OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC BOOSTER HEATER ELECTRIC HEATER COMPANY BASE MODEL “ J ” ASME ANSI/NSF5 2007 Edition Rev.
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. 2. Tank is to be completely filled with water and all air is to be vented before energizing. 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 4 II INSTALLATION AND START-UP 8 III SCHEDULED MAINTENANCE AND OPERATION 19 IV TROUBLESHOOTING 21 V SERVICING & REPLACEMENT OF PARTS 26 VI SERVICE PARTS LIST 29 VII TORQUE VALUES 30 VIII WARRANTY INFORMATION 31 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), 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 TP). TANK CONNECTIONS The heater is supplied with separate connections for the cold/warm inlet and the hot water outlet.
DIAL TEMPERATURE AND PRESSURE GAUGE A combination temperature (30°-240° F / 0°-120°C) and pressure (0–200 psi / 01400 kPa) gauge with 3-inch dial is supplied with the unit for in-line installation (shipped loose). The connection is ½” NPT with a 2” long sensing probe. PRESSURE REDUCING VALVE A bronze pressure reducing valve with built-in bypass is supplied with the unit. This valve is shipped separately for in-line installation. The ¾” NPT valve is adjustable from 25-psi to 75-psi.
SECTION II – INSTALLATION AND START-UP 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.
• • • 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. Teflon tape should be used on all NPT threaded pipe connections. 1. Connect the cold/warm water inlet and hot water outlet to the appropriate connections as shown; refer to the specifications for location and sizes. IMPORTANT – Be certain to connect the outlet piping to the final rinse and not to the wash tank.
7. Install the dial temperature and pressure gauge in the outlet line. The temperature sensing element must be in the hot water stream and the gauge must be mounted upright. FILLING THE HEATER 1. 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 through the dishwasher rinse nozzles. NOTE: Flush the tank at full flow for 10 minutes prior to putting into service. ELECTRICAL INSTALLATION 1.
4. Make connections as required to the relay terminal block. When the temperature drops below the XB1 setpoint the relay is open between Normally Open (NO) and Common (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.
FOR REMOTE ON/OFF CONTROL To remotely control the On / Off operation of the heater, it is recommended that a DPST switch or relay (by others) be used to break both power legs (white and black wires) connected to the top two terminals of the J5 connector on the control board. See diagram at right. Use a NC (Normally Closed) relay to turn the booster ON when energizing the relay coil or to turn the booster OFF when deenergizing the relay coil.
Wiring Chart kW 4 5 6 7 9 10.5 12 13.5 15 18 Volt Ph 208 240 480 208 240 480 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 1 1 1 1 1 1 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 Unit Amp Draw 19.2 16.7 8.3 24.0 20.8 10.4 28.8 16.7 25.0 14.4 7.2 6.0 32.5 18.7 30.5 17.6 8.4 6.8 43.3 25.0 37.5 21.
kW 24 27 30 36 39 40.5 45 54 58.5 Volt Ph 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 208 240 240 480 600 208 240 240 480 600 208 240 480 600 208 240 480 600 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 1 3 1 3 3 3 3 1 3 3 3 3 3 3 3 3 3 3 3 Unit Amp Draw 115.4 66.6 100.0 57.7 28.9 22.6 130.0 74.9 112.5 65.0 32.5 27.2 144.2 83.3 125.0 72.2 36.1 29.4 173.1 99.9 150.0 86.6 43.3 36.2 187.5 108.3 162.
1(WT) L1 1(NT) L2 3A L1 L1 L2 L2 Control Module & Display J7 J5 J2 J3 Control, Low Water, & Hi-Limit Probe Leak Detection Probe J7 J2 J5 J3 J7 Control Module & Display J5 J2 J3 Control Module & Display Control, Low Water, & Hi-Limit Probe Control, Low Water, & Hi-Limit Probe Leak Detection Probe Leak Detection Probe 4 (DB) 4 L1 L1 L2 6A L2 J7 J2 J5 J2 J3 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control, Low Water, & Hi-Limit Probe 15 J2 J5 J3 J3 Leak Dete
12 (WT) 13 (NT) L1 L2 L3 L1 L2 L3 J7 J2 J5 J3 Control Module & Display J7 J2 J5 J3 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control Module & Display Control, Low Water, & Hi-Limit Probe Leak Detection Probe 10(WT) 10(NT) 13(WT) L1 L2 L3 L1 L2 L3 L1 L2 L3 Control Module & Display J7 J2 J5 J3 J7 J2 J5 J3 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Control Module & Display Control, Low Water, & Hi-Limit Probe J7 Leak Detection Probe J2 J5 J3 Control, Low Wa
12 (NCB) 12 L1 L2 L3 L1 L2 L3 Control Module & Display J7 Control Module & Display J7 J3 J3 Control, Low Water, & Hi-Limit Probe Control, Low Water, & Hi-Limit Probe Leak Detection Probe 14 Leak Detection Probe 15 L1 L2 L3 L1 L2 L3 Control Module & Display J7 J7 J5 J5 J3 J2 Control, Low Water, & Hi-Limit Probe Leak Detection Probe J2 J5 J2 J5 J3 J2 Control, Low Water, & Hi-Limit Probe Leak Detection Probe Note: Wiring diagrams 3, 5, 6, 7 (NT), 7 (WT), and 11 are obsolete.
J6 Plumbing Connections (Rear View) J16 Plumbing Connections (Front View) 18
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. LOn, for low water on. (Factory Default) 2. LOF, for low water off. iii. Low water reset – sets the low water reset for either automatic or manual 1. LAU, for low water automatic reset. (Factory Default) 2. LAn, for low water manual reset. iv. Temperature units – sets the temperature units to either degrees Fahrenheit or Celsius. 1. DEF, for degrees Fahrenheit. (Factory Default) 2. DEC, for degrees Celsius. v.
a. b. c. d. Shut off power supply. Remove front cover. Visually inspect around heating element for evidence of leaks. Rub around the heating element with a rag. Check for any evidence of moisture. If moisture is present or a water drip is observed, follow procedure outlined in Section V. CAUTION: The area around the heating element may be hot. 4. Scale and mineral build-up on heating elements is a normal condition.
error will clear. If the low water reset is set for manual, when the tank is full press RESET. Check the heater and the piping for leaks. Check for mineral buildup on the probe and clean as required. Check for continuity between the yellow wire and ground. See diagram 2 on the following page. 4. Err, H2O, LEA a. This message displays if the leak detection sensor determines there is water in the base of the heater shell. To clear this message, remove the water from the leak detection sensor.
TROUBLESHOOTING FLOW CHARTS Is the display on? No Hot Water No See 'No Display' flowchart Yes See Error Message section of this manual Yes Continuous Low Water Temperature Is there an error message? No Verify setpoint Check for loose wires and tighten as necessary Verify water inlet pressure and temperature OK? No Magnetic contactor pull in? OK? No Yes Verifythat all wires are installed and in correct positions (see wiring diagrams) 208/240V at contactor coil? Yes Replace contactor No No
Continuous over-temperature condition Do contactors pull out at setpoint? Yes Is there zero amp draw when the contactors drop out at setpoint? Yes No 1 Red 3 Yellow 4 Yes Yes Properly set temperature setpoint No 2 J5 Is there 208/240V across terminals of J5 on the control board as shown in the diagram 3? For 1 contactor: check voltage across 1 & 4 For 2 contactor: check voltage across 1 & 3 and 1 & 4 No Contact factory Replace contactor Yes Plug probe end into RJ45 pigtail (not supplied
Is the circuit breaker tripped at source? No Display Reset circuit breaker Yes No Is the circuit breaker tripped inside heater (if supplied)? Reset circuit breaker Yes No Press ON/OFF button on heater OK? No Is correct voltage measured at power distribution block or line side of contactor for each phase? No Check incoming power Yes Is there 480V at the line side of the transformer (480V models only)? No Check wiring Contact factory No Yes OK? Is there 208/240V at the load side of the tr
SECTION V - SERVICING & 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.
CONTROL BOARD 1. Disconnect power from unit. 2. Disconnect display cable, probe cable (J3), leak detection wire (J2), ground wire (J7), and terminal block (J5) from the control board. NOTE: The terminal block (J5) is removable from the control board. Grasp the terminal block on the ends and pull straight away from the board.
SENSOR PROBE 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 probe wire from control board. (See picture) Probe connection (J3) 7. Remove probe from tank using a 13/16” slotted socket or 13/16” spark plug wrench to accommodate the probe cable.
SECTION VI – SERVICE PARTS LIST Category Description Accessories 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 Relief Valve (4-27 kw) Relief Valve (30-58 kw) Slide Brackets (J6 models only, 2 per set) Water Treatment System (blended phosp.
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 All All All KA8C KA4C All Wire Size N/A All N/A All All #14-#10 #8 #6-#4 All Torque (in•lbs) 600 15 300 25 45 35 40 45 15 Torque (ft•lbs) 50 1.25 25 2.08 3.75 2.92 3.33 3.75 1.25 All All 3.5 0.29 15 25 40 45 40 45 50 275 20 25 35 50 120 20 25 35 1.25 2.08 3.33 3.75 3.33 3.75 4.17 22.92 1.67 2.08 2.92 4.17 10 1.67 2.08 2.
SECTION VIII – WARRANTY INFORMATION LIMITED WARRANTY 1. PRODUCT WARRANTY.
