American Water Heater ITCE3-52/80/119 manual Control System Unresponsive, Fault Conditions

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Fault Conditions

TROUBLESHOOTING

ELECTRONIC CONTROL MODELS

The remainder of the Troubleshooting section covers Electronic Control Models only.

Fault Conditions

When the control system declares a Fault condition it will display a Fault message on the UIM and lock out. Voltage to the contactor coils and heating elements is terminated to prevent further heating operation.

Alert Conditions

When the control system declares an Alert condition it will continue heating but will display an Alert message on the UIM notifying the user that the water heater requires servicing.

Resetting Control System

Turn the power supply to the water heater off for approximately 20 seconds and then back on. If the operational problem that caused the control system to declare a Fault or Alert condition has not been corrected the control system will continue to display the Alert or Fault message and lock out.

CONTROL SYSTEM UNRESPONSIVE

DISPLAYED MESSAGE

CHECK/REPAIR

CONDITION/INDICATES

 

 

 

UIM Display Is Blank

• Check/restore power supply to the water heater

 

at Power Distribution Block - see pages 12 - 14.

UIM is not energized - LCD display is blank.

• Check control circuit transformer fuses see Fig-

Possible Causes:

ure 2 page 9 and checking fuses page 17.

• Check communication cable connections at

 

No power to water heater

UIM’s J2 Socket (page 47) and the CCB’s J11

Port (page 42).

Blown control circuit transformer fuses

 

120 VAC power problems

• Install a new communication cable between

24 VAC power problems

UIM’s J2 Socket and the CCB’s J11 Port - use

Defective transformer(s)

standard Cat 5 network cable.

Wiring or plug/socket connection problems

• Closely inspect communication ports on CCB

UIM communication cable problems

and UIM ensure they are mating properly and

 

Important Service Reminder:

providing good contact (pages 42 & 47).

• Ensure 120 VAC power/ground is supplied to

 

When performing any troubleshooting steps outlined

CCB’s J2 Socket; follow procedure on page 46.

in this service manual always consider the wiring

• Check J1 and J2 plug/socket connections on

and connectors between components. Perform a

the CCB - ensure they are mating properly and

close visual inspection of all wiring and connectors

providing good contact (page 42).

to a given component before replacement.

• Check 24 VAC transformer: follow procedure

 

Ensure wires were stripped before being crimped in

outlined on page 36.

a wire connector, ensure wires are crimped tightly in

• Call the technical support phone number on the

their connectors. Ensure pins inside plugs/sockets

back cover of this manual for further assistance

are not damaged or worn, ensure plugs/sockets are

if the problem has not been corrected after per-

mating properly & providing good contact.

forming the procedure outlined here.

 

 

Servicing should only be performed by a Qualified Service Agent

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Contents Technical Support and Parts Service HandbookCOMMERCIAL ELECTRIC WATER HEATERS MODELS STCE3-52/80/119 & ITCE3-52/80/119Page SERVICE MANUAL TABLE OF CONTENTSCOMMERCIAL ELECTRIC WATER HEATER INTRODUCTION QUALIFICATIONS - QUALIFIED SERVICE AGENTSERVICE WARNING IMPORTANT SERVICE REMINDERTOOLS REQUIRED INSTRUCTION MANUALCLOSED WATER SYSTEMS INSTALLATION CONSIDERATIONSTHERMAL EXPANSION ELECTRICAL REQUIREMENTS Power SupplyGrounding WIRING CONNECTIONS PRE SERVICE CHECKSSERVICE PRECAUTIONS ELECTRONIC CONTROL MODELS HEATING ELEMENT CONFIGURATIONSWATER HEATER CONSTRUCTION SURFACE MOUNT CONTROL MODELSWATER HEATER CONSTRUCTION SURFACE MOUNT CONTROL MODELSWATER HEATER CONSTRUCTION Amperage OPERATION & SERVICEPRINCIPLES OF ELECTRICITY VoltageOhms Law Ohms Law applied to “SINGLE PHASE” 1Ø powerCalculating Amps/Ohms/Volts/Watts L1 L2 L3 SINGLE AND THREE PHASE POWERChecking Single Phase 1Ø Power 3 L1 and L3 terminals of the water heater’s Power Distribution Block Checking Three Phase 3Ø Power1 L1 and L2 terminals of the water heater’s Power Distribution Block 2 L2 and L3 terminals of the water heater’s Power Distribution BlockSurface Mount Control Models Three Phase to Single Phase PHASE CONVERSIONS - SURFACE MOUNT CONTROL MODELSSurface Mount Control Models Single Phase to Three Phase Electronic Control Models Three Phase to Single Phase PHASE CONVERSIONS - ELECTRONIC CONTROL MODELSElectronic Control Models Single Phase to Three Phase Ohm Meter Method FUSESVolt Meter Method SURFACE MOUNT THERMOSTATS Thermostat & ECO Test Heating Element Construction HEATING ELEMENTSWire conductor inside tube TOTAL Heating Element ConfigurationsNUMBER OF FACTORY INSTALLED Heating Element Ratings208 VAC Heating Element AmperageELEMENT APPROXIMATE CURRENT - AMPSHeating Element Amperage Test Heating Element Voltage Test Measuring Resistance Heating Element Resistance & Ground TestsReplacing Heating Elements Heating Element Ground TestThree Current Sensors Element Sensor Functions ELEMENT SENSORSElement Sensor Construction Element SensorElement Sensor Operation Contactor Construction - How They Work CONTACTORSContactors Contactor ConfigurationsPower Connection Terminals Element Numbers/Connections Wire Colors to ElementsPhysically Operate Mechanical Contactor InspectionContactor Coil Voltage - At Contactor Contactor Coil Voltage - At CCB H1 H2 H3 H4 H5 N/A Primary Winding Secondary Winding 120 VAC Control Circuit Transformer WiringX1 120 VAC TRANSFORMERSPrimary Winding Voltage Test 120 VAC Control Circuit Transformer TestSecondary Winding Voltage Test 24 VAC Transformer Test IMMERSION TEMPERATURE PROBE ECO High Temperature Limit SwitchTemperature Sensor WATER TEMPERATURE Temperature Sensor Resistance TestTemperature Sensor Resistance Data Checking Temperature Sensor ResistanceDC Voltage To Temperature Sensor Temperature Sensor DC Voltage TestECO Continuity Test Checking ECO Switch ContinuityGround Connection ECO Voltage Test120 VAC To ECO 120 VAC From ECOUIM User Interface Module CCB Central Control Board ELECTRONIC CONTROLSCCB - CENTRAL CONTROL BOARD J4 Wiring Terminals - Contactor Coils CCB Socket & Wiring Terminal IdentificationJ2 Socket - 120 VAC Power Supply J3 Wiring Terminals - Alarm Output Relay see pageJ13 Socket - Heating Element Sensors Bank J7 Socket - Enable / Disable Circuits 1 & 2 see pages 45J16 Socket - Not Used J17 Wiring Terminals - Not Used J8 Socket - Not Used J9 Socket - Not Used J10 Socket - Not UsedCCB Enable/Disable Circuits Test Checking for 120 VAC Checking Power and Ground To The CCBChecking for Ground UIM Circuit Board Front Service Notes - Button Pad Ribbon CableUIM - USER INTERFACE MODULE UIM Circuit Board BackUIM - User Interface Module CONTROL SYSTEM FEATURESELECTRONIC CONTROL SYSTEM CONTROL SYSTEM NAVIGATIONTHE DESKTOP SCREEN ICON Table 1 Status IconsMENUS† Table 2 - Operating StatesTable 3 - Control System Menus STATETank Temperature Differential SettingsTEMPERATURES MENU Operating Set PointTemperature Settings HEATER STATUS MENU Enable / Disable 1Alarm Condition Alarm Relay OutputCurrent Time ECONOMY MODE SETUP MENUSetpoint Adjustment Desktop Screen During Economy Mode Economy Mode Setup MenuEconomy Mode Settings Setpoint Adjustment Value Economy Mode Settings Time Clock Settings Economy Mode All Day Economy Mode Settings Daily Operating Mode SettingsNormal Operation Between Alarm Output Settings ALARM OUTPUT SETUP MENUTemp Alarm SP Used for external Alarm SPBacklight Delay DISPLAY SETTINGS MENUDisplay Settings Temperature UnitsBank # Cycles HEATER INFORMATION MENUElapsed Time Total Heating TimeMain Menu - Current Fault Selected Fault History Menu CURRENT FAULT / ALERT MENUFAULT HISTORY MENU FAULT OCCURRENCE MENURestore Factory Defaults RESTORE FACTORY DEFAULTS MENUFactory Default User Settings Not Enough Hot Water TROUBLESHOOTINGCOMMON SERVICE PROBLEMS No Hot WaterAlert Conditions Fault ConditionsResetting Control System CONTROL SYSTEM UNRESPONSIVEControl System Unresponsive cont Heating Cycle DisabledUIM is Inoperable “No Current Detected” FAULT AND ALERT MESSAGES“Temp Probe Open” Fault & Alert Messages“Temp Probe Short” “Energy Cut Out ECO” Page Page Page Page Technical Support and Parts