Bradford White ElectriFLEX LD RE1 Series User manual

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Manual 238-51544-00C REV /21
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
Residential:
RE1, RE2 & RE3 Upright Models.
RE1 & RE2 Lowboy Models.
RE1 Utility Models.
RE1 Wall Hung Models.
Light Duty:
LE Upright Models.
LE Utility Models.
LE Lowboy.
LE Wall Hung.
Residential Electric and Light Duty
Commercial Electric Water Heaters
MANUAL

2
Residential and Light Duty
Commercial Electric Water Heaters
Page
2
2
3
6
6
7
8
9
10
11
12
14
15
16
16
16
17
19
21
23
25
25
27
29
31
33
34
35
36
Service Procedure
- - -
- - -
- - -
- - -
- - -
---
- - -
- - -
- - -
- - -
- - -
RE-I
RE-II
RE-III
Introduction……………………………………………………………………
Tools……………………………………………………………………………
General Information…………………………………………………………..
Sequence of Operation………………………………………………………
Single Element Operation……………………………………..........
Double Element Non-Simultaneous Single Phase……………….
Double Element Simultaneous Single Phase 4 wire Service……
Double Element Non-Simultaneous 3 Phase………....................
Double Element Simultaneous 3 Phase…………………………..
Double Element Non-Simultaneous Single Phase Off Peak …..
Troubleshooting……………………………………………………………...
Line Voltage and High Limit ECO Testing…………………………………
Heating Element Testing……………......................................................
Residential Thermostat Testing ……......................................................
Single Element …………………………….....................................
Double Element, 4 wire, Simultaneous, Single Phase …………..
Double Element, Non-Simultaneous, Single Phase ……….........
Double Element, Non-Simultaneous, 3 Phase …………………...
Double Element, Simultaneous, 3 Phase …………………………
Double Element, Non-Simultaneous, Single Phase, Off Peak …
Light Duty Commercial Thermostat Testing ….......................................
Double Element, Non-Simultaneous, Single Phase……………...
Double Element, Simultaneous, Single Phase …………………...
Double Element, Non-Simultaneous, 3 Phase ……………………
Double Element, Simultaneous, 3 Phase ………………………….
Thermostat Removal and Replacement ……………………………………
Heating Element Removal and Replacement ……………………………..
DipTube and Anode Inspection and Replacement ……………………….
Generic Parts List …………………………………………………………….
RE
IV
RE-V
RE-VI
RE-VII
-
-
-
This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis
and repair of Bradford White residential electric and light duty 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.
-
Multi Meter
- 1-½ Deep Well Socket
- ¼" Nut Driver
-
Phillips
Head
Screw Driver
- Thermometer
- Drain Hose
- Various Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers, Flash Light.
Page 2

3
GENERAL
INFORMATION
Commonly
Used
Formulas
Watts
Amps
=
(for single phase
units)
Example:
4500W/240V
=
18.75A
Volts
Watts
Amps
=
(for
balanced 3
phase units)
Example:
4500W/240V
x
1.732
= 10.82A
Volts
x
1.732
Watts
=
Example:
18.75A
x
240V
=
4500W
Amps
x Volts
Volts
2
2
Example: (240V) / 4500W = 12.8 Ohms
Ohms
=
Watts
WHITE
Grounded
(Neutral)
BLACK
Ungrounded
GREEN
Grounding
BLACK
Ungrounded
GREEN
Grounding
RED
Ungrounded
120
0
240
120
120
120
Neutral
A
B
C
Neutral
A
B
C
Neutral
A
B
C
RED
BLACK
RED
RED
BLACK
RED
RED
BLACK
RED
Page 3
120
120
208
120
208 208
277
277
480 277
480 480
120
120
240 120
240 240

4
GENERAL
INFORMATION
Wattage
Limitations
at
Various
Voltages
Residential Electric Upright RE2 & RE3 Series (Non-Simultaneous Operation)
Residential High Efficiency Upright RE2 Series (Non-Simultaneous Operation)
Residential Electric Lowboy RE2 Series (Non-Simultaneous Operation)
Voltage
Maximum
Wattage
Element
Upper/Lower
3,000/3,000 120
3,000
6,000/6,000 208, 240
6,000
277, 480
6,000 6,000/6,000
Residential Electric Upright RE2 & RE3 Series (Simultaneous Operation)
Residential High Efficiency Upright RE2 Series (Simultaneous Operation)
Residential Electric Lowboy RE2 Series (Simultaneous Operation)
Light Duty Commercial Electric LE Series (Non-Simultaneous Operation)
Light Duty Commercial Electric LE Series (Simultaneous Operation)
Voltage
Maximum
Wattage
Element
Upper/Lower
1,500/1,500 120
3,000
5,000/5,000 208
10,000
5,500/5,500 240
11,000
6,000/6,000
277, 480
12,000
Residential Electric Utility Series (Single Element Operation)
Light Duty Utility Series (Single Element Operation)
Voltage
Maximum
Wattage
Single
Element
3,000 120
3,000
6,000 208, 240
6,000
6,000 277
6,000
6,000 480
6,000
Page 4

5
GENERAL
I
NFORMATION
Surface
Mounted
Thermostats
Surface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the tank.
Surface mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperature
settings and high limit (ECO) activation. It is important that the entire back surface of the thermostat is in full contact or
flush with the tank. Improperly mounted thermostat will lead to improper water heater operation.
Manual
ECO (high limit)
Reset button
Temperature
control Dial
Temperature
control Dial
Surface Mount
Combination Thermostat/
ECO (high limit)
59T/66T Series
Surface Mount
Combination Thermostat/
ECO (high limit)
59T/66T Series
Surface Mount
Thermostat
59T Series
Direct
Immersion
“Screw
-
in”
Type
Heating
Element
1-½ Hex
Screw-in Flange
Terminal Block
Zinc Plated Copper or
Incoloy Sheath
Terminal Block
Screw Element Rating Ink Stamped
on side of Terminal Block.
Page 5

6
SEQUENCE
OF
OPERATION
Residential and light duty commercial electric water heaters are designed to operate using several different operating
modes. The common modes and sequence of operation are as follows:
1. Single Element Operation.
2. Double Element Non-Simultaneous Operation (single phase).
3. Double Element Non-Simultaneous Operation (3 phase).
4. Double Element Simultaneous Operation (single phase).
5. Double Element Simultaneous Operation (3 phase).
Sequence
of
Operation
-
Single
Element
Operation.
1
Line voltage is applied across terminals
L1 & L3 of the thermostat. ECO is
closed, so there is voltage at terminal L4
and to one side of the element.
1
ECO
Closed
2
Tank is cold therefore thermostat
is closed at terminal T2 (calling for heat).
This completes the circuit and allows
current to flow through the element.
2
Thermostat closed
at terminal T2
3
3
When the thermostat is satisfied, it opens at
terminal T2 interrupting current flow through the
element. System is now in stand-by mode, waiting
for the next call for heat.
Thermostat opens
at terminal T2
Page 6

7
SEQUENCE
OF
OPERATION
Non
-
Simultaneous
and
Simultaneous
Operation
Double element electric water heaters are designed to operate in either Non-Simultaneous or Simultaneous mode.
Non-Simultaneous Mode: Allows only one heating element to operate at a time. For example, when the tank is cold,
the upper element is energized first, heating the top of the tank. Only when the upper thermostat is satisfied, the upper
element is de-energized and power is directed to the lower thermostat, energizing the lower element and heating the
bottom portion of the tank until the lower thermostat is satisfied. As hot water is drawn off the tank, it is replaced with cold
water delivered through the diptube to the bottom of the tank. When the tank cools at the lower thermostat level, the
lower thermostat will call for heat, energizing the lower element. If enough hot water is drawn from the tank, the top
portion of the tank cools and the upper thermostat will call for heat, de-energizing the lower element and allowing only
the top element to energize until the upper thermostat is satisfied.
Simultaneous mode: allows both heating elements to operate at the same time. That is, if either thermostat (upper or
lower) is calling for heat, the corresponding heating element is energized independent of the other.
Sequence
of
Operation
-
Double
Element,
Non
-
Simultaneous
Operation,
Single
Phase.
1
Line voltage is applied across terminals
L1 & L3 of the upper thermostat. ECO is
closed, so there is voltage at terminal L4
and to one side of the upper and lower
elements.
Tank is cold. Therefore, the thermostats
are closed at terminals T2 & 2 (calling for heat).
The circuit is complete through the upper
thermostat only, allowing current to flow through
upper element.
When the upper thermostat is satisfied, it opens at
terminal T2, interrupting current flow through the
upper element. Terminal T4 closes, allowing voltage
to pass to terminal 1 of the lower thermostat. This
completes the circuit through the lower thermostat
and allows current flow through the lower element.
When the lower thermostat is satisfied, it opens at
terminal 2, interrupting current flow through lower
element. The system is now in stand-by mode
waiting for the next call for heat.
1
2
2
ECO
Closed
Thermostat closed
at terminal T2
3
Upper
T’stat
Upper
T’stat
Upper
Element
Upper
Element
Thermostat closed
at terminal 2
4
Lower
T’stat
Lower
T’stat
Lower
Element
Lower
Element
5
The lower thermostat/element
combination will generally
cycle on and off more often
than the upper. In some cases,
such as a cold tank or in high
demand periods, the upper
thermostat will call for heat
3
4 5
(opening at terminal
Thermostat closed
at terminal T4
Thermostat closed
at terminal T2
T4 and closing at
terminal T2) prior to the lower
thermostat being satisfied. This
will interrupt current flow
through the lower thermostat
and element and allow current
to flow through the upper
element only. When the upper
thermostat is satisfied, it
resumes operation as
described in sequence #3
above.
Upper
T’stat
Upper
T’stat
Upper
T’stat
Upper
Element
Upper
Element
Upper
Element
Thermostat open
between terminals
1 and 2
Thermostat closed
between terminals
1 and 2
Lower
T’stat
Lower
T’stat
Lower
T’stat
Lower
Element
Lower
Element
Lower
Element
Page 7

8
SEQUENCE
OF
OPERATION
A 4 wire, double element heater wired for simultaneous operation is essentially two single element systems operating
independently. The heaters are wired internally with two independent circuits, one circuit for each thermostat/element
combination. When installed using a two wire service, the blue and red (or white) wires will be connected together,
likewise black and yellow wires will be connected together.
Sequence
of
Operation
-
Double
Element,
Simultaneous
Operation,
Single
Phase,
4
wire
service
installation.
Circuit two Circuit two
1 2
1
Line voltage from circuit one is applied
across terminals L1 & L3 of the lower
thermostat. Likewise, line voltage from
circuit two is applied across terminals L1 &
L3 of the upper thermostat. ECO in both
upper and lower thermostat is closed, so
there is voltage at terminal L4 of each
thermostat and to one side of the upper and
lower elements.
Circuit one Circuit one
ECO
Closed
Thermostat closed
at terminal T2
2
Tank is cold therefore both thermostats
are closed at terminal T2 (calling for heat).
This completes the circuit through the
thermostats and allows current to flow
through the elements.
ECO
Closed
Thermostat closed
at terminal T2
Circuit two
3
3
When either thermostat is satisfied, it will
open at terminal T2, interrupting current
flow through the corresponding element. As
both thermostats satisfy, the system will be
in stand-by mode waiting for the next call
for heat. Thermostats will operate
independent of each other.
Circuit one
Thermostat open
at terminal T2
Thermostat open
at terminal T2
Page 8

9
SEQUENCE
OF
OPERATION
Sequence
of
Operation
-
Double
Element,
Non
-
Simultaneous
Operation,
3
Phase.
1 2
1
Line voltage is applied across terminals L1
& L3 of upper thermostat. Likewise, Line
voltage is applied to terminal L3 of lower
thermostat. ECO in both upper & lower
thermostat is closed, so there is voltage at
terminal L4 of both thermostats and to one
side of both upper & lower elements.
ECO
Closed
Thermostat closed
at terminal T2
2
Tank is cold therefore both thermostats
are closed at terminal T2 (calling for heat).
The circuit is complete through the upper
thermostat only allowing current to flow
through the upper element.
ECO
Closed
Thermostat closed
at terminal T2
3
When the upper thermostat is satisfied, it
opens at terminal T2 interrupting current
flow through upper element, and closes at
terminal T4 allowing voltage to pass to
terminal L1 of lower thermostat. This
completes the circuit through the lower
thermostat allowing current flow through
lower element.
3
4
Thermostat closed
at terminal T4
Thermostat closed
at terminal T4
4
When the lower thermostat is satisfied, it
opens at terminal T2 interrupting the
current flow through the lower element. The
system is now in stand-by mode waiting for
the next call for heat.
Thermostat closed
at terminal T2 Thermostat open
at terminal T2
5
The lower thermostat/element combination
will generally cycle on and off more often
than the upper. In some cases, such as a
cold tank or in high demand periods, the
upper thermostat will call for heat (opening
at terminal T4 and closing at terminal T2)
prior to the lower thermostat being satisfied.
This will interrupt current flow through the
lower thermostat and element and allow
current to flow through the upper element
only. When the upper thermostat is
satisfied, it resumes operation as described
in sequence #3 above.
5
Thermostat closed
at terminal T2
Thermostat closed
at terminal T2
Page 9

10
SEQUENCE
OF
OPERATION
Sequence
of
Operation
-
Double
Element,
Simultaneous
Operation,
3
Phase.
1
2
1
Line voltage is applied across terminals L1
& L3 of upper thermostat. Line voltage also
extends to terminal L1 of lower thermostat.
Also, line voltage is applied to terminal L3
of lower thermostat. ECO in both upper &
lower thermostat is closed, so there is
voltage at terminal L4 of both thermostats
and to one side of both upper & lower
elements.
ECO
Closed
Thermostat closed
at terminal T2
2
Tank is cold therefore both thermostats
are closed at terminal T2 (calling for heat).
This completes the circuit through the
thermostats and allows current to flow
through the elements.
ECO
Closed at terminal T2
3
3
When either thermostat is satisfied, it will
open at terminal T2, interrupting current
flow through the corresponding element. As
both thermostats satisfy, the system will be
in stand-by mode waiting for the next call
for heat. Thermostats will operate
independent of the other.
Thermostat open
at terminal T2
Thermostat open
at terminal T2
Page 10

11
SEQUENCE
OF
OPERATION
Some electric utility companies will offer discounts for using electricity during “Off Peak” Times of the day. The system
allows the use of an “Off Peak” meter, which interrupts power to the lower element during high power demand periods.
Sequence
of
Operation
-
Double
Element,
Non
-
Simultaneous
Operation,
Single
Phase,
Off
Peak.
1
Line voltage is
applied
across
terminals
L1 & L3 of the upper thermostat. Line voltage from
off peak meter is supplied to terminal L1 of lower
thermostat. ECO in the upper thermostat is closed,
so there is voltage at terminal L4 of upper
thermostat and to one side of the upper element.
1
Tank
is
cold therefore both thermostats
are closed at terminal T2 (calling for heat). The
circuit is complete through the upper thermostat
only, allowing current to flow through upper
element.
From
Off
Peak
Meter
2
ECO
Closed
Thermostat closed
at terminal T2
3
When upper thermostat is satisfied, it opens at
terminal T2 interrupting current flow through upper
element, and closes at terminal T4 allowing voltage
to pass to one side of the lower element. This
completes the circuit through the lower thermostat
and off peak meter allowing current flow through
lower element. Thermostat closed
at terminal T2
4
When the lower thermostat is satisfied, it opens at
terminal T2 interrupting current flow through lower
element. The system is now in stand-by mode
waiting for the next call for heat
5
During peak power demand periods as determined
by the local utility, the off peak meter will interrupt
power to terminal L1 of lower thermostat. Only the
top thermostat/element combination is allowed to
operate during this period.
3
5
From
Off Peak
Meter
Off Peak
Power interrupted
Thermostat closed
at terminal T4
Thermostat closed
at terminal T2
Thermostat
Thermostat closed
at terminal T2 at terminal
Page 11
open
T2
4
2

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’s always a good idea to check the heating elements first by following the procedure on page 15.
Common Heating Element Failures:
1. Dry Firing. Element may be partially submerged in water or most likely, completely exposed with no water in
tank. In some cases, sediment or lime build up around an element can eventually cause an air pocket, and
within seconds, result in a dry fired element. At this point the element becomes inoperative. When element
replacement is required, be sure the tank is full of water prior to energizing the water heater.
2. Grounded Element. An element with a short circuit to ground will in most cases 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 ECO or Energy Cut Out. Repeated actuation of the ECO is
usually the result of a grounded 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.
Figure 1, below shows a common “Screw-In” type heating element identifying certain features commonly referred to
throughout this manual.
1-½ Hex
Screw-in Flange
Terminal Block
Zinc Plated Copper or
Incoloy Sheath
Terminal Block
Screw Element Rating Ink Stamped
on side of Terminal Block.
Figure
1
Typical Direct Immersion “Screw-In”
Type Heating Element
Page 12
0642
4500W 240V
RC02404524

13
TROUBLESHOOTING
Quick
Step
Plan
to
Hot
Water
1. TURN OFF power to water heater and check all wire
connections to ensure they are tight and corrosion free.
2. Turn power “ON” and determine that service voltage is
present, and the high limit (ECO) has not actuated
(see procedure on page 14).
3. Check for inoperative heating element (see procedure on page 15).
4. Check for proper thermostat operation (see procedures beginning on page 16). NOTE: Thermostat testing procedures
assume items 2 and 3 above are in working order.
SERVICE
SYMPTOM
PROBABL
E
CAUSE
CORRECTIVE
ACTION
PROCEDURE
1.
Check fuses or circuit breakers in service
panel.
2.
Check all wire connections.
3.
Check heating element(s). Replace as
needed.
4.
Check thermostat(s) operation. Replace as
needed.
5.
Check ECO. Reset or replace
thermostat(s) as needed.
3.
See Service Procedure
RE-II, Page 15.
4. See Service Procedure
RE-III, Page 16.
5.
See Service Procedure
RE-I, Page 14.
1.
No Power to heater.
2.
Loose wire connections.
3.
Inoperative upper heating element.
4. Inoperative upper thermostat.
5.
Open ECO.
No
Hot
Water
1.
Check heating element(s), replace as
needed.
2.
Increase thermostat setting.
3.
Check thermostat(s), replace as needed.
4.
Check all wire connection.
5.
Remove heating element(s) and check for
lime build up.
6. Reduce demand.
7.
Replace with larger heater.
8.
Temper water to heater.
9.
Correct plumbing connections.
10.
Check dip tube, replace as needed.
1.
Inoperative lower heating element.
2.
Thermostat(s) set to low.
3.
Inoperative thermostat(s).
4.
Loose wire connection.
5.
Sediment or lime build up on element(s).
6.
High demand period.
7.
Undersized heater.
8.
Very cold inlet water to heater.
9.
Plumbing connections reversed.
10.
Damaged diptube.
1. See Service Procedure
RE-II, Page 15.
3. See Service Procedure
RE-III, Page 16.
5. See Service Procedure
RE-VI, Page 34.
10. See Service Procedure
RE-VII, Page 35.
Not Enough
Hot
Water
1.
Remove heating element(s) and check for
lime build up.
2.
Check all wire connections.
3.
Check thermostat(s), replace as needed.
4.
Check terminal block of element for proper
voltage and wattage rating.
1.
Sediment or lime build up on element(s).
2.
Loose wire connections.
3.
Inoperative thermostat(s).
4.
Derated heating element installed.
1. See Service Procedure
RE-VI, Page 34.
3. See Service Procedure
RE-III, Page 16.
Slow Hot Water
Recovery
1.
Position thermostat flush with tank surface.
2.
Check heating element(s). Replace as
needed.
3.
Adjust thermostat(s) to desired setting.
4.
Check thermostat(s), replace as needed.
5. Check ECO, replace thermostat as
needed.
6.
Replace with larger heater.
1.
See Service Procedure
RE-V, Page 33.
2.
See Service Procedure
RE-II, Page 15.
4.
See Service Procedure
RE-III, Page 16.
5.
See Service Procedure
RE-I, Page 14.
Over Heated
Water or
Continued
Operation
1.
Thermostat not in contact with tank.
2.
Grounded heating element(s).
3.
Thermostat set too high.
4.
Inoperative thermostat(s).
5. Inoperative ECO.
6.
Undersized water heater.
Noisy (singing or
hissing) Elements
1. Lime formation on elements.
1. Remove and clean heating elements.
Replace as needed.
1. See Service Procedure
RE-VI, Page 34.
Page 13
WARNING
High voltage exposure. Use caution when
making voltage checks to avoid personal
injury.

14
SERVICE
PROCEDURE
RE
-
I
Line Voltage & High Limit (ECO)
Testing
Line Voltage Testing
1. Turn “OFF” power to water heater.
2. Remove access cover(s) from front of water
heater. Remove insulation and plastic cover
from thermostat.
ECO reset
button
3. Set multi-meter to “Volts AC.”
4. Turn power “ON” to water heater.
5. Check voltage across terminals L1 & L3
of upper thermostat (see Figure 2).
A) Rated voltage IS present, power to the water
heater is okay.
B) Rated voltage NOT present, Check circuit breaker
at service panel.
Figure
2
Figure
3
High Limit
(ECO) Testing
1. Check voltage across terminals L1 & L4 upper thermostat (see Figure 3).
A) Rated Voltage IS present, ECO is okay.
B) Rated voltage NOT present, proceed to step 2.
2. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s). Turn power “ON” and recheck
voltage across terminals L1 & L4 of upper thermostat (see Figure 3).
A) Rated voltage IS present, the ECO has previously opened indicating the water in the tank, at
some point did overheat, check the following:
1. Thermostat must be in full contact with tank.
2. Be sure heating element(s) is not shorted to ground (see page 15).
3. Proper thermostat operation (see procedures beginning on page 16).
B) Rated voltage NOT present, water in tank may be over heated.
1. If water is hot, turn “OFF” power to water heater and flow water through tank to cool below set point
of upper thermostat. Recheck voltage per step 1.
2. If water is cool, Replace upper thermostat.
Page 14
WARNING
High voltage exposure. Use caution when
making voltage checks to avoid personal injury.

15
SERVICE
PROCEDURE
RE
-
II
Heating Element Testing
Testing For Open Or Burned Out
Element
Step 1.
TURN
OFF POWER TO WATER HEATER
Step 2.
Remove access cover(s) from front of water
heater. Remove insulation and plastic cover
from thermostat.
Step 3.
Disconnect wires from heating element(s).
Step 4. Set multi-meter to “ohms” setting.
Step 5.
Touch probes of multi-meter to screw
terminals of heating element(s)
(see Figure 4).
Step 6.
Reading should be 12.8 ohms (±6%) for a 240
volt, 4500 watt element:
Ohms = Volts2
Watts
A reading outside the range using the formula
beyond (±6%), indicates a bad element and the
element must be replaced.
Element Screw Terminals
Figure
4
Testing
For
Heating Element Short Circuit
To
Ground
Step 1.
TURN
OFF POWER TO WATER HEATER
Step 2.
Remove access cover(s) from front of water
heater. Remove insulation and plastic cover
from thermostat.
Step 3.
Disconnect wires from heating element(s).
Step 4. Set multi-meter to “ohms” setting.
Element Screw Terminal
Meter Probe
terminal of heating element and the other on
the element flange (see figure 5). 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. Element Flange
Figure
5
Page 15
Meter Probe
WARNING
High voltage exposure. Be sure power is turned
OFF to water heater prior to performing this
procedure.

16
SERVI
CE
PROCEDURE
RE
-
III
Residential Thermostat Testing
Single
Element
Operation
or
Double
Element,
4 Wire, Simultaneous, Single Phase Operation
Water In Tank
Is Cold With Power ON
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater.
3. Set multi-meter to “Volts AC.”
4. Check across terminals L4 and T2 of
thermostat (see Figure 6).
A) Rated voltage NOT present,
Recheck ECO. If ECO is okay,
replace thermostat.
B) Rated voltage IS present,
proceed to next step.
5. Check across element terminals
(see Figure 7).
A) Rated voltage NOT present,
check wire connections from
thermostat to element.
B) Rated voltage IS present,
Repeat element testing
see page 15.
Figure
6
Figure
7
Water
Temperature
In
Tank
Is
Above Thermostat
Setting
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater.
3. Set multi-meter to “Volts AC.”
4. See Figure 6 above, check across terminals L4 and T2
of thermostat.
A) Rated voltage IS present,
replace thermostat.
B) Rated voltage NOT present,
thermostat is okay.
C) Lower than rated voltage IS present,
recheck for grounded element
(see page 15).
Reference 4 Wire, Simultaneous, Single Phase
Wiring diagram.
Page 16
NOTE: Wiring consists of two single element configurations
operating independently.
WARNING
High voltage exposure. Use caution to avoid
personal injury during this procedure.

17
SERVICE
PROCEDURE
RE
-
III
Residential Thermostat Testing
Double
Element,
Non
-
Simultaneous,
Single Phase
Operation.
Water In Tank
Is Cold With Power ON.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater.
3. Set multi-meter to “Volts AC.”
4. Check across terminals L4 and T2 of
upper thermostat (see Figure 8).
A) Rated voltage NOT present,
Recheck ECO. If ECO is okay,
replace thermostat.
B) Rated voltage IS present,
proceed to next step.
5. Check across element terminals
(see Figure 9).
A) Rated voltage NOT present,
check wire connections from
thermostat to element.
B) Rated voltage IS present,
Repeat element testing
see page 15.
Figure
8
Figure
9
Tank Does Not
Deliver Enough
Hot
Water.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater and set multi-meter to “Volts AC.”
3. Adjust temperature setting of upper thermostat to the highest setting.
Water temperature in tank must be below thermostat setting for this test.
4. See Figure 8 above, check voltage across terminals L4 and T2 of upper
thermostat.
A) Rated voltage IS present, okay, upper thermostat is
calling for heat. Go to step 5 below.
B) Rated voltage NOT present, replace upper thermostat.
5. Adjust temperature setting of upper thermostat to the minimum setting.
Water temperature in tank must be above thermostat setting for this test.
6. Check voltage across terminals L4 and T4 of upper thermostat
(see Figure 10).
A) Rated voltage NOT present, replace upper thermostat.
B) Rated voltage IS present, thermostat is okay. Go to step 7 on next page.
Figure 10
Page 17
WARNING
High voltage exposure. Use caution to avoid
personal injury during this procedure.

18
SERVICE
PROCEDURE
RE
-
III
Residential Thermostat Testing
Double Element,
Non
-
Simultaneous, Single Phase
Operation (continued).
Not Enough Hot
Water
(continued).
7. Check voltage across terminal L4 of upper
thermostat and terminal 1 of lower thermostat
(see Figure 11).
A) Rated voltage NOT present,
- check wire connection between thermostats.
B) Rated voltage IS present, okay, go to step 8.
8. Adjust lower thermostat to highest setting. Water temperature in
tank must be below the lower thermostat setting for this test.
9. Check voltage across terminal L4 of upper
thermostat and terminal 2 of lower thermostat (see Figure 12).
A) Rated voltage NOT present, replace lower thermostat.
B) Rated voltage IS present, thermostat is ok.
Figure
11
Water
Temperature
In
Tank
Is
Above Thermostat
Setting.
1. This procedure assumes Line voltage, ECO and elements are in working
order.
2. Adjust upper and lower thermostats to the lowest setting.
3. Turn power “ON” to water heater and set multi-meter to “Volts AC.”
4. Check across terminals L4 and T2 of upper thermostat
(see Figure 8 on page 17).
A) Rated voltage IS present, replace upper thermostat.
B) Rated voltage NOT present, upper thermostat is okay. Go to step
5 below.
C) Lower than rated voltage IS present, recheck for grounded upper
element (see page 15).
5. Check across terminals L4 and 2 of lower thermostat (see Figure 12).
A) Rated voltage IS present, replace lower thermostat.
B) Rated voltage NOT present, lower thermostat is okay.
C) Lower than rated voltage IS present, recheck for grounded lower
element (see page 15).
Figure 12
Page 18
WARNING
Be sure thermostats are reset to their original
temperature settings as found prior to
thermostat testing
WARNING
High voltage exposure. Use caution to avoid
personal injury during this procedure.

19
SERVICE
PROCEDURE
RE
-
III
Residential Thermostat Testing
Double
Element,
Non
-
Simultaneous,
Three
Phase
Operation.
Water In Tank Is Cold With Power ON.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater.
3. Set multi-meter to “Volts AC.”
4. Check across terminals L4 and T2 of
upper thermostat (see Figure 13).
A) Rated voltage NOT present,
recheck ECO. If ECO is okay,
replace thermostat.
B) Rated voltage IS present,
proceed to next step.
5. Check across element terminals
(see Figure 14).
A) Rated voltage NOT present,
check wire connections from
thermostat to element.
B) Rated voltage IS present,
repeat element testing,
see page 15.
Figure
13
Figure
14
Tank Does Not
Deliver Enough
Hot
Water.
1. This procedure assumes line voltage, ECO and
elements are in working order.
2. Turn power “ON” to water heater and set multi-meter to “Volts AC.”
3. Adjust temperature setting of upper thermostat to the highest setting.
Water temperature in tank must be below thermostat setting for this test.
4. See Figure 13 above, check voltage across terminals L4 & T2 of upper
thermostat.
A) Rated voltage IS present, okay, upper thermostat is
calling for heat. Go to step 5 below.
B) Rated voltage NOT present, replace upper thermostat.
5. Adjust temperature setting of upper thermostat to the minimum setting.
Water temperature in tank must be above thermostat setting for this test.
6. Check voltage across terminals T4 of upper thermostat & L3 of lower thermostat
(see Figure 15).
A) Rated voltage NOT present, replace upper thermostat.
B) Rated voltage IS present, upper thermostat is okay. Go to step 7 on next
page.
Figure
15
Page 19
WARNING
High voltage exposure. Use caution to avoid
personal injury during this procedure.

20
SERVICE
PROCEDURE
RE
-
III
Residential Thermostat Testing
Double Element, Non-Simultaneous,
Three Phase Operation (continued).
Tank Does Not
Deliver Enough
Hot
Water (continued)
7. Check voltage across terminal L1 & L3 of lower thermostat (see Figure 16).
A) Rated voltage NOT present, check wire connection between thermostats.
B) Rated voltage is present, okay, go to step 8.
8. Adjust lower thermostat to highest setting. Water temperature in tank must be below
the lower thermostat setting for this test.
9. Check voltage across terminal L4 & T2 of lower thermostat (see Figure 17).
A) Rated voltage NOT present, recheck ECO (see page 14). If ECO okay,
replace lower thermostat.
B) Rated voltage IS present, thermostat is ok. Check wire connection to lower
element. If connection okay, recheck lower element (see page 15).
Figure
16
Water
Temperature
In
Tank
Is
Above Thermostat
Setting.
1. This procedure assumes line voltage, ECO and elements are in working
order.
2. Adjust upper and lower thermostats to the lowest setting.
3. Turn power “ON” to water heater and set multi-meter to “Volts AC.”
4. Check across terminals L4 and T2 of upper thermostat
(see Figure 13 on page 19).
A) Rated voltage IS present, replace upper thermostat.
B) Rated voltage NOT present, upper thermostat is okay. Go to step
5 below.
C) Lower than rated voltage IS present, recheck for grounded upper
element (see page 15).
5. Check across terminals L4 and T2 of lower thermostat (see Figure 17).
A) Rated voltage IS present, replace lower thermostat.
B) Rated voltage NOT present, lower thermostat is okay.
C) Lower than rated voltage IS present, recheck for grounded lower
element (see page 15).
Figure 17
Page 20
WARNING
Be sure thermostats are reset to their original
temperature settings as found prior to
thermostat testing
WARNING
High voltage exposure. Use caution to avoid
personal injury during this procedure.