Hubbell Electric Heater Company V6 User's Manual
Contents
1. Hot Water 4 Incoming Cold Water 1 V Model Water Heater 2 Pressure and Temperature Relief Valve pipe overflow to floor drain or sink 3 Drain Valve 4 Pressure Temperature Gauge 5 Shut Off Valve 6 Union 12 3 Element 3 Hairpins 3 Phase 1 Contactor 3 Elements Hairpin Single Phase 2 Contactors 3 Element 3 Hairpins Single Phase 3 Contactors 1 Terminal Block 2 Magnetic Contactor 3 Heating Element 4 Low Water Cut Off if supplied 5 Transformer 480 Volt 240 Volt installed on 480 Volt models only 6 High Temperature Limit Switch 7 Control Thermostat 8 Illuminated On Off Switch JUMPER CONFIGURATION PHASE 208 OR 240 VOLT Z ZT MM 5 I QD os O 3 PHASE WYE 380 TO 575 VOLT 3 PHASE DELTA 208 OR 240 VOLT 0 SOS OQ 480 VOLT SECTION III SCHEDULED MAINTENANCE AND OPERATION WARNING CAUTION Before performing any maintenance procedure make certain power supply is OFF and cannot accidentally be turned on MAINTENANCE AND OPERATION The water heater is automatic in its operation It will maintain a full tank of water at the temperature setting of the thermostat The water heater should not be turned on without first making sure that the tank is full of water and that all air has been released FREEZING The tank should be fully drained in the event the electricity has been2. KW x 1000 SS 1 79 Volts panes KW x 1000 vn Amps 1 D Liters x 0 2641 Gallons Gallons x 3 79 Liters Gallons x 0 003785 m3 m3 x 264 2 Gallons 1 C AT 1 8 F AT oF 26 x 1 8 82 C F 32 x 0 556 psi x 0 06896 Bar Bar x 14 5 psi psi x 6 86 kPa kPa x 0 1456 psi Lbs x 0 4536 Kg Kg x 2 2 Lbs Watts Sq Cm x 6 4 Watts Sq In Watts Sq In x 0 155 Watts Sq Cm TORQUE VALUES SILICON ALUMINU 18 8 S S BRASS S S MONEL BOLT SIZE BRONZE 2024 ret HR Se JG ripe mo so so 90 18 _147_ 132 107 13 51624 142 116 ni 86 5848 I 3110 2545 2885 1995 3250 370 29
3. flush sediment from the bottom of the tank out through the drain Let water run for 3 4 minutes e Close drain valve f Open hot water valve g Turn power supply ON 18 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy No hot water Circuit breaker tripped at source Reset circuit breaker On Off switch in OFF position Turn switch to ON position Blown fuse in transformer if installed Replace fuse Circuit breaker at control cabinet tripped if installed Reset circuit breaker Blown fuse in element fuse block Replace fuse if installed High limit switch tripped Reset high limit switch Loose wires Tighten wires Torque screws per torque chart included in Section VI Heating element inoperable Check heating element operation by clamping an Amprobe around each wire to the element The ampere reading should agree with the nameplate AMP figure Low line voltage Have source electrical system checked by an electrician Faulty thermostat Move thermostat dial through full range A definite click should be heard If not replace thermostat Faulty low water cut off if installed Check to see if tank is full of water If not fill tank If problem continues and tank is full check for continuity between the common and normally open contact of the relay board If continuity is
4. not observed replace low water cut off Magnetic contactor does not energize Replace complete magnetic contactor Because of the design of this particular contactor it is more desirable to replace complete control rather than rebuilding coil contacts and springs etc 19 Water temperature below settings at all times Faulty thermostat Check thermostat adjustment Monitor thermostat as described in Section Quarterly Inspection Replace if necessary Heating element not working on all phases Check to see that heating element is working on all phases by checking the resistance ohms value for each element and comparing with the chart included in Section VI Blown fuse in element fuse block if installed Replace fuse Heater improperly sized Verify heater is properly sized for the flow rate and temperature rise of your system See formulas included in Section VI Replace elements with proper size as necessary Relief valve discharges continuously Excessive temperature or pressure in tank Temperature and pressure relief valves are made to operate if the water temperature exceeds 210 F or water pressure exceeds the pressure rating of the safety relief valve If trouble is excessive temperature then thermostat is not shutting off at the right setting and thermostat must be replaced 20 SECTION V SERVICING amp REPLACEMENT OF PARTS W
5. or an optional immersion high temperature cut off switch with manual reset adjustable through a range of 100 240 F is provided In the event of an over temperature condition the thermostat will disengage the power from the system The high limit must be manually reset thereafter to restart the heater Surface Mounted High Temperature Cut Off Switch MAGNETIC CONTACTOR The magnetic contactor s is a heavy duty resistive load type rated for 100 000 cycles The contactor supplies power to the heating element s based on the resistive load non inductive of the heater only when the thermostatic switch is engaged thereby pulling in the contacts until the desired temperature is reached At this point the contacts will drop out which in tum disconnects power from the elements Cutler Hammer 25 350 OUTER SHELL INSULATION AND SUPPORTS The tank is encapsulated in 2 inches of high density fiberglass insulation The protective shell is constructed of galvaneel and is coated with a durable silver hammertone finish NSF approved adjustable plastic legs are provided for support FUSED LOW VOLTAGE TRANSFORMER A fused low voltage transformer is supplied with all models rated for 480 volts This component is used to step down the 480 volt power supply to 240 volts for safety when working with control circuits As an option a transformer may be installed on any unit 56 7 DRE to step down the voltage to
6. 120 volts mite 8 BOSOBTZISIK MEET 24992 x x ON OFF SWITCH An illuminated on off switch is provided for positive verification heater status OPTIONS The following optional features may be included in your water heater Reference included drawing specific to your heater for further details Low Water Cut Off Used as a safety device the electronic low water cut off is used to detect a low water situation and disengage the operating coils in the magnetic contactor s Once the condition is remedied the low water cut off switch is automatically reset Stainless Steel Outer Jacket An optional stainless steel outer jacket may replace the standard galvaneel jacket Dial Temperature and Pressure Gauge A combination temperature 70 250 F and pressure 0 200 psi gauge with 24 inch dial may be supplied for in line installation shipped loose Vacuum Relief Valve A vacuum relief valve may be provided with the unit to reduce the risk of back siphonage and back pressure of the system The valve will be shipped loose for in line installation Instructions for installation are provided with the valve Individually Fused Elements To prevent the possibility of damage to control circuits and other elements in case of electrical overloads fuses may be supplied for each element Two types of fuses may be used a type NON for voltages less than 250 volt or type JJS for voltage less than 600 volt Built in Circuit
7. ARNING CAUTION Before servicing or replacing any part make sure to turn the power supply switch to the OFF position SURFACE TEMPERATURE HIGH LIMIT CUT OFF 1 Disconnect power from unit 2 Remove access cover 3 Disconnect the four 4 14 gauge wires Control Wires 4 Remove the two 2 mounting screws Mounting Screws 5 Replace control and install new high limit switch by performing above steps in reverse order See wiring diagram included with drawing for assistance 21 IMMERSION TEMPERATURE HIGH LIMIT CUT OFF 1 Disconnect power from unit 2 Remove access cover 3 Remove high limit cover screw and cover Cover Screw gt Reset Switch XL 4 Disconnect the two 2 14 gauge wires Capillary Tube 5 Remove capillary tube and bulb from thermowell 6 Remove two 2 mounting screws Mounting Screws 7 Remove control and install new high limit switch by performing above steps in reverse order Note Be sure to place capillary tube into slot in base prior to installing cover 22 HEATING ELEMENT 1 2 3 4 Lift manual release lever on relief valve to let air into system or break union on outgoing ONA 8 9 Disconnect power from unit Shut off incoming water supply Attach hose to drain connection water line Drain water from tank Disconnect the wires from the heating element terminals Remove the 3 8 16
8. Breaker A built in circuit breaker may be provided with or without shunt trip protection for protection from circuit overload Building Management System BMS A Building Management System control package may be supplied for remote operation and alarm capabilities Pump Interlock Terminal Block An optional pump interlock terminal block may be installed to prevent energizing when the pump is not running Silicon Control Rectifier A silicon control rectifier SCR zero fired power controller for 0 100 proportional control of heaters may be supplied Digital Display A 1 16 DIN electronic temperature control package may be installed A separate manufacturer s operating manual will be hromalo supplied with the unit Optional Connections Flanged inlet and outlet connections 150 Threaded inlet and outlet connections 1 2 MNPT Sanitary Connections Special Customized Features Please reference drawing for details SECTION II INSTALLATION WARNING CAUTION DO NOT TURN ON THE ELECTRIC POWER SUPPLY to this equipment until heater is completely filled with water and all air has been released If the heater is NOT filled with water when the power is turned on the heating elements will burn out For protection against excessive pressures and temperatures local codes require the installation of a temperature and pressure T amp P relief valve certified by a nationally recognized laboratory that maintains p
9. Install the combination temperature and pressure safety relief valve in the tapping provided Note that this is required by law for safety considerations Outlet to floor drain ia Install into provided tapping Manual Release I Temperature and Pressure Relief Valve Temperature Probe 5 Install a relief valve overflow pipe to a nearby floor drain CAUTION No valve of any type should be installed between the relief valve and tank or in the drain line FILLING THE HEATER 1 Open the pressure relief valve test lever to allow air to escape 2 Open the valve to the cold water inlet and allow the heater and piping system to completely fill as indicated by a steady flow of water from the relief valve ELECTRICAL INSTALLATION 1 Enter electric enclosure with properly sized feeder leads Single phase installations require two 2 leads three phase installations require three 3 leads 2 Install these power leads into the box lugs on the terminal block or magnetic contactor See wiring diagrams below 3 Torque screws per torque chart included in Section VI 4 All other electrical connections are made at the factory therefore no other electrical connections are necessary 11 FINAL CHECKS 1 Check all connections for tightness 2 Ensure that all the above steps are completed 3 After the water is heated for the first time monitor the water temperature as described in Section Quarterly Inspection Outgoing
10. OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC INDUSTRIAL PROCESS WATER HEATER ft ELECTRIC HEATER COMPANY BASE MODEL V6 and V15 HUBBELL ELECTRIC HEATER COMPANY P O BOX 288 STRATFORD CT 06615 PHONE 203 378 2659 FAX 203 378 3593 INTERNET l http www hubbellheaters com IMPORTANT Always reference the full model number and serial number when calling the factory WARNING CAUTION Tank is to be completely filled with water and all air is to be vented before energizing Due to the rigors of transportation all connections should be checked for tightness before heater is placed in operation Safety relief valve must be installed in tapping provided The refractory material used in heating elements may absorb some moisture during transit periods of storage or when subjected to a humid environment This moisture absorption results in a cold insulation resistance of less than twenty 20 megohms If this heater has been subjected to the above condition each heating element must be checked for insulation resistance before energizing A low megohm condition can be corrected by removing the terminal hardware and baking the element in an oven at 350 F 700 F for several hours or until the proper megohm reading is obtained KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS Do not perform any maintenance make any adjustments or replace any components inside the control panel with the high voltage power
11. e Capacity 6 gallons KW Range 4 thru 18 KW Shipping Weight 75 Ibs Storage Capacity 15 gallons KW Range 12 thru 58 Shipping Weight 140 Ibs KW MODEL NUMBER SELECTION CHART WITH AMPERAGE Amperage Draw By Voltage amp Pha 5 ETRE erter TARTE IT rg 04 03 17 14 7 er 10 09 Tan m 28 42 12 18 31 22 e aM 58 14 0 9 18 He 34 17 0 6 24 21 29 105 a 1 7 08 144 36 HBS 10 42 48 3 9 3 1 26 12 54 4 6 3 1 15 65 40 16 70 SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This booklet describes an electric water heater designed for use in an industrial or commercial application The complete assembly consists of the storage tank immersion electric heating element s thermostat safety relief valve safety high temperature cut out magnetic contactor s and any other required electrical operating control Optional equipment may be supplied with your unit Please consult the product drawing for details specific to your assembly The unit is factory assembled insulated jacketed wired tested and ready for electrical and plumbing service connections CONSTRUCTION TANK The storage tank is constructed of type 316L stainless steel for maximum tank longevi
12. eriodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves and Automatic Gas Shutoff for Hot Water Supply Systems ANSI Z21 22 1971 THE CUSTOMER IS RESPONSIBLE TO PROTECT PROPERTY AND PERSONNEL FROM HARM WHEN THE VALVE FUNCTIONS All water heaters have a risk of leakage at some unpredictable time IT IS THE CUSTOMER S RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER ADEQUATE MEANS SO THAT THE RESULTANT FLOW OF WATER WILL NOT DAMAGE FURNISHINGS OR PROPERTY WATER HEATER PLACEMENT 1 Place the heater on a solid foundation in a clean dry location nearest to the point of hot water use 2 The water heater should be protected from freezing and waterlines insulated to reduce energy and water waste 3 Leave a minimum of 18 clearance for element withdrawal if necessary 4 Do not install in an area where flammable liquids or combustible vapors are present PIPING INSTALLATION NOTE The most effective means for preventing deterioration from accelerated corrosion due to galvanic and stray current is the installation of dielectric fittings unions The installation of these fittings is the responsibility of the installing contractor 1 Connect the cold water inlet and hot water outlet to the appropriate connections as shown refer to the drawing for location and sizes 2 Install in line pressure and temperature gauge if supplied 3 Install in line vacuum breaker if supplied 10 4
13. in tank Disconnect overflow piping Unscrew relief valve remove assembly and replace with new one Connect overflow piping Turn on incoming water supply and check for leaks Turn safety switch to ON position Test Tank Connection Temperature Probe SECTION VI MISCELLANEOUS CHARTS AND FORMULAS ELEMENT CHART Power Watts Immersion Element Element Part 120V 208V 240V 480V Length Resistance Ohms 3500 11 3 8 12 36 4000 11 3 8 10 82 5000 13 1 4 8 65 2000 6000 13 3 8 7 21 3000 9 3 4 19 20 2500 3500 9 3 4 16 46 1 3000 4000 11 1 2 14 40 4500 11 1 2 12 80 5000 11 1 2 11 52 1500 4500 6000 13 1 2 9 60 1000 4000 13 5 8 41 62 4500 13 1 4 36 99 1000 5000 9 3 4 33 29 1500 6000 15 1 2 27 74 Power kW Immersion Resistance Ohms 2 5 3 4 13 576 192 576 386 4 5 6 13 344 115 344 230 5 6 8 13 279 93 279 187 1618 10 13 216 72 216 145 8 10 13 171 57 171 15 iof 15 13 144 48 144 96 N 11731 1 1 15 75 25 75 50 FORMULAS 28 GPH x FAT 0 00244 KW KW xX 410 GPR FAT KW x 410 __ F AT GPH Note 1 KW will heat 4 1 GPH at a 100 F AT
14. nuts Tank Flange Nuts Withdraw element assembly and remove gasket Gasket Element Assembly Install new gasket and insert new heating element 10 Rewire element according to the voltage and phase rating of the unit as shown below 11 Fill tank and check around gasket for any leaks 23 IMMERSION THERMOSTAT 1 Disconnect power from unit 2 Remove access cover and locate thermostat 3 Remove high limit cover screw and cover Cover Cover Screw l 4 Disconnect the two 2 14 gauge wires Wires Capillary Tube 5 Remove capillary tube and bulb from thermowell 6 Remove two 2 mounting screws Mounting Screws 7 Replace thermostat using reverse procedure Note Be sure to place capillary tube into slot in base prior to installing cover 24 MAGNETIC CONTACTOR 1 Disconnect power from unit 2 Disconnect line and load wires to contactor 3 Disconnect two 2 14 gauge control circuit wires Control Wires Line Wires Load Wires 4 Loosen two 2 holding screws and remove contactor Mounting Screws Bottom screw not shown 5 Replace with new contactor using reverse procedure 25 RELIEF VALVE Overflow Piping Outlet 26 1 O ON AR 909 Disconnect power from unit Shut off incoming water supply Lift test lever on relief valve to relieve pressure
15. supply turned on Under certain circumstances dangerous potentials may exist even when the power supply is off To avoid casualties always turn the power supply safety switch to off turn the charge or ground the circuit before performing any maintenance or adjustment procedure The unit is designed to operate at pressure not more than 150 psi Generalized instructions and procedures cannot anticipate all situations For this reason only qualified installers should perform the installations A qualified installer is a person who has licensed training and a working knowledge of the applicable codes regulation tools equipment and methods necessary for safe installation of an electric resistance water heater If questions regarding installation arise check your local plumbing and electrical inspectors for proper procedures and codes If you cannot obtain the required information contact the company TABLE OF CONTENTS SECTION TITLE Il VI GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING amp REPLACEMENT OF PARTS MISCELLANEOUS CHARTS AND FORMULAS PAGE 10 17 19 21 27 OUTLINE DIMENSIONS MODELS V6 AND V15 V6 Model V15 Model D T amp P Relief Valve Inlet 0 et i 141 181 2 Conduit Outlet Inlet J Opening 201 2 lt 31 Rear View Side View Front View Side View Storag
16. turned off and if there is danger of freezing QUARTERLY INSPECTION 1 Monitor thermostat Let water heater completely heat to a designated thermostat setting After thermostat satisfies that is when the thermostat actually clicks off draw water from heater Compare water temperature of drawn water to the temperature setting of the thermostat when it satisfies Normal variation between the two points is approximately 5 F If these two readings do not coincide within acceptable tolerances and verification has been made of the accuracy of the temperature reading gauge replace the thermostat 2 Lift test lever on relief valve and let water run through valve for a period of approximately 10 seconds This will help flush away any sediment that might build up in water passageways 3 Inspect element flange for leakage as follows e Shut off Power Supply Remove element housing cover Visually inspect heating element gasket for evidence of leaks Rub finger around gasket that is between the heating element and tank flange for any evidence of moisture If moisture is present or a water drip is observed follow procedure outlined in Section V 4 Check for loose electrical connections Tighten as necessary 17 ANNUAL INSPECTION 1 Flush tank as follows a Shut off power supply b Close valve on hot water outlet piping c Open valve on drain piping d Cold water inlet line pressure will be strong enough to
17. ty The tank is formed by all welded construction and is designed for a maximum allowable working pressure of 150 psi 300 psi TP TANK CONNECTIONS The heater is supplied with separate connections for the cold water inlet and the hot water outlet Water entering the cold water inlet is deflected by means of baffle within the tank 7 inch FNPT connection is provided for mounting a combination safety temperature and pressure relief valve An overflow line should be utilized from the relief valve outlet to a floor drain See drawing for locations and sizes HEATING ELEMENT The water heater is supplied with an electric immersion heating element assembly s composed of incoloy or copper sheathed elements that are brazed into a brass flange Each assembly is fastened to a corresponding tank flange using a gasket and four 4 3 8 16 x 1 inch long hex head steel bolts and nuts See drawing for voltage and power ratings CONTROL THERMOSTAT The water heater is supplied with a single stage immersion thermostatic switch that is installed and wired at the factory The thermostat can be adjusted through a range of 100 195 F an optional low range 30 110 F is available and is adjustable with a flat tip screwdriver Other thermostatic controls are available see Options below TEMPERATURE HIGH LIMIT SWITCH As a safety device either a surface mounted high temperature cut off switch with manual reset factory set at 205 F
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