Marley K404A Installation and operating instructions

“K” Series
(Model A)
Fan Forced
Wall Heaters
Read Carefully - These instructions are written to help you
prevent difficulties that might arise during installation of
heaters. Studying the instructions first may save you consid-
erable time and money later. Observe the following proce-
dures and cut your installation time to a minimum.
To reduce risk of fire or electric shock:
1. To prevent electrical shock, disconnect all power coming
to heater at main service panel before wiring or servicing.
2. All wiring must be in accordance with the National and
Local Electrical Codes and the heater must be grounded
as a precaution against possible electric shock.
3. Verify the power supply voltage coming to heater match-
es the ratings printed on the heater nameplate before
energizing.
4. This heater is hot when in use. To avoid burns, do not let
bare skin touch hot surfaces.
5. Do not insert or allow foreign objects to enter any ventila-
tion or exhaust opening as this may cause an electric
shock, fire, or damage to the heater.
6. To prevent a possible fire, do not block air intakes or
exhaust in any manner. Keep combustible materials, such
as crates, drapes, etc., away from heater. Do not install
behind doors, furniture, towels, or boxes.
7. A heater has hot and arcing (sparking) parts inside. Do
not use it in areas where gasoline, paint, or flammable
liquids are used or stored.
8. Use this heater only as described in this manual. Any
other use not recommended by the manufacturer may
cause fire, electric shock, or injury to persons.
9. This heater is not approved for use in corrosive atmos-
pheres such as marine, green house, or chemical storage
areas.
WAR I G
SAVE THESE I STRUCTIO S
!
(400mm)
15-3/4"
(485mm)
19-1/8"
(35mm)
1-3/8"
(95mm)
3-3/4"
(463mm)
18-1/4"
Dear Owner,
Congratulations! Thank you for purchasing this new heater manufactured by Marley Engineered
Products. You have made a wise investment selecting the highest quality product in the heating indus-
try. Please carefully read the installation and maintenance directions shown in this manual. You should
en oy years of efficient heating comfort with this product from Marley Engineered Products... the indus-
try’s leader in design, manufacturing, quality and service.
... The Employees of
Marley Engineered Products
Installation & Maintenance Instructions
1
F LE #E21609

Installation of Recessed Back Box
in ew Construction
1. Mounting Back Box (See Figure 1).
a. Place the back box between two 16" (406mm)
center-to-center wall studs at the desired mounting
height but no closer than 8" (203mm) to adjacent wall
or floor.
ote: f wall studs are spaced greater than 16” on center,
additional framing supports may be necessary.
b. Align back box such that the bottom and sides will be
flush with finished wall surface (top flange of back box
should protrude approximately 1/2" (13mm) from fin-
ished wall surface).
c. Secure the back box in position with wood screws or
nails as shown in Figure 1.
2. Power Supply Wiring (See Figure 1).
OTE: Wire Compartment Volume - 119in3(1950cm3).
a. Run a power supply cable into the knockout area in
the upper right hand corner of the back box. Refer to
Figure 1.
b. nstall a cable clamp in the “knockout” in the top of
the back box.
c. nsert power supply cable through cable clamp, allow-
ing at least 6" (152mm) of leads to extend inside the
back box.
d. Ground the back box by connecting the supply ground
leadwire to the green ground screw located in the
inside top of the back box.
Installation of Recessed
Back box in Exisiting Construction
1. Provide a wall opening 14-1/2" (362mm)wide x 18-1/2"
(470mm) high at the desired mounting height, but no
closer than 8" (203mm) to any adjacent wall or floor and
36” (915mm) to ceiling. (See Figure 2.)
OTE: Locate so at least one side of the opening is at stud.
2. Power Supply Wiring
OTE: (Wiring Compartment Volume - 119in3(1950cm3).
a. Run a power supply cable into the area above the top
of the wall opening.
b. nstall a cable clamp in the knockout in the top of
back box.
c. nsert power supply cable through cable clamp, allow-
ing at least 6" (152mm) of cable length to remain
inside the back box to facilitate connections.
d. Ground the back box by connecting the supply ground
leadwire to the green ground screw located in the
inside top of the back box.
3. Mounting Back Box
a. Place the back box into wall opening flush with fin-
ished wall surface on bottom and sides of box. (Top
flange of back box should protrude approximately 1/2"
(13mm) from finished wall surface).
b. Secure the back box in place with wood screws or nails.
OTE: For correct wire sizing, please refer to the
ational Electrical Code, Section 310. Only use copper
wire rated at least 75° C Do not use alluminum wire with
this unit.
IMPORTA T
CAUTIO
WAR I G
DO OT NSTALL HEATER UPS DE DOWN OR S DE-
WAYS.
DO OT USE HEATER W THOUT GR LLE.
FOR WALL MOUNT NG ONLY. DO OT NSTALL HEATER
CLOSER THAN 8" (203 mm) TO THE FLOOR OR ANY
ADJACENT WALL SURFACE. DO OT NSTALL CLOSER
THAN 36" (915 mm) TO THE CE L NG.
Fig. 1: Locating Recessed Back Box in New Construction
Fig. 2: Locating Recessed Back Box in Existing Construction
!
!
!
2
GROUND
SCREW
BACK BOX
BACK BOX
CABLE
CLAMP
8” M N.
(203mm)
8” M N.
(203mm) 8” M N.
(203mm)
18-1/2” M N.
(470mm)
MN. 36” (915mm)
to ceiling
14-1/2” M N.
(362mm)
NA L OR SCREW
(2 EACH S DE)
GROUND SCREW
CABLE CLAMP
NA L OR SCREW
(2 EACH S DE)
8” M N.
(203mm)
POWER SUPPLY CABLE
POWER SUPPLY CABLE

Installation of Back Box With Optional
Surface-Mounting Frame (See Figure 3).
1. Secure back box to wall (with knockouts in upper right
hand corner) using screws and anchors.
2. Hang the surface-mounting frame on the back box.
Ensure that the back edge of the surface-mounting
frame is flush against the wall.
OTE: f heater is located in a high traffic area where it may
be subjected to vandalism or abuse, take extreme care to see
that the back box is firmly attached to the wall.
3. Power Supply Wiring
OTE: Wiring Compartment Volume - 119in3(1950cm3).
a. Run a power supply cable into the area of the upper
right corner of the mounting frame.
OTE: f the wiring is to run through the wall, cut a hole in the
area of the top of the back box. Run the supply wire through
this hole. Then remove the knockout from the top of the box
and proceed to step c.
b. Remove the knockout on the top side of the frame.
c. Feed the power supply cable through the frame allow-
ing 6" (152mm) of lead to remain inside the frame
d. Secure the power supply cable to the back box
(using cable clamps, connector, or other suitable strain
relief) allowing 6”(152mm) of lead to remain inside the
back box.
e. Ground the back box by connecting the supply ground
leadwire to the green ground screw located in the
inside top of the back box.
Installation of Heater Assembly and Grille
After back box is competely installed and no further con-
struction dirt is expected, clean debris from back box, remove
heater assembly from its carton, then refer to Figure 4 and
proceed as follows:
1. nsert the heater assembly into back box, placing
the four mounting holes (with key-hole slots) over the
screws in the back box. Tighten all screws securely.
2. f surface-mounting frame is used, ensure that the
frame is even with all four heater assembly tabs before
tightening screws.
3. Connect the power lead wires (field wiring) to the lead
wires from the heater assembly. See wiring diagram
in next column.
4. Turn thermostat to the extreme counterclockwise
position.
5. Mount the grille using four (4) long screws provided.
The screws thread into holes located in the side
flanges of the back box.
6. Push thermostat knob onto thermostat shaft.
Fig. 3: Surface Mounting Installation
Fig. 4
HANG FRAME
ON BACK BOX
15-5/32"
(385mm)
19"
(482mm)
3-13/16"
(97mm)
MOUNT BACK BOX TO
WALL US NG REAR
MOUNT NG HOLES.
3
POWER
LEADS
RECESS BACK
BOX
HEATER
ASSEMBLY
THERMOSTAT
KNOB
GR LLE
1500, 4800, 4000, & 3000 WATT HEATERS
120V, 208V, 240V, OR 277V (Full wattage heaters can be converted to half
wattage by removing the red jumper wire connecting the top and bottom element ter-
minals.)
OTE: Conversion not applicable on K151.
4800, 4000, & 3000 WATT HEATERS
347V, 600V
2000 & 1500 WATT HEATERS
208V, 240V, OR 277V
WIRI G DIAGRAMS (S NGLE PHASE)
Element
Element
Element
Element
Element
Red
Fan Motor
TʼStat
GND
GND
F.D.
F.D.
Manual
Reset
Limit
Manual
Reset
Limit
Manual
Reset
Limit
Field
Wiring
Fan Motor
TʼStat
Field
Wiring
Fan Motor
!
CAUTIO
To assure proper operation of fan, thermostat must not cycle fan
on and off. Follow wiring diagram exactly.

Operation
1. Turn power to heater on at main switch panel. Rotate the
thermostat knob fully clockwise. This should energize the
heating elements and the fan, causing air to flow from the
air discharge at the openings in the bottom of the grille.
2. After the discharge air has become warm, rotate the
thermostat knob to the desired postion to obtain room
comfort.
OTE: For best results, the heater should be left ON con-
stantly during the heating season since the thermostat, when
properly set, will maintain the desired temperature.
IMPORTA T I FORMATIO
Maintenance
TO RESET MANUAL RESET L M T
Your heater is equipped with a manual reset safety thermal
limit control that will automatically turn the heater off to pre-
vent a fire if the heater overheats. This control is located on
the fan panel assembly between the element and fan blade
and marked “reset”. The red reset button can be seen
through the front grille when the heater is installed. To reset,
allow the heater to cool, then push the red button that is vis-
ible through the hole in the fan panel. The heater should
immediately return to normal operation.
The heater should be cleaned annually to remove dust and
other foreign material which has collected during the heating
season. This is a simple operation when performed as fol-
lows:
1. Turn off the electric power at main line switch (or
remove all fuses) to disconnect electric power from the
heater. TH S S MPORTANT.
2. Remove the grille (Fig. 4).
3. With a vacuum cleaner nozzle or dust cloth, remove
dust and other foreign material.
4. After cleaning reinstall the grille.
5. Turn on the main line switch (or replace fuses) to
restore power to the heater. The heater is now ready
for another season of operation.
MODEL NO. K404A DATE CODE: 0595
FAN FORCED WALL HEATER
APPARE L DE CHAUFFAGE MURAL À A R PLUSÉ
VOLTS AC 60HZ WATTS PHASE
240/208 4000/3000 1
MUST BE USED W TH BACK BOX
DO NOT OPERATE W THOUT FRONT COVER N
PLACE.
DO T ÉTRE UT L SÉ AVEC BOÎT ER ARR ÈRE AWH-BB
NE PAS UT L SER S LE COUVERCLE AVANT NʼEST PAS EN PLACE.
MARLEY ENG NEERED PRODUCTS
BENNETTSV LLE, SC 29512 4104-2093-028
774G L STED
ROOM HEATER
CAUTIO
!
CAUTIO
!
OPERAT ON OF THE MANUAL RESET SAFETY THERMAL L M T
CONTROL S AN ND CAT ON THAT THE HEATER HAS BEEN
SUBJECTED TO SOME ABNORMAL COND T ON. T S RECOM-
MENDED THAT THE HEATER BE CHECKED BY A REPUTABLE
ELECTR C AN OR REPA R SERV CE TO ENSURE THE HEATER
HAS NOT BEEN DAMAGED.
DO OT USE WATER OR DAMP CLOTH FOR CLEAN NG
AND DO OT D STURB THE HEAT NG ELEMENT.
4
EXAMPLE

LIMITED WARRA TY
All products manufactured by Marley Engineered Products are warranted against defects in workmanship and materials for one year from date of
installation, except heating elements which are warranted against defects in workmanship and materials for five years from date of installation. This
warranty does not apply to damage from accident, misuse, or alteration; nor where the connected voltage is more than 5% above the nameplate volt-
age; nor to equipment improperly installed or wired or maintained in violation of the productʼs installation instructions. All claims for warranty work must
be accompanied by proof of the date of installation.
The customer shall be responsible for all costs incurred in the removal or reinstallation of products, including labor costs, and shipping costs incurred
to return products to Marley Engineered Products Service Center. Within the limitations of this warranty, inoperative units should be returned to the
nearest Marley authorized service center or the Marley Engineered Products Center, and we will repair or replace, at our option, at no charge to you
with return freight paid by Marley. t is agreed that such repair or replacement is the exclusive remedy available from Marley Engineered Products.
THE ABOVE WARRANT ES ARE N L EU OF ALL OTHER WARRANT ES EXPRESSED OR MPL ED. AND ALL MPL ED WARRANT ES OF MER-
CHANTAB L TY AND F TNESS FOR A PART CULAR PURPOSE WH CH EXCEED THE AFORESA D EXPRESSED WARRANT ES ARE HEREBY
D SCLA MED AND EXCLUDED FROM TH S AGREEMENT. MARLEY ENG NEERED PRODUCTS SHALL NOT BE L ABLE FOR CONSEQUENT AL
DAMAGES AR S NG W TH RESPECT TO THE PRODUCT, WHETHER BASED UPON NEGL GENCE, TORT, STR CT L AB L TY, OR CONTRACT.
Some states do allow the exclusion or limitation of incidental or consequential damages, so the above exclusion or limitation may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
For the address of your nearest authorized service center, contact Marley Engineered Products in Bennettsville, SC, at 1-800-642-4328. Merchandise
returned to the factory must be accompanied by a return authorization and service identification tag, both available from Marley Engineered Products.
When requesting return authorization, include all catalog numbers shown on the products.
04/10
Part No. 5200-2267-007
ECR 38696
HOW TO OBTAI WARRA TY SERVICE A D
WARRA TY PARTS PLUS GE ERAL I FORMATIO
1. Warranty Service or Parts 1-800-642-4328
2. Purchase Replacement Parts 1-800-654-3545
3. General Product nformation www.marleymep.com
ote: When obtaining service always have the following:
1. Model number of the product
2. Date of manufacture
3. Part number or description
Replacement Parts
Key
No. Description Part Number
1 Fro t Cover 1402-2239-000
2 Motor: 208V 3900-2010-000
240V 3900-2010-000
120V 3900-2010-003
3 Ma ual Limit 4520-2013-000
4 Fa Delay 410074000
5 Thermostat 5813-2027-000
6 Eleme t: 208V/2000W 302015001
240V/2000W 302015002
277V/2000W 302015003
277V/3000W 302012006
208V/4000W 302012007
240V/4000W 302012008
240V/3000W 302012009
240V/4800W 302012010
277V/4800W 302012011
120V/1500W 302012827
7 Fa Blade 490030103
8 Parts Bag 1205-2070-001
470 Beauty Spot Rd. East
Bennettsville, SC 29512 USA