OPERATING AND MAINTENANCE MANUAL FOR POWER BURNER SERIES FORCED DRAFT COMMERCIAL WATER HEATER ELECTRIC HEATER COMPANY BASE MODEL “ DF ”
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 ¾ Do not use or store gasoline or any other flammable vapors, liquids, or materials in the vicinity of this or any other appliance.
FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS ¾ DO NOT try to light any appliance. ¾ DO NOT touch any electrical switch. ¾ DO NOT use any phone in the building. ¾ Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department. ¾ WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
SAFETY TEMPERATURE AND PRESSURE RELIEF VALVE (T&P) A listed and properly rated combination temperature and pressure relief valve shall be installed in the opening provided and marked for this purpose at the time of installation. Local codes shall govern installation of relief devices. The pressure rating of the relief valve must not exceed the working pressure shown on the rating plate affixed to the front of the water heater.
TABLE OF CONTENTS SECTION TITLE PAGE # I GENERAL DESCRIPTION 9 II INSTALLATION 10 III START UP AND OPERATION 16 IV SCHEDULED MAINTENANCE AND SERVICING 18 V TROUBLESHOOTING 25 VI MISCELLANEOUS CHARTS AND FORMULAS 26 5
SECTION I - GENERAL DESCRIPTION GENERAL DESCRIPTION This is a commercial storage water heater designed and constructed in accordance with UL and ASME requirements. Its thermal efficiency and standby loss exceed the levels established by ASHRAE 90.1 and incorporated by federal EPACT legislation. Given a reasonable amount of maintenance, this water heating product will perform reliably for many years.
SECTION II – INSTALLATION WARNING / CAUTION For protection against excessive pressures and temperatures, local codes require the installation of a temperature-and-pressure (T&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 National Fuel Gas Code, (ANSI Z223.1 and Can 1 -Bl 49.1 or Bl 49.
LOCATION NOTE: Do not run uninsulated water pipes in front of or directly above a fresh air opening. If an exhaust fan is installed in the mechanical room, the combustion air inlet must allow for the fan's exhaust air volume. An undersized opening may cause down drafts resulting in poor combustion, sooting and carbon monoxide. 1. Position the water heater in a clean and dry location as close as possible to the greatest use of hot water (and the oil storage tank if used).
be installed so the heater may be disconnected for servicing if necessary. Hot water and return circulation lines should be insulated. The cold water supply line should be insulated if subjected to freezing temperatures. When a check valve is installed in the cold water line to the water heater, a diaphragm type expansion tank suitable for potable water shall be installed in the system.
ELECTRICAL CONNECTIONS Electrical connections to the water heater should conform to the National Electrical Code or the code legally authorized in your locality. A fused disconnect switch should be used in the burner control circuit. The contractor shall run the properly sized electrical service to the terminals indicated on burner wiring diagram. Refer to burner manufacturer's manual for specific electrical requirements.
GAS CONNECTION PIPING FOR GAS AND COMBINATION GAS/OIL BURNERS WARNING / CAUTION LP UNITS; liquefied petroleum (L.P.) gas is heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking L.P gas. Before operating the water heater, sniff at floor level. IF YOU SMELL GAS, follow applicable instructions on cover page.
3. A Rule of Thumb to determine total suction for suction line sizing is to add 10% to suction determined from the burner manufacturer's instruction manual. 4. It is good practice to size the oil pump return-line (to the tank) the same size as the selected suction line. PRESSURE AND TEMPERATURE SAFETY RELIEF VALVE 1. Install the combination temperature and pressure safety relief valve in the tapping provided. Note that this is required by law for safety considerations.
SECTION III – START UP AND OPERATION WARNING / CAUTION Temperatures above 130ºF (54º C) can cause scalding. Scalding temperatures are especially hazardous to young children, aged or handicapped persons. A serious or disabling injury can occur. Note that a mixing valve installed at the hot water outlet can reduce the risk of scalding at such points of use as lavatories, sinks and bathing facilities Excessively hot water may suggest that the upper operating thermostat has failed.
2. The burner manufacturer's installation and operation manual, included with this manual, contains a detailed start up procedure that should be studied and followed precisely. NOTE: Rated gas input for this water heater can be established by adjusting manifold gas pressure to the value listed on the burner data plate. Rated oil input can be established by adjusting oil pressure to the burner at 300 psi (pressure may have to be slightly reduced to obtain clean, smokefree combustion).
SECTION IV - SCHEDULED MAINTENANCE AND SERVICING WARNING / CAUTION Before performing any maintenance procedure, turn off the water heater main disconnect switch before performing any cleaning or service. Also close both the pilot and main manual shutoff valves. Keep the equipment room clean. Clean the burner at regular intervals. The blower inlet can collect dust and debris from the air during operation. Clean blower wheel and flame scanner when necessary.
RECOMMENDED PERIODIC INSPECTION DAILY 1. Inspect area around water heater for moisture. If present, determine if cause is condensation or leakage. a. If cause is condensation - May be due to very cold incoming water. Consider installation of intra-tank circulator; contact manufacturer for details. b. If cause is leakage - May be due to leaking fitting; repair as soon as possible. If tank leak is suspected, contact manufacturer. 2. Inspect vent for corrosion.
RECOMMENDED PERIODIC TESTING TESTING ITEM Gauges, monitors and operating log Instrument and equipment settings HOW OFTEN COMPLETED BY REMARKS Daily Daily Operator Operator Weekly Semiannually Annually Monthly Operator Service Tech Service Tech Operator Igniter Weekly Operator Fuel valves: pilot and main (primary and secondary) Weekly Operator Pilot and main gas or oil train Combustion safety controls (flame failure) Annually Weekly Service Tech Operator Flame signal strength Weekly Operato
SCALE AND SEDIMENT REMOVAL THE MANUFACTURER CANNOT CONTROL USE OF THE WATER HEATER, WATER CONDITIONS OR MAINTENANCE.
BURNER SERVICE IMPORTANT IT IS HIGHLY RECOMMENDED THAT REPLACEMENT PARTS OR ASSEMBLIES BE OBTAINED FROM THE WATER HEATER OR BURNER MANUFACTURER. The enclosed burner installation and operation manual contains a service suggestion (troubleshooting) section and a periodic checklist that recommends a variety of component tests designed to help maintain the water heater's reliable, efficient and safe operation. For additional assistance, contact the burner manufacturer's customer service department.
RELIEF VALVE 1. Disconnect power from unit. 2. Shut off incoming water and boiler 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.
IMMERSION TEMPERATURE HIGH LIMIT CUT-OFF, HIGH, OR LOW THERMOSTAT 1. Disconnect power from unit. 2. Remove access cover. 3. Remove high limit cover screw and cover. Cover Cover Screw Reset Tab (High Limit Only) 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.
SECTION V – TROUBLESHOOTING (See separate component O&M for additional details.) Symptom No hot water. Probable Cause Flame safeguard locked out. Manual gas valve closed. Blown control circuit. No power. Water not hot enough. Gas pressure too high or too low. Operating control thermostat set too low. Recovery rate too low for demand. Water temperature too hot. Water leaks. Gas odors. Operating control thermostat failed. Operating control thermostat set too high.
SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS TORQUE VALUES BOLT SIZE 18-8 S/S IN.-LBS. BRASS IN.-LBS. 4-40 4-48 5-40 5-44 6-32 5.2 6.6 7.7 9.4 9.6 4.3 5.4 6.3 7.7 7.9 26 SILICON BRONZE IN.-LBS. 4.8 6.1 7.1 8.7 8.9 ALUMINUM 316 S/S 2024-T4 IN.-LBS. IN.-LBS. 2.9 5.5 3.6 6.9 4.2 8.1 5.1 9.8 5.3 10.1 MONEL IN.-LBS. 5.3 6.7 7.8 9.6 9.
METRIC CONVERSIONS 27
