Marathon Service Tech's Toubleshooting Guide Troubleshoot

User Manual: Marathon-troubleshoot-guide

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© Water Heater Innovations 2005 1

Service Technician’s

Troubleshooting Guide

Note: This guide is intended for experienced contractors and service staff familiar with electric and plumbing test and service

equipment, and proper safety procedures. Do not attempt any service work unless you are a qualified service technician!

Symptom Possible Cause Test Remedy

No Hot Water 1. Tripped breaker at service panel

2. Upper limit (ECO) on top thermostat

has tripped

3. Failed top element

4. Malfunctioning upper thermostat

1. Check service panel

2. Check reset button at upper thermostat

3. Check element(s) resistance and continuity using

VOM meter (see Element Guide). If good, check

for voltage at element.

4. Check for power to thermostat; If no power

examine breaker and circuit

1. Reset breaker

2. Re-set ECO

3. Replace elements if out of spec

4. Replace thermostat, if necessary

Not enough

hot water

1. Thermostat setting is too low

2. Failed lower element

3. Malfunctioning thermostat

4. Heater is on load control program

5. Dip tube failure

6. Loose wire connection

7. Incorrect sizing

8. Incorrect plumbing (cold going

into hot connection)

1. Check thermostat setting

2. Check resistance/continuity of element

3. Cool tank and then monitor if power is

switched to top (first) and then to bottom.

4. Research control hours

5. Check faucet screens for particles. Run draw

test with thermometer. Does hot water run

out after just a few minutes?

6. Check all wire connections.

7. Is tank large enough for demand?

8. Check for “cross-over” in plumbing lines

1. Refer to Page 9 of Owners Manual

2. Replace failed element

3. Replace thermostat if necessary

4. Adjust control period

5. Replace failed dip tube and flush tank.

6. Tighten any loose connections.

7. Increase tank capacity

8. Separate Hot and Cold mixing

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© Water Heater Innovations 2005

2

Symptom Possible Cause Test Remedy

Repeated

element failure

1. Sediment build up in bottom of

tank

2. Very hard water

3. Watt density of elements too high

4. Aggressive (Extreme pH) water

5. Loose wire connection

1. Drain tank to check for sediment

2. Perform water hardness/pH/dissolved

solids test

3. Refer to Element Data

4. Check element series and wattage

5. Check connections

1. Remove sediment from tank bottom. See

Tank Cleaning Instruction sheet.

2. Install water softening equipment

3. Install lower watt density elements (3800 or

3000 watt)

4. Install Titanium sheathed elements

5. Tighten any loose connections

Pressure relief

valve leaks

1. Thermostat set too high

2. Excessive water pressure

3. Malfunctioning T&P

1. Check thermostat settings

2. Is back flow prevention installed?

3. Examine for signs of mineral deposits

1. Lower thermostat setting – Refer to Page 8 –

section titled: Water Temperature Setting

2. Add expansion tank to water system

3. If any concern about the condition of the T&P

valve, replace it. It is a safety device.

High electric

bill …or Water

is Too Hot

1. Hot water leak somewhere in

plumbing system

2. Above normal use

3. Element shorted to ground

1. Inspect water system

2. Review patterns of use

3. Check element filament wire for

continuity/resistance (See Element

Guide) Check resistance terminals to

brass element screw plug (ground)

1. Repair leaks

2. Monitor hot water usage

3. Replace element if necessary

© Water Heater Innovations 2005

3

Symptom Possible Cause Test Remedy

Water on the floor

near heater

1. Overhead leak in plumbing

2. Weeping T&P valve

3. Union connections at top of heater

leaking

4. Element seal leaking

5. Tank has failed

6. Hydrostatic pressure – New cement

floor – Water appears as narrow halo.

1. Check for plumbing leaks

2. Check T&P drain pipe for water

3. Examine union connections; seal rings

4. Inspect elements

5. Carefully observe source of water

leaking from heater.

6. Tape clear plastic to floor around water

heater; Observe for several days.

Presence of moisture on underside of

plastic is from concrete.

1. Tighten or repair connections

2. See “Relief Valve Leaks” above

3. Repair/tighten connections, or replace

damaged seal rings

4. Tighten element, or replace gasket

5. Replace heater if determination is

made it is an internal leak

6. Further aging of concrete