Hubbell Electric Heater Company B User's Manual
Contents
1. 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 15 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 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 16 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy No hot water Circuit breaker tripped at source Reset circuit breaker Blown fuse in transformer if Replace fuse 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 figure Low line voltage Have source electrical system checked by an electrician Faulty thermostat Move thermostat dial through full range A def2. 23 SECTION VI MISCELLANEOUS CHARTS AND FORMULAS ELEMENT CHART Element Immersion Pan Length 12 qm 1 0 Eum c nue 36 4 561 i 34 us ma 230 FORMULAS RECOVERY GPH x 0 00244 KW KW x 400 F AT KW x 410 F AT GPH Note 1 KW will heat 4 1 GPH at a 100 F AT ELECTRICAL 1000 173 Amps Volts KW x 1000 Ame S Amps 1 24 5 6 8 m 279 93 279 187 16 8 10 13 216 72 216 145 8 2 13 171 57 174 15 12 15 13 144 48 96 METRIC CONVERSION Liters x 0 2641 Gallons Gallons x 3 79 Liters Gallons x 0 003785 ms ms x 264 2 Gallons 1 C AT 1 8 F AT C x 1 8 32 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 n ret JG TX EY me we 20 99 138 147 12 107 123 5 624 142 116 13 86 5848 l 3110 2545 2885 1995 3250 370 23
3. 308 154 E 17 T amp P Relief Outlet Valve 51 2 Front View Side View Storage Capacity 20 gallons KW Range 12 thru 58 KW Shipping Weight 150 Ibs Recovery Rate in GPH For F Temperature Rise Listed Below Base Model Number 461 308 264 231 54 1107 554 369 316 277 58 1189 595 396 340 297 SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes a packaged electric booster heater that is typically used to provide 180 F sanitizing rinse water 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 longevity 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 18 supplied with separate connections for the cold warm inlet and the
4. 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 18 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 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 Lifttest 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 ao Shut off Power Supply Remove element housing cover
5. hot water outlet Water entering the cold water inlet is deflected by means of a baffle within the tank A 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 5 The water heater is supplied with an immersion thermostatic switch that is installed and wired at the factory The thermostat can be adjusted through a range of 100 195 F and is adjustable with a flat tip screwdriver TEMPERATURE HIGH LIMIT SWITCH A surface mounted high temperature cut off switch with manual reset factory set at 205 F 1s provided In the event of an over temperature condition the thermostat will disengage the operating coils in the magnetic contactor s The high limit must be manually reset thereafter to restart the heater Manual Reset 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 eleme
6. 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 18 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 19 HEATING ELEMENT 1 Disconnect power from unit 2 Shut off incoming 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 the wires from the heating element terminals Note that picture shown is a three phase heating element a single phase element has only two terminals 7 Remove the 3 8 16 nuts Tank Flange Nuts 8 Withdraw element assembly and remove gasket Gasket Element Assembly 9 Install new gasket and insert new heating element 10 Rewire element according to the installation instructions as shown in the Section I
7. GE FURNISHINGS OR PROPERTY WATER HEATER PLACEMENT 1 Place the heater on a solid foundation in a clean dry location as near as possible to the dish washing machine 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 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 water pressure regulator if supplied and adjust to the pressure recommended by the dishwasher manufacturer WHEN A STANDARD PRESSURE REGULATOR IS USED other than that purchased with the booster it acts as a check valve and it is possible that thermal expansion will cause the relief valve to drip or occasionally blow off a small amount of water To over come this condition it is recommended that a 3 8 by pass arrangement with a horizontal check valve be installed around the pressure regulator This will prevent annoyance caused by the relief valve dripping or blowing off 3 I
8. I 11 Fill tank and check around gasket for any leaks 20 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 hs 4 Disconnect the two 2 14 gauge wires 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 21 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 27 RELIEF VALVE 1 OO ON Mam 909 Overflow Piping Outlet 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 ic Tank Connection Temperature Probe a
9. OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC BOOSTER HEATER fubbe ELECTRIC HEATER COMPANY BASE MODEL B 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 turned on Under certain cir
10. cumstances 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 II VI GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING amp REPLACEMENT OF PARTS MISCELLANEOUS CHARTS AND FORMULAS PAGE 15 17 19 24 B10 Model GENERAL SPECIFICATIONS B20 Model T amp P Relief et Valve 17 48 291 2 Side View Rear View Storage Capacity 10 gallons KW Range 6 thru 20 KW Shipping Weight 85 105 Recovery Rate in GPH For F o Rise Listed Below 164 205 246 123
11. inite 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 not observed replace low water cut off Magnetic contactor does not energize Replace complete magnetic contactor Because of design of this particular contactor it is more desirable to replace complete control rather than rebuilding coil contacts and springs etc 17 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 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
12. nstall in line pressure and temperature gauge if supplied 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 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 Allother electrical connections are made at the factory therefore no other electrical connections are necessary 10 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 tempera
13. nt 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 18 reached At this point the contacts will drop out which in turn 1 Cutler Hammer disconnects power from the elements Es 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 Heavy gauge steel support legs are provided 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 Fused Low Voltage Transformer A fused low voltage transformer may be supplied This option is used only in 480 volt systems with low water cut offs to step down the voltage to 240 volt for safety when working with control circuits 23 hs Ld mi MICRON r de ce 13JK Bae TS 050 213 RI STE Dial Temperature and Pressure Gauge A combination temperature 70 250 F and pressure 0 200 psi gauge with 2 inch dial may be su
14. pplied for in line installation shipped loose Pressure Reducing Valve An optional pressure reducing valve with built in bypass may be supplied This valve is shipped separately for in line installation Stainless Steel Outer Jacket An optional stainless steel outer jacket may replace the standard galvaneel jacket Suspension Straps For under counter off the floor operation an optional suspension strap may be supplied in place of the standard support legs 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 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 DAMA
15. ture as described in Section III Quarterly Inspection lt gt P ABE Important Do not install any valves other than those shown between the primary water heater and the booster heater Incoming Water 140 F 1 B Model Booster 2 Dishwasher 3 Pressure Regulator w built in by pass 4 Pressure Temperature Gauge 5 Shut Off Valve 6 Union 7 Drain Valve 8 Pressure and Temperature Relief Valve pipe overflow to floor drain or sink 11 Dual Element Single Phase 2 Contactors 3 Elements 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 with low water cut off only 6 High Temperature Limit Switch 7 Control Thermostat LI 12 L3 3 Element 3 Phase I Contactor I 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 with low water cut off only 6 High Temperature Limit Switch 7 Control Thermostat 3 Element 3 Phase 3 Contactors JUMPER CONFIGURATION 1 PHASE 208 OR 240 VOLT f 3 PHASE WYE 380 TO 575 VOLT 655 3 PHASE DELTA 208 OR 240 VOLT A 5 p O 480 VOLT SECTION III
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