OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC BOOSTER HEATER ELECTRIC HEATER COMPANY BASE MODEL “ A ”
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 1. Tank is to be completely filled with water and all air is to be vented before energizing. 2. Due to the rigors of transportation, all connections should be checked for tightness before heater is placed in operation. 3.
TABLE OF CONTENTS SECTION TITLE PAGE # I GENERAL DESCRIPTION AND CONSTRUCTION 5 II INSTALLATION 9 III SCHEDULED MAINTENANCE AND OPERATION 16 IV TROUBLESHOOTING 18 V SERVICING & REPLACEMENT OF PARTS 20 VI MISCELLANEOUS CHARTS AND FORMULAS 25 3
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.
CONTROL THERMOSTAT 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 is provided. In the event of an over-temperature condition, the thermostat will disengage the operating coils in the magnetic contactor(s).
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. 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.
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. Stainless Steel Legs As an option, 6-inch adjustable stainless steel legs may be supplied.
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.
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. Install 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.
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. Outgoing Water (180°F) !Important!! Do not install any valves other than those shown between the primary water heater and the booster heater.
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.
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.
ANNUAL INSPECTION 1. Flush tank as follows a. b. c. d. Shut off power supply. Close valve on hot water outlet piping. Open valve on drain piping. 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.
SECTION IV – TROUBLESHOOTING Symptom No hot water Probable Cause Circuit breaker tripped at source. On/Off switch in ‘OFF’ position Blown fuse in transformer, if installed. High limit switch tripped. Corrective Action / Remedy Reset circuit breaker. Turn switch to ‘ON’ position Replace fuse. Loose wires. Tighten wires. Torque screws per torque chart included in Section VI. Check heating element operation by clamping an Amprobe around each wire to the element.
Water temperature below settings at all times Faulty thermostat. Heating element not working on all phases Heater improperly sized Relief valve discharges continuously Excessive temperature or pressure in tank Check thermostat adjustment. Monitor thermostat as described in Section III, Quarterly Inspection. Replace if necessary. 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.
SECTION V - SERVICING & 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.
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 threephase heating element; a single-phase element has only two terminals. 7. Remove the 3/8-16 nuts. Tank Flange Element Terminals Nuts 8.
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 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.
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.
RELIEF VALVE 1. Disconnect power from unit. 2. Shut off incoming water supply. 3. Lift test lever on relief valve to relieve pressure in tank. 4. Disconnect overflow piping. 5. Unscrew relief valve, remove assembly and replace with new one. 6. Connect overflow piping. 7. Turn on incoming water supply and check for leaks. 8. Turn safety switch to ON position.
SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS ELEMENT CHART Power (Watts) Element Part # 120V 208V 240V CH-FO-358 ---3500 ---CH-FO-408 ---4000 ---CH-FO-508 ---5000 ---CH-FO-608 2000 6000 ---CH-FO-304 ------3000 CH-FO-354 ---2500 3500 CH-FO-404 ---3000 4000 CH-FO-454 ------4500 CH-FO-504 ------5000 CH-FO-604 1500 4500 6000 TGB-1403-480 ------1000 TGB-2457-480 ---------TGB-2503-480 ---1000 ---TGB-2603-480 ------1500 *Red wattage indicates the stamped element rating Power (kW) Element Part # 208V 240V 480V 2
FORMULAS 26
TORQUE VALUES BOLT SIZE 18-8 S/S IN.-LBS. BRASS IN.-LBS. 4-40 4-48 5-40 5-44 6-32 6-40 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-14 5.2 6.6 7.7 9.4 9.6 12.1 19.8 22.0 22.8 31.7 75.2 94.0 132 142 236 259 376 400 517 541 682 752 1110 1244 1530 1490 2328 2318 3440 3110 4.3 5.4 6.3 7.7 7.9 9.9 16.2 18.0 18.6 25.9 61.5 77.
