OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC BOOSTER HEATER ELECTRIC HEATER COMPANY BASE MODEL “ J ” UM ANSI/NSF5 2017 Edition 1
HUBBELL ELECTRIC HEATER COMPANY 45 SEYMOUR STREET 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 No.
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), electronic control module, safety relief valve, magnetic contactor(s), and any other required electrical operating control. Optional equipment may be supplied with your unit.
CONSTRUCTION TANK The storage tank is designed, manufactured, and stamped in accordance with ASME Section VIII, Division 1. The tank is constructed of type 304L stainless steel for maximum tank longevity and fabricated by all welded construction and is designed for a maximum allowable working pressure of 150 psi (225 psi test pressure). TANK CONNECTIONS The heater is supplied with separate connections for the cold/warm inlet and the hot water outlet.
STANDARD PRESSURE REDUCING VALVE A pressure reducing valve with built-in bypass is supplied with the unit. This valve is shipped separately for in-line installation. The standard PRV has internal ¾” female NPT threading and is adjustable from 10psi to 70 psi and is preset to 25psi. The set screw located at the top of the diaphragm adjusts the pressure, turn clockwise to increase the pressure and counter-clockwise to decrease the pressure. Pressure reducing valves for the J3 and J4 models are optional.
24-Volt Heater Interlock Adapter An optional plug adapter is available to interlock the heater via a 24-volt signal through the J1 connector on the control board. The 24-volt heater interlock adapter is supplied standard on the J3 model. See page 13 for installation details. (Only available with r23 or later software). Protective Shrouds (J6 and J16 only) An optional durable protective plastic shroud is available to prevent damage to the booster due to water intrusion.
2. Attach slide bracket angles to heater with #8 sheet metal screws. It will be necessary to drill 1/8” holes into heater jacket for screw pilot holes. 3. Slide heater onto slide rails under dishtable. PIPING INSTALLATION – See Diagrams NOTES: • No check valve may be installed in the supply line to the booster. • All shut-off valves must be gate or ball valves – not globe valves. • To minimize heat loss and maximize efficiency, hot water piping should be insulated.
e. No valve of any type to be installed between the relief valve and tank or in the drain line. 6. A shock absorber is recommended in the hot water outlet line to soften the water hammer caused by automatic dishwasher solenoid valves. 7. Install the in-line pressure and temperature gauge, when supplied, in the entering cold/warm water line. If supplied, install the optional second dial temperature and pressure gauge in the outlet line.
(C) and the LED will flash green. When the temperature is above the XB1 setpoint the relay is closed between NO and C and the LED will be solid green. Use NO and C for low temperature interlock or high temperature alarm. Use Normally Closed (NC) and C for low temperature alarm. A red LED indicates an error. (JX6) Ground Note: Alarm Rating (resistive): Max.
OPTIONAL FIELD CONVERSION FROM SINGLE TO THREE PHASE OR THREE TO SINGLE PHASE (J6 and J16 models in 6, 7, and 9 kW at 208 and 240 volts and J411 models only) 1. Re-wire the unit to desired configuration as indicated below. NOTE: The wire to be used for internal wiring must conform to SEW-2 or PTFE (200°C) and must match the wire size currently in use. Contact the factory for assistance, if required. 2. Contact the factory for correct labels. The factory will need the serial number for proper identification.
J6 and J16 Wiring Chart Min. Internal Element PhaseCopper Feed Unit Branch Conduit Power Jumper Phase Power Feed Diagram Breaker kW Volt Ph Amp Amp Size Wire Wire Resistance Wire Size or Fuse Draw Draw Size Size (Ohms) Size 1 120 1 8.3 8.3 14.4 15 12 N/A 14 ½" 1(NT) 1.5 120 1 12.5 12.5 9.6 20 12 N/A 14 ½" 1(NT) 2 120 1 19.8 19.8 6.1 25 12 N/A 12 ½" 1(NT) 3 120 1 25.0 25.0 4.8 35 12 12 10 ½" 1(NT) 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) 4 380 1 10.7 10.7 36.
J6 and J16 Wiring Chart (cont.) kW 15 18 24 27 30 36 39 Min. PhaseInternal Element Unit Branch Feed Copper Phase Power Jumper Conduit Volt Ph Amp Amp Breaker Power Feed Diagram Resistance Wire Wire Size Draw Draw or Fuse Wire Size (Ohms) Size Size Size 208 1 72.1 72.1 2.9 95 6 8 3 1" 4 (DB) 208 3 41.6 41.6 5.8 55 10 12 6 ¾" 10(NT) 240 1 62.5 62.5 3.8 80 8 10 4 1" 4 240 3 36.1 36.1 7.7 50 10 12 8 ½" 10(NT) 380 3 22.9 22.9 19.3 30 12 12 8 ½" 10(WT) 480 3 18.0 18.0 30.7 25 12 12 10 ½" 10(WT) 600 3 16.
J6 and J16 Wiring Chart (cont.) Min. PhaseInternal Element Unit Branch Feed Copper Phase Power Jumper Conduit kW Volt Ph Amp Amp Breaker Power Feed Resistance Wire Wire Size Draw Draw or Fuse Wire Size (Ohms) Size Size Size 208 1 196.8 65.6 1.1 250 8 10 250 2" 208 3 113.8 56.9 2.1 145 8 10 1/0 1¼" 240 1 168.8 56.3 1.4 215 8 10 250 1½" 40.5 240 3 97.4 48.7 2.8 125 10 12 1 1" 380 3 60.8 60.8 7.1 80 8 10 3 1" 480 3 48.7 48.7 11.4 65 8 10 4 ¾" 600 3 36.2 36.2 19.1 50 10 12 8 ¾" 208 3 119.1 59.5 1.
J3 Wiring Chart kW Volt Ph 2.9 5.7 120 120 208 208 208 208 240 240 277 380 415 480 600 1 1 1 3 1 3 1 3 1 3 3 3 3 9.9 10.4 11.4 Min. PhaseInternal Element Unit Feed Copper Phase Power Jumper Conduit Amp Breaker Power Feed Diagram Resistance Wire Wire Size Draw or Fuse Wire Size (Ohms) Size Size Size 23.8 5.0 30 12 12 10 ½" 4 47.5 2.5 60 10 12 6 ¾" 4 47.6 4.4 60 10 12 6 ¾" 4 27.5 8.7 35 12 12 8 ½" 10 (NT) 51.9 4.2 65 10 12 6 ¾" 4 28.8 8.3 40 12 12 8 ½" 10 (NT) 47.5 5.1 60 10 12 6 ¾" 4 27.4 10.
Note: Wiring diagrams 3, 5, 6, 7 (NT), 7 (WT), and 11 are obsolete.
6A L1 3A L2 L1 L2 Control Module & Display J8 J2 J5 J7 J3 J8 J2 J5 J7 J3 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control Module & Display Control, Low Water, & Hi-Limit Probe Leak Detection Probe 12 (WT) 13 (NT) L1 L2 L3 L1 L2 L3 J8 J2 J5 J7 J3 Control Module & Display J8 J2 Control J5 Module & J7 J3 Display Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control, Low Water, & Hi-Limit Probe 13(WT) 12 L1 L2 L3 Leak Detection Probe L1 L2 L3 Control Module &
12 (NCB) 15 L1 L2 L3 L1 L2 L3 Control Module & Display J8 Control Module & Display J2 J5 J7 J3 J8 J5 J7 J3 J2 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control, Low Water, & Hi-Limit Probe Leak Detection Probe 14 L1 L2 L3 J8 J5 J7 J3 J2 Control, Low Water, & Hi-Limit Probe Leak Detection Probe 21
Typical J6 Plumbing Connections (Rear View) Typical J16 Plumbing Connections (Front View) 22
Typical J3 Plumbing Connections (Front View, shown with optional legs) 23
SECTION III – SCHEDULED MAINTENANCE AND OPERATION WARNING / CAUTION Before performing any maintenance procedure, make certain the power supply is turned 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 controller. 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.
ii. Low water detection – sets the low water detection on or off. 1. L O n , for low water on. (Factory Default) 2. L O F , for low water off. iii. Low water reset – sets the low water reset for either automatic or manual 1. L A U , for low water automatic reset. (Factory Default) 2. L A n , for low water manual reset. iv. Temperature units – sets the temperature units to either degrees Fahrenheit or Celsius. 1. D E F , for degrees Fahrenheit. (Factory Default) 2. D E C , for degrees Celsius. v.
2. 3. 4. 5. d. 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 control board and/or the sensor probe. Lift test 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. Inspect element for leakage as follows: a. Shut off power supply. b. Remove front cover. c.
3. 4. 5. 6. 7. a. This message will display if the temperature of the water exceeds the high limit temperature setpoint. To clear this error, wait until the temperature is below the operating setpoint and press RESET. Note that the unit will not reset until the indicated temperature is below 195°F. If this message continually occurs, follow the troubleshooting flow chart for continuous over-temperature condition. Err, No, H2O a.
GENERAL TROUBLESHOOTING Symptom Water reaches setpoint temperature but does not last through the entire dishwasher cycle. Water at the dishwasher is not the proper temperature. Corrective Action Incoming water temperature must be adequate for the booster size. Increase the incoming water temperature. Incoming water Primary water supply is not adequate to temperature is dropping. continually provide correct temperature in sufficient quantities. Increase the supply of primary warm water.
Symptom Probable Cause No pressure reducing Temperature and pressure relief valve valve or wrong valve installed causing seeps excessive pressure in the unit. Pressure reducing valve bypass is blocked. Anti-siphon valve or check valve installed in the warm water inlet line. Unit is overheating due Temperature and pressure relief valve to improper P65 probe calibration. opens and/or high limit temperature Unit is overheating due error occurs. to the magnetic contactor staying in the closed position.
CONTROL BOARD (T1000) / DISPLAY (TD1000) TROUBLESHOOTING 1. Verify proper power supply voltage between each phase (L1 to L2, L2 to L3, and L1 to L3). The power supply voltage should match the voltage listed on the booster nameplate. If voltage is incorrect, check main supply wiring or replace unit with proper booster heater. 2. Check for 208/240VAC between pin 1 (white wire) and pin 2 (black wire) of the J5 connector on the T1000 control board. If no voltage is present, skip to step 4. 3.
3. If the unit has two contactors, with the unit ON and calling for heat and two decimals lit, check for 240VAC between pin 1 (white wire) and pin 3 (red wire) of the J5 connector on the T1000 control board. If no voltage is present, replace the control board (T1000). If voltage is present, check for voltage across the contactor coil. If voltage is present at the contactor coil, replace the magnetic contactor.
SECTION V – SERVICING AND REPLACEMENT OF PARTS WARNING / CAUTION Before servicing or replacing any part, make 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 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. 7.
pulling straight away from the board. Probe Ground (J7) Ground Wire (J8) Display Cable Expansion (J1) Leak Detection Wire (J2) (D1) Probe Cable (J3) Alarm Relay (J4) Power Wire (Common, White) Power Wire (Black) Connector (J5) Wire to #1 Contactor (yellow) Wire to #2 Contactor (red) Note: Probe connector J3 comes filles with a dielectric gel that should remain in the connector. 3. Remove four (4) screws securing control board to panel. 4. Remove and replace control board. 5.
3. Twist the cord and shrink-wrap end of the P65 probe (or cut the shrink-wrap with a sharp knife) to loosen the P65 sensor assembly from the P65 thermowell. 4. Remove the old P65 sensor assembly by pulling on the cord coming out of the P65 thermowell. Note: It is unnecessary to unscrew the thermowell from the vessel to replace the P65 sensor. Cord P65 Sensor Shrink-Wrap Cap 5. Insert the new P65 sensor assembly into the P65 thermowell.
SECTION VI – SERVICE PARTS LIST Category Accessories Description Bronze Pressure Reducing Valve Plastic Legs (Price each, 4 Req'd.) Nickel Plated Legs (Price each, 4 Req'd.) Stainless steel adjustable legs (Price each) Floor Mount Legs S/S (Price each, 4 Req'd.) Temp. and Pressure Gauge Dielectirc Union, 3/4" Relief Valve (up to 58 kw) Relief Valve (64-90 kw) Slide Brackets (J6 models only, 2 per set) J6, 3 Element Plastic Protective Shroud (1 to 18 kW) J6, 6 Element Plastic Protective Shroud (24 to 58.
SERVICE PARTS LIST (cont.) Category Misc.
SECTION VII – TORQUE VALUES Part Element to Tank Wire to Element Probe to Tank Wire to Ground Lug Wire to Circuit Breaker Transformer Wire to Control Board Wire to Contactor P/N Wire Size Torque (in•lbs) Torque (ft•lbs) All N/A 600 50 All All 15 1.25 All KA8C KA4C All N/A All All #14-#10 #8 #6-#4 All 300 25 45 35 40 45 15 25 2.08 3.75 2.92 3.33 3.75 1.25 All All 3.5 0.
SECTION VIII – WARRANTY INFORMATION LIMITED WARRANTY 1. PRODUCT WARRANTY.
NOTES 39
P.O. BOX 288 STRATFORD, CT 06615-0288 PHONE: (203) 378-2659 FAX: (203) 378-3593 INTERNET: http://www.hubbellheaters.
