OPERATING AND MAINTENANCE MANUAL FOR PACKAGED ELECTRIC TEPID WATER HEATING SYSTEM ELECTRIC HEATER COMPANY BASE MODEL “ EMV ”
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 7 III SCHEDULED MAINTENANCE AND OPERATION 9 IV TROUBLESHOOTING 12 V SERVICING & REPLACEMENT OF PARTS 13 VI ELEMENT CHARTS 22 3
SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This manual describes a packaged electric water heater system designed to meet the requirements of ANSI Z358.1-1998 for tepid water delivery to an emergency drench system. The complete assembly consists of the storage tank, immersion electric heating element(s), thermostat(s), safety relief valve, safety high temperature cut out, mixing valve, and any other required electrical operating control.
TEMPERATURE HIGH LIMIT SWITCH As a safety device, a surface mounted high temperature cut-off switch with manual reset is supplied. As an option, an immersion high temperature cut-off switch with manual reset may be provided. Either high temperature cut-out switch is factory preset at 190°F. In the event of an over-temperature condition, the thermostat will disengage the power from the system. The high limit must be manually reset thereafter to restart the heater.
OPTIONS The following optional features may be included in your water heater. Reference included drawing specific to your heater for further details. Low Temperature Alarm Dry Contacts A low temperature thermostat is available with dry contacts to remotely alarm when the tank water temperature falls below a specified setpoint. The low temperature thermostat is adjustable from 30-110°F.
PIPING INSTALLATION NOTE: The most effective means for preventing deterioration from accelerated corrosion due to galvanic and stray current is the installation of dielectric fittings/unions. The installation of these fittings is the responsibility of the installing contractor. 1. Connect the cold water inlet and tepid water outlet to the appropriate connections as shown below; refer to the drawing for location and sizes. 2.
FILLING THE HEATER 1. Completely close the drain valve. 2. Open the highest tepid water outlet to allow all air to escape from piping. 3. The black plastic knob on the air vent valve must be opened two turns to allow air to escape from the system. 4. Open the valve to the cold water inlet and allow the heater and piping system to completely fill, as indicated by a steady flow of water from the open outlet. ELECTRICAL INSTALLATION 1. Enter junction box with properly sized feeder leads. 2.
QUARTERLY INSPECTION 3. Monitor thermostat a. Let water heater completely heat to a designated thermostat setting. b. After thermostat satisfies (that is, when the thermostat actually clicks off), draw water from the relief valve. c. Compare water temperature of drawn water to the temperature setting of the thermostat when it satisfies. Normal variation between the two points is approximately + 7°F. d.
MIXING VALVE INSPECTION AND TEST LOG COMPANY: HEATER SERIAL NUMBER: DATE START-UP SPIKE OUTPUT TEMPERATURE COMMENTS TESTED BY 11
SECTION IV – TROUBLESHOOTING Symptom No hot water in tank Probable Cause Circuit breaker tripped at source. High limit switch tripped. Loose wires. Heating element inoperable. Low line voltage. Faulty thermostat. Water temperature in tank below settings at all times Faulty thermostat.
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.
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.
SINGLE PHASE 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. Tank Flange Wires 7. Remove the 3/8-16 nuts. 8. Withdraw element assembly and remove gasket. Gasket Element Assembly Nuts 9. Install new gasket and insert new heating element. 10.
3-PHASE 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. Remove the 3/8-16 nuts. Tank Flange Element Terminals Nuts 8. Withdraw element assembly and remove gasket. Gasket Element Assembly 9. Install new gasket and insert new heating element.
3-PHASE ELEMENT JUMPER CONFIGURATION 17
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.) 18 .
MAGNETIC CONTACTOR (3-PHASE ONLY) 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.
MIXING 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. Drain tank. 5. Disconnect unions on both sides of the mixing valve. 6. Remove mixing valve. 7. Replace mixing valve. 8. Fill system in accordance with procedures on page 9. Acorn Nut Cap Hot Water Inlet Cold Water Inlet Union Union Tepid Water Outlet RE-CALIBRATE MIXING VALVE 1. Remove small domed acorn nut cap on top of the diaphragm actuator. 2.
SECTION VI – ELEMENT CHARTS SINGLE PHASE ELEMENT CHART Power (Watts) Immersion Element Resistance Element Part # Length (Ohms) 120V 208V 240V 277V 480V CH-FO-358 ---3500 ---------11 3/8" 12.36 CH-FO-408 ---4000 ---------11 3/8" 10.82 CH-FO-508 ---5000 ---------13 1/4" 8.65 CH-FO-608 2000 6000 ---------13 3/8" 7.21 CH-FO-304 ------3000 4000 ---9 3/4" 19.20 CH-FO-354 ---2500 3500 ------9 3/4" 16.46 CH-FO-404 ---3000 4000 ------11 1/2" 14.40 CH-FO-454 ------4500 ------11 1/2" 12.
