Hubbell Electric Heater Company HSE Water Heater User Manual
Contents
1. power supply 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 II GENERAL DESCRIPTION AND CONSTRUCTION INSTALLATION SCHEDULED MAINTENANCE AND OPERATION TROUBLESHOOTING SERVICING AND REPLACEMENT OF PARTS MISCELLANEOUS CHARTS AND FORMULAS PAGE 11 13 14 20 OUTLINE DIMENSIONS Note Contractor to supply 2 8 diameter Tie Rod for hanging installation Front View Side View 3 8 Tie Rod 7 s By Contractor with ial 168 9 Magnetic Space Contactor Model HSE Hi Limit only Cut Out Mountin2. 995 3250 3730 22
3. OPERATING AND MAINTENANCE MANUAL FOR COMMERCIAL HORIZONTAL CEILING HUNG ELECTRIC WATER HEATER fubbe ELECTRIC HEATER COMPANY BASE MODELS HE and HSE 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
4. RT Power Watts Immersion Element Element Part 120V 208V 240V 277V 480V Length Resistance Ohms 3500 11 3 8 12 36 4000 11 3 8 10 82 5000 13 1 4 8 65 2000 6000 13 3 8 7 21 3000 4000 9 3 4 19 20 2500 3500 9 3 4 16 46 3000 4000 11 1 2 14 40 4500 11 1 2 12 80 5000 11 1 2 11 52 1500 4500 6000 13 1 2 9 60 2000 7 5 8 83 23 500 1000 3500 12 1 2 47 56 2500 9 5 8 5 76 500 1500 2000 2500 13 3 8 28 80 990 3000 10 1 2 55 49 1000 1350 4000 13 5 8 41 62 2000 2500 3500 10 5 8 23 04 2500 13 1 4 66 59 4500 13 1 8 17 05 1500 4500 13 1 4 36 99 1000 5000 9 3 4 33 29 5000 15 15 35 6000 15 1 2 12 79 1500 2000 6000 15 1 2 27 74 Red wattage indicates the stamped element rating 21 TORQUE VALUES SILICON ALUMINU 18 8 S S BRASS S S MONEL BOLT SIZE BRONZE 2024 n a e TX EY me we so 99 80 138 147 12 107 123 5 624 142 116 13 86 5 18 0 I 3110 2545 2885 1
5. Turn power supply ON e op mo 12 SECTION IV TROUBLESHOOTING Symptom Probable Cause Corrective Action Remedy No hot water Circuit breaker tripped at source Reset circuit breaker 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 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 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 Water temperature below settings at all times Faulty thermostat Check thermostat adjustment Monitor thermostat as described in Section III 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 Heater improper
6. crew not shown 5 Replace with new contactor using reverse procedure RELIEF VALVE l OO ON Mam 909 Overflow Piping Outlet 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 19 SECTION VI MISCELLANEOUS CHARTS AND FORMULAS FORMULAS RECOVERY METRIC CONVERSION GPH x F AT x 0 00244 KW Liters x 0 2641 Gallons KW x 410 GPH AT Gallons x 3 79 Liters KW x 410 k A Gallons x 0 003785 qu mu T GPH 5 m3 x 264 2 Gallons Note 1 KW will heat 4 1 GPH at a 1009 AT 190 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 T 1 73 psi Volts mps 3 Bar x 14 5 psi psi x 6 86 kPa KW x 1000 ue Amps 1 kPa x 0 1456 psi Lbs x 0 4536 Kg Kg x 2 2 Lbs Watts Sq Cm 6 4 Watts Sq In Watts Sq In x 0 155 Watts Sq Cm 3 PHASE ELEMENT CHART Element Immersion Part Length Hp o ar 34 s 34 230 NN 5 13 8 38683 10 12 15 13 144 48 144 96 m3 15 75 25 75 50 20 SINGLE PHASE ELEMENT CHA
7. eeder leads Single phase installations require two 2 leads three phase installations require three 3 leads Install these power leads onto terminals 1 and 3 of the high temperature cut off for single phase installation or the magnetic contactor for 3 phase installation Torque screws per torque chart included in Section VI All other electrical connections are made at the factory therefore no other electrical connections are necessary FINAL CHECKS l 2 10 Check all connections for tightness Ensure that all the above steps are completed 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 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 satisf
8. ef valve An overflow line should be utilized from the relief valve outlet to a floor drain A 4 inch GHT connection is supplied for draining See drawing for locations and sizes CONTROL THERMOSTAT The water heater is supplied with an immersion thermostatic switch that is installed and wired at the factory The immersion thermostat can be adjusted through a range of 100 190 F and is adjustable with a flat tip screwdriver An optional low range 30 110 F thermostat may be supplied 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 provided In the event of an over temperature condition the thermostat will disengage the power from the unit in the HSE model the thermostat will disengage the operating coils in the magnetic contactor The high limit must be manually reset thereafter to restart the heater Manual Reset HEATING ELEMENT The water heater is supplied with an electric immersion heating element assembly s composed of incoloy or copper sheathed elements 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 3 Phase Incoloy Sheathed Element Single Phase Copper Sheathed Element MAGNETIC CONTACTOR HSE Models Only The magnetic contactor s is a heavy du
9. g Assemblies Thermostat ET storage Bulb 7 Vesse Protective Jacket Thermostat Heatin Elemen Optional Drip Pan Assembly 28 Rear View Hot Water Outlet T amp P Safety Relief Valve 1p Combination Cold Water 10 Inlet and Drain SECTION I GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes a packaged electric water heater that is a stationary self contained unit The complete assembly consists of the storage tank immersion electric heating element s thermostat 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 The standard storage tank is constructed of steel and internally lined with specially formulated Hydrastone cement to a 5 inch minimum thickness The tank is designed for a maximum allowable working pressure of 150 psi 300 psi TP TANK CONNECTIONS The heater is supplied with separate cold water and hot water connections Water entering the cold water inlet is deflected by means of a baffle within the tank A 4 inch FNPT connection is located on the side of the heater for mounting a combination safety temperature and pressure reli
10. ies that 15 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 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 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 11 4 Inspect ceiling supports for tightness and or damage 5 Check for loose electrical connections Tighten as necessary 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
11. ion 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 Thread cold water inlet and diffuser assembly into tank Diffuser slots must be pointing down toward the bottom of the tank VE Cold Water Inlet 27 Diffuser N Diffuser Slots Drain Valve 2 Connect the cold water inlet and hot water outlet to the appropriate connections as shown refer to the drawing for location and sizes 3 Install in line vacuum breaker if supplied 4 Install in line pressure and temperature gauge if supplied 5 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 I Install into provided tapping Manual Release Lever Temperature Probe 6 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 l 2 3 Completely close the drain valve Open the highest hot water faucet to allow all air to escape from piping 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 electric enclosure with properly sized f
12. ly sized Verify heater 18 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 temperature then thermostat is not shutting off at the right setting and thermostat must be replaced 13 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 14 HEATING ELEMENT l 2 3 4 Lift manual release lever on relief valve to let air into system or break union on outgoing ON 8 9 Disconnect power from unit Shut off incoming 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 Fla
13. nge Nuts Withdraw element assembly and remove gasket Gasket Element Assembly Install new gasket and insert new heating element 10 For 3 phase heaters rewire the element according to the voltage and phase rating of the unit as shown below For single phase operations connect wires to terminals 11 Fill tank and check around gasket for any leaks 15 JUMPER CONFIGURATION 1 PHASE 208 OR 240 VOLT f I I I O 3 PHASE WYE 380 TO 575 VOLT ue 3 PHASE DELTA 208 OR 240 VOLT 8 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 hs 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 17 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 Load Wires 4 Loosen two 2 holding screws and remove contactor Mounting Screws Bottom s
14. r 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 Locate heater in a dry location nearest to the point of most frequent hot water use 2 Mount tank using 3 8 diameter threaded rod not supplied to suitable ceiling supports not supplied 3 Install 3 8 diameter threaded rod not supplied into the four 4 mounting assemblies on the tank 4 Install drip pan if supplied 5 The water heater should be protected from freezing and waterlines insulated to reduce energy and water waste 6 Leave a minimum of 13 clearance for element withdrawal 1f necessary 7 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 corros
15. ty 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 18 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 _ C25FNF350 OUTER SHELL AND INSULATION The tank is encapsulated in 2 inch thick polyurethane foam insulation The insulation is protected by a high impact non corroding colorized composite protective Jacket DRIP PAN Optional A drip pan assembly may be supplied as an option with the unit It is designed to mount directly beneath the water heater as shown in the sketch on page 4 SWAY RESISTANT MOUNTS Optional Optional sway resistant mounts may be supplied to further secure the tank from longitudinal movement Additional 3 8 diameter threaded rods not supplied are fastened into additional nuts that are welded to the support mount 3 8 Threaded Tie Rod Connected to Building lar Structure Standard Mount Optional Sway Resistant Mount 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 Fo
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