OPERATING AND MAINTENANCE MANUAL FOR

MARINE ELECTRIC WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ ME ”

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. Safety relief valve must be installed in tapping provided.

4. 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.

5. 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 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.

6. The unit is designed to operate at pressure not more than 100 psi.

7. 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.

2

TABLE OF CONTENTS

SECTION TITLE PAGE #

I GENERAL DESCRIPTION AND CONSTRUCTION 5

II INSTALLATION 8

III SCHEDULED MAINTENANCE AND OPERATION 12

IV TROUBLESHOOTING 14

V SERVICING AND REPLACEMENT OF PARTS 15

VI MISCELLANEOUS CHARTS AND FORMULAS 23

VII ABS TYPE APPROVAL PROGRAM 26

3

4

SECTION I -

GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This book describes a packaged electric water heater, approved by ABS Americas (A Division of the

American Bureau of Shipping) and the USCG (United States Coast Guard), which is a stationary, self contained unit and is designed and constructed specifically for marine applications on board a surface vessel. 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 is 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 a ½-inch minimum thickness. The tank is designed for a maximum allowable working pressure of 100 psi (150 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 is required due to the nonferrous materials used in the construction of the pressure vessel. The tank is designed for a maximum allowable working pressure of 100 psi (150psi 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. The hot water outlet includes a built in heat trap to prevent hot water from radiating out from the heater. A ¾-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 ¾-inch GHT 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.

5

CONTROL THERMOSTAT

The water heater is supplied with either a surface mounted or immersion thermostatic switch that is installed and wired at the factory. See drawing for specific details. The surface mounted thermostat can be adjusted through a range of 110° - 170° F. The immersion thermostat can be adjusted through a range of 100° - 190° F. Both thermostats are adjustable with a flat tip screwdriver.

Surface Mounted Thermostat

Immersion Thermostat

TEMPERATURE HIGH LIMIT SWITCH

As a safety device, either a surface mounted high temperature cut-off switch with manual reset, factory set at 190° F, or an immersion high temperature cut-off switch with manual reset, factory set at 180° F, is 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

Surface Mounted High

Temperature Cut-Off Switch Immersion High Temperature Cut-Off Switch

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.

6

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 cutoff 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.

Dial Temperature and Pressure Gauge

A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge with 2½-inch dial may be supplied for in-line installation (shipped loose) or factory installed in the tank.

Vacuum Relief Valve

A 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.

Electro-Mechanical Timer

An electro-mechanical 7-day time clock with battery back-up may be supplied for specific timing operations. A set of instructions will be supplied with the timer.

7

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&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 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.

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, if necessary.

4. Do not install in an area where flammable liquids or combustible vapors are present.

SECURING OF HEATER

1. The heater is supported by four 2-inch x 2-inch x ¼-inch thick angle iron legs each with a 3inch x 3-inch x ¼-inch thick steel base pad. Each leg is provided with one 9/16-inch diameter bolt hole for one ½-inch bolt which should be used to secure heater to the deck.

2. In addition to the leg supports, two 3-inch x 3-inch x ¼-inch thick brackets with 7/8-inch diameter mounting holes are attached to the upper portion of the heater. These brackets should be attached to bulkhead secured tie-rods thus insuring further support of the heater for shipboard installation.

8

Mounting Dimensions

Tank

Diameter

“A”

Overall

Diameter

“B”

Bolt

Circle

“C”

Bulkhead Mounting

Dimension

“D”

Gallon

Capacity

16 20 12 None 10

16 20 12 None 20

16 20 12 None 30

16 20 12 12 40

18 3/4 22 3/4 16 12 50

22 26 16 12 65

22 26 16 12 80

24 28 18 12 100

24 28 18 12 120

9

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, if supplied.

3. Install in-line pressure and temperature gauge, if supplied.

4. 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 Probe

Temperature and Pressure Relief Valve

5. 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.

10

ELECTRICAL INSTALLATION

1. Enter junction box with properly sized feeder leads. Single-phase installations require two (2) leads; three phase installations require three (3) leads.

2. Connect these power leads to wires enclosed in junction box with wire nuts.

3. All 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 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 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 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. 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: a. Shut off Power Supply. b. Remove element housing cover. c. Visually inspect heating element gasket for evidence of leaks. d. 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.

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

Symptom

No hot water

Water temperature below settings at all times

Relief valve discharges continuously

SECTION IV –

TROUBLESHOOTING

Probable Cause Corrective Action / Remedy

Circuit breaker tripped at source. Reset circuit breaker.

High limit switch tripped.

Loose wires.

Reset high limit switch.

Tighten wires. Torque screws per torque chart included in Section VI.

Heating element inoperable.

Low line voltage.

Faulty thermostat.

Check heating element operation by clamping an Amprobe around each wire to the element. The ampere reading should agree with the nameplate ‘AMP’ figure.

Have source electrical system checked by an electrician.

Move thermostat dial through full range. A definite ‘click’ should be heard. If not,

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 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 is 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 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.

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.

14

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 or three (3) 14 gauge wires and a jumper, as required.

Control Wires

4. Remove the two (2) mounting screws or disconnect from thermostat, as required.

Mounting Screws

5. Replace control and install new high limit switch by performing above steps in reverse order.

15

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

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.)

16

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.

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. Rewire element according to type of unit as shown below.

11. Fill tank and check around gasket for any leaks.

17

L1 L2 L3

L1 L2

1

2

2

3

4

Single Element Operation

1

2

1

2

1

2

1

2

3

4

3

4

3 Ø Open Delta Wiring for Simultaneous Operation

18

L1 L2 L1 L2

1 3 1

2

4

2

1 1

4

3

4

4

2 2

1 1

2 2

Interlocked for Non-Simultaneous Operation Non-Interlocked for Simultaneous Operation

19

SURFACE MOUNTED THERMOSTAT

1. Disconnect power from unit.

2. Remove access cover and locate thermostat.

3. Disconnect the two (2) or three (3) 14 gauge wires and jumpers, as required.

Control Wires

4. Remove two (2) mounting screws and disconnect from high limit cut-off, if required.

Mounting Screws

5. Replace thermostat using the reverse procedure.

20

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) 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.)

21

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.

Test Lever

Overflow Piping Outlet

Tank Connection

Temperature Probe

22

SECTION VI –

MISCELLANEOUS CHARTS AND FORMULAS

ELEMENT CHART

Power (Watts)

Element Part # 120V 208V 240V 277V 480V

Immersion

Length

Element

Resistance (Ohms)

---- ---- ---- 13 8.65

---- ---- ---- 13 7.21

CH-FO-304 ---- ---- 3/4" 19.20

---- ---- 9 16.46

TGB-1203-480

---- ---- 13 9.60

2000 7 5/8" 83.23

TGB-2257L

---- 500 ---- 1000 12 1/2"

2500 ---- ---- ---- ---- 9

47.56

5.76

TGB-1207-240 500 1500 2000 2500 ---- 13 28.80

TGB-1303-480 ---- ---- 990 3000 10 1/2"

TGB-1403-480 ---- ---- 1000 1350 4000 13 5/8"

55.49

41.62

TGB-2257-240 ---- 2000 2500 3500 ---- 10 23.04

TGB-2257-480 2500 13 1/4" 66.59

TGB-2457-277 4500

---- ---- ---- 1500 13 1/4"

TGB-2503-480

---- 13 17.05

5000 9 3/4"

36.99

33.29

TGB-2507-277

TGB-2603-277

5000

6000

TGB-2603-480 ---- ---- 1500 2000

*Red wattage indicates the stamped element rating

---- 15" 15.35

---- 15 12.79

6000 15 1/2" 27.74

23

FORMULAS

24

TORQUE VALUES

BOLT SIZE 18-8 S/S

7/16-14

7/16-20

1/2-13

1/2-20

9/16-12

9/16-18

5/8-11

5/8-18

3/4-10

3/4-16

7/8-9

7/8-14

1-8

1-14

10-24

10-32

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

4-40

4-48

5-40

5-44

6-32

6-40

8-32

8-36

1530

1490

2328

2318

3440

3110

376

400

517

541

682

752

1110

1244

22.8

31.7

75.2

94.0

132

142

236

259

5.2

6.6

7.7

9.4

9.6

12.1

19.8

22.0

BRASS

IN.-LBS.

1249

1220

1905

1895

2815

2545

317

327

422

443

558

615

907

1016

18.6

25.9

61.5

77.0

107

116

192

212

4.3

5.4

6.3

7.7

7.9

9.9

16.2

18.0

697

1030

1154

1416

1382

2140

2130

3185

2885

131

219

240

349

371

480

502

632

SILICON

BRONZE

IN.-LBS.

4.8

6.1

7.1

8.7

8.9

11.2

18.4

20.4

21.2

29.3

68.8

87.0

123

316 S/S

IN.-LBS.

1582

1558

2430

2420

3595

3250

393

418

542

565

713

787

1160

1301

23.8

33.1

78.8

99.0

138

147

247

271

5.5

6.9

8.1

9.8

10.1

12.7

20.7

23.0

456

715

798

980

958

1495

1490

2205

1995

86

143

157

228

242

313

328

413

ALUMINUM

2024-T4

IN.-LBS.

2.9

3.6

4.2

5.1

5.3

6.6

10.8

12.0

13.8

19.2

45.6

57.0

80

MONEL

IN.-LBS.

1832

1790

2775

2755

4130

3730

427

451

584

613

774

855

1330

1482

25.9

34.9

85.3

106.0

149

160

266

294

5.3

6.7

7.8

9.6

9.8

12.3

20.2

22.4

25

SECTION VII –

ABS TYPE APPROVAL PROGRAM

26

27

28

29

30