Bradford White 6A User manual

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Manual 238-47202-00A
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
6A, 12A, 20A, 30A, 40A, 50A, 80A, 120A
ASME SERIES IMMERSION THERMOSTAT
WITH CONTACTORS
COMMERCIAL ELECTRIC ENERGY SAVER
WATER HEATER
®

Table of Contents
Page Service Procedure
Introduction ………………………………………………………………………. 2 - - -
Tools……………………………………………………………………………… 2 - - -
General Information ……………………………………………………………… 3 - - -
Sequence of Operation …………………………………………………………… 10 - - -
Troubleshooting ………………………………………………………………….. 13 - - -
Heating Element Testing ……………..................................................................... 15 ACE-I
Line Voltage Testing………………...…………………………………………… 16 ACE-II
Fuse Testing…......................................................................................................... 17 ACE-III
High Limit (ECO) Testing……………………………………………………..…. 18 ACE-IV
Immersion Thermostat Operation Testing………................................................... 19 ACE-V
Contactor Operation Testing……………………………………………………… 20 ACE-VI
Immersion Thermostat Removal and Replacement…………….………………… 21 ACE-VII
High Limit (ECO) Removal and Replacement……………..…………………….. 22 ACE-VIII
Heating Element Removal and Replacement …………………………………….. 23 ACE-IX
Anode Inspection and Replacement ……………………………………………… 24 ACE-X
Generic Parts List ………………………………………………………………… 25 - - -
Glossary of Terms…………………………………………………………………. 26 - - -
Page 2
This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair of
Bradford White Commercial Electric Water Heaters.
The text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshooting
procedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using the
methods described in this service manual.
Introduction
ASME Series
Commercial Electric Water Heaters
Tools
- Multi Meter. - Phillips Head Screw Driver.
- 2-1/8" Deep Well Socket. - Common Screw driver.
- 1-1/16" Deep Well Socket. - Thermometer.
- ¼" Nut Driver. - Drain Hose.
- Other Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers,
Allen Wrench Set, Flash Light.
2

GENERAL INFORMATION
120A - 24 - 3 - 108B - BBG
Pressure Gage Option.
Control Circuit Option Code.
Any combination of the following optional controls:
- Heating Element Time Delay Sequencing.
- Low Water Power Interrupt.
- Panel Door Interlock
- High Pressure Power Interrupt
- Low Pressure Power Interrupt
- Alarm Horn
Power Circuit Code.
- Voltage
- kW Rating
- Phase
- Amp Rating
Warranty
Tank
BRADFORD WHITE CORPORATION
200 LAFAYETTE ST. MIDDLEVILLE MI 49333
Model No: 120A-24-3-108B-BBG
Serial No: ZB2564812
Cap. 120(gal.)/454.2(liters)
Press: Test 300(psi), Working 150(psi)
Volts 240 Max Temp 180°
Phase Single Amps 100
kW Each 6 Total kW 24 4 Elements
Wattage Rating Based Upon 60 Hz
Page 3
Typical Rating Plate
Located On Front Of Water Heater
Model Number
Electrical Characteristics
Model Number Breakdown
kW Rating
In the Field, this information
is obtained from the heaters
rating plate
NOTE: Code “AA”
denotes no optional
controls used.
3

Page 4
GENERAL INFORMATION
General Controls Layout
Pressure
Gage
(optional)
Control Circuit
Transformer
Thermostat
Control
Heating Element
Time Delay
Sequencers
(optional)
Terminal strip
High Limit
(ECO)
Power Circuit
Fuse Blocks
Terminal
Block
Control Circuit
Fuse Block
Contactors
High Limit
Immersion Bulb
Thermostat
Immersion
Bulb
Heating
Element
Alarm
Horn
(optional)
Alarm
Horn Relay
(optional)
Low Water
Level Control
(optional)
Low Pressure
Limit Switch
(optional)
High Pressure
Limit Switch
(optional)
Contactor
Terminal connections to the
fuse block and/or terminal block
Terminal connections to the
heating elements
Terminal connections of
contactor operating coil.
Contactor operation is achieved by energizing a 120 volt operating coil located within the contactor in response to a call
for heat from the immersion thermostat. Upon a call for heat, one or more contactors will energize all heating elements
simultaneously. Optionally, time delay sequencers may be used to stage contactor activation thereby reducing the
inrush of current to the water heater.
Standard Controls
4

GENERAL INFORMATION
Page 5
Immersion Style Thermostat Control
Immersion Thermostat Control
Standard Controls (continued)
Direct
Immersion
bulb
The thermostat will complete control circuit
voltage upon a call for heat. Likewise, the control
will interrupt control circuit voltage when the water
temperature is sufficient to satisfy the adjustable
temperature limit of control.
The high limit (ECO) control will interrupt control circuit voltage
causing the heater to shut down when the high temperature limit of
the control is reached (196°F±4°F). Once the cause for over
heated water has been determined, The control must be manually
reset to restore normal operation.
Immersion Style High Limit (ECO) Control for
Contactor Models
Direct
Immersion
bulb
Manual Reset
Buttons
5

Page 6
GENERAL INFORMATION
Optional Controls
High and Low Water Pressure Controls-
These controls interrupt the electrical current to the contactor coil when the pressure settings are exceeded. The
operation and setting of these controls are described in the manual provided by the control manufacturer. This manual is
included with the water heater Installation and Operating Instruction manual provided with the water heater.
The pressure settings for these controls are adjustable. These controls are specified for use when the installation has
unique pressure requirements that must be safeguarded. Therefore, before adjusting the pressure values, it is
recommended that you consult the person responsible for the facility that the water heater is servicing.
The electrical connections are referenced in the Control Circuit Wiring Diagram and in the pressure control manual
provided by the control manufacturer. Refer to these instructions when servicing the controls.
2-1/8 Hex
Screw-in Flange
Terminal Block
Screw
Terminal Block
Zinc Plated Copper or
Incoloy Sheath
Element Rating Ink Stamped
on face of Terminal Block.
Direct Immersion “Screw-in” Type Heating Element
Standard Controls (continued)
Certain control components are available as “Optional“. When these optional components are installed with the water
heater, the control circuit wiring diagram accordingly will include these components. The optional equipment available
from the manufacturer includes the following:
-High Water Pressure Switch -Heating Element Time Delay Sequencers
-Low Water Pressure Switch -Electrical Door Lock
-Low Water Level Switch -Alarm Horn
6

GENERAL INFORMATION
Optional Controls (continued)
This control will interrupt the electrical current to the contactor coil when a low water level condition is sensed inside the
water heater tank. When the low water level condition is corrected the control will automatically sense the new situation
and electrical current will again energize the contactor coil. Normal water heater operation will be resumed.
To remove the low water level control from the tank you must first loosen the control by un-threading it from the tank
fitting and then rotating the control until the arrow printed on the side of the hex fitting is pointing downward. This will
enable the float orientation to align itself with the opening in the tank-fitting.
Low Water Level Control-
When installed, refer to the direction of the arrow on the hex and insure that it is pointing upwards. If it is not pointing
upward, the control switch will not activate when the tank is refilled with water. Refer to illustration below for clarification.
Heating Element Time Delay Sequencers-
Heating element sequencers are available in order to stage the activation of the heating elements thereby, reducing the
inrush of electrical current to the water heater. The sequencers will control one or more contactor coils depending upon
the water heater voltage, phase, and KW.
One contactor will be energized immediately when there is heating demand, the second contactor, controlled with a
sequencer, will be activated approximately 20 seconds later, and the third contactor will be activated in another 20
seconds thereby, staging the three contactors over the 40 second time period. The staging occurs in a similar manner
for applications having more than three contactors.
Refer to the Control Circuit Wiring Diagram for the specific application being serviced.
Note: On the occasion of servicing the water heater where frequent restarts in a short time interval are encountered (i.e.
on, off, on, etc.), the timing sequences will not begin until the sequencers have experienced a time interval to reset.
Page 7
7

GENERAL INFORMATION
Optional Controls (continued)
Electrical Door lock-
An electrical door lock is offered in order to secure the access to the water heater control cabinet. This device will lock
the control cabinet door when the 120VAC control circuit voltage is applied to it.
Note: Once the door is opened, the water heater can be re-energized, if necessary, for service diagnosis.
Alarm Horn-
The Alarm Horn is an option specified when the installation desires an audible signal to immediately sound an alert
when the water heater operation is interrupted for certain faults. Referring to the control circuit wiring diagram, the alarm
will activate when any one of the following events occur:
The Hi-Limit control has been tripped
The High Water Pressure Control senses excessive pressure
The Low Water Pressure Control senses insufficient pressure
The Low Water Level Control senses an insufficient quantity of water
The alarm will sound only for the options specified (i.e. if a low water level control is not specified then the alarm will not
recognize a low water level condition).
Horn Relay
Horn Relay
Internal Wiring
Page 8
Combination Temperature and Pressure Gage-
A non-electrical device to visually reference water temperature and internal tank pressure.
8

GENERAL INFORMATION
Watts
Volts x 1.732
Watts = Amps x Volts Volts
Watts
2
Commonly Used Formulas
240V 1Ph
Ungrounded
Ungrounded
Grounding
BLACK
RED
GREEN
240
120
Common Service Wire
Configurations
Page 9
120
(balanced 3 phase)
Amps =
Watts
Volts
(Single phase)
Amps = Ohms =
120
ABCNeutral
RED BLACK RED
120
120 208
208 208
208 3Ph
120
ABCNeutral
RED BLACK RED
120
120 240
240 240
240 3Ph
277
ABCNeutral
RED BLACK RED
277
277 480
480 480
480 3Ph/277 1Ph
Full Load Current Amps
208 Volt
1 Ph 3 Ph
6
kW
9
12
13.5
15
18
24
27
30
36
45
54
28.8 16.6
43.2 25.0
57.6 33.3
64.9 37.5
72.1 41.6
86.5 50.0
115.4 66.7
129.8 75.0
144.2 83.3
173.0 100.0
216.3 125.0
259.6 150.0
240 Volt 277 Volt 380 Volt 415 Volt 480 Volt
25.0 14.4
37.2 21.6
50.0 28.9
56.2 32.5
62.5 36.1
75.0 43.4
100.0 57.8
112.5 65.0
125.0 72.2
150.0 86.7
187.5 108.3
225.0 130.0
12.5 7.2
18.7 10.8
25.0 14.4
28.1 16.2
31.2 18.0
37.5 21.6
50.0 28.9
56.2 32.5
62.5 36.1
75.0 43.3
93.7 54.1
112.5 65.0
1 Ph
21.6
32.4
43.3
48.7
54.1
64.9
86.6
97.4
108.3
129.9
162.4
194.9
3 Ph
8.3
12.5
16.7
18.8
20.9
25.0
33.4
37.5
41.7
50.1
62.6
75.1
3 Ph
9.1
13.6
18.2
20.5
22.7
27.3
36.4
41.0
45.6
54.7
68.4
82.0
1 Ph 3 Ph 1 Ph 3 Ph
314.4 -12.5 -6.3 -10.8 --
81 389.4 224.8 337.5 194.8 168.7 97.4292.4 112.6123.1
600 Volt
3 Ph
5.7
8.66
11.5
13.0
14.4
17.3
23.1
26.0
28.8
34.6
43.3
52.0
-
78.0
9

SEQUENCE OF OPERATION
This water heater has two distinct electrical systems. One system, referred to as the “Control Circuit”, controls the
water heater operation, while the other system referred to as the “Power Circuit”, connects the electrical power to the
heating elements, The electrical contactors interconnect these two systems. In order to clearly illustrate the electrical
circuits, two wiring diagrams are provided. These diagrams are labeled as the “Control Circuit Wiring Diagram” and the
“Power Circuit Wiring Diagram” and they are attached to the surface of the panels inside the water heater control
cabinet.
The control circuit operates with 120VAC electrical service. This voltage is provide by the multi-tap transformer which
has the primary coil connected to the field wiring that is serving the water heater. The Transformer, Thermostat, Hi-Limit
control, and the Contactor Coil are always included in the Control Circuit.
Control Circuit Description-
Certain other control components are available as “Optional“. When these optional components are installed with the
water heater, the control circuit wiring diagram accordingly will include these components. The optional equipment
available from the manufacturer includes the following:
High Water Pressure Switch
Low Water Pressure Switch
Low Water Level Switch
Alarm Horn
Heating Element Sequencers
Electrical Door Lock
Control Circuit Wire Diagram
4When the thermostat calls for heat, contacts close
inside the thermostat completing the circuit and
energizing the contactor coil.
The energized contactor coil causes the contactor to
close energizing the heating elements.
5
When the temperature setting of the thermostat is
reached, the contacts in the thermostat open. This
interrupts current flow through the control circuit de-
energizing the contactor coil.
6The de-energized contactor coil causes the contactor
to open, interrupting current flow through the Heating
elements.
7
Page 10
NOTE: To help understand the concept of the operating sequence,
the control circuit shown is without any optional controls. See page
11 For control circuit showing all available optional controls
Control Circuit Sequence of Operation-
Line voltage from
power circuit
1Line voltage is applied to control circuit fuse block.
2Line voltage continues to transformer with one leg of
voltage connecting to the common terminal and the
other leg connecting to the appropriate line voltage
multi-tap terminal. Transformer output (always 120
volts) continues to high limit (ECO) control.
3Hi limit (ECO) control is closed so one leg of 120 volts
continues to one side of the contactor coil. The other
leg is connected to the thermostat.
Appropriate line
voltage multi-tap
terminal
10

SEQUENCE OF OPERATION
Page 11
Certain other control components are available as “Optional“. These controls are specified when the installation has
unique requirements that must be safeguarded. When these optional components are installed the control circuit wiring
diagram accordingly will include these components. The optional equipment available from the manufacturer includes
the following:
High Water Pressure Switch
Low Water Pressure Switch
Low Water Level Switch
Alarm Horn
Heating Element Sequencers
Electrical Door Lock
-Heating Element Sequencers are wired in series with
contactor coils staging contactor activation at
intervals of approximately 20 seconds.
Control Circuit Sequence (Continued)-
-Hi and Low Pressure Switch and Low Water Level Switch
when specified are always wired in series ahead of the
Hi-limit control.
Control Circuit Sequence of Operation
with Optional Controls-
Control Circuit Wire Diagram
Showing Optional Controls
Line voltage from
power circuit
Same as explained on page 10 with the following exceptions:
-Alarm Horn is wired in series ahead of the thermostat.
It monitors only the Hi and Low pressure switch, Low
water level Switch and the hi-limit (ECO). If either of
these switches open, power to the horn relay is
interrupted causing the relay to close sounding the
alarm horn.
-Electrical Door Lock is wired in parallel to secure the
access to the water heater control cabinet. This
device will lock the control cabinet door when the
120VAC control circuit voltage is applied. Once the
door is opened, the water heater can be re-energized,
if necessary, for service diagnosis.
Appropriate line
voltage multi-tap
terminal
11

SEQUENCE OF OPERATION
The Power Circuit Wiring Diagram illustrates the electrical connections from the incoming power supply through the
contactors to the heating elements. The power circuits are available with internal circuit fusing and without internal
circuit fusing.
As it would be impractical to show all wired configurations in this service manual, a reference wiring diagram is
illustrated below to aid in the understanding of the power circuit operating sequence. Service providers must refer to the
water heaters power circuit wiring diagram attached to the inside panel of the control cabinet for the specific connections
of the water heater being serviced.
The power circuit components and supporting information that appear on the wiring diagram include the following:
Field wiring connection via terminal block or other connection point
Fuse block with amperage ratings displayed (when provided)
Contactors with amperage ratings displayed
Electrical elements with voltage and wattage ratings displayed
Water heaters total amperage draw is displayed
Power Circuit Description-
Line voltage is applied across terminals of fuse block
or a terminal block. Line voltage continues down and
connects to terminals L1, L2 & L3 of one or more
contactors.
A) Contactor is open (no call for heat), so there is no
voltage across terminal T1, T2 & T3
of contactor.
B) The contactor is controlled by the control circuit
as explained on pages 10 & 11.
1
2The control circuit senses a call for heat and
energizes the operating coil within the contactor.
The energized contactor coil causes the contactor to
close energizing the elements from terminals T1, T2
& T3 of the contactor.
3
When the temperature setting of the thermostat is
reached, the contacts in the thermostat open. This
interrupts current flow through the control circuit de-
energizing the contactor coil.
4
The de-energized contactor coil causes the contactor
to open, interrupting current flow through the
elements.
5
Power Circuit Sequence-
Line voltage from
service panel
Line voltage to
control circuit
Page 12
12

TROUBLESHOOTING
Most common cause for improper electric water heater operation can be linked to heating element
failure.
When troubleshooting an electric water heater with the incidence of “No Hot Water” or “Insufficient Amount of Hot
Water” It is always a good idea to check the heating elements first following the procedure on page 15.
Common Heating Element Failures Are:
1.Dry Firing. Elements may be partially submerged in water or most likely, completely exposed with no water
in the tank at all. In open air, an energized element (Dry Fired) will become completely inoperable within
seconds. In some cases sediment or lime build up around an element can eventually cause an air pocket,
resulting in a dry fired element. When element replacement is required, be sure tank is full of water prior to
energizing the water heater.
2. Grounded Element. In most cases, an element with a short circuit to ground will cause the circuit breaker in
the service panel to open or shut off. In some cases there may not be enough current draw for the circuit
breaker to open. This will allow the heating element to be in continuous operation resulting in over heated
water, limited only by the hi-limit (ECO) located in the control circuit. Repeated actuation of the
hi-limit usually is the result of a grounded heating element.
3. Sediment build up. Slow hot water recovery can usually be traced back to sediment or lime build up around
heating element. Sediment build up can also over time cause a dry fired element.
If an heating element is found to be inoperative, it must be replaced. Follow service procedure ACE-IX on page 23.
The illustration below shows a common “Screw-In” type heating element identifying certain features commonly referred
to throughout this manual.
Typical Direct Immersion “Screw-In”
Type Heating Element
Page 13
2-1/8 Hex
Screw-in Flange
Terminal Block
Screw
Terminal Block
Zinc Plated Copper or
Incoloy Sheath
Element Rating Ink Stamped
on face of Terminal Block.
13

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
No Hot Water
1. No power to heater.
2. Blown water heater fuses.
3. Loose wire connections.
4. Inoperative heating element(s).
5. Inoperative thermostat.
6. Open ECO.
7. Inoperative contactor(s).
1. Inoperative heating element(s).
2. Thermostat set to low.
3. Inoperative thermostat.
4. Inoperative contactor(s).
5. Loose wire connection.
6. High demand period.
7. Undersized heater.
8. Very cold inlet water to heater.
9. Plumbing connections reversed.
Not Enough Hot
Water
Slow Hot Water
Recovery
1. Sediment or lime build up on element(s).
2. Loose wire connections.
3. Inoperative contactor(s).
4. Derated heating element installed.
Over Heated
Water
1. Grounded heating element(s).
2. Thermostat set to high.
3. Inoperative thermostat.
4. Inoperative ECO.
1. Check circuit breakers at service panel.
2. Check water heater fuses.
3. Check all wire connections.
4. Check heating element(s).
5. Check thermostat operation.
6. Reset (check) ECO.
7. Check contactor operation.
1. Check heating element(s).
2. Increase thermostat setting.
3. Check thermostat.
4. Check contactor operation.
5. Check all wire connection.
6. Reduce demand.
7. Replace with larger heater.
8. Temper water to heater.
9. Correct plumbing connections.
1. Clean or replace heating elements.
2. Check all wire connections.
3. Check contactor operation.
4. Verify element voltage and wattage rating.
1. Check heating element(s).
2. Adjust thermostat to desired setting.
3. Check thermostat.
4. Check ECO.
SERVICE
PROCEDURE
2. ACE-III, Page 17
4. ACE-I, Page 15.
5. ACE-V, Page 19.
6. ACE-IV, Page 18
7. ACE-VI, Page 20
1. ACE-I, Page 15.
3. ACE-V, Page 19.
4. ACE-VI, Page 20.
1. ACE-IX, Page 23.
3. ACE-VI, Page 20.
4. See page 6.
1. ACE-I, Page 15.
3. ACE-V, Page 19.
4. ACE-IV, Page 18.
Page 14
Noisy (singing or
hissing) Elements
1. Lime formation on elements.
2. High or low line voltage.
1. Clean or replace heating elements.
2. Verify line voltage to heater.
1. ACE-IX, Page 23.
2. ACE-II, Page 16.
TROUBLESHOOTING
WARNING
High voltage exposure. Use caution when
making voltage checks to avoid hazard to
life or property.
Noisy Contactor
1. Low line voltage.
2. Debris between contactor plates.
3. Incorrect or defective operating coil.
4. Loose wire connections.
1. Verify line voltage to heater
2. Replace contactor.
3. Replace contactor.
4. Check wire connections.
1. ACE-II, Page 16
Quick Step Plan to Hot Water
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Check all wire connections to insure they are snug
and corrosion free.
3. Reset high limit (ECO) (page 18).
4. Check for inoperative heating element (page 15).
5. Check line voltage (pg 16), and internal fuses (page 17).
6. Refer to table below if items 1 through 5 above do not correct problem.
14

SERVICE PROCEDURE ACE-I
Heating Element Testing
1.STOP, DANGER! Turn power “OFF” to water heater.
2. Open control panel access door.
3. Disconnect wires from heating element.
4. Set multi-meter to “ohms” setting.
5. Touch probes of multi-meter to screw
terminals of heating element
(see illustration 1).
6. Reading should be 12.8 ohms (±6%) for a 240
volt, 4500 watt element, see table below for other elements.
A reading outside the range using the formula
above (±6%), indicates a bad element and the
element must be replaced.
Test for Open or Burned Out Element. DANGER
High voltage exposure. To avoid hazard to
Life or property, be sure power is turned
OFF to water heater while performing this
procedure.
Test For Grounded Heating Element
(damaged heating element with short circuit to ground).
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Open control panel access door.
3. Disconnect wires from heating element.
4. Set multi-meter to “ohms” setting.
5. Touch one probe of multi-meter to either screw
terminal of heating element and the other on
the element flange (see illustration 2). There
should be no reading on the ohm meter. Any
reading indicates a grounded element and the
element must be replaced. Repeat this step for
the other screw terminal.
Ohms = Volts2
Watts
Element Screw Terminals
Element
Screw Terminal
Element Flange
Illustration 1
Illustration 2
Page 15
NOTE
Disconnect
element
Wires
NOTE
Disconnect
element
Wires
Ohms of electrical Resistance
For commonly Used Elements
Voltage Rating of Element
Element
Wattage 208 240 480 600
2000 21.6 28.8 115.2 180
3000 14.4 19.2 76.8 120
4000 10.8 14.4 57.6 90
4500 9.6 12.8 51.2 80
5000 8.7 11.5 46.1 72
6000 7.2 9.6 38.4 60
9000 4.8 6.4 25.6 40
15

SERVICE PROCEDURE ACE-II
Line Voltage Testing
Line Voltage Testing
Illustration 3
Page 16
1.STOP, DANGER! Turn power “OFF” to water heater.
2. Open control panel door.
3. Determine connection point for line voltage
from service panel, terminal block or
fuse block
4. Set multi-meter to volts AC. Be sure to scale
meter for appropriate voltage.
5. Use caution and turn power “ON” to water heater.
6. Use caution and check voltage across top terminals
where service voltage connects to water heater.
(see illustration 3).
A) Rated voltage IS present, power to
the water heater is okay.
B) Rated voltage NOT present, Check
service panel.
Line voltage (single phase or three phase) will
connect to a terminal block or directly to a fuse block
located inside control panel.
Determine heaters voltage and phase by referring to the rating plate located on the front of the heater. Apply the
appropriate phase procedure below to determine if proper line voltage is present.
Single Phase Line Voltage Testing
Line voltage from
service panel
connected to Terminal block
of heater
Line voltage from
service panel
connected to Fuse block
of heater
OR
Check voltage across
top terminals.
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Open control panel door.
3. Determine connection point for line voltage
from service panel, terminal block or
fuse block
4. Set multi-meter to volts AC. Be sure to scale
meter for appropriate voltage.
5. Use caution and turn power “ON” to water heater.
6. Use caution and check voltage across top terminals
where service voltage connects to water heater.
(see illustration 4).
A) Rated voltage IS present, power to
the water heater is okay.
B) Rated voltage NOT present, Check
service panel.
Three Phase Line Voltage Testing
Line voltage from
service panel
connected to Terminal block
of heater
Line voltage from
service panel
connected to Fuse block
of heater
OR
Check voltage across
top terminals.
Illustration 4
DANGER
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
16

SERVICE PROCEDURE ACE-III
Fuse Testing
Fuse Testing
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Open control panel door to allow access
to fuse block.
3. Locate fuse block and remove fuses.
4. Set multi-meter to the “Ohms” setting.
5. Check continuity across fuse
(see illustration 5).
A) Continuity IS present, fuse is okay.
B) Continuity NOT present, Replace with new fuse
Illustration 5
Page 17
DANGER
High voltage exposure. To avoid hazard to Life
or property, be sure power is turned OFF to
water heater while performing this procedure.
17

SERVICE PROCEDURE ACE-IV
High Limit Control Testing
High Limit Control (ECO) Operation
1. Determine if Hi-Limit has actuated. This can be done by simply
depressing the reset buttons. If you hear and/or feel
a small click, the switch has actuated.
2. Use caution and turn power on to water heater and observe
heating cycle following the Hi-Limit Heating Cycle flow chart.
Switch Contacts:
Normally closed.
Open on rise @ 196°F ±4°F
Manual Reset.
Page 18
DANGER
High voltage exposure. To avoid
hazard to Life or property, be sure
power is turned OFF to water heater
while performing this procedure.
NIs water temp
over 196°F
N
Observe heating cycle.
Does switch open?
Switch OK
Is water temp
over 196°F
Replace switch
N
Y
Y
1. STOP, DANGER! Turn power “OFF” to water heater.
2. Water temperature must be below 196°F ±4°F
3. Remove Hi-Limit switch from control panel. It is not necessary
to remove immersion bulb from tank at this time. See
general controls layout on page 4 for location.
4. Disconnect wire leads to Hi-Limit Control.
5. Depress reset buttons to insure switch contacts are closed.
6. Set multi-meter to Ohms setting, Check continuity Thru circuit A & B as shown in the illustrations below.
- Continuity IS present, Switch is okay.
- Continuity NOT present, Replace switch.
High Limit Control Continuity Testing
High Limit Heating Cycle Flow Chart
NOTE
Disconnect
Wire Leads to Control
Circuit “A” Continuity Testing Circuit “B” Continuity Testing
Y
18

SERVICE PROCEDURE ACE-V
Immersion Thermostat Testing
Immersion Thermostat Operation Testing
Thermostat Control Continuity Testing.
1. This procedure assumes line voltage, ECO and contactor(s) are in working order.
2. STOP, DANGER! Turn power “OFF” to water heater.
3. Open control panel door.
4. Locate thermostat control (see general controls layout on page 4) and remove wire leads to control screw terminals.
5. Water temperature in tank must be within operating range of thermostat for this test. If above or below, it will be
necessary to drain tank and remove thermostat immersion bulb from tank to warm or cool the bulb to be
within operating range of thermostat.
6. Set multi-meter to the “Ohms” setting.
7. Rotate thermostat dial to highest setting.
8. Check across screw terminals of control
(see illustration 7).
A) Continuity IS present, okay,
Go to step 9.
B) Continuity NOT present,
replace thermostat.
9. Rotate thermostat dial to lowest setting.
10. Check across screw terminals of control
(see illustration 7).
A) Continuity NOT present, thermostat is okay,
B) Continuity IS present, replace thermostat.
Providing the water temperature in tank is within the operating range of the
thermostat, checking thermostat operation can be as simple as rotating the
thermostat dial and listening to the contactor(s) to see if they respond to a call
for heat.
Use caution and turn Power “ON” and rotate the thermostat dial to call for heat.
With water temperature below the thermostat setting, the contactor(s) close.
With the contacts closed, use caution and check for rated voltage across lower
terminals of contactor(s) (see illustration 10), If rated voltage is present, the
thermostat is calling for heat.
Rotate thermostat dial to the minimum setting. With water temperature above
the thermostat setting the contactor(s) will open. With the contacts open,
voltage should not be present at lower terminals of contactor(s).
Follow the procedure below If preliminary testing above does not verify
thermostat operation.
Thermostat Specification:
Calibration: 184°F/176°F
Max Differential: 6°F
Operating Range 80 to 180°F
Page 19
DANGER
High voltage exposure. To avoid hazard to
life or property use extreme caution when
making voltage checks .
T1 T2 T3
L1 L2 L3
Check voltage across
lower terminals of contactor(s)
NOTE: Disconnect
Wire Leads to Control
Screw Terminals
Thermostat
Dial
Thermostat Immersion Bulb
Illustration 6
Illustration 7
19

SERVICE PROCEDURE ACE-VI
Contactor Testing
Contactor Operation Testing
Noisy or chattering contactor operation in most cases is due to voltage variations being supplied to the water heater.
Extended periods of voltage variations will cause damage to the operating coil of the contactor causing noisy operation.
Determine that service voltage to the unit meets the electrical requirements per the rating plate located on the front of
the water heater, see page 16
In addition, debris between the contact plates will cause noisy operation.
Noisy Contactor
This procedure assumes control circuit is operating correctly.
Providing the water temperature in tank is within the operating range of the thermostat, checking contactor operation
can be as simple as rotating the thermostat dial and listening to the contactor(s) to see if they respond to a call for heat.
1. Turn Power “ON” and rotate thermostat dial to the maximum setting, with water temperature in tank below the
thermostat setting, the contactor(s) will close. With the contacts closed, check for 120 volts across operating coil
terminals (see illustration 8).
A) 120 volts IS present, okay, go to step 2.
B) 120 volts NOT present, verify control circuit
operation.
2. Check for rated voltage across lower terminals of
contactor(s) (see illustration 9).
A) Rated voltage IS present, okay,
go to step 3.
B) Rated voltage NOT present, replace
contactor.
3. Rotate thermostat dial to the minimum setting.
With water temperature in tank above thermostat
setting, the contactor(s) will open. With the contacts
open, voltage should not be present at lower terminals
of contactor(s).
4. Check for 120 volts across operating coil
terminals (see illustration 8).
A) 120 volts IS present, verify control circuit operation.
B) 120 volts NOT present, okay go to step 5.
5. Check for rated voltage across lower terminals
of contactor(s) (see illustration 9).
A) Rated voltage IS present, replace contactor.
B) Rated voltage NOT present, contactor is okay.
Page 20
DANGER
High voltage exposure. To avoid hazard to
life or property, use extreme caution when
making voltage checks .
Illustration 8
Contactor operation is achieved by energizing an
operating coil located within the contactor. The contactor
coil is considered part of the control circuit operating at
120 volts as described on page 10.
Contactor Operating Coil
T1 T2 T3
L1 L2 L3
Check voltage across
lower terminals of contactor(s)
Illustration 9
20