OPERATING AND MAINTENANCE MANUAL FOR

ELECTRIC INDUSTRIAL PROCESS

WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ V6 and V15 ”

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 150 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 10

III SCHEDULED MAINTENANCE AND OPERATION 17

IV TROUBLESHOOTING 19

V SERVICING & REPLACEMENT OF PARTS 21

VI MISCELLANEOUS CHARTS AND FORMULAS 27

3

4

SECTION I -

GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This booklet describes an electric water heater designed for use in an industrial or commercial application. The complete assembly consists of the storage tank, 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).

TANK CONNECTIONS

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 a baffle within the tank. A ¾-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 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.

5

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 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

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.

6

OUTER SHELL, INSULATION, AND SUPPORTS

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. NSF approved adjustable plastic legs are provided for support.

FUSED LOW VOLTAGE TRANSFORMER

A fused low voltage transformer is supplied with all models rated for 480-volts. This component is used to step down the 480-volt power supply to 240-volts 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.

ON/OFF SWITCH

An illuminated on/off switch is provided for positive verification heater status.

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 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.

Stainless Steel Outer Jacket

An optional stainless steel outer jacket may replace the standard galvaneel jacket.

7

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).

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.

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 element. 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.

Type JJS Type NON

Built-in Circuit Breaker

A built-in circuit breaker may be provided with or without shunt trip protection for protection from circuit overload.

Building Management System (BMS)

A Building Management System control package may be supplied for remote operation and alarm capabilities.

Pump Interlock Terminal Block

An optional pump interlock terminal block may be installed to prevent energizing when the pump is not running.

8

Silicon Control Rectifier

A silicon control rectifier (SCR) “zero fired” power controller for 0-100% proportional control of heaters may be supplied.

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.

Optional Connections

Flanged inlet and outlet connections (150#)

Threaded inlet and outlet connections (1 ½”, 2” MNPT)

Sanitary Connections

Special Customized Features

Please reference drawing for details.

9

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 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, if 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 pressure and temperature gauge, if supplied.

3. Install in-line vacuum breaker, if supplied.

10

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. 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 included in Section VI.

4. All other electrical connections are made at the factory; therefore, no other electrical connections are necessary.

11

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.

Outgoing Hot

Water

Incoming Cold Water

1 – V Model Water Heater

2 – Pressure and Temperature Relief Valve (pipe overflow to floor drain or sink)

3 – Drain Valve

4 – Pressure/Temperature Gauge

5 – Shut-Off Valve

6 – Union

12

13

14

1 – Terminal Block

2 – Magnetic Contactor

3 – Heating Element

4 – Low Water Cut-Off, if supplied

5 – Transformer, 480-Volt/240-Volt, installed on 480-Volt models only.

6 – High-Temperature Limit Switch

7 – Control Thermostat

8 – Illuminated On/Off Switch

15

16

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.

17

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.

18

Symptom

No hot water

SECTION IV –

TROUBLESHOOTING

Probable Cause Corrective Action / Remedy

Circuit breaker tripped at source.

On/Off switch in ‘OFF’ position

Blown fuse in transformer, if installed.

Circuit breaker at control cabinet tripped, if installed.

Blown fuse in element fuse block, if installed.

High limit switch tripped.

Reset circuit breaker.

Turn switch to ‘ON’ position

Replace fuse.

Reset circuit breaker.

Replace fuse.

Reset high limit switch.

Loose wires.

Heating element inoperable.

Low line voltage.

Faulty thermostat.

Faulty low water cut-off, if installed.

Magnetic contactor does not energize.

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 ‘AMP’ 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 is not observed, replace low water cut-off.

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.

19

Water temperature below settings at all times

Relief valve discharges continuously

Faulty thermostat.

Heating element not working on all phases

Blown fuse in element fuse block, if installed.

Heater improperly sized

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.

Replace fuse.

Excessive temperature or pressure in tank

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.

20

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.

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.

21

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.)

22

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. Remove the 3/8-16 nuts.

Element Terminals

Nuts

Tank Flange

8. Withdraw element assembly and remove gasket.

Gasket

Element Assembly

9. 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.

23

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) 14 gauge wires.

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.)

24

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 screw not shown)

5. Replace with new contactor using reverse procedure.

25

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

26

SECTION VI –

MISCELLANEOUS CHARTS AND FORMULAS

ELEMENT CHART

Element Part # 120V

Power (Watts)

208V 240V 480V

Immersion

Length

Element

Resistance (Ohms)

CH-FO-358 ---- 3500

CH-FO-408 ---- 4000

CH-FO-508 ---- 5000

CH-FO-608 2000 6000

CH-FO-304 ---- ---- 3000

CH-FO-404 ---- 3000 4000

CH-FO-454 ---- ---- 4500

CH-FO-504 ---- ---- 5000

CH-FO-604 1500 4500 6000 ---- 13 9.60

TGB-1403-480 ---- ---- 1000 4000

TGB-2457-480 4500

13 5/8"

13 1/4"

41.62

36.99

TGB-2503-480 5000 9 3/4" 33.29

TGB-2603-480 ---- ---- 1500 6000

*Red wattage indicates the stamped element rating

15 1/2" 27.74

Element

Part #

Power (kW)

208V 240V 480V

Immersion Resistance (Ohms)

Length Hairpin 1 Φ 3 Φ DELTA 3 Φ WYE

2-38683N 2.5 3 4 13" 57.6 19.2 57.6 38.6

3-38683N 3 4 5 13" 43.2 14.4 43.2 28.9

4-38683N 4 5 6 13" 34.4 11.5 34.4 23.0

5-38683N 5 6 8 13" 27.9 9.3 27.9 18.7

6-38683N 6 8 10 13" 21.6 7.2 21.6 14.5

7-38683N 8 10 12 13" 17.1 5.7 17.1 11.5

8-38683N 10 12 15 13" 14.4 4.8 14.4

9-38683N 12 15 20 15" 12.1 4.0 12.1

9.6

8.1

10-38683N 15 20 ---- 15"

11-38683N 17.3 ---- ---- 15"

9.1 3.0

7.5 2.5

9.1

7.5

6.1

5.0

27

FORMULAS

28

TORQUE VALUES

BOLT SIZE 18-8 S/S

4-40

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

10-32

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

4-48

5-40

5-44

6-32

6-40

8-32

8-36

10-24

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

29