Electric Instant Water Heater Plans

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Table of Contents

3.1 DISCLAIMER ..........................................................................................................................................................13.2 GENERAL INTRODUCTION......................................................................................................................................1

3.3 PARTS LIST ............................................................................................................................................................2

3.4 TOOLS LIST ............................................................................................................................................................5

3.4.1 Going to the store .................................................................................................................................................6

3.4.2 Cutting the pipe. ...................................................................................................................................................6

3.4.3 Cleaning................................................................................................................................................................6

3.5 SWEATING PRACTICE .............................................................................................................................................8

3.6 ASSEMBLY ..........................................................................................................................................................10

3.7 HEATER ELEMENT INSTALLATION ....................................................................................................................32

3.8 SYSTEM PRESSURE CHECK ..................................................................................................................................35

3.9 ELECTRICAL ........................................................................................................................................................36

3.10 INCREASED CAPACITY .................................................................................................................................51

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17 Nov 2009 Free Plans and Ideas1

3.1 DISCLAIMER

User’s of this manual and its content accept full responsibility and release theauthor, employees, assignees, company, and subsidiaries from any and all liabilitypertaining to the construction / fabrication of materials, and product containedwithin. Electrical wiring and plumbing may require inspection prior to installation;contact the local construction authorities in the area where the final product will beinstalled.

Reproduction of this manual in part of in entire is strictly prohibited without writtenconsent of the author PV

3.2 GENERAL INTRODUCTION

This manual is for the construction of an instant electric hot water heater. Keep in

mind that this manual offers additional information that can be expanded to includeservice to the complete home. However, the basic unit was designed for a 110 ACelectrical outlet for mounting under a sink. The cost for a similar unit is around$300.00. The plans as described will costs less the eight dollars. Each sectionhas a parts list and tools list. The parts list may change depending on pluminghook up needs. Plans shown use ¾ NPT pluming connection. Estimated time ofcompletion is 2 ½ hours.








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3.3 PARTS LIST

Quick

Reference:

The total length of 1” pipe needed is 32” PV

The total length of ¾” pipe needed is 15” PV

* NOTE: Because of different thread sizes not all heater elements will fit the 1”female adapterPV The Camco 3800W heater element worked well for me PV It’srecommended that the heater elements and 1” adapters are check to see if theyfit together prior to leaving the storePV


Letter Description QTY

A 1" x 12" long pipe 2

B Over pressure / temp regulator 1

C Heater element 2D thermostat lower unit 2

E Solder 12 oz

F Plumbing flux 1 can

G 120 grit sand paper 1 Small roll

H 1" x 1 1/2" Long Pipe 3

I 3/4" x 3/4" x 3/4" Tee 1

J 1" female adapter 2

K 3/4" male adapter 1

L 1" x 1" x 3/4" tee 2

M 1" 90°Elbow 2

N 3/4" Female adapter 1

O Insulation 1 Small rollP 12 gage wire 3 feet

Q Teflon tape 1 small spool

R 110 V AC Plug 1

S 3/4" x 3/4" 90°Elbow 2

T 3/4" x 1 1/2" Long Pipe 3

U 3/4" x 3" Long Pipe 1

V 3/4" x 4" Long Pipe 1

W 8-32 screw with nut 4

X 3/4" Copper Clamp 2

Y 3/4" Copper Grounding Strap 1

Z Electrical Silicone 1







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PARTS LIST CONTINUED

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3.4 TOOLS LIST


Tool # Description Qty

T1 Pipe cutter (1" or larger) 1

T2 Propane 1T3 Torch Tip (for sweating pipe) 1

T4 Small Crescent Wrench 1 sheet

T5 Measuring tape (5' or larger) 1

T6 Wire Strippers 1

T7 Pipe Wrench 2

T8 Medium Pliers 1

T9 Screw Driver Flat head and Phillips 1 Each

T10 Electrical Tester 1

T11 Element Installation W rench (Optional) 1







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3.4.1 GOING TO THE STORE

All the items above were purchase at a local hardware store. When purchasingthe copper pipe many stores have them per cut to length. If pre-cut copper pipingis not available request that they cut them for you. Often this is done as a freeservice. This will help in getting the parts home. The longest piece of pipe neededis 12” in length.

3.4.2 CUTTING THE PIPE.

It may be necessary to purchase a long piece of copper pipe and cut it to theneeded length. Using letter number T1 from figure 1 cut each piece to the proper

length. Refer to the parts list for correct sizes and length.

3.4.3 CLEANING

Sweating pipes can be some what of a challenge. The key is to make sure thatthe pipe and mating surfaces are cleaned well. Using the 120 grit sand paperplace the sandpaper on the inside or outside of the copper pipe. (As shown below)

Figure: 2

With small twisting action sand the pipe until the surface area is bright.








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Cleaning should extend no less than ¾ of an inch down the pipe. Use the samemethod for cleaning internal areas of the tee, adapter, and elbows.

Figure: 3

Using a cloth wipe the excess sand off the pipe and place pipe on a clean surface.

Figure: 4

Perform this on each piece that will be sweated together.


¾”







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Applying the flux

When applying the flux make sure a there is no dirt on any part of the pipe or inthe flux this will cause the solder not to seal. A brush sometimes comes with flux.If not don’t worry use you finger just make sure the ir clean Apply the flux to all

surfaces that will be assembled.

Figure: 5

NOTE:

Make sure that parts and flux are clean.

3.5 SWEATING PRACTICE

The purpose of sweating is to form a water tight seal all the way around thesurface of the pipe.

CAUTION:

The propane torch may cause injury. Precautions arerequired in the event of fire. Have a fire extinguisher near by.Clear area of any flammable materials. Keep clothing awayfrom flame. Refer to the propane tanks’ data label sheet.


NOTE:

Practice on scrap piece.







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For practice find scrap pieces. Clean and apply flux. Lay the part on a nonflammable table ensuring that the heated end is hanging over the edge. Apply theheat of the torch to the larger diameter part.

Figure: 6

After the flux burns/bubbles away and while maintaining the heat at the samelocation take the solder and gently make contact at the pipe seam. The soldershould flow like butter and run into the seams creating a nice seal. A silver ring willfill the seam and a small bead / drip will form on the bottom side of the pipe. Allowparts to cool.

If you want you can try this on a separate piece of scrap piping without flux applied.The result will be extremely different. Notice that the solder runs around the pipebut will not fill the seams. This is why it is very important to clean the pipes and

apply the flux to both parts.


Apply Heat hereAs the partsheat up the

Flux willbubble andburn away.







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3.6 ASSEMBLY

After the completion of this section the unit should look like the picture below.








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MAIN BODY

STEP1

To begin clean and apply flux to parts shown by labels in figure 7. Flux is neededon all mating surfaces to ensure a proper seal.

Figure: 7

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NOTE:

This section requires that all parts are cleaned andflux applied to each mating surface.

¾” Male Adapter

1” x 1” x ¾’ Tee

3/4” x 1 1/2'” Pipe







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Assemble the unit as shown in Figure: 8. Slide the ¾” x 1 1/2” pipe between the ¾”male adapter and 1” x 1” x ¾” tee. Leave a 1/8” gap between the male adapter and tee. Keep in mind that the ¾ male adapter is the inlet. This size may not be

what is needed for your unit.

Figure: 8


NOTE:

The ¾” x 1 ½” pipe should share equally betweeneach piece. 1/8” gap is for solder to flow between

seams.

1” x 1” x ¾’ Tee

¾” Male Adapter

1/8” Gap







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Step 2

Clean and apply flux to parts shown by labels in figure 9. Flux is needed on allmating surfaces to ensure a proper seal.

Figure: 9

Assemble the unit as shown in Figure: 10. Slide the 1” x 1 1/2” pipe between the 1”female adapter and the top of the 1” x 1” x ¾” tee. Leave a 1/8” gap between thefemale adapter and tee.

Figure: 10


1” x 1” x ¾’ Tee

1” FemaleAdapter

1/8” Gap







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Step 3


Figure: 11

Assemble the unit as shown in Figure: 12. Slide the 1” x 12” long pipe into thebottom of the 1” x 1” x ¾” tee. The pipe should be inserted about ¾” into the tee.Some tees will have stops ensuring a proper fit others will not.

Figure: 12


NOTE:

The 1” x 1 ½” pipe should share equally between

each piece. 1/8” gap is for solder to flow betweenseams.







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STEP 4


Figure: 13


NOTE:

Some tees will have internal stop ensuring aproper fit others will not. Inserted at least ¾”

into tee.







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Assemble the unit as shown in Figure: 14. Slide the 1” x 1” 90° elbow onto the 1” x12” pipe until it stops.

Figure: 14

Step 5


Figure: 15








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Apply flux and assemble the unit as shown in Figure 16. Take a 1” x 1 ½’ shortpipe and slide it into the other end of the 90°elbow. Take the other 1” x 1” 90°elbow and slide it onto the 1” x 1½ pipe. Leave a 1/8” gap between the two

elbows.

Figure: 16


NOTE:

The 1” x 1 ½” pipe should share equally between

each piece. 1/8” gap is for solder to flow betweenseams.







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Step 6

Clean and apply flux to parts shown by labels in figure 17. Flux is needed on all

mating surfaces to ensure a proper seal.

Figure: 17

Assemble the unit as shown in Figure 18. Insert the 1” x 12” long pipe into the topof the elbow until seated.

Figure 18








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STEP 7


Figure: 19

Assemble the unit as shown in Figure 20. Insert the 1” x 1” x ¾’ tee onto the top of the 1” x 12” pipe. Take the 3/4” x 1” ½” short pipe and insert it into the side of the1” x 1” x ¾” tee. Take the 1” x 1” ½” short pipe and insert it into the top of the 1” x1” x ¾” tee.

Figure: 20


1” x 12” Pipe

1” x 1” x ¾” Tee

3/4” x 1 ½” Pipe

1” x 1” x ¾” Tee







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Step 8


Figure: 21

Assemble the unit as shown in Figure 22. Slide the 1” female adapter over the 1” x1 ½” short pipe. Leave 1/8” gap between the 1” female adapter and the 1” x 1” x¾” tee.

Figure: 22


1/8” Gap

1” FemaleAdapter







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The unit should look like the picture in Figure 23.

Figure 23: Main Body

Step 9

Sweat the unit to lock the position of each part and allow to cool. This will behelpful when continuing thru the remaining steps of this section.

Locate the 3/4 “pipe material. There should be one (1) ¾” x ¾” x ¾” Tee, one (1)¾” female adapter, one (1) 3/4” male adapter, three (3) ¾” x 1 ½” long pipe, one(1) ¾” x 3” long pipe, and one (1) ¾” x 4” long pipe.


NOTE:

The 1” x 1 ½” pipe should share equally betweeneach piece. 1/8” gap is for solder to flow between

seams.







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Step 10


Figure 24:

Assemble the unit as shown in Figure 25. Slide the ¾” x 1 ½” long pipe into the both ¾” 90°elbows and leave a 1/8” gap. Insert the ¾” x 3” long pipe into the other end of the 90° elbow.

Figure 25


1/8” Gap







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Step 11


Figure 26

Assemble the unit as shown in Figure 27. Take the ¾” x ¾” x ¾” tee and slide it over theother end of the ¾” x 3” long pipe.

Figure 27


¾” x 3” Pipe

¾” x ¾” x ¾” T







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Step 12

Clean and apply flux to parts shown by labels in figure 28. Flux is needed on all matingsurfaces to ensure a proper seal.

Figure 28

Assemble the unit as shown in Figure 29. Slide the ¾” x 1 ½” long pipe into the other side ofthe ¾” x ¾” x ¾” tee.

Figure 29


¾” x ¾” x ¾” Tee

¾” x 1 ½” Pipe







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Step 15

Clean and apply flux to parts shown by labels in figure 30. Flux is needed on all matingsurfaces to ensure a proper seal.

Figure 30

Assemble the unit as shown in Figure 31. Slide the ¾” male adapter over the remaining part

of the ¾” x 1 ½” long pipe leaving a 1/8” gap between the adapter and ¾” x ¾” x ¾” tee.

Figure 31


¾” male adapter

¾” x 1 ½” Pipe







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Step 16

Clean and apply flux to parts shown by labels in figure 32. Flux is needed on all mating

surfaces to ensure a proper seal.

Figure 32

Assemble the unit as shown in Figure 33. Slide the ¾” x 4” long pipe into the lower part of the¾” x ¾” x ¾” tee.

Figure 33


¾” x ¾” x ¾” tee

¾” x 4” Pipe







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Step 17

Clean and apply flux to parts shown by labels in figure 34. Flux is needed on all mating

surfaces to ensure a proper seal.

Figure 34

Assemble the unit as shown in Figure 35. Take the ¾” female adapter and slide it over theother end of the ¾” x 4” long pipe.

Figure 35


¾” x 4” long pipe

¾” female adapter







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Step 18

NOT ALL PIECES WILL BE SWEATED IN THIS PART OF THE SECTION . Notice thatthe joint at the second 90° elbow and ¾” x 3” pipe will not be sweated. This joint is used as a

pivot and must remain free during the installation onto the main body shown in figure 23.(This part of the section assumes that all parts have been cleaned and flux was applied)Sweat the following locations: Sweat the ¾” female adapter to the ¾” x 4” long pipe, Sweatthe ¾” x 4” long pipe to the tee, Sweat the ¾” male adapter to the tee, Sweat the ¾” x 3”long pipe to the tee, Sweat both 90°elbows. Allow to cool.

Discharge Tube


Sweat female adapter tothe ¾” x 4” i e

Sweat the ¾” x 4” longpipe to the tee

Sweat the ¾” maleadapter to the tee

Sweat the ¾” x 3” longpipe to the tee

Sweat both 90°elbows

DO NOT SWEAT

HERE. SECOND 90

AND 3” LONG PIPE







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Step 19

Locate and apply flux to the Main Body’s ¾” x 1 ½” pipe and to the inside of the first 90°

elbow located on the Discharge Tube. Join the Discharge Tube and Main Body at the ¾” x 1½” pipe and the ¾” 90° elbow.

Step 20

Angle the discharge tubes at about 135°downward or about the 3:30 mark on a clock. Asshown in Figure 36.

Figure 36:


Join Main Bodyand Discharge

Tube here.

Main Body

Discharge Tube







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Step 21

Sweat the 90°elbow and Main Body together. Allow to cool .

Step 22

Take the portion of the Discharge Tube that has not been sweated (Figure 37 & 37A) andswing it away from the Main Body until the pipes run inline/parallel between the Main Bodyand the Discharge Tube. While maintaining this position sweat the remaining joint at the

second 3/4” 90°elbow and ¾” x 3” pipe. Allow to cool.

Figure 37


Sweat 90°elbowand Main Body

here

Swing away from Main Bodyuntil pipes are parallel







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Figure 37A:


Not sweatedportion.

Sweat here whilemaintaining position







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3.7 HEATER ELEMENT INSTALLATION

Step 23Located the heater elements and apply Teflon tape to the threats as shown in thepicture below.

Step 24

Insert the elements into the top of the 1” female adapters and tighten using a setof pipe wrenches or with the optional Element Wrench.








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Step 20Locate the pressure/temp relief valve and apply Teflon tape to the

threadsPV When applying the tape ensure that the tape is installed in the oppositedirection of the threadsPV The tape should never be applied in the same direction asthe threadsPV

Step 21Insert the pressure/temp relief valve into the lower 1” female adapter PV








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Step22

Using a set of pipe wrenches tighten the pressure/temp relief valve making surethat the valve faces away from the inlet and outlet connections.


Inlet Connection

OutletConnection









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3.10 ELECTRICAL

This section describes the installation of the water heats thermostats and powerleadsPV Below is a picture of what the unit should look like when this section iscompleted








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Installation of the thermostats will require four (4) 1” long 8-32 screws, four (4) 8-32nuts, two (2) ¾” cooper clamps, and two (2) ther mostats.

Step 23

Insert on of the 8/32 screws into either side of the thermostats mounting holes(Figure E1). Slide the cooper clamp onto the screw and install the 8/32 nut.

Figure E1:








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Step 24

Take the water heater and place the thermostat and cooper clamp around the topside of the water heater and install the other 8/32 nut. (Figure E2)

Figure E2

Step 25

Position the thermostats sensor (Figure E2) inline with the center of the 1” X 1” X¾” tee (Figure E3) and snug the 8/32 nuts by finger.

Figure E3


ThermostatSensor







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Figure E4

Step 26

Tighten the 8/32 nuts ensuring that the thermostats mounting holes do not bend;yet enough torque to keep the thermostats in place. (Figure E4)

Figure E5


Unit Rear View

Unit Front View

ThermostatSensor is inline

with the center ofcooper Tee







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Installation of the power leads should be performed after the unit has been pressurechecked PV Refer to the Pressure Check section instructionsPV

Step 27

Take the 5 foot 12-2 wire and measure 7” then cut PV Do this process fourtimeP VRemove only the outer casing exposing the white, black PVRetain four(4) black and one (1) white wirePVPlace the remaining 7” white and 7” cooper wires to one sidePV








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Step 28

Using the wire strippers cut back the insulation about ¼” on each end of the white andblack 7” wiresPV(The exposed wire will be placed under the clamping screws located on thetop of the elements and side of the thermostats) PV

Step 29

Take the remaining wire with the outer casing on itPV

This would be the otherpiece that was not cut in step 27 PVStrip back the outer casing about 4” to expose the white,black, and copper leadsPV Now, strip back about ¼” of the insulation on the exposed white andblack wires








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Step 34

Loosing the power clamp screws located on the top of the elements with a screw drive andinsert the stripped black wire from Step13 and one of the 7” stripped black leads under one of the screw head on either elements.








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Step 35

Loosen one of the other screw on the second element and insert the other end of the 7”black lead wire from step 14 into the screw and tighten.

Step 36

Loosen the other screw on either element and insert the other 7” black lead under the screwhead and tighten.










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Step 39

Loosen the top screw on the thermostat just below the last 7” black lead inserted under theelement screw head. Take the other end of that lead and place it under the top thermostatscrew head and tighten. Make sure that the element and the thermostat share the samecopper pipe.

Step 40

Loosen the lower screws on both thermostats and insert the 7” white lead under the screwhead of the right thermostat and tighten.








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Step 41

After tightening the 7” white lead in place fold the lead over toward the left to theother thermostat. Insert the lead under the screw head. Find the white lead on thepower cord or remaining longer leads previously performed in step 13 and step 14.Insert this lead on the opposite side of the 7” white lead and tigh ten.

Step 42

Install the ¾” grounding strap onto the ¾’ x 3” pipe located on thedischarge tube








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Step43: Locate the bare cooper wire on the 110V AC power cord power cord PV

Loosen and insert bare cooper wire into the screw clamp and tighten

Step 44: Locate and install the plastic covers that came with the thermostats








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Step 45: Apply silicone (letter Z) to the top of the heater elements ensuring that allmetal parts are covered PV

Now it’s time to insulate and mount the unit in the desired location PV The insulationcan be wrapped around the unit before mounting or installed after mountingPV

Mounting note: When mounting the unit; place the unit on it’s side as shownbelow ensuring that the heater elements are submerge in waterPVAlso, rememberthat the outlet is located on the discharge tube PV










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