value ........................................65
Time Clock Settings ..................................................66
Daily Operating Mode Settings..................................67
Alarm Output Setup Menu................................................68
Display Settings Menu......................................................69
Heater Information Menu..................................................70
Current Fault/Alert Menu..................................................71
Fault History Menu ...........................................................71
Fault Occurrence Menu....................................................71
Restore Factory Defaults Menu........................................72
TROUBLESHOOTING.............................................................73
Common Service Problems..............................................73
Control System Diagnostics .............................................74
Fault Conditions ........................................................74
Alert Conditions.........................................................74
Resetting The Control System ..................................74
Control System Unresponsive..........................................74
UIM Display Is Blank.................................................74
UIM Is Inoperable......................................................75
Heating Cycle Disabled.............................................75
Fault & Alert Messages ....................................................76
No Current Detected .................................................76
Temp Probe Open .....................................................77
Temp Probe Short .....................................................77
Energy Cut Out (ECO) ..............................................78
LWCO Fault...............................................................79
No Anode Current .....................................................80
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