Hubbell Electric Heater Company EMV User's Manual
Contents
1. Element Assembly RPA RES 92 9 Install new gasket and insert new heating element 10 Rewire element according to the drawing and in accordance with the jumper configuration as shown below for your heater 11 Fill tank and check around gasket for any leaks 16 3 PHASE ELEMENT JUMPER CONFIGURATION JUMPER CONFIGURATION 3 PHASE DELTA 208 OR 240 VOLT 89 EY 3 PHASE WYE 380 TO 575 VOLT 480 VOLT IMMERSION THERMOSTAT 1 Disconnect power from unit 2 Remove access cover and locate thermostat 3 Remove high limit cover screw and cover oO Cover ee RR Cover Screw 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 18 MAGNETIC CONTACTOR 3 PHASE ONLY 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 19 RELIEF VALVE Overflow Piping Outlet 20 l 9o2. 15 15 35 joo 6000 15 1 2 12 79 1500 2000 6000 15 1 2 27 74 wattage indicates the stamped element rating Note Element part numbers ratings and lengths are subject to change without notice 3 PHASE ELEMENT CHART Immersion Length 576 192 576 386 42 144 42 289 1 216 72 216 145 5 57 171 115 13s 44 48 96 1 1 1 91 30 91 61 75 25 75 50 22
3. Ug eA Disconnect power from unit Shut off incoming 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 Test Lever Tank Connection Temperature Probe essai MIXING VALVE l Hot Water Inlet 9o c gy on secas Disconnect power from unit Shut off incoming water supply Lift test lever on relief valve to relieve pressure in tank Drain tank Disconnect unions on both sides of the mixing valve Remove mixing valve Replace mixing valve Fill system in accordance with procedures on page 9 Acorn Nut Cap Cold Water Inlet Tepid Water Outlet RE CALIBRATE MIXING VALVE l 2 3 525929054 Remove small domed acorn nut on top of the diaphragm actuator Without turning the adjustment screw loosen the locknut securing the adjustment screw Turn on the water at the shower or eye face wash and monitor the water temperature during calibration Using a 1 8 allen wrench turn the adjustment screw counter clockwise to raise the outlet water temperature or clockwise to lower the outlet water temperature Start by turning the adjustment screw only one full turn then observe the water temperature and the shower or eye face wash fixture If needed turn the ad
4. OPERATING AND MAINTENANCE MANUAL FOR PACKAGED ELECTRIC TEPID WATER HEATING SYSTEM AP ELECTRIC HEATER COMPANY BASE MODEL 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 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 supply turne
5. d 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 CONTENTS SECTION TITLE II GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING amp REPLACEMENT OF PARTS ELEMENT CHARTS PAGE 12 13 22 OUTLINE DIMENSIONS 19 Withdrawal Space Pr Automatic Air Vent Valve Tank Cross Section T amp P Relief Valve prr T amp P Gauge Hi Limit Thermostat B Mixing Valve Protective Jacket Tepid Water Outlet Thermostat Sensor 3 Foam Insulation D D
6. fill as indicated by a steady flow of water from the open outlet ELECTRICAL INSTALLATION 1 Enter junction box with properly sized feeder leads 2 Connect these power leads to wires enclosed in junction box with wire nuts 3 All other electrical connections are made at the factory therefore no other electrical connections are necessary 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 III Quarterly Inspection 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 been turned off and if there is danger of freezing MONTHLY INSPECTION MIXING VALVE NOTE The mixing valve should be tested in conjunction with regular OSHA required shower eyewash testing These tests confirm that the equipment is safe and operational and also serve to purge potential bacteria laden water from the system 1 Monito
7. gh temperature alarm dry contacts are available with the optional immersion high limit cut out switch to remotely alarm when the tank water temperature rises above the high limit setpoint Outdoor Weather Package The optional outdoor weather package includes a 304 stainless steel outer protective Jacket a weather resistant electrical housing and 6 high tank legs to raise the entire unit off the floor Flow Alarm An optional flow alarm may be included to signal that there 15 tepid water flow Explosion Proof Construction The system may be constructed for installation in a hazardous location Mixing Valve Enclosure An optional fiberglass enclosure provides added protection for the mixing valve in outdoor environments Multiple Units Multiple units may be piped together to meet the needs of larger demand systems Alternate Heat Sources An optional heat exchanger may be factory installed to utilize steam or boiler water as the heating source 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 f 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 period
8. ic 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 PROPERTY WATER HEATER PLACEMENT 1 Place the heater on a solid foundation in a clean dry location nearest to the point of most frequent tepid water use 2 The water heater should be protected from freezing and waterlines insulated to reduce energy and water waste Leave a minimum of 18 clearance for element withdrawal 4 Do not install in an area where flammable liquids or combustible vapors are present except when installed with the explosion proof option 95 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 tepid water outlet to the appropriate connections as shown below refer to the drawing for location and sizes 2 Install the combination temperature and pressure safety relief valve in the tapp
9. ing provided Note that this is required by law for safety considerations Install into provided tapping Manual Release Lever N Temperature Probe N Outlet to floor drain Temperature and Pressure Relief Valve 3 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 4 On startup thermal expansion will cause the water to expand Hubbell recommends that a thermal expansion tank or supplementary pressure relief device be installed in the hot water outlet to allow for this expansion Pressure Relief Device or Thermal Expansion Tank Vacuum Breaker Air Vent Valve Hubbell EMV Package Hi 279 FE 4 Temperature A Safety Shower ressure Gau T amp P Relief i g Valve Heat Trace i for Freeze Protection PN If Required e Face Eyewash Solar Gain Y Strainer Protection Freeze Protection i Valve To Atmosphere Water Feed Floor Drain Backflow To Drain Preventor If Required FILLING THE HEATER 1 Completely close the drain valve 2 Open the highest tepid water outlet to allow all air to escape from piping 3 The black plastic knob on the air vent valve must be opened two turns to allow air to escape from the system 4 Open the valve to the cold water inlet and allow the heater and piping system to completely
10. justment screw an additional 0 turn at a time until the desired water temperature is reached Turn off the water at the shower or eye face wash fixture Lock the adjustment screw with the locknut Replace the domed acorn nut cap over the adjustment screw Re check the outlet water temperature as described in Section III Scheduled Maintenance and Operation Monthly Inspection Mixing Valve 21 SECTION VI ELEMENT CHARTS SINGLE PHASE ELEMENT CHART Power Watts Immersion Element Resistance 120V 208V 240V 2TIN 480V Length 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 4000 9 3 4 19 20 2500 3500 9 3 4 16 46 3000 4000 11 v2 14 40 4500 11 1 2 12 80 5000 11 1 2 11 52 1500 4500 6000 13 1 2 9 60 2000 7 5 8 83 23 500 1000 3500 12 1 2 47 56 2500 9 5 8 5 76 500 1500 2000 2500 13 3 8 28 80 990 3000 10 1 2 55 49 1000 1350 4000 13 5 8 41 62 2000 2500 3500 10 5 8 23 04 2500 13 1 4 66 59 4500 13 1 8 17 05 1500 4500 13 1 4 36 99 1000 5000 9 3 4 33 29 5000
11. lace the thermostat 4 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 5 Inspect element flange for leakage as follows a Shut off Power Supply b Remove element housing cover c Visually inspect heating element gasket for evidence of leaks d 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 6 Check for loose electrical connections Tighten as necessary ANNUAL INSPECTION 1 Flush tank as follows 10 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 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 MIXING VALVE INSPECTION AND TEST LOG COMPANY HEATER SERIAL NUMBER DATE START UP OUTPUT COMMENTS TESTED BY SPIKE TEMPERATURE 11 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy No hot water in tank Circuit breaker tripped at source Rese
12. move capillary tube and bulb from thermowell 6 Remove two 2 mounting screws Mounting Screws d 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 14 SINGLE PHASE HEATING ELEMENT l QUE E I d 7 8 9 10 Rewire element according to type of unit as shown 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 Disconnect the wires from the heating element terminals Tank Flange SN Wires Remove the 3 8 16 nuts Withdraw element assembly and remove gasket Gasket Nuts Install new gasket and insert new heating element in your drawing 11 Fill tank and check around gasket for any leaks 15 3 PHASE HEATING ELEMENT 1 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 Disconnect the wires from the heating element terminals Remove the 3 8 16 nuts TION Oe YN Element Terminals Nuts 8 Withdraw element assembly and remove gasket Gasket
13. nting a combination safety temperature and pressure relief valve An overflow line should be utilized from the relief valve outlet to a floor drain A inch GHT connection is supplied for draining See drawing for locations HEATING ELEMENT The water heater is supplied with an electric immersion heating element assembly s composed of a copper sheathed element s 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 an immersion thermostat factory preset at 170 The immersion thermostat can be adjusted through a range of 100 180 F and is adjustable with a flat tip screwdriver TEMPERATURE HIGH LIMIT SWITCH As a safety device a surface mounted high temperature cut off switch with manual reset is supplied As an option an immersion high temperature cut off switch with manual reset may be provided Either high temperature cut out switch is factory preset at 190 F 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 Manual Reset Surface Mounted High Immersion High Temperature Cut Off Switch Temperature Cut Off Switch Optional Standard MIXING VALVE The mixing valve is a tri
14. ple redundant thermostatic pressure balanced valve specifically designed for emergency safety shower face eyewash application The valve is factory mounted and piped to the water heater The mixing valve meets OSHA and ANSI requirements and is capable of providing 85 F output regardless of inlet pressure and temperature variations and the temperature setting is tamper proof and can not be inadvertently adjusted in the field Alternate mixing valve tepid water set temperatures of 70 75 80 and 90 F are available AUTOMATIC AIR VENT VALVE An automatic air vent valve is supplied in the highest point of the system to allow trapped air in the system to escape DUAL TEMPERRATURE AND PRESSURE GAUGE A combination temperature 70 250 F and pressure 0 200 psi gauge with 3 inch dial is installed in the tank OUTER SHELL AND INSULATION The tank is encapsulated in 3 inch thick polyurethane foam insulation The insulation is protected by a high impact non corroding colorized composite protective jacket OPTIONS The following optional features may be included in your water heater Reference included drawing specific to your heater for further details Low Temperature Alarm Dry Contacts A low temperature thermostat is available with dry contacts to remotely alarm when the tank water temperature falls below a specified setpoint The low temperature thermostat is adjustable from 30 110 F High Temperature Alarm Dry Contacts Hi
15. r temperature a Recordall information on the Mixing Valve Inspection and Test Log see page 11 b Using an accurate thermometer turn on the shower eyewash and record the maximum start up spike temperature of the water c Aftera few minutes of running record the normal temperature d Ifthe temperature does not match required temperature 3 F recalibrate the mixing valve See Section V Service and Replacement of Parts Re Calibrate Mixing Valve 2 Monitor flow rate a OHSA ANSI recommends a potable water system maintain a pressure of 30 psig minimum with a flow rate of 20 GPM minimum to a shower head and 3 GPM minimum to an eye face wash fixture b One simple method of testing is to collect the water in a 5 gallon container At the required flow rate the shower head will fill the container in approximately 15 seconds and the eye face wash will fill the container in approximately 15 seconds QUARTERLY INSPECTION 3 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 the relief valve c Compare water temperature of drawn water to the temperature setting of the thermostat when it satisfies Normal variation between the two points 1s approximately 7 F d Ifthese two readings do not coincide within acceptable tolerances and verification has been made of the accuracy of the temperature reading gauge rep
16. rain Valve Cold Water Inlet Cold Water Inlet EMV DIMENSIONAL DATA EMV120 30 6925 SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This manual describes a packaged electric water heater system designed to meet the requirements of ANSI Z358 1 1998 for tepid water delivery to an emergency drench system The complete assembly consists of the storage tank immersion electric heating element s thermostat s safety relief valve safety high temperature cut out mixing valve 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 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 tepid water connections A 1 77 inch FNPT connection is supplied for the cold water inlet The cold water is deflected by means of a baffle within the tank A 1 inch FNPT union connection is supplied at the mixing valve for tepid water A inch FNPT connection is located on the side of the heater for mou
17. t circuit breaker High limit switch tripped Reset high limit switch Loose wires Torque screws holding wires 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 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 in Faulty thermostat Check thermostat adjustment Monitor tank 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 the chart included in Section VI 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 1s not shutting off at
18. the right setting and thermostat must be replaced Tepid water temperature too hot Blockage in cold water inlet to mixing valve Disconnect mixing valve and clean out cold water inlet pipe Mixing valve out of calibration Re calibrate mixing valve as described in Section V Service and Replacement of Parts Re Calibrate Mixing Valve Tepid water temperature too cold Blockage in hot water inlet to mixing valve Disconnect mixing valve and clean out hot water inlet pipe Mixing valve out of calibration Re calibrate mixing valve as described in Section V Service and Replacement of Parts Re Calibrate Mixing Valve 12 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 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 13 IMMERSION TEMPERATURE HIGH LIMIT CUT OFF 1 Disconnect power from unit 2 Remove access cover 3 Remove high limit cover screw and cover 27 Bcc 5 Cover Screw Wires Capillary Tube 5 Re
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