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DURAWATT
®
ELECTRIC WATER HEATER
PV500-6 09/07 6
START-UP PROCEDURES AND OPERATION
1. The tank must be full of water before turning on electricity. If elements are energized without water in the tank, they
will burn out immediately. Warranty is void on dry starts. Use multimeter to check resistance to ground between all
element terminals and the element mounting flange. (See table 1, page 10)
Fill the heater with water. Open the relief valve to allow air in the tank to escape. Be sure all connections into the tank
are tight as leaks at tank fittings or heating elements can cause damage.
Check inside of electrical enclosure for leaks with tank full of water at water line pressure. Heating element gaskets
are pressure tested at factory but may leak if unit has been in dry storage for a long period of time.
If leaks are present, tighten all four nuts uniformly on the element mounting flange in a criss-cross pattern. Tighten
one nut, then the nut on the diagonal from the first nut. Next, tighten the nut adjacent to the second nut, and then the
nut diagonal from the third nut. Repeat this sequence until all nuts are tight. Each nut should be tightened to 15 foot
pounds of torque. To avoid warping the flange, do not over tighten.
IMPORTANT: All leaks must be corrected prior to turning on electricity to avoid damage to electrical components
within the enclosure.
Electric element (design may vary): 3 phase elements have 3 terminals; 1 phase elements have 6 terminals
FIGURE 3
2. Check all electrical connections for tightness before turning the unit on.
3. Energize manual disconnect switch. Check for proper voltage (with voltmeter) on power circuit. Voltage should not
vary more than 5% from voltage shown on data plate. If voltage exceeds these limits, immediately turn off main
disconnect and contact utility company.
4. Energize control circuit switch. Check for proper voltage.
5. Check for proper amperage with ammeter on power circuit. Amperage should not vary more than 5%, when under full
load, from amperage shown on data plate. (Element Continuity Checks, page 10). If amperage exceeds these limits,
immediately turn off main manual disconnect and refer to Electric Water Heater Trouble Shooting Guide (page 14).
6. Check magnetic contactors for noise. If noisy, i.e., buzzing or chattering, turn off main power disconnect, disassemble
contactor and blow out foreign particles. Drill filings, dirt or other particles can cause pitting of points which will in turn
burn out contactor and/or wire. Extra care has been taken during fabrication and inspection for cleanliness; however,
field installation is often responsible for debris collecting on the contactor points.
7. The top thermostat is a temperature limiting safety device set at 200°F. The upper operating thermostat is factory set
at 130°F. The lower operating thermostat is set at 120°F Adjust stored water temperature by turning the Operating
thermostat dial to the desired temperature. The Upper Operating and Operating thermostats should be set minimum
10°F higher.