Hubbell Electric Heater Company E User's Manual
Contents
1. water heaters have a risk of leakage at some unpredictable time IT IS THE CUSTOMER S RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER ADEQUATE MEANS SO THAT THE RESULTANT FLOW OF WATER WILL NOT DAMAGE FURNISHINGS OR PROPERTY WATER HEATER PLACEMENT 1 Place the heater on a solid foundation in a clean dry location nearest to the point of most frequent hot water use If the heater is to be raised off the floor the entire bottom of the heater should be supported by a solid surface 2 The water heater should be protected from freezing and waterlines insulated to reduce energy and water waste 3 Leave a minimum of 18 clearance for element withdrawal 1f necessary 4 Do not install in an area where flammable liquids or combustible vapors are present 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 hot water outlet to the appropriate connections as shown refer to the drawing for location and sizes 2 Install in line vacuum breaker and in line pressure and temperature gauge if supplied 3 Install the combination temperature and pressure safety relief valve in the tapping provided Note that this is required by law for safety considerations Outlet to floor drain an I2. 2 Remove access cover and locate thermostat 3 Disconnect the two 2 or three 3 14 gauge wires and jumpers as required Mounting Screws 5 Replace thermostat using the reverse procedure 18 Capillary Tube 19 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 hs 4 Disconnect the two 2 or three 3 14 gauge wires as required Wires 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 RELIEF VALVE Disconnect power from unit Shut off incoming water supply Lift test lever on relief valve to relieve pressure in tank Disconnect overflow piping Unscrew relief valve remove assembly and replace with new one Connect overflow piping Turn on incoming water supply and check for leaks Turn safety switch to ON position Test ic Tank Connection Temperature Probe 1 OO ON Overflow Piping Outlet 20 21 SECTION VI MISCELLANEOUS CHARTS AND FORMULAS Element Resistance Ohms 12 36 10 82 8 65 7 21 19 20 16 46 14 40 12 80 11 52 9 60 83 23 47 56 5 76 28 80 55 49 41 62
3. ANNUAL INSPECTION 1 Flush tank as follows Shut off power supply Close valve on hot water outlet piping Open valve on drain piping Cold water inlet line pressure will be strong enough to flush sediment from the bottom of the tank out through the drain Let water run for 3 4 minutes Close drain valve Open hot water valve g Turn power supply ON mo 11 SECTION IV TROUBLESHOOTING Corrective Action Remedy Reset circuit breaker Reset high limit switch Tighten wires Torque screws per torque chart included in Section VI Check heating element operation by clamping an Amprobe around each wire to the element The ampere reading should agree with the nameplate figure Have source electrical system checked by an electrician Move thermostat dial through full range A definite click should be heard If not replace thermostat Check to see if tank is full of water If not fill tank If problem continues and tank is full check for continuity between the common and normally open contact of the relay board If continuity 15 not observed replace low water cut off Check thermostat adjustment Monitor thermostat as described in Section III Quarterly Inspection Replace if necessary Check to see that heating element is working on all phases by checking the resistance ohms value for each element and comparing with the chart included in Section VI Verify heater 18 properly siz
4. 23 04 66 59 17 05 36 99 33 29 15 35 12 79 27 74 Immersion Length 11 3 8 11 3 8 13 1 4 13 3 8 9 3 4 9 3 4 111 72 11 1 2 11172 13 1 2 7 5 8 12 1 2 9 5 8 13 3 8 10 1 2 13 5 8 10 5 8 13 1 4 13 1 8 13 1 4 9 3 4 15 15 1 2 15 1 2 480V 2000 3500 3000 4000 2500 4500 5000 6000 Power Watts 208V 240V 277V 3500 4000 5000 6000 3000 4000 2500 3500 3000 4000 4500 5000 4500 6000 500 1000 1500 2000 2500 990 1000 1350 2000 2500 3500 0 0 1000 0 22 0 1500 0 ELEMENT CHART Element Part 120V 2000 1500 2500 500 Red wattage indicates the stamped element rating Note Element part numbers ratings and lengths are subject to change without notice FORMULAS RECOVERY METRIC CONVERSION GPHx x 0 00244 KW Liters x 0 2641 Gallons KW x 410 GPH AT Gallons x 3 79 Liters 410 Gallons x 0 003785 m3 m3 x 264 2 Gallons Note 1 KW will heat 4 1 GPH at a 100 F AT 196 AT 1 8 AT C x 1 8 32 ELECTRICAL 32 0 556 psi 0 06896 Bar E 173 Amps 30 Bar x 14 5 psi psi x 6 86 kPa Amps 1 0 1456 psi 105 0 45
5. any leaks 15 11 12 nop 5 np UME P 116 Single Element Operation 1 2 3 6 Open Delta Wiring for Simultaneous Operation 16 pa 3 gt POL 4 1 1 N 4 4 21 3r 20 JU 9 1 1 0 D D 2 PM Qi 9 6 3 ME gu Interlocked for Non Simultaneous Operation Non Interlocked for Simultaneous Operation SURFACE MOUNTED THERMOSTAT 1 Disconnect power from unit
6. vacuum relief valve may be provided with the unit to reduce the risk of back siphonage and back pressure of the system The valve will be shipped loose for in line installation Instructions for installation are provided with the valve Horizontal Constructions The unit can be designed for horizontal installation either ceiling hung or base mounted Building Management System BMS Building Management System control package may be supplied for remote operation and alarm capabilities Electro Mechanical Timer An electro mechanical 7 day time clock with battery back up may be supplied for specific timing operations set of instructions will be supplied with the timer 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 For protection against excessive pressures and temperatures local codes require the installation of a temperature and pressure T amp 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 CUSTOMER IS RESPONSIBLE TO PROTECT PROPERTY AND PERSONNEL FROM HARM WHEN THE VALVE FUNCTIONS
7. 36 Kg x 2 2 Lbs Watts Sq Cm 6 4 Watts Sg In Watts Sq In x 0 155 Watts Sq Cm 22 23 TORQUE VALUES SILICON ALUMINU 18 8 S S BRASS S S MONEL BOLT SIZE BRONZE 2024 pm ret HR Se JG TX EY me we so 99 18 dem 12 107 13 5 624 14 116 13 86 5818 3110 2545 2885 195 3250 370
8. IONS The heater is supplied with separate cold water and hot water connections Water entering the cold water inlet is deflected by means of a within the tank The hot water outlet includes a built in heat trap to prevent hot water from radiating out from the heater 4 inch FNPT connection is located on the side of the heater for mounting a combination safety temperature and pressure relief valve An overflow line should be utilized from the relief valve outlet to a floor drain A connection is supplied for draining See drawing for locations and sizes HEATING ELEMENT The water heater is supplied with an electric immersion heating element assembly s composed of a copper sheathed element s that are brazed into a brass flange Each assembly is fastened to a corresponding tank flange using a gasket and four 4 3 8 16 x 1 inch long hex head steel bolts and nuts See drawing for voltage and power ratings CONTROL THERMOSTAT The water heater is supplied as standard with surface mounted thermostatic switch that is installed and wired at the factory As an option an immersion thermostat is available See drawing for specific details The surface mounted thermostat can be adjusted through range of 1107 170 immersion thermostat be adjusted through a range of 100 190 Both thermostats are adjustable with a flat tip screwdriver Surface Mounted Thermostat Standard Immersion Therm
9. Jacket Lower Thermostat Lower Heatin WS Withdrawal Element Space Combination Cold Water Inlet And Drain With Diffuser Front View Side View SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes packaged electric water heater that is stationary self contained unit The complete assembly consists of the storage tank immersion electric heating element s thermostat s safety relief valve safety high temperature cut out and any other required electrical operating control Optional equipment may be supplied with your unit Please consult the product drawing for details specific to your assembly The unit 1s factory assembled insulated jacketed wired tested and ready for electrical and plumbing service connections CONSTRUCTION TANK Standard Tank Construction The standard storage tank is constructed of steel and internally lined with specially formulated Hydrastone cement to inch minimum thickness The tank is designed for a maximum allowable working pressure of 150 psi 300 psi TP Optional Tank Construction Optionally the storage tank may be constructed of all welded solid copper silicon alloy ASTM B 96 or type 316L stainless steel for maximum tank longevity No internal lining 18 required due to the non ferrous materials used in the construction of the pressure vessel The tank is designed for a maximum allowable working pressure of 150 psi 300psi TP TANK CONNECT
10. OPERATING AND MAINTENANCE MANUAL FOR COMMERCIAL ELECTRIC WATER HEATER Fuel ELECTRIC HEATER COMPANY BASE MODEL E 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 full model number and serial number when the factory WARNING CAUTION 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 Safety relief valve must be installed in tapping provided The refractory material used in heating elements may absorb some moisture during transit periods of storage or when subjected to humid environment This moisture absorption results in cold insulation resistance of less than twenty 20 megohms If this heater has been subjected to the above condition each heating element must be checked for insulation resistance before energizing low megohm condition can be corrected by removing the terminal hardware and baking the element in an oven at 350 F 700 F for several hours or until the proper megohm reading is obtained KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS Do not perform any maintenance make any adjustments or replace any components inside the control panel with the high voltage power supply turned on Under
11. certain circumstances dangerous potentials may exist even when the power supply is off To avoid casualties always turn the power supply safety switch to off turn the charge or ground the circuit before performing any maintenance or adjustment procedure The unit is designed to operate at pressure not more than 150 psi Generalized instructions and procedures cannot anticipate all situations For this reason only qualified installers should perform the installations A qualified installer is a person who has licensed training and a working knowledge of the applicable codes regulation tools equipment and methods necessary for safe installation of an electric resistance water heater If questions regarding installation arise check your local plumbing and electrical inspectors for proper procedures and codes If you cannot obtain the required information contact the company TABLE OF CONTENTS SECTION TITLE PAGE I GENERAL DESCRIPTION AND CONSTRUCTION 5 INSTALLATION 8 SCHEDULED MAINTENANCE 10 IV TROUBLESHOOTING 12 V SERVICING amp REPLACEMENT OF PARTS 13 VI MISCELLANEOUS CHARTS AND FORMULAS 2 MODEL DIMENSIONAL DATA P T amp P Relief Valve Hot Water Outlet 30 1 E Top View Combination Thermostat And Hi Limit Hot Water Qutlet T amp P Relief Valve Electrical Upper Heatin Element Junction Box Tank Cross Section 2 Insulation Protective
12. ed for the flow rate and temperature rise of your system See formulas included in Section VI Replace elements with proper size as necessary Temperature and pressure relief valves are made to operate if the water temperature exceeds 210 F or water pressure exceeds the pressure rating of the safety relief valve If trouble is excessive temperature then thermostat is not shutting off at the right setting and thermostat must be replaced Probable Cause Circuit breaker tripped at source High limit switch tripped Loose wires Heating element inoperable Low line voltage Faulty thermostat Faulty low water cut off if installed Faulty thermostat Heating element not working on all phases Heater improperly sized Excessive temperature or pressure in tank Symptom No hot water Water temperature below settings at all times Relief valve discharges continuously 12 SECTION SERVICING amp 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 or three 3 14 gauge wires and a jumper as required Control Wires Manual Reset Control Wires Temperature Controller 4 Disconnect the high limit cut off switc
13. er should not be turned on without first making sure that the tank is full of water and that all air has been released FREEZING The tank should be fully drained in the event the electricity has been turned off and if there is danger of freezing QUARTERLY INSPECTION 1 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 heater 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 5 F d Ifthese two readings do not coincide within acceptable tolerances and verification has been made of the accuracy of the temperature reading gauge replace the thermostat 2 Lifttest 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 3 Inspect element flange for leakage as follows Shut off Power Supply Remove element housing cover Visually inspect heating element gasket for evidence of leaks Rub finger around gasket that is between the heating element and tank flange for any evidence of moisture If moisture is present or a water drip is observed follow procedure outlined in Section V 4 Check for loose electrical connections Tighten as necessary 10
14. h from the temperature controller by pulling the cut off switch up and away from temperature controller 5 Replace control and install new high limit switch by performing above steps in reverse order 13 IMMERSION TEMPERATURE HIGH LIMIT CUT OFF 1 Disconnect power from unit 2 Remove access cover 3 Remove high limit cover screw and cover Cover Screw gt Reset Switch ___ St 4 Disconnect the two 2 14 gauge 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 Note Be sure to place capillary tube into slot in base prior to installing cover 14 HEATING ELEMENT Disconnect power from unit Shut off incoming water supply Attach hose to drain connection Lift manual release lever on relief valve to let air into system or break union on outgoing water line Drain water from tank 6 Disconnect the wires from the heating element terminals Wires 7 Remove the 3 8 16 nuts 8 Withdraw element assembly and remove gasket Gasket Element Assembly gt Nuts 9 Install new gasket and insert new heating element 10 Rewire element according to type of unit as shown below 11 Fill tank and check around gasket for
15. nstall 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 2 Open the highest hot water faucet to allow all air to escape from piping 3 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 faucet ELECTRICAL INSTALLATION 1 Enter junction box with properly sized feeder leads 2 Connect these power leads to wires enclosed in junction box with wire nuts 3 other electrical connections are made at the factory therefore no other electrical connections are necessary FINAL CHECKS 1 Check all connections for tightness 2 Ensure that all the above steps are completed 3 After the water is heated for the first time monitor the water temperature as described in Section IIL Quarterly Inspection 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 water heater is automatic in its operation It will maintain a full tank of water at the temperature setting of the thermostat The water heat
16. ostat Optional TEMPERATURE HIGH LIMIT SWITCH As a safety device a surface mounted high temperature cut off switch with manual reset factory set at 190 F is supplied As an optional an immersion high temperature cut off switch with manual reset factory set at 180 F may be provided 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 Manual Reset Immersion High Temperature Cut Off Switch Optional Surface Mounted High Temperature Cut Off Switch Standard OUTER SHELL AND INSULATION The tank is encapsulated in 2 inch thick polyurethane foam insulation The insulation is protected by 8 high impact non corroding colorized composite protective jacket OPTIONS The following optional features may be included in your water heater Reference included drawing specific to your heater for further details Low Water Cut Off Used as a safety device the electronic low water cut off is used to detect 8 low water situation and disengage the operating coils in the magnetic contactor s Once the condition is remedied the low water cut off switch is automatically reset Dial Temperature and Pressure Gauge A combination temperature 70 250 and pressure 0 200 psi gauge with 2 inch dial may be supplied for in line installation shipped loose or factory installed in the tank Vacuum Relief Valve
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