American Water Heater COMMERCIAL ELECTRIC WATER HEATERS manual Surface Mount Thermostats

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SURFACE MOUNT THERMOSTATS

OPERATION & SERVICE

SURFACE MOUNT THERMOSTATS

The Surface Mount Control Model water heaters covered in this manual have “separate” thermostat/ECO (energy cut out) combination controls mounted to the surface of the storage tank directly above the heating elements they control. IE: a water heater equipped with 9 heating elements will have 9 thermostat/ECO controls. These controls contain two bimetal thermal switches that react to heat sensed from the surface of the water heater’s storage tank.

Thermostat: The thermostat portion of these controls is an automatic SPST (single pole single throw) switch - see the Internal Wiring illustration below. As the tank (water) temperature rises and falls each individual thermostat will de-energize (contact opens) and energize (contact closes) one heating element according to it’s temperature setting. The temperate setting is adjustable using the dial on the lower portion of the control. The adjustable range is 120°F/49°C to 180°F/82°C. The factory default setting is 140°F/60°C.

ECO: The ECO portion of these controls is a manual reset DPDT (double pole double throw) switch - see the Internal Wiring illustration below. The ECO is a high temperature limit switch designed to protect against excessively high water temperatures that can be caused by defective thermostats and grounded heating elements. The ECO temperature setting is non adjustable and fixed at 200°F/93°C. If the ECO activates (contacts open) in response to abnormally high temperatures the contacts will not close automatically, the ECO must be manually reset by pressing the red button on the top of the control. The tank temperature must cool to approximately 120°F/49°C before the ECO can be reset. When activated (contacts open) the ECO will interrupt all power supplied to the thermostat portion of the control and the heating element.

THERMOSTAT/ECO FRONT VIEW

THERMOSTAT/ECO INTERNAL WIRING

ECO DPDT

Contacts Manual background L1

Thermostat SPST

 

Contacts

T2

 

Heating Element

 

Power Supply to

Manual background L1 and L3 Terminals

 

ECO DPDT

L3

Contacts

L4

 

Servicing should only be performed by a Qualified Service Agent

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Contents Service Handbook COMMERCIAL ELECTRIC WATER HEATERSMODELS STCE3-52/80/119 & ITCE3-52/80/119 Technical Support and PartsPage COMMERCIAL ELECTRIC WATER HEATER TABLE OF CONTENTSSERVICE MANUAL QUALIFICATIONS - QUALIFIED SERVICE AGENT SERVICE WARNINGIMPORTANT SERVICE REMINDER INTRODUCTIONINSTRUCTION MANUAL TOOLS REQUIREDTHERMAL EXPANSION INSTALLATION CONSIDERATIONSCLOSED WATER SYSTEMS Grounding Power SupplyELECTRICAL REQUIREMENTS SERVICE PRECAUTIONS PRE SERVICE CHECKSWIRING CONNECTIONS HEATING ELEMENT CONFIGURATIONS WATER HEATER CONSTRUCTIONSURFACE MOUNT CONTROL MODELS ELECTRONIC CONTROL MODELSSURFACE MOUNT CONTROL MODELS WATER HEATER CONSTRUCTIONELECTRONIC CONTROL MODELS OPERATION & SERVICE PRINCIPLES OF ELECTRICITYVoltage AmperageCalculating Amps/Ohms/Volts/Watts Ohms Law applied to “SINGLE PHASE” 1Ø powerOhms Law SINGLE AND THREE PHASE POWER L1 L2 L3Checking Single Phase 1Ø Power Checking Three Phase 3Ø Power 1 L1 and L2 terminals of the water heater’s Power Distribution Block2 L2 and L3 terminals of the water heater’s Power Distribution Block 3 L1 and L3 terminals of the water heater’s Power Distribution BlockSurface Mount Control Models Single Phase to Three Phase PHASE CONVERSIONS - SURFACE MOUNT CONTROL MODELSSurface Mount Control Models Three Phase to Single Phase Electronic Control Models Single Phase to Three Phase PHASE CONVERSIONS - ELECTRONIC CONTROL MODELSElectronic Control Models Three Phase to Single Phase Volt Meter Method FUSESOhm Meter Method SURFACE MOUNT THERMOSTATS Thermostat & ECO Test Wire conductor inside tube HEATING ELEMENTSHeating Element Construction Heating Element Configurations NUMBER OF FACTORY INSTALLEDHeating Element Ratings TOTALHeating Element Amperage ELEMENTAPPROXIMATE CURRENT - AMPS 208 VACHeating Element Amperage Test Heating Element Voltage Test Heating Element Resistance & Ground Tests Measuring ResistanceHeating Element Ground Test Replacing Heating ElementsELEMENT SENSORS Element Sensor ConstructionElement Sensor Three Current Sensors Element Sensor FunctionsElement Sensor Operation CONTACTORS Contactor Construction - How They WorkContactor Configurations Power Connection TerminalsElement Numbers/Connections Wire Colors to Elements ContactorsContactor Inspection Physically Operate MechanicalContactor Coil Voltage - At Contactor Contactor Coil Voltage - At CCB 120 VAC Control Circuit Transformer Wiring X1 120 VACTRANSFORMERS H1 H2 H3 H4 H5 N/A Primary Winding Secondary WindingSecondary Winding Voltage Test 120 VAC Control Circuit Transformer TestPrimary Winding Voltage Test 24 VAC Transformer Test Temperature Sensor ECO High Temperature Limit SwitchIMMERSION TEMPERATURE PROBE Temperature Sensor Resistance Test Temperature Sensor Resistance DataChecking Temperature Sensor Resistance WATER TEMPERATURETemperature Sensor DC Voltage Test ECO Continuity TestChecking ECO Switch Continuity DC Voltage To Temperature SensorECO Voltage Test 120 VAC To ECO120 VAC From ECO Ground ConnectionELECTRONIC CONTROLS UIM User Interface Module CCB Central Control BoardCCB - CENTRAL CONTROL BOARD CCB Socket & Wiring Terminal Identification J2 Socket - 120 VAC Power SupplyJ3 Wiring Terminals - Alarm Output Relay see page J4 Wiring Terminals - Contactor CoilsJ7 Socket - Enable / Disable Circuits 1 & 2 see pages 45 J16 Socket - Not Used J17 Wiring Terminals - Not UsedJ8 Socket - Not Used J9 Socket - Not Used J10 Socket - Not Used J13 Socket - Heating Element Sensors BankCCB Enable/Disable Circuits Test Checking for Ground Checking Power and Ground To The CCBChecking for 120 VAC Service Notes - Button Pad Ribbon Cable UIM - USER INTERFACE MODULEUIM Circuit Board Back UIM Circuit Board FrontCONTROL SYSTEM FEATURES ELECTRONIC CONTROL SYSTEMCONTROL SYSTEM NAVIGATION UIM - User Interface ModuleTHE DESKTOP SCREEN Table 1 Status Icons ICONTable 2 - Operating States Table 3 - Control System MenusSTATE MENUS†Differential Settings TEMPERATURES MENUOperating Set Point Tank TemperatureTemperature Settings Enable / Disable 1 Alarm ConditionAlarm Relay Output HEATER STATUS MENUECONOMY MODE SETUP MENU Setpoint AdjustmentDesktop Screen During Economy Mode Economy Mode Setup Menu Current TimeEconomy Mode Settings Setpoint Adjustment Value Economy Mode Settings Time Clock Settings Normal Operation Between Economy Mode Settings Daily Operating Mode SettingsEconomy Mode All Day ALARM OUTPUT SETUP MENU Temp Alarm SP Used for externalAlarm SP Alarm Output SettingsDISPLAY SETTINGS MENU Display SettingsTemperature Units Backlight DelayHEATER INFORMATION MENU Elapsed TimeTotal Heating Time Bank # CyclesCURRENT FAULT / ALERT MENU FAULT HISTORY MENUFAULT OCCURRENCE MENU Main Menu - Current Fault Selected Fault History MenuFactory Default User Settings RESTORE FACTORY DEFAULTS MENURestore Factory Defaults TROUBLESHOOTING COMMON SERVICE PROBLEMSNo Hot Water Not Enough Hot WaterFault Conditions Resetting Control SystemCONTROL SYSTEM UNRESPONSIVE Alert ConditionsUIM is Inoperable Heating Cycle DisabledControl System Unresponsive cont FAULT AND ALERT MESSAGES “No Current Detected”“Temp Probe Short” Fault & Alert Messages“Temp Probe Open” “Energy Cut Out ECO” Page Page Page Page Technical Support and Parts