STORAGE TANK

INSTALLATION and OPERATION

MANUAL

The information contained in

this manual is intended for use by

qualified professional installers, or

service technicians. Consult your

local expert for proper installation

or service procedures.

Save this manual for future reference.

LST-I-O 100161529_2000014416 Rev G

LOW LEAD CONTENT

⚠WARNING

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels

or to important information concerning the life of the product.

⚠CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not

related to personal injury or property damage.

Contents

CONTENTS ....................................................................... 2

HAZARD DEFINITIONS ................................................... 2

1. GENERAL INFORMATION ........................................ 3

Tank construction ...................................................... 3-4

2. INSTALLATION ........................................................... 5

Transporting and unpacking the unit ............................ 5

Examining the unit ....................................................... 5

Anchoring the unit ......................................................... 5

Recommended service clearances ............................. 5

Connecting the hot water source ............................... 5-6

Cold water supply .......................................................... 6

Hot water outlet ............................................................ 6

Mixing valve .................................................................. 6

Aquastat / bulbwell ........................................................ 7

Piping the relief valve ................................................... 7

Drain ............................................................................. 7

Completing the installation ........................................... 7

3. OPERATION ................................................................ 8

Startup procedure .......................................................... 8

Shutdown procedure ...................................................... 8

4. INSPECTION ............................................................... 9

5. MAINTENANCE ......................................................... 10

Flushing the tank ........................................................ 10

Cleaning the tank ................................................... 10-11

Magnesium anode rod inspection ............................... 12

Water piping and valve replacement ..................... 12-13

Temperature and pressure gauge replacement ......... 13

Notes ............................................................................14-15

Revision Notes .................................................. Back Cover

Hot Water Can Scald!

• Water heated to temperatures for clothes washing, dish washing, and other sanitizing needs can

scald and cause permanent injury.

• Children, elderly, and infirm or physically handicapped persons are more likely to be

permanently injured by hot water. Never leave them unattended in a bathtub or shower.

Never allow small children to use a hot water tap or draw their own bath.

• If anyone using hot water in the building fits the above description, or if state laws or

local codes require certain water temperatures at hot water taps, you must take special

precautions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such as an automatic mixing

valve, at hot water tap or water heater. Automatic mixing valve must be selected and

installed according to valve manufacturer’s recommendations and instructions.

• Water passing out of drain valves may be extremely hot. To avoid injury:

• Make sure all connections are tight.

• Direct water flow away from any person.

Protection Must Be Taken Against Excessive Temperature and Pressure!

--Installation of a Temperature & Pressure (T&P) relief valve is required.

⚠WARNING

⚠DANGER

Storage Tank Installation and Operation Manual

This manual is intended to cover installation, operation,

and maintenance procedures for Lochinvar’s Hot Water

Storage Tank. Some storage tanks are built to meet customer

specifications. Instructions may not be specific to every system.

If questions are not answered by this manual, or if specific

installation, operation, and/or maintenance procedures are not

clearly understood, contact Lochinvar for clarification before

proceeding.

Most Hot Water Storage Tanks are designed for indoor use

only, unless otherwise constructed by design specifications. It

should be located on a level surface (no more than one-half

degree of slope), capable of supporting the total weight of the

unit when filled to capacity.

The unit should be mounted to the floor following applicable

architectural and local code requirements for the specific

installation site. NOTE: Tanks do not come standard with

floor tie downs. Seismic tie downs are available upon request.

The high quality enamel paint, applied to the jacket of the

unit, will provide years of protection against corrosion. If it is

necessary to clean the outside of the unit, a mild cleaning agent

should be used that will not damage the paint.

For all piping connections, the use and/or type of joint

compound or sealer on the joints should be determined

by referring to local codes, accepted standards, and/or the

requirements of the installing contractor.

Tank construction

Hot Water Storage Tanks are pre-engineered and pre-assembled

complete with all fittings. And like every Lochinvar product,

they are thoroughly tested to ensure proper performance from

the moment they are installed.

Gallon Capacities -- Lochinvar tanks are available in gallon

capacities from 120 to 5000 gallons. Standard construction

tanks from 120 to 940 gallons are maintained in regular

inventory. Tanks over 1000 gallons are custom manufactured

per order.

Tank Orientation -- Lochinvar tanks are available in vertical or

horizontal orientation.

Tank Lining -- Lochinvar tanks are available in glass (standard)

or cement (optional) linings, and unlined.

ASME -- All Lochinvar storage tanks are constructed per ASME

Section IV requirements, or Section VIII.

Pressure Rating -- Lochinvar tanks are available in 125 psi

working pressure (standard) or 150 psi working pressure

(optional).

Cathodic Protection -- All glass lined tanks are equipped with

magnesium anodes to provide protection against corrosion.

• Before using product, read and

understand instructions.

• Save these instructions for future

reference.

• All work must be performed by

qualified personnel trained in the

proper application, installation, and

maintenance of the water systems in

accordance with all applicable codes

and ordinances.

• To prevent serious burns, wear heat

resistant gloves when handling hot

equipment.

Failure to follow this warning could cause

property damage, personal injury, or

death.

1 General information

The following chart (Table 1A) details the relationship of

water temperature and time with regard to scald injury

and may be used as a guide in determining the safest water

temperature for your applications.

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F 1 1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1 1/2 seconds

155°F About 1 second

Table 1A Approximate Time / Temperature Scald Chart

⚠WARNING

Storage Tank Installation and Operation Manual

Manway - A 12" x 16" manway is provided as an option on

glass lined tanks and is standard on cement lined tanks. Four

by six inch (4" x 6") hand holes are available on tanks under

300 gallons. Manways may not be installed on tanks under

30" diameter.

Jacketing -- Lochinvar tanks are available as “Bare”, having

no jacket or insulation.

Tanks with a round sheet metal jacket are insulated with a

2" thick foam mixture that has an R value of R-13. Square

sheet metal jacketed tanks are insulated with a 3 1/2" thick

fiberglass wrap that has an R value of R-13. These tanks are

for indoor installation only.

Outdoor rated tanks are available with 2" thick foam insulation

with no exposed metal surfaces. All jacketed storage tanks

meet the energy efficiency requirements of the latest edition

of ASHRAE 90.1.

Relief Valve Tapping -- A tapping is provided for the

installation of a field supplied ASME safety relief valve.

Hot Water Recirculation Tappings -- Lochinvar storage

tanks will have two (2) tappings on the tank to provide

recirculation piping between the tank and a hot water source.

These tappings may be ordered in custom sizes, either threaded

or flanged. Extra tappings are also available upon request.

Hot Water Outlet -- A Hot Water Outlet Tapping is

positioned on the top of the tank for connection to the

building system.

This tapping may be ordered in custom sizes, either threaded or

flanged. Extra tappings are also available upon request.

Drain -- A tapping or drain pipe will be connected to a low

point on the tank for drainage.

Temperature and Pressure Gauge (optional) -- Lochinvar

tanks may be fitted with an optional temperature and

pressure gauge.

Aquastat Bulbwell -- All Lochinvar tanks are provided with

a bulbwell for the location of control sensors.

Five-Year Limited Tank Warranty -- Provides warranty

protection against tank failure (see warranty for details).

One-Year Limited Warranty -- Parts and accessories (see

warranty for details).

Areas of potential danger:

1. All water lines, joints, and valves.

2. All power connections and cables.

3. If the unit has been in operation, allow

the water in the heater and all

components and surfaces (tank surface,

water piping, etc.,) to cool before

starting the procedure.

4. Assure that all power to associated water

heating equipment has been shut off

and disconnected before attempting

any procedures.

5. Assure that all incoming and outgoing

water lines have been shut off at the

manual shutoff valves.

⚠WARNING

Heated water presents situations that can be

very dangerous due to the fact they are under

pressure and at very high temperatures.

To avoid possible injury or death, use

common sense and follow all accepted and

recommended procedures when performing

installation, operation, and maintenance

procedures.

The combination of electricity and water can

pose a very dangerous situation. Assure that

all power has been shut off / disconnected

before attempting any installation or

maintenance procedures.

1 General information

⚠WARNING

Storage Tank Installation and Operation Manual

Transporting and unpacking the

unit

Each jacketed Lochinvar Hot Water Storage Tank is crated

as necessary at the factory. The crating is designed to provide

protection for the unit during transportation, and to provide

a safe means by which to lift and move the unit with a fork

lift or hand truck.

Examining the unit

After the unit has been uncrated and set in place, it should be

carefully examined to assure the tank has not been damaged

during shipping. If any evidence of damage is detected that

could affect the safe operation of the unit, contact Lochinvar,

LLC., or your authorized sales representative, to report the

damage and to receive instructions on how to proceed.

After the unit and all components have been inspected for

damage, it is suggested that all optional or independent

pressure and temperature control components be checked

to assure that they meet or exceed design specifications.

If any discrepancy is found, contact Lochinvar, LLC., or

your authorized representative, before proceeding with the

installation.

Anchoring the unit

The unit should be anchored to the floor, following applicable

architectural / local code requirements, or accepted standards

for the specific installation site. The unit should be installed

in a location with sufficient clearance for service and repair.

Check local codes for Seismic anchoring requirements. If

further assistance is needed, call the Lochinvar Technical

Service Department and request a Seismic Report.

On horizontal tanks, the saddles should be located 6" to

12" from the head/shell seam. Both saddles must be placed

using the same dimensions (FIG. 2-1). If there are tappings

in the recommended space or if there are any concerns

about the proper location for the saddles, please contact the

manufacturer.

Before making any connections of water

inlet or outlet to the unit, assure that

all piping is clean and free of foreign

material or scale. This can usually be

accomplished by “blowing out” the pipe.

Any foreign material or scale entering the

unit can adversely affect operation and

performance.

The two (2) tappings on the lower side of a vertical tank or

the two (2) tappings on the bottom of a horizontal tank shall

provide recirculation between the tank and the water heating

source. See example piping diagram between a storage tank

and an indirect gas fired water heater (FIG’s 2-2 and 2-3).

NOTICE

See the Water Heater’s Installation and

Operation manual for specific piping

diagrams that match the inlet / outlet

water tappings on the tank to the inlet /

outlet water tappings on the water heater.

Tapping locations on the water heater

may vary by product or manufacturer.

Figure 2-2_Vertical Tank Piping Diagram, Non-Condensing

COPPER-FIN WATER HEATER

BUILDING RETURN

BUILDING HOT

WATER SUPPLY

STORAGE TANK

COLD WATER SUPPLY

MIXING VALVE

DRAIN

OUTLET

RELIEF VALVE

INLET

THERMOMETER

EXPANSION TANK

2 Installation

Connecting the hot water source

⚠WARNING

The upper side tapping on a vertical storage tank is the tank’s

water recirculation inlet. The lower side tapping on a vertical

storage tank is the tank’s water recirculation outlet. On a

horizontal tank, either recirculation tapping can be used for

recirculation inlet or outlet.

Recommended service clearances:

• 24 inches around the magnesium anode rod(s)

• 24 inches around the manway or hand hole

Figure 2-1_Saddle locations

SADDLES

6” MIN TO 12” MAX

Storage Tank Installation and Operation Manual

Hot water outlet

The next step in the installation process is to connect the hot

water system piping to the hot water outlet port. The hot

water supply tapping is located on top of the tank.

A manual shutoff valve should be installed downstream on

the hot water outlet line as an isolation device in case the

unit must be disconnected from the system. The shutoff

valve should be in the closed position and remain so until the

installation is complete.

Mixing valve

Field supplied. An anti-scald mixing valve is recommended

when storing domestic hot water above 115°F.

2 Installation

NOTICE

For all piping connections, the use and

/ or type of joint compound or sealer

on the joint should be determined

by referring to local codes, accepted

practices, or the requirements of the

installing contractor.

Figure 2-4_Vertical Tank Piping Diagram, Condensing

Cold water supply

The next step in the installation process is to connect the cold

water supply to the recirculation piping between the heater(s)

and the tank(s).

NOTICE

If the cold water supply to the system is

equipped with an in-line check valve or

backflow preventer, a suitable expansion

tank must be installed in the cold water

supply line.

e location of the cold water supply connection will vary

based on the type of water heater installed. If a non-condensing

water heater is installed, connect the cold water supply to the

recirculation pipe on the water heater’s outlet. is allows the

cold water to mix with the stored water, so tempered water is

recirculated back into the non-condensing water heater.

If a condensing water heater is installed, connect the cold water

supply to the recirculation pipe on the water heater’s inlet. is

allows the cold water to enter the condensing water heater rst

for high-eciency condensing operation.

Review the water heater’s installation manual to conrm the

ideal connection for the cold water supply.

Figure 2-3_Horizontal Tank Piping Diagram - Non-Condensing

COPPER-FIN WATER HEATER

BUILDING RETURN

BUILDING HOT

WATER SUPPLY

STORAGE TANK

COLD WATER SUPPLY

MIXING VALVE

DRAIN

OUTLET

INLET

RELIEF VALVE

THERMOMETER

EXPANSION TANK

Storage Tank Installation and Operation Manual

Do not install a manual shut off valve

between the relief valve and the discharge.

Doing so could cause serious injury or

death if the relief valve released and the

manual valve was closed. This would

cause excessive buildup of pressure in

the storage tank which could result in an

explosion.

Drain

The tanks’ drain connection must be piped to a suitable floor

drain. Brass drain cocks are acceptable. A brass full port ball

valve is recommended to improve water flow.

Completing installation

Installation of the Lochinvar Hot Water Storage Tank is

now complete. All documentation supplied with the unit

should be passed along to maintenance personnel for future

reference.

Piping the relief valve (Relief valve is field

supplied)

All Lochinvar Hot Water Storage Tanks are equipped with a

relief valve tapping on the tank. The valve should be piped

to a discharge line leading to a suitable drain. Piping the

pressure relief valve to a suitable drain will prevent both

water and heat damage to the unit, as well as reduce the risk

of injury from released heated water. The pipe must be of

adequate size to properly handle the capacity of the relief

valve and discharge line.

Check local codes to assure compliance. If a check valve has

been installed on the inlet water line, thermal expansion may

take place causing build up of excessive pressure when the

water is being heated. This expansion will cause the relief

valve to open, releasing hot water to the discharge line. A

properly sized expansion tank must be installed to protect

the system from water expansion.

⚠WARNING

2 Installation (continued)

Aquastat bulbwell

Review the controls for the hot water source equipment. Some

equipment or systems designs will require an independent

aquastat (field supplied) to control the equipment. The

aquastat may be surface mounted onto the sheet metal

jacket of the tank or a nearby surface. The water sensing

probe may be installed in the dry bulbwell supplied with all

Lochinvar Hot Water Storage Tanks. The equipment may

employ a water sensing thermistor. The thermistor would be

installed into the dry bulbwell and wired back to the hot water

equipment.

In installations with more than one water heater, more than

one probe may need to be installed in the storage tank. A field

supplied brass or stainless steel bulbwell may be installed to

accommodate multiple sensing probes. The standard bulbwell

has a bulb area depth of 2 15/16" and can accommodate a

sensor/bulb that is 3/8" in diameter.

An optional “Super-Bulbwell” has a two chamber bulb area.

The inner chamber depth is 3" and can also accommodate a

3/8" diameter sensor/bulb. The outer chamber has a 3 5/16"

depth and can easily fit a 3/8" diameter sensor/bulb plus the

wires or capillary tube from the inner chamber sensor/bulb.

Contact Lochinvar customer service for information on

special, oversized bulbwells.

Storage Tank Installation and Operation Manual

After all installation procedures have been completed, and

all water piping to the energy source and power connections

have been double checked, the unit is ready for operation.

The following Startup Procedure focuses on the storage tank.

Check the Installation and Operation Manual of the hot water

source for additional startup and shutdown procedures.

Startup procedure

1. Assure that all manual shutoff valves are closed.

2. Slowly open the manual shutoff valve on the cold water

supply line and the valves in the hot water source

recirculation piping. Check to assure that there are not

leaks at the valve or any joints. Allow the tank to fill with

water. As the tank is filling, hold the relief valve

open to allow air to bleed out of the tank. Hot water

faucets at the highest location in the building should also

be opened. This will speed the filling process. Make sure

the tank is full of water and free of air.

3. Open the manual shutoff valves.

4. Turn on the recirculation pump between the water heater

and the tank.

After the power to the pump is turned on verify that the

pump is working. If the pump is an oil lubricated unit,

verify proper oiling.

Heated water presents situations that

can be very dangerous because of the

high temperatures and pressures. Use

common sense and follow all accepted

and recommended procedures when

performing installation, operation,

and maintenance procedures to avoid

possible injury or death.

Shutdown procedure

1. Turn off all power to the circulating pump and the hot

water source controls.

2. Close all valves in the system in the following order:

• the hot water outlet line;

• the recirculation water piping

3. Relieve the pressure where possible.

4. After the system has cooled, drain the unit by opening

the tank drain valve and holding the relief valve

in the open position. This will prevent the formation of

a vacuum and increase the drainage flow.

5. Proceed with the required maintenance or repairs.

6. After performing the required maintenance or repairs,

return the unit to operation by following the Startup

Procedure.

5. Follow the Startup procedure for the water heater to

initiate a call for heat. Adjust the operating temperature

control to the desired operating temperature and set the

safety high limit.

6. As the unit is heating the water, carefully re-inspect water

recirculation piping and the tank hot water outlet for

signs of leakage.

7. After the unit has reached operating temperature,

re-inspect all joints for signs of leakage. In addition,

check all gauges and controls to verify that the water

temperature and pressure are within design specifications.

8. The unit is now ready for normal operation.

3 Operation

⚠WARNING

It is recommended that the tank be

flushed before startup in order to clear

the vessel of loose particles and material

from the installation process. This is

strongly recommended for cement lined

tanks. To flush the tank, see “Flushing

the storage tank” instructions in the

“Maintenance” section of this manual.

NOTICE

Tank Pre-Start Flush

Storage Tank Installation and Operation Manual

The following table summarizes the recommended time intervals for inspections of the tank, components, water piping and

power connections.

RECOMMENDED INSPECTIONS

To Be Inspected

Time Interval

Per

Manufacturer

Specs

Weekly Monthly Quarterly Annually

Circulating Pump

Gauges - Pressure &

Temperature

Lines - Inlet, Outlet, &

Return

Pressure Relief Valve

Shutoff Valves - Manual

Temperatures - Water &

Operating

Thermometer

Magnesium Anode Rods

Interior for Sediment or Scale

Flush tank at six (6) month

intervals

4 Inspection

Storage Tank Installation and Operation Manual

5 Maintenance

Figure 5-2_Horizontal Tank

T&P GAUGE

CONNECTORS

(OPTIONAL)

3" NPT COLD WATER INLET

**MANWAY

(OPTIONAL)

LIFTING LUGS (OPTIONAL)

1 1/4" T&P

RELIEF VALVE

OPENING

2" NPT*

HOT WATER OUTLET

DRAIN VALVE

*3" NPT HOT WATER OUTLET ON 1250 GALLON AND UP.

** STANDARD ON CEMENT, AND REQUIRED ON TANKS

WITH BUNDLES 48" AND LONGER.

END VIEW

SIDE VIEW

Cleaning the storage tank

The mineral accumulation in an un-fired tank will be in a soft

sediment form that can be removed by a regular cleaning of the

lower portion of the tank. Many tanks will have a hand hole or

a larger manway to allow access to the interior of the tank for

complete removal of accumulated sediment. An access opening

to remove the manway or hand hole is provided in the exterior

jacket. The sheetmetal jacket components are removed with

hand tools. The opening will be in the bottom portion of a

vertical tank and on the end of a horizontal tank (see FIG’s 5-1

and 5-2 below).

Figure 5-1_Vertical Tank

1 1/4" T&P

RELIEF VALVE OPENING

T&P GAUGE

CONNECTORS

(OPTIONAL)

3" NPT

AQUASTAT

2" NPT*

HOT WATER OUTLET

**MANWAY

(OPTIONAL)

**Manway standard on cement and required on tanks with bundles 48” and larger.

A new tank installation should have a regular inspection program set up. The first inspection should be within the first three

months of operation. Once the tendency to accumulate sediment has been established, the inspection program can be modified

to suit the water conditions. Typical inspection programs flush the tank at six-month intervals and clean the tank in yearly

intervals.

Deliming solvents or acid type flush agents are not recommended for use in lined storage tanks. These chemical cleaners are

usually designed for use in non-potable systems such as heating boilers. These chemicals may be aggressive and cause damage

to the tank lining and deteriorate the magnesium anodes supplied in glass-lined storage tanks.

Hot water will be released under pressure. Avoid contact with the hot discharge water to prevent the risk of

severe scald injury.

Flushing the storage tank

Since mineral accumulation occurs in an un-fired tank it

will be in a soft sediment form. This soft sediment can be

removed by a regular flushing of the lower portion of the

tank.

To flush the tank, follow these steps:

1. Turn off electrical power to the circulating pump and any

other tank accessories.

2. Close the valve on the hot water outlet on top of the

storage tank.

3. Ensure that the drain located on the bottom of the tank

is routed to a floor drain with adequate capacity to allow

the tank to be flushed.

4. Open the drain valve and allow the incoming cold water

to flush the soft sediment out the bottom of the storage

tank. Use extreme caution, as the water exiting the tank

drain may be very hot. Avoid contact with the hot

discharge water to prevent the risk of severe scald injury.

5. Observe the color of the water initially discharged from

the tank drain. This water will generally be milky or

slightly discolored by the sediment discharge. Allow the

drain to run until the water runs clear.

6. Close the drain valve on the tank.

7. Open the hot water outlet valve on top of the tank.

8. Open an adjacent hot water tap to purge any air that may

have entered the storage tank during the draining

process. Close the hot water tap if no air discharge is

observed.

9. Turn on electric power to the circulating pump and other

electrical components if necessary.

10. Observe tank and piping to ensure all components are

functioning properly.

⚠WARNING

Storage Tank Installation and Operation Manual

5 Maintenance (continued)

10. Replace the jacket cover over the manway or hand hole.

Over tightening can result in cutting

the gasket and allowing a water leak to

occur.

⚠CAUTION

To clean the tank, follow these steps (reference FIG.’s 5-3

and 5-4):

1. Turn off electrical power to the circulating pump and

other electrical components if necessary.

2. Close the valve on the hot water outlet on top of the

storage tank and the cold water supply to the system.

3. Ensure that the drain located on the bottom of the tank

is routed to a floor drain with adequate capacity to allow

the tank to be drained.

4. Open the drain valve and open a vent to allow the air to

enter the tank (manually opening the relief valve will

usually accomplish this). Use extreme caution, as the

water exiting the tank drain may be very hot. Avoid

contact with the hot discharge water to prevent the risk

of severe scald injury.

5. Allow the tank to drain completely.

6. Remove the jacket cover over the manway or hand hole.

Remove the bolt(s) securing the tank access opening.

Use a flashlight to observe the sediment collected in the

tank.

7. Use hand tools to remove all sediment from the interior

of the tank. Use care not to damage the interior lining of

the storage tank.

8. Use a water hose to flush the remaining sediment from

the interior surfaces of the tank and ensure that all debris

is removed. Scale or sediment allowed to reach the

potable system can foul valves, pumps, strainers, and

other water fixtures. Ensure that the tank interior is clean

before refilling the vessel.

9. Install a new gasket on the manway or hand hole to

prevent any possible leaks. Tighten the gasket properly to

prevent leaks.

NOTICE

For this procedure, a new manway gasket

or hand hole gasket should be acquired

before beginning this procedure.

11. Close the drain and open the cold water supply and hot

water outlet. If the relief valve was used for a vent ensure

that it is now closed. Open the closest hot water valve to

allow the air in the tank to vent as water enters the vessel.

Close the valve opened for a vent when water flows from

the valve.

12. Check the manway or hand hole and all related piping for

any water leaks.

13. Turn on electric power to the circulating pump and other

electric components if necessary.

14. Turn on the water heater.

15. Open the valves in the hot water source recirculation

piping.

16. Observe tank and piping to ensure all components are

functioning properly.

Water piping and valve replacement

If any of the inlet, outlet, return lines, or shutoff valves are

damaged and must be replaced, follow the steps outlined in

this section.

The combination of electricity and water

can pose a very dangerous situation.

Turn off / disconnect all electric power

before attempting any maintenance

procedure.

1. Follow Steps 1 through 5 of the Shutdown Procedure on

page 8 to take the hot water source off-line before

attempting to replace damaged lines or shutoff valves.

2. Make certain that the hot water source recirculation

valves and hot water outlet valves have been shut off;

that the tank has been completely drained; that the

pressure has been bled from both the water and energy

source systems; and that all components and surfaces

have cooled.

3. Carefully break the joint between the unit and the line

or valve to be replaced.

4. Remove the section of the line or valve to be replaced.

5. Replace the damaged section of the line or valve.

6. Reconnect the line or valve to the unit. Follow

recommendations contained in the manufacturer’s

documentation, local codes, or accepted contractor

practices as to the use and /or type of joint compound

or sealer at the connections.

7. Follow the Startup Procedures on page 8 to place the

unit back on-line. Carefully check all connections for

any sign of leakage.

While it might seem feasible to replace

inlet and outlet water lines, and shutoff

valves without shutting down the entire

unit, it is not advised. Unless the unit

is completely shut down, and the water

and the energy source are isolated from

the system, failure of a manual shutoff

valve during the replacement process

could result in serious injury.

Figure 5-4_Vertical Storage Tank w/Anodes

NOTICE

Anode rods showing excessive

decomposition may indicate electrolysis.

An earth ground should be attached to

the vessel to divert stray current and

prevent tank damage.

Service Note:

Replace the anode(s) when more than six (6) inches of the core

wire is exposed at either end of the rod.

⚠WARNING

5 Maintenance

Storage Tank Installation and Operation Manual

Magnesium anode rod inspection

Glass lined storage tanks have a magnesium anode(s) to provide

cathodical protection of the lining and minimize corrosion.

Aggressive water conditions in some areas of the country may

accelerate the deterioration of the anode(s). The anode(s)

should be periodically removed and inspected to determine if

replacement is necessary.

The tank must be valved off from the system and fully drained

to remove an anode for inspection. Anodes are supplied in

threaded fittings on the top head of small vertical storage

tanks. Top mounted anodes may be accessed by removing the

plastic plugs in the jacket top. Medium sized tanks with round

jackets provide an opening for individual anode rod access.

Large vertical storage tanks and horizontal storage tanks have

multiple anodes installed in threaded tappings along the length

of the tank. These anodes may be accessed by removing a

jacket panel and/or corner post corresponding to the mounting

point of the anodes. Adequate service clearance is required to

allow removal of an anode. Field insulated tanks should make

considerations for access to the anode rods.

& P RELIEF VALVE

HOT WATER OUTLET

ANODE RODS

COLD WATER INLETS

DRAIN

MANWAY

OPTIONAL

Figure 5-3_Horizontal Storage Tank w/Anodes

ANODES

TANK SENSOR / AQUASTAT

LOCATION

MANWAY

3” NPT

1” DRAIN

5 Maintenance

Storage Tank Installation and Operation Manual

The combination of electricity and water

can pose a very dangerous situation. Turn

off / disconnect all electric power before

attempting any maintenance procedure.

1. Follow Steps 1 through 5 of the Shutdown Procedure on

page 8 to take the unit off-line before attempting to

replace the water temperature / pressure gauge.

2. Carefully unscrew the water temperature / pressure

gauge from the port in the tank.

3. Install the new gauge into the port in the tank in place of

the old one removed in Step 2. Follow recommendations

contained in the manufacturer’s documentation, local

codes, or accepted contractor practices as to the use of

joint compound or sealer at the connections.

4. Follow the Startup Procedures on page 8 to place the unit

back on-line. Carefully check all connections for any

sign of leakage.

Temperature / pressure gauge (optional)

replacement

If the temperature / pressure gauge for the water tank is

not functioning correctly and must be replaced, follow the

procedure outlined below.

⚠WARNING

Notes

Storage Tank Installation and Operation Manual

Notes

Storage Tank Installation and Operation Manual

Revision Notes: Revision A (ECO #C04161) initial release.

Revision B (ECO C12972) reflects the addition of the CSA Low Lead

logo to the manual cover.

Revision C (ECO C13309) reflects the addition of FIG. 2-1 on page

5 and a note about saddle location.

Revision D (ECO C16201) reflects the update of the logo and

removal of the gas warning on the manual cover, as well as the

addition of the “Tank Pre-Start Flush” notice on page 7.

Revision E (ECO C16466) reflects the addition of four pages to the

manual, a cold water supply section on page 6, the renaming of

FIG.’s 2-2 and 2-3 as well as the addition of FIG. 2-4 on pages 5

and 6.

Revision F (PCP# 3000003860 / CN# 500009480) reflects updates

made to FIG. 5-4 on page 12.

Revision G (PCP #3000058943 / CN #500045185) reflects and

update to the R-13 reference on page 4.

100161529_2000014416 Rev G

01/24