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Hubbell Electric Heater Company T User's Manual

1. SURFACE MOUNTED THERMOSTAT if supplied 1 Disconnect power from unit 2 Remove access cover and locate thermostat 3 Disconnect the two 2 or three 3 14 gauge wires and jumpers as required Mounting Screws 5 Replace thermostat using the reverse procedure 23 IMMERSION THERMOSTAT if supplied 1 Disconnect power from unit 2 Remove access cover and locate thermostat 3 Remove high limit cover screw and cover Cover Cover Screw hs 4 Disconnect the two 2 or three 3 14 gauge wires as required Wires 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 Capillary Tube SECTION VI MISCELLANEOUS CHARTS AND FORMULAS FORMULAS GPH x F AT x 0 00244 KW KW x 410 GPH FAT KW x 410 F AT GPH Note 1 KW will heat 4 1 GPH at a 100 F AT _ ELECTRICAL KW x 1000 M Volts 3 Amps 3 KW x 1000 wap CTS IC CONVERSION Liters x 0 2641 Gallons Gallons x 3 79 Liters Gallons x 0 003785 m3 m3 x 264 2 Gallons 1 C AT 1 89F AT OF C x 1 8 32 90 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 Lb
2. annual scheduled maintenance Excess silt in bottom of tank Drain and flush tank per Section annual scheduled maintenance Overheating Ruptured tube s in heating Remove replace heating coil coil Thermostat needs adjusting Adjust thermostat Circulator not operating Repair or replace per separate O amp M Immediate loss of heating Blockage in return line Clean blockage from return line capacity Excessive vibration High rate of flow beyond Consult factory design conditions Under sized piping to the Re pipe lines to unit using proper unit sized lines Water hammer Undersized return lines Re pipe return line using proper sized lines Insufficient slope on return lines causing backup Increase slope on return lines Red symptom indicates that equipment should be shut down immediately and cause of malfunction corrected before unit is re started or serious damage may result 14 BACK UP ELECTRCIAL HEATER SYSTEM if supplied Symptom Probable Cause Corrective Action Remedy No hot water Circuit breaker tripped at source Reset circuit breaker 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 readi
3. Open valve on drain piping d Cold water inlet line pressure will be strong enough to 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 Units subject to fouling or scaling should be cleaned periodically A marked increase in pressure drop and or reduction in performance usually indicates cleaning is necessary To clean inside of tubes remove all heads and covers Caution Do not loosen heads until you are sure all pressure is off the equipment and the unit is drained Clean the unit using the following methods a Circulate hot fresh water at a reasonable velocity b Try spraying with water hose c Consult with manufacturers of cleaning compounds and chemicals They will check the nature of the deposit recommend the right cleaning compound and in many cases provide equipment and personnel for a complete cleaning job Ifthe unit is dismantled for any reason it should be reassembled using new gaskets Do not tighten bolts until gaskets are properly seated When tightening bolts in the element head tighten the bolts in a criss cross pattern This will evenly distribute pressure around the flange and help prevent warping 13 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy Gradual loss of heating capacity Tubes are fouled Clean tubes per Section
4. air has been released FREEZING The tank should be fully drained in the event the boiler water has been turned off and if there is danger of freezing QUARTERLY INSPECTION 1 Monitor thermostat a Let water heater completely heat to a designated thermostat setting b After thermostat satisfies that is when the thermostat actually clicks off draw water from heater c 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 d Ifthese 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 heating coil flange for leakage as follows a Remove heating coil housing cover b Visually inspect heating coil gasket for evidence of leaks c Rub finger around gasket that is between the heating coil 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 12 ANNUAL INSPECTION 1 Flush tank as follows a Shut off power supply b Close valve on hot water outlet piping c
5. 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 All integral components have been properly sized to meet design conditions Piping to the unit should be sized to meet the design conditions as dictated by good engineering practices 2 Connect boiler water supply and return lines to heating coil assembly 3 Connect the cold water inlet and hot water outlet to the appropriate connections as shown refer to the drawing for location and sizes 4 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 Install into provided tapping Manual Release Lever I Temperature Probe Temperature and Pressure Relief Valve 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 TRANSFLOW MODEL TYPICAL INSTALLATION Boiler Water Return Boiler Water Hot Water Supply Outlet T amp P Relief Valve Immersion Thermostat Boiler Water To Coil Removable Heating Coil Boiler Water Cold Water Out Of Coil 23 10 ELECTRICAL INSTALLATION 1 Connect electrical wiring from boiler controls and ci
6. nr 95 np UME PIO B 3 2 er ENG 1 lt _ i M e I LA e 9 6 de 6 f 9 8 2 Single Element Operation 4 2 I ST 3 0 Open Delta Wiring for Simultaneous Operation 21 Interlocked for Non Simultaneous Operation 22 Ll L2 155 L 9 Jelh0 D D N 2 7 N 2 0 9 9 ele D Z Z EN Non Interlocked for Simultaneous Operation NS
7. solid foundation in a clean dry location nearest to the point of most frequent hot water use If the heater is to be raised off the floor the entire bottom of the heater should be supported by a solid surface 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 1f necessary INSTALL THE HEAT EXCHANGER COIL Remove the access panel See diagram below 2 Insert the heat exchanger and align the holes in the cover plate with the slotted holes in the flange Note align heat exchanger pipe connections with the opening in the access panel 3 WARNING THE NYLON BUSHINGS MUST BE IN THE OPENINGS BEFORE THE BOLTS ARE INSERTED FAILURE TO DO THIS WILL VOID THE WARRANTY 4 Insert and secure the bolts to the nuts one at a time in the following manner Place the nut behind the slotted flange opening Hold the nut in place with one hand insert the bolt with the other Thread the bolt into the nut and tighten Proceed to the next opening NOTE BE SURE TO PLACE BOLTS IN ALL OF THE OPENINGS Nylon Bushing One of Eight Insulation Metal 144 x Vs Bolt H i eat Exchanger Coil m One of Eight y Steei Tank Va Hex Nut One of Eight Slotted Steel Flange Steel Flange Cover Plate Rubber PIPING INSTALLATION NOTE The most effective means for preventing deterioration
8. temperature cut off switch with manual reset factory set at 180 F may be provided In the event of an over temperature condition the thermostat will disengage the power from the back up electric heating system The high limit must be manually reset thereafter to restart the heater Manual Reset Surface Mounted High Temperature Cut Off Switch Immersion High Temperature Cut Off Switch SECTION II INSTALLATION WARNING CAUTION DO NOT TURN ON THE BOILER WATER SUPPLY to this equipment until heater is completely filled with water and all air has been released f the heater is NOT filled with water when the power is turned on damage to the heating coil may result 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 periodic 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
9. OPERATING AND MAINTENANCE MANUAL FOR COMMERCIAL INDIRECT POWERED WATER HEATER PHubbelt ELECTRIC HEATER COMPANY BASE MODEL T HUBBELL ELECTRIC HEATER COMPANY P O BOX 288 STRATFORD CT 06615 PHONE 203 378 2659 FAX 203 378 3593 INTERNET 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 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 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 ap
10. ating coil designed for a maximum working pressure of 150 psi The tubing is installed in a heavy duty fabricated steel head with threaded NPT connections Each assembly is fastened to a corresponding tank flange using a gasket and hex head steel bolts and nuts Double walled tubing may be supplied as an option CONTROL THERMOSTAT The water heater is supplied with an immersion thermostatic switch The thermostat can be adjusted through a range of 120 140 F OPTIONAL BACK UP ELECTRIC HEATING SYSTEM Back up Electric Heating Element The water heater may be supplied with an electric immersion heating element assembly s 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 may be supplied with either a surface mounted or immersion thermostatic switch to control the back up electric heating system See drawing for specific details The surface mounted thermostat can be adjusted through a range of 110 170 F The immersion thermostat can be adjusted through a range of 100 190 F Both thermostats are adjustable with a flat tip screwdriver Surface Mounted Thermostat Immersion Thermostat Temperature High Limit Switch As a safety device either a surface mounted high temperature cut off switch with manual reset factory set at 190 F or an immersion high
11. hut off incoming water and boiler water supply Lift test lever on relief valve to relieve pressure 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 EAM A E E Overflow Piping Outlet Tank Connection Temperature Probe 16 HEATING COIL 1 Disconnect power from unit 2 Shut off incoming cold and boiler water supply 3 Attach hose to drain connection 4 Lift manual release lever on relief valve to let air into system or break union on outgoing water line 5 Drain water from tank 6 Disconnect supply and return lines from heating coil 7 Remove bolts securing the heating coil to the tank flange Tank Flange gt Heating Coil Assembly Supply and Return Connections S 2 8 Withdraw heating coil assembly and remove gasket 9 Install new gasket and insert new heating coil assembly 10 Secure heating coil assembly to tank flange using bolt tightening pattern and torque as shown in Section III 11 Reconnect supply and return lines to heating coil 12 Fill tank and check around gasket for any leaks 17 SURFACE TEMPERATURE HIGH LIMIT CUT OFF if supplied 1 Disconnect power from unit 2 Remove access cover 3 Disconnect the four 4 14 gauge wires or three 3 14 gauge wires and a jumper as required Contro
12. l Wires Mounting Screws 5 Replace control and install new high limit switch by performing above steps in reverse order 18 IMMERSION TEMPERATURE HIGH LIMIT CUT OFF if supplied 1 Disconnect power from unit 2 Remove access cover 3 Remove high limit cover screw and cover 9 i Cover Screw Reset Ldbg i 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 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 19 HEATING ELEMENT if supplied Disconnect power from unit Shut off incoming water supply Attach hose to drain connection Lift manual release lever on relief valve to let air into system or break union on outgoing water line Drain water from tank 6 Disconnect the wires from the heating element terminals Pepe pls Wires 7 Remove the 3 8 16 nuts 8 Withdraw element assembly and remove gasket Gasket Element Assembly gt Nuts 9 Install new gasket and insert new heating element 10 Rewire element according to type of unit as shown below 11 Fill tank and check around gasket for any leaks 20 11 12
13. ng 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 Water temperature Faulty thermostat Check thermostat adjustment Monitor below settings at all times thermostat as described in Section III 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 expected rating Heater improperly sized Verify heater is properly sized for the flow rate and temperature rise of your system 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 15 SECTION V SERVICING amp REPLACEMENT OF PARTS WARNING CAUTION Before servicing or replacing any part make sure to turn the power supply switch to the OFF position RELIEF VALVE 1 Disconnect power from unit S
14. plicable 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 II GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING AND REPLACEMENT OF PARTS MISCELLANEOUS CHARTS AND FORMULAS PAGE 12 15 16 25 OUTLINE DIMENSIONS Top View 45 1 T amp P Relief Valve Hot Water Outlet Combination Cold Water Inlet amp Drain Thermostat Hot Water Outlet Protective Jacket T amp P Relief Valve Tank Cross Section 2 Foam Insulation Immersion Thermostat Controller Boiler Water Inlet Heating Coil Combination Cold Boiler Water Outlet Water Inlet amp Drain PPR RELY al Hg Side View Front View First hour ratings based on a 80 F rise 40 120 F when supplied with 6 GPM of 200 F boiler water SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes a packaged boiler water powered indirect water heater that is a stationary self contained unit The complete assembly on a standard unit consists of the storage tank immersion heating coil and an ASME rated combination tempe
15. rature and pressure safety relief valve 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 standard storage tank is constructed of steel and internally lined with specially formulated Hydrastone cement to a inch minimum thickness The tank is designed for a maximum allowable working pressure of 150 psi 300 psi TP TANK CONNECTIONS The heater is supplied with separate cold water and hot water connections Water entering the cold water inlet is deflected by means of a baffle within the tank The hot water outlet includes a built in heat trap to prevent hot water from radiating out from the heater 34 inch FNPT connection is located on the side of the heater for mounting a combination safety temperature and pressure relief valve An overflow line should be installed from the relief valve outlet to a floor drain A 4 inch GHT connection is supplied for draining See drawing for locations and sizes OUTER SHELL AND INSULATION The tank is encapsulated in 2 inch thick polyurethane foam insulation The insulation is protected by a high impact non corroding colorized composite protective jacket HEATING COIL The water heater is supplied with a high quality factory installed high efficiency single walled copper finned he
16. rculator pump to immersion thermostat 2 If supplied with a back up electric heating element enter electric enclosure with properly sized feeder leads Be sure to properly ground the water heater Install these power leads into the box lugs on the terminal block 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 FILLING THE HEATER 1 Completely close the drain valve 2 Open the highest hot water faucet to allow all air to escape from piping 3 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 open faucet FINAL CHECKS 1 2 Check all connections for tightness Ensure that all the above steps are completed After the water is heated for the first time monitor the water temperature as described in Section III Quarterly Inspection 11 SECTION III SCHEDULED MAINTENANCE AND OPERATION WARNING CAUTION Before performing any maintenance procedure make certain boiler water and electric 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
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Hubbell Electric Heater Company T User's Manual

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