Residential Electric

Water Heater
Installation
Instructions and
Use & Care Guide
To obtain technical, warranty or service assistance during or
after the installation of this water heater, call toll free 1-800-
999-9515
When calling for assistance, please have the following
information ready:
1. Model number
2. 7 Digit product number
3. Serial number
4. Date of installation
5. Place of Purchase

Table Of Contents PAGE

Water Heater Safety ..................................................................... 2
Installing Your Electric Water Heater ........................................ 3-8
Unpacking Instructions ................................................ 3
Location Requirements ................................................ 4
Electrical Requirements ............................................... 5
Water System Piping ................................................... 6
Installation Checklist .................................................... 8
Operating Your Water Heater ....................................................... 9-11
Water Temperature Regulation .................................... 9
Adjusting the Thermostat ..................................................... 10
Operational Conditions ........................................................ 11
Maintenance of Your Water Heater ................................................. 12-13
Trouble Shooting Chart ............................................................. 14
Repair Parts Illustration ............................................................. 15
Thermostat Wiring Chart and Diagram ..................................... 16
6510236
October 2001
Supercedes 6510159
 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 all
safety 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't

immediately follow instructions.

You can be killed or seriously injured if you don't

follow instructions.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what 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 long
period of time (2 weeks or more). Hydrogen is extremely flammable. To reduce the risk of injury under these conditions,
it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical
appliance connected to the hot water system. When hydrogen is present, there will be an unusual sound such as air
escaping through the pipe as the water begins to flow. There should be no smoking or open flame near 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 of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses 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 other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde.

2
INSTALLING YOUR WATER HEATER
Consumer Information Unpacking the Water Heater
This water heater should be installed in accordance with
the local code authority having jurisdiction, the power
company or electric utility, and this installation manual. WARNING
In the absence of local code requirements, follow the
regulations set forth in the latest edition of The National Excessive Weight Hazard
Electric Code, NFPA 70. This is available from the Use two or more people to move and install
following: water heater.
National Fire Protection Agency
1 Batterymarch Park Failure to do so can result in back or other
Quincy, MA 02269 injury.
American National Standards Institute
1430 Broadway
New York, NY 10018 Removing Packaging Materials
Check your phone listings for the local authorities having Important: Do not remove any permanent instructions,
jurisdiction over your installation. labels, or the data label from outside of the water heater
or on the inside of panels.
Consumer Responsibilities · Remove exterior packaging and place installation
This manual has been prepared to acquaint you with the components aside.
installation, operation and maintenance of your electric · Inspect all parts for damage prior to installation
water heater and to provide important safety information and start-up.
in these areas.
We urge you to read all of the instructions thoroughly · Completely read all instructions before attempting
before attempting the installation or operation of this to assemble and install this product.
water heater. This manual should be kept for future · After installation, dispose of packaging material
reference. in the proper manner.
The manufacturer of this water heater will not be liable
for any damages caused by failure to comply with the
installation and operating instructions outlined in this
manual.
If you lack the necessary skills required to properly install
this water heater or you have difficulty following the
directions, you should not proceed but have a qualified
person perform the installation of this water heater.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR section 2.00 and 5.00.
A data plate identifying your water heater can be found
adjacent to the element door. When referring to your
water heater always have the information listed on the
data plate readily available.
Retain your original receipt as proof of purchase.

3
 Location Requirements Note: The water heater shall be located so it is not subject
to physical damage by moving vehicles or area flooding.
Site location FIGURE 1
RESIDENTIAL GARAGE
Select a location near the center of the water piping INSTALLATION
system. It must be installed indoors and in a vertical
position on a level surface.
The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) May VEHICLE
require the water piping and drain piping to be insulated STOP
to protect against freezing. The drain and controls must
be easily accessible for operation and service.
Do not use this water heater in conjunction with a spa
or hot tub. DRAIN DRAIN
PAN
Note: Local codes and requirements in your area may
require the installation of your water heater be
State of California
accomplished in a way that the bottom element is elevated
from the floor at least 18 inches. Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
Important: The water heater should be located in an 1-800-999-9515 and request instructions.
area where leakage of the tank or connections will not
result in damage to the area adjacent to the water heater
or to lower floors of the structure. Due to the normal
corrosive action of the water, the tank will eventually leak
after an extended period of time. It is recommended that
a suitable drain pan be installed under the water heater
as shown below. This pan is to protect the property from
damage which may occur from normal condensate
formation on the tank or leaks in the tank and pipe
connections. The pan must limit the water level to a
maximum depth of 2-1/2 inches and be two inches wider
than the heater and piped to an adequate drain. Locate
the water heater near a suitable indoor drain. Outside
drains are subject to freezing temperatures which can
obstruct the drain line. The piping should be at least 3/4”
ID and pitched for proper drainage.
Under no circumstance will the manufacturer be held
liable for any water damage in connection with this
water heater.

2 1/2” MAX

PIPE TO
ADEQUATE
DRAIN

AT LEAST 2” INCHES GREATER

THAN THE DIAMETER OF THE
WATER HEATER.

4
 FIGURE 2
Electrical Requirements HEATING ELEMENT

WARNING
Electrical Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in Notice: Applying electrical power to elements that are not
submerged in water will destroy them. The manufacturer
death or electrical shock. will not warranty any elements damaged in this manner.

WARNING FIGURE 3
120/240V 2-WIRE MODELS
Fire Hazard GROUND
Use proper size solid copper JUNCTION BOX
COVER
GREEN
GROUND
WIRE
CONDUIT
wire. SCREW

Use a UL approved strain relief.

Connect ground wire to green
ground screw.
Failure to do so can result in
death, fire, or electrical shock.
If you lack the necessary skills required to properly install
the electrical wiring to this water heater, do not proceed WHITE WIRE (120V MODELS)
BLACK WIRE
but have a qualified electrician perform the installation. RED WIRE (240V MODELS)

When making the electrical connections, always make

FIGURE 4
sure:
WIRING DIAGRAM
OVERLOAD
· The electrical supply has the proper overload fuse 120V MODELS ONLY PROTECTION
CIRCUIT
BREAKER
or breaker protection. APPROVED CONNECTORS

· Wire sizes and connections comply with all BLACK HOT

applicable codes. TO 120/160V
WHITE POWER SUPPLY
· Wiring enclosed in approved conduit (if required NEUTRAL
by local codes).
· The water heater and electrical supply are properly
grounded.
GROUND
Figures 3, 4, and 5 are provided as reference drawings SCREW
for the 120/240v 2-wire models only. Always reference
the wiring diagram located on the water heater for the ELECTRICAL
SERVICE GROUND
correct electrical connections.
When installing the electrical wiring to the water heater:
1. Be sure tank is completely filled with water before FIGURE 5
making any electrical connections. (See Figure 2) WIRING DIAGRAM
208/240V MODELS ONLY
2. Shut-off the power to the unit. OVERLOAD
PROTECTION CIRCUIT
BREAKER
3. Loosen the screw holding the junction box cover
APPROVED CONNECTORS
to the top of the water heater. Set the cover aside.
BLACK L1
4. Connect the electrical supply to the water heater
in accordance with local utility requirements and RED L2
codes. A standard 1/2 inch opening has been made
TO 208/240V
in the junction box for conduit connections. @60Hz
1 PHASE
5. Ground the water heater by connecting a grounding GROUND
POWER SUPPLY

wire from the electrical service ground terminal to SCREW

the green grounding screw in the junction box of

ELECTRICAL
the water heater. SERVICE GROUND

5
 Water System Piping FIGURE 6
WATER PIPING INSTALLATION IN A CLOSED SYSTEM
USE EITHER:

Piping Installation 1.
2.
THERMAL EXPANSION TANK
PRESSURE RELIEF VALVE

Piping, fittings, and valves should be installed according PRESSURE REDUCING

VALVE WITH BYPASS
to the installation drawing (Figure 6). If the indoor HOT WATER
installation area is subject to freezing temperatures, the OUTLET

water piping must be protected by insulation. COLD WATER

INLET
COLD WATER
Water supply pressure should not exceed 80% of the UNION INLET VALVE
working pressure of the water heater. The working
pressure is stated on the water heater’s data plate. If TEMPERATURE AND
this occurs a pressure limiting valve with a bypass may PRESSURE RELIEF VALVE

need to be installed in the cold water supply line. This

DISCHARGE LINE
should be placed on the supply to the entire house in 6 INCHES MAXIMUM
order to maintain equal hot and cold water pressures. ABOVE DRAIN

Important: Heat cannot be applied to the water fittings

DRAIN LINE
on the heater as they may contain nonmetallic parts. If 1 INCH 3/4 INCH ID
MINIMUM
solder connections are used, solder the pipe to the MIN.
DRAIN
adapter before attaching the adapter to the hot and cold MASSACUHSETTS: INSTALL A
VACUUM RELIEF IN COLD WATER
water fittings. DRAIN PAN LINE PER SECTION 19 MGL 142.
2-1/2 INCH DEPTH MAX.
Important: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight. FIGURE 7
TEMPERING VALVE
1. Install the water piping and fittings as shown in the SIDE WATER CONNECTIONS
Figure 6. Connect the cold water supply (3/4 NPT) HOT
FOLLOW THE TEMPERING
to the fitting marked “C”. Connect the hot water VALVE’S MANUFACTURER’S WATER OUT
INSTALLATION INSTRUCTIONS
supply (3/4 NPT) to the fitting marked “H”.
Important: Some models may contain energy saving
TEMPERED WATER
heat traps to prevent the circulation of hot water within TO FIXTURES
the pipes. Do not remove these inserts. TEMPERING VALVE
SET TO 120° F MAXIMUM
2. The installation of unions in both the hot and cold
water supply lines are recommended for ease of
removing the water heater for service or replacement. COLD WATER IN

3. The manufacturer of this water heater recommends

installing a tempering valve in the domestic hot water FIGURE 8
line as shown in Figures 7 and 8. These valves reduce TEMPERING VALVE
the point-of-use temperature of the hot water by TOP WATER CONNECTIONS
mixing cold and hot water and are readily available. COLD
Contact a licensed plumber or the local plumbing FOLLOW THE TEMPERING
VALVE MANUFACTURER’S
WATER
INLET
authority. INSTRUCTIONS

4. If installing the water heater in a closed water system,

install a relief valve or expansion tank in the cold HOT
WATER
water line as specified under "Closed System/Thermal OUTLET
Expansion".
5. Install a shut off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.
6. Install a temperature and pressure relief valve and
discharge line in the opening marked "T & P RELIEF
VALVE". Install as specified under "Temperature and
Pressure Relief Valve." TEMPERED
WATER TO
FIXTURES
7. After piping has been properly connected to the water TEMPERING VALVE
(SET TO 120° F)
heater, open the nearest hot water faucet and allow
the tank to completely fill with water. To purge the
lines of any excess air and sediment, keep the hot
water faucet open for 3 minutes after a constant flow
of water is obtained. Close the faucet and check all
connections for leaks.

6
Please note the following: Temperature and Pressure
DO NOT install this water heater with iron piping. The Relief Valve
system should be installed only with new piping that
is suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. DO NOT use PVC water
piping.
WARNING
DO NOT use any pumps, valves, or fittings that are
not compatible with potable water.
DO NOT use valves that may cause excessive
restriction to water flow. Use full flow ball or gate
valves only.
DO NOT use 50/50 tin-lead solder (or any lead based Explosion Hazard
solder) in potable water lines. Use 95/5 tin-antimony
or other equivalent material.
If the temperature and pressure relief valve
is dripping or leaking, have a licensed
DO NOT tamper with the thermostat, heater elements, plumber repair it.
electrical connections, or temperature and pressure
relief valve. Tampering voids all warranties. Only Do not plug valve.
qualified technicians should service these components. Do not remove valve.
DO NOT use with piping that has been treated with Failure to follow these instructions can
chromate's, boiler seal, or other chemicals. result in death, or explosion.
DO NOT add any chemicals to the system piping
which will contaminate the potable water supply. FIGURE 9
TEMPERATURE AND PRESSURE
Closed System/Thermal Expansion RELIEF VALVE INSTALLATION
OPTIONAL LOCATION
SOME MODELS ONLY
Periodic discharge of the temperature and pressure TEMPERATURE AND
relief valve may be due to thermal expansion in a closed PRESSURE VALVE
water supply system. The water utility supply meter may
contain a check valve, backflow preventer or water
pressure reducing valve. This will create a closed water DISCHARGE LINE
3/4 INCH MIN.
system. During the heating cycle of the water heater, DO NOT CAP OR PLUG
the water expands causing pressure inside the water
heater to increase. This may cause the temperature
and pressure relief valve to discharge small quantities
of hot water. To prevent this from happening, there are DRAIN PAN
two recommendations: 6 INCH
MAXIMUM
1. Install a diaphragm-type expansion tank that is
suitable for potable water on the cold water supply
DRAIN
line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons
of stored water. For protection against excessive pressures and
temperatures, a temperature and pressure relief valve
2. Install a 125 PSI pressure relief valve in the cold must be installed in the opening marked “T & P RELIEF
water supply line. Make sure the discharge of VALVE” (See Figure 9).
this valve is directed to an open drain and
protected from freezing. Caution: To reduce the risk of excessive pressures and
temperatures in this water heater, install temperature
Contact the local water supplier or plumbing inspector and pressure relief protective equipment required by
for information on how to control this situation. Do not local codes, but no less than a combination temperature
plug the temperature and pressure relief valve. and pressure relief valve certified by a nationally
recognized testing laboratory that maintains periodic
inspection of the production of listed equipment or
materials, as meeting the requirements for Relief Valves
and Automatic Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22 - 1986. This valve must be marked
with the maximum set pressure not to exceed the marked
maximum working pressure of the water heater. Install
the valve into an opening provided and marked for this
purpose in the water heater, and orient it or provide
tubing so that any discharge from the valve exits only
within 6 inches above, or at any distance below, the
structural floor, and does not contact any live electrical
part. The discharge opening must not be blocked or
reduced in size under any circumstance.
7
 Important: Only a new temperature and pressure relief
valve should be used with your water heater. Do not use Installation Check List
an old or existing valve as it may be damaged or not
adequate for the working pressure of the new water Water Heater Location
heater. Do not place any valve between the relief valve
and the tank. · Centrally located with the water piping system.
The Temperature & Pressure Relief Valve: · Located indoors and in a vertical position. Protected
from freezing temperatures.
· Must not be in contact with any electrical part.
· Provisions made to protect the area from water
· Must be connected to an adequate discharge line. damage. Drain pan installed and piped to an
· Must not be rated higher than the working pressure adequate drain.
shown on the data plate of the water heater. · Sufficient room to service the water heater.
The Discharge Line:
Water System Piping
· Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in · Temperature and pressure relief valve properly
the discharge line. installed with a discharge line run to an open drain
· Must not be capped, blocked, plugged or contain and protected from freezing.
any valve between the relief valve and the end of · All piping properly installed and free of leaks.
the discharge line.
· Heater completely filled with water. (See Figure 2)
· Must terminate a maximum of 6 inches above a
· Closed system pressure buildup precautions
floor drain or external to the building.
installed.
· Must be capable of withstanding 250°F (121°C)
· Tempering valve installed per manufacturer’s
without distortion.
instructions.
· Must be installed to allow complete drainage of
both the valve and discharge line. Electrical Connections
Solar Installation · Wiring and connections comply with all applicable
codes.
If this water heater is used as a solar storage heater or
as a backup for the solar system, the water supply · Water heater and electrical supply are properly
temperatures to the water heater tank may be in excess grounded.
of 120°F. A tempering valve or other temperature limiting · Proper overload fuse or circuit breaker protection
valve must be installed in the water supply line to limit installed.
the supply temperature to 120°F.
Note: Solar water heating systems can often supply
water with temperatures exceeding 180°F and may result
in water heater malfunction.

8
OPERATING YOUR WATER HEATER
Before operating the water heater, perform the Water Temperature
following:
1. Make sure the water heater has been properly
Regulation
installed.
2. Completely fill the tank with water. (See Figure 2)
3. Apply power to the water heater only after the tank
WARNING
is completely filled with water.
4. Carefully read and understand the "Water
Temperature Regulation" section of this manual.
5. Adjust the thermostat to the desired temperature
setting as directed under "Adjusting the Thermostat/
High Limit Control".
Important: Do not attempt to operate this water heater
if the thermostat(s), or surrounding insulation has been
exposed to water in any way. Immediately call a qualified
service technician to inspect the water heater and replace Water temperature over 125°F can cause
any thermostat or insulation that has been exposed to severe burns instantly or death from
water. Do not attempt to repair these parts. Water heaters scalds.
subjected to flood conditions or any time the thermostat(s) Children, disabled and elderly are at
have been submerged in water require replacement of highest risk of being scalded.
the entire water heater.
See instructions manual before setting
Safety Shut-off temperature at water heater.
This water heater is designed to automatically shut-off Feel water before bathing or showering.
in the event that the water temperature exceeds 170°F Temperature limiting valves are available.
(77°C). A high limit control switch is used to shut off the
power to the elements if the water temperature exceeds The thermostat is adjusted to a temperature setting of
170°F (77°C). The high limit control can be reset by 120°F or lower when it is shipped from the factory.
firmly pushing in the red reset button located on the Water temperature can be regulated by adjusting the
thermostat. Follow the instructions under "Adjusting the thermostat to the preferred setting as shown in " Adjusting
Thermostat/High Limit Control" to properly reset the high the Thermostat/High limit Control." The preferred
limit control. starting point is 120°F. There is a hot water scald
potential if the thermostat is set too high.
Important: Adjusting the thermostat past 120°F on the
thermostat 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
During low demand periods when hot water is not being
used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs.
If hot water use is expected to be more than normal, a
higher thermostat setting may be required to meet the
increased demand.
When leaving your home for extended periods
(vacations, etc.) turn the thermostat to its lowest setting.
This will maintain the water at low temperatures with
minimum energy losses and prevent the tank from
freezing during cold weather.

9
 Adjusting the Thermostat/High Limit Control
This water heater is equipped with one or more adjustable temperature regulating thermostats and a manual reset
high limit control. The following procedures must be performed when changing the temperature of the stored water
or resetting the high limit control. Upper and lower thermostats must be adjusted to the same temperature.
Before attempting to adjust the thermostat, make sure you read and understand the section of "Water
Temperature Regulation". Any other adjustments must be made by qualified service personnel.
1. Shut-off the power to the water heater.
2. Remove the access cover(s) and fold the insulation outward and away from the thermostat(s). Do not
remove the plastic cover.
3. Using a screwdriver to adjust the thermostat pointer, set the thermostat(s) to the desired water temperature.
Be sure the RED reset button (High Limit Control) is properly set: push in firmly to reset.
4. Replace the insulation. Make sure the thermostat(s) are well covered. Replace the access cover(s).
5. Apply power to the water heater.

FIGURE 10 THERMOSTAT / HIGH LIMIT CONTROL

THERMOSTAT

OPTIONAL
DOOR
150°F 90°F

RED
125°F

RESET
BUTTON

ACCESS ACCESS
COVERS COVER

SCREW
SLOT
150°F

125°F
90°F

150°F 90°F
150°F 90°F

125°F

125°F

DOUBLE ELEMENT
HEATER THERMOSTAT SETTING SINGLE ELEMENT
AND ADJUSTMENT HEATER

10
Operation Conditions
Anode Rod/Water Odor Maintenance
Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank Temperature and Pressure
from corrosion and prolonging the life of the water heater.
Certain water conditions will cause a reaction between Relief Valve
this rod and the water. Once the anode is depleted, the
tank will start to corrode, eventually developing a leak.
The most common complaint associated with the anode
WARNING
rod is a “rotten egg smell” produced from the presence
of hydrogen sulfide gas dissolved in the water. Do not
remove this rod permanently as it will void any
warranties, stated or implied. The parts list includes
a special anode that can be ordered if water odor or
discoloration occurs. This rod may reduce but not eliminate
water odor problems. The water supply system may
require special filtration equipment from a water Explosion Hazard
conditioning company to successfully eliminate all water If the temperature and pressure relief valve
odor problems. is dripping or leaking, have a licensed
Artificially softened water is exceedingly corrosive plumber repair it.
because the process substitutes sodium ions for Do not plug valve.
magnesium and calcium ions. The use of a water softener
may decrease the life of the water heater tank. Do not remove valve.
The anode rod should be removed from the water heater Failure to follow these instructions can
tank every 3 years for inspection. If the rod is more than result in death, or explosion.
50% depleted, the anode rod should be replaced.
Manually operate the temperature and pressure relief
For replacing the anode, shut-off the power to the water valve at least once a year to make sure it is working
heater. Be sure the cold water supply to the heater is properly. To prevent water
turned off. Open the hot water faucet to depressurize damage, the valve must
the water tank. Drain out 5 gallons of water from the be properly connected to
drain valve at the bottom of the heater. Remove the a discharge line which
anode rod. See the "Repair Parts Illustration" for anode terminates at an adequate
rod location on page 15. drain.
Water Heater Sounds Standing clear of the
outlet (discharged water
During the normal operation of the water heater, sounds may be hot), slowly lift and
or noises may be heard. These noises are common and release the lever handle
may result from the following: on the temperature and
1. Normal expansion and contraction of metal parts pressure relief valve to allow the valve to operate freely
during periods of heat-up and cool-down. and return to its closed position. If the valve fails to
completely reset and continues to release water,
2. Sediment buildup in the tank bottom will create
immediately shut-off the electrical power and the cold
varying amounts of noise and may cause
water inlet valve and call a qualified service technician.
premature tank failure. Drain and flush the tank
as directed under “Draining and Flushing”.
Stacking
Stacking occurs when a series of short draws of hot
water (3 gallons or less) are taken from the water heater
tank. This causes increased cycling of the heater elements
and can result in increased water temperatures at the
hot water outlet. An anti-scald device is recommended
in the hot water supply line to reduce the risk of scald
injury.

11
Draining and Flushing Heating Element
The water heater should be drained if being shut down Replacement
during freezing temperatures. It is recommended that
the tank be drained, and flushed every 6 months to
remove sediment which may buildup during operation.
To drain the tank perform the following steps:
WARNING
Electrical Shock Hazard
1. Turn off the power to water heater.
Disconnect power before
2. Close the cold water inlet valve and open a nearby
hot water faucet.
servicing.
3. Connect a hose to the drain valve and terminate it
Replace all parts and panels
to an adequate drain. before operating.
Important: Drain hose should be rated for at least 200°F. Failure to do so can result in
If the drain hose does not have this rating, open the cold death or electrical shock.
water inlet valve and a nearby hot faucet until water is no Replacement heating elements must be of the same
longer hot. style and voltage/wattage rating as the ones presently
4. Open the water heater drain valve and the nearest in the water heater. This information can be found on
hot water faucet. Allow all the water to drain from the the flange or terminal block of the element or on the
tank. Flush the tank with water as needed to remove water heater data plate.
sediment. 1. Shut-off the electric power to the water heater.
5. Close the drain valve, refill the tank, and restore 2. Drain the water heater as directed under "Draining
power. and Flushing".
If the water heater is going to be shut down for an 3. Remove the access cover(s). Fold the insulation
extended period, the drain valve should be left open. outward and away from the heater element(s).
Remove the plastic thermostat cover from the
NOTE: When draining Table Top models, remove the screw thermostat(s) making sure to disengage the
securing the drain access cover. Remove the cover by pulling attachment point from the thermostat.
down and away from the water heater.
4. Disconnect the electric wires from the heating element
(Figure 13). Remove the screw-in elements by turning
the element counterclockwise with a 1-1/2 inch
socket wrench. Remove the existing gasket.
FIGURE 13

WIRES

ELEMENT

SCREWS

5. Clean the area where the gasket fits to the tank. If

you are replacing the bottom element, remove the
accumulated sediment on the bottom of the tank.
6. Make sure the replacement element has the correct
voltage and wattage rating. Position the new gasket
on the element and insert it into the water heater
tank (Figure 14). Tighten the element by turning it
clockwise until secure.

12
 FIGURE 14 9. Connect the electric wires to the heater element.
THERMOSTAT
Make sure the wires are secure. Replace the plastic
HOLDING
thermostat cover making sure the attachment points
BRACKET are engaged on the thermostat.
SCREW-IN
ELEMENT
10. Replace the access cover(s).
SPUD
11. Make certain the tank is filled with water. Applying
electric current to heater elements not submerged in
water will destroy them.
12. Restore the electric power supply to the water heater.
GASKET

7. Close the drain valve. Open the nearest hot water

faucet and allow the tank to fill completely with water.
To purge the lines of any excess air and sediment,
keep the hot water faucet open for 3 minutes after a
constant flow of water is obtained.
8. Check for leaks around the element(s).

TROUBLESHOOTING CHART
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
NO HOT WATER 1. No power to heater 1. Turn on electrical switch. Check for blown fuses or
2. High Temperature Limit Switch open tripped breaker
3. Defective upper thermostat 2. Reset. Check for source of trouble and correct
3. Replace thermostat
INSUFFICIENT HOT WATER 1. Defective thermostats 1. Replace thermostats
2. Defective lower element 2. Replace element
3. Improper calibration 3. Replace thermostats
4. Thermostats set too low 4. Set thermostats to desired temperature
5. Sediment or lime in tank 5. Drain. Determine if water treatment is needed
6. Heater too small for job 6. Install adequate water heater
7. Wrong piping connections 7. Correct piping
8. Leaking faucets 8. Repair faucets
9. Wasted hot water 9. Advise customer
10. Long runs of exposed pipe 10. Insulate piping
11. Hot water piping on outside wall 11. Insulate piping
HIGH OPERATION COSTS 1. Improper Calibration 1. Replace thermostats
2. Thermostats set too high 2. Set thermostat to desired setting
3. Sediment or lime in tank 3. Drain. Flush-Provide water treatment if needed
4. Heater too small for job 4. Install adequate heater
5. Wrong piping connections 5. Correct piping
6. Leaking faucets 6. Repair faucets
7. Wasted hot water 7. Advise customer
8. Long runs of exposed piping 8. Insulate piping
9. Hot water piping in exposed wall 9. Insulate piping
SLOW HOT WATER 1. Defective upper element 1. Replace element
RECOVERY 2. Defective lower element 2. Replace element
1. Use Pressure Reducing Valve and Pressure Relief
DRIP FROM RELIEF VALVE 1. Excessive water pressure Valve
2. Closed system 2. See page 7, "Closed System"

THERMOSTAT FAILS TO 1. Defective thermostats

2. Improper calibration 1. Replace thermostats
SHUT OFF 2. Replace thermostats
WATER ODOR 1. Sulfides in the water
1. See page 11, "Water Odor"

13
REPAIR PARTS ILLUSTRATION
ALTERNATE
7
T&P
LOCATION 13 TOP WATER
12
8
CONNECTIONS
9
8
11

10
6

5
3

14
5
4
17
2

18

TABLE TOP MODEL

8
7

13

11
16 6
2
3
5

6
5

4 14 10
15
2

14
REPAIR PARTS ILLUSTRATION
SIDE WATER CONNECTIONS

13 11

19

5
3
2
18
1 7

10

20
14
5
4

18

ITEM PARTS DESCRIPTION

REPAIR PARTS NO.
1 ACCESS DOORS
Repair parts may be ordered through your plumber, local 2 THERMOSTAT COVERS (UPPER & LOWER)
distributor, home improvement center, or by calling 1- 3 UPPER THERMOSTAT
800-999-9515. When ordering repair parts always give 4 LOWER THERMOSTAT
the following information: 5 ELEMENT
6 ELEMENT GASKET
1. Model, serial and product number 7 TEMPERATURE AND PRESSURE RELIEF VALVES
2. Item number 8 HEAT TRAPS
3. Parts description 9 DIP TUBE
10 HEAT TRAP/DIP TUBE COMBINATION
REPAIR PARTS LIST
11 ANODE ROD
LEGEND 12 HEAT TRAP/ANODE ROD COMBINATION
13 JUNCTION BOX COVER
Special anode rod (See page 11) 14 DRAIN VALVE
Temperature and Pressure Relief Valve is required, but may not 15 PANEL DRAIN ACCESS
be factory installed. 16 FRONT PANEL
17 TOP PANEL
Specify thermostat type when ordering.
18 INSULATION
Exclusive to the Table Top Water Heaters. 19 HEAT TRAP/J-TUBE COMBINATION
20 FLANGE

15
 THERMOSTAT WIRING DIAGRAM
FUSED DISCONNECT
OR CIRCUIT BREAKER FUSED DISCONNECT FUSED DISCONNECT

OPTIONAL OFF-PEAK
OR CIRCUIT BREAKER OR CIRCUIT BREAKER FUSED DISCONNECT

SERVICE CONTACT
OR CIRCUIT BREAKER FUSED DISCONNECT
L1 L2 OR CIRCUIT BREAKER
L1 L2 HOT NEUTRAL
L1 L2 L1 L2
L1 L2

UPPER
RED THERMOSTAT
BLACK

&

YELLOW
BLACK THERMOSTAT

RED
HIGH LIMIT & UPPER THERMOSTAT
CONTROL HIGH LIMIT BLACK WITH HIGH LIMIT

RED
WHITE
CONTROL BLACK THERMOSTAT CONTROL
&
HIGH LIMIT
CONTROL
UPPER THERMOSTAT 1 3 BLUE
WITH HIGH LIMIT
BLACK

CONTROL
2 4
1 3

BLACK
1 4

BLACK
RED
2 4

WHITE
2
1 YELLOW

BLUE
RED

RED
2 UPPER
BLUE

YELLOW ELEMENT
BLACK
BLACK
UPPER
UPPER BLACK ELEMENT LOWER THERMOSTAT
ELEMENT WITH HIGH LIMIT
LOWER THERMOSTAT CONTROL
HEATING WITH HIGH LIMIT
CONTROL
LOWER
ELEMENT 1
HEATING 1 3
BLUE

THERMOSTAT

RED
ELEMENT
2
ELECTRICAL 2 4
SERVICE 1
GROUND GROUND 1
SCREW
YELLOW ELECTRICAL 2

RED
SERVICE 2
GROUND GROUND
LOWER SCREW BLACK BLACK
ELEMENT
LOWER
ELEMENT
LOWER
6603461G

6603461H
ELEMENT
ELECTRICAL
SERVICE
ELECTRICAL
6603461F

GROUND GROUND WIRING NO. 7 WIRING NO. 1 ELECTRICAL

SCREW SERVICE

6610013
SINGLE ELEMENT HEATER SINGLE ELEMENT HEATER SERVICE GROUND GROUND
GROUND GROUND

6610009
SCREW SCREW
WIRING NO. 6
INTERLOCKING WIRING NO. 9 WIRING NO. 13
(NON-SIMULTANEOUS) WIRING DOUBLE ELEMENT NON- DOUBLE ELEMENT INTERLOCKING
FOR DOUBLE ELEMENT HEATER INTERLOCKING (SIMULTANEOUS) (NON-SIMULTANEOUS)

FUSED DISCONNECT FUSED DISCONNECT

OR CIRCUIT BREAKER
BRANCH CIRCUIT SIZING GUIDE
OR CIRCUIT BREAKER

L1 L2 L3
L1 L2 L3
Based on N.E.C. NFPA NO. 70 - 1999
Recommend Copper Wire Size
WATT Over Current AWG Based on
YELLOW

RED

Protection Rating N.E.C.

BLUE

YELLOW LOAD Table 310 - 16 (60°C)

UPPER THERMOSTAT
BLACK

UPPER THERMOSTAT
120 208 240 120 240
BLUE

WITH HIGH LIMIT

CONTROL
WITH HIGH LIMIT
CONTROL 208
V V V V V
BLACK

1 3
1 3 V
2 4 1500* 15 15 15 12 14 14
2 4
1 2000 20 15 15 10 14 14
1 4
2500 30 15 15 10 14 14
BLUE

2
BLUE

2
YELLOW
3000 30 20 15 8 12 12
YELLOW
UPPER
UPPER
ELEMENT 3500 - 20 20 - 10 12
ELEMENT

LOWER THERMOSTAT
4000 - 25 20 - 10 10
LOWER THERMOSTAT
WITH HIGH LIMIT
WITH HIGH LIMIT
CONTROL 4500 - 30 25 - 10 10
CONTROL

1
1 3 5000 - 30 30 - 10 10
2 4 5500 - 35 30 - 8 10
2
RED

1
1 6000 - 35 30 - 8 8
9000 - 50 45 - 6 6
RED

2
2
BLACK 12000 - 70 60 - 3 4
BLACK LOWER
LOWER
ELEMENT
ELEMENT * Wattages less than 1500 may be wired 14 gage with 15 amp
protection
ELECTRICAL
6600837

SERVICE
ELECTRICAL GROUND GROUND
SERVICE SCREW
6600838

GROUND GROUND
SCREW 3 PHASE BRANCH CIRCUIT
3 PHASE BRANCH CIRCUIT DOUBLE ELEMENT SIMULTANEOUS
DOUBLE ELEMENT
(NON-SIMULTANEOUS)

16