American Water Heater 52 Series User manual

1
100293647 2000548787 (Rev. A)
COMMERCIAL ELECTRIC WATER HEATER
52/80/120 SERIES 100
INSTALLATION - OPERATION - SERVICE
MAINTENANCE - LIMITED WARRANTY
Instruction Manual
PRINTED 0917
(OPTIONAL)
Thank you for buying this energy efcient water heater. We
appreciate your condence in our products.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
Tennessee Waltz Parkway
Ashland City, TN 37015

2
SAFE INSTALLATION, USE, AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
• Qualied Installer or Service Agency:
Installation and service of this water heater requires ability equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, electrical supply are required in addition to electrical testing skills when
performing service.
• ANSI Z223.1 2006 Sec. 3.3.83:
“Qualied Agency” - “Any individual, rm, corporation or company that either in person or through a representative is engaged in
and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair
or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that
has complied with all the requirements of the authority having jurisdiction.”

3
GENERAL SAFETY INFORMATION
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately
call a qualied service technician to inspect the water heater
and to replace any part of the control system which has been
under water.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
technician.
1. External re.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the
National Electrical Code and/or local codes. These must be
followed in all cases. Failure to ground this water heater properly
may also cause erratic control system operation on ELECTRONIC
CONTROL models.
This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor
must be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater.
HYDROGEN GAS (FLAMMABLE)
Hydrogen gas can be produced in a hot water system served
by this heater that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
ammable. To reduce the risk of injury under these conditions, it is
recommended that the hot water faucet be opened for several minutes
at the kitchen sink before using any electrical appliance connected to
the hot water system. If hydrogen is present there will probably be an
unusual sound such as air escaping through the pipe as the water begins
to ow. THERE SHOULD BE NO SMOKING OR OPEN FLAME
NEAR THE FAUCET AT THE TIME IT IS OPEN.
Improper installation, use and service may
result in property damage.
CAUTION
• Do not operate water heater if any part has been
exposed to flooding or water damage.
• Inspect anode rods regularly, replace when significantly depleted.
• Install in location with drainage.
• Fill tank with water before operation.
• Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.

4
TABLE OF CONTENTS
TEMPERATURE REGULATION .......................................21
HIGH TEMPERATURE LIMIT CONTROLS (ECO) .......21
THERMOSTAT CONTROLS .........................................21
THERMOSTAT SETTINGS - SURFACE MOUNT
CONTROL ....................................................................21
ELECTRONIC CONTROL MODELS OPERATION...........22
Control System Features ..............................................22
Control System Navigation............................................22
The Desktop Screen .....................................................22
TEMPERATURES MENU .............................................24
Temperature Settings ....................................................25
HEATER STATUS MENU..............................................26
ECONOMY MODE SETUP MENU ...............................26
Economy Mode Settings ...............................................27
ALARM OUTPUT SETUP MENU..................................30
DISPLAY SETTINGS MENU.........................................30
HEATER INFORMATION MENU ..................................30
CURRENT FAULT / ALERT MENU...............................31
FAULT HISTORY MENU...............................................31
FAULT OCCURRENCE MENU.....................................31
RESTORE FACTORY DEFAULTS MENU ....................32
MAINTENANCE ................................................................32
General .........................................................................32
Anode Rod Inspection...................................................33
FLUSHING the Water Heater........................................33
SEDIMENT REMOVAL .................................................33
LIME SCALE REMOVAL...............................................33
TROUBLESHOOTING CHECKLIST .................................35
CHECKLIST ..................................................................35
Leakage Checkpoints....................................................36
PIPING DIAGRAMS ..........................................................37
PIPING DIAGRAMS ..........................................................41
PIPING DIAGRAMS ..........................................................47
MANIFOLD KITS...............................................................49
NOTES ..............................................................................50
NOTES ..............................................................................51
SAFE INSTALLATION, USE, AND SERVICE......................2
GENERAL SAFETY INFORMATION...................................3
Precautions .....................................................................3
Hydrogen Gas (Flammable)............................................3
INTRODUCTION.................................................................5
Preparing for the Installation ...........................................5
DIMENSIONS AND CAPACITIES .......................................6
APPROVALS .......................................................................7
MODEL AND RATING .........................................................7
FEATURES AND COMPONENTS ......................................8
LOCATING THE NEW WATER HEATER..........................10
Facts to Consider About the Location ...........................10
INSTALLATION ................................................................. 11
Required Ability .............................................................11
General .........................................................................11
Contaminated Water ..................................................... 11
Circulating Pump........................................................... 11
Insulation Blankets ........................................................ 11
Temperature-Pressure Relief Valve .............................. 11
Water Line Connections................................................12
Closed Water Systems..................................................12
Thermal Expansion .......................................................12
ELECTRICAL ....................................................................13
GENERAL .....................................................................13
AMPERAGE TABLE/OVER-CURRENT PROTECTION14
HEATER CIRCUITS - ELECTRONIC CONTROL
MODELS .......................................................................14
CONTROL CIRCUIT - ELECTRONIC CONTROL
MODELS .......................................................................14
WIRING DIAGRAMS.........................................................15
POWER CIRCUIT DIAGRAMS - ELECTRONIC CONTROL
MODELS .......................................................................16
POWER CIRCUIT DIAGRAMS - SURFACE MOUNT
CONTROL MODELS.....................................................18
OPERATION......................................................................20
GENERAL .....................................................................20
FILLING THE WATER HEATER....................................20
INITIAL START UP........................................................20
Draining the Water Heater.............................................20

5
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• AHRI - Air Condition, Heating and Refrigeration Institute
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
PREPARING FOR THE INSTALLATION
1. Read the “General Safety Information” section of this manual
rst and then the entire manual carefully. If you don’t follow
the safety rules, the water heater may not operate safely. It
could cause DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
This manual contains instructions for the installation, operation,
and maintenance of the electric water heater. It also contains
warnings throughout the manual that you must read and be
aware of. All warnings and all instructions are essential to the
proper operation of the water heater and your safety. READ
THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL
OR OPERATE THE WATER HEATER.
Detailed installation diagrams are in this manual. These
diagrams will serve to provide the installer with a reference
for the materials and method of piping suggested. IT
IS NECESSARY THAT ALL WATER PIPING AND THE
ELECTRICAL WIRING BE INSTALLED AND CONNECTED
AS SHOWN IN THE DIAGRAMS.
Particular attention should be given to the installation of
thermometers at the locations indicated in the diagrams as
these are necessary for checking the operation of the heater.
Be sure to turn off power when working on or near the electrical
system of the heater. Never touch electrical components with
wet hands or when standing in water. When replacing fuses
always use the correct size for the circuit. see page 13.
The principal components of the heater are identied on pages
7 & 8. The model and rating plate on page 6 interprets certain
markings into useful information. Both of these references
should be used to identify the heater, its components and
optional equipment.
2. The installation must conform with these instructions and the
local code authority having jurisdiction and the requirements
of the power company. In the absence of local codes, the
installation must comply with the current editions of the National
Electrical Code, NFPA 70 or the Canadian Electrical Code CSA
C22.1. The National Electrical Code may be ordered from:
National Fire Protection Association, 1 Batterymarch Park,
Quincy, MA 02269. The Canadian Electrical Code is available
from the Canadian Standards Association, 8501 East Pleasant
Valley Road, Cleveland, OH 44131.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the toll free
number listed on the back cover of this manual for technical
assistance.
A sample rating plate is shown on page 6 of this manual. In
order to expedite your request, please have full model and
serial number available for the technician.
4. Carefully plan your intended placement of the water heater.
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
Installation and service of this water heater requires ability
equivalent to that of a licensed tradesman or qualied agency
(page 2) in the eld involved. Plumbing and electrical work
are required.
5. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
for instructions for correct installation procedures. Instructions
may be obtained from California Ofce of the State Architect,
1102 Q Street, Suite 5100, Sacramento, CA 95811.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
INTRODUCTION

6
DIMENSIONS AND CAPACITIES
3/4” NPT
OPENING
DISPLAY FOR
ELECTRONIC
CONTROL
MODELS ONLY
WATER
OUTLET
CONDUIT
OPENING
INLET
OPENING
DRAIN
VALVE
A
C
B
5.25
Figure 1. Components and Physical Dimensions
Table 1. Tank Capacities and Dimensions
Model Number Tank Capacity in Gallons (Liters) A - Inches (mm) B - Inches (mm) C - Inches
(mm) Inlet/Outlet
52 50 (189.3) 55 3/4 (1416) 21 3/4 (552) 27 (685) 1 1/4
80 80 (302.8) 60 1/4 (1350) 25 1/2 (648) 31 (787) 1 1/4
120 119 (450.5) 62 1/4 (1581) 29 1/2 (749) 35 (889) 1 1/4
Table 2. Recovery Rate in Gallons Per Hour Temperature Rise °F
Standard
KW Input
BTU/
Hour 30° 40° 50° 60° 70° 80° 90° 100° 110° 120° 130° 140°
620,478 82 62 49 41 35 31 27 25 22 21 19 18
930,717 123 92 74 62 53 46 41 37 34 31 28 26
12 40,956 164 123 98 82 70 61 55 49 45 41 38 35
13.5 46,075 184 138 111 92 79 69 62 55 50 46 43 40
15 51,195 205 154 123 102 88 77 68 61 56 51 47 44
18 61,434 246 184 148 123 105 92 82 74 67 61 57 53
24 81,912 328 246 197 164 140 123 109 98 89 82 76 70
27 92,151 369 276 221 184 158 138 123 111 101 92 85 79
30 102,390 410 307 246 205 176 154 137 123 112 102 95 88
36 122,868 492 369 295 246 211 184 164 148 134 123 113 105
40.5 138,226 554 418 3332 277 237 208 1185 166 151 138 128 119
45 153,585 615 461 369 307 263 230 205 184 168 154 142 132
54 184,302 738 553 443 369 316 277 246 221 201 184 170 158
*Figured at 1 KW (3413 Btu) = 4.1 gallons at 100°F temperature rise.
To determine recovery rate per minute, divide recovery rate per hour by 60.
This Instruction Manual covers two models of
commercial electric water heaters:
These two models are equipped from the factory with
different controls.
In this Instruction Manual ,one model is factory equipped
with a surface mounted thermostat/ECO combination
control and is referred to as the “Surface Mount Control”
model.
The other model is equipped with an electronic control
system and is referred to as the “Electronic Control” model.

7
APPROVALS
Low Lead Content
All models meet National
Sanitation Foundation
NSF-5 requirements.
All models are listed by
Underwriters Laboratories
Inc.
MODEL AND RATING
LISTED
22U1
No. OF
WATTS
PHASE VOLTS - AC ELEMENTS EACH
RATED MEASURED
%
WATTS
COMMERCIAL STORAGE
TANK WATER HEATER
MODEL NUMBER SERIAL NUMBER ITEM ID / PART NUMBER
WATTS
TOTAL
CAPACITY US GAL STANDBY LOSS MAX WORKING
PRESSURE
Low Lead Content
Figure 2. Example Rating Plate

8
FEATURES AND COMPONENTS
Figure 3. Electronic Control Models

9
FEATURES AND COMPONENTS
Figure 4. Surface Mount Control Models

10
LOCATING THE NEW WATER HEATER
FACTS TO CONSIDER ABOUT THE LOCATION
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Carefully choose a location for the new water heater. The
placement is a very important consideration for the safety of
the occupants in the building and for the most economical use
of the water heater.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed.
The water heater must be located:
• On a level surface. Shim the channel type skid base as
necessary if levelling is required.
• Near a oor drain. The heater should be located in an area
where leakage of the tank or connections will not result in
damage to the area adjacent to the heater or to lower oors
of the structure.
• Close to the point of major hot water usage and the power
supply.
• Hot water piping and branch circuit wiring should be as short
as possible.
• Insulate hot and cold water piping where heat loss and
condensation may be a problem.
• Heater construction permits installation, maintenance, and
service work to be performed through the front control panel.
• Suggested clearances from adjacent surfaces are 12 inches
on top, 30 inches in front for access to the unit.
• The heater may be installed on or against combustible
surfaces. The left side and back may be placed ush against
adjacent surfaces.
• The temperature of the space in which the water heater is
installed must not go below 32°F or above 122°F.

11
INSTALLATION
REQUIRED ABILITY
Installation and service of this water heater requires ability
equivalent to that of a qualied agency (page 2) in the eld
involved. Plumbing and electrical work is required.
GENERAL
The installation must conform with these instructions
and the local code authority having jurisdiction and the
requirements of the power company. In the absence of local
codes, the installation must comply with the current editions
of the National Electrical Code, NFPA 70 or the Canadian
Electrical Code CSA C22.1. The National Electrical Code
may be ordered from: National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269. The Canadian
Electrical Code is available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland,
OH 44131.
Note: To comply with NSF Standard 5 installation requirements
the bottom of the water heater must be sealed to the oor with
a silicone based sealant or elevated 6 inches above the oor.
Do NOT test electrical system before heater is lled with water, follow
the START UP procedure in the OPERATION section of this manual.
The principal components of the heater are identified in the
Features and Components illustrations on pages 6 and 7.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
MIXING VALVE USAGE:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dish washing, cleaning and other sanitizing needs can scald
and permanently injure you upon contact. Some people are
more likely to be permanently injured by hot water than others.
These include the elderly, children, the inrm, or physically/
developmentally disabled. If anyone using hot water in your home
ts into one of these groups or if there is a local code or state
law requiring a maximum water temperature at the hot water tap,
then you must take special precautions. In addition to using the
lowest possible temperature setting that satises your hot water
needs, a means such as a MIXING VALVE, should be used at
the hot water taps used by these people or at the water heater.
MIXING VALVES for reducing point of use temperature are
available. Consult a qualied installer or service agency. Follow
all manufacturer’s Instructions for installation of these valves.
Before changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
CONTAMINATED WATER
This water heater shall not be connected to any heating
system(s) or component(s) used with a non-potable water
heating appliance.
Toxic chemicals, such as those used for boiler treatment shall
not be introduced into this system.
CIRCULATING PUMP
Field installed circulating pumps should be of all bronze
construction.
INSULATION BLANKETS
Insulation blankets are available to the general public for external
use on electric water heaters but are not necessary with this
product. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. Your
water heater meets or exceeds the EPACT and ASHRAE/IES
90.1 standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions below. Failure to follow these
instructions can result in re, serious personal injury, or death.
• Do not cover the temperature and pressure relief (T & P)
valve with an insulation blanket.
• Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
• Do obtain new warning and instruction labels for placement
on the blanket directly over the existing labels.
TEMPERATURE-PRESSURE RELIEF VALVE
This water heater is provided with a properly rated/sized and
certied combination temperature - pressure relief valve by the
manufacturer. The valve is certied by a nationally recognized
testing laboratory that maintains periodic inspection of production
of listed equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA
4.4, and the code requirements of ASME.

12
If replaced, the new valve must meet the requirements of local
codes, but not less than a combination temperature and pressure
relief valve rated/sized and certied as indicated in the above
paragraph. The new valve must be marked with a maximum set
pressure not to exceed the marked hydrostatic working pressure
of the water heater (150 psi = 1,035 kPa) and a discharge
capacity not less than the water heater Btu/hr or KW input rate
as shown on the water heater’s model rating plate.
For safe operation of the water heater, the temperature and
pressure relief valve must not be removed from its designated
opening nor plugged. The temperature-pressure relief valve must
be installed directly into the tting of the water heater designed
for the relief valve. Install discharge piping so that any discharge
will exit only within 6 inches (15.2 cm) above, or external to
the structure. Do not pipe the discharge to a crawl space. Be
certain that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size under
any circumstances. Excessive length, over 30 feet (9.14 m), or
use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve.
No valve or other obstruction is to be placed between the relief
valve and the tank. Do not connect discharge piping directly to
the drain unless a 6” (15.2 cm) air gap is provided. To prevent
bodily injury, hazard to life, or property damage, the relief valve
must be allowed to discharge water in adequate quantities should
circumstances demand. If the discharge pipe is not connected
to a drain or other suitable means, the water ow may cause
property damage.
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a oor drain
or external to the building. In cold climates, it is recommended
that the discharge pipe be terminated at an adequate drain
inside the building.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
The temperature-pressure relief valve must be manually operated
at least once a year. Caution should be taken to ensure that
(1) no one is in front of or around the outlet of the temperature-
pressure relief valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot. If after manually
operating the valve, it fails to completely reset and continues
to release water, immediately close the cold water inlet to the
water heater, follow the draining instructions in this manual, and
replace the temperature-pressure relief valve with a properly
rated/sized new one.
If you do not understand these instructions or have any questions
regarding the temperature-pressure relief valve call the toll free
number listed on the back cover of this manual for technical
assistance.
WATER LINE CONNECTIONS
This manual provides detailed piping installation diagrams (see
back section of this manual) for typical methods of application.
For the heater inlet and outlet connections, dielectric unions are
recommended. The water heater may be installed by itself, or
with a separate storage tank, on both single and two-temperature
systems. When used with a separate storage tank, the circulation
may be either by gravity or by means of a circulating pump. When
a circulating pump is used it is important to note that the ow
rate should be slow so that there will be a minimum of turbulence
inside the heater.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements
or such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check valves,
and back ow preventers. Devices such as these cause the water
system to be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase
in water pressure due to thermal expansion. Thermal expansion
can cause premature tank failure (leakage). This type of failure
is not covered under the limited warranty. Thermal expansion
can also cause intermittent temperature-pressure relief valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The temperature-pressure relief valve is not intended
for the constant relief of thermal expansion.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed.

13
ELECTRICAL
Table 3. Allowable Ampacities of Insulated Conductors1
Size Temperature Rating of Conductor Size
60 °C
(140 °F) 75 °C (167 °F) 85 °C (185 °F) 90 °C (194 °F) 60 °C (140 °F) 75 °C (167 °F) 85 °C (185 °F) 90 °C (194 °F)
AWG
MCM
Types
RUW,
TTW,
and UF
Types
FEPW,
RH,
RHW,
RUH,
THW,
THWN,
XHHW,
USE,
and
ZW
Types
V, and
MI
Types
TA, TBS,
SA,
AVB,
SIS,
FEP2,
FEPB2,
RHH2,
THHN2,
and
XHHW
2, 3
Types
RUW,
TTW,
and UF
Types
RH,
RHW,
RUH,
THW,
THWN,
XHHW,
and
USE
Types
V, and
MI
Types
TA,
TBS,
SA,
AVB,
SIS,
RHH2,
THHN2,
and
XHHW
2, 3
AWG
MCM
Copper Aluminum or Copper-Clad Aluminum
18 .... .... .... 21 .... .... .... .... ....
16 .... .... 22 22 .... .... .... .... ....
14 15 15 25 25 .... .... .... .... ....
12 20 20 30 30 15 15 25 25 12
10 30 30 40 40 25 25 30 30 10
8 40 45 50 50 30 40 40 40 8
6 55 65 70 70 40 50 55 55 6
4 70 85 90 90 55 65 70 70 4
3 80 100 105 105 65 75 80 80 3
2115 120 120 75 90 95 95 2
1 130 140 140 100 110 110 1
0 150 155 155 120 125 125 0
00 175 185 185 135 145 145 00
000 200 210 210 155 165 165 000
0000 230 235 285 180 185 185 0000
250 255 270 270 205 215 215 250
300 285 300 300 230 240 240 300
350 310 325 325 250 260 260 350
400 335 360 360 270 290 290 400
500 380 405 405 310 330 330 500
Correction Factors
Ambient
Temp °C
For ambient temperatures over 30 °C, multiply the ampacities shown above by the
appropriate correction factor to determine the maximum allowable load current.
Ambient
Temp °F
1. Not more than three conductors in raceway, cable, or earth (directly buried), based on ambient temperature of 30°C (86°F)
2. +The load current rating and the overcurrent protection for these conductors shall not exceed 15 amperes for 14 AWG. 20
amperes for 12 AWG and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum
and copper-clad aluminum.
3. *For dry locations only. See 75°C column for wet locations.
GENERAL
The installation must conform with these instructions and the
local code authority having jurisdiction and the requirements of
the power company. In the absence of local codes, the installation
must comply with the current editions of the National Electrical
Code, NFPA 70 or the Canadian Electrical Code CSA C22.1.
An electrical ground is required to reduce risk of electrical shock
or possible electrocution. The water heater should be connected
to 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.
Voltage applied to the heater should not vary more than +5%
to -10% of the model and rating plate marking for satisfactory
operation.

14
AMPERAGE TABLE/OVER-CURRENT PROTECTION
The tables above provides the total connected heating element
load in amperes for branch circuit conductor and over-current
protection sizing. Single-phase heaters are two wire circuits.
Three-phase heaters are three wire circuits. In addition to the
foregoing, a grounded conductor is required.
The rating of the over-current protection must be computed on
the basis of 125% of the total connected load amperage. Where
the standard ratings and settings do not correspond with this
computation, the next higher standard rating or setting should
be selected.
HEATER CIRCUITS - ELECTRONIC CONTROL MODELS
The water heater’s electrical components are pictured and
identified in Figure 3 and Figure 4 The model and rating
plate illustration on page 4 identies heater circuit ratings. The
ELECTRONIC CONTROL model has two electrical circuits:
• The control circuit, which controls the electrical power to
heating elements, referring the following control circuit
diagram Figure 8.
• The power circuit, which is operated by the control circuit
carries the electrical load of the heating elements. The
following describes the heater circuits and includes
wiring diagrams for Delta configuration, refer to the
“WYE Conguration Insert” for water heaters operating at
380V/400V/416V/575V. All heater circuits are designed for
50/60 cycle alternating current.
CONTROL CIRCUIT - ELECTRONIC CONTROL MODELS
These models are equipped with an electronic control system.
The system includes a CCB (Central Control Board), an
immersion temperature probe with ECO for temperature sensing
and limiting, a UIM (User Interface Module) for user interface &
information display and element current sensors for monitoring
the power circuits. Refer to the control circuit label on the water
heater for details. The CCB is powered by a small 120V/24V
transformer. The control circuit operates on 120V supplied by a
larger 100VA transformer. Standard equipment includes control
circuit fusing using two, 3 amp, class G fuses with 600 volt rating.
Do not substitute fuses of a different rating.
Sequence of Operation
1. When the control is powered, the UIM should display model
information, water temperature, Operating Set Point, heating
status and operating mode.
2. If the control determines that the actual water temperature inside
the tank is below the programmed Operating Setpoint minus
the (1st) differential, a call for heat is activated.
3. After all safety checks are veried, the CCB will energize
contactor coils starting with the lower bank of heating elements
(each diagonal row of three heating elements is considered
a “bank” - see Figure 3) then energize the middle bank (if so
equipped) and top bank (if so equipped). The middle and top
banks (if so equipped) are energized according to programmed
2nd and 3rd differential set points.
4. The control remains in the heating mode until the water
temperature reaches the programmed Operating Setpoint.
At this point the contactors will be de-energized in the
reverse order.
5. The control system now enters the standby operating mode
while continuing to monitor the water temperature and the
state of other system devices. If the water temperature drops
below the programmed Operating Setpoint minus the (1st)
differential, the control will automatically return to step 2 and
repeat the heating cycle.
NOTE: See the Electronic Control Models Operation section
for more detailed information on temperature settings
mentioned above.
120 VAC CONTROL CIRCUIT TRANSFORMER CONNECTIONS
- ELECTRONIC CONTROL MODELS
Figure 5. Transformer Connections
Figure 6. Transformer Secondary Loop
Figure 7. Transformer Secondary Line Volts
Table 4. Required Electrical Characteristics
KW Input Number Of Elements Element wattage
Full Load Current In Amperes
Number Of Ther-
mostats Number Of Fuses
Single Phase Three Phase
208V 240V 277V 480V 208V 240V 480V
12
3
4000 58 50 44 25 34 29 15
3 6
13.5 4500 65 57 49 29 38 33 17
15 5000 73 63 55 32 42 37 18
18 6000 - - - 75 65 38 - - - 44 22
18
6
3000 87 - - - - - - - - - 50 - - - - - -
6 12
24 4000 116 100 87 50 67 58 29
27 4500 130 113 98 57 75 65 33
30 5000 145 125 109 63 84 73 37
36 6000 - - - 150 130 75 - - - 87 44
36
9
4000 173 - - - - - - - - - 100 - - - - - -
9 18
40.5 4500 195 169 147 85 113 98 49
45 5000 217 188 163 94 125 109 55
54 6000 - - - 225 195 113 150 130 65

15
WIRING DIAGRAMS
Figure 8. CCB (Central Control Board) Control Circuit Diagram - Electronic Control Models

16
WIRING DIAGRAMS
POWER CIRCUIT DIAGRAMS - ELECTRONIC CONTROL MODELS
The water heater’s electrical components are pictured and identied on page 7. The following describes the heater circuits and
includes wiring diagrams. All heater circuits are designed for 60/50 hertz alternating current. The water heater circuit wiring is 12
AWG, AWM, or TEW type, rated 600 volts, 105°C. Fusing consists of three 30 amp fuses for each contactor. Fusing is an optional
feature for Canadian models.
Figure 9. Three- and Six-Element Single- and Three-Phase Power Circuits

17
CONVERSION TO SINGLE PHASE
When the heater is shipped for connection to a three-phase
electrical service, it may be connected to a single-phase electrical
service of the same voltage by:
1. Disconnect blue wires and yellow wires from terminal L3.
2. Reconnect all blue wires to terminal L1 (with black wires).
3. Reconnect all yellow wires to terminal L2 (with red wires).
4. Connect incoming power to terminals L1 and L2.
CONVERSION TO THREE PHASE
When heater is shipped for connection to a single-phase electrical
service, it may be connected to a three-phase electrical service
of the same voltage by:
1. Disconnect blue wires from terminal L1.
2. Disconnect yellow wires from terminal L2.
3. Reconnect all blue wires and yellow wires to terminal L3.
4. Connect incoming power to terminals L1, L2, and L3.
WIRING DIAGRAMS
Figure 10. Nine-Element Single- and Three-Phase Power Circuits

18
WIRING DIAGRAMS
POWER CIRCUIT DIAGRAMS - SURFACE MOUNT CONTROL MODELS
The water heater’s electrical components are pictured and identied on page 8. The following describes the heater circuits and
includes wiring diagrams. All heater circuits are designed for 60/50 hertz alternating current. The water heater circuit wiring is 12 AWG,
AWM, or TEW type, rated 600 volts, 105°C. Fusing consists of two 30 amp fuses for each element. Fusing is an optional feature for
Canadian models.
Figure 11. Three- and Six-Element Single- and Three-Phase Power Circuits

19
WIRING DIAGRAMS
Figure 12. Nine Elements - Single And Three Phase
CONVERSION TO SINGLE PHASE
When the heater is shipped for connection to a three-phase
electrical service, it may be connected to a single-phase electrical
service of the same voltage by:
1. Disconnect blue wires from terminal L2.
2. Connect all blue wires to terminal L1 (with black wires).
3. Disconnect all red wires from terminal L3.
4. Connect all red wires to terminal L2 (with yellow wires).
5. Connect incoming power to terminals L1 and L2.
CONVERSION TO THREE PHASE
When heater is shipped for connection to a single-phase
electrical service, it may be connected to a three-phase electrical
service of the same voltage by:
1. Disconnect blue wires from terminal L1
2. Disconnect red wires from terminal L2.
3. Connect all blue wires to terminal L2 (with yellow wires).
4. Connect red wires to terminal L3.
5. Connect incoming power to terminals L1, L2 and L3.

20
OPERATION
GENERAL
Refer to the Features and Components section of this manual
(pages 7 & 8) for the location of components mentioned in the
instructions that follow.
NEVER turn on power to the water heater without being certain
the water heater is lled with water and a temperature and
pressure relief valve is installed in the relief valve opening.
DO NOT TEST ELECTRICAL SYSTEM BEFORE HEATER IS
FILLED WITH WATER. FOLLOW FILLING AND START-UP
INSTRUCTIONS IN OPERATION SECTION.
FILLING THE WATER HEATER
1. Turn off the electrical disconnect switch.
2. Close the water heater drain valve.
3. Open a nearby hot water faucet to permit the air in the system
to escape.
4. Fully open the cold water inlet pipe valve allowing the heater
and piping to be lled.
5. Close the hot water faucet as water starts to ow. The heater is
now ready for STARTUP and TEMPERATURE REGULATION.
INITIAL START UP
The following checks should be made by the installer when the
heater is placed into operation for the rst time.
1. Turn off the electrical disconnect switch.
2. Open the front panel, check all water and electrical connections
for tightness. Also check connections on top and side of
heater. Repair water leaks and tighten electrical connections
as necessary.
3. Depress the red manual reset button on each Thermostat/
ECO combination control (Surface Mount Control Models only).
4. Turn on the electrical disconnect switch.
5. Observe the operation of the electrical components during
the rst heating cycle. Use care as the electrical circuits are
energized.
6. Close the front panel.
Temperature control and contactor operation should be checked
by allowing heater to come up to temperature and shut off
automatically. Use care as the electrical circuits are energized.
DRAINING THE WATER HEATER
It is recommended that the water heater storage tank be drained
and ushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures. See Features And Components in this manual for
the location of the water heater components described below.
Burn harzard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
TO DRAIN THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater at the breaker
or disconnect switch.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
4. Close the cold water inlet valve to the water heater.
5. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
6. Open the water heater drain valve and allow all the water to
drain from the storage tank.
7. Close the water heater drain valve when all water in the storage
tank has drained.
8. Close the hot water faucet opened in Step 3.
9. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.