Bradford White Corp Water Heater Commercial Electric Energy Saver Medium Duty E32 Series Models User Manual

(To be performed ONLY by qualified service providers)  
Commercial Electric Energy Saver:  
E32-50S  
E32-80R  
E32-120R  
Manual 239-47157-00B  
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GENERAL INFORMATION  
Commonly Used Formulas  
Amps = Watts (for single phase units) Example 4500W/240V = 18.75A  
Volts  
Amps = Watts  
Volts x 1.732  
(for balanced 3 phase units) Example 4500W/240V x 1.732 = 10.82A  
Watts = Amps x Volts Example 18.75A x 240V = 4500W  
Ohms = Volts2 Example (240V)2 / 4500W = 12.8 Ohms  
Watts  
BLACK  
GREEN  
RED  
Grounding  
Ungrounded  
Ungrounded  
240  
120  
120  
Neutral  
A
B
C
Neutral  
A
B
C
Neutral  
A
B
C
120  
240  
277  
480  
120  
208  
120  
120  
277  
277  
120  
120  
240  
240  
480  
480  
208  
208  
RED BLACK RED  
Page 3  
RED BLACK RED  
RED BLACK RED  
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GENERAL INFORMATION  
Full Load Amperes-(Phase 1/Phase 3)  
Input Kw  
208V  
240V  
277V  
21.6  
32.4  
43.3  
48.7  
54.1  
64  
380V  
10  
415V  
8.3  
480V  
6
9
28.8/16.6  
43.2/25  
25/14.4  
12.5/7.2  
18.7/10.8  
25/14.4  
37.5/21.6  
50/28.9  
14  
12.5  
16.7  
18.8  
20.9  
25  
12  
13.5  
15  
18  
57.6/33.3  
64.9/37.5  
72.1/37.5  
86.5/50  
19  
56.2/32.5  
62.5/36.1  
75/43.4  
21  
28.1/16.2  
31.2/18  
23  
28  
37.5/21.6  
Surface Mounted Thermostats  
E32 series medium duty commercial water heaters use only 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 import that the entire back surface of the thermostat is in full contact or flush with the tank. An  
improperly mounted thermostat will lead to improper heater operation.  
Manual  
Surface Mount  
ECO (high limit)  
Combination Thermostat/  
Reset button  
ECO (high limit)  
89T Series  
Temperature  
control Dial  
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 4  
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SEQUENCE OF OPERATION  
E32 series medium duty, field convertible commercial electric water heaters are designed to operate using single phase  
or three phase service connections. One size fits all Internal fusing is factory installed for all units. When field  
conversions are required, no fuse change is necessary. Three surface mounted thermostats operating independently  
are used to control a corresponding heating element.  
Fuse Block  
Sequence of Operation.  
1
1
Single phase line voltage is applied  
across terminals L1 and L2 of terminal  
block. Or Three phase line voltage is  
applied to terminals L1 through L3 of  
terminal block. Line voltage continues  
through terminal block and fuse blocks  
and connects to thermostats at  
terminals L1 & L3.  
Terminal Block  
2
2
3
ECO (high limit) in thermostat is closed,  
so there is line voltage present at  
terminal L4 of thermostats and to one  
side of each element.  
Thermostat closed  
at terminal T2  
ECO Closed  
Water in tank is cold, so all thermostats  
are closed at terminal T2 (calling For  
heat). This completes the circuit and  
allows current to flow through heating  
element.  
3
Power to one  
side of element  
4
Thermostat open  
at terminal T2  
As each thermostat is satisfied,  
4
it opens at terminal T2 interrupting  
current flow through the respective  
element. The system is now in stand-by  
mode, waiting for the next call for heat.  
Page 5  
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FIELD CONVERSION FOR:  
KW, Voltage and Phase  
The E32 series medium duty commercial electric water heaters are field convertible. This allows Qualified Service  
Providers the ability to convert wattage, voltage and phase using a factory supplied conversion kit as required per the  
installation. Underwriters Laboratories Inc. recognizes this procedure as herein presented and no deviation from these  
instructions are allowed.  
KW Conversion  
All E32 series medium duty commercial water heaters are factory wired to the maximum electrical duty for which they  
have been designed. Therefore, internal electrical components satisfy the maximum voltage and maximum electrical  
current conditions.  
These instructions do not allow for a modification that adds or deletes the number of heating elements originally supplied  
with the heater; therefore such a modification must not be attempted.  
Special factory prepared “Conversion Kits” must be used for these conversions. These kits contain the heating  
elements, element gaskets and product labeling overlays related to the newly created electrical parameters.  
18 KW heaters suitable for operation with 208vac cannot be created by conversion since there are no “kits” established  
for this electrical system. These heaters can be obtained by ordering directly from the factory.  
Conversion Kit Available  
Required  
Total  
Element  
---------- Kit Part Numbers ----------  
Heater KW Wattage  
208 volts  
240 volts  
480 volts  
6
9
2000  
3000  
265-43942-13  
265-43942-14  
265-43942-07  
265-43942-08  
265-43942-01  
265-43942-02  
12  
4000  
4500  
5000  
6000  
265-43942-15  
265-43942-16  
265-43942-17  
265-43942-18*  
265-43942-09  
265-43942-10  
265-43942-11  
265-43942-12  
265-43942-03  
265-43942-04  
265-43942-05  
265-43942-06  
13.5  
15  
18  
*265-43942-18 will require control box replacement (included in kit).  
Following the heating element removal and replacement instruction on page 16, remove elements and replace with  
elements from appropriate kit listed above.  
The heaters rating plate will need to be modified because the conversion altered the electrical characteristics of the  
heater. This rating plate is placed on every Commercial Electric water heater produced by Bradford White Corporation.  
Element kits above contain rating plate label overlays related to the newly created electrical parameters. Follow the  
instruction on page 8 For placement of overlays.  
Voltage Conversion  
1. Voltage conversion is accomplished by replacing the existing elements with elements that are rated at the  
required voltage.  
2. To accomplish this conversion refer to the above procedure for KW Conversion ---- Element Changes.  
Control Box Conversion  
NOTICE  
1.  
2.  
3.  
Open front panel of control box installed on water heater and  
disconnect the (6) load wires from fuse blocks.  
Control box conversion is ONLY required  
when converting water heater to 18kw 208v  
(Kit# 265-43942-18)  
Remove (4) screws joining control box to water heater and  
remove control box.  
Install new control box onto the water heater by feeding the  
wires through the back of the control box and reinstall (4)  
mounting screws.  
CAUTION  
Use caution to not damage any of the wire  
insulation when removing control box.  
4.  
Reconnect wires to new fuse blocks. Be certain to  
match wire colors to Line side of fuse blocks.  
Page 6  
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FIELD CONVERSION FOR:  
KW, Voltage and Phase  
Electrical Phase Conversion  
Electrical phase conversion will require a change from single-phase to three-phase or an opposite conversion change  
from three-phase to single-phase. Each of these conversions will be explained separately as follows:  
Three-Phase to Single-Phase  
1. Disconnect blue and yellow wires from terminal L-3 of the terminal block  
2. Connect yellow wire to terminal L-1 of the terminal block. The black wires should remain connected to L-1 of the  
terminal block as it was originally manufactured.  
3. Connect blue wire to terminal L-2 of the terminal block. The red wires should remain connected to L-2 of the  
terminal block as it was originally manufactured.  
4. Field wiring for the heater power supply will eventually be connected to terminals L-1 and L-2 of the terminal block  
when the product is installed.  
Single-Phase to Three-Phase  
1. Disconnect yellow wire from terminal L-1 of the terminal block  
2. Disconnect blue wire from terminal L-2 of the terminal block  
3. Connect blue and yellow wires to L-3 of the terminal block  
4. Field wiring for the heater power supply will eventually be connected to terminals L-1, L-2, and L-3 of the terminal  
block when the product is installed.  
Fuse Block  
Three Phase and Single Phase  
Connections at Terminal Block  
Terminal Block  
Phase  
L1  
L2  
L3  
BK & Y R & BL  
Single  
Three  
Wires  
Wires  
BK  
R
BL & Y  
Wires  
Wire  
Wire  
Terminal Block  
E32 Series Phase Conversion Rating Plate Overlay Kits  
6KW  
9KW  
12KW  
Volt  
Conversion Kit  
Volt  
Conversion Kit  
Volt  
Conversion Kit  
208  
240  
480  
265-45246-13  
265-45246-07  
265-45246-01  
208  
240  
480  
265-45246-14  
265-45246-08  
265-45246-02  
208  
240  
480  
265-45246-15  
265-45246-09  
265-45246-03  
13.5KW  
15KW  
18KW  
Volt  
Conversion Kit  
Volt  
Conversion Kit  
Volt  
Conversion Kit  
208  
240  
480  
265-45246-18  
265-45246-12  
265-45246-06  
208  
240  
480  
265-45246-16  
265-45246-10  
265-45246-04  
208  
240  
480  
265-45246-17  
265-45246-11  
265-45246-05  
The heaters rating plate will need to be modified because the conversion altered the electrical characteristics of the  
heater. This rating plate is placed on every Commercial Electric water heater produced by Bradford White Corporation.  
Phase conversion kits above contain rating plate overlays related to the newly created electrical parameters. Follow the  
instruction on page 8 For placement of overlays.  
Page 7  
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FIELD CONVERSION FOR:  
KW, Voltage and Phase  
Rating Plate Modification  
The heaters rating plate will need to be modified because the conversion altered the electrical characteristics of the  
heater. Refer to the illustration below that displays a typical commercial electric rating plate that is to be altered. This  
rating plate is placed on every Commercial Electric water heater produced by Bradford White Corporation. Locate this  
rating plate on the heater you have just converted.  
BRADFORD WHITE CORPORATION  
200 LAFAYETTE ST. MIDDLEVILLE MI 49333  
Model No: E32-50S3  
Serial No: ZB2564812  
Cap.  
50(gal.)/189.3(liters)  
Press:  
Test 300(psi), Working 150(psi)  
Volts  
Phase  
240  
Three  
Max Temp 180°  
Amps 43.3  
Kw Each 6  
Total Kw 18  
3 Elements  
Wattage Rating Based Upon 60 Hz  
Locate the adhesive backed label (marked as part # 238-43990-00) (see illustration below) that was provided inside the  
kit. It is marked with the new electrical data that is accurate for the conversion just executed. The kit will contain two  
labels for this voltage and KW. One for three phase and one for single phase. Select the correct label for the electrical  
phase in this conversion.  
Volts  
Phase  
480  
Three  
Max Temp 180°  
Amps 7.2  
Part number  
Kw Each 2  
Total Kw 6  
3 Elements  
Wattage Rating Based Upon 60 Hz  
238-43990-00  
Remove the adhesive peel strip and place this label onto the rating plate in such a manner that the new electrical data  
will appear in place of the data originally marked. Refer to the illustration below that displays the rating plate revision.  
BRADFORD WHITE CORPORATION  
200 LAFAYETTE ST. MIDDLEVILLE MI 49333  
Model No: E32-50S3  
Serial No: ZB2564812  
Cap.  
50(gal.)/189.3(liters)  
Press:  
Test 300(psi), Working 150(psi)  
Overlay placed over old  
rating plate data  
Volts  
Phase  
480  
Three  
Max Temp 180°  
Amps 7.2  
Kw Each 2  
Total Kw 6  
3 Elements  
Wattage Rating Based Upon 60 Hz  
238-43990-00  
Page 8  
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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 11.  
Common Heating Element Failures Are:  
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 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 Off located in the thermostat. Repeated actuation of the ECO  
reset button on the thermostat usually is 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.  
The illustration 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.  
Typical Direct Immersion “Screw-In”  
Type Heating Element  
Page 9  
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TROUBLESHOOTING  
Quick Step Plan to Hot Water  
WARNING  
High voltage exposure. Use caution when  
making voltage checks to avoid personal  
injury.  
1. TURN OFF power to water heater and check all wire  
connections to insure they are tight and corrosion free.  
2. Turn power “ON” and determine that line voltage is  
present (see pg 12), and the high limit (ECO) has not  
actuated (see pg 13).  
3. Check for blown fuse (see pg 13).  
4. Check for inoperative heating element (see procedure on page 11).  
5. Check for proper thermostat operation (see pg 14). NOTE: Thermostat testing procedures  
assume items 2, 3 and 4 above are in working order.  
SERVICE  
PROCEDURE  
SYMPTOM  
PROBABLE CAUSE  
CORRECTIVE ACTION  
1. Check fuses or circuit breakers at service  
panel.  
2. Check water heater fuses.  
3. Check all wire connections.  
4. Check heating element(s). Replace as  
needed.  
5. Check thermostat(s) operation. Replace as  
needed.  
6. Check ECO. Reset or replace  
thermostat(s) as needed.  
2. See Service Procedure  
E32-III, Page 13  
4. See Service Procedure  
E32-I, Page 11.  
5. See Service Procedure  
E32-IV, Page 14.  
6. See Service Procedure  
E32-III, Page 13  
1. No Power to heater.  
2. Blown water heater fuses.  
3. Loose wire connections.  
4. Inoperative heating elements.  
5. Inoperative thermostat.  
6. Open ECO.  
No Hot Water  
1. Check heating element(s), replace as  
needed.  
1. Inoperative 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.  
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.  
1. See Service Procedure  
E32-I, Page 11.  
3. See Service Procedure  
E32-IV, Page 14.  
5. See Service Procedure  
E32-VI, Page 16.  
Not Enough Hot  
Water  
7. Undersized heater.  
6. Reduce demand.  
8. Very cold inlet water to heater.  
9. Plumbing connections reversed.  
10. Damaged dip tube.  
7. Replace with larger heater.  
8. Temper water to heater.  
9. Correct plumbing connections.  
10. Check dip tube, replace as needed.  
10. See Service Procedure  
E32-VII, Page 17.  
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).  
1. See Service Procedure  
E32-VI, Page 16.  
3. See Service Procedure  
E32-IV, Page 14.  
Slow Hot Water  
Recovery  
4. Derated heating element installed.  
1. Position thermostat flush with tank surface. 1. See Service Procedure  
1. Thermostat(s) not in contact with tank.  
2. Grounded heating element(s).  
3. Thermostat set to high.  
4. Inoperative thermostat(s).  
5. Inoperative ECO.  
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.  
E32-V, Page 15.  
2. See Service Procedure  
E32-I, Page 11.  
4. See Service Procedure  
E32-IV, Page 14.  
Over Heated  
Water or  
Continues  
Operation  
6. Undersized water heater.  
5. See Service Procedure  
E32-III, Page 13.  
6. Replace with larger heater.  
Noisy (singing or  
hissing) Elements  
1. Lime formation on elements.  
1. Remove and clean heating elements.  
Replace as needed.  
1. See Service Procedure  
E32-VI, Page 16.  
Page 10  
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SERVICE PROCEDURE E32-I  
Heating Element Testing  
Testing For Open Or Burned Out Element.  
WARNING  
High voltage exposure. Be sure power is turned  
OFF to water heater prior to performing this  
procedure.  
Step 1. TURN OFF POWER TO WATER HEATER.  
Step 2. Remove thermostat/element access cover(s)  
from front of water heater. Remove insulation  
and plastic cover from thermostat.  
Step 3. Disconnect wires from heating element.  
Step 4. Set multi-meter to “ohms” setting.  
Step 5. Touch probes of multi-meter to screw  
terminals of heating element  
(see illustration 1).  
Step 6. Reading should be 12.8 ohms (±6%) for a 240  
volt, 4500 watt element, see table below:  
Ohms = Volts2  
Watts  
A reading outside the range using the formula  
above (±6%), indicates a bad element and the  
element must be replaced.  
Ohms of electrical Resistance  
Element Screw Terminals  
Voltage Rating of Element  
Element  
NOTE  
Illustration 1  
Disconnect  
Wattage  
208  
240  
480  
element  
Wires  
2000  
3000  
4000  
4500  
5000  
6000  
21.6  
14.4  
10.8  
9.6  
28.8  
19.2  
14.4  
12.8  
11.5  
9.6  
115.2  
76.8  
57.6  
51.2  
46.1  
38.4  
8.7  
7.2  
Testing For Heating Element Short Circuit To  
Ground.  
Step 1. TURN OFF POWER TO WATER HEATER.  
NOTE  
Disconnect  
element  
Wires  
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.  
Step 4. Set multi-meter to “ohms” setting.  
Element Screw Terminal  
Meter Probe  
Step 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.  
Element Flange  
Illustration 2  
Page 11  
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SERVICE PROCEDURE E32-II  
Line Voltage Testing  
Line Voltage Testing  
WARNING  
High voltage exposure. Use caution when  
making voltage checks to avoid personal injury.  
1. Turn “OFF” power to water heater.  
2. Open control box located at the top of the heater to allow access to terminal block.  
3. Set multi-meter to volts AC.  
Check voltage across  
Single phase  
L1 & L2 of terminal block  
Service from panel  
4. Turn power “ON” to water heater.  
5. For 3 phase service, go to step 7.  
6. For single phase service, check voltage across terminals  
L1 & L2 of terminal block (see illustration 3).  
A) Rated voltage IS present, power to the water  
heater is okay.  
Illustration 3  
B) Rated voltage NOT present, Check circuit breaker  
at service panel.  
Check voltage across  
Three phase  
L1 & L2 of terminal block  
Service from panel  
7. For 3 phase service check across L1 & L2 and across  
L1 and L3 (see illustrations 4 & 5)  
A) Rated voltage IS present, power to the water  
heater is okay.  
B) Rated voltage NOT present, Check circuit breaker  
at service panel.  
Illustration 4  
Three phase  
Check voltage across  
Service from panel  
L1 & L3 of terminal block  
Illustration 5  
Page 12  
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SERVICE PROCEDURE E32-III  
Fuse Testing  
Fuse Testing  
WARNING  
High voltage exposure. Be sure power is turned  
OFF to water heater prior to performing this  
procedure.  
1. Turn “OFF” power to water heater.  
2. Open control box located at the top of the heater to  
allow access to fuse block.  
3. Disconnect wire leads from fuse block. NOTE: It may be  
necessary to label wires for proper re-connection when  
finished.  
4. Set multi-meter to the “Ohms” setting.  
5. Check continuity across upper and lower screw terminal  
of fuse block for each individual fuse, six total  
(see illustration 6).  
A) Continuity IS present, fuse is okay.  
B) Continuity NOT present, Replace with new fuse  
Class “G”, 480 Volt MAX, 30 Amp.  
Illustration 6  
ECO (high limit) testing  
1. This procedure assumes line voltage and  
fuses are in working order.  
WARNING  
2. Turn power “OFF” to water heater.  
High voltage exposure. Use caution to avoid  
personal injury during this procedure.  
3. Remove thermostat/element access cover(s) located  
near the bottom of the water heater.  
4. Remove insulation and plastic cover from thermostat.  
5. Turn power “ON” to water heater.  
ECO reset  
button  
6. Check voltage across terminals L1 & L4 for all thermostats  
(see illustration 7).  
A) Rated Voltage IS present, ECO is okay.  
B) Rated voltage NOT present, proceed to step 7.  
7. Turn power “OFF” to water heater and firmly press ECO reset button on thermostat(s).  
Turn power “ON” to water heater and recheck voltage across terminals L1 & L4 of thermostat(s).  
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 11).  
3. Proper thermostat operation (see procedures on page 14).  
Illustration 7  
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 6.  
2. If water is cool, Replace thermostat(s).  
Page 13  
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SERVICE PROCEDURE E32-IV  
Thermostat Testing  
Thermostat Operation Testing  
WARNING  
High voltage exposure. Use caution to avoid  
personal injury during this procedure.  
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 L1 & L3 of thermostat  
(see illustration 8)  
A) Rated voltage NOT present,  
Check fuses.  
B) Rated voltage IS present,  
proceed to next step.  
5. Check across terminals L4 and T2 of  
thermostat (see illustration 9).  
A) Rated voltage NOT present,  
Recheck ECO. If ECO is okay,  
replace thermostat.  
Illustration 8  
Illustration 9  
B) Rated voltage IS present, okay thermostat is  
calling for heat, proceed to next step.  
6. Check across element terminals  
(see illustration 10).  
A) Rated voltage NOT present,  
check wire connections from  
thermostat to element.  
B) Rated voltage IS present,  
Repeat element testing  
see page 11.  
Water Temperature In Tank Is Above Thermostat Setting.  
1. This procedure assumes line voltage, ECO and  
elements are in working order.  
Illustration 10  
2. Turn power “ON” to water heater.  
3. Set multi-meter to “Volts AC”.  
4. See illustration 9 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 11).  
Page 14  
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SERVICE PROCEDURE E32-V  
Thermostat Removal and Replacement  
Thermostat Removal  
WARNING  
High voltage exposure. Be sure power is  
“OFF” when performing this procedure.  
1. Turn power “OFF” To water heater.  
2. Remove access cover(s) and insulation.  
3. Remove plastic thermostat protector from thermostat(s).  
4. Disconnect wires from thermostat terminals. It may be necessary to label wires for proper re-connection to  
new thermostat.  
5. Note thermostat temperature setting for proper setting of new thermostat.  
6. Slide thermostat upwards and out of mounting bracket.  
Thermostat Replacement  
1. Use a stiff brush to remove any debris or loose scale from tank surface where new thermostat will be installed.  
2. Slide new thermostat down into thermostat bracket until it snaps into place. IMPORTANT! Thermostat must set  
completely flat or flush to tank surface. An improperly installed thermostat will cause improper water heater  
operation.  
3. Refer to the wire diagram located on the inside of the control box cover and re-connect wires to the thermostat. Be  
sure wire connections are snug and corrosion free. Do not over tighten, doing so may damage thermostat.  
4. Set thermostat to the original thermostat setting found on the old thermostat.  
5. Re-install plastic thermostat protector.  
6. Re-install insulation and access cover.  
7. Restore power to water heater and verify proper heater operation.  
Tank Surface  
Proper Thermostat mounting  
flush with tank surface  
Thermostat  
Improper Thermostat mounting.  
Thermostat not flush with tank surface  
Thermostat  
mounting  
bracket  
Front View  
Thermostat Mounting  
Side View  
Improper Thermostat  
Mounting  
Side View  
Proper Thermostat  
Mounting  
Page 15  
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SERVICE PROCEDURE E32-VI  
Heating Element Removal  
and Replacement  
WARNING  
High voltage exposure. Be sure power is  
“OFF” when performing this procedure.  
Heating Element Removal  
1. Turn power “OFF” To water heater.  
2. Turn off cold water supply to heater. Connect hose to drain  
spigot of water heater and route to an open drain. Open  
a nearby hot water faucet to vent heater for draining. Open  
drain spigot of water heater and allow heater to drain  
to a point below the Element(s).  
WARNING  
Heater components and stored water may be  
HOT when performing the following steps in  
this procedure. Take necessary precaution to  
prevent personal injury.  
3. Close drain spigot and remove hose.  
3. Remove access cover(s) and insulation.  
4. Remove plastic thermostat protector from thermostat(s).  
5. Disconnect wires from element terminals.  
6. Remove element from tank using 1-½ deep well socket or appropriate wrench. Unscrew element counter-clockwise to  
remove from tank.  
7. Be sure to remove old element gasket from the tank. It is not recommended to be re-used.  
Heating Element Replacement  
1. Check element terminal block for proper electrical rating. NOTE: Some elements have dual ratings, be sure to check  
all surfaces of the element terminal block (see illustration below).  
2. Apply new element gasket to the new element. Be sure gasket is seated flat against element flange without rolls or  
gaps (see illustration below).  
3. Clean any debris from element fitting on tank. Lubricate element threads as needed with thread lubricant.  
4. Thread new element clockwise into tank. Tighten element using 1-½ deep well socket or appropriate wrench. Do not  
over tighten, over tightening may damage element gasket.  
5. Reconnect wires to element, be sure connections are snug and corrosion free. Do not over tighten, doing so may  
damage terminal block.  
6. Resume water supply to heater, be sure tank is full of water and check for leaks.  
7. Re-install plastic thermostat protector(s).  
8. Re-install insulation and access cover(s).  
9. To resume operation, BE SURE TANK IS FULL OF WATER and restore power to water heater. Verify proper heater  
operation.  
Element Rating.  
Example: (4500 Watt, 240 Volt)  
Date Code  
Element Flange  
Element Gasket Seated Flat Against  
Element Flange Without Rolls or Gaps  
Terminal  
Block  
Manufacturer Identification  
Page 16  
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SERVICE PROCEDURE E32-VII  
Dip Tube and Anode Inspection and  
Replacement  
Dip Tube Inspection and Replacement  
WARNING  
Heater components and stored water may be HOT when performing the following steps in  
this procedure. Take necessary precaution to prevent personal injury.  
Step 1.  
Turn power “OFF” to water heater.  
Step 2.  
Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.  
Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow  
heater to drain to a point below the inlet connection nipple.  
Step 3.  
Step 4.  
Step 5.  
Close drain spigot and remove hose.  
Disconnect inlet nipple from plumbing system.  
With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage  
nipple threads.  
Step 6.  
Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage.  
Hydro-jets located near the bottom of the dip tube should be open and free of any blockage.  
Anti-siphon hole located approximately 6" from the bottom of nipple, should be free of any blockage.  
Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable  
and the inlet nipple/dip tube must be replaced.  
Step 7.  
Step 8.  
Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Connect  
nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with  
water.  
To resume operation, BE SURE TANK IS FULL OF WATER and turn power “ON” to water heater.  
Anode Inspection and Replacement  
Step 1.  
Step 2.  
Turn power “OFF” to water heater.  
Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.  
Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow  
heater to drain to a point below the outlet connection nipple.  
Step 3.  
Step 4.  
Step 5.  
Close drain spigot and remove hose.  
Disconnect outlet nipple from plumbing system.  
With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage  
nipple threads.  
Step 6.  
Step 7.  
Step 8.  
Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.  
If depletion is ½ of the original anode diameter (original diameter approximately ¾”), replacement is  
recommended. If any of the  
steel core of the anode is exposed, replacement is recommended.  
Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Connect  
nipple to plumbing system, close spigot and remove drain hose, resume water supply and refill heater with  
water.  
To resume operation, BE SURE HEATER IS FULL OF WATER and turn power “ON” to water heater.  
Page 17  
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Generic Parts List  
1. Hot Water Outlet Anode  
2. T&P Relief Valve  
3. Cold Water Inlet Dip Tube  
4. Control Box  
8. Terminal Block  
9. Brass Drain Valve  
10. Thermostat Mounting Bracket  
11. Element Gasket  
5. Ground Lug  
12. Heating Element  
6. Fuse  
7. Fuse Block  
13. Thermostat Surface Mount  
14. Thermostat Protector  
15. Thermostat/Element Access Cover  
16. ASSE Approved Mixing Valve (optional)  
Page 18  
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