Hubbell Electric Heater Company D User's Manual
Contents
1. 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 21 RELIEF VALVE Overflow Piping Outlet 22 1 OO ON A ce 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 SECTION VI MISCELLANEOUS CHARTS AND FORMULAS ELEMENT CHART Element Immersion Part Length 70 3868388N 8 10 I2 13 171 5 7 171 11 5 80 38683SSN 10 12 15 13 48 96 90 38683SSN 12 15 20 15 121 40 12 1 81 FORMULAS RECOVERY METRIC CONVERSION GPH x F AT x 0 00244 KW Liters x 0 2641 Gallons KW x 410 GPH OF AT Gallons x 3 79 Liters KW x 410 TER Gallons x 0 003785 m3 Eme mcr T GP s H m3 x 264 2 Gallons Note 1 KW will heat 4 1 GPH at a 100 F AT 1 C AT 1 8 F AT OF 6 1 8 32 ELECTRICAL C F 32 x 0 556 KW x 1000 psi x 0 06896 Bar X 173 pei Volts mps 3 Bar x 14 5 psi psi x 6 86 kPa KW x 1000 uS Amps 1 kPa x 0 1456 psi Lbs x 0 4536 Kg Kg x 2 22. Cold Water Inlet Temperature Sensor Note 18 withdrawal space required for Mele ie s removal of heating elements one two or three Pressure Vessel Note HORN 1 Model D1 is available in 1 KW 120 Volt or 240 Volt 1 Phase only 6 10 12 15 20 24 30 35 6 10 12 15 20 24 30 35 40 45 54 58 120 GPM HEATING CAPACITY WITH AMPERAGE CHART SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This booklet describes an electric heater designed specifically for use in deionized DI water applications The complete assembly consists of a type 316L stainless steel storage tank type 316L stainless steel immersion electric heating element s thermostat safety relief valve safety high temperature cut out magnetic contactor s 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 is factory assembled insulated jacketed wired tested and ready for electrical and plumbing service connections CONSTRUCTION TANK The storage tank is constructed of type 316L stainless steel for maximum tank longevity The tank is formed by all welded construction and is designed for a maximum allowable working pressure of 150 psi 300 psi TP As an optional the tank may be supplied with a passivated electropolished finish TANK CONNECT
3. stainless steel float Fused Low Voltage Transformer A fused low voltage transformer may be supplied This option is provided only in 480 volt systems with low water cut offs to step down the voltage to 240 volt for safety when working with control circuits As an option a transformer may be installed on any unit to step down the voltage to 120 volts ge eme T gt lt n xe ESTE 768 Stainless Steel Outer Jacket An optional stainless steel outer jacket may replace the standard galvaneel jacket Optional Connections Flanged inlet and outlet connections 150 Threaded inlet and outlet connections 1 7 2 MNP T Sanitary Connections NEMA 4 or NEMA 4X Electric Control Panel A NEMA 4 control panel may be supplied to provide watertight construction for installation in wet areas Individually Fused Elements To prevent the possibility of damage to control circuits and other elements in case of electrical overloads fuses may be supplied for each circuit Two types of fuses may be used a type NON for voltages less than 250 volt or type JJS for voltage less than 600 volt Digital Display A 1 16 DIN electronic temperature control package may be installed A separate manufacturer s operating manual will be supplied with the unit Stainless Steel Pressure Only Relief Valve Optionally a 24 NPT type 316 stainless steel pressure only relief valve may be supplied as show
4. IONS The heater is supplied with separate connections for the cold water inlet and the hot water outlet Water entering the cold water inlet is deflected by means of baffle within the tank A inch FNPT connection is provided 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 See drawing for locations and sizes HEATING ELEMENT The water heater is supplied with an electric immersion heating element assembly s composed of type 316L stainless steel sheathed elements that are welded into a stainless steel flange Each assembly is fastened to a corresponding tank flange using a Teflon 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 with a single stage immersion thermostatic switch that is installed and wired at the factory The thermostat can be adjusted through a range of 100 195 F an optional low range 30 110 F is available and is adjustable with a flat tip screwdriver Other thermostatic controls are available see Options below TEMPERATURE HIGH LIMIT SWITCH As a safety device either a surface mounted high temperature cut off switch with manual reset factory set at 205 F or an optional immersion high temperature cut off switch with manual reset adjustable through a range of 100 240 F is p
5. Lbs Watts Sq Cm x 6 4 Watts Sq In Watts Sq In x 0 155 Watts Sq Cm 23 TORQUE VALUES SILICON ALUMINU 18 8 S S BRASS s S S MONEL BOLT SIZE BRONZE 2024 n or a el HR Se JG EY L5 me we so 99 80 138 147 12 107 123 5 624 142 116 13 8 5818 eee 0 I 3110 2545 2885 1995 3250 3730 24
6. OPERATING AND MAINTENANCE MANUAL FOR ELECTRIC STAINLESS STEEL HEATER FOR DEIONIZED DI WATER fubbe ELECTRIC HEATER COMPANY BASE MODEL D 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 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 a humid environment This moisture absorption results in a 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 A 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 s
7. ater 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 is not observed replace low water cut off Magnetic contactor does not energize Replace complete magnetic contactor Because of the design of this particular contactor it is more desirable to replace complete control rather than rebuilding coil contacts and springs etc 14 Water temperature below settings at all times Faulty thermostat Check thermostat adjustment Monitor thermostat as described in Section 11 Quarterly Inspection Replace if necessary Heating element not working on all phases 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 Blown fuse in element fuse block if installed Replace fuse Heater improperly sized Verify heater is properly sized for the flow rate and temperature rise of your system See formulas included in Section VI Replace elements with proper size as necessary Relief valve discharges continuously Excessive temperature or pressure in tank 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 tem
8. coming water supply Attach hose to drain connection water line Drain water from tank Disconnect the wires from the heating element terminals Remove the 3 8 16 nuts Tank Flange Nuts Withdraw element assembly and remove gasket Gasket Element Assembly Install new gasket and insert new heating element 10 Rewire element according to the voltage and phase rating of the unit as shown below 11 Fill tank and check around gasket for any leaks 18 JUMPER CONFIGURATION 1 PHASE 208 OR 240 VOLT f I I I O 3 PHASE WYE 380 TO 575 VOLT lt a 3 PHASE DELTA 208 OR 240 VOLT s A t o SORS Oo p O 480 VOLT 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 l 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 20 MAGNETIC CONTACTOR 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
9. e 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 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 Install into provided tapping Manual Release Lever Temperature and Pressure Relief Valve Temperature Probe 3 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 Open the pressure relief valve test lever to allow air to escape 2 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 relief valve ELECTRICAL INSTALLATION 1 Enter electric enclosure with properly sized feeder leads Single phase installations require two 2 leads three phase installations require three 3 leads 2 Install these power leads into the box lugs on the terminal block or magnetic contactor See wiring diagrams below 3 Torque screws per torque chart
10. included in Section VI 4 All other electrical connections are made at the factory therefore no other electrical connections are necessary 10 THERMOSTAT SETTING BULB AND CAPILLARY IMMERSION TYPE The bulb and capillary type thermostat is immersed in a Type 316L stainless steel well in the storage vessel The full thermostat range is 100 240 F but should not be operated over 195 F There is a setting screw which can be locked at a particular setting to prevent an operator from turning the dial beyond a determined temperature point To change the locking set screw open the thermostat cover and follow the printed directions on the inside of the cover To change the operating temperature setting on the thermostat within the allowed range simply insert a screwdriver in the slot and make the appropriate adjustment to the temperature setting according to the desired point on the dial 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 III Quarterly Inspection 11 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 se
11. n below 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 All 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 hot water use 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 Th
12. ons Tighten as necessary 12 ANNUAL INSPECTION 1 Flush tank as follows a Shut off power supply b Close valve on hot water outlet piping c Open valve on drain piping d 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 e Close drain valve f Open hot water valve g Turn power supply ON 13 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy No hot water Circuit breaker tripped at source Reset circuit breaker Blown fuse in transformer if installed Replace fuse Circuit breaker at control cabinet tripped if installed Reset circuit breaker Blown fuse in element fuse block Replace fuse if installed High limit switch tripped Reset high limit switch Loose wires Tighten wires Torque screws per torque chart included in Section VI Heating element inoperable Check heating element operation by clamping an Amprobe around each wire to the element The ampere reading should agree with the nameplate AMP figure Low line voltage Have source electrical system checked by an electrician Faulty thermostat Move thermostat dial through full range A definite click should be heard If not replace thermostat Faulty low water cut off if installed Check to see if tank is full of w
13. perature then thermostat is not shutting off at the right setting and thermostat must be replaced 15 SECTION V 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 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 See wiring diagram included with drawing for assistance 16 IMMERSION TEMPERATURE HIGH LIMIT CUT OFF 1 Disconnect power from unit 2 Remove access cover 3 Remove high limit cover screw and cover pais Cover Screw gt Reset Switch al 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 17 HEATING ELEMENT 1 2 3 4 Lift manual release lever on relief valve to let air into system or break union on outgoing ONA 8 9 Disconnect power from unit Shut off in
14. rovided 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 Surface Mounted High Temperature Cut Off Switch MAGNETIC CONTACTOR The magnetic contactor s is a heavy duty resistive load type rated for 100 000 cycles The contactor supplies power to the heating element s based on the resistive load non inductive of the heater only when the thermostatic switch is engaged thereby pulling in the contacts until the desired temperature is reached At this point the contacts will drop out which in turn disconnects power from the elements Magnetic contactors are installed only on units rated greater than 6kW Cutler Hammer C25FNF350 OUTER SHELL AND INSULATION The tank is encapsulated in 2 inches of high density fiberglass insulation The protective shell is constructed of galvaneel and is coated with a durable silver hammertone finish 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 float type 316 stainless steel low water cut off is used to detect a 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 This type of low water cut off uses a 316
15. tting of the thermostat 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 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 Let water heater completely heat to a designated thermostat setting After thermostat satisfies that is when the thermostat actually clicks off draw water from heater 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 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 thermostat 2 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 3 Inspect element flange for leakage as follows e gt 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 connecti
16. upply turned on Under 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 I GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING AND REPLACEMENT OF PARTS MISCELLANEOUS CHARTS AND FORMULAS PAGE 12 14 16 23 MODEL D DIMENSIONAL DATA Front View Top View Hot Water Outlet PAM Electrical N iy Control Relief Valve Panel Relief Valve Hi Temp Cut Out Protective Jacket Electrical Control 450 6 Panel N Vi 2 Insulation 3 Hot Water Outlet
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