Hubbell Electric Heater Company J manual

1 OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC BOOSTER HEATER ELECTRIC HEATER COMPANY BASE MODEL “ J ” ASME ANSI/NSF5 2007 Edition Rev. A[...]

2 HUBBELL ELECTRIC HEATER COMPANY 45 SEYMOUR STR EET P.O. BOX 288 STRATFORD, CT 06615 PHONE: (203) 378-2659 FAX: (203) 378-3593 INTERNET: http://www.hubbellheaters.com -- IMPORTANT -- Always reference the f ull model number and serial num ber when calling the factory. WARNING / CAUTION 1. Tank is to be completely filled w ith w ater and all air is [...]

3 TABLE OF C ONTENTS SECTION TITLE PAGE # I GENERAL DESCRI PTION AND CONSTRUCTION 4 I I I NSTALL ATION AND START-UP 8 III S C H E D U LE D M A I N T E NAN C E AND O P E R AT I ON 1 9 I V T R OUB L E S HOOT I NG 2 1 V S E R V I C I NG & R E P L A C EMENT OF P A R TS 2 6 V I SER V I C E P A RTS L I ST 2 9 V I I TO R QUE VA L UES 30 VIII W A R R A[...]

4 SECTION I - GENERAL DESCRI PTI ON AND CONSTRUCTI ON GENERAL DESCRIPTI ON This book describes a packaged electric booster heater that is typically used to provide 180° F sanitizing rinse water. The comp lete assembly consists of the storage tank, im m ersion electric heating element(s), electronic control module, safety relief valv e, mag netic c[...]

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6 CONSTRUCTIO N TANK The storage tank is designed, manufactured, and stam ped in accordance with ASME section V III Di vi s i on 1 . The tank is constructed of type 304L stainless steel for m axim um tank longev ity and fabricated by all welded construction and is designed for a m aximum allowable working pressure of 150 psi (225 psi TP). TANK CONN[...]

7 DIAL TEMP ERATURE AND PRESSURE GAUGE A combination temperature (30°- 240° F / 0°- 120°C) and pressure (0–200 psi / 0- 1400 kPa) g auge with 3- inch dial is supplied with the unit for in-line installation (shipped loose). The connection is ½” NPT with a 2” long sensing probe. PRESSURE REDUCING VALVE A bronze pressure reducing valv e wit[...]

8 SECTION II – INSTALLATIO N AND START-UP WARNING / CAUTI ON • DO NOT TURN ON THE ELECTRI C POWER SU PPLY 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 excessiv e pres[...]

9 • All shut- off valves m ust be gate or ball v alves – not g lobe valves. • To minim ize heat loss and m aximize efficiency , hot water piping should be insulated. • Teflon tape should be used on all NPT threaded pipe connections. 1. Connect the cold/warm water inlet and hot water outlet to the appropriate connections as shown; refer to t[...]

10 7. Install the dial tem perature and pressure g auge in the outlet line. The temperature sensing element must be in the hot water stream and the gaug e must be m ounted upright. FILLI NG THE HEATER 1. Open the valv e to the cold water inlet and allow the heater and piping system to completely fill, as indicated by a steady flow of water through [...]

11 4. Make connections as required to the relay terminal block . When the temperature drops below the XB1 setpoint the relay is open betw een No rm ally Ope n (NO) and C om m on (C ) and the LED w ill flash green. When the tem perature is above the XB1 setpoint the relay is closed between NO and C and the LED will be solid green. Us e N O an d C fo[...]

12 FOR REM OTE ON/ OF F CO NTROL To remotely control the On / Off operation of the heater, it is recomm ended that a DPST switch or relay (by others) be used to break both power leg s (white and black wires) connected to the top two terminals of the J5 connector on the control board. See diagram at right. Use a NC (N ormally Closed) relay to turn t[...]

13 Wiring Chart kW Vol t Ph Unit Amp Draw Branch Amp Dra w Phase-Pha se Resistance (Ohms) Mi n. Feed Breake r or Fus e S iz e In t e r n a l Power W ire Size Elemen t Jumper Wir e Si ze Coppe r Po we r Feed Wire Si ze Conduit Size Diagram 208 1 19.2 19.2 10.8 25 12 N/A 10 ½" 1(NT ) 240 1 16.7 16.7 14.4 25 12 N/A 12 ½" 1(NT ) 480 1 8.3 8[...]

14 kW Vol t Ph Unit Amp Draw Branch Amp Dra w Phase-Pha se Resistance (Ohms) Mi n. Feed Breake r or Fus e S iz e In t e r n a l Power W ire Size Elemen t Jumper Wir e Si ze Copper Po wer Feed Wire Si ze Conduit Size Diagram 208 1 115.4 38.5 1.8 145 10 12 1/0 1¼" 3A 208 3 66.6 66.6 3.6 85 8 10 4 1" 13(NT ) 240 1 100.0 33.3 2.4 130 12 12 1[...]

15 1(WT) L1 L2 J5 J3 J2 Control , Low W ater, & Hi-L imit Pro be Leak Detecti on Probe Control Modu le & Display 1(NT) L1 L2 J5 J3 J2 Control, Low W ater , & H i-Lim it Pro be Leak Detecti on Probe Control Module & Disp lay 4 L1 L2 J5 J3 J2 Control, Low W ater , & Hi- Limi t Pr obe Leak De te ction Probe Control Module & Dis[...]

16 10(WT) L1 L3 L2 J5 J3 J2 Control, Low Water, & Hi- Lim it Pro be Leak Detection Probe Control Module & Displa y 10(NT) L1 L3 L2 J5 J3 J2 Control, Low Water, & Hi- Lim it Pro be Leak Detection Probe Control Module & Displa y 13(WT) L1 L3 L2 J5 J3 J2 Control, Low Water, & Hi- Lim it Pro be Leak Detection Probe Control Module &a[...]

17 12 L1 L2 L3 J5 J3 J2 Control, Low Water, & Hi- Lim it Pro be Leak Detection Probe Control Module & Displa y J7 12 (NCB) L1 L2 L3 J5 J3 J2 Control, Low Water, & Hi- Lim it Pro be Leak Detection Probe Control Module & Displa y J7 L1 L3 L2 Control, Low Water, & Hi-L imit Probe Leak Detection Probe J5 J3 J2 J7 14 15 L1 L3 L2 Cont[...]

18 J6 Plumbing Connections (Rear View) J16 Plumbing Connections (Front View)[...]

19 SECTION III - SCHEDULED MAINTENANCE AND OP ERATION WARNING / CAUTION Before performing any m aintenance procedure, mak e certain the power supply is turned OFF and cannot accidentally be turned on. MAINTENANCE AND OP ERATIO N The water heater is automatic in its operation. It will m aintain a full tank of water at the tem perature setting of the[...]

20 ii. Low water detection – sets the low water detection on or off. 1. LOn , for low water on. (Factory Default) 2. LOF , for low water off. iii. Low w ater reset – sets the low water reset for either autom atic or manual 1. LAU , for low water autom atic reset. (Factory D efault) 2. LAn , for low water m anual reset. iv. Tem perature units ?[...]

21 a. Shut off power supply. b. Remov e front cover. c. Visually inspect around heating elem ent for evidence of leaks. d. Rub around the heating elem ent with a rag. Check for any evidence of m oisture. I f moisture is present or a w ater drip is observed, follow procedure outlined in Section V. CAUTION : T he area around the heating elem ent may [...]

22 error will clear. I f the low water reset is set for m anual, when the tank is full press R ESET. Check the heater and the piping for leaks. Check for m ineral buildup on the probe and clean as required. Check for continuity between the yellow wire and ground. See diag ram 2 on the following pag e. 4. Err, H2O, LEA a. This messag e displays if t[...]

23 TROU BLESHOOT ING FLOW C HART S No H ot Wate r Continuous Low Wa te r Temperat ure Unit pr operly sized? Replace wit h correct ly s ized unit Is t he disp lay on? See ' No Displ ay' flowchar t Is there an error mess age? No Yes No Yes No Check for loos e wires and tight en as nec essary Magnetic conta ctor pull in? See Err or Message s[...]

24 Cont inuo us over -temper ature condition Do cont act ors pull out at s etp oi nt? Correct tem per atur e setpoint ? Yes Prop erly set tem per atur e setpoin t Yes Plug prob e end i nto RJ45 pi gta il (not supplied ). Che ck ohms acros s t erm ina ls 1an d 4 (see di agr ams 1 & 2). Com pare thi s with th e ohm s t he t herm is to r shoul d s[...]

25 No Display Is the circu it break er t ripp ed at source ? Rese t c irc ui t break er Is the circu it break er t ripp ed ins ide heat er (if supp lie d)? Yes No No Pre ss ON/OF F butt on on heat er Is corr ect volta ge meas ured a t power dis tri but ion bl ock or lin e side o f conta ctor for each phase? Rese t c irc ui t break er Yes OK? Che ck[...]

26 SECTION V - SERVICI NG & REPLACEM ENT OF PARTS WARNING / CAUTION Before servicing or replacing any part, m ake sure to turn the power supply to the unit OFF. HEATING ELEMENT 1. Disconnect power from unit. 2. Shut off incoming water supply. 3. Attach hose to drain connection. 4. Lift manual release lev er on relief valv e to let air into syst[...]

27 CONTROL B OARD 1. Disconnect power from unit. 2. Disconnect display cable, probe cable (J3), leak detection wire (J2), ground wire (J7), and terminal block (J5) from the control board. NOTE: The term inal block (J5) is remov able from the control board. Grasp the terminal block on the ends and pull straight away from the board. Ground Wire (J7) [...]

28 SEN SOR PROBE 1. Disconnect power from unit. 2. Shut off incoming water supply. 3. Attach hose to drain connection. 4. Lift manual release lev er on relief valv e to let air into system or break union on outgoing water line. 5. Drain water from tank . 6. Disconnect probe wire from control board. (See picture) Probe connection (J3) 7. Rem ove pro[...]

29 SECTION VI – SERVICE PARTS L IST Category Descri ption Volts Ohms Hubbell P/N Accessori es Bronze Pre ssure Reducin g Valve 36C-304 -01T Plastic Legs (Pr ice each, 4 Req'd.) AP 61-4003- C Nickel Plat ed Legs (Pri ce each, 4 Req'd.) AE61 -4002-C Stainless steel adjustable legs (Pr ice each) A50 -5048-C Floor Mount Le gs S/S (Price eac[...]

30 SECTION VII – TORQUE VALUES Part P/ N Wire Size Torque (in•lbs) Torque (ft•lbs) Element to Tank All N/A 600 50 Wire to Element All All 15 1.25 Probe to Tank All N/A 300 25 KA8C All 25 2.08 Wire to Ground Lug KA4C All 45 3.75 #14-#10 35 2.92 #8 40 3.33 Wire to Circuit Breaker All #6-#4 45 3.75 Transformer All All 15 1.25 Wire to Control Boa[...]

31 SECTION VII I – WARRANT Y INFORMATION LIMITED WARRANTY 1. PRODUCT WARRANTY . Hubbell w arrants the booster h eater it m anufact ures and it s compon ents (th e "Product") to be free from def ects in m aterials and w orkm anship, u nder normal u se and serv ice for the period of tim e identified below beginn ing from the date of insta[...]