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Service Handbook
commercial electric W ater HeaterS
model S Stce3-52/80/119
& itce3-52/80/119
inSalla t tion conSiderationS - pre Service
cHecKS - W ater Heater conStruction -
Technical Support and Parts: 800-456-9805
operation & Service - troubleSHooting
www.americanwaterheater.com
Servicing SHould only be performed by a Qualified Service agent.
PRINTED IN THE U.S.A 1008 315016-000
1
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COMMERCIAL ELECTRIC WATER HEATER SERVICE MANUAL TABLE OF CONTENTS INTRODUCTION .......................................................................2 ELECTRONIC CONTROLS..................................................... 41 Qualifications ......................................................................2 CCB - Central Control Board............................................ 42 Service Warning .................................................................2 CCB Socket & Wiring Termina
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INTRODUCTION INTRODUCTION This Service Manual is designed to be an aid in servicing and troubleshooting the commercial electric water heater models listed on the cover.The instructions, illustrations and procedures contained in this manual are used to verify proper operation and to diagnose and repair common service problems. This Service Manual does not replace or supersede the Instruction Manual that came with the water heater. Always refer to the Instruction Manual that came with the wate
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INTRODUCTION INSTRUCTION MANUAL Have a copy of the Instruction Manual that came with the water heater on hand for the correct model water heater you are working with before servicing. Installation information given in this Service Manual IS NOT a complete installation instruction. Installation information covered in this Service Manual has a limited focus as it applies to servicing. This Service Manual does not replace or supersede the Instruction Manual that came with the water heater. Alwa
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INSTALLATION CONSIDERATIONS INSTALLATION CONSIDERATIONS Installation information given in this Service Manual IS NOT a complete installation instruction. Installation information covered in this Service Manual has a limited focus as it applies to servicing. This Service Manual does not replace or supersede the Instruction Manual that came with the water heater. Always refer to the Instruction Manual that came with the water heater for complete installation instructions. If the instruction Ma
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INSTALLATION CONSIDERATIONS ELECTRICAL REQUIREMENTS Grounding Review the electrical ground requirements given in the Instruction Manual that came with the water heater and ensure the water heater has been properly grounded. The water heater must be grounded in accordance with the National Electric Code and/or local codes. These codes must be followed in all cases. The water heater must be connected to a grounded metal, permanent wiring system; or an equipment grounding conductor must be run w
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PRE SERVICE CHECKS PRE SERVICE CHECKS WIRING CONNECTIONS With the power supply to the water heater turned off ensure the wiring connections are properly tightened to all components including: high voltage terminal blocks, fuse blocks, contactors, transformers and heating elements. Loose connections at any connection point will cause increased amperage and excessive heat which can damage wiring and components. Whenever worn or damaged wiring and components must be replaced ensure all wiring
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WATER HEATER CONSTRUCTION WATER HEATER CONSTRUCTION There are two types of commercial electric water heaters covered in this manual. See Figure 1 on page 8 and Figure 2 on page 9. SURFACE MOUNT CONTROL MODELS The first type of water heater covered in this manual is equipped with surface mount thermostat/ECO controls - Surface Mount Control Models. There will be separate thermostat/ECO (energy cut out) combination controls mounted to the surface of the storage tank directly above the heating
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WATER HEATER CONSTRUCTION SURFACE MOUNT CONTROL MODELS Figure 1 Servicing should only be performed by a Qualified Service Agent 8
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WATER HEATER CONSTRUCTION ELECTRONIC CONTROL MODELS Figure 2 Servicing should only be performed by a Qualified Service Agent 9
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OPERATION & SERVICE OPERATION & SERVICE This section of the manual will cover the principles of electricity, single and three phase power, fuses, surface mount thermostat/ECO combination controls, heating element construction & operation, heating element sensors, contactors, common service procedures and more. Information and service procedures presented in this section will be referenced in the troubleshooting sections. PRINCIPLES OF ELECTRICITY Voltage The unit of measurement used to quant
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OPERATION & SERVICE Ohms Law A law that explains the relationship between voltage, current and resistance. The law states that the electric current flowing through a conductor is equal to the voltage divided by the resistance. The following equations further explain ohms law. Ohms Law applied to “SINGLE PHASE” (1Ø) power: V = Volts (electrical pressure) A = Amps (electrical flow/current) O = Ohms (resistance to electrical flow/current) W = Watts (rate or amount of electricity used) V ÷ A = O
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OPERATION & SERVICE SINGLE AND THREE PHASE POWER The water heaters covered in this manual can be field converted for a single or three phase power supply - see pages 15 and 16. These water heaters can be factory ordered for standard North American power supplies; 277/208/240/480 volt models. 277 volt models are single phase only. Voltage conversion kits with instructions are available from the manufacturer - voltage conversions are not covered in this manual. Verifying the power supply is a
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OPERATION & SERVICE Checking Single Phase (1Ø) Power A single phase power supply consists of two wires connected to the L1 and L2 terminals of the Power Distribution Block, the L3 terminal is not used. On a single phase (1Ø) 277 volt power supply one of the two wires is a “neutral” wire and does have voltage present. On a single phase (1Ø) 277 volt power supply the “hot” wire should be connected to the L1 terminal and the “neutral” wire should be connected to the L2 terminal. On 208, 240 and
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OPERATION & SERVICE Checking Three Phase (3Ø) Power A three phase power supply consists of three wires connected to the L1, L2 and L3 terminals of the Power Distribution Block. All three wires are “hot” with voltage present. Voltage Between Terminals: Set the volt meter to an AC voltage range above the expected voltage (600 VAC or higher range initially). Checking three phase (3Ø) power requires that three voltage readings be taken between all possible parings of the terminals on the Power D
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OPERATION & SERVICE PHASE CONVERSIONS - SURFACE MOUNT CONTROL MODELS Internal wiring connections between the Power Distribution Block and the heating elements are different on Surface Mount Control (see Figure 1 page 8) and Electronic Control (see Figure 2 page 9) model water heaters. Because of these differences there are two methods for field converting these models to work with single and three phase power supplies. Service Note: 208 volt 54 KW models are 3 phase only and CAN NOT be conver
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OPERATION & SERVICE PHASE CONVERSIONS - ELECTRONIC CONTROL MODELS Internal wiring connections between the Power Distribution Block and the heating elements is different on Surface Mount Control (see Figure 1 page 8) and Electronic Control (see Figure 2 page 9) model water heaters. Because of these differences there are two methods for field converting these models to work with single and three phase power supplies. Service Note: 208 volt 54 KW models are 3 phase only and CAN NOT be converted
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OPERATION & SERVICE FUSES The water heaters covered in this manual have power circuit fuses to protect the heating element circuits. Electronic Control models will have two additional fuses to protect the primary winding of the 120 Volt Control Circuit Transformer. See Figures 1 and 2 on pages 8 and 9 for location. Testing fuses requires an ohm meter, an AC volt meter and an insulated fuse puller - see Tools Required page 3. Service Note - Replacement Fuses: Replacement power circuit fuses M
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OPERATION & SERVICE SURFACE MOUNT THERMOSTATS The Surface Mount Control Model water heaters covered in this manual have “separate” thermostat/ECO (energy cut out) combination controls mounted to the surface of the storage tank directly above the heating elements they control. IE: a water heater equipped with 9 heating elements will have 9 thermostat/ECO controls. These controls contain two bimetal thermal switches that react to heat sensed from the surface of the water heater’s storage tank
