INSTALLATION AND SERVICE MANUAL Post these instructions in
Contents
1. DISHWASHERS BOOSTER HEATER SIZING CHART 40 F RISE 70 F RISE ADAMATION CSL 1390 CA 2 CA 3 CA 4 439B 2 436B CA CA 1 554B 2 545B UC 21 306B 312B D 8 309B 313B Series amp F CC EE LL MM LLL MMM PCC PEE PLL PMM Multi tank with suffix LC 313B BEAP Series XF LL XF PLL XF MM XF PMM XF EEE XF LLL XF MMM 5175 4308 BLAKESLEE Multi tank with suffix LC DD 8 318B 430B Series R L R PL R M R PM F L F PL F M F PM single tank 436B 554B Series XF L XF PL XF M XF PM single tank 2 436B Series XF PEE XF PLL XF PMM XF EEE XF LLL XF MMM Multi tank 545B 2 430B FA Flight A Round and RA Rack A Round use comparable listing UH1 306B 309B DH1 DH1C 309B 318B 44WS 66WS 315B 427B CHAMPION PP28 427B 545B 40KB 44KB 54KB 60KB 64KB 436B 554B UC C 545B 2 436B UC CW 6 ft center max 554B 2 439B CHEMICAL METHODS CMA 44H with tank heater 424B 545B ASSOC LX 30 304B 307B LX 18C XL 30C LX 40C UM 4D UMP 4D WM 1D WMP 1D WM 5 304B 307B LX 18 305B 309B WM 5C 306B 309B SM 6T2 306B 312B WM 5 307B 312B AM 14T AM 14F AM 14TC 309B 313B UM 4 UMP 4 WM 1 WMP 1 309B 315B AM 12 AM 12C AM 14 AM 14C 309B 312B C 44AW CRS 66AW CPW 80AW 312B 424B HOBART C 64W CRS 86W CPW 100W C 88W CRS 110W CPW 124W 424B 436B FT800W 424B 439B C 64A CRS 86A CPW 100A CMT 44 430B 554B cer UR CPW 80 C 44A CRS2. att 93 MM PRESSURE REDUCING VALVE WITH BY PASS ALL MODELS 140 60 INLET e oh m 19 MM DRAIN UNION Figure 1 Dimensions and Piping Diagram 1 2 TECHNICAL SPECIFICATIONS Maximum Operating Pressure Maximum Operating Water Temperature Water Capacity in boiler 4 18kW Water Capacity in boiler 24 54kW Inlet and Outlet Pipe Size CSA 130 p s i 210 F 4 27 US Gallons 5 80 US Gallons 3 4 NPT Electric Booster Installation Operating and Maintenance Instructions i Dimensions Piping Diagram and Specifications Section 1 TABLE 1 Super Hot Electric Booster Heater Specifications Flange Type Elements BOOSTER MODEL NUMBERS kW RATINGS AND MAX AMPERAGE DRAW Approx Number kW Btu Hr Capacity 40 F Rise Single Phase Three Phase Shipping U S Gal 208 240 208 240 480 Weight 304B 4 13 649 4 27 41 19 2 16 7 60 LBS 305B 5 17 062 4 27 52 24 0 20 8 60 LBS 306B 6 20 474 4 27 62 28 8 25 0 16 6 14 4 7 2 5 8 60LBS 307B 7 23 884 4 27 72 33 7 29 2 21 0 18 2 9 1 7 3 60LBS 309B 9 30 711 4 27 93 43 3 37 5 250 21 6 10 8 87 60LBS 312B 12 40 948 4 27 124 57 7 50 0 33 3 288 144 11 5 65
3. INSTALLATION AND SERVICE MANUAL SPACESAVER ELECTRIC BOOSTER HOT WATER HEATERS MAKE DISHWASHING CLEANER SAFER AND MORE EFFICIENT 4 kW to 54 kW 208 Vac to 600 Vac Single or Three Phase 180 F instantaneous hot water for commercial dishwashers Suitable for installation with all name brand dishwashers WARNING Risk of electric shock This unit may be connected to more than one electrical circuit Disconnect all electrical circuits before servicing IMPORTANT The booster heater must be installed in accordance with all local codes This manual must be left with owner and should be hung adjacent to the booster heater for reference Ensure booster heater is full of water before turning on electricity Elements will burn out immediately without water in the booster heater Booster heater voltage must be correct for voltage available Check nameplate on the booster heater for full information Overcurrent protection between the power supply and the booster heater must be provided in accordance with the related code Always ensure power switch is turned off before servicing Under no circumstances should any electrical wiring or internal controls be touched except by a qualified electrician or any heating system be adjusted except by a qualified service technician Post these instructions in a visible place DATE OF INSTALLATION INSTALLED BY PHONE Manufactured by Allied Engineering Company S p Division of E Z R
4. 124 469 100 379 83 314 71 269 62 235 55 208 313B 13 180 681 135 511 108 409 90 341 77 291 67 254 60 227 315B 15 208 787 156 590 125 473 104 394 89 337 78 295 69 261 318B 18 249 942 187 708 149 564 125 473 107 405 93 352 83 314 424B 24 332 1256 249 942 199 753 166 628 142 537 125 473 111 420 427B 27 374 1415 280 1060 224 848 187 708 160 606 140 530 125 473 430B 30 415 1571 311 1177 249 942 207 783 178 673 156 590 138 522 436B 36 498 1885 373 1412 299 1132 249 942 213 806 187 708 166 628 439B 39 539 2040 405 1533 324 1226 270 1022 231 874 202 765 180 681 545B 45 622 2354 467 1767 373 1412 311 1177 267 1010 233 882 207 783 554B 54 747 2827 560 2120 448 1695 373 1412 320 1211 280 1060 249 942 Electric Booster Installation Operating and Maintenance Instructions Installation Instructions Section 2 2 1 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipment or non delivery must be filed immediately against the carrier by the consignee 2 2 INTRODUCTION With a great reputation of quality and reliability Super Hot boost
5. 66A CPW 80A C 88A CRS 110A 436B 554B C 64 CRS 86 CPW 100 545B 2 436B FT 600 FT 700 C 54 CRS 76 CPW 90 554B 2 439B FT 300 554B 2 545B FT800 439B 554B FT800S CRS 76A CPW 90A C 54A 439B 2 436B UTW 28 UTW 28C 318B 436B jr Electric Booster Installation Operating and Maintenance Instructions Booster Heater Size for Dishwasher Instructions Section 6 DISHWASHERS BOOSTER HEATER SIZING CHART 40 F RISE 70 F RISE Commander 18 3 18 4 18 4h Ensign 40 2 306B 312B Trac 321 Trac 321 2 RPW 318B 430B Admiral 44 4 66 4 424B 436B Acmiral 44 66 3 424B 439B INSINGER Speeder 7 64 86 3 Century 14 424B 545B Master all 436B 554B Clipper all 424B 545B R106 2 Super 106 2 427B 545B Defender 436B 554B JP 24 JP 24B JP 24F JP 24BF 304B 306B 24B Series 304B 10AB 10APRB 305B 44CE 66 CERPW 430B 554B 54CE 76 CERPW 436B 2 430B 64CE 86 CERPW 427B 439B 100 312B 424B JACKSON 100B 100PRB 150B 150PRB 309B 150 312B 318B 200 307B 312B 200B 306B Tempstar Tempstar SDS 306B 312B AJ 44 AJ 66 AJ 80 424B 545B AJ 54 AJ 76 AJ 90 436B 2 430B AJ 64 AJ 86 AJ 100 424B 439B Model 44CE w SN1999 or below requires larger booster than listed KNIGHT EQUIPMENT KLE 112 HL 307B 312B CANADA LTD FW4 312B 318B SF 1RA SC20 1 307B 312B SF 2RA SF 2DRA SD 2RA SDRA SDRA PACK 31
6. 2B 318B SCT 44 SCT 44 10 SCT 54 SCT 76S SCT 76SC SCT 76SM 436B 554B SCT 64 SCT 76 SCT 80 SCT 94 SCT 108 SCT 120 SCT 948 SCT 108S SCT 120S SCT 94SC SCT 108SC SCT 120SC SCT 94SM 545B 554B SCT 120SM SCT 150SM U 31 A 436B 554B uat STPCW 19 STPCW 19PS STPCW 20 STPCW 22 45B 2 436B STERO STPCW 12PS STPC 15S 554B 2 554B STPC 12PS STPC 15S 554B 2 439B STPC 15 STPC 19 STPC 19S STPC 20 STPC 22 STPC 24 436B 2 430B STBUW 14 554B 2 554B SC 2 4 SC 6 4 SC 1 2 3 SC 1 6 4 SC 5 6 4 SC 5 2 4 436B 545B eua so eae 1 2 7 4 SC 1 6 3 4 SC 5 2 3 4 430B 2 427B SC20 2 312B 424B iu 5 6 8 SC 6 8 SC 6 9 SC 1 6 8 SC 5 6 9 318B 436B R16BTF CU16BTF 309B 318B VULCAN HART 3D201FCD201IF l 312B 424B A 64 Series A 81 Series 430B 554B A44 Series A54 Series CP 2 CP 3 HP 3 545B 2 439B Sue Electric Booster Installation Operating and Maintenance Instructions General Information Section 7 7 1 REPLACEMENT PARTS DESCRIPTION z o FRONT PANEL INDICATOR LIGHT OPERATING AQUASTAT HIGH LIMIT AQUASTAT LOW LEVEL CUT OFF PROBE OPTIONAL FLANGE TYPE ELEMENT FLANGE TYPE ELEMENT GASKET TANK LEGS 10 HANGING SUPPORT BRACKETS OPTIONAL 11 CASING 12 REAR PANEL 13 GROUND LUG 14 CONTACTOR 15 TRANSFORMER 16 RIGHT CASING PANEL 17 FUSE HOLDER SOME MODELS 18 FUSE SOME MODELS 19 LOW WATER CUT OFF CONTROLLER OPTIONAL 20 POWER TE
7. LBS 313B 13 44 356 4 27 135 62 5 54 2 37 6 32 65 16 3 13 0 65LBS 315B 15 51 185 4 27 156 72 1 62 5 46 4 40 2 20 1 16 1 65LBS 318B 18 61 422 4 27 187 86 5 75 0 54 6 47 3 23 7 189 70LBS 424B 24 81 895 5 80 249 115 100 66 5 577 288 231 70LBS 427B 27 92 124 5 80 280 130 113 749 649 324 260 70LBS 430B 30 102 369 5 80 311 144 125 832 721 360 288 75LBS 436B 36 122 843 5 80 373 173 150 100 86 5 433 346 75LBS 439B 39 133 068 5 80 405 188 163 108 93 7 48 8 39 1 80LBS 545B 45 153 554 5 80 467 216 188 125 108 54 1 43 3 90LBS 554B 54 184 264 5 80 560 260 225 150 130 649 519 90LBS SPECIFY MODEL NUMBER VOLTAGE AND EITHER 1 OR 3 PHASE WHEN ORDERING Delta connection unbalanced load amperage of high leg indicated 1 3 WATER TEMPERATURE RECOVERY Booster Heater water recovery formulas 415 x kW 874 x kW G P H U S L P H Temp Rise F Temp Rise C TABLE 2 Water Temperature Recovery in GPH LPH Model kW 30 F 17 40 F 22 C 50 F 28 C 60 F 33 C 70 F 39 80 F 44 90 F 50 C 304B 4 55 208 41 155 33 125 28 106 24 91 21 79 18 68 305B 5 69 261 52 197 41 155 34 129 29 110 26 98 23 87 306B 6 83 314 62 235 50 189 41 155 35 132 31 117 27 102 307B 7 97 367 72 272 58 219 48 181 41 155 36 136 32 121 309B 9 124 469 93 352 75 284 62 235 53 200 47 178 41 155 312B 12 166 628
8. RMINAL BLOCK 1 o o Figure 3 Replacement Parts 7 2 ORDERING A replacement or replacement parts may be purchased through any Allied Engineering Company distributor call us to help locate a distributor near your area If you require any technical assistance or have any comments about our product please write or phone us Service Department Allied Engineering Company 94 Riverside Drive North Vancouver B C V7H 2M6 Telephone 604 929 1214 Fax 604 929 5184 10 Electric Booster Installation Operating and Maintenance Instructions Trouble Shooting Section 8 831 TROUBLE SHOOTING Problem Possible Cause Solution Temperature too low or too Incorrect thermostat setting Remove booster heater front panel high Read rinse thermometer Adjust thermostat to correct setting on dishwasher and check thermometer during rinse cycle If machine cold run rinse cycle twice before checking proper reading Temperature should reach 180 F 185 F 82 C 85 Thermostat fault Check and replace if necessary Rinse water temperature still Water supply to booster Read incoming water temperature by too low during continuous use heater below 140 F 60 C combination gauge Incoming temperature should be 140 F 60 unless booster heater is specifically designed for l
9. becoming involved in corrective work on the booster heater the following steps should be followed Check the temperature of the water feeding into the booster heater tank It must be 140 F or the temperature designed and must be in sufficient quantity to hold its temperature throughout the dishwashing operation Incoming water temperature to the booster heater should not exceed 170 F If incoming water exceeds 20 psi a pressure reducing valve must be installed If the wash tank of the dishwasher is filled through the booster heater this will use up all the 180 F water in storage Sufficient time must be allowed to reheat the water in storage before starting the dishwasher Water pressure at the inlet to the booster heater must be adequate for proper operation of the rinse cycle of the dishwasher Be sure that the relief valve is one supplied by Allied Engineering Company A check valve should not be installed ahead of the booster heater Remove if present Electric Booster Installation Operating and Maintenance Instructions Booster Heater Size for Dishwasher Installations 6 1 BOOSTER HEATER SIZING CHART All sizing are based on dishwasher manufacturer ratings applications TABLE 3 Super Hot Booster Heater Sizing for Dishwashers Section 6 Confirm the booster size with dishwasher manufacturer before ordering it Allied Engineering Company is not responsible for incorrect sizing of
10. dea 11 9 0 Notes cuoio on ey 13 100 Madek X 14 14
11. ect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Tankless Coils Electric Boosters 94 Riverside Drive North Vancouver B C V7H 2M6 e Telephone 604 929 1214 e FAX 604 929 5184 C US Branches Calgary e Edmonton e Toronto OPTIONAL PN5152451 PRICE 6 Electric Booster Installation Operating and Maintenance Instructions Dimensions Piping Diagram and Specifications 1 1 DIMENSIONS AND PIPING DIAGRAM Section 1 19 4 TO 15 KW 483MM TEMPERATURE AND PRESSURE RELIEF VALVE IE end DIATROL 536 MUST BE INSTALLED ON BOOSTER OUTLET AS CLOSE TO DISHWASHER AS POSSIBLE POSITION WHEN INSTALLING WITH BODY ABOVE PIPELINE PREFERABLY IN A VERTICAL POSITION m 24 18 TO 54 KW 610MM 1 1 12 THIS PANEL IS REMOVABLE 5 805 MM FOR ELECTRICAL CONNECTION 318 MM J 3 T6 MM Y 1 1 05MM Thm 88 DISHWASHER DENOTES FURNISHED ITEMS 17 432 MM 113 298 A 4 A 28 61 MM 3 NPT OUTLET 3 NPT INLET 2 61 MM gt 1 25 MM t NPT RELIEF VALVE ei OPENING 31 83 MM 180 F 82 C HOT WATER TO RINSE HEADER OF DISHWASHER 7 1 TEMPERATURE AND 1 PRESSURE GAUGE l 1 1 T v 616 163 MM
12. er heaters can produce 180 F rinse water making dishware cleaner odorless and safer Compared with other methods of sanitizing the Super Hot Electric Booster is the economical choice having high efficiency and using less detergent and rinse additives Super Hot booster heaters provide the best sanitation method for your dishware dishwashing 2 3 CAUTION 1 Disconnect all power supplies to prevent electrical shock and damage to equipment 2 Installer must be a qualified experienced service technician 3 Conduct a thorough checkout when installation is complete 2 4 BOOSTER HEATER LOCATION The space saving compact booster heaters can be installed almost anywhere The booster heater may be installed in an enclosed space and attached directly to a combustible surface however allow ample space for connecting disconnecting and servicing the unit Locate booster heater as close to dishwasher as possible Dimensions are shown in Figure 1 Sturdy plated steel legs are standard but stainless steel hanging brackets for under counter suspension are also available specify when ordering see Figure 2 2 5 PIPING Figure 2 Optional Hanging Brackets The recommended piping arrangement is shown in Figure 1 Use copper tubing only Install the pressure reducing valve preset for 20 psi Install the temperature and pressure relief valve on the booster heater and plumb discharge in accordance with local codes The temperature and pre
13. hould be installed between the pressure reducing valve and booster heater When dishwasher is not equipped with a temperature gauge a second gauge should be installed as close to dishwasher as possible to verify 180 F rinse temperature Temperature and Pressure Relief Valve The relief valve protects the tank from becoming overheated and or over pressurized It opens and releases water if the temperature exceeds 210 F or if the pressure exceeds 125 psi satisfies most local codes This device must be installed directly on the booster heater Pressure Reducing Valve with By Pass When the supply pressure exceeds the final rinse pressure requirements a pressure reducing valve with built in by pass should be installed in the supply line to the booster heater A pressure reducing valve without a by pass should not be installed as water expansion due to heating will cause the relief valve to open Optional Extra Low Water Cut Off A number of service calls are caused by energizing the heating elements in a dry tank Even momentary testing of the installation when the tank is dry will appreciably shorten the life of the element or burn it out and affect the calibration of the aquastat The low water cut off will protect from burnout of heating elements by checking that the tank is completely filled with water before allowing the elements to operate Electric Booster Installation Operating and Maintenance Instructions Wi
14. noperative Relief valve not reseating properly Element and thermostat threads may be leaking Section 8 Solution Remove front cover Adjust thermostat to a lower setting Replace with correct pressure reducing valve While unit in heating cycle tap pressure reducing valve with wood hammer or screwdriver handle If pressure gauge does not show drop in pressure replace pressure reducing valve Quickly lift and release manual discharge lever on relief valve to assist proper reseating If this fails replace temperature and pressure relief valve Turn off electricity to booster heater and tighten elements Turn off water drain remove and apply sealant if necessary Be sure to turn off electricity before draining or elements will burn out Plumbing connections may Tighten incoming pipes heating be leaking elements temperature 12 pressure relief valve Turn off water drain and remove and apply sealant if necessary Be sure to turn off electricity before draining or elements will burn out Electric Booster Installation Operating and Maintenance Instructions Notes Section 9 13 Electric Booster Installation Operating and Maintenance Instructions Index Section 10 10 0 INDEX Section DescriptlOri fective d eA a dares ieee de entr et Edo di ka Re n Ra OR Y REPRE Page 1 0 Dimensions Piping Diagram and Specifications 1 1 Dimensi
15. ons and Piping Diagram nennen nnne ener rennes 2 1 2 Technical Specifications 4 22 tei eat aeta de dd eens Mae a 2 1 3 Water inneren nnne nn 3 2 0 Installation Instructions 2 1 aeu 4 2 2 LEen o n m 4 2 3 erum 4 24 Booster Heater Location reden cet edo o dede dde ded au edu din 4 2 5 uu E M 4 2 6 Function of Piping 4 3 0 Wiring and Control Instructions 3 1 6 3 2 i rise oi debby die Do ee NR 6 4 0 Start up Instructions 4 1 URN TOt S RTI eT n n UA eT LAT 7 5 0 Maintenance 5 1 ImpOEFLant enema ete es tre e 7 6 0 Booster Heater Size for Dishwasher Installations 6 1 Booster Heater Sizing Chart etate etu e etit edes 8 7 0 General Information 7 1 Replacement Parts it indere a UR E ht desee bia ash e 10 7 2 Orderirigssss irm au c LU chc dM cc DL M Ebr 10 8 0 Trouble Shooting 8 1 Trouble Shooting 5 uto eon e te e c ue pae P eb
16. ower supply temperature Increase incoming water temperature to 140 F 60 C at hot water supply tank Pressure setting of pressure Read pressure on combination gauge reducing valve too high during rinse cycle Pressure reducing valve PRV should be adjusted to dishwasher specifications usually between 20 25 p s i Thermometer on dishwasher Tap thermometer gauge with finger not functioning properly during rinse cycle If needle does not move freely contact dishwasher manufacturer Booster heater too far from Insulate pipe from booster heater to dishwasher more than 3 ft dishwasher Relocate booster heater closer to dishwasher Heating element s burned Turn off electricity to the booster out faulty contactor or loose heater Check elements contactor wires and wiring for continuity 11 Electric Booster Installation Operating and Maintenance Instructions Trouble Shooting Problem Pressure temperature relief valve discharges water Pressure temperature relief valve discharges water after checking above Water leaking from booster heater Possible Cause Thermostat set too high above 185 F 85 C Pressure increases to 125 p s i during booster heater heating cycle because A Pressure reducing valve is an incorrect style without relief by pass Letter should be in model number B By pass in pressure reducing valve plugged or i
17. ring and controls Instructions Section 3 3 14 WIRING CAUTION AC ONLY USE COPPER WIRE ONLY DO NOT USE ALUMINUM All electrical wiring is to be done in accordance with the Canadian Electrical Code CSA C22 2 part 1 and or any local regulations and codes in Canada or the National Electrical Code ANSI NFPA 70 latest edition and or any local regulations and codes in U S A Verify the nameplate rating and check the related codes to properly size conductors switches and over current protection Check the voltage at the feeder panel compare to the values shown in Table 1 and supply the correct voltage power to the power supply block on the booster heater For wire connections refer to the wiring diagram sticker on the back of the booster heater front cover 3 2 CONTROLS A custom designed rapid response aquastat provides temperature control ensures safe operation The aquastat switch incorporates a magnetic contactor to complete the power circuit to the heating elements and control the water temperature By use of an adjustable dial the operating aquastat can control the water to the desired temperature The electrical controls come pre wired on the right hand side of each booster heater where it is protected from high ambient temperatures An indicator light visible on the front panel indicates that there is power to the heating elements when the booster heater is in operation The low water cut off optional uses a resistance
18. sensing probe to determine if the booster heater is filled with water If the booster heater is filled with water the relay coil will close and allow the element to turn on Sensing resistance is dial adjustable turn dial clockwise to increase sensitivity Electric Booster Installation Operating and Maintenance Instructions Start up Instructions Section 4 4 1 START UP WARNING The following instructions are intended as a guide for qualified persons Before switching power on fill system with water and vent air Check for and repair any leaks in water piping Perform the following procedure to check for proper booster heater operation 1 Set operating aquastat to give desired water temperature for dishwasher usually 180 F 2 The operating aquastat setting should be at least 20 F less than the temperature relief setting 2109F 3 Lift relief valve handle to ensure the booster heater is completely filled with water 4 Check flow pressure with water flowing through the booster heater and if necessary readjust the pressure reducing valve to 20 psi or to pressure recommended by dishwasher manufacturer 5 The pilot lamp indicates that power is on when booster heater is operating Maintenance Instructions Section 5 5 1 IMPORTANT Many times when a booster heater does not appear to be functioning properly the fault lies not with the booster heater itself but with factors outside of the heater Therefore before
19. ssure gauge attaches to a tee on the inlet between reducing valve and booster heater It is mandatory that a diatrol expansion chamber and shock absorber be installed in the line between booster heater and dishwasher as close to dishwasher as possible In addition it is recommended that the inlet and outlet lines be insulated to prevent heat loss and that unions be used for piping connections to ease service All Super Hot booster heaters have 3 4 NPT inlet and outlet pipe size Dielectric couplings should be used in connecting dissimilar metals such as galvanized to copper to prevent electrolysis A check valve should not be installed in the supply line to the booster heater All shut off valves must be gate or ball valves not globe valves 2 6 FUNCTION OF PIPING ACCESSORIES Expansion Chamber Quick closing solenoid valves on the dishwasher will produce a shock pressure exceedingly high up to 800 Ibs This may cause leaks the plumbing and damage equipment such as relief valves gauges tank and etc To extend the life of the booster heater and other equipment we recommend that a Diatrol be installed on all installations 4 Electric Booster Installation Operating and Maintenance Instructions Installation Instructions Section 2 Temperature and Pressure Indicating Gauge This gauge indicates the temperature and pressure and is useful when determining incoming water temperature or adjusting the pressure reducing valve It s
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