KUUMA 11842 Marine Water Heater Owner’s Manual

KUUMA 11842 Marine Water Heater

IMPORTANT SAFEGUARDS

Read all instructions and warnings before operating.
If this product is dealer installed, leave these instructions for the end user for future reference.

INTRODUCTION

Thank you for selecting a Kuuma Products Marine Water Heater. Your unit was carefully inspected and tested at our factory. We take pride in producing one of the finest water heaters for marine use. Please take the time to read this manual carefully; many of its instructions are essential to the safe operation of your unit. Because of the continuing refinement of our product designs, your water heater may possess features not discussed in the manual. We have tried to supply all the information you might need, so please take time to read this manual before using your Water Heater.
Unauthorized modification of this product is strongly discouraged and will void the warranty. However, we do encourage you to perform the maintenance outlined in this manual. Proper maintenance is essential to the continuing safety and performance of this product.

IMPORTANT SAFETY INSTRUCTIONS

WARNING – When using electrical appliances, basic safety precautions to reduce the risk of fire, electric shock, or injury to persons should be followed, including:

1. READ ALL INSTRUCTIONS BEFORE USING THIS WATER HEATER.
2. This water heater must be grounded. Connect only to properly grounded outlet. See “GROUNDING INSTRUCTIONS” found on Page 5, Item 4.
3. Install or locate this water heater only in accordance with the provided installation instructions.
4. Use this water heater only for its intended use as described in this manual.
5. Do not use an extension cord set with this water heater. If no junction box is available adjacent to the water heater, contact a qualified electrician to have one properly installed.
6. As with any appliance, close supervision is necessary when used by children.
7. Do not operate this water heater if it has a damaged power supply line, if it is not working properly, or if it has been damaged or dropped.
8. This water heater should be serviced only by qualified service personnel. Contact nearest authorized service facility for examination, repair, or adjustment.
9. Do not use multi-outlet adaptors (i.e. power strips) with this water heater.

(SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE)

THOROUGHLY READ AND UNDERSTAND ALL INFORMATION PRESENTED IN THIS MANUAL PRIOR TO USING THIS APPLIANCE.

Safety precautions are essential when any electrical equipment is involved. These precautions are necessary when using, storing, and servicing. Using this equipment with the respect and caution demanded will reduce the possibilities of personal injury or property damage.

This manual contains important information about the installation, operation and maintenance of this product. General safety information is presented in these first few pages and is also located throughout the manual. Particular attention should be paid to information accompanied by the safety alert symbols:

DANGER

WARNING

CAUTION

WARNING: Fire Hazard

Do not smoke or have any flame near an open faucet.

If you have not used this water heater for more than two weeks, hydrogen gas may have been produced within the hot water system. To reduce the risk of injury, open the hot water faucet that is highest in the system (generally the galley faucet) for several minutes before you use any electrical appliance connected to hot water system. If hydrogen is present, you will probably hear sounds like air escaping through the pipe as water begins to flow. Allow the water to flow until the sounds stop.

CAUTION: Product Damage

Small electric currents move between boats and shore through the safety ground wire in the shore cord, causing galvanic damage to your water heater. To prevent galvanic damage, this product should be used in conjunction with a galvanic isolator. These devices are inexpensive and easily installed. Galvanic corrosion is not covered by warranty.

CAUTION

To reduce the risk of excessive pressure and temperatures in this water heater, install temperature and pressure protective equipment required by local codes and no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspections of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with a maximum set pressure not to exceed the marked maximum working pressure of the water heater, this maximum pressure is 150psi (1034 kPa). 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 circumstances.

INSTALLATION

Mounting & Plumbing 

1. Position the water heater on structural floor such that Temperature and Pressure Relief Valve will not discharge on to live electrical components or wiring. If heat exchanger is to be used, locate at or below engine level. Do not install water heater on an incline or upside down.
2. Secure to flooring through the front and rear hold-down bracket, or left and right side hold down brackets. Using the appropriate 1/2˝ NPT fittings, connect both the Hot Water Out and Cold Water In ports. Always use a PTFE based pipe sealant on threads when connecting hot and cold water fittings. It is recommended that a suitable plastic fittings be used.
3. Turn on the water supply. Completely fill the hot water system by opening each of the hot water faucets to allow the trapped air to escape.
4. If using engine heat exchanger, connect 5/8˝ diameter SAE 20R3 or equivalent coolant hose to heat exchange tubes per the diagram below. Use a SAE J536a type E hose clamp or equivalent.
5. Refill the engine coolant system with the manufacturer’s recommended coolant. For proper operations of both the engine and water heater all air must be bled from the coolant system. Failure to properly bleed air from engine coolant system could result in engine damage.
6. Check the system for leaks.

CAUTION: Product Damage Do not use raw water or any chemical that is not PH neutral in the heat exchanger circuit. Damage caused by a chemical or salt reaction is not covered under warranty

1. Cold water in
2. Drain valve
3. Heat Exchanger Inlet/Return
4. Temperature and Pressure (T&P) Relief Valve
5. Hot water out
6. Control Access Cover
7. Manual reset access

Engine Heat Exchanger

Typical water/water heat exchanger, or radiator

Electrical Connections

CAUTION: Electric Shock Hazard

Locate circuit breaker(s) and/or remote switches in an area where ignition protection is not required.

1. Remove the Control Access Cover. Wiring diagram is located on the inside of access cover.

2. This Water Heater comes with a strain relief installed; if it is not appropriate for the cable being used, replace with one that is appropriate. Remember to only use wiring/cable that meets NEC code ANSI/NFPA 70-2011 and/or Chapter S, part 183.425, table 5 of chapter 1 per the Coast Guard Department of Transportation Code of Federal Regulations Title 33. With strain relief installed, pass the cable through the strain relief.

3. Connect the electrical supply:
   a. 120V Models: Locate the hot wire (black) and neutral wire (white) leads, these can be tucked under the cover and/or insulation. The hot wire (black) lead will be coming off the high temp limit switch and the neutral wire (white) will be coming off the heating element. DO NOT connect wires from incoming cable directly to any component inside the access panel other than one of these two leads. Using approved wiring connection methods per code, connect the incoming hot leg (typically black) from the cable to the hot wire (black) lead coming off the high temp limit switch and connect the incoming neutral leg (typically white) from the cable to the neutral wire (white) lead coming off the heating element.
   b. 240V Models: Locate the hot wire (black) and neutral wire (white) leads, both of these leads are connected to the high temp limit switch, these leads can be tucked under the cover and/or insulation. The hot wire (black) lead will be coming off the top right connection of the high temp limit switch and the neutral wire (white) will be coming off the top left connection of the high temp limit switch. DO NOT connect wires from incoming cable directly to any component inside the access panel other than one of these two leads. Using approved wiring connection methods per code, connect the two incoming hot legs (typically black and red) from the cable to the hot wire (black) lead coming off the top right connection of the high temp limit switch and connect the incoming neutral leg (typically white) from the cable to the neutral wire (white) lead coming off the top left connection of the high temp limit switch.

4. Grounding Instructions: Connect the ground wire (typically green) from the incoming cable to the Ground Connection Screw located on the strain relief. Do not use a switch in the grounding circuit.

5. Verify all connections are tight and that they provide good continuity.

6. Reinstall the Control Access Cover and secure the strain relief.

7. Line-in pigtail (HOT)

8. High-Temperature Limiter

9. Thermostat

10. Heating Element (1500W

11. Neutral connection terminal

12. Ground wire

13. Manual reset
    

Access cover, Fishpaper and insulation not shown (for clarity)

USE COPPER CONDUCTORS ONLY UTILISER DES CONDUCTEURS EN CUIVRE SEULEMENT

OPERATION

CAUTION: Product Damage

Do Not operate water heater without water in the tank.

When the heater is operating on AC power, the water temperature is regulated by a thermostat to 140°F (60 °C).
The thermostat is not adjustable or field serviceable.
In the event of a thermostat or element failure, the water heater is equipped with a high temp limiter that interrupts the circuit if the tank exceeds 185°F (85 °C). This high temp limiter is equipped with a manual reset.

1. Check/verify water heater is filled with water and there are no leaks.
2. Locate the remote water heater operation switch (see vehicle/boat owners manual for location of switch).
3. Turn “ON” the remote switch. Your water heater is now operating.
4. The water heater is equipped with a high temp limiter in the event of a thermostat or element failure, the high temp limiter will interrupt the circuit if the tank exceeds 185°F. If it should need to be reset:
   a. Turn “OFF” the remote power switch to the water heater.
   b. Allow the water to cool below 185°F (85 °C).
   c. Depress the reset button on the high temp limiter.
   d. Turn “ON” the remote power switch to the water heater.
   e. If the water heater malfunctions again, contact an authorized Service Center to troubleshoot and repair.

WARNING: High Temperature
When the water heater is operating from the engine heat exchanger, the water temperature in the tank will approach the temperature of the engine coolant. This can be in excess of 170°F (77 °C).

If desired, an external thermostatic mixing valve can be installed to limit the water temperature at the taps.
In addition to the high temp limiter, the water heater is also equipped with a temperature and pressure (T&P) relief valve that complies with ANSI Z21.22, Relief Valves for Hot Water Supply Systems. This valve is designed to open if the water inside of the tank exceeds its rated temperature and/or pressure rating (listed on the ID plate under the handle).

WARNING: Scalding Hazard
Discharging water above 120°F (49 °C) can result in severe burns or death.
WARNING: Explosion Hazard
The T&P valve is not serviceable. Tampering with the valve will void the warranty and could create an explosion hazard. Do not place a valve, plug or reducing coupling in the outlet port of the T&P valve. If you use a discharge line, do not use a reducing coupling or any other restriction that is smaller than the outlet of the relief valve. Restricting the outlet of this valve could result in dangerously high pressure within the hot water system.
The discharge line must terminate within 6 inches of the floor or any distance beneath the structural floor.

During normal operation the water within the tank will expand when heated. This expansion results in an increased pressure within the closed hot water system. The T&P valve may occasionally weep to relieve the excess pressure.
This is normal and does not represent a faulty valve.

The water heater tank is designed with an internal air pocket at the top of the tank to reduce the possibility of dripping.
In time, the expanding water will absorb this air and it must be restored. To restore the air pocket take the following steps.

1. Disconnect the power supply to the water heater.
2. Let water cool or let run until cool.
3. Turn off the main water supply.
4. Open the hot water faucet closest to the water heater.
5. Pull the discharge handle of the T&P valve and allow water to flow until it stops.
6. Allow the T&P valve to close.
7. Close the faucet.
8. Turn water supply back on.
9. Restore the power to the water heater.
10. Turn on water heater and test.
11.  Perform this procedure at least once a year or whenever the T&P valve begins to weep.

For a permanent solution, we recommend one of the following: Install a pressure relief valve in cold water inlet line to water heater and attach a drain line from valve to thru-hull fitting.
Set to relieve at 100-125 PSI.
Install a diaphragm-type expansion tank in cold water inlet line. Tank should be sized to allow for expansion of approximately 15 oz. of water and pre- charged to a pressure equal to water supply pressure. These devices can be obtained from a plumbing supply center.

MAINTENANCE

Regularly check the system for leaks and inspect all lines to and from the heat exchanger.
At least once a year disconnect the power to the water heater, allow water to cool, and manually operate the T&P valve discharge handle. Verify that the discharge port is clear of obstruction and that it flows freely.
Replacement parts may be ordered from Camco Manufacturing LLC. Contact Camco’s customer service at 1-800-334-2004 or info@camco.net to obtain replacement parts. When contacting Camco to order replacement parts, please provide:

1. Item or Model Number of water heater
2. Serial Number of water heater
3. Part description of item required for replacement

The model number and serial number of the water heater can be found on the front panel of the water heater. There is also a place on the second sheet of this manual to record these two items for future use.

Winterizing & Flushing Instructions

To ensure the best performance of your water heater and add to the life of the tank, periodically drain and flush the tank.
It is also recommended that a drain and flush be performed before long term storage or freezing weather.

1. Disconnect the power supply to the water heater.
2. Turn off the main water supply.
3. Drain water heater tank by opening the drain valve. If desired, a garden hose can be connected to the drain outlet to run the water outside the boat.
4. Open the faucet that is highest in the system to allow air to displace the water. It may also help to open the T&P valve once the system has drained down to water heater level.
5. Due to the placement of the drain valve, approximately two quarts of water will remain in the tank. Sediment collects in this remaining water. To remove it, flush the tank with either air or water. Whether using air or water pressure, it may be applied through the water inlet or outlet. The pressure will force out the remaining water and sediment.
6. Close the drain valve, faucet, and T&P valve. The approximately two quarts of water remaining in the tank after draining will not cause damage to the tank should freezing occur. However, you can add non-toxic, propylene-glycol based anti-freeze that is designs for use in potable water systems. Always follow the manufacturer’s instructions.

LIMITED WARRANTY

Camco Manufacturing warrants this product to be free from defects in material and workmanship under normal use and service conditions for 12 months from the date of first purchase. Camco’s liability is limited solely to the replacement of any defective product returned to us. To the extent allowable by law, Camco makes no other warranty; either expressed or implied, nor assumes any liability for incidental or consequential damages resulting from the use of this product or for breach of warranty of merchantability or fitness for a particular purpose. Submit warranty claims to Camco Manufacturing, 121 Landmark Drive, Greensboro, NC 27409.
Retain this manual for future reference.

Customer Support

Camco Manufacturing, LLC 121 Landmark Drive, Greensboro, NC 27409
www.camco.net / info@camco.net

References

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