Use and Care Manual
Contents
1. 3 Loa 2 PROBE WIRE COLOR CODE NOTE Diagrams do not show wiring from terminal block to fuses contactors W White and heating elements Control circuit BL Blue only is shown LITO709 Rev A POWER CIRCUIT ONE WIRE PER ELEMENT CONTACTORS Power Circuits fused when total amperage exceeds 120 amps CIRCUIT LIMITED TO 48 AMPS LITO712 Rev A CUSTOM POWER CHP WIRING DIAGRAMS POWER CIRCUIT TWO WIRES PER ELEMENT MAIN TERMINAL BLOCK FUSE BLOCK CONTACTOR Power Circuits fused when total amperage exceeds 120 amps CIRCUIT LIMITED TO 48 AMPS LITO713 Rev A Power Circuits fused when total amperage exceeds 120 amps CONTACTORS CIRCUIT LIMITED TO 48 AMPS HEATING ELEMENT LITO714 Rev A P Lochinvar Lochinvar Corporation Nashville Tennessee 615 889 8900 Fax 615 547 1000 www Lochinvar com 07 07 Printed in U S A Custom Hi Power Commercial Electric Water Heaters 150 to 2500 Gallons Storage Vertical and Horizontal Energy Saving Performance Dimensions Vertical Round Models 150 1000 B ADDITIONAL T amp P HEIGHTIF RELIEF REQUIRED _ HOT WATER VALVE OUTLET CONNECTION CONTROL VOLTAGE ON OFF SWITCH WITH PILOT LIGHT A CLEANOUT L COLD WATER INLET D DRAIN CHANNEL HV 150 amp HV 200 do not have channel 3 4 DRAIN 150 amp 200 N 0 1 DRAIN P d2. 1 Insure that the electrical power to the water heater is in the OFF position If the power disconnect point is out of sight lock it in the open OFF position and tag to prevent unexpected application of power Close the water heater drain valve s Open a nearby hot water faucet to allow the air in the system to escape as the tank fills Fully open the cold water inlet valve to the water heater to begin filling the heater and piping The cold water supply must be left in the open position when the water 22 heater is in use 5 Check the nearby hot water faucet to verify that air is exiting the tank as it fills with water Allow water to run until a constant flow is obtained at the faucet This will insure that all air is purged from the system The power supply must remain off until the water heater and all related piping are completely filled with water to insure that there will not be a possible problem with heating element burn out 6 8 While the tank is filling open the electrical control panel and set the thermostat s to the desired water temperature If equipped with multiple thermostats all individual thermostats may be adjusted to the same temperature set point or they may be set a 2 F to 4 F 1 C to 2 C apart to step the elements on in stages Insure that any pilot switches or manual limiting switches are placed the ON position When a constant fl
3. 25 Sediment Removal 25 Scale Removal Elements Trouble Shooting Not Enough Hot Water 27 Water Is Too Hot 27 Water Heater Sounds 27 Leakage 27 FIG 1 Front View Vertical Round Models FIG 2 Front View Vertical Square Models FIG 3 Front View Horizontal Models OWNER WARNING A The information contained in this manual is intended for use by qualified professional installers service technicians or the electric utility Consult your local expert for proper installation or service procedures Consult and follow local Electrical Codes Building and Fire Regulations and other Safety Codes that apply to this installation Consult local codes officials and electric utility company to authorize and inspect all field installed electrical connections i Ye EV INE Be sure to turn off power when working on or near the electrical system of the water heater Never touch electrical components with wet hands or when standing in water When replacing fuses always use the correct size for the circuit Do not test electrical system before the water heater is completely filled with water Follow the start up procedure SEF N To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules 1 Always keep the area around your appliance free of combustible materials gasoline
4. s electronic temperature control AE RAM Error The internal RAM of the microprocessor in the boiler s electronic temperature control is defective This error cannot be field repaired Replace the water heater s electronic temperature control HIGH WATER TEMPERATURE LIMIT CONTROL TOP VIEW FIG 21 High Water Temperature Limit Control Fixed Setting The unit is equipped with a fixed setting manual reset high water temperature limit control The water heater temperature limit control has a fixed limit setting of 195 F 90 6 C If water temperature exceeds the limit set point the limit will break the control circuit and shut down the unit The limit control can only be reset after the water temperature has cooled below the set point of the limit The high water temperature limit control is mounted on the surface of the tank above the heating element installed at the highest point in the tank The high limit control is reset by pushing the red reset button on the control Operation of the limit control usually indicates a major problem with the thermostat contactors or heating elements Do not continue to push the 18 reset multiple times The source of the problem must be found and corrected to insure proper operation The limit control is covered with an insulation blanket which must be removed to push the red reset button The blanket of insulation must be replaced before the power is turned on and the water hea
5. SAFETY DOOR INTERLOCK Optional FIG 23 Safety Door Interlock The optional safety door interlock is an electrically operated locking pawl that is energized when main power to the water heater is turned ON The interlock is mounted to the inside of the electrical control panel door and extends behind a locking flange when energized Main power may be turned off and the electrical access door may be opened for service With the door open main power may be energized if required to service or troubleshoot the operation of selected components DANGER 4 HAZARD OF ELECTRICAL SHOCK Full power is present whenever the cabinet door is opened and main power is turned ON even with the pilot switch es turned off LOW WATER CUTOFF Optional transrorwer 2 Control Board Probe FIG 24 Electronic Low Water Cut off Control This water heater may be equipped with an optional electronic low water cut off installed at the factory This low water cut off device uses a water level sensing probe located above the heating element installed in the highest point in the storage tank If the internal water level drops below this point the low water cut off will shut down operation of the heating elements An electronic type low water cut off is available as a factory supplied option on all models The optional electronic low water cut off has an LED located on the main circuit board This LED will be illuminat
6. Safety Warnings Checking the Equipment COES a haat ces SVR Installation Requirements n Drain Pan Requirements Clearances Mounting Water Connections Tank Construction Relief Valve Thermal Expansion Cathodic Protection Electrical Service Electrical Connection Wire Sizing Fusing Electrical Connection Jacket Assembly Standard and Optional Controls Components and Controls Terminal Block Fuses and Fuse Blocks Contactors Transformer Immersion Thermostat Temperature Regulation Risk of Scald Warnings Temperature Control Sequencer Displ y sese pau TEES Temperature Adjustment Error Temperature Limit Control Immersion Heating Elements Safety Door Lock Low Water Cut Off Low Water Pressure Switch High Water Pressure Switch Manual Limiting Switches Time NOC es sr PS Pilot Lights Cua c RA E EAR Alarm Bell Start Up Procedure Filling the Water Heater 22 Start Up Checks 23 Shutdown Procedure 24 Maintenance T amp P Relief Valve 24 Water 25 Flushing the Tank
7. kW input vertical square water heaters may have an additional control access panel located on the right side of the jacket requiring an additional service access from the right side MOUNTING The water heater should be mounted to the floor following applicable architectural and local code requirements or accepted standards for the specific site and model purchased In areas prone to seismic activity it is recommended that the water heater be mounted to the floor according to recommended procedures for the site In some geographic areas additional strapping or braces may be required consult local codes for specific requirements Proper mounting will help to make the water heater less susceptible to seismic damage WATER CONNECTIONS HOT WATER FIG 9 Water Connections Horizontal Models TEMPERATURE amp PRESSURE HOT WATER RELIEF VALVE OUTLET HANDHOLE CLEANOUT COLD WATER valli INLET DRAIN _ FIG 7 Water Connections Vertical Round Models TEMPERATURE amp PRESSURE RELIEF VALVE HOT WATER E OUTLET N E ta COLD WATER INLET DRAIN PAN CONNECTION FIG 8 Water Connections Vertical Square Models TEMPERATURE amp PRESSURE RELIEF VALVE MANWAY OPTIONAL COLD WATER FA INLET Before making connections to the cold water inlet or hot water outlet insure that all piping is clean and free of material or scale This can usually
8. which affect the amount of this formation are 1 Amount of hot water used As the volume of water increases more scale results 2 Water temperature As the temperature of the water is increased more scale is deposited on the elements Characteristics of water supply Regardless of water treatment the elements should be examined regularly Scale accumulation in the bottom of the storage tank may be removed by turning off main power and draining the tank Once all water is removed the hand hole access can be removed This will allow large accumulations of scale to be cleaned from the bottom of the tank gaskets on disassembled clean out openings must be replaced with new gaskets re assembly Gaskets are available from your distributor Water scale accumulations on the immersion heating element reduce the ability of the elements to heat water and may cause noise to occur during operation It is recommended that a heating element be removed at least once a year for examination If it is scaled all of the elements should be removed and cleaned The element gasket must be replaced when the element is removed for cleaning Small accumulations of lime scale may be removed with a stiff bristle brush Severe accumulations of lime scale should be removed by dissolving the accumulation in a commercial delimer Do not use muratic or hydrochloric acid base deliming solutions to remove lime scale from the elements Do
9. and building that are occupied on a fixed schedule As an additional feature time clocks may be furnished with a spring wound carry over function to insure that a switching schedule is maintained in periods where there may be power interruptions The time clock works by making and breaking the 120 VAC control circuit to the contactor coils to shut down operation of the heating elements in the desired time periods PILOT LIGHTS Optional The water heater may be provided with optional pilot lights to provide an external indicator for each contactor or stage of heating elements that is energized Each pilot light is wired in parallel with the 120 VAC control circuit feed to the contactor coil s The pilot will be turned on as the contactor coil s is energized by the temperature controls SHUNT TRIP DISCONNECT Optional Shunt trip disconnect provides a power disconnect upon a control sensed malfunction via a circuit breaker installed in the main power supply to the water heater The circuit breaker is shipped as a separate item that must be field installed The water heater 120 VAC control circuit provides a feed to the circuit breaker that will shut down main power on either a low water level condition if equipped or high water temperature Once the water heater is installed and all power is connected the toggle switch that arms the shunt trip must be placed in the on position to provide the shunt trip function on the desired
10. and other flammable liquids and vapors Never cover your appliance lean anything against it store trash or debris near it stand on it or in any way block the access to your appliance CODES The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition of the National Electrical Code NFPA 70 When the appliance is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes APPROVALS This complete appliance is design certified and Listed by Underwriters Laboratories as a commercial storage electric water heater This water heater bears the UL certification for the United States as tested under the Standard for Electric Booster and Commercial Storage Tank Water Heaters UL1453 and C UL in Canada as tested under the Standard for Construction and Test of Electric Storage Tank Water Heaters CAN CSA C22 2 No 110 M90 All water heater storage tanks conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV INSTALLATION PROCEDURE LOCATION OF UNIT 1 Locate the appliance so that if water connections should leak water damage will n
11. be accomplished by blowing out the pipe Any foreign material or scale entering the water heater can adversely affect operation and performance hen using copper tubing solder tubing to an adapter before attaching to the threaded nipple connection provided on the water heater Soldering directly to the threaded connection may harm a lining in the nipple or damage the tank lining Inlet and Outlet Connections For ease of service install unions on the cold water inlet and hot water outlet of the water heater The cold water inlet connection 15 located on the lower right side of the water heater A manual shutoff valve should be installed upstream on the cold water source as an isolation device The hot water outlet connection is located on the top center of the water heater A manual shutoff valve should be installed downstream on the hot water outlet source as an isolation device in case the water heater must be disconnected from the system STORAGE TANK This appliance uses a glass lined steel tank to store the heated water for use The storage tank is constructed in accordance with the ASME Boiler and Pressure Vessel Code requirements stamped and registered with the National Board of Boiler and Pressure Vessel Inspectors The tank is furnished with threaded connections for cold water inlet hot water outlet a relief valve and a drain connection The storage tank has a hand hole for ease of inspection cleanout and
12. below are items that must be checked to insure safe reliable operations Verify proper operation after servicing WARNING 4 HAZARD OF ELECTRICAL SHOCK Before opening the access panel to perform service on any electrical component make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage HEINE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation TEMPERATURE AND PRESSURE RELIEF VALVE OPERATION The temperature and pressure relief valve s should be manually operated at least once a year A relief valve that fails to completely reseat after manual operation and continues to discharge water must be immediately replaced with a new properly sized temperature and pressure relief valve The relief valve s should be installed in the vertical position and mounted in the tapping provided in the storage tank No valve should be placed between the relief valve and the water heater To prevent water damage the discharge from the relief valve must be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line The discharge line from the relief valve 24 should be metallic pipe or a high temper
13. come up to temperature and shut off automatically 7 The water heater is now ready continuous normal operation SHUTDOWN PROCEDURE Draining the Water Heater 1 Turn off the main electrical power to the water heater If the power disconnect point is out of sight lock it in the open OFF position and tag to prevent unexpected application of power 2 Turn the valve in the water heater s cold water supply to the closed or OFF position 3 Turn the valve in the water heater s hot water outlet to the closed or OFF position 4 Manually open the temperature and pressure relief valve to remove any pressure from the storage tank I Ee HEINE Any water discharged from the manually opened relief valve may be hot and cause a scald injury 5 Allow the system to cool and then open the drain valve to empty the storage tank It will be necessary to manually hold the temperature and pressure relief valve in the open position to break the vacuum in the tank and allow it to vent and drain Insure that the water heater drain is routed to a properly sized floor drain to allow the water to be removed from the tank Ifa floor drain is not available a hose may be attached to the water heater drain to take the water outdoors 6 The water heater is now shut down and ready for service or maintenance 7 Follow the filling and start up procedure to place the water heater back into service MAINTENANCE Listed
14. floor When such locations can not be avoided a suitable drain pan must be installed under the water heater Drain pans may be fabricated or purchased from your plumbing wholesaler The drain pan must be piped to an adequate drain Under no circumstances is the manufacturer to be held liable for any water damage in connection with this water heater CLEARANCES FROM COMBUSTIBLE CONSTRUCTION O jh FIG 5 Clearances from Combustible Construction FIG 6 Clearances from Combustible Construction TABLE A CLEARANCES FROM COMBUSTIBLE CONSTRUCTION Right Side 6 15cm 24 0 61m for high kW vertical square models with an additional control panel on right side Rear 0 Left Side 0 Front 36 0 91m for service access to controls and heating elements Top 12 30cm for service access to electrical service water connections and piping Water Pipes 25 4mm Maintain minimum specified clearances for adequate operation installations must allow sufficient space for servicing the electrical components water pipe connections piping and other auxiliary equipment as well as the appliance Multiple appliances may be installed in a modular water heater installation Multiple appliances may be installed side by side with minimum clearance between the sides of adjacent appliances because no service access is required from the sides on most models Note that high
15. placed in a well located above the heating elements it is controlling A liquid crystal display is provided to indicate sensed temperature and operating parameters The temperature control may operate in as many as four stages of control For more stages of operation multiple electronic temperature control sequencers are installed and wired to operate in series 125 5 23 4 HEAT STAGE ENERGIZED 1 SELECT ENTER IMAC J FIG 20 Electronic Temperature Control Digital Display and Programming Keys SPECIFICATIONS Set Point Adjustment Range Max setting 220 F 105 Temperature Accuracy 1 F Display Resolution 1 F via Liquid Crystal Display LCD Sensor Thermistor 4 8 ohms F Operating Humidity 5 95 RH Noncondensing Operating Ambient Temperature 30 to 125 E Access to the control is achieved by opening the hinges control panel door covering the electrical components Four programming keys are provided to program set point and differential values for each stage and to control the display The four keys are Select Up arrow Down arrow and Enter Select Key Sequentially prompts the user as to what parameter is being displayed set point differential stage energized operation mode heat indication of assigned stage 1 2 3 Once the last parameter value has been viewed pressing the Select key will display the control values again from the beginning of the
16. point The temperature setting shown at the top of the knob is the selected set point The immersion thermostat has a fixed 6 F 3 3 C differential TEMPERATURE REGULATION WARNING A HAZARD OF ELECTRICAL SHOCK Before opening the electrical access panel to adjust the thermostat make sure the electrical supply to the water heater is turned OFF 13 Full power is present whenever the cabinet door is opened even with the pilot switch es turned off Set temperature control to the lowest setting which satisfies the hot water requirements of the system Lower water temperatures help minimize scale formation on the heating elements See thermostat information below For sequencer specifications consult controller literature WATER TEMPERATURE SETTINGS This water heater has an adjustable thermostat to control water temperature The thermostat is factory pre set at approximately 125 F 51 7 C or less Households with small children or invalids may require a 120 48 9 C or lower temperature setting to reduce risk of scald injury Some states may require a lower temperature setting Check with your local codes or electric utility for local requirements governing the temperature setting Remember no water heating system will provide exact temperatures at all times Allow a few days of operation at the setting to determine the correct temperature setting consistent with your needs 1 This water hea
17. service An optional manhole may be specified for greater ease of inspection The interior of the storage tank is glass lined and fired to 1600 F 871 C to insure a molecular fusing of glass and steel to protect the steel base metal against corrosion A magnesium anode s is standard to help prevent dissipation of the tank material by electrolytic action RELIEF VALVE This water heater is supplied with a temperature and pressure relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Some water heaters may be supplied with an optional pressure only relief valve The relief valve s is installed in the vertical position and mounted in the tapping provided in the storage tank No valve is to be placed between the relief valve and the water heater To prevent water damage the discharge from the relief valve must be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year A relief valve that fails to completely reseat and continues to discharge water must be immediately replaced with a new properly sized temperature and pressure relief valve Avoid contact with hot discharge water Insure that no one is in front of or around the relief valve discharge li
18. the use of the four programming keys TEMPERATURE ADJUSTMENT 11 1 Turn OFF the electrical power to the water heater If the power disconnect point is out of sight lock it in the open OFF position and 9 Press Select to display the current stage switching differential 10 Press Up Arrow key to increase or Down Arrow key to decrease to the desired switching differential Press Enter to enter the displayed value into memory odio 12 Repeat steps 6 through 11 to program each tag to prevent unexpected application additional stage of power 13 Press Select Select Select Select 4 times 2 Open the water heater s electrical access panel to return to stage 1 parameters Scroll through the programming loop a second 3 Verify that the unit is properly applied and the time to confirm that the appropriate values model number on the rating plate correctly have been entered into memory by identifies the unit pressing Select 4 Turn the electrical power switch 10 ON 14 Press Select after viewing the switching position The control will begin counting differential for the final stage to display down from 210 This countdown sequence stored water temperature will last for approximately 3 1 2 minutes 15 Close the water heater s electrical access panel 16 The temperature control is now ready 17 for operation control values programmed into memory will not be lost because of a power
19. 00 950 58 126 1 4 54 1 4 13 1 2 2 1 2 24 3 040 HH kW 1250 900 1 250 64 130 1 4 60 1 4 15 au 3 750 HH kW 1500 900 1 500 70 126 1 4 66 1 4 16 3 Ju 4 340 HH kW 2000 900 2 000 707 137 1 4 72 1 4 IBI TA 3 34 4 580 HH kW 2500 900 2 500 82 144 1 4 78 1 4 16 1 2 Js 3 6 060 Walne ME kW Kilowatt J 208V 16 Y 380V 3 Te K 206V 30 1 415V 36 NA Xe Ns A MV lo X 4800 30 Ne NG B 240V 30 N 600V 3s W 27N lo This unit is a Custom Hi Power Vertical 480 Volt Three Phase 72 Kilowatt 250 gallon water heater tandard Features Glass Lined Steel Tank Channel Iron Skid Base Except 150 amp 200 gallon round ncoloy Heating Elements Approved for 180 F Temperature Operation nternal Fusing above 120 amps ASME Construction and National Board Listed Enamel Finished Galvanized Steel Jacket All models meet or exceed ASHRAE Magnesium Tank Saver Anodes energy efficiency standards Immersion Thermostat 125 psi Working Pressure Manual Reset High Limit Handhole Cleanout Full Length Hinged Doors with Key Lock UL Listed U S and Canada Terminal Block Connections Safety Drain Pan Square Models ASME Temperature and Pressure Relief Valve 3 Year Limited Tank Warranty Supplied but not installed Control Voltage On Off Switch w Pilot Light Optional Equipment Low Water Cut Off BMS Enable Disable Contacts Pilot Light
20. 18 6 8 6 450 389 195 180 738 614 160 10 4 18 20 10 8 8 500 434 217 216 886 736 992 12 4 18 24 8 8 8 600 519 260 234 959 798 408 13 5 18 26 13 8 8 650 563 282 252 1 033 859 824 14 5 18 28 14 8 8 700 607 304 210 1 107 921 240 15 5 18 30 10 12 10 150 649 325 288 1 181 982 656 16 6 18 32 16 12 12 800 692 347 306 1 255 1 044 072 17 6 18 34 17 12 12 850 136 368 324 1 328 1 105 488 18 6 18 36 12 12 12 900 780 390 342 1 402 1 166 904 19 1 18 38 19 12 12 950 822 42 360 1 476 1 228 320 20 7 18 40 20 12 12 1 000 865 435 378 1 550 1 289 736 21 7 18 42 14 14 14 1 050 909 455 396 1 624 1 351 152 22 8 18 44 22 15 16 1 100 952 477 414 1 697 1 412 568 23 8 18 46 23 16 16 1 150 995 498 432 171 1 473 984 24 8 18 48 16 16 16 1200 1 040 520 For KW above 432 or other voltages please consult factory Lochinvar A V High Efficiency Water Heaters Boilers and Pool Heaters US Lochinvar Corporation 300 Maddox Simpson Pkwy Lebanon TN 615 889 8900 Fax 615 547 1000 www Lochinvar com CHP 10 Replaces CHP 09 7 06 2 08 Printed in U S A
21. 350 500 415 476 600 2 350 480 QU 300 t 350 480 600 2 350 600 173 225 4 0 600 32 450 2 4 0 208 600 800 3 300 208 999 1600 5 400 240 500 300 2 500 240 866 1200 4 350 380 328 450 2 4 0 380 E2547 700 2 500 415 x 301 400 2 3 0 415 bl 700 2 500 480 260 350 500 480 433 600 2 350 600 208 300 350 600 546 450 2 4 0 208 650 2 400 208 1049 1600 5 400 240 563 2 300 240 909 1200 4 350 380 356 2 250 380 574 800 3 300 415 326 2 4 0 415 56 2 500 480 281 2 3 0 480 455 2 350 600 S225 350 600 564 2 250 208 694 3 400 208 1099 5 400 240 606 3 300 953 4 350 380 383 2 250 602 3 300 415 22088535 2 4 0 55 2 500 480 303 2 3 0 476 2 350 600 20 500 x 38 2 250 208 749 3 400 ar 5 400 240 650 3 400 996 5 400 380 410 2 350 3 3 300 415 3 6 2 250 3 3 300 480 5505325 2 4 0 498 2 500 600 260 500 398 2 250 208 799 3 400 5 5 400 240 693 3 400 E 5 400 380 438 2 350 656 3 400 415 401 2 350 60 3 300 480 96 2 4 0 520 2 500 600 559090777 500 416 2 350 208 849 4 350 240 ps 3 400 380 i 2 350 415 Ey 2 350 480 2 250 600 x 2 3 0 208 NER E 27 Consult factory for 432 kW and higher 240 3 400 380 2 2 500 415 k 2 350 480 2 250 600 a 2 3 0 07 07 Printed in U S A Lochinv
22. 395 50 97 46 52 3 4 gt gt gt Y 1 700 HV kW 600 3 97 52 60 3 4 nim 21 7 21 2 200 HV KW 800 356 750 10 52 60 3 4 241 2 2 1 2 21 07 240 HV KW 1000 3 950 1 5 60 3747 041 07 yr 21 07 3160 NOTES Vertical Round models above 90 kW at 208V 240V or 380V and 162 kW at 415V 480V or 600V exceed the capacity of a single control box and may require multiple control panels Consult the factory for specific details and optional construction Vertical Square construction is available as an option for models that exceed the listed kW limits Control panel height on Vertical Round models may exceed tank height consult factory for specific heights on models with inputs above 72 kW Vertical Square HV kW 1250 900 1 250 132 2 64 1 2 64 1 2 23 1 4 JE 3 3 560 HV kW 1500 900 1 500 128 1 2 70 1 2 70 1 2 25 1 4 3 Ju 4120 HV kW 2000 900 2 000 140 1 2 76 1 2 76 1 2 27 4 3 du 4 350 HV kW 2500 900 2 500 146 2 82 1 2 82 1 2 29 3 3 5 750 HH kW 150 135 150 Spe 68 1 2 34 1 4 12 2 2 1 180 HH kW 200 180 200 Syn 79 34 1 4 12 2 24 1 370 HH kW 250 225 250 39 90 1 4 36 1 4 13 2i 2 1 450 HH kW 300 270 300 45 78 1 4 42 1 4 14 3 4 2 2 1 530 HH kW 400 360 400 52 78 1 4 48 1 4 16 7 9 150 HH kW 500 450 500 52 90 3 4 48 1 4 16 2 2 1 860 HH kW 600 540 600 58 90 3 4 54 1 4 13 1 2 2 1 2 7 2 340 HH kW 800 720 750 58 102 1 4 54 1 4 13 1 2 2 1 2 X 2 850 HH kW 1000 9
23. CHP I amp S 01 INSTALLATION AND SERVICE MANUAL Commercial Electric Water Heaters 9kW 900kW Input Models c UL us Installation and service must be performed by Qualified Service Personnel Only WARRANTY Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems Excessive water hardness causing a lime scale build up in the heater and or on the immersion heating elements is not the fault of the equipment and is not covered under the manufacturer s warranty See Water Treatment and Water Chemistry Do not energize electrical system before heater is completely filled with water Damage caused to the immersion heating elements by dry fire is not covered under the manufacturer s warranty Follow start up procedure in the manual Water heater corrosion and component failure caused by air borne chemical vapors is not covered under the manufacturer s warranty Corrosion damage caused by current leakage due to improper grounding of electrical systems or electronic components to the storage tank and related piping is not covered by the manufacturer s warranty Under no circumstance will the manufacturer be liable for consequential damages resulting from the installation or use of this equipment Correct installation procedure and local cod
24. TROLS FAIL TO SHUT OFE TURN OFF OR DISCONNECT THE ELECTRICAL 4 Close the water heater s electrical access panel SUPPLY AT THE MAIN POWER DISCONNECT EXTERNAL TO THE 5 Turn ON the electrical power to the APPLIANCE water heater setpoint that should be set for the Immersion Thermostats or programmed Water temperature over 125 F 51 7 C into the Electronic Temperature Control can cause severe burns instantly or death Sequencer is 190 F 88 C from scalding Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at heating appliance SELECT y SET ENTER Feel water before bathing or showering If this appliance is used to produce water that could scald if too hot such as domestic hot water use adjust the outlet control limit or use temperature NC limiting valves to obtain a maximum ze E water temperature of 125 F 51 7 C j Always close the electrical control panel door after making a temperature adjustment Turn on FIG 19 Electronic Temperature Control electricity with Digital Display V 14 The water heater uses an optional adjustable electronic temperature control to provide staged ON OFF control of the electric heating elements Operation is based on temperature input from an immersion temperature sensor The sensor is a positive coefficient platinum thermistor The sensor is
25. ank opening where it was originally installed Tighten the flange with the socket and breaker bar used to remove the element 10 Attach wires to element terminals from which they were removed 11 Follow FILLING THE WATER HEATER instructions to restore hot water service Check for water leaks around elements and proper operation when heater is filled TROUBLE SHOOTING Checklist Before calling for service check the following points to see if the cause of trouble can be identified and corrected Reviewing this checklist may eliminate the need of a service call and quickly restore hot water service Not enough or no hot water 1 Ensure that the electrical disconnect switch serving the water heater is in the ON position The pilot switch es on the cabinet should also be in the on position In some areas water heater electrical service may be limited by the power company If the heater operates on a controlled circuit heater recovery may be affected Check the fuses The electrical disconnect switch usually contains fuses The water heater has fuses located behind the cabinet front door When replacing internal fuses in the water heater control panel insure that the same type and size of fuse is used If the water was excessively hot and is now cold the manual reset high limit may have operated To reset turn off electricity and push the reset button The high limit is located above the upper most heating
26. ar Corporation e e ar Nashville Tennessee Wiring Diagrams 615 889 8900 Fax 615 547 1000 High Efficiency Water Heaters Boilers and Pool Heaters WWW Lochinva r com CH P WI 04 CUSTOM HI POWER IMMERSION THERMOSTAT WITH OPTIONS Control Circuit R B BL MAIN TERMINAL BLOCK GROUND LUG SAFETY DOOR R c INTERLOCK w OPTIONAL P c c PILOT SWITCH OPTIONAL LIMITING SWITCH OPTIONAL TRANSFORMER LOW WATER CUTOFF OPTIONAL CONTACTOR HI LIMIT IMMERSION THERMOSTAT LITO716 Rev A BASIC IMMERSION THERMOSTAT Control Circuit R B MAIN TERMINAL BLOCK k GROUND LUG w TRANSFORMER HI UMIT CONTACTOR IMMERSION THERMOSTAT WIRE COLOR CODE NOTE Diagrams do not show wiring R Red W White from terminal block to fuses contactors B Black BL Blue and heating elements Control circuit G Green only is shown LITO717 Rev A CUSTOM HI POWER CHP WIRING DIAGRAMS SOLID STATE STEP CONTROL WITH OPTIONS Control Circuit MAIN TERMINAL BLOCK 8 om GROUND LUG a SAFETY DOOR INTERLOCK OPITIONAL I E T SELECT mST ENTER E DAO LE PILOT SWITCH TRANSFORMER OPITIONAL 4 Li DODDO Y y uY u CUTOFF SENSOR A PILOT SMTCH OPITIONAL i GROUND 8 Oo HI LIMIT SA TOO 24VAC f T T v 1 ue 4
27. ature plastic pipe CPVC etc to insure that hot water flow will not damage the discharge piping from the relief valve oF NERO EINE Avoid contact with hot discharge water Insure that no one is in front of or around the relief valve Make sure that the discharge line extremely hot water manually discharged from the relief valve will not cause bodily injury or property damage WATER CHEMISTRY In hard water areas water treatment should be used to reduce the introduction of minerals to the system Minerals in the water can collect in the storage tank and on the immersion heating elements causing noise on operation Excessive build up of minerals on the surface of the heating elements can reduce the service life of the elements and lead to a non warrantable failure Proper operation of this electric water heater is based on heating potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 PPM Consult the manufacturer when heating potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water may require frequent cleaning of the storage tank and heating elements to achieve proper operation The higher the level of dissolved solids or water hardness the faster the dissolved minerals in the water will precipitate out and form scale deposits on the heating elements and in the storage tank The level of scale formation is also accelerat
28. control sensed malfunction ALARM BELL Optional FIG 28 Alarm Bell An alarm bell with silencing switch is available as an option on this water heater The alarm bell can be used to provide an audible indication of a control sensed malfunction The user must specify the safety function or multiple safety functions that the alarm bell will sound on when the water heater is ordered from the factory The alarm bell typically is used to indicate a low water condition or a high water temperature condition The alarm is furnished with a silencing switch to turn off the audible alarm while trouble shooting a control sensed malfunction that is indicated by an audible alarm Once the control sensed malfunction is corrected the silencing switch must be returned to the ON position to re establish the audible alarm function START UP PROCEDURE Never operate the heating elements without being certain the water heater is filled with water and a temperature and pressure relief valve is installed in the relief valve opening on top of the heater The pilot switch es if equipped mounted on the control cabinet permit the heater to be turned on and off without having to operate the electrical disconnect switch The pilot switch interrupts only the 120 VAC control circuit in the water heater Full power is still present at the terminal block fuses and contactors DANGER 4 Full power is present whenever t
29. ctric Power Connections Electrical Control Panel Round Models Y T 1 1 k 1 y 1 E ELECTRIC ACCESS i gt HINGED DOOR TO i TE ELECTRIC CONTROL COMPARTMENT FIG 11 Electric Power Connections Electrical Control Panel Square Models UGODEN WATER HEATER 15 EQUIPPED FOR OPERATION ON ONE VOLTAGE ONLY Check the rating plate on the front of the control panel access for the correct voltage and phase DO NOT use this water heater with any other voltage other than the voltage specified on the rating plate Failure to use the correct voltage can cause problems that can result in death serious bodily injury or property damage Ie Ye DO NOT CONNECT THE WATER HEATER TO AN IMPROPER SOURCE OF ELECTRICITY The appliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code NFPA No 70 When the appliance is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 Use copper conductors only All wiring between the appliance and field installed devices shall be made with copper wire suitable for at least 75 C 167 F temperature rating If the wiring from an old water heater installation was aluminum replace the old wire with copper wire The facto
30. d by the factory for safe easy wiring connection Manual reset high water temperature limit control Immersion thermostat one per 54kW of input as standard 180 F 82 2 C temperature operation is possible to provide water for sanitizing applications Insulated to meet the latest edition of ASHRAE 90 1 energy efficiency standards 3 year limited warranty provides protection against failure of tanks due to defects in material and workmanship in commercial application Underwriter s Laboratories Inc listing for all models as a commercial electric water heater 10 OPTIONAL EQUIPMENT COMPONENTS AND CONTROLS The following items are available as extra cost options Electronic low water cut off prevents energizing of the heater when it is not filled with water Pilot lights Monitor on off cycle of contactors Manual limiting switches with indicating lights to permit heater kW input to be manually limited as desired Temperature and pressure gauges are available installed flush with the jacket to monitor heater performance Electronic step controller modulates power in put and balances load to demand Safety door interlock prevents opening of access door while heater is energized Shunt trip disconnect provides power disconnect upon control sensed malfunction Alarm bell provides an audible alarm to warn of various control failures Time clock to control off on cycles of the heater as pr
31. display loop Up and Down Arrow Keys Allow the displayed parameter to be increased or decreased After pressing the Select key a control value can be changed by using the Arrow keys Control values will be increased or decreased by 1 F for each time the Arrow keys are depressed Enter Key Places the new value into the memory of the microprocessor Me control value or operation will not be entered in the memory of the microprocessor until the Enter key is pressed Control values and operation selection will remain in the device memory even after power is removed Select and Enter Keys simultaneously pressed Changes operation mode of the control from heat to cool mode DO NOT CHANGE THIS SETTING This control must always be in the HEAT position for proper operation of the water heater When all stages have been programmed the display will revert back to sensed temperature and load energized status DISPLAY Once power is applied to the temperature controller the display will countdown from 210 until the display reads zero All outputs are de energized at this time This countdown process will repeat each time main power is interrupted To avoid viewing this entire countdown press the Select key The display will now show normal readings load sensed temperature and stages energized At any time during the programming procedure the display wil revert back to showing the sensed temperature and stage stat
32. ed as stored water temperature increases Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non warrantable damage to the storage tank heating elements and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions 25 Water heater maintenance includes periodic tank flushing cleaning and removal of lime scale from the heating elements Where used the water heating system circulating pump should be oiled FLUSHING THE STORAGE TANK 1 Turn off main power at the electrical disconnect switch 2 Open the drain valve Allow water to flow until it runs clean 3 Close the drain valve when finished flushing 4 Turn on the electrical disconnect switch after filling SEDIMENT REMOVAL Water born impurities consist of dissolved minerals which precipitate out of the heated water and fine particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank In time if not removed the level of sediment might reach the heating elements For convenience sediment removal and element lime scale removal should be performed at the same time as follows Sediment and Lime Scale Removal Sediment and lime scale accumulation on the heating elements is a normal condition common to all immersion type elements Factors
33. ed and the control circuit will be completed between the common and normally open contacts on the circuit board when the sensing probe is below the water level in the storage tank An optional manual reset function and test button is available on the electronic low water cut off The operation of a low water cut off should be inspected every six months PRESSURETROL U FIG 25 Low Water Pressure Switch LOW WATER PRESSURE SWITCH Optional A low water pressure switch is available as an option on this water heater A water pressure switch is used to monitor the water pressure in the water heater storage tank If the water pressure drops below an adjustable set point the control circuit is opened and operation of the water heater is shut down The low water pressure switch may be specified with either a auto reset function or a manual reset function on low water pressure HIGH WATER PRESSURE SWITCH Optional PRESSURETROL FIG 26 High Water Pressure Switch Honeywell A high water pressure switch is available as an option on this water heater A water pressure switch is used to monitor the water pressure in the water heater storage tank If the water pressure rises above an adjustable set point the control circuit is opened and operation of the water heater is shut down The low water pressure switch may be specified with either a aut
34. element in the storage tank On some high input models additional hi limits may be located behind the side access panel Repeat operation of the high temperature cut off should be investigated by your mechanical contractor or by a qualified technician A contactor or thermostat may be malfunctioning 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 27 5 Cold incoming water temperature will lengthen the time required to heat water to the desired temperature If the heater was installed in the summer when incoming water temperature was warm colder ground water in the winter months can create the effect of less hot water Look for wasted hot water and leaking or open hot water faucets Sediment or lime scale may be affecting water heater operation Refer to Maintenance for details Water is too hot Refer to Temperature Regulation and reset the thermostat setpoint to a lower temperature that will meet requirements for hot water Water heater makes sounds 1 Sediment or lime scale accumulation on the elements causes sizzling and hissing noises when the heater is operating If this occurs the tank bottom and elements should be cleaned Refer to MAINTENANCE for details Some of the electrical components of the water make sounds which are normal Contactors will click or snap as the heater starts and
35. es must be adhered to Dogg ea Retain this manual for future reference 1 SPECIAL INSTRUCTIONS TO OWNER WARNING Improper Installation Adjustment Alteration Service or Maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the electric utility CHECKING EQUIPMENT This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation Upon receiving equipment check for signs of shipping damage Pay particular attention to parts accompanying the water heater which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing slip with those actually received In case there is damage or a shortage immediately notify carrier e USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER THE POSSIBLE DAMAGE TO A FLOODED APPLIANCE CAN BE EXTENSIVE AND PRESENT NUMEROUS SAFETY HAZARDS ANY APPLIANCE THAT HAS BEEN UNDER WATER MUST BE REPLACED If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance CONTENTS Warranty
36. failure ERROR MESSAGES DISPLAYED BY THE ELECTRONIC TEMPERATURE CONTROL There are seven error messages that can be displayed in response to software or hardware problems with the boiler s internal electronic temperature control The error codes that may be seen flashing on the display are SF Sensor Failure The display flashing SF indicates an out of range or defective sensor Make sure sensors are properly installed wired and connected to the control Correct sensor installation or replace sensor EF EEPROM Failure The values read form the EEPROM are not the same as the values written into the EEPROM This error cannot be field repaired Replace the water heater s electronic temperature control CF Calibration Failure The calibration resistor reading was not within the range of the Analog to Digital converter This error cannot be field repaired Replace the water heater electronic temperature control OF Stray Interrupt Failure An unused interrupt occurred This error cannot be field repaired Replace the water heater s electronic temperature control CE Configuration Error The device hardware was configured to a nonexistent device This error cannot be field repaired Replace the water heater s electronic temperature control OE ROM Error The internal ROM of the microprocessor in the boiler s electronic temperature control is defective This error cannot be field repaired Replace the water heater
37. ge of operation and enter into the worksheet below Programming Worksheet Stage 1 Set Point 1 Differential 1 Off at On at Stage 2 Set Point 2 Differential 2 Off at On at Stage 3 Set Point 3 Differential 3 Off at On at Stage 4 Set Point 4 Differential 4 Off at On at These values will be programmed into the temperature controller WARNING 4 HAZARD OF ELECTRICAL SHOCK PROGRAMMING When power is initially applied to a new water heater the control points will be pre programmed The factory final quality test sets the unit for test firing The preset values are as follows 5 Full power is present whenever the cabinet door is open and the main power disconnect is in the ON position even with the pilot switch es turned off To override this time delay press Select Set Point Differential 2 2 A F T 2 F Stage 1 125 F Press Select to display the current stage 123 F set point 2 3 121 F 4 120 F Press Up Arrow key to increase or Down Arrow key to decrease to the desired set point Re program the set points and differentials to 8 Press Enter to enter the displayed value meet your system hot water requirements into memory The operating control uses a Liquid Crystal Display for interactive prompting during programming and display of sensed and assigned set point and differential values Programming is accomplished through
38. he cabinet door is opened even with the pilot switch es turned off THERMAL EXPANSION OF WATER A relief valve that discharges periodically may be due to thermal expansion in a closed system Many water systems are equipped with pressure reducing valves check valves or back flow preventers which may cause the water system to be closed As water is heated it will expand in volume due to thermal expansion The system must make allowance for this expansion If an expansion tank is not provided in the system water pressure may increase to the point where the water heater s temperature and pressure relief valve opens to relieve the excess pressure The temperature and pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected Do not plug or cap the relief valve discharge properly sized expansion tank is typically installed in the potable water system to relieve the pressure built up by thermal expansion of heated water Consult your local plumbing contractor and plumbing wholesaler for assistance in properly selecting an expansion tank for your system As the water heater operates there may be noises generated by the expansion and contraction of the metal parts of the water heater and related piping These noises may occur during periods of heat up or cool down They do not represent harmful or dangerous conditions FILLING THE WATER HEATER
39. i 250 THRU 1000 d HINGED DOOR TO ELECTRICAL COMPARTMENT TOP VIEW Vertical Square Models 1250 2500 3 4 T amp P RELIEF VALVE CONNECTION HOT WATER OUTLET 1 CONTROL VOLTAGE ON OFF SWITCH WITH PILOT LIGHT A l CLEANOUT n WATER INLET Y D DRAIN PAN CONNECTION B c OPTIONAL HINGED DOOR TO ELECTRIC CONTROL COMPARTMENT p M V 4 N lt X i i E mos IP c T Me M E T i M P o HINGED DOOR TO ELECTRIC CONTROL COMPARTMENT An oversized control panel may be required on models with inputs above 72 kW An oversized control panel may increase the width and depth of the square jacket by up to 2 TOP VIEW HOT WATER OUTLET HEIGHT IF T amp P RELIEF VALVE 4 REQUIRED fus Jj ET CONTROL VOLTAGE ON OFF SWITCH WITH PILOT LIGHT HANDHOLE END VIEW A amp D ELEVATION FROM FINISHED FLOOR EXTRA PANEL BOX MAY BE NECESSARY FOR INPUTS HIGHER THAN 72KW CONSULT FACTORY Specifications HV kW 150 135 150 65 1 2 30 33 73 v M V2 650 Hv KW 200 180 20 7 32 33 7 3 4 107 11 07 750 HV KW 250 216 20 97 34 wi V HV kW 300 20 300 80 40 4 3 4 2 2 2 1 350 HkW40 30 40 80 46 52 3 4 gt gt Y d 1 590 HV KW 500
40. lectricians use LS E T WI Never turn on the electric power or attempt to use this electric water heater unless it is completely full of water Water must flow from the hot water faucet before turning electrical power ON Operation of a water heater without a completely filled tank may result in serious damage to the appliance and heating element burn out JACKET ASSEMBLY Outer Jacket The outer jacket assembly is constructed from steel galvanized on both sides The galvanized surface is specially prepared and phosphate coated to allow application of a multiple coat enamel paint process This coating process insures a long life from the jacket assembly STANDARD EQUIPMENT Your commercial electric water heater is equipped with the following as standard equipment Low watt density immersion heating elements with an incoloy sheath Internal fusing of all elements in a maximum of 48 amp increments provides additional safety Fuse cartridges are related at 1 000 000 amps interrupting capacity A galvanized steel outer jacket and electrical control panel are provided Channel iron skid base Electrical control panel is provided with a hinged door and key lock A glass lined steel tank constructed to ASME specifications and provided with magnesium anode s ASME rated temperature and pressure relief valve provided by factory to insure safe heater operation Terminal block connections are installe
41. mponents in the control panel during shipping installation or service Close the electrical control panel and turn on main power The water heater is now ready for normal operation INITIAL START UP CHECKS The following checks should be made by the installer when the water heater is placed into operation for the first time WARNING A HAZARD OF ELECTRICAL SHOCK Before opening the access panel to perform service on any electrical component make sure the electrical supply to the water heater is turned Failure to do this could result in death serious bodily injury or property damage Allow the water heater to heat for approximately thirty minutes after following the filling and start up procedures Turn off the main electrical power to the water heater If the power disconnect point is out of sight lock it in the open OFF position and tag to prevent unexpected application of power Open the electrical control panel door and feel each wire connection and fuse clip for excessive temperature If any connection is found to be excessively hot check the tightness ofthe connection Check all factory internal wiring connections and the field made main power connections for tightness 4 Close and lock the electrical control panel door 5 Turn on the main electrical power to the water heater 6 Temperature control and contactor operation should be checked by allowing the water heater to
42. ne Make sure that the extremely hot water manually discharged from the relief valve will not cause bodily injury or property damage THERMAL EXPANSION OF WATER A relief valve that discharges periodically may be due to thermal expansion in a closed system A water heater installed in a closed system such as one with a backflow preventer or check valve installed in the cold water supply shall be provided with means to control expansion Contact the water supplier or local plumbing inspector on how to correct this situation DO NOT plug or cap the relief valve CATHODIC PROTECTION Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet be open for several minutes at a sink close to the water heater before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow There should be no smoking or open flames near the faucet at the time it is open ELECTRICAL CONNECTIONS All installation procedures involving electric power connection should only be performed by a trained certified electrician ELECTRIC ACCESS HINGED DOOR MU TO ELECTRICAL COMPARTMENT FIG 10 Ele
43. nician 28 CP 5M 5 02 Reprinted in U S A Lochinvar Corporation P a Nashville Tennessee Electrical Data 615 889 8900 Fax 615 547 1000 High Efficiency Water Heaters Boilers and Pool Heaters www Loch i nvar com 01 ELECTRICAL DATA FOR CUSTOM HI POWER AMP CHART Total Main Line Field Wire Total Main Line Field Wire Total Ele AMPS Fuse Per Leg Total Ele AMPS Fuse Per Leg KW KW Qnty Volt 10 30 10 30 10 30 KW KW Qnty Volt 10 30 10 30 10 30 12 12 1 208 58 50 4 60 15 4 208 289 167 400 225 500 4 0 240 50 40 4 250 144 350 200 400 4 0 380 j 25 i5 9 i us 1 415 25 sg 83 480 20 72 600 15 58 208 60 200 240 173 380 109 415 100 480 87 600 69 208 250 500 240 217 350 380 137 3 0 415 125 3 0 480 108 2 0 600 87 2 208 300 2 3 0 240 260 500 380 164 4 0 415 150 3 0 480 130 2 0 600 104 0 208 333 2 4 0 240 289 2 3 0 380 182 250 415 167 480 14 600 115 208 375 240 325 380 205 415 188 480 162 600 130 208 400 240 346 380 415 480 600 208 240 380 415 480 600 ELECTRICAL DATA FOR CUSTOM HI POWER AMP CHART continued Total Main Line Field Wire Total Main Line Field Wire Total Ele AMPS Fuse Per Leg Total Ele AMPS Fuse Per Leg KW KW Qnty Volt 10 30 10 30 10 30 KW KW Qnty Vol 10 30 10 30 10 30 180 18 10 208 500 700 2 500 342 18 19 208 049 1200 4 350 240 433 600 2 350 240 82 1200 4 350 380 5500513 350 i 500 380 520 700 2 500 415 250
44. not pour delimer into tank Deliming solutions may damage the glass lined interior of the tank DANGER Keep all delimers away from anode rods to prevent the formation of flammable and explosive gas 1 Drain the heater following SHUTDOWN PROCEDURE instructions On some high kW input models it is necessary to remove a side panel to gain access to the exposed ends of the elements which are not accessible through the front element access door 26 Disconnect the wires attached to the element terminals Try not to disturb the wiring unnecessarily and reconnection will be easier Loosen the screw in element flange with a socket and breaker bar Do not use an impact gun air or electric to remove the element flanges from the tank Mark the location of each element in the tank openings so they may be returned to their original position Remove the elements from the opening with a twisting pulling action if the elements are scaled beyond the size of the tank flange openings Brush loose scale from elements Place scaled ends of heating elements into a delimer solution and allow scale to dissolve Do not permit delimer or water to contact heating element electrical terminals Flush clean ends of elements with water when deliming or cleaning is completed Clean remaining gasket recess on each screw in element flange Do not reuse element gaskets Install a new gasket on each element Install element into the t
45. o reset function or a manual reset function on high water pressure MANUAL LIMITING SWITCHES Optional As an option a switch or multiple switches may be provided to interrupt the 120 VAC control circuit feed to the contactor coil or coils from the immersion heating thermostat s This switch may be used to manually turn offa portion of the heating element input This feature may be used to reduce electrical input of the water heater in the summer months when ground water temperatures are warmer and full electrical input from the immersion heating elements is not required The water heater may be restored to full input by moving the switches to the ON position TIME CLOCK Optional FIG 27 Time Clock The water heater may be provided with an optional time clock The time clock will allow the water heater to be turned on and off with a pre set schedule The time clock may be specified with a 24 hour scheduling period or with a 7 day scheduling period By the adjustment of the setpoints on the time clock the water heater may be turned off when hot water is not needed or in periods when the building may not be occupied The time clock allows the water heater to automatically cycle on in advance of the time when hot water may be needed This will insure that hot water is always available yet save energy when there are scheduled periods when there will be no requirement for hot water This feature is especially useful for schools
46. ogrammed by the owner or electric utility requirements Low water pressure switch High water pressure switch 11 TERMINAL BLOCK x GROUND LUG el E V E CONTROL CIRCUIT FUSE BLOCK 5 o 5i IT FUSE BLOCK id 7 TRANSFORMER i CONTROL CIRCUIT FUSE BLOCK IMMERSION THERMOSTAT 5j e BIS He In B TO EU CONTACTOR IF EQUIPPED LOW WATER CUTOFF IF EQUIPPED FIG 12 Electrical Panel Component Location Drawing ee jeee jeee LOAD FIG 13 Main Power Terminal Block A main power terminal block is provided for field connection of the branch power supply to the electric water heater All internal power circuits to the immersion heating elements are connected to the load side of the main terminal block The line side of the terminal block has individual lug type connections properly sized for the recommended copper field wire size FUSE AND FLUE BLOCKS FIG 14 Fuse Block with Power Circuit Fuses Each internal power ci
47. ot occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the unit Under no circumstances is the manufacturer to be held responsible for water damage in connection with this unit or any of its components 2 Insure that the appliance is located near an acceptable drain so that the vessel can be properly drained when performing service or maintenance The drain must also provide adequate drainage in the event of leakage the tank or related piping The drain must prevent water damage to the adjacent area and lower floors of the structure 10 11 The appliance must be installed so that the electrical components are protected from water dripping spraying etc during appliance operation and service replacing of fuses elements etc Appliances located in a garage or parking structure shall be installed so that the jacket and all piping shall be located or protected so that it is not subject to physical damage by a moving vehicle The appliance must be installed on a level floor Shim the base as necessary if leveling is required The floor on which the appliance is installed must be capable of supporting the total weight of the water heater when completely filled with water Combustible floor locations may be used Maintain required clearances from combustible surfaces The appliance must not be installed on carpet The appliance must be in
48. ow is obtained at the faucet it may be turned off The temperature and pressure relief valve should be manually opened to insure that there is no captive air in the storage tank A constant stream of water must flow from the manually opened relief valve Release the handle on the relief valve and allow it to close after water flow is observed Carefully check the tank pipe and fittings for any sign of a water leak Immediately repair as needed Open the access door to the immersion heating elements and check for leaks at the element mounting flanges If any leak is detected tighten the screw in element START UP 10 Id 12 Insure that the electrical access panel field wiring compartment is closed and the heating element access panel is in place before proceeding After assuring that the tank is completely filled with water and no leaks are detected you are now ready to start operation of the water heater Turn on the electric power at the main disconnect point The contactors should be energized as the elements start to heat the water in the tank 23 13 14 15 As the water heater starts heating check the contactors for buzzing or chattering during operation If noise is detected turn off main power open the control panel and clean the contact points of the magnetic contactor s Remove any dust dirt or foreign matter that may have found its way into the contactor or other electrical co
49. rcuit is fused for safety Each power circuit to an immersion element 15 fused at a maximum of 48 amps Power circuits may be fused at lower current levels as needed to balance current on three phase units The power circuit fuses are held by a spring loaded fuse block rated for the voltage specified to operate the water heater The control circuit is also fused on both the primary and secondary sides of the control circuit transformer CONTACTORS FIG 15 Magnetic Contactor 12 The power to the immersion electric heating elements is switched by a definite purpose magnetic contactor The contactor is supplied with 120 VAC from the control circuit when the immersion thermostat senses a drop in stored water temperature below the desired set point A magnetic coil in the contactor is energized to complete the electrical circuit supplying power to the immersion heating elements When the thermostat is satisfied the contactor coil is de energized and power to the heating elements is turned off CONTROL CIRCUIT TRANSFORMER He H4 Fi re x WEN ug tu FIG 16 Control Circuit Transformer A transformer is used to reduce the line voltage to 120 VAC for internal control operation The transformer is fu
50. ry internal wiring is attached to a terminal block inside the unit The branch circuit is connected to the terminal block through an opening provided on the top of the water heater electrical access panel Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable To avoid serious damage DO NOT energize the appliance until the system is full of water Ensure that all air is removed from the storage tank and piping before beginning initial operation Operation of a water heater without a completely filled tank may result in serious damage to the appliance and heating element burn out 5 The water heater should be connected with a separate grounded branch circuit with over current protection and disconnect switch The water heater should be grounded in accordance with national and local codes ground terminal is provided for ground connection only 6 Provide the appliance with proper overload protection in the branch circuit It is suggested that the electrician size the branch circuit at 125 percent of the heater ampere rating and further increase wire size as necessary to compensate for voltage drop in long runs Branch circuit voltage drop should not exceed 3 at the heater 7 Voltage applied to the heater should not vary more than 5 to 10 of the model and rating plate marking for satisfactory operation 8 A wiring diagram is provided with the water heater for the e
51. s Safety Door Interlock Manual Limiting Switches Temperature and Pressure Gauges Alarm Bell Manway 250 Gallon and Larger Only Shunt Trip Disconnect Field Installed 150 psi or 160 psi Working Pressure Low or High Water Pressure Switch Electronic Step Controller Lifting Lugs Seismic Attachment Points 250 Gallon and Larger Only Time Clock 7 day or 24 hour customer must provide seismic zone or city and state of install Standard kW Input amp Amperage Suggested GPH Max No of kW No of Modulating Amperage Draw 100 F Btu hr No of Control Contactors Control Steps Single Phase Three Phase Rise Equivalent Elements Steps Element 240 480V 240 480V 208V 240V 208V 240V 480V 12 49 40 944 1 1 12 2 1 58 50 33 29 14 15 62 51 180 1 1 15 2 1 72 63 42 36 18 18 14 61 416 1 1 18 2 1 87 15 50 44 22 30 123 102 360 2 1 15 2 1 144 125 83 12 36 36 148 122 832 2 1 18 42 4 2 174 150 100 87 44 45 185 153 540 3 1 15 3 2 3 2 216 188 125 108 54 54 221 184 248 3 1 18 6 2 3 2 260 225 150 130 65 60 246 204 720 4 2 15 12 6 4 3 289 250 167 144 72 72 295 245 664 4 2 18 8 4 4 4 200 174 87 90 369 307 080 5 2 18 6 3 3 3 250 217 109 108 443 368 496 6 2 18 12 4 4 4 300 260 130 120 492 409 440 8 3 15 8 4 4 4 333 289 144 135 554 460 620 9 3 15 9 6 4 4 375 325 162 144 590 491 328 8 3 18 16 8 4 4 400 347 174 162 664 552 144 9 3 18
52. sed on both the primary and secondary side The common side of the secondary control circuit is grounded The VA rating of the control circuit transformer is based on the load of the various components in the water heater control circuit WARNING A HAZARD OF ELECTRICAL SHOCK Before opening the electrical access panel to adjust the thermostat or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage IMMERSION THERMOSTAT S FIG 17 Immersion Thermostat with Adjustment Knob This water heater uses an immersion thermostat s to activate magnetic contactors allowing current to flow to the immersion heating elements The standard control system uses one immersion thermostat for each 54kW of electric heating power in a water heater As an option additional immersion thermostats may be provided to add additional steps of thermostatic control The sensing bulb for each immersion thermostat is immersed in the stored water in the tank to provide quick accurate response to changes in water temperature The thermostat sensing bulb is located in the tank just above the elements it is controlling The immersion thermostat set point is adjustable by rotating a knob on the control Turning the knob counter clockwise decreases the temperature set point and turning the knob clockwise increases the set
53. stalled indoors where it is protected from exposure to wind rain and weather Locate the appliance as close as possible to the point of major hot water usage the water piping and branch electrical circuit wiring Insulate water piping to control heat loss and possible condensation The appliance must be located in an area that is not subject to freezing The ambient temperature of the space where the appliance is installed must not go below 32 F 0 C or above 104 F 40 C Drain Pan on Horizontal Models and Vertical Square Models 1250 Gallons and Larger The lower pan of the horizontal water heater jacket or vertical square water heater jacket is specially constructed to function as a drain pan A water discharge opening is located in either end of the pan The discharge opening s used must be piped to a suitable floor drain If only one discharge opening in the jacket pan is piped to a floor drain the unused opening must be plugged This jacket pan provides an extra margin of protection against water damage on vertical square or horizontally constructed models CAUTION This water heater as well as all water heaters will eventually leak Installation of the water heater should be accomplished in such a manner that if the tank piping or any connections should leak the flow of water will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper
54. stops Transformers and contactors often hum Water leakage is suspected 1 Check to see if the drain valve is tightly closed 2 The apparent leakage may be condensation which forms on cool surfaces of the heater and piping 3 If the outlet of the relief valve if leaking it may represent a Excessive water pressure b Excessive water temperature c Faulty relief valve Excessive water pressure is not the most common cause of relief valve leakage It is often caused by a closed system A check valve back flow preventer or pressure reducing valve in the inlet system will not permit the expanded hot water volume to equalize pressure with the main A relief valve must release this water or the water heater and plumbing system will be damaged When such a condition is encountered local codes or inspection agency should be consulted to determine which of the following procedures is acceptable in your area nstallation of an expansion tank Removal of the check valve 4 Examine the flange area of the elements for gasket leakage Tighten the screw in flange or if necessary follow the Water and Lime Scale Removal procedure to remove the element and replace the O ring gaskets that seal each element IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF MALFUNCTION 1 Place the water heater electrical disconnect switch on the OFF position 2 Contact your mechanical contractor or service tech
55. ter when set at the lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes 2 Higher stored water temperature increases the ability of the heater to supply desired quantities of hot water however remember e Ee HT WE Hotter water increases the risk of scald injury Setting the temperature selector dial higher provides hotter water which increases the risk of scald injury A DANGER Water temperature over 125 F can 1 cause severe burns instantly or death from scalds Turn OFF the electrical power to the water heater If the power disconnect point is out of Children disabled and elderly are at highest risk of being scalded sight lock it in the open OFF position See instruction manual before setting temperature at heating and tag to prevent unexpected application appliance of power If this appliance is used to produce water that could scald if too hot such as domestic hot water use adjust the outlet control limit or p use temperature limiting valves to obtain a maximum water temperature of 125 F SEE MANUAL Open the water heater s electrical access panel 3 Adjust each immersion thermostat to the desired temperature setting by turning the WARNING adjusting knob Each thermostat will be WARNING SHOULD OVERHEATING factory pre set to approximately 125 F OCCUR OR THE TEMPERATURE 51 7 C or less as shipped CON
56. ter is returned to service i Ee Disconnect the main power to the heater before opening the element access panel to reset the high limit control The high limit control will not reset until the water temperature has dropped below the set point of the high limit IMMERSION HEATING ELEMENT FIG 22 Immersion Heating Element WARNING A HAZARD OF ELECTRICAL SHOCK Before opening the access panel to remove or service the immersion heating elements make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage The heating input to this commercial electric water heater is provide by low watt density immersion heating elements The heating elements are constructed from an incoloy sheath with a tin plate on the exterior surface Three 19 element blades are mounted on a single hex head screw in mounting flange The element flange mounts into a 1 1 2 NPT threaded connection welded to the storage tank The hex head screw in mounting flange seals to the tank with an O ring gasket at the base of the threaded portion of the flange The tank flange has a matching recess for the O ring gasket to insure a proper water tight seal The O ring element gasket must be replaced with a new gasket when an element 15 removed for inspection cleaning or replacement
57. us indication 60 seconds after the last programming key 15 pushed SETUP OF THE TEMPERATURE CONTROLLER Each stage on the controller has its own independent set point and differential which are determined by the programming keys Each stage of heating is de energized as the sensed temperature reaches the programmed set point Each available stage of heating is energized as the sensed temperature reaches the set point minus the differential EXAMPLE Using stage one of the control as an example the corresponding load would be energized and de energized at the following temperatures based on the programmed settings Settings Set point 160 F Differential 8 F Output Energized Stage One Energized at 152 F Output De energized Stage One De energized at 160 F Each available stage of operation must be programmed with a set point and a differential If two stages are programmed with the same set 16 point and differential the control will sequence both stages on and off with only a slight delay between switching of the stages The control is normally programmed with a few degrees difference between the set point of each stage to sequence individual stages on as required by demand This will allow input to be balanced to system demand The exact settings will be determined by your system hot water requirements Based on your system requirements determine the set point and switching differential for each sta
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