OPERATING AND MAINTENANCE MANUAL FOR INSTANTANEOUS ELECTRIC CIRCULATION HEATER ELECTRIC HEATER COMPANY BASE MODEL “ CR ”
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 12 III SCHEDULED MAINTENANCE AND OPERATION 14 IV TROUBLESHOOTING 15 V SERVICING & REPLACEMENT OF PARTS 17 VI MISCELLANEOUS CHARTS AND FORMULAS 22 3
SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes a packaged electric heater that is a stationary, self-contained unit. The complete assembly consists of the pressure vessel, immersion electric heating element, thermostat, safety relief valve, safety high temperature cut out, magnetic contactor(s), power circuit fusing, fused low voltage control circuit transformer, and any other required electrical operating control. Optional equipment may be supplied with your unit.
OUTER SHELL, INSULATION, AND SUPPORTS The pressure vessel 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. The horizontal configuration is supported on heavy-duty steel I-beam supports. Also available in a vertical configuration or wall hung for off the floor installation.
CONTROL THERMOSTAT The control panel is supplied standard with a single-stage immersion thermostatic switch. As an optional any of the following may be supplied; a four-stage immersion thermostatic switch, a solid-state staging controller with thermistor, or a digital 1/16 DIN temperature controller with thermocouple. See drawing for specific details. The single-stage immersion thermostat can be adjusted through a range of 100° - 190° F.
TEMPERATURE HIGH LIMIT SWITCH As a safety device, an immersion high temperature cut-off switch with manual reset, adjustable through a range of 100° - 240° F, is provided. The high limit must be manually reset thereafter to restart the heater. Optionally a 1/16 DIN digital controller may be used as a high-limit. Manual Reset MAGNETIC CONTACTOR The magnetic contactor(s) is a heavy-duty resistive load type rated for 100,000 cycles.
INDIVIDUALLY FUSED ELEMENTS To prevent the possibility of damage to control circuits and other elements in case of electrical overloads, fuses may be supplied for each element. Two types of fuses may be used; a type NON for voltages less than 250-volt or type JJS for voltage less than 600-volt. Type JJS Type NON 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).
On / Off Control Switch A built-in non-fused On/Off disconnect switch may be supplied with the control panel to decrease the risk of injury when working with the control panel. Built-In Circuit Breaker A built-in circuit breaker may be provided with or without shunt trip protection for protection from circuit overload. Audible Alarm An audible alarm may be installed on the outside of the control panel to give warning of an overtemperature condition.
Silicon Control Rectifier An SCR “zero fired” power controller for 0-100% proportional control of heaters may be supplied. Dial Temperature and Pressure Gauge A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge with 2½-inch dial may be supplied for in-line installation (shipped loose) or factory installed in the tank. Special Customized Features Please reference drawing for details.
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.
Outlet to floor drain Install into provided tapping Manual Release Lever Temperature Probe Temperature and Pressure Relief Valve 4. 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. Completely close the drain valve and open the highest hot water valve to allow all air to escape from piping. 2.
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 heater is automatic in its operation. It will maintain water at the temperature setting of the thermostat. The heater should not be turned on without first making sure that the vessel is full of water and that all air has been released.
SECTION IV – TROUBLESHOOTING Symptom No hot water Probable Cause Circuit breaker tripped at source. On/Off switch in ‘OFF’ position, if installed. Circuit breaker at control cabinet tripped, if installed. Blown fuse in element fuse block, if installed. Blown fuse in transformer, if installed. High limit switch tripped. Corrective Action / Remedy Reset circuit breaker. Loose wires. Tighten wires. Torque screws per torque chart included in Section VI.
Water temperature below settings at all times Faulty thermostat. Blown fuse in element fuse block, if installed. Heating element not working on all phases Heater improperly sized Relief valve discharges continuously 16 Excessive temperature or pressure in tank Check thermostat adjustment. Monitor thermostat as described in Section III, Quarterly Inspection. Replace if necessary. Replace fuse.
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. 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.
IMMERSION TEMPERATURE HIGH LIMIT CUT-OFF 1. Disconnect power from unit. 2. Remove access cover. 3. Remove high limit cover screw and cover. Cover Cover Screw Reset Switch 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.
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.
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. Remove element housing cover 7. Disconnect the wires from the heating element terminals. 8. Disconnect conduit from coupling. Conduit Coupling Element Housing Cover 9. Remove nuts and bolts from flanges. 10. Withdraw element assembly and remove gasket.
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 NEMA ENCLOSURES 22
ELECTRICAL DATA 23
FORMULAS 24
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.
