SERV ICE M ANUAL - bradfordwhite.com

1 Save this manual for future referenceManual 238-47104-00 ASERVICEMANUALT roubleshooting Guideand Instructions for Service(To be performed ONLY byqualified service providers)Models Coveredby This Manual:Residential Energy Saver:M1& M2(HE) M2 Lowboy M2 M2 Wall DutyEnergy Saver:LD Upright Utility Barn Deluxe Energy Saver:DB electric AND LIGHT DUTYCOMMERCIAL electric water HEATERSP hoto is ofM-2-50T6 DSTable of ContentsPage Service ProcedureIntroduction .. 2 General Information .. 3- - -Sequence of Operation .. 6- - -Single Element Operation .. 6- - -Double Element, Non-Simultaneous, Single 7- - -Double Element, Simultaneous, Single Phase, 4 wire Service .. 8- - -Double Element, Non-Simultaneous, 3 Phase .. 9- - -Double Element, Simultaneous, 3 Phase.

2 10- - -Double Element, Non-Simultaneous, Single Phase, Off Peak .. 11- - -Troubleshooting .. 12- - -Line Voltage and High Limit ECO 14RE-IHeating Element Testing ..15RE-IIResidential Thermostat Testing .. 16RE-IIIS ingle Element .. 16 Double Element, 4 wire, Simultaneous, Single Phase .. 16 Double Element, Non-Simultaneous, Single Phase .. 17 Double Element, Non-Simultaneous, 3 Phase .. 19 Double Element, Simultaneous, 3 Phase .. 21 Double Element, Non-Simultaneous, Single Phase, Off Peak ..23 Light Duty commercial Thermostat Testing .. 25RE IVDouble Element, Non-Simultaneous, Single Phase .. 25 Double Element, Simultaneous, Single Phase .. 27 Double Element, Non-Simultaneous, 3 Phase .. 29 Double Element, Simultaneous, 3 Phase .. 31 Thermostat Removal and Replacement.

3 33RE-VHeating Element Removal and Replacement .. 34RE-VIDip Tube and Anode Inspection and Replacement .. 35RE-VIIG eneric Parts List .. 36- - -Page 2 This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair ofBradford White residential electric and light duty commercial electric water text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshootingprocedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using themethods described in this service and Light DutyCommercial electric water HeatersTools- Multi Phillips Head Screw 1- Deep Well Socket (element removal).- " Nut Drain Various Hand Tools.

4 Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers, Flash INFORMATION120 VOLTU ngroundedGrounded(Neutral)GroundingBLACK WHITEGREEN1200120240 VOLTU ngroundedUngroundedGroundingBLACKREDGREE N240120120120 ABCN eutralREDBLACK RED120120208208208208 3Ph277 ABCN eutralREDBLACK RED277277480480480480 3Ph/277 1 Ph120 ABCN eutralREDBLACK RED120120240240240240 3 PhCommon Service Wire ConfigurationsAmps = Watts (for single phase units) Example 4500W/240V = = Watts (for balanced 3 phase units) Example 4500W/240V x = x = Amps x Volts Example x 240V = 4500 WOhms = Volts Example (240V) / 4500W = OhmsWatts22 Commonly Used FormulasPage 33 GENERAL INFORMATIONW attage Limitations at Various VoltagesResidential electric Upright M1 & M2 Series (Non-Simultaneous operation)MaximumWattageElementUpper/Low erVoltage3,000021000,3/000,36,0006,000/6 ,000208, 2406,000277, 480 Residential electric Upright M1 & M2 Series (Simultaneous Operation)MaximumWattageElementUpper/Low erVoltage3,000021005,1/005,110,000802000 ,5/000,511,000042005,5/005,512,0006,000/ 6,000277, 4806,000/6,000 Residential High Efficiency Upright M2HE Series (Simultaneous Operation)Light Duty commercial electric LD Series (Simultaneous Operation)Residential electric Lowboy M1 & M2 Series (Non-Simultaneous Operation)

5 MaximumWattageSingleElementVoltage3,0000 21000,36,000042,802000,66,000772000,66,0 00084000,6 Residential electric Utility Series (Single Element Operation)Light Duty Utility Series (Single Element Operation)Dairy Barn Deluxe DB Series (Non-Simultaneous Operation)Dairy Barn Deluxe DB Series (Simultaneous Operation)Residential High Efficiency Upright M2HE Series (Non-Simultaneous operation)Residential electric Lowboy M1 & M2 Series (Simultaneous Operation)Page 4 Light Duty commercial electric LD Series (Non-Simultaneous Operation)4 GENERAL INFORMATIONS urface MountCombination Thermostat/ECO (high limit)89T SeriesManualECO (high limit)Reset buttonTemperaturecontrol DialTemperaturecontrol DialSurface MountThermostat59T SeriesSurface MountCombination Thermostat/ECO (high limit)89T SeriesSurface Mounted ThermostatsSurface mounted thermostats are mounted into a bracket which holds the thermostat against the side of the mounted thermostats respond to tank surface temperatures to sense a call for heat, set point temperaturesettings and high limit (ECO) activation.

6 It is import that the entire back surface of the thermostat is in full contact or flushwith the tank. Improperly mounted thermostat will lead to improper heater HexScrew-in FlangeTerminal BlockScrewTerminal BlockZinc Plated Copper orIncoloy SheathElement Rating Ink Stampedon side of Terminal Immersion Screw-in Type Heating ElementPage 55 SEQUENCE OF OPERATIONR esidential and light duty commercial electric water heaters are designed to operate using several different operatingmodes. The common modes and sequence of operation are as follows:1. Single Element 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).

7 Sequence of Operation- Single Element voltage is applied across terminalsL1 &L3 of the thermostat. ECO isclosed, so there is voltage at terminal L4and to one side of the the thermostat is satisfied, it opens atterminal T2 interrupting current flow through theelement. System is now in stand-by mode, waitingfor the next call for closedat terminal T23 Thermostat opensat terminal T2 Tank is cold therefore thermostatis closed at terminal T2 (calling for heat).This completes the circuit and allowscurrent to flow through the 66 Non-Simultaneous and Simultaneous OperationDouble element electric water heaters are designed to operate in a Non-Simultaneous or 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.

8 Only when the upper thermostat is satisfied, the upperelement is de-energized and power is directed to the lower thermostat, energizing the lower element and heating thebottom portion of the tank until the lower thermostat is satisfied. As hot water is drawn off the tank, it is replaced withcold water delivered through the dip tube to the bottom of the tank. The bottom of the tank cools, the lower thermostatwill call for heat energizing the lower element. If enough hot water is drawn from the tank, the top portion of the tankcools and the upper thermostat will call for heat, de-energizing the lower element and allowing only the top element toenergize until the upper thermostat is mode: allows both heating elements to operate at the same time. That is, if either thermostat (upper orlower) is calling for heat, the corresponding heating element is energized independent of the OF OPERATIONS equence of Operation- Double Element, Non-Simultaneous Operation, Single voltage is applied across terminalsL1 & L3 of the upper thermostat.

9 ECO isclosed, so there is voltage at terminal L4and to one side of the upper and is cold therefore both thermostatsare closed at terminal T2 & 2 (calling for heat). Thecircuit is complete through the upper thermostatonly, allowing current to flow through closedat terminal T2 When upper thermostat is satisfied, it opens atterminal T2 interrupting current flow through upperelement, and closes at terminal T4 allowing voltageto pass to terminal 1 of lower thermostat. Thiscompletes the circuit through the lower thermostatand allows current flow through lower closedat terminal T44 Thermostat openbetween terminals1 and 2 UpperT statUpperElementUpperT statUpperElementLowerT statLowerElementLowerT statLowerElementWhen the lower thermostat is satisfied, it opens atterminal 2 interrupting current flow through lowerelement.

10 The system is now in stand-by modewaiting for the next call for heat4 The lower thermostat/elementcombination will generallycycle on and off more oftenthen the upper. In some cases,such as a cold tank or in highdemand periods, the upperthermostat will call for heat(opening at terminalT4 and closing atterminal T2) prior to the lowerthermostat being satisfied. Thiswill interrupt current flowthrough the lower thermostatand element and allow currentto flow through the upperelement only. When the upperthermostat is satisfied, itresumes operation asdescribed in sequence # closedbetween terminals1 and 2 UpperT statUpperElementLowerT statLowerElementUpperT statUpperElementLowerT statLowerElementUpperT statUpperElementLowerT statLowerElementThermostat closedat terminal 2 Thermostat closedat terminal T2 Page 77 SEQUENCE OF OPERATIONS equence of Operation-Double Element, Simultaneous Operation, Single Phase, 4 wire service wire, double element heater wired for simultaneous operation is essentially two single element systems operatingindependently.