Hatco FFR2-3 Installation Manual

HYDRO-HEATER

Food Rethermalizers/Hot Food Table Heater

FFR2 Series

Installation & Operating Manual &

Replacement Parts List

I&W #07.05.125.00

This manual contains important safety information
concerning the maintenance, use and operation
of this product. Failure to follow the instructions
contained in this manual may result in serious injury.
If you are unable to understand the contents of this
manual, please bring it to the attention of your
supervisor. Do not operate this equipment unless
you have read and understood the contents of
this manual.

Este manual contiene importante información sobre
seguridad concerniente al mantenimiento, uso
y operación de este producto. Cualquier falla en
el seguimiento de las instrucciones contenidas en
este manual puede resultar en un serio daño. Si usted
no puede entender el contenido de este manual por
favor pregunte a su supervisor. No opere este equipo
al menos que haya leído y comprendido el contenido
de este manual.

i

INTRODUCTION

Falcon FFR2 Hydro-Heater Food Rethermalizers/Hot
Food Table Heaters are designed to supply temperature­controlled water to a holding vessel (sink or tank)
located above the heater. Water flows by natural
convection from the holding vessel directly into
a tubular water chamber with heating elements uniquely
wrapped on the outside of the flow tube. The heating
elements do not come in direct contact with the water
eliminating sediment and lime buildup on the element,
resulting in longer life. The heated water flows upward
and returns to the holding vessel. A special electronic
controller maintains the setpoint temperature assuring
a responsive and efficient operation.

The unit electrical and plumbing connections
are factory-assembled and ready for installation.

This manual provides the installation, safety
and operating instructions for the Hydro-Heater Food

Rethermalizers/Hot Food Table Heaters. We recommend
all installation, operating and safety instructions
appearing in this manual be read prior to installation
or operation of your Falcon Hydro-Heater. Safety
instructions that appear in this manual after a warning
symbol and the words WARNING or CAUTION
printed in bold face are very important.

WARNING means there is the possibility of serious
injury or death to yourself or others. CAUTION
means there is the possibility of minor or moderate
injury. CAUTION without the symbol signifies the
possibility of equipment or property damage only.

Falcon Hydro-Heaters are a product of extensive
research and field testing. The materials used were
selected for maximum durability, attractive appearance
and optimum performance. Every unit is thoroughly
inspected and tested prior to shipment.

CONTENTS

Important Owner Information.....................................i

Introduction ...................................................................i

Important Safety Instructions .....................................1

Model Descriptions .......................................................2

All Models ..............................................................2

FFR2 Models ..........................................................2

Units with Built-In Temperature Control................2

Units with Remote Temperature Control................2

Specifications.................................................................3

Electrical Rating Chart - FFR2 Models..................3

Sizing Information ..................................................4

Dimensions..............................................................4

Electrical .................................................................4

Installation.....................................................................5

Plumbing .................................................................5

Auto-Fill..................................................................6

Operation.......................................................................7

Start-Up Procedures ................................................7

Minutes to Heat Table.............................................8

Maintenance ..................................................................9

General ....................................................................9

Daily........................................................................9

Weekly...................................................................10

Deliming Instructions............................................10

Replacement Parts List ..............................................11

IMPORTANT OWNER INFORMATION

Record the model number, serial number (identification
plate located on the lower right hand side, front corner
of the unit), voltage and purchase date of your
Hydro-Heater in the spaces below. Please have this
information available when calling Falcon for service
assistance.

Model No. ____________________________________

Serial No. ____________________________________

Voltage ______________________________________

Date of Purchase ______________________________

Contact the Hatco Corporation for Service Assistance,
Replacement Parts and Warranty Information.

Phone: [phone]

Fax: [phone]

Additional information can be found by visiting our
web site at www.hatcocorp.com.

Form No. FFR2M-1103

CAUTIONS

Water in the unit and holding vessel is very hot.
Wear protective gloves and proper attire when
operating to avoid injury.

Do not use extension pipes on the inlet and outlet
connections on heater units. Poor performance
or unsafe conditions may occur.

CAUTIONS

Do not overtighten unions or nuts. Overtightening
may cause leaks.

Do not turn the electrical current to the unit
on until the holding vessel has been filled with
water or element burnout may occur.

Inspect weekly for lime buildup inside unit.
Excessive amounts can affect unit performance
and reduce the operating life of the unit.

To avoid any damage to the heater unit
use only delimers that are non-corr

osive
to aluminum, brass and stainless steel. Damage
caused by corrosive material or solutions
is not covered under warranty.

Drain holding vessel with power to the unit off,
or element burnout may occur.

Water Quality Requirements - Incoming water
in excess of 3.0 grains of hardness per gallon
(GPG) (.75 grains of hardness per liter) must
be treated or softened before being supplied
to a Hydro-Heater. Water containing over

3.0 GPG (.75 GPL) will decrease the efficiency
and reduce the operating life of the unit.

IMPORTANT SAFETY INSTRUCTIONS

1

WARNINGS

Falcon FFR2 series units are designed
for commercial use only by properly trained
personnel!

To avoid any injury, turn the power switch
off at the fuse disconnect switch/circuit breaker
or unplug the unit from the power source
and allow to cool completely before performing
any maintenance or cleaning.

For proper electrical installation conforming
to local electrical codes, consult a licensed
electrical contractor.

Units are designed to heat water up to 190ºF
(88ºC). DO NOT set temperature controls
to a setting higher than 190ºF (88ºC).

For proper plumbing installation conforming
to local plumbing codes consult a licensed
plumbing contractor.

If service is required on this unit, contact your
Authorized Falcon Service Agent, or contact
the Falcon Service Department at 513-752-1894;
fax [phone].

This product has no “user” serviceable parts. To
avoid damage to the unit or injury to personnel,
use only Authorized Falcon Service Agents and
Genuine Falcon Parts when service is required.

Genuine Falcon Replacement Parts are specified
to operate safely in the environments in which
they are used. Some aftermarket or generic
replacement parts do not have the characteristics
that will allow them to operate safely in
Falcon equipment. It is essential to use
Falcon Replacement Parts when repairing Falcon
equipment. Failure to use Falcon Replacement
Parts may subject operators of the equipment
to hazardous electrical voltage, resulting
in electrical shock or burn.

Form No. Form No. FFR2M-1103

IMPORTANT! Read the following important safety instructions to avoid personal injury or death,
and to avoid damage to the equipment or property.

MODEL DESCRIPTIONS

2

ALL MODELS

The Hydro-Heater mounts easily to the underside
of a holding vessel, leaving the entire vessel area free.
Units are shipped ready to install with all gaskets
and fittings. Hydro-Heaters include a stainless steel
front, powder coated body, a low-water cut-off system
and a convenient drain outlet.

FFR2 MODELS

The Falcon FFR2 model heaters are designed
to be used with a Bain-Marie or Food Rethermalizer
to heat or hold foods at temperatures between 140ºF
(60ºC) and 190ºF (88ºC). The desired holding
temperature is maintained by a special electronic
controller and “free flow”technology.

UNITS WITH BUILT-IN TEMPERATURE
CONTROL

Units with built-in electronic temperature controller
and display are excellent for installations where the unit
is easily accessible and viewing is not obstructed.

UNITS WITH REMOTE TEMPERATURE
CONTROL

Units supplied with remote electronic temperature
controller and display allow for easy operator
monitoring and temperature control.

Figure 1. Hydro-Heater

with Built-In Temperature Controller

Figure 2. Hydro-Heater

with Remote Electronic Controller

Form No.

Form No. FFR2M-1103

SPECIFICATIONS

3

Form No. Form No. FFR2M-1103

Kilowatts Wire Sizing Fuse or

Model Voltage (kW) Phase Amps AWG

*

†

Circuit Breaker

*

Shipping Weight

FFR2-3 208 3 1 14.5 14 20 24 lbs. (11 kg)

240 3 1 12.5 14 20 24 lbs. (11 kg)

FFR2-4 208 4 1 19.2 12 30 24 lbs. (11 kg)

240 4 1 16.7 12 30 24 lbs. (11 kg)

FFR2-6 208 6 3 16.7 12 30 27 lbs. (12 kg)

240 6 3 14.5 14 20 27 lbs. (12 kg)

FFR2-9 208 9 3 25.0 10 40 27 lbs. (12 kg)

240 9 3 21.7 10 30 27 lbs. (12 kg)

ELECTRICAL RATING CHART – FFR2 MODELS

NOTE: Models with “A” suffix equipped with auto-fill. Models with “R” suffix equipped with remote temperature
control. Models with “AR” suffix equipped with auto-fill and remote temperature control.

*

Based upon NEC 2002 Code

†

Based upon THHN wire rated 90ºC.