AquaMAX E80 Series User manual

Aquamax Australia Pty Ltd ABN 17 138 189 689
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Stainless Steel Electric Water
Heaters
AQ0903010-A
Revision: A
Published: November 2012
E80 to E315
Series

2
Contents
Introduction ..........................................................................................................................3
Safety Warning ....................................................................................................................3
Heater Model Identification ..................................................................................................3
Specifications.......................................................................................................................4
Preventative Maintenance ...................................................................................................4
Operation .............................................................................................................................5
Components and their Function...........................................................................................6
Plumbing Diagrams .............................................................................................................7
Fault Finding ........................................................................................................................8
General Fault Finding Chart .......................................................................................10
Fault Finding Chart 1 – No Hot Water ........................................................................11
Fault Finding Chart 2 – Insufficient Hot Water / Water Not Hot Enough.....................14
Fault Finding Chart 3 – Water Too Hot.......................................................................15
Fault Finding Chart 4 – Leaking Water Heater...........................................................16
Fault Finding Chart 5 – Noisy Water Heater...............................................................16
Component Adjustment Procedures ..................................................................................20
Component Replacement Procedures...............................................................................21
Document Revision History................................................................................................26
Single Element Models ....................................................................................................5
Twin Element Non-Simultaneous Models ........................................................................5
Common Faults................................................................................................................8
Fault Finding Charts.......................................................................................................10
Fault Finding Tests ........................................................................................................17
Electrical Insulation Testing ...........................................................................................19
Thermostat Adjustment ..................................................................................................20
Replacement Parts Diagram – Single Element Models .................................................24
Replacement Parts List – Single Element Models .........................................................24
Replacement Parts Diagram – Twin Element Models....................................................25
Replacement Parts List – Twin Element Models............................................................25

3
Introduction
The information provided in this manual is based on the water heater being installed in
accordance with the Installation Instructions provided with each water heater.
Should you require further technical advice on an Aquamax Electric Water Heater, contact
your nearest Aquamax Service Department where all genuine replacement parts are also
available.
Safety Warning
The purpose of this Service Manual is to provide sufficient information to allow a person
with the skills as required by the controlling Regulatory Authorities to carry out effective
repairs to an Aquamax Electric Water Heater in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting tests
outlined in this service manual are indicated by print in bold italics and/or a warning
symbol. Take care to observe the recommended procedure.
“Live” testing to be conducted. Personal Protective Clothing (PPE) must
be worn to prevent the risk of electric shock.
Isolate power before conducting the indicated test
Hot surface or liquid. Personal Protective Clothing (PPE) must be worn to
reduce the risk of scalding.
General warning symbol. Observe the instructions accompanying the
symbol.
Heater Model Identification
All identification numbers are designed to convey detailed information about the water
heater to which it is attached.
E 160 S 48 SS
E – Electric series
160 – Rated hot water delivery in Litres
S – Single Heating Unit
T – Two Heating Units
18 – 1800W
24 – 2400W
36 – 3600W
48 – 4800W
Element wattage
SS - Stainless Steel Cylinder
Model number, serial number and date of manufacture should be quoted in all correspondence.

4
Specifications
Specification E80 E125 E160 E250 E315
Storage capacity (L) 83 130 165 260 315
Rated HW delivery (L) 80 125 160 250 325
Boost capacity (L)
(1)
N/A NA 46 69 79
PTR valve rating (kPa) 1400 1400 1400 1000 1000
ECV rating (kPa) 1250 1250 1250 850 850
Max inlet pressure (kPa) With ECV 960 960 960 650 650
W/out ECV 1120 1120 1120 850 850
Thermostat setting (°C) Top
(1)
N/A N/A 60 60 60
Bottom
(
2
)
60 ~ 75 60 ~ 75 60 ~ 75 60 ~ 75 60 ~ 75
Water connections
Inlet (Female)
RP20 (¾”) RP20 (¾”) RP20 (¾”) RP20 (¾”) RP20 (¾”)
Outlet (Female)
RP20 (¾”) RP20 (¾”) RP20 (¾”) RP20 (¾”) RP20 (¾”)
PTR valve ( Female)
RP15 (½”) RP15 (½”) RP15 (½”) RP15 (½”) RP15 (½”)
Electrical connection 240 Volts 50 Hz AC
(1)
Twin element models only.
(2)
Factory setting 70°C for twin element models and 65°C for all other single element models.
Preventative Maintenance
Annual Service
It is suggested for peak performance that the water heater be serviced annually.
1. Check for discharge from the PTR valve. When the element is operating a small
discharge of water may be evident. Operate the valve-easing lever to ensure the valve
opens and resets properly. Always open and close the valve gently.
2. Check for discharge from the ECV if fitted. When the element is operating a small
discharge of water may be evident. Operate the valve-easing lever to ensure the valve
opens and resets properly. Always open and close the valve gently.
3. Check for leaks at all tank fittings.
4. Check for signs of excessive corrosion on the water heater jacket.
5. If an overflow tray is installed, check to ensure the overflow tray drain pipe is not
blocked.
6. Isolate power to the water heater and check all electrical connections for signs of
overheating due to poor connection.
7. Conduct an electrical insulation test on the water heater (refer to “Electrical Insulation
Testing” on page 19).
Major Five Year Service
It is recommended that a major five year service be conducted on the water heater.
1. Replace pressure temperature relief valve (PTR).
2. Inspect and flush expansion control valve (if ECV fitted) and replace if required.
3. Check electric heating unit for excessive calcium build up or corrosion and replace
heating unit if required.
4. Visually check water heater for any potential problems.
5. Inspect all plumbing and electrical connections.

5
Operation
Single Element Models
Water temperature is maintained via a thermostat switching the active conductor to an
electric immersion element positioned towards the bottom of the cylinder.
When the water temperature within the cylinder falls sufficiently, the thermostat contacts
close suppling power to the element.
Once the water temperature reaches the set point of the thermostat, the contacts open
cutting power to the element.
A double pole ‘manual reset’ over temperature cut out is incorporated into the thermostat
to provide additional protection in the event the controlling thermostat contacts fail. The
ECO contacts open between 80ºC and 88ºC.
Twin Element Non-Simultaneous Models
Water temperature is maintained via two electric immersion elements, one is positioned
near the top of the cylinder and the other towards the bottom. Only one element is
operational at any time (known as non simultaneous operation).
A thermostat, positioned adjacent to each element is utilised to maintain water
temperature.
The top thermostat switches the neutral from the top element to the bottom element, this
ensures only one element can be energised at a time. The top thermostat is factory set at
60ºC. The bottom thermostat switches the active to the bottom element only.
Both thermostats incorporate a double pole ‘manual reset’ ECO to provide additional
protection in the event the controlling thermostat contacts fail.
Once the top thermostat senses a temperature of approximately 60ºC the thermostat
contacts open the neutral circuit to the top element (between terminals 1 and 2), causing
the top element to be de-energised, and close the neutral circuit to the bottom element
(between terminals 1 and 5).
When the water temperature at the bottom of the tank reaches the set point of the bottom
thermostat, the thermostat contacts open cutting the active circuit to the bottom element.
Under normal usage the top element is unlikely to operate, the water temperature being
maintained by the bottom element. During periods of heavy use when the complete supply
of hot water is depleted, the top element will operate to maintain the water temperature at
the top of the tank (above the top element).
When the bottom element is connected to an off peak tariff full recovery of the tank will
occur whenever power from the off peak tariff is available, usually overnight.

6
Components and their Function
Temperature and Pressure Relief Valve
A valve designed to provide automatic relief by discharging water in case of excessive
temperature, pressure or both.
Never fit a PTR Valve with a pressure rating greater than that indicated on
the product-rating label.
Pressure Limiting Valve (P.L.V.)
A valve that controls its outlet pressure to a predetermined limit.
Stainless Steel Inlet Tube and Diffuser Assembly
A stainless steel tube assembly is installed in the cold water inlet of the water heater
cylinder to assist with stratification.
Thermostat
A device, responsive to temperature, which controls the supply of electrical energy to the
element to maintain the stored water at the required temperature.
Non-simultaneous (Top) Thermostat – Twin Element Models
A device, responsive to temperature, which controls the supply of electrical energy to the
top element to maintain the stored water at the required temperature. It also switches the
neutral supply between the top and bottom elements to ensure only one element can be
operational at any time. This is known as non-simultaneous operation.
Over Temperature Energy Cut Out (E.C.O.)
A temperature-sensing device in combination with the thermostat that automatically cuts
off the supply of electrical energy to prevent excessive water temperature occurring. This
device will not reset automatically but may be manually reset once temperatures have
fallen to a safe level. DETERMINE CAUSE OF OPERATION.
Heating Unit (Element)
A tubular device containing an electric resistance element that converts electrical energy
to heat. Standard ratings are 1.8, 2.4, 3.6, and 4.8 kW.

7
Plumbing Diagrams
The following information and plumbing diagrams are provided as a guide only. For more
information refer to the relevant Installation Instructions.
Two Temperature Zone Plumbing Diagram
Circulated Flow & Return Plumbing Diagrams
For circulated hot water flow and return systems, a temperature limiting device can only be
installed on a dead leg which branches off the circulated hot water flow and return pipe.
Installing a temperature limiting device in the circulated flow and return
pipe work, or circulating tempered water from a temperature limiting device
may cause water to be delivered to ablution areas at a temperature
exceeding the requirements of AS/NZS 3500.4.

8
Fault Finding
Common Faults
When a complaint is lodged about the performance of a hot water system there are a
number of causes that should be checked and eliminated. In an attempt to pinpoint the
most likely cause it is important to discuss with the customer their reasons for the
complaint, the duration of the problem, any change in circumstances or usage and recent
weather conditions. This information in conjunction with the following listed common
complaints will assist you in locating the most likely cause. All procedures assume there is
water flowing through the water heater.
Excessive hot water usage
The complaints of insufficient hot water and no hot water can on many occasions be
attributed to hot water usage exceeding the capacity of the water heater to provide hot
water.
When first attending a call of this nature it is essential to establish the probable hot water
usage by querying the usage habits of the household and compare this with the potential
delivery of the model water heater installed. It can then be established if the usage is
within or outside the capacity of the model. The areas to look at for excessive usage are:
1. Automatic washing machines.
2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration.
3. Two or more showers operating at the same time.
4. Change of occupancy or number of persons increased.
5. High water pressure area (Excessive pressure relief valve discharge).
6. Plumbing leaks.
7. Thermostat temperature setting.
8. Crossed connection.
Discoloured water
This may be the result of discoloured water entering from the cold water mains. Check if
the cold water is also discoloured.
Water hammer
A water heater will not cause water hammer, however valves associated with the water
heater may be the source of the problem i.e. cold-water stopcock, non-return valve or relief
valve.
Most water hammer problems are associated with plumbing, hot and cold or appliances
i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve
parts, loose tap washers or neighbouring equipment.
High water pressure areas will have more complaints of this nature and the use of a
pressure-limiting valve (PLV) to reduce the household cold-water pressure will usually
solve most problems.

9
Hot water plumbing leaks
If hot water has not been used for a period of time, feeling the temperature of the hot water
line may give an indication of water flow if the pipe is warm. The method of checking for
plumbing leaks is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is
operating correctly.
3. Turn off the hot tap.
4. Turn on the stopcock to make up the water pressure in the cylinder and then turn the
stopcock off again.
5. Wait approximately 5 minutes then do either of the following:
a. With your ear close to the stopcock turn it on slightly and listen for any water
passing. If there are no leaks, water should not pass.
b. Open a hot tap while listening for any pressure release. If there is a pressure
release there will be no leaks in the plumbing system.
Mixing or crossed connections
If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or
thermostatic mixing valve is installed there is always the possibility that the cold water
could mix with the hot water through a faulty or incorrectly installed valve. This is referred
to as a cross connection. The complaints of insufficient hot water, water not hot enough or
excessive discharge from the pressure relief valve may be attributed to a cross
connection. The method of checking for a cross connection is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap. If water flow is persistent and cold then a cross connection exists.

10
Fault Finding Charts
General Fault Finding Chart
Chart Complaint Page
1 No hot water 11
2 Insufficient hot water / Water not hot enough 14
3 Water too hot 15
4 Leaking water heater 16
5 Noisy water heater 16

11
Fault Finding Chart 1 – No Hot Water
Fault Finding Chart 1.1

12
Fault Finding Chart 1.2
Fault Finding Chart 1.3

13
Fault Finding Chart 1.4

14
Fault Finding Chart 2 – Insufficient Hot Water / Water Not Hot Enough
INSUFFICIENT HOT WATER / WATER NOT HOT ENOUGH
2
Has the usage pattern
changed recently i.e.
additional appliances or
people using hot water.
YES
NO
YES
NO
Recommend a hot water usage
pattern that will suit the water
heater and the customers needs
YES
NO
Is the heater of sufficient
size for the customers
on going needs
Refer to sizing guide.
Recommend a water heater of
sufficient capacity to meet the
customers needs.
Is the water supply
pressure more than
80% of the PTR valve
rating
Fit pressure limiting valve if not
already installed.
Existing pressure limiting valve
faulty – Replace.
Faulty PTR valve – Replace.
YES
Is the PTR valve
continuously
discharging water
Is the correct PTR valve
fitted
NO
Check for crossed water
connection. Replace PTR valve.
YES
Replace PTR valve with one of
the correct pressure rating.
NOTE: Do not use
reconditioned PTR valves
NO
Are there any plumbing
leaks, crossed
connections or dripping
taps
Repair any leaks.
Isolate crossed connections.
YES
NO
Is cylinder water temp
8ºC less than the
thermostat setting
YES
NO
Bottom thermostat if twin
element model
Is water heater a single
or twin element model
1.2
1.3
Single element model
Twin element model
Has there been a recent
large draw off of hot
water
NO
YES
Is a tempering valve
installed
YES
Are tempering valve
filters blocked
Check inlet diffuser is not
restricted, missing or damaged.
Check dip tube is not missing
broken or incorrectly fitted.
NO
YES
Clean or replace tempering
valve filters. Refer to
manufacturers instructions for
tempering valve.
YES
Is tempering valve outlet
water temp approx
48ºC
NO
Replace tempering valve. Refer
to manufacturers instructions for
tempering valve.
NO
Normal Operation of tempering valve
Tempering valves are generally set to deliver water at 48 - 50ºC.
Depending on the length of pipe work and insulation to the
fixture(s), water temperature can be lower due to heat loss.
NOTE: AS/NZS 3500 Part 4 only requires fixtures used for
ablution purposes to be tempered.
If practical a 2 zone plumbing solution may be offered.
YES
Is the element(s)
installed in the correct
orientation
Install element(s) in correct
orientation.
NO
Check inlet diffuser is not
restricted, missing or damaged.
Check dip tube is not missing
broken or incorrectly fitted.
Confirm a recent large draw off of hot water has
not depleted the hot water supply temp. Allow time
for the heater to recover (Note: for models on off
peak tariffs this may not occur until the next day).
If water heater has a tempering valve installed:
Typically the hot inlet temperature to the tempering
valve must be 10º higher than the required outlet
temperature.

15
Fault Finding Chart 3 – Water Too Hot

16
Fault Finding Chart 4 – Leaking Water Heater
Fault Finding Chart 5 – Noisy Water Heater

17
Fault Finding Tests
Fault Finding Tests 1 – 3
Test 1 – Single Element Models Test 1 – Twin Element Models
Using a multimeter set on the AC voltage
scale, measure between the Active
terminal ‘A’ and the Neutral terminal ‘N’ on
the terminal block.
Normal voltage is 240 Volts AC.
Using a multimeter set on the AC voltage
scale, measure between the off peak
Active terminal ‘A1’ and the Neutral
terminal ‘N’ on the terminal block. Then
measure between the boost Active terminal
‘A2’ and the Neutral terminal ‘N’ on the
terminal block. The following results should
be obtained:
Active ‘A1’ to Neutral ‘N’ – 240 Volts AC.
Active ‘A2’ to Neutral ‘N’ – 240 Volts AC.
Test 2 – ST Thermostat Test 3 – ST Thermostat
Using a multimeter set on the resistance
scale, measure between the thermostat
terminals marked ‘3’ and ‘4’ (bottom
thermostat on twin element models).
Normal resistance is less than 1 ohm when
the ECO contacts are closed.
Using a multimeter set on the resistance
scale, measure between the thermostat
terminals marked ‘1’ and ‘2’ (bottom
thermostat on twin element models).
Normal resistance is less than 1 ohm when
the thermostat contacts are closed.

18
Fault Finding Tests 4 – 7
Test 4 Test 5
ST thermostat shown
Single element model shown
Disconnect both element wires from the
thermostat and using a multimeter set on
the resistance scale, measure between the
two disconnected element wires.
Normal resistance is as follows:
1.8kW element: 29 ~ 35Ω.
2.4kW element: 22 ~ 26Ω.
3.6kW element: 15 ~ 17Ω.
4.8kW element: 11~ 13Ω.
Using a multimeter on the resistance scale,
measure between the Active wire ‘A’ and
the Neutral wire ‘N’ on the terminal block.
Note: If model is a twin element model,
mark, disconnect and twist ‘A1’ and ‘A2’
actives together to form one active
connection for testing purposes.
Normal overall resistance when thermostat
is closed will depend on element size.
Refer to test results for test 4.
Test 6 – ST Thermostat Test 7 – ST Thermostat
Using a multimeter set on the resistance
scale, measure between the top thermostat
terminals marked ‘3’ and ‘4’.
Normal resistance is less than 1 ohm when
the ECO contacts are closed.
Using a multimeter set on the resistance
scale, measure between the top thermostat
terminals marked ‘1’ and ‘2’.
Normal resistance is less than 1 ohm when
the neutral contact to the top element is
closed.

19
Fault Finding Test 8
Test 8 – ST Thermostat
Using a multimeter set on the resistance
scale, measure between the top thermostat
terminals marked ‘1’ and ‘5’.
Normal resistance is less than 1 ohm when
the neutral contact to the bottom element is
closed.
Electrical Insulation Testing
There are three basic test procedures that should be carried out when the operation and
function of a water heater’s electrical system is in doubt.
Personal Protective Equipment should be worn when conducting this
procedure to reduce the risk of electric shock.
To check insulation resistance of the water heater Neutral Circuit (reading not to be
below 1 mega-ohm).
1. Isolate the power supply to the water heater by removing fuse or switching off
circuit breaker. Confirm with a multi-meter across the Active(s) and Neutral
wires at the terminal block that voltage is not present (refer to “Test 1” on page
17).
2. Once satisfied, disconnect the power supply active and neutral wires from the terminal
block. Note: If model is a twin element model, mark and disconnect both active wires
(marked ‘A1’ and ‘A2’).
3. Connect megger leads to the neutral of the water heater wiring and earth.
4. Operate megger on 500 VDC setting. A reading above 1 mega-ohm should be
obtained.
5. If a reading below 1 mega-ohm is obtained, all component parts will need to be
individually tested to locate the fault (refer to “fault finding chart 1.1” on page 11).

20
To check insulation resistance of the water heater Active Circuit (reading not to be
below 1 mega-ohm).
6. Connect megger leads to the active of the water heater wiring and earth. Note: If
model is a twin element model, mark, disconnect and twist ‘A1’ and ‘A2’ actives
together to form one active connection for testing purposes.
7. Operate megger on 500 VDC setting. A reading above 1 mega-ohm should be
obtained.
8. If a reading below 1 mega-ohm is obtained, all component parts will need to be
individually tested to locate the fault (refer to “fault finding chart 1.1” on page 11).
To check “Continuity” of the water heater electrical circuit.
9. Set megger to resistance scale or multimeter to x1 resistance scale and measure
between the active and neutral wires on the water heater. Note: If model is a twin
element model, keep ‘A1’ and ‘A2’ actives twisted together to form one active
connection for testing purposes (previously performed in step 6).
10. If a reading of less than 10 ohms or greater than 35 ohms is obtained, all electrical
component parts will need to be individually tested to locate the fault (refer to “Test 5”
on page 18).
11. Reconnect power supply active cable to ‘A’ terminal and neutral cable to ‘N’ terminal at
heater terminal block. Note: If model is a twin element model, untwist water heater ‘A1’
and ‘A2’ active wires and reconnect to terminal block as per markings.
12. Replace fuse or reset circuit breaker. Note: If continuing with diagnosis procedures
do not replace fuse or reset circuit breaker.
Component Adjustment Procedures
Thermostat Adjustment
The main (bottom) thermostat has been factory preset to 70°C for twin element models
and 65°C for all other single element models. It is possible to adjust this thermostat (60 ~
75°C) but is recommended that the main thermostat’s maximum setting does not exceed
70°C.
The boost (top) thermostat is set to 60°C and is non adjustable.
To adjust the main thermostat:
Personal Protective Equipment should be worn when conducting step 3 of
this procedure to reduce the risk of electric shock.
1. Isolate the power supply to the water heater by removing fuse
or switching off circuit breaker.
2. Remove lower access cover.
3. Confirm with a multi-meter between each Active and Neutral at
the terminal block that voltage is not present.
4. Turn thermostat temperature adjustment dial clockwise to increase
temperature setting or anticlockwise to decrease temperature
setting.
5. Replace lower access cover.
6. Restore the power supply to the water heater.