OPERATING AND MAINTENANCE MANUAL FOR
MARINE ELECTRIC WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ MSE ”
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TABLE OF CONTENTS
SECTION TITLE
PAGE #
I
II
GENERAL DESCRIPTION AND CONSTRUCTION
INSTALLATION
5
10
14
16
18
26
28
III
IV
V
SCHEDULED MAINTENANCE AND OPERATION
TROUBLESHOOTING
SERVICING AND REPLACEMENT OF PARTS
MISCELLANEOUS CHARTS AND FORMULAS
ABS TYPE APPROVAL PROGRAM
VI
VII
3
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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This book describes a packaged electric water heater, approved by ABS Americas (A Division of the
American Bureau of Shipping) and the USCG (United States Coast Guard), which is a stationary, self
contained unit and is designed and constructed specifically for marine applications on board a surface
vessel. The complete assembly consists of the storage tank, immersion electric heating element(s),
thermostat, safety relief valve, safety high temperature cut out, magnetic contactor(s), and any other
required electrical operating control. Optional equipment may be supplied with your unit. Please
consult the product drawing for details specific to your assembly. The unit is factory assembled,
insulated, jacketed, wired, tested, and ready for electrical and plumbing service connections.
CONSTRUCTION
TANK
Standard Tank Construction:
The standard storage tank is constructed of steel and internally lined with specially formulated
Hydrastone cement to a ½-inch minimum thickness. The tank is designed for a maximum allowable
working pressure of 100 psi (150 psi TP).
Optional Tank Construction:
Optionally, the storage tank may be constructed of all welded solid copper-silicon alloy (ASTM B-96)
or type 316L stainless steel for maximum tank longevity. For these options, no internal lining is
required due to the non-ferrous materials used in the construction of the pressure vessel. The tank is
designed for a maximum allowable working pressure of 100 psi (150 psi TP).
TANK CONNECTIONS
The heater is supplied with separate cold water and hot water connections. Water entering the cold
water inlet is deflected by means of a baffle within the tank. The hot water outlet includes a built in heat
trap to prevent hot water from radiating out from the heater. A ¾-inch FNPT connection is located on
the side of the heater for mounting a combination safety temperature and pressure relief valve. An
overflow line should be installed from the relief valve outlet to a floor drain. A ¾-inch GHT connection
is supplied for draining. See drawing for locations and sizes.
HEATING ELEMENT
The water heater is supplied with an electric immersion heating element assembly(s), composed of
incoloy sheathed elements that are brazed into a brass flange. Each assembly is fastened to a
corresponding tank flange using a gasket and four (4) 3/8-16 x 1-inch long hex head steel bolts and
nuts. See drawing for voltage and power ratings.
5
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CONTROL THERMOSTAT
The water heater is supplied with either a surface mounted or immersion thermostatic switch that is
installed and wired at the factory. See drawing for specific details. The surface mounted thermostat can
be adjusted through a range of 110° - 170° F. The immersion thermostat can be adjusted through a
range of 100° - 190° F. Both thermostats are adjustable with a flat tip screwdriver.
Surface Mounted Thermostat
Immersion Thermostat
TEMPERATURE HIGH LIMIT SWITCH
As a safety device, either a surface mounted high temperature cut-off switch with manual reset, factory
set at 190° F, or an immersion high temperature cut-off switch with manual reset, factory set at 180° F,
is provided. In the event of an over-temperature condition, the thermostat will disengage the operating
coils in the magnetic contactor(s). The high limit must be manually reset thereafter to restart the heater.
Manual Reset
Surface Mounted High
Temperature Cut-Off Switch
Immersion High Temperature Cut-Off Switch
6
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MAGNETIC CONTACTOR
The magnetic contactor(s) is a heavy-duty resistive load type rated for 100,000 cycles. The contactor
supplies power to the heating element(s) and is sized based on the resistive load(non-inductive) rating
of the circuit. The contactor supplies power only when the thermostatic switch is engaged, thereby
pulling in the contacts until the desired temperature is reached. At this point, the contacts will drop
out, which in turn disconnects power from the elements.
OUTER SHELL AND INSULATION
The tank is encapsulated in 2-inch thick polyurethane foam insulation. The insulation is protected by a
high impact non-corroding colorized composite protective jacket.
OPTIONS
The following optional features may be included in your water heater. Reference included drawing
specific to your heater for further details.
Low Water Cut-Off
Used as a safety device, the electronic low water cut-off is
used to detect a low water situation and disengage the
operating coils in the magnetic contactor(s). Once the
condition is remedied, the low water cut-off switch is
automatically reset.
Low Water Cut-Off Probe
Low Water Cut-Off Relay
7
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Fused Low Voltage Transformer
A fused low voltage transformer may be supplied. This option is used to step down higher voltages to
120-volt for the control circuit.
Dial Temperature and Pressure Gauge
A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge with 2½-inch dial may be
supplied for in-line installation (shipped loose) or factory installed in the tank.
Vacuum Relief Valve
A vacuum relief valve may be provided with the unit to reduce the risk of back siphonage and back
pressure of the system. The valve will be shipped loose for in-line installation. Instructions for
installation are provided with the valve.
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On/Off Switch
A built-in non-fused On/Off disconnect switch may be supplied with the control panel to disconnect
power to the control panel control and power circuit wiring.
Individually Fused Elements
To prevent the possibility of damage to circuits and elements in case of electrical overloads, fuses may
be supplied for each circuit. Two types of fuses may be used; a type NON for voltages less than 250-
volt or type JJS for voltages less than 600-volt.
Type JJS
Type NON
Built-in Circuit Breaker
A built-in circuit breaker may be provided with or without shunt trip protection for protection from
circuit overload.
Electro-Mechanical Timer
An electro-mechanical 7-day time clock with battery back-up may be supplied for specific timing
operations. A set of instructions will be supplied with the timer.
9
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SECTION II – INSTALLATION
WARNING / CAUTION
DO NOT TURN ON THE ELECTRIC POWER SUPPLY to this equipment until heater is
completely filled with water and all air has been released. If the heater is NOT filled with water when
the power is turned on, the heating elements will burn out.
For protection against excessive pressures and temperatures, code requires the installation of a
temperature-and-pressure (T&P) relief valve certified by a nationally recognized laboratory that
maintains periodic inspection of production of listed equipment of materials, as meeting the
requirements for Relief Valves and Automatic Gas Shutoff for Hot Water Supply Systems. ANSI
Z21.22-1971. THE CUSTOMER IS RESPONSIBLE TO PROTECT PROPERTY AND
PERSONNEL FROM HARM WHEN THE VALVE FUNCTIONS.
All water heaters have a risk of leakage at some unpredictable time. IT IS THE CUSTOMER'S
RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER ADEQUATE MEANS, SO THAT
THE RESULTANT FLOW OF WATER WILL NOT DAMAGE PROPERTY.
WATER HEATER PLACEMENT
1. Place the heater on a solid foundation in a clean, dry location nearest to the point of most
frequent hot water use.
2. The water heater should be protected from freezing and waterlines insulated to reduce energy
and water waste.
3. Leave a minimum of 18” clearance for element withdrawal, if necessary.
4. Do not install in an area where flammable liquids or combustible vapors are present.
SECURING OF HEATER
1. The heater is supported by four 2-inch x 2-inch x ¼-inch thick angle iron legs each with a 3-
inch x 3-inch x ¼-inch thick steel base pad. Each leg is provided with one 9/16-inch diameter
bolt hole for one ½-inch bolt which should be used to secure heater to the deck.
2. In addition to the leg supports, two 3-inch x 3-inch x ¼-inch thick brackets with 7/8-inch
diameter mounting holes are attached to the upper portion of the heater. These brackets should
be attached to bulkhead secured tie-rods thus insuring further support of the heater for
shipboard installation.
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Mounting Dimensions
Tank
Diameter
“A”
16
Overall
Diameter
“B”
20
Bolt
Circle
“C”
12
12
12
Bulkhead Mounting
Gallon
Capacity
Dimension
“D”
None
None
None
12
10
20
30
16
16
16
20
20
20
12
40
18 3/4
22
22 3/4
26
16
16
12
12
50
65
22
26
16
12
80
24
24
28
28
18
18
12
12
100
120
11
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PIPING INSTALLATION
NOTE: The most effective means for preventing deterioration from accelerated corrosion due to
galvanic and stray current is the installation of dielectric fittings/unions. The installation of these
fittings is the responsibility of the installing contractor.
1. Connect the cold water inlet and hot water outlet to the appropriate connections as shown;
refer to the drawing for location and sizes.
2. Install in-line vacuum breaker, if supplied.
3. Install in-line pressure and temperature gauge, if supplied.
4. Install the combination temperature and pressure safety relief valve in the tapping provided.
Note that this is required by law for safety considerations.
Outlet to floor drain
Install into provided tapping
Manual Release
Lever
Temperature Probe
Temperature and Pressure Relief Valve
5. Install a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of any type
should be installed between the relief valve and tank or in the drain line.
FILLING THE HEATER
1. Completely close the drain valve.
2. Open the highest hot water faucet to allow all air to escape from piping.
3. Open the valve to the cold water inlet and allow the heater and piping system to completely
fill, as indicated by a steady flow of water from the open faucet.
12
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ELECTRICAL INSTALLATION
1. Enter electric enclosure with properly sized feeder leads. Be sure to properly ground the
water heater.
2. Install these power leads into the box lugs on the terminal block or magnetic contactor.
3. Torque screws per torque chart included in Section VI.
4. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed
3. After the water is heated for the first time, monitor the water temperature as described in
Section III, Quarterly Inspection.
13
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SECTION III - SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before performing any maintenance procedure, make certain power supply is OFF and cannot
accidentally be turned on.
MAINTENANCE AND OPERATION
The water heater is automatic in its operation. It will maintain a full tank of water at the temperature
setting of the thermostat. The water heater should not be turned on without first making sure that the
tank is full of water and that all air has been released.
FREEZING
The tank should be fully drained in the event the electricity has been turned off and if there is danger
of freezing.
QUARTERLY INSPECTION
1. Monitor thermostat
a. Let water heater completely heat to a designated thermostat setting.
b. After thermostat satisfies (that is, when the thermostat actually clicks off), draw water from
heater.
c. Compare water temperature of drawn water to the temperature setting of the thermostat when
it satisfies. Normal variation between the two points is approximately + 5°F.
d. If these two readings do not coincide within acceptable tolerances and verification has been
made of the accuracy of the temperature-reading gauge, replace the thermostat.
2. Lift test lever on relief valve and let water run through valve for a period of approximately 10
seconds. This will help flush away any sediment that might build up in water passageways.
3. Inspect element flange for leakage as follows:
a. Shut off Power Supply.
b. Remove element housing cover.
c. Visually inspect heating element gasket for evidence of leaks.
d. Rub finger around gasket that is between the heating element and tank flange for any
evidence of moisture. If moisture is present or a water drip is observed, follow procedure
outlined in Section V.
4. Check for loose electrical connections. Tighten as necessary.
14
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ANNUAL INSPECTION
1. Flush tank as follows
a. Shut off power supply.
b. Close valve on hot water outlet piping.
c. Open valve on drain piping.
d. Cold water inlet line pressure will be strong enough to flush sediment from the bottom of the
tank out through the drain. Let water run for 3-4 minutes.
e. Close drain valve.
f. Open hot water valve.
g. Turn power supply ON.
15
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SECTION IV – TROUBLESHOOTING
Symptom
No hot water
Probable Cause
Circuit breaker tripped at
source.
On/Off switch in ‘OFF’
position, if installed.
Circuit breaker at control
cabinet tripped, if installed.
Blown fuse in element fuse
block, if installed.
Corrective Action / Remedy
Reset circuit breaker.
Turn switch to ‘ON’ position.
Reset circuit breaker.
Replace fuse.
Blown fuse in transformer, if
installed.
Replace fuse.
High limit switch tripped.
Reset high limit switch.
Loose wires.
Tighten wires. Torque screws per
torque chart included in Section
VI.
Heating element inoperable.
Check heating element operation
by clamping an Amprobe around
each wire to the element. The
ampere reading should agree with
the nameplate ‘AMP’ figure.
Have source electrical system
checked by an electrician.
Move thermostat dial through full
range. A definite ‘click’ should be
heard. If not, replace thermostat.
Check to see if tank is full of
water. If not, fill tank. If problem
continues and tank is full, check
for continuity between the
Low line voltage.
Faulty thermostat.
Faulty low water cut-off, if
installed.
common and normally open
contact of the relay board. If
continuity is not observed, replace
low water cut-off.
Magnetic contactor does not
energize.
Replace complete magnetic
contactor. Because of the design
of this particular contactor, it is
more desirable to replace complete
control rather than rebuilding coil,
contacts and springs, etc.
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Water temperature below
settings at all times
Faulty thermostat.
Check thermostat adjustment.
Monitor thermostat as described in
Section III, Quarterly Inspection.
Replace if necessary.
Blown fuse in element fuse
block, if installed.
Replace fuse.
Heating element not working
on all phases
Check to see that heating element
is working on all phases, by
checking the resistance (ohms)
value for each element and
comparing with the chart included
in Section VI.
Heater improperly sized
Verify heater is properly sized for
the flow rate and temperature rise
of your system. See formulas
included in Section VI. Replace
elements with proper size as
necessary.
Relief valve discharges
continuously
Excessive temperature or
pressure in tank
Temperature and pressure relief
valves are made to operate if the
water temperature exceeds 210°F
or water pressure exceeds the
pressure rating of the safety relief
valve. If trouble is excessive
temperature, then thermostat is not
shutting off at the right setting and
thermostat must be replaced.
17
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SECTION V - SERVICING & REPLACEMENT OF PARTS
WARNING / CAUTION
Before servicing or replacing any part make sure to turn the power supply switch to the OFF position.
SURFACE TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover.
3. Disconnect the four (4) 14 gauge wires.
Control Wires
4. Remove the two (2) mounting screws.
Mounting Screws
5. Replace control and install new high limit switch by performing above steps in reverse order.
See wiring diagram included with drawing for assistance.
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IMMERSION TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover.
3. Remove high limit cover screw and cover.
Cover
Cover Screw
Reset Switch
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tube
5. Remove capillary tube and bulb from thermowell
6. Remove two (2) mounting screws.
Mounting Screws
7. Remove control and install new high limit switch by performing above
steps in reverse order. (Note: Be sure to place capillary tube into slot in base prior
to installing cover.)
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HEATING ELEMENT
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on outgoing
water line.
5. Drain water from tank.
6. Disconnect the wires from the heating element terminals.
7. Remove the 3/8-16 nuts.
Tank Flange
Element Terminals
Nuts
8. Withdraw element assembly and remove gasket.
Gasket
Element Assembly
9. Install new gasket and insert new heating element.
10. Rewire element according to the voltage and phase rating of the unit as shown below.
11. Fill tank and check around gasket for any leaks.
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SURFACE MOUNTED THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Disconnect the two (2) 14 gauge wires.
Control Wires
4. Remove two (2) mounting screws.
Mounting Screws
5. Replace thermostat using the reverse procedure.
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IMMERSION THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Remove high limit cover screw and cover.
Cover
Cover Screw
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tube
5. Remove capillary tube and bulb from thermowell.
6. Remove two (2) mounting screws.
Mounting Screws
7. Replace thermostat using reverse procedure. (Note: Be sure
to place capillary tube into slot in base prior to installing cover.)
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MAGNETIC CONTACTOR
1. Disconnect power from unit.
2. Disconnect line and load wires to contactor.
3. Disconnect two (2) 14 gauge control circuit wires.
Control Wires
Line Wires
Load Wires
4. Loosen two (2) holding screws and remove contactor.
Mounting Screws
(Bottom screw not shown)
5. Replace with new contactor using reverse procedure.
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RELIEF VALVE
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Lift test lever on relief valve to relieve pressure in tank.
4. Disconnect overflow piping.
5. Unscrew relief valve, remove assembly and replace with new one.
6. Connect overflow piping.
7. Turn on incoming water supply and check for leaks.
8. Turn safety switch to ON position.
Test Lever
Overflow Piping Outlet
Tank Connection
Temperature Probe
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SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS
ELEMENT CHART
Resistance (Ohms)
Immersion
Length
Element
Part #
Hairpin
57.6
43.2
34.4
27.9
21.6
17.1
14.4
12.1
9.1
1 Φ
19.2
14.4
11.5
9.3
7.2
5.7
4.8
4.0
3 Φ DELTA 3 Φ WYE
2-38683N
3-38683N
4-38683N
5-38683N
6-38683N
7-38683N
8-38683N
9-38683N
10-38683N
11-38683N
13"
13"
13"
13"
13"
13"
13"
15"
15"
15"
57.6
43.2
34.4
27.9
21.6
17.1
14.4
12.1
9.1
38.6
28.9
23.0
18.7
14.5
11.5
9.6
8.1
6.1
5.0
3.0
7.5
2.5
7.5
FORMULAS
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TORQUE VALUES
SILICON ALUMINUM
18-8 S/S
IN.-LBS. IN.-LBS.
BRASS
316 S/S MONEL
IN.-LBS. IN.-LBS.
BOLT SIZE
BRONZE
IN.-LBS.
4.8
2024-T4
IN.-LBS.
2.9
4-40
4-48
5.2
6.6
4.3
5.4
5.5
6.9
5.3
6.7
6.1
3.6
5-40
7.7
6.3
7.1
4.2
8.1
7.8
5-44
9.4
7.7
8.7
5.1
9.8
9.6
6-32
6-40
8-32
8-36
9.6
7.9
9.9
8.9
5.3
6.6
10.1
12.7
20.7
23.0
23.8
33.1
78.8
99.0
138
147
247
271
393
9.8
12.1
19.8
22.0
22.8
31.7
75.2
94.0
132
142
236
259
376
11.2
18.4
20.4
21.2
29.3
68.8
87.0
123
131
219
240
349
12.3
20.2
22.4
25.9
34.9
85.3
106.0
149
160
266
294
427
16.2
18.0
18.6
25.9
61.5
77.0
107
116
192
212
317
327
422
443
558
615
907
1016
1249
1220
1905
1895
2815
2545
10.8
12.0
13.8
19.2
45.6
57.0
80
86
143
157
228
242
313
328
413
456
715
798
980
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
400
517
541
682
371
480
502
632
418
542
565
713
451
584
613
774
752
697
787
855
1110
1244
1530
1490
2328
2318
3440
3110
1030
1154
1416
1382
2140
2130
3185
2885
1160
1301
1582
1558
2430
2420
3595
3250
1330
1482
1832
1790
2775
2755
4130
3730
958
1495
1490
2205
1995
7/8-14
1-8
1-14
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SECTION VII – ABS TYPE APPROVAL PROGRAM
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