Marathon MR50245 Instructions / Assembly
Contents
1. No threads permitted on end of Drain Pipe 6 Maximum distance from drain pipe to suitable open drain Figure 3 Typical method of supporting relief valve drain pipe DRAIN PIPE FROM RELIEF VALVE Connect the outlet of the relief valve to a suitable open drain so that the discharge water cannot contact live electrical parts and to eliminate potential water damage check Local Codes regarding Relief Valve discharge methods Piping used should be of a type approved for hot water distribution The discharge line must be no smaller than the outlet of the valve and must pitch downward from the valve to allow complete drainage by gravity of the relief valve and dis charge line The end of the discharge line should not be threaded or con cealed and should be protected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line Following all of the above rules install the drain valve discharge piping using thread sealer on all male threads IMPORTANT Do not apply heat directly to the relief valve con nection If sweat connections are used sweat tubing to adapter before fitting adapter to relief valve on heater Any heat applied lo the relief valve will permanently damage it and or the tank Installation To prevent stress on the relief valve fitting which may damage the tank support the drain pipe using metal strapping or similar method to an over head2. can be described as a banging noise heard in a water pipe following an abrupt alteration of the flow with resulting pressure surges Strategically located risers in the water pipe system can be used to minimize the problem Also water hammer arresting devices are usual ly available from your plumber or local plumbing supply store 2 REPLACING THE TEMPERATURE amp PRESSURE RELIEF VALVE If the Temperature and Pressure Relief Valve should ever need replacing use only a valve specified by local codes but not less than a new combina tion temperature and pressure relief valve complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 The pressure rating of the relief valve must not exceed 150 PSI the maximum working pressure of the water heater as marked on the rating plate The BTUH Rating of the relief valve must not be less than the input rating of the water heater as indicated on the rating label located on front of the heater 1 watt 3 412 BTUH A CAUTION Before starting to replace the Temperature amp Pressure Relief Valve be sure to turn the power supply to the water heater OFF at the electrical distribution panel A With the power supply turned OFF close the shut off valve installed in the cold water supply pipe B Open a nearby hot water faucet and KEEP OPEN C Fasten a length of garden hose to the drain valve Place the other end of the
3. Main Fuse or d Panel Grounding Conductor Bare or Green Non Metallic Sheathed Cable with sepa rate grounding conductor Water Heater Junction Box Figure 5B Water heater field wiring connections using non metallic sheathed cable and separate grounding con ductor Grounding conductor must be attached to the ground terminal of water heater and the electrical distribution panel Installation The complete wiring schematic diagram for standard non local codes the latest edition of National Electrical Code ANSI NFPA 70 simultaneous operation units is shown below in Figure 6 The Specification Table supplied separately with the water heater recom From 240 V mends minimum branch circuit sizing based on National Electric Code Power Source The branch circuit wiring must include either A Metallic conduit or metallic sheathed cable approved for use as a grounding conductor and installed with fittings approved for the pur pose refer to Figure 5A B Non metallic sheathed cable or metallic conduit or metallic sheathed posed cable not approved for use as a ground conductor shall include a Separate conductor for grounding It should be attached to the ground High Limit terminals of the water heater and the electrical distribution box Refer Switch to Fig 5B Ta Be sure to follow local and national codes as well as any electric utility Thermostat requirements when making the connections CONNECTING THE WATER
4. lines should be protected from freezing temperatures Do not install the water heater in outdoor unprotected areas or near any other appliances where high temperature are present such as wood burning stoves boilers or furnaces High temperatures can warp or otherwise damage the non metallic construc tion of this water heater To open drain line should be at least ID and pitched for proper drainage A Diameter of water heater plus 2 min B Maximum 2 Figure 1 Auxiliary Drain Pan A CAUTION The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent to itor to lower floors of the structure Where such areas cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the water heater NOTE Auxiliary drain pan installation MUST conform to local codes Drain Pan Kits are available at your local retail outlet or service center RESTAURANT INSTALLATION If the water heater is to be installed in a restaurant or other location where NSF International listing is required it must be weather sealed to the floor a raised base or shelf so that seepage cannot accumulate under it or elevated to provide at least 6 inches of clearance from the floor In order to meet NSF International requirements for Standard 5 the base of the water heater must be sealed to the floor to prevent se
5. 2 thermostat insulation pads exposing the thermostat The plastic personnel protector should not be removed C With a small screwdriver adjust the thermostat setting This thermostat is marked LOW MED HI The 120 F factory set position the recom mended setting is at the 5 o clock position Refer to Figure 11 The temperature settings range from approximately 110 F LOW to approx imately 170 F HI The MED position results in approximate water tem perature of 140 F D Replace the two 2 pieces of fiberglass insulation over the thermostat and attach the thermostat access panel Temperature Adjustment Screw Shown at Factory Setting of approx 120 F J LOW setting equals approximately 110 F water temperature HI setting equals approxi mately 170 F water temperature Q MED setting equals approximately 140 F water temperature Figure 11 Upper Thermostat temperature adjustment E Replace the single piece of fiberglass insulation inside the thermostat access panel cover and snap in position NOTE It is important that the fiberglass insulation is replaced to maintain the water heater s high energy efficiency performance RESETTING THE LOWER THERMOSTAT It is recommended that any water temperature adjustment be made at the lower thermosta
6. Complete Wiring Schematic Diagram Non Simulta taneous Operation on separate Off Peak Meter neous Operation on separate Time Switch Installation Pipe Wrap Energy Kit Seal Tighty NOTE Do Not Cover or Block This E Opening on Vacuum Valve Figure 9 Pipe Wrap Energy Kit Limit Switch must be disconnected and replaced totally or discon nected and joined with a new section of wire using a proper con nector Be sure to follow all local and national codes and electric utility requirements when making the connections Dual element water heaters are designed to allow only one element to heat at a time This method is called non simultaneous operation and is neces sary to avoid overloading the wiring in the house per the National Electrical Code Off Peak wiring methods must insure proper use of the high limit control in at least one line to each element and the use of the non simulta neous feature A CAUTION Tank MUST BE full of water before power is turned on Heating ele ments WILL BE DAMAGED if energized for even a short time while tank is dry The water heater s warranty does not cover damage or failure resulting from operation with an empty or partially empty tank Refer to the limited warranty for complete terms and condi tions 8 PIPE WRAP ENERGY KIT A pipe wrap energy saving kit consisting of two lengths of foam insulation is included with this water heater To realize max
7. HEATER TO A TIME SWITCH OR OFF PEAK METER In some installations it may be desired or required by Upper Element j local utility regulations to connect the water heater to a Time Switch or Off Peak Meter Refer to Figure 7 or 8 below for complete wiring schematic diagram for standard non simultaneous operation units installed in con junction with these energy management devices Lower T Control Temes A WARNING Connecting the water heater to a Time Switch or Off Peak Meter requires splicing or complete replacement of internal wiring For this reason itis strongly recommended that this work be per Lower Element formed by a licensed electrician qualified appliance service per son or utility company representative IMPORTANT When connecting the water heater to a Time Switch or Off Peak Meter the Black wire from Terminal No 4 of the Figure 6 Complete Wiring Schematic Diagram Standard Non Simultaneous Operation From 240 V Power Source From 240 V Power Source Water Heater 4 From Time Clock Switch i l 4 High Limit Switch From Off Peak Meter Water Heater Junction Box High Limit Switch U pper Upper Temperature Control Thermostat Temperature Control Thermostat Upper Element Upper Element Lower Temperature Control Lower Thermostat Temperature Control Thermostat Lower Element Figure8 Complete Wiring Schematic Diagram Non Simul Figure 7
8. Off Valve d Union Vacuum Valve Ass y included with heater Seal Ring included with heater COLD Inlet Hex Union Nut Hot Water 7 Outlet lt dx 90 Elbow pe Union a 3 4 Female Coupling Extension Fitting included with heater Seal Ring included with heater COLD Inlet Hex Union Nut Cold Water Inlet Vacuum Valve Ass y included with heater Seal Ring included with heater HOT Outlet Hex Union Nut COLD Inlet Hex Union Nut CAUTION DO NOT SWEAT SOLDER DIRECTLY TO THE WATER HEATER HEX UNION NUTS AS SOLDERING See Temperature amp Pressure T amp P Relief Valve section for drain pipe installation details TORCH HEAT WILL DAMAGE THE WATER HEATER BEYOND REPAIR Figure 2 Typical installation methods using Water Heater Installation Kit top Soldered Copper or CPVC Pipe center or Threaded Pipe bottom Installation 3 WATER SUPPLY CONNECTIONS Refer to Fig 2 for suggested typical installation The installation of unions or flexible copper connectors is rec ommended on the hot and cold water connections so that the water heater may be easily disconnected for servicing if necessary The HOT and COLD water connections are clearly marked and are 3 4 NPT on all mod els Install a shut off valve in the cold water line near the water heater NOTE If the incoming water pressure is
9. disconnect the two wires from the element terminals See Figure 18 Yellow Wire Heating Element 1 7 8 Hex With wires removed from the element terminals remove the old ele ment by turning it counterclockwise O using a 17 wrench or socket J With a new gasket in place install and tighten the new element NOTE Be sure the gasket sealing surface is clean Wet the new gasket with water to lubricate and make a good seal K Close the water heater drain valve and completely fill tank with water Check the element for leaks Repairs any leaks as needed L Reconnect wiring to the terminals on the element see Figure 18 A WARNING Failure to properly tighten element terminal screws can cause a fire which can result in property damage bodily injury or death M Lower the hinged portion of the thermostat protective cover to cover the element and its wiring connections A WARNING Make sure the thermostat is flush against the thermostat mounting plate and the protective cover is in place before replacing the insu lation pads and access cover Failure to do so can result in proper ty damage bodily injury or death N Replace the two pieces of fiberglass insulation over the thermostat and attach the thermostat access panel Replace the single piece of insula tion in the thermostat access panel cover and snap it into position O Tum on the electrical power supply
10. hose at a floor drain or other suitable location See Figure 15 D Open the drain valve for about a minute or until the water level in the tank is below the relief valve AL DANGER DANGER The water drained from the tank may be hot enough to present a SCALD HAZARD and should be directed to a suitable drain to pre vent injury or damage E Remove the discharge pipe from the relief valve then remove the old relief valve see Figure 3 on pg 4 Use two wrenches one to hold the union hex nut on the heater and one to remove the relief valve NEVER use just one wrench Doing so can damage the tank beyond repair n Be sure a seal ring is inside the center relief valve union hex nut Use factory seal washers only DO NOT use sealants with seal ring wash ers Next turn the valve into the union fitting on the tank Face the relief valve outlet in a direction of the old valve Hold the valve in place and tighten the union hex nut IMPORTANT Do not apply heat directly to the relief valve con nection If sweat connections are used sweat tubing to adapter before fitting adapter to relief valve on heater Any heat applied to the relief valve will permanently damage it and or the tank G Install the discharge pipe to the new relief valve see Figure 3 on pg 4 H Open the cold water supply shut off valve When water from hot water faucet opened earlier runs smooth with no more air bubbles close the faucet Turn the e
11. to a suitable drain to pre vent injury or damage When preparing to place the water heater in service again be sure to com pletely fill the tank with water before turning the power on A CAUTION CAUTION Tank MUST BE full of water before power is turned on Heating ele ment s WILL BE DAMAGED if energized for even a short time while tank is dry The water heater s warranty does not cover dam age or failure resulting from operation with an empty or partially empty tank Reference is made to the limited warranty for com plete terms and conditions After a very long shut down period the water heater s operation and con trols should should be checked by a qualified service technician A WARNING If water heater has been subjected to flood fire or physical dam age turn off power and water to water heater Do not operate the water heater again until it has been thoroughly checked by quali fied service personnel Trouble Shooting Guide NATURE OF TROUBLE POSSIBLE CAUSE SERVICE Manual disconnect switch turned off Improper Wiring No Hot Water No Power blown fuse or circuit breaker tripped 8 Shorted wiring b Circuit overloaded c Improper wiring d Grounded element or thermostat Manual Reset High Limit Switch ECO open a Thermostat s defective Thermostat out of calibration Heat build up due to loose wires Defective High Limit Switch ECO Turn to ON Rewir
12. to bring the heater into service again A WARNING Tank MUST BE full of water before power is turned on Heating ele ment s WILL BE DAMAGED if energized for even a short time while tank is dry The water heater s warranty does not cover dam age or failure resulting from operation with an empty or partially empty tank Reference is made to the limited warranty for com plete terms and conditions Maintenance 4 VACATION AND LONG TIME SHUTDOWN If the water heater is installed where it could freeze summer cabin lake home etc you must drain all water from it and the piping If the tank is full of water and it freezes the tank will break Freeze damage is not covered by the warranty DRAINING THE WATER HEATER A CAUTION Always shut off power to water heater before draining water In order to drain water heater turn off the power supply then turn off cold water supply Next itis necessary to open a hot water faucet or lift the han dle on the relief valve to admit air to the tank and KEEP OPEN Attach a garden hose to the drain valve on the water heater and open the valve Direct the stream of water to a drain where it will do no damage See Fig ure 19 Drain Valve Floor Drain or other suitable drain ws AO Garden Hose Figure 19 Draining the Tank DANGER The water drained from the tank may be hot enough to present a SCALD HAZARD and should be directed
13. to support the tank In conclusion non metallic water heaters are designed and built to provide years of service Having them properly installed and accurately adjusted is essential if they are to perform reliably in the many challenging applications in which they are installed 2 WATER TEMPERATURE SETTING To comply with safety regulations the thermostats are factory set at 120 F or less where local codes require and is usually sufficient for most household needs Maximum water temperatures occur just after the elements have shut off To find out exact temperature of the water being delivered turn on a hot water faucet and allow it to run until maximum temperature is reached then insert a thermometer in the water stream and read the temperature Safety and energy conservation are factors to be considered when select ing the water temperature setting of the water heater s thermostats The lower the temperature setting the greater the safety and savings in energy and operating costs If a different temperature setting is desired read and follow the following warnings and instructions A DANGER There is a Hot Water SCALD Potential if the thermostat is set too high NOTE Households with small children or invalids may require a 120 F or lower thermostat setting to prevent con tact with HOT water Mixing valves for reducing point of use water temperature by mixing hot and cold water in branch water lines are avai
14. 15 A DANGER The water drained from the tank may be hot enough to present a SCALD HAZARD and should be directed to a suitable drain to pre vent injury or damage Drain Valve Floor Drain or other suitable drain y NOVO q NA Garden Hose Figure 15 Draining the Tank Maintenance Properly maintained your new non metallic water heater will provide years of dependable trouble free service It is suggested that a routine preventive main tenance program be established and followed by the user It is further recom mended that a periodic inspection of the operating controls heating element and wiring should be made by service personnel qualified in electric appliance repair 1 ROUTINE PREVENTATIVE MAINTENANCE A Most electrical appliances make some sound when in operation even when new If the hissing or singing sound level increases excessively the electric heating element may require cleaning Contact your installer or plumbing contractor to inspect B The area near the water heater must be kept free of flammable liquids such as gasoline or paint thinners adhesives or other combustible materials C Atleast once a year lift and release the lever handle on the tempera ture pressure relief valve located on top of the water heater to make certain the valve operates freely and allow several gallons to flush through discharge line see Figure 16 Make certain the discharged water is directed to an ope
15. Heater oci IPI PUR Y ES tele as was KR ROUEN NS P nce e OR Pe ER 5 Electrical Connections cuu x etate o Aa ett RU Ed xa khekes amp VM Mh RP orit Sa GR R5 5 Wiring Diagrams e Le 6 Pipe Wrap Energy Wit cig os eva e Epor DUO ERO ICE ES EEE SENI Qr oe VENCER EA EE NOU YR RERO 7 Installation Checklist et se ded vet resa ce toten sere d tene tire ec cus 7 Operation Safety PIeCalllOns 2 1 20 9 wnat RC deor ede iD RUMOR RETO Wace in ARR Ae SERO Saw ee EE aon 8 Thermal Performante icc 2 osea eder Om noe mcm c oO C cR cdi Db ol CE c UC Ro E I 8 Setting the Water Temperature ccc cece ete eee Hmmm rn 8 Safety Control Score eH etr ie weeny Een da eb p E une frr aad t ahead wae IRR nA 10 Emergency InstT clofis co oe reo afe Ro RN Ried Pa ERI Sb ae beh ee a SiC oe RC ae 10 Vacation and Long Time Shut Down ssssssseeeessseee III nn 10 Draining the Water Heater ook n EROR ROC Un E PON CI SORIA GO eat Uk CC FAQ aC E AGORRTUE ROUEN ET 10 Maintenance Routine Preventive Maintenance susesseseseeeen RII nn 11 Temperature and Pressure Relief Valve ccc cece cece eee cence IH 11 Heating Elements 2 6orruis Ihr ELEC rg X ERERY ARE Ee VEEREDERYX AYERWEREKKERAP RANK E EYE G 12 Trouble Shooting Guide 5 0e ya esr e Dee tb a donee notre ares a Tea E ed 13 Wiring Schematic Diagrams iio sects Ones ter token I xe EUExpE RP ER Far bote I tua DEM 6 Warranty i toketoate dieses ye BEAT etf beca biete a See Separate Supp
16. Non Metallic Electric Water Heater USE amp CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE INSTALLER Residential Electric Models INSTALLERS 1 Appliance Requires 30 105 Gallon Capacity ce say Carefully The purpose of this manual is twofold one for the installer to provide requirements and recommendations for the prop Recognize this symbol as an Indication of er installation and adjustment of the water heater and two Important Safety Information for the owner operator to explain the features operation safety precautions maintenance and trouble shooting of the water heater This manual also includes a parts list sup plement ad Do Not Destroy this Manual Please read It is imperative that MEERE who are expected to install carefully and keep in a safe place for maintain operate or adjust this water heater read the K iruenens carefully so that they may understand how to Future Reference 0 SO Table of Contents General Safety Precautions i030 seed an Eoex FREE Ure ba POCO aO UC EN neon ene Datus 1 liio Pere EXE 2 Installation Instructions Thermal EXPANSION ii ccd accio dira EXE X Ion e ec ra e x E a a cS x Go eb a cR d eod D e 2 Water Supply Connections i 515 vei roa wpR a ee Era icr ARR ER C PRESE psa e ERA dove E 4 Temperature and Pressure Relief Valve ccc cece cece eee I HH 4 Drain Valve i aid vit icces buta v bis qtd eso torem a cam dade dod Roues La irte ed e E RSS UA 4 Filling Water
17. close the faucet s Check all plumbing work for leaks and repair as necessary before proceeding with installation A WARNING Tank MUST BE full of water before power is turned on Heating ele ments WILL BE DAMAGED if energized for even a short time while tank is dry The water heater s warranty does not cover damage or failure resulting from operation with an empty or partially empty tank Reference is made to the limited warranty for complete terms and conditions Junction Box Cover Figure 4 Water heater junction box location 7 ELECTRICAL CONNECTIONS The water heater is completely wired to the junction box inside jacket at top front of water heater see Figure 4 An opening for a 12 or 4 electrical fitting is provided for field wiring connec tions A separate branch circuit with copper conductors overcurrent protec tive device and suitable disconnecting means must be provided by a quali fied electrician The voltage requirements and wattage load for the water heater is specified on the rating plate on front of heater Be certain that the Main Fuse or Circuit Breaker Panel Metallic Conduit or Metal Sheathed Cable and fittings approved for use as a ground ing conductor Water Heater Junction Box Figure 5A Water heater field wiring connections using metallic conduit or metallic sheathed cable approved for use as a grounding conductor and installed with fittings approved for the purpose
18. e per Wiring Diagram Replace fuse or reset breaker Replace or repair Provide adequate circuit or reduce load Rewire per diagram Replace Refer to Operation Section Replace Lower setting or replace Tighten wire connections Replace Heater undersized Defective Element s Miswired or defective thermostat causing only one element to work Not enough Hot Water Reduce rate of hot water use Check amperage replace element if low Check wiring or replace Water too hot or not hot enough Thermostat setting too high or low Thermostat out of calibration A CAUTION For your safety DO NOT attempt repair of Electrical Wiring Thermostat s Heating Elements or other Operating Controls Refer repairs to qualified personnel Change setting as required Replace continued service Trouble Shooting Guide cont d NATURE OF TROUBLE POSSIBLE CAUSE SERVICE Water too hot or not 3 Thermostat access panel s and or insulation not in place Inspect and replace as needed hot enough cont d 4 Thermostat s not resting tightly against mounting plate Inspect and insure that retaining spring s or mounting screws hold thermostat s tightly to mouting plates Noisy heating element s 1 Scale build up on elements Remove and clean Water Leaks 1 Loose connection between inlet outlet piping relief valve or Tighten hex nut union fitting drain valve and hex nut union on tank fitting
19. el A DANGER Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see manual TIME TEMPERATURE RELATIONSHIPS IN SCALDS Temperature Time to Produce Serious Burn 120 F More than 5 minutes 125 F 11 2 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 15F Less than 3 seconds 150 F About 11 2 seconds 155 F About 1 second Table courtesy of Shriners Burn Institute The chart shown above may be used as a guide in deter mining the proper water temperature for your home NOTE Households with small children disabled or elderly persons may require a 120 F or lower thermostat setting to prevent contact with HOT water The temperature of the water in the heater is regulated by the adjustable surface mounted thermostat s located behind the Jacket Access Panel s Dual element heaters have two thermostats To comply with safety regulations the thermostat s were set at 120 F before the water heater was shipped from the factory A DANGER There is a Hot Water SCALD Potential if the thermostat is set too high Mixing valves for reducing point of use water temperature by mixing
20. epage underneath Apply a 3 8 bead of RTV Silicone completely around the floor edge of the base of the tank Installation 1 INSPECT SHIPMENT Inspect water heater for possible damage Check the markings on the rating plate of the water heater to be certain the power supply corresponds to that for which the water heater is equipped 2 THERMAL EXPANSION Determine if a check valve exists in the inlet water line It may have been installed in the cold water line as a separate back flow preventer or it may be part of a pressure reducing valve water meter or water softener A check valve located in the cold water inlet line can cause what is referred to as a closed water system A cold water inlet line with no check valve or back flow prevention device is referred to 8s an open water system As water is heated it expands in volume and creates an increase in the pressure within the water system This action is referred to as thermal expansion In an open water system expanding water which exceeds the capacity of the water heater flows back into the city main where the pressure is easily dissipated A closed water system however prevents the expanding water from flowing back into the main supply line and the result of thermal expan Sion can create a rapid and dangerous pressure increase in the water heater and system piping This rapid pressure increase can quickly reach the safety setting of the relief valve causing it
21. ere is any difficulty in understanding or following the OPERATION or MAINTENANCE instructions it is recommended that a qualified person or serviceman perform the work 1 WATER TEMPERATURE SETTING AND THERMAL PERFORMANCE Water heaters see a wide range of applications Some of the most chal lenging are those involved in thermal storage tempering valves or large volumes of heated water used for cleaning and sanitizing Achieving satisfactory service from a water heater in these applications is Critical The solution is found in understanding the operation of the typical water heater In a dual element water heater the upper thermostat is given priority and will operate first when the tank is completely cold By operating first a small amount of hot water is available quickly When the upper ther mostat is satisfied the electrical current is switched to the lower thermostat As the lower element begins to heat the water above it energy heat is also being put into the water at the very top of the tank If the upper ther mostat is set at or very near its upper limit the temperature at the top of the tank can possibly be elevated to the point of tripping the T amp P valve or the Thermal Cut Out on the upper thermostat In either case the mecha nisms sense temperatures beyond the predetermined limit and activate to lower the temperature In other words they do their job Reliable performance can be achieved in most applications if the uppe
22. g valve must be used in any area used for washing or bathing and where access is available to the elderly or children We also recommend that the thermostats be set at the lowest possible setting to meet the appli cation Please refer Thermostat Setting section of this manual for additional information and recommendations A CAUTION CAUTION NEVER use this water heater unless it is completely full of water To prevent damage to the tank and heating elements the tank must be filled with water Water must flow from the hot water faucet s before turning power ON One other reminder is to be sure that the T amp P Valve is properly installed It is a plumbing code requirement in most parts of the country to plumb the T amp P Valve to discharge within six inches of the floor This is clearly described in the Installation section of this manual Failure to do this is not only a violation of the plumbing code but a safety hazard for anyone near the water heater in the event the T amp P discharges Not having the T amp P plumbed with a drain line also allows water to be potentially discharged onto the top of the water heater if the valve opens The consequence of this could be inaccurate temperature sensing by the thermostats if they are cooled by the discharged water as it evaporates Another negative result could be saturated insulation which would waste energy be the source of a high bill complaint and reduce the insulation s ability
23. hot and cold water in branch water lines are available Contact a licensed plumber or the local plumb ing authority for further information A WARNING After installing do not turn on or operate the water heater unless the temperature and pressure relief is in place and operating properly you have properly installed the drain pipe on the temperature and pressure relief valve the vac uum relief valve has been installed and you have com pletely filled the water heater with water WARNING HAZARD OF ELECTRICAL SHOCK Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Fail ure to do this could result in property damage bodily injury or death Introduction Thank you for buying your non metallic electric water heater Your new water heater is made of the latest materials and will not rust or corrode It will give many years of hot water service when installed operated and maintained according to the instructions in this manual Your water heater is completely assembled and ready to install This manual provides the general instructions for installation Because of several variables such as the installation location existing piping and local codes it is impossi ble to provide exact instructions for everyone s specific needs For this reason it is suggested that the entire manual be read prior to beginning any installation
24. imum energy savings all exposed pipes should be insulated However most of the energy losses occur close to the water heater This kit is designed to minimize this loss Install one piece of insulation on the cold water supply line and the other piece on the hot water line Refer to Figure 9 Install the pipe wrap as close to the water heater as the installation allows Make sure fittings are covered and the joint in the pipe wrap is sealed The water heater tank is insulated with 2 1 2 of foam insulation to stop heat loss More insulation is not needed DO NOT install an insulating blanket A CAUTION If local codes require external application of insulation blanket kits the manufacturer s instructions included with the kit must be care fully followed Application of any external insulation to this water heater will require careful attention to the following e Do not cover the temperature and pressure relief valve Do not cover jacket access panels to thermostats and heat ing elements e Do not cover electrical junction box of water heater Donotcover operating or warning labels attached to the water heater nor attempt to relocate them on exterior of insu lation blanket A WARNING The manufacturer s warranty does not cover any damage or defect caused by installation attachment or use of any type of energy saving or other unapproved devices other than those authorized by the manufacturer i
25. lable Contact a licensed plumber of the local plumbing authority for further information The following chart may be used as a guide in determining the proper water temperature for your home Operation TIME TEMPERATURE RELATIONSHIPS IN SCALDS Temperature Time to Produce Serious Burn More than 5 minutes 11 5 to 2 minutes About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 1 seconds About 1 second Table courtesy of Shriners Burn Institute RESETTING THE UPPER THERMOSTAT It is recommended that the upper thermostat remain at the factory setting for most normal applications All water temperature adjustments should be made at the lower thermo stat If your application requires adjustment of the upper thermostat it can be changed as follows DANGER Make certain power to water heater is OFF before removing jacket access panel s FOR ANY REASON Failure to do so could result in property damage bodily injury or death A Remove the upper thermostat snap in access panel cover Insert finger into latch hole on the bottom of the cover and push up to release the latch Then pull forward to remove the cover and insulation See figure 10 Access Panel Cover AN UJ Upper Thermostat Access Panel Cover Figure 10 Removing Upper Thermostat Access panel B Remove the four 4 screws securing the thermostat access panel and the two
26. lectric power on to place the water heater in service again A CAUTION Be sure the water heater is completely filled with water before turn ing on electric power Maintenance 3 HEATING ELEMENTS Most water supplies will cause scale or mineral deposits to form on the heating elements As the scale forms it gets increasingly harder for the element to heat water If you hear a rumbling noise coming from the water heater it is probably caused by scale build up on the elements Element life can be lengthened by installing a water softener or other water treating equipment that removes most of the minerals that cause scale TO REPLACE BURNED OUT ELEMENTS IMPORTANT The elements used in the lower element posi tion are different than those in the upper position It is important to note that STANDARD REPLACEMENT ELEMENTS WILL NOT FIT THIS WATER HEATER Proper replacement elements are available at your local retail outlet or service center Be sure to refer to parts illustration supplied with the heater for proper identification of replacement elements Care must be taken to insure that the correct element is being used The tank warranty may be voided if the wrong element is used A CAUTION Before starting to remove an Element be sure to turn the power supply to the water heater OFF at the electrical distribution panel A With the power supply turned OFF close the shut off valve installed in
27. lement Specifications 1h osi csciesbiated une Cos ete ah a a Co PU od See Separate Supplement Repair PANS 52545 Sac E E Grier d nel Ct be Ead LA See Separate Supplement Abbreviations found in this Instruction Manual U L Underwriters Laboratories 333 Pfingsten Rd Northbrook IL 60062 National Electrical Code This publication is available from your local government public library electric company or by writing to U L A N S I American National Standards Institute A S M E American Society of Mechanical Engineers A General Safety Precautions Be sure to read and understand the entire Use amp Care Manual before attempting to install or operate this water heater It may save you time and cost Pay particular attention to the General Safety Precautions Failure to follow these warnings could result in serious bodily injury or death Should you have problems understanding the instructions in this manual or have any questions STOP and get help from a qualified installer service technician or the local electric utility WATER TEMPERATURE ADJUSTMENT Safety and ener gy conservation are factors to be considered when select ing the water temperature setting of water heater s thermo stat Water temperatures above 125 F can cause severe burns or death from scalding Be sure to read and follow the warnings outlined on the label pictured below This label is also located on the water heater near the thermostat access pan
28. lling the vacuum relief valve and water inlet piping DO NOT use pipe sealant on this joint IMPORTANT DO NOT attempt to turn the pipe or extension piece after the hex union nuts are tightened Doing so will dam age the water heater beyond repair 4 RELIEF VALVE A relief valve is essential for safety and to protect the water heater Too high of a temperature and or pressure could cause the tank to burst The relief valve is designed to automatically open if tempera ture and or pressure reaches a pre determined point a temperature of 210 F or pressure of 150 PSI Anew combination temperature and pressure relief valve complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 has been factory installed in the opening provided and marked for the purpose on the water heater Refer to Figure 2 A WARNING DO NOT operate the water heater unless the Temperature and Pressure relief valve is installed properly and working correctly Doing so will result in an unsafe operating condition that can result in property damage bodily injury or death Temperature amp Pressure Support the relief valve drain pipe Relief Valve using metal strapping or wire fas tened to the structure overhead Seal Ring Hex Union Nut Relief Valve Union The addition of a union at this point will help in the replacement of the T amp P Relief Valve should the need arise
29. m the heater to accommodate final connection to supply piping The hex union fitting on the water heater can then be used to make the connection between the tank and the valve supply piping Remember to use the seal ring provided with the heater when re installing the vacuum valve and water inlet piping DO NOT use pipe sealant on this joint IMPORTANT DO NOT attempt to turn the pipe or fittings after the hex union nuts are tightened Doing so will damage the water heater beyond repair HOT WATER SUPPLY LINE FROM WATER HEATER The hot water outlet has a factory installed extension fitting Run the hot water supply line to the top of the extension fitting using the piping of choice for this installa tion as shown in Figure 2 IMPORTANT Do not apply heat directly to the extension fit ting If sweat connections are used sweat tubing to adapter before fitting adapter to extension fitting on heater Any heat applied to the extension fitting and hot water fittings will perma nently damage them and or the tank The connection between the extension fitting and the water heater uses a seal ring If unions are not used on the water supply lines the extension fitting can be removed from the heater to accommodate final connection to hot water supply piping The hex union fitting on the water heater can then be used to make the connection between the tank and the piping system Remember to use the seal ring provided with the heater when re insta
30. n drain Lift and release lever on T amp P Valve several times to be sure that it opens and operates freely Allow several gallons of water to flush through the discharge pipe Support Temperature amp Strap Pressure Relief Vale 2 p Figure 16 Manually Operating the Temperature and Pressure Relief Valve DANGER Before manually operating the relief valve make certain no one will be exposed to the danger of coming in contact with the hot water released by this valve The water may be hot enough to cre ate a SCALD hazard The water released should be directed to a suitable drain to prevent injury or damage NOTE If the temperature and pressure relief valve on the water heater discharges periodically this may be due to thermal expan sion in a Closed water system Contact the water supplier or your plumbing contractor on how to correct this DO NOT plug the relief valve outlet D A water heater s tank can act as a settling basin for solids sand silt dirt and mineral scale suspended in the water It is therefore not uncommon for these deposits to accumulate in the bottom of the tank It is suggested that a few quarts of water be drained from the water heater s tank ONCE EVERY MONTH to clean the tank of these deposits See Figure 15 E Rapid closing of faucets or solenoid valves in automatic water using appliances can cause a pounding water hammer sound Water hammer
31. ne protesctor SHOULD NOT be removed Press the RESET button see Figure 14 Replace insulation and jacket access panel s before turning on power to water heater 4 EMERGENCY INSTRUCTIONS A WARNING If water heater has been subjected to flood fire or physical dam age turn off power and water to water heater Do not operate the water heater again until it has been thoroughly checked by quali fied service personnel 5 VACATION AND LONG TIME SHUT DOWN If the water heater is to remain idle for an extended period of time the power and water to the water heater should be turned off to conserve energy The water heater and piping should be drained if they might be subjected to freezing temper atures After a very long shut down period the water heater s operation and con trols should be checked by qualified service personnel Make certain the water heater is completely filled before again placing it in operation 6 DRAINING THE WATER HEATER A CAUTION Always shut off power to water heater before draining water In order to drain water heater turn off the power supply then turn off cold water supply Next it is necessary to open a hot water faucet or lift the han dle on the relief valve to admit air to the tank and KEEP OPEN Attach a garden hose to the drain valve on the water heater and open the valve Direct the stream of water to a drain where it will do no damage See Fig ure
32. nto onto or in conjunction with the water heater The use of unauthorized energy saving devices may short en the life of the water heater and may endanger life and property The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices Installation Check List A Water Heater Location Ul Close to area of heated water demand U Indoors and protected from freezing temperatures U Area free of flammable vapors LL Provisions made to protect area from water damage LJ Sufficient room to service water heater B Water Supply LJ Water heater completely filled with water L Water heater and piping air vented U Water connections tight and free of leaks Model No Serial No C Relief Valve M Temperature and Pressure Relief Valve properly installed and discharge line run to open drain M Discharge line protected from freezing D Wiring LJ Power supply voltage agrees with water heater rating plate U Branch circuit wire and fusing or circuit breaker of prop er size LL Electrical connections tight and unit properly grounded Date of Installation Installed By Operation SAFETY PRECAUTIONS Do turn off power to water heater if it has been subjected to over heating fire flood or physical damage Do Not turn on water heater unless it is completely filled with water DoNot turn on water heater if cold water supply shut off valve is closed If th
33. on over the thermostat and attach the thermostat access panel E Replace the single piece of fiberglass insulation inside the thermostat access panel cover and snap in position NOTE It is important that the fiberglass insulation is replaced to maintain the water heater s high energy efficiency performance 3 SAFETY CONTROLS The water heater is equipped with a combination Thermostat and High Temperature Limit Switch that is located above the upper heating element If for any reason the water temperature becomes excessively high the Limit Switch breaks the power circuit to the heating element Once the control opens it must be reset manually Limit Switch Located at Upper Element on Dou ble Element Models Temperature Adjustment Screw Shown at Factory Setting of prox 120 F 4 O Figure 14 Upper Thermostat amp High Limit Switch 10 A CAUTION The cause of the High Temperature Condition must be investigated by qualified service personnel and corrective action taken before placing the water heater in service again To reset High Limit Switch turn off power to water heater remove upper jacket access panel and insulation and the access panel and insulation to expose the Thermostat and High Limit Switch Refer to Figure 10 The plastic person
34. over 80 PSI be sure to install a pressure reducing valve water pressure regulator somewhere in the inlet water line upstream of the water heater COLD WATER SUPPLY LINE TO HEATER The cold water inlet has a factory installed vacuum relief valve in it Refer to Figure 2 Certain condi tions such as a break in the main water supply line pump failure on a well system or other plumbing system malfunctions could produce a vacuum or negative pressure in the water heater s tank The vacuum relief valve pro vides a means to eliminate the negative pressure or vacuum in the event of such a failure by admitting air into the tank to equalize the pressure NOTE DO NOT remove the vacuum valve for any reason Doing so will void the manufacturer s warranty Run the cold water supply line to the top of the vacuum valve using the pip ing of choice for this installation as shown in Figure 2 Be sure to install a shut off valve not supplied with the heater in the cold water line near the water heater IMPORTANT Do not apply heat directly to the vacuum valve connection If sweat connections are used sweat tubing to adapter before fitting adapter to vacuum valve on heater Any heat applied to the vacuum relief valve and cold water fittings will permanently damage them and or the tank The connection between the vacuum valve and the water heater uses a seal ring If unions are not used on the water supply lines the vacuum valve can be removed fro
35. point Refer to Figure 3 for typical strapping method NOTE Local codes shall govern the installation of relief valves If the Temperature and Pressure Relief Valve should ever need replacing use only a valve specified by local codes but not less than a new combina tion temperature and pressure relief valve complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 The pressure rating of the relief valve must not exceed 150 PSI the maximum working pressure of the water heater as marked on the rating plate The BTUH Rating of the relief valve must not be less than the input rating of the water heater as indicated on the rating label located on front of the heater 1 watt 3 412 BTUH 5 DRAIN VALVE The drain valve is factory installed If required to face the drain valve outlet in a different direction loosen the union hex nut posi tion drain valve outlet as desired and retighten union hex nut NOTE DO NOT attempt to turn the drain valve without first loosen ing the union hex nut Doing so could damage the water heater beyond repair 6 TOFILL WATER HEATER Make certain drain valve is completely closed Open shut off valve in cold water supply line Open each hot water faucet slowly to allow air to vent from the water heater and piping A steady flow of water from the hot water faucet s indicates a full water heater When the water heater is completely filled
36. r thermostat is left at the factory set temperature of 120 F During heavy water usage the upper thermostat will provide a limited amount of hot water quickly The temperature of this water at the factory set temperature will satisfy most household needs After the upper thermostat is satisfied the lower thermostat will then heat all of the water in the tank to it desired setting This temperature setting method will not increase the total heating time or reduce the final temperature of the water in the tank For normal applications it is recommended that the upper thermostat be left at the fac tory set temperature of 120 F and all water temperature adjustments be made at the lower thermostat only If an application requires adjustment of the upper thermostat it can be adjusted by following the instructions in the Resetting the Thermostat section later in this manual To achieve the most consistent operation have the upper thermostat adjusted 10 to 15 degrees below the setting of the lower thermostat This will reduce the stacking effect inside the water heater but will still allow the water heater to produce water at the desired temperature Caution is important in installations where very high water temperatures are needed for a required application Water at high temperatures can quickly cause severe scalding especially in children or elderly people It is strongly recommended that great care be taken to prevent scalding A tem perin
37. s 2 Damaged seal ring washer Replace seal rings as required 3 Gasket around heating element s Inspect and replace gasket if needed A CAUTION For your safety DO NOT attempt repair of Electrical Wiring Thermostat s Heating Elements or other Operating Controls Refer repairs to qualified service NOTICE FOR INSTALLATIONS IN THE STATE OF CALIFORNIA California Law requires that residential water heaters must be braced anchored or strapped to resist falling or horizontal displacement due to earthquake motions For residential water heaters up to 52 gallon capacity a brochure with generic earthquake bracing instructions can be obtained from OFFICE OF THE STATE ARCHITECT 400 P Street Sacramento CA 95814 Telephone 916 324 5315 or ask a water heater dealer However applicable Local Codes shall govern installations For residential water heaters of capacity greater than 52 gallons consult the local building jurisdiction for acceptable bracing installa tions CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Water Heater Innovations Inc 3107 Sibley Memorial Highway Eagan Minnesota 55121 Phone 651 688 8827 FAX 651 688 6615 A i Subsidiary Printed in USA SP213270 04 04
38. t only If your application requires adjustment of the lower thermostat it can be changed as follows 7 DANGER Make certain power to water heater is OFF before removing jacket access panel s FOR ANY REASON Failure to do so could result in property damage bodily injury or death A Remove the lower thermostat snap in access panel cover Insert finger into latch hole on the bottom of the cover and push up to release the latch Then pull forward to remove the cover and insulation See Figure 12 Thermostat Insulation 2 Access Panel Cover NOV Lower Thermostat Access Panel Cover Thermostat Access Panel ncc eed L J Latch Hole Figure 12 Removing Lower Thermostat Access panel Operation B Remove the four 4 screws securing the thermostat access panel and the two 2 thermostat insulation pads exposing the thermostat The plastic personnel protector should not be removed C With a small screwdriver adjust the thermostat setting This thermostat is marked in degrees from 110 F to 170 F The thermostat is factory set to the 120 F position the recommended setting Refer to Figure 13 Temperature Adjustment Screw Shown at Factory Setting of approx 120 F 2 U 160 150 440 130 Figure 13 Lower Thermostat temperature adjustment D Replace the two 2 pieces of fiberglass insulati
39. the cold water supply pipe B Open a nearby hot water faucet and KEEP OPEN C Fasten a length of garden hose to the drain valve Place the other end of the hose at a floor drain or other suitable location See Flg 15 D Open the drain valve and drain the heater until the water level in the tank is below the element needing replacement 7 DANGER The water drained from the tank may be hot enough to present a SCALD HAZARD and should be directed to a suitable drain to pre vent injury or damage E Close the drain valve and remove the hose F Remove the thermostat snap in access panel cover Insert finger into latch hole on the bottom of the cover and push up to release the latch Then pull forward to remove the cover and insulation Remove the four 4 screws securing the thermostat access panel and the two 2 ther mostat insulation pads exposing the thermostat See Figure 17 Thermostat Insulation 2 l 2 UT L s J E ee Latch Hole Access Panel Cover Access Panel Cover Insulation Figure 17 Removing Access panel for replacement of element 12 G To expose the element for removal lift up the hinged portion of the ther mostat protective cover by gently pulling the lower corners up and away from the thermostat Be careful to avoid pulling the thermostat from its mounting bracket or bending the thermostat bracket H After again insuring that the electrical power is off
40. to operate during each heating cycle Thermal expansion and the resulting rapid and repeated expansion and contraction of components in the water heater and piping system can cause premature failure of the relief valve and possibly the heater itself Replacing the relief valve will not correct the problem The suggested method of controlling thermal expansion is to install an expansion tank in the cold water line between the water heater and the check valve The expansion tank is designed with an air cushion built in that compresses as the system pressure increases thereby relieving the over pressure condition and eliminating the repeated operation of the relief valve Other methods of controlling thermal expansion are also available Contact your installing contractor water supplier or plumbing inspector for additional information regarding this subject Installation WATER HEATER Hot Water Cold Water Flexible Connector Extension Fitting Seal Ring included with heater HOT Outlet Hex Union Nut Hot Water Outlet f 3 4 Adaptor Sweat X Female Pipe Outlet f Inlet T amp P Relief Valve We iE Extension Fitting included with heater Seal Ring Cold Water Inlet included with heater HOT Outlet Hex Union Nut Hot Water Outlet 3 4 Female Co
41. upling Extension Fitting included with heater _ Seal Ring included with heater Cold Water Inlet HOT Outlet Hex Union Nut INSTALLATION KIT Flexible Connector Vacuum Valve Ass y included with heater Seal Ring included with heater COLD Inlet Hex Union Nut included with heater included with heater Hot Water Outlet A 90 Elbow CJ Flexible Connector Extension Fitting Seal Ring Cold Water lt kinet 90 Elbow ea Flexible Connector Vacuum Valve Ass y included with heater Seal Ring included with heater HOT Outlet Hex Union Nut SOLDERED COPPER OR CPVC PLASTIC PIPE Union 3 4 Adaptor Sweat x Male Pipe Vacuum Valve Ass y included with heater included with heater COLD Inlet Dp Hex Union Nut Hot Water Outlet U 90 Elbow Union ee 3 4 Adaptor Sweat X Female Pipe Ss Extension Fitting included with heater Seal Ring COLD Inlet Hex Union Nut Shut Off Valve Cold Water Inlet 90 Elbow d Union 3 4 Adaptor Sweat x Male Pipe Vacuum Valve Ass y included with heater Seal Ring included with heater included with heater HOT Outlet Hex Union Nut THREADED PIPE Shut
42. work then carefully plan the installation This can help to avoid costly mistakes including damage to the water heater not covered under terms of the warranty Almost all new products automobiles boats clothing plastic and wood items etc have an odor or smell to them for a time This water heater may also have anew smell or odor to it due to the non metallic materials used in the manu facturing process This new smell is not harmful and will disappear in a short time The vacuum valve which must be used when installing the water heater is factory installed The location chosen for the water heater must take into consideration the fol lowing LOCAL INSTALLATION REGULATIONS This water heater must be installed in accordance with these instructions local codes utility company requirements or in the absence of local codes the latest edition of the National Electrical Code It is available from some local libraries or can be purchased from the National Fire Prevention Association Batterymarch Park Quincy MA 02269 as booklet ANSI NFPA 70 LOCATION Locate the water heater in a clean dry area as near as practical to the area of greatest heated water demand Long uninsulated hot water lines can waste energy and water Place the water heater in such a manner that the thermostat and element access panels can be removed to permit inspection and servicing such as removal of elements or checking controls The water heater and water
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