WATER HEATERS

TM

Energy Smart ®Residential Electric

Water HeaterInstallation Instructions

and Use & CareGuide

To obtain technical, warranty, or service assistance during orafter the installation of this water heater,call toll free:

1-877-817-6760

When calling for assistance, please have the followinginformation ready:1. Model Number2. 7 Digit Product Number3. Serial Number4. Date of Installation5. Place of Purchase

Table Of Contents PAGEWater Heater Safety .......................................................................... 2Installing Your Electric Water Heater ................................................ 3-8

Unpacking Instructions ................................................................ 3

Location Requirements ................................................................ 4Water System Piping ............................................................... 5ElectricalRequirements ................................................................. 7Installation Checklist ................................................................... 8

Operating Your Water Heater ......................................................... 9-11Water Heater Start-Up ................................................................. 9

Water Temperature Regulation .................................................... 9Operating the Temperature Control System ............................... 10

Operational Conditions ..................................................................... 11Maintenance of Your Water Heater .............................................. 12-13

Diagnostic Code and Trouble Shooting Chart ................................... 14Repair Parts Illustration ..................................................................... 15

i

6510288March 2003

Your safety and the safety of others are very important.

We have provided many important safety messages in this manual and on your appliance. Always read and obey allsafety messages.

This is the safety alert symbol.

This symbol alerts you to potential hazards that can kill or hurt you and others.

All safety messages will follow the safety alert symbol and either the word "DANGER" or"WARNING." These words mean:

You can be killed or seriously injured if you don'timmediately follow instructions.

You can be killed or seriously injured if you don'tfollow instructions.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell youwhat can happen if the instructions are not followed.

Important Safety Instructions

CAUTION: Hydrogen gas is produced in a hot water system served by this heater that has not been used for a longperiod of time (2 weeks or more). Hydrogen is extremely flammable. To reduce the risk of injury under theseconditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before usingany electrical appliance connected to the hot water system. When hydrogen is present, there will be an unusualsound such as air escaping through the pipe as the water begins to flow. There should be no smoking or open flamenear the faucet at the time it is open.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list ofsubstances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requiresbusinesses to warn of potential exposure to such substances.Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or otherreproductive harm.This appliance can cause low-level exposure to some of the substances listed, including formaldehyde.

INSTALLING YOUR WATER HEATER

Consumer Information

This water heater should be installed in accordancewith the local code authority having jurisdiction, thepower company or electric utility, and this installationmanual. In the absence of local code requirements,follow the regulations set forth in the latest edition of theNational Electric Code, NFPA 70. This is available fromthe following:

National Fire Protection Agency1 Batterymarch ParkQuincy, MA 02269American National Standards Institute1430 BroadwayNew York, NY 10018

Check your phone listings for the local authoritieshaving jurisdiction over your installation.

Consumer Responsibilities

This manual has been prepared to acquaint you withthe installation, operation, and maintenance of yourelectric water heater and to provide important safetyinformation in these areas.

We urge you to read all of the instructions thoroughlybefore attempting the installation or operation of thiswater heater. This manual should be kept for futurereference.

The manufacturer of this water heater will not be liablefor any damages caused by failure to comply with theinstallation and operating instructions outlined in thismanual.

If you lack the necessary skills required to properlyinstall this water heater or you have difficulty followingthe instructions, you should not proceed but have aqualified person perform the installation of this waterheater. Massachusetts code requires this water heaterto be installed in accordance with MassachusettsPlumbing and Fuel Gas Code 248 CMR section 2.00and 5.00.

A data plate identifying your water heater can be foundadjacent to the element door. When referring to yourwater heater always have the information listed on thedata plate readily available.

Retain your original receipt as proof of purchase.

Unpacking the Water Heater

Removing Packaging Materials

Important: Do not remove any permanent instructions,labels, or the data label from outside of the water heateror on the inside of panels.

Remove exterior packaging and place installationcomponents aside.

Do not remove the envelope bag containing thewater heater literature from the side of the waterheater.

Inspect all parts for damage prior to installation andstart-up.

Completely read all instructions before attemptingto assemble and install this product.

_. Replace this manual inside the envelope bag wheninstallation is complete.

_. After installation, dispose of packaging material inthe proper manner.

Location RequirementsSite location

Select a location near the center of the water pipingsystem, tt must be installed indoors and in a verticalposition on a level surface.

The water heater should be located in an area notsubject to freezing temperatures. Water heaters locatedin unconditioned spaces (i.e., attics, basements, etc.)may require the water piping and drain piping to beinsulated to protect against freezing. The drain andcontrols must be easily accessible for operation andservice.

Do not use this water heater in conjunction with a spaor hot tub.

Note: Local codes and requirements in your area mayrequire the water heater to be installed such that thebottom element is elevated from the floor at least 18inches.

Important: The water heater should be located in anarea where leakage of the tank or connections will notresult in damage to the area adjacent to the waterheater or to lower floors of the structure. Due to thenormal corrosive action of the water, the tank willeventually leak after an extended period of time. It isrecommended that a suitable drain pan be installedunder the water heater as shown below. This pan is to3rotect the property from damage which may occurfrom normal condensate formation on the tank orleaks in the tank and pipe connections. The pan mustlimit the water level to a maximum depth of 2-1/2inches and be two inches wider than the heater andpiped to an adequate drain. Locate the water heaternear a suitable indoor drain. Outdoor drains aresubject to freezing temperatures which can obstructthe drain line. The piping should be at least 3/4"1Dand pitched for proper drainage.Under no circumstance will the manufacturer beheld liable for any water damage in connectionwith this water heater.

021/2" Max

t Pipe toadequatedrain

At least 2" inches greater thanthe diameter of the waterheater.

Note: The water heater shall be located so it is notsubject to physical damage by moving vehicles or areaflooding.

Figure 1Residential GarageInstallation

VehicleStop

Drain DrainPan

State of California

Note: The water heater must be braced, anchored, orstrapped to avoid moving during an earthquake. Contactlocal utilities for code requirements in your area or call1-877-817-6750 and request instructions.

Water System Piping

Piping Installation

Piping, fittings, and valves should be installed accordingto the installation drawing (Figure 2). If the indoorinstallation area is subject to freezing temperatures, thewater piping must be protected by insulation.

Water supply pressure should not exceed 80% of theworking pressure of the water heater. The workingpressure is stated on the water heater's data plate. Ifthis occurs a pressure limiting valve with a bypass mayneed to be installed in the cold water supply line. Thisshould be placed on the supply to the entire house inorder to maintain equal hot and cold water pressures.

Important: Heat cannot be applied to the water fittingson the heater as they may contain nonmetallic parts. Ifsolder connections are used, solder the pipe to theadapter before attaching the adapter to the hot and coldwater fittings.

Important: Always use a good grade of joint compoundand be certain that all fittings are drawn up tight.

1. Install the water piping and fittings as shown inFigure 2. Connect the cold water supply (3/4 NPT)to the fitting marked "C". Connect the hot watersupply (3/4 NPT) to the fitting marked "H".

Important: Some models may contain energy savingheat traps to prevent the circulation of hot water withinthe pipes. Do not remove these inserts.

2. The installation of unions in both the hot and coldwater supply lines is recommended for ease ofremoving the water heater for service orreplacement.

3. The manufacturer of this water heater recommendsinstalling a tempering valve in the domestic hotwater line as shown in Figures 3 and 4. Thesevalves reduce the point-of-use temperature of thehot water by mixing cold and hot water and arereadily available. Contact a licensed plumber or thelocal plumbing authority.

4. If installing the water heater in a closed watersystem, install a relief valve or expansion tank inthe cold water line as specified under "ClosedSystem/Thermal Expansion".

5. Install a shut-off valve in the cold water inlet line. Itshould be located close to the water heater and beeasily accessible. Know the location of this valveand how to shut off the water to the heater.

.

.

Install a temperature and pressure relief valve anddischarge line in the opening marked "T & PRELIEF VALVE". Install as specified under"Temperature and Pressure Relief Valve."

After piping has been properly connected to thewater heater, open the nearest hot water faucet andallow the tank to completely fill with water. To purgethe lines of any excess air and sediment, keep thehot water faucet open for 3 minutes after a constantflow of water is obtained. Close the faucet andcheck all connections for leaks.

Figure 2Water Piping Installation In A Closed SystemUse Either:

1 Thermal Expansion Tank2 Pressure Relief Valve

O _ Pressure ReducingValve With Bypas_7Hot Water

Outlet _ I_ _

t 11 Ma,.• ,L--_C-,---_ II ColdWater U sWuat)_r

Union _ ----------- Inlet Valve Cold Water PP Y

/ Supply to

Fixtures

/ Temperature and

Pressure Relief Valve

Discharge line6 inches maximum

above drain

Drain linelinch / (_) _ 3/4inch ID l

Min --_ I _-- ,_) U / minimum Massachusetts:• I| _ / . Install vacuum relief I

/Dram in cold water line perf ::_ j¢" section 19 MGL 142• /s J

Drain Pan

2-1/2 inch depth max.

Figure 3Tempering ValveSide Connection

Follow the tempering Hotvalve manufacturer's Water Outinstructions _1_

Tempered waterto fixtures

Tempering valveset to 120 ° F max.

._

Cold Water In

Figure 4Tempering ValveTop Water Connections

Follow the

tempering valvemanufacturer'sinstructions

ColdWater

inlet

t

Temperedwater tofixtures

Tempering Valve(Set to 120 ° F)

Please note the following:

DO NOT install this water heater with iron piping.The system should be installed only with new pipingthat is suitable for potable (drinkable) water such ascopper, CPVC, or polybutylene. DO NOT use PVCwater piping.

DO NOT use any pumps, valves, or fittings that arenot compatible with potable water.

DO NOT use valves that may cause excessiverestriction to water flow. Use full flow ball or gatevalves only.

DO NOT use 50/50 tin-lead solder (or any leadbased solder) in potable water lines. Use 95/5 tin-antimony or other equivalent material.

DO NOT tamper with the electronic control board,temperature sensors, heating elements, electricalconnections, or temperature and pressure reliefvalve. Tampering voids all warranties. Only qualifiedtechnicians should service these components.

DO NOT use with piping that has been treated withchromates, boiler seal, or other chemicals.

DO NOT add any chemicals to the system pipingwhich will contaminate the potable water supply.

Closed System/Thermal Expansion

Periodic discharge of the temperature and pressurerelief valve may be due to thermal expansion in aclosed water supply system. The water utility supplymeter may contain a check valve, backfiow preventer,or water pressure reducing valve. This will create aclosed water system. During the heating cycle of thewater heater, the water expands causing pressureinside the water heater to increase. This may cause thetemperature and pressure relief valve to dischargesmall quantities of hot water. To prevent this fromhappening, there are two recommendations:

1. Install a diaphragm-type expansion tank that issuitable for potable water on the cold water supplyline. The expansion tank must have a minimumcapacity of 1.5 U.S. gallons for every 50 gallons ofstored water.

. Install a 125 PSI pressure relief valve in the coldwater supply line. Make sure the discharge of thisvalve is directed to an open drain and protectedfrom freezing. Contact the local water supplier orplumbing inspector for information on how tocontrol this situation. Do not plug the temperatureand pressure relief valve.

Temperature and PressureRelief Valve

Explosion Hazard

If the temperature and pressure reliefvalve is dripping or leaking, have alicensed plumber repair it.

Do not plug valve.Do not remove valve.

Failure to follow these instructions canresult in death or explosion.

Figure 5Temperature and PressureRelief Valve Installation

Optional location some

r'-'l F models only

Temperature and,/_ Pressure Relief Valve

Discharge Line314 inch rain.

Do not cap or plug.

Drain Pan (_ _ _ ._ 6ianxChmum

Drain _

For protection against excessive pressures andtern peratures, a tern peratu re and pressu re relief valvemust be installed in the opening marked "T & P RELIEFVALVE" (See Figure 5).

Caution: To reduce the risk of excessive pressures andtemperatures in this water heater, install temperatureand pressure relief protective equipment required bylocal codes, but not less than a combinationtemperature and pressure relief valve certified by anationally recognized testing laboratory that maintainsperiodic inspection of the production of listed equipmentor materials, as meeting the requirements for ReliefValves and Automatic Shutoff Devices for Hot WaterSupply Systems, ANSI 721.22 -1986. This valve mustbe marked with the maximum set pressure not toexceed the marked maximum working pressure of thewater heater. Install the valve into an opening providedand marked for this purpose in the water heater, andorient it or provide tubing so that any discharge from thevalve exits only within 6 inches above, or at anydistance below, the structural floor, and does notcontact any live electrical part. The discharge openingmust not be blocked or reduced in size under anycircumstance.

Important:Onlya newtemperatureandpressurereliefvalveshouldbeusedwithyourwaterheater.Donotuseanoldorexistingvalveas itmaybedamagedornotadequatefortheworkingpressureofthenewwaterheater.Donotplaceanyvalvebetweenthereliefvalveandthetank.

The Temperature & Pressure Relief Valve:

)- Must be connected to an adequate discharge line.

Must not be in contact with any electrical part.

_- Must not be rated higher than the working pressureshown on the data plate of the water heater.

The Discharge Line:

_- Must terminate a maximum of 6 inches above afloor drain or external to the building.

_- Must be capable of withstanding 250°F (121°C)without distortion.

_. Must be installed to allow complete drainage ofboth the valve and discharge line.

_. Must not be smaller than the pipe size of the reliefvalve or have any reducing coupling installed in thedischarge line.

_. Must not be capped, blocked, plugged, or containany valve between the relief valve and the end ofthe discharge line.

Solar Installation

If this water heater is used as a solar storage heater oras a backup for the solar system, the water supplytemperatures to the water heater tank may be in excessof 120°E A tempering valve or other temperaturelimiting valve must be installed in the water supply lineto limit the supply temperature to 120°R

Note: Solar water heating systems can often supplywater with temperatures exceeding 180°F and mayresult in water heater malfunction.

Electrical Requirements

Electric Shock Hazard

Disconnect power beforeservicing.

Replace all parts and panelsbefore operating.Failure to do so can result indeath or electric shock.

Fire Hazard

Use 10 gauge solid copper wire.

Use a UL approved strain relief.

Connect ground wire to greenground screw.Failure to do so can result indeath, fire, or electrical shock.

If you lack the necessary skills required to properlyinstall the electrical wiring to this water heater, do notproceed, but have a qualified electrician perform theinstallation.

When making the electrical connections, always makesure:

The electrical supply has the proper overload fuseor circuit breaker protection.

Wire sizes and connections comply with allapplicable codes.

Wiring is enclosed in approved conduit (if requiredby local codes).

The water heater and electrical supply are properlygrounded.

Figure 6 and the wiring diagram can be found on thenext page. Always reference the wiring diagram for thecorrect electrical connection. The wiring diagram canalso be found on the inside of the junction box cover.

When installing the electrical wiring to the water heater:

1. Shut off the power to the unit.

2. Be sure tank is completely filled with water beforemaking any electrical connections.

3. Remove junction box cover that is secured by 3screws. Place the cover aside and view the wiringdiagram on the inside.

4. Connect the electrical supply to the water heater inaccordance with the local utility requirements andcodes. A standard 1/2 inch opening has been madein the junction box for the conduit connections. Useapproved conduit with copper wires only or Romex.

5. Groundthewaterheaterbyconnectingthegroundingwirefromtheelectricalservicegroundtothe(green)groundscrewlocatedinthejunctionbox.Note: Onlyuse10gaugewiresforelectricalconnectionsanda 30amperedoublepolebreaker.

6. Connecttheredandblackwirestothe incomingpowerleads.

7. Replacecoverandsecurewithscrews.Figure 6Field Wiring240V - 30A Service

Junction BoxCover

Orange WireLeads

BlackWire

Field WiringCompartment

L_Ground Screw

(green)

Color Code

Stripe

Red Wire

Blu

r_ ElectronicControl Board

TemperatureSensor Socket

Wiring Diagram

240 Volts OnlyLI L2 FUSED DISCONNECT

CIRCUIT BREAKER

I o o I EL,O,R,C,,LS_RVlCE

/ 8L,cK I_

CONNECTOR

ELECTRONIC

CONTROL

BOARD

III I-....

H_TERGROU_ID

TOO

L_. =__UPPER

SENSOR

LOWERELEMENT

6603491

Installation Checklist

Water Heater Location

_" Centrally located with the water piping system.

_" Located indoors and in a vertical position.

_" Protected from freezing temperatures.

_" Provisions made to protect the area from waterdamage.

_" Drain pan installed and piped into an adequatedrain.

_" Sufficient clearance to service the water heater.

Water System Piping

_" Temperature and pressure relief valve properlyinstalled with a discharge line plumbed to an opendrain and protected from freezing.

_" All piping properly installed and free of leaks.

_" Water heater completely filled with water.

_" Closed system pressure buildup precautionsinstalled.

_" Tempering valve installed per manufacturer'sinstructions.

Electrical Connections

Wiring and connections comply with all applicablecodes.

Water heater and electrical supply are properlygrounded.

Proper overload fuse or circuit breaker protectioninstalled.

OPERATING YOUR WATER HEATER

Water Heater Start-Up

1. Before operating the water heater, make sure thewater heater has been properly installed.

2. Completely fill the tank with water.

3. Carefully read and understand the section, "WaterTemperature Regulation", of this manual and adjustthe temperature control knob to the desired setting.

4. Read the section, "Operating Mode Descriptions"on page 10 and select the desired operating mode.

5. After the tank is completely filled with water, turn onpower to the water heater. Note: The water heaterperforms self-diagnostics that takes approximately10 minutes. During this time, the elements may notbe energized. If a failure is detected, the DiagnosticLight flashes the related failure code. See page 14for "Diagnostic Code Chart."

Important: Operation of this water heater withoutaccess doors or insulation could result in much higherwater temperatures than the desired set point,increasing the risk of scald injury. Do not operatewater heater with the access doors or insulationremoved, r'-m

Access Doors

Important: Do not attempt to operate this water heaterif the temperature sensor(s), electronic control board, orsurrounding insulation has been exposed to water inany way. Immediately call a qualified service technicianto inspect the water heater and replace anytemperature sensor(s), electronic control board, orinsulation that has been exposed to water. Do notattempt to repair these parts. Water heaters subjectedto flood conditions or any time the temperaturesensor(s) or electronic control board have beensubmerged in water require replacement of the entirewater heater.

Safety Shut-off

This water heater is equipped with a high limit controlswitch that is designed to shut off the power to theelements if the water temperature exceeds170°F(77°C). Use the diagnostic control chart on page 14 tohelp determine the cause of the high limit shut-off. Afterthe cause has been corrected, reset the control asdirected under "Reset Function" on page 10.

Water Temperatu reRegulation

Water temperature over 125°F can causesevere burns instantly or death fromscalds.

Children, disabled, and elderly are athighest risk of being scalded.

See the instruction manual before settingtemperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available.

The temperature control is adjusted to a setting of120°F or lower when it is shipped from the factory.Water temperature can be regulated by adjusting thetemperature control system to the preferred setting asshown in "Operating the Temperature Control System."The recommended starting point is 120°F. There is ahot water scald potential if the temperature controlis set too high.

Important: Adjusting the temperature past 120°F on thetemperature control will increase the risk of scald injury.Hot water can produce first degree burns within:

120°F (49°C) more than 5 minutes

130°F (54°C) at 20 seconds

140°F (60°C) at 3 seconds

150°F (66°C) at 1-1/2 seconds

160°F (71°C) at less than 1 second

Operating the Temperature Control SystemFigure 7Temperature ControlSystem

Water Temperature AdjustmentThe water temperature can be adjusted from 80°F to 150°F. Use the temperature control knob to change to thedesired temperature.

Operating Mode Descriptions

1. Smart Mode - The controller operates the water heater to maintain the customer's selected temperature.

2. Energy Smart Mode - The controller adjusts the water temperature to lowest temperature required to meet thehousehold demands. This mode minimizes operating costs. The controller will not adjust temperature higher thancustomer's selected set point or lower than 115°E

3. Low Temperature Mode - The controller limits the water temperature to 120°F or at the temperature selectedwhichever is lower. See page 9 for more information on scalds.

4. Vacation/Cabin Mode - The controller adjusts the water temperature to approximately 50°F. This mode isrecommended when the water heater is not in use for a long period of time. This effectively turns the water heateroff and prevents the water from freezing.

Diagnostic Indicator Light Analysis

Light On - Indicates power applied and operating correctly.

Light Off - Indicates no power or a controller problem.

One Flash - Indicates the power was applied to water heater before the tank filled with water.

Two Flashes - Indicates the high limit temperature has been reached.

Three Flashes - Indicates a problem with the temperature sensors.

Four Flashes - Check upper element.Five Flashes - Check lower element.

Reset Function

The reset function is used to restart the Temperature Control System after an error condition has been detected andcorrected.

Reset the control by pushing the red reset button on the controller. After a reset, the control performs self diagnosticsbefore normal operations begin. This takes approximately 10 minutes.

10

Operation ConditionsAnode Rod/Water Odor

Each water heater contains at least one anode rod,which will slowly deplete while protecting the glass-linedtank from corrosion and prolonging the life of the waterheater. Certain water conditions will cause a reactionbetween this rod and the water. Once the anode isdepleted, the tank will start to corrode, eventuallydeveloping a leak.

The most common complaint associated with the anoderod is a "rotten egg smell" produced from the presenceof hydrogen sulfide gas dissolved in the water. Do notremove this rod permanently as it will void anywarranties, stated or implied.

The parts list includes a special anode that can beordered if water odor or discoloration occurs. This rodmay reduce but not eliminate water odor problems. Thewater supply system may require special filtrationequipment from a water conditioning company tosuccessfully eliminate all water odor problems.

Artificially softened water is exceedingly corrosivebecause the process substitutes sodium ions formagnesium and calcium ions. The use of a watersoftener may decrease the life of the water heater tank.

The anode rod should be removed from the waterheater tank every 3 years for inspection. If the rod ismore than 50% depleted, the anode rod should bereplaced. (See "Replacing the Anode Rod" in themaintenance section.)

Water Heater Sounds

During the normal operation of the water heater,sounds or noises may be heard. These noises arecommon and may result from the following:

1. Normal expansion and contraction of metal partsduring periods of heat-up and cool-down.

2. Sediment buildup in the tank bottom will createvarying amounts of noise and may causepremature tank failure. Drain and flush the tank asdirected under "Draining and Flushing".

Stacking

Stacking occurs when a series of short draws of hotwater (3 gallons or less) are taken from the waterheater tank. This causes increased cycling of the heaterelements and can result in increased watertemperatures at the hot water outlet. An anti-scalddevice is recommended in the hot water supply line toreduce the risk of scald injury.

11

MAINTENANCE OF YOUR WATER HEATERIf you lack the necessary skills required to properly service this water heater or you have difficulty following theinstructions, you should not proceed but have a qualified person perform the maintenance of this water heater.

Draining and FlushingIt is recommended that the tank be drained and flushedevery 6 months to remove sediment which may buildupduring operation. To drain the tank perform the followingsteps:

1. Turn off the power to water heater.

2. Close the cold water inlet valve and open a nearbyhot water faucet.

3. Connect a hose to the drain valve and terminate itto an adequate drain.

Important: Drain hose should be rated for at least200°R If the drain hose does not have this rating, openthe cold water inlet valve and open a nearby hot waterfaucet until water is no longer hot.

4. Open the water heater drain valve and allow all thewater to drain from the tank. Flush the tank withwater as needed to remove sediment.

5. Close the drain valve and refill the tank until waterflows from the open hot water faucet. Allow water torun for a couple of minutes to make sure all air isout of tank.

6. Restart the water heater as directed under"Operating Your Water Heater." If the water heateris going to be shut down for an extended period,the drain valve should be left open.

Replacing the Anode Rod

1. Turn off the power to the water heater.

2. Shut off the water supply and open a nearby hotwater faucet to depressurize the water tank.

3. Drain approximately 5 gallons of water from thetank. (Refer to "Draining and Flushing" for properprocedures.) Close drain valve.

4. Remove old anode rod.

5. Use Teflon_' tape or approved pipe sealant onthreads and install new anode rod.

6. Turn on water supply and open nearby hot waterfaucet to purge air from water system.

7. Restart the water heater as directed under"Operating Your Water Heater." See the "RepairParts Illustration" for anode rod location onpage 15.

Temperature and PressureRelief Valve

Explosion Hazard

If the temperature and pressure reliefvalve is dripping or leaking, have alicensed plumber repair it.

Do not plug valve.Do not remove valve.

Failure to follow these instructions canresult in death or explosion.

Manually operate the temperature and pressure reliefvalve at least once a year to make sure it is workingproperly. To prevent waterdamage, the valve mustbe properly connected toa discharge line whichterminates at anadequate drain.

Standing clear of theoutlet (discharged watermay be hot), slowly liftand release the leverhandle on the

Figure 8

Temperature and PressureRelief Valve

i_Manual Relief

Discharge line to drain

temperature and pressure relief valve to allow thevalve to operate freely and return to its closed position.If the valve fails to completely reset and continues torelease water, immediately shut off the electrical powerand the cold water inlet valve and call a qualifiedservice technician.

12

Heating ElementReplacement

Electrical Shock Hazard

_¢ isconnect power before

servicing.

Replace all parts and panelsbefore operating.Failure to do so can resultin death or electrical shock.

Replacement heating elements must be of the samestyle and voltage/wattage rating as the ones presentlyin the water heater. This information can be found onthe flange or terminal block of the element or on thewater heater data plate.

1. Shut off the electric power to the water heater.

2. Drain the water heater as directed under "Drainingand Flushing".

3. Remove the access door(s), insulation and elementcover(s).

4. Disconnect the electric wires from the heatingelement (Figure 9). Remove the screw-in elementsby turning the element counterclockwise with an1-½ inch socket wrench. Remove the existinggasket.

Figure 9Etement WiringConnection

Ground /

Wire (green)

Screws

Element

5. Clean the area where the gasket fits to the tank. Ifyou are replacing the bottom element, remove theaccumulated sediment on the bottom of the tank.Refer to "Draining and Flushing."

6. Make sure the replacement element has the correctvoltage and wattage rating. Position the new gasketon the element and insert it into the water heatertank (Figure 10). Tighten the element by turning itclockwise until secure.

Figure 10 Temperature Sensor

SensorElementand Temperature BracketSens°r_ /1/1/1

Screw-in /t

Element /i

X Spud _._ /i,__tlj,_/1

Gasket,4

. Close the drain valve. Open the nearest hot waterfaucet and allow the tank to fill completely withwater. To purge the lines of any excess air andsediment, keep the hot water faucet open for 3minutes after a constant flow of water is obtained.

8. Check for leaks around the element(s).

9. Connect the electric wires to the heater element.Make sure all wires are secure.

10. Replace the insulation and access door(s).

Important: Operation of this water heater withoutaccess doors or insulation could result in much highertemperatures than the desired set point, increasing therisk of scald injury. Do not operate water heater with theaccess doors or insulation removed.

11. Make certain the tank is filled with water.

12. Restore the electric power supply to the waterheater.

13

Diagnostic Code ChartDIAGNOSTIC LIGHT INDICATES CORRECTIVE ACTION*

LIGHTON Normaloperation None

NOLIGHT Nopowerto controlboardor diagnostic 1. Checkfor blownfusesor trippedbreakerlightburnedout 2. Checkpower leadsoncontrolboardwith meterfor 240 volts

3. If poweris okay,replacecontrolboard

1 FLASH Poweronwith nowaterin tank 1. Addwater andresettemperaturecontrolsystem.See"ResetFunction"onpage 10

2 FLASHES Watertemperatureexceededhighlimit 1. Makesure upperandloweraccessdoorsand insulationareproperlyin place

2. Checkelementcircuitsfor resistanceof 5 - 25ohms3. Replaceelementifnecessaryand resetcontrolsystem

3 FLASHES Sensorfailure 1. Removepower2. Checktemperaturesensorfor openor shortedcircuit3. If noproblemis found,replacesensors

4 FLASHES Upperelementcircuitfailure 1. Removepower2. Checkelementcircuit for resistanceof 5 - 25ohms3. Checkwiresat elementandboardfor damage4. If this 4 flashesconditioncontinues,replacecontrolboard

5 FLASHES Lowerelementcircuitfailure 1. Removepower2. Checkelementcircuit for resistanceof 5 - 25ohms3. Checkwiresat elementandboardfor damage4. If this 5 flashesconditioncontinues,replacecontrolboard

*These instructions are brief and intended as guidance for a qualified service technician. If you lack the necessaryskills to perform these procedures call 1-877-817-6750 for assistance.

14

Troubleshooting ChartPROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

NO HOTWATER 1. Nopowerto heater 1. Referto "No Light"of DiagnosticCodeChart2. Hightemperaturelimitshut-down 2. Referto "2 Flashes"of DiagnosticCodeChart3. Defectivesensor 3. Referto "3 Flashes"of DiagnosticCodeChart

INSUFFICIENTHOTWATER

HIGHOPERATIONCOSTS

1. Defectivelowerelement2. Temperatureset too low3. Sedimentor limein tank4. DefectiveDipTube5. Heatertoosmallfor job6. Wrongpipingconnections

1.

2.3.4.5.

6.7.8.9.10.

1.2.3.4.5.

7. Leakingfaucets8. Wastedhotwater9. Longrunsof exposedpipe10.Hotwaterpipingonoutsidewall

1. Temperatureset toohigh2. Sedimentor limein tank3. Heatertoosmallforjob4. Leakingfaucets5. Wastedhotwater6. Longrunsof exposedpiping 6.7. Hotwaterpipingin exposedwall 7.

1. Upperelementdefective 1.2. Leakingfaucets 2.

1. Excessivewaterpressure 1.

2. Closedsystem 2.3. DefectiveT & P valve 3.

1. Sulfidesinthe water 1.

Referto "5 Flashes"of DiagnosticCodeChartSet temperatureto desiredsettingDrain.Determineifwater treatmentis needed

ReplaceDipTubeCheckand Installadequatewater heaterCorrectpipingRepairfaucetsAdvisecustomer

InsulatepipingInsulatepiping

Lowertemperaturecontrolor changeto EnergySaverModeDrain.Flush-Providewater treatmentif neededInstall adequateheaterRepairfaucetsAdvisecustomerInsulatepipingInsulatepiping

SLOWHOTWATERRECOVERY Referto "4 Flashes"of DiagnosticCodeChartRepairfaucets

DRIPFROMT&P VALVE Usepressurereducingvalve andpressurereliefvalve(Seepage6)Seepage 6, "ClosedSystem/ThermalExpansion"ReplaceT & Pvalve

WATERODOR Seepage 11,"WaterOdor"

REPAIR PARTS ILLUSTRATIONALTERNATE

T&PLOCATION

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Repair Parts

Repair parts may be ordered through your plumber,local distributor, home improvement center, or by calling1-877-817-6750. When ordering repair parts alwaysgive the following information:

1. Model, serial and product number2. Item number

3. Parts description

Repair Parts List

Legend

• Special anode rod (See page 1!)

• Temperature and Pressure Relief Valve is required, but may not

be factory installed.

• Specify element type when ordering

ITEM PARTS DESCRIPTIONNo.

1 ACCESS DOORS2 INSULATION PLUG

3 ELEMENT COVERS4 LOWER ELEMENT•

5 UPPER ELEMENT •6 ELEMENT GASKET7 TEMPERATURE SENSOR8 TEMPERATURE AND PRESSURE RELIEF VALVE •9 HEAT TRAPS

10 DIP TUBE11 ANODE ROD •12 NIPPLE13 DRAIN VALVE14 JUNCTION BOX

© 2003 American Water Heater Company. All Rights Reserved. ® Registered trademark/TM Trademark of Whirlpool, U.S.A Printed in the U.S.A.

ENERGY SMART is a trademark of American Water Heater Company used under license.

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