Hatco PMG-60M-0705-7 User Manual

POWERMITE®GAS BOOSTER HEATER

INSTALLATION, OPERATING, SERVICE AND PARTS MANUAL

MODEL: PMG-60

58,000 BTU

I&W #07.05.053.00

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

- WHA

T T

O DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

- Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil.

- QUE F

AIRE SI VOUS SENTEZ UNE

ODEUR DE GAZ:

•Ne pas tenter d’allumer d’appareil.

•Ne touchez à aucun interrupteur; ne

pas vous servir des téléphones se trouvant dans le bâtiment.

•Appelez immédiatement votre

fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

•Si vous ne pouvez rejoindre le

fournisseur, appelez le service des incendies.

- L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.

WATER HEATERS FOR OTHER THAN RECREATIONAL VEHICLE INSTALLATION

ONL

CHAUFFE-EAU POUR INSTALLATION AUTRE QUE DANS DES VÉHICULES DE

LOISIR UNIQUEMENT

WARNING: If the information in these instructions is not followed exactly , a fire or explosion may result causing property damage, personal injury or death.

AVERTISSEMENT: Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter out dommage matériel, toute

blessure ou la mort.

Form No. PMG-60M-0705

CONTENTS

INTRODUCTION

Hatco Powermite Gas Booster Heaters are instantaneous fin tube type heaters designed to boost the temperature of regularly available hot water, usually 110°F to 150°F (43°C to 66°C) to a minimum of 180°F (82°C). Water at 180°F (82°C) can be used as sanitizing rinse water in commercial dishwashers in accordance with Health Codes and National Sanitation Foundation Standard #5.

The Hatco Gas Booster Heater is design certified by CSA International and tested under the requirements of the American National Standard, ANS Z21.10.3*CSA 4.3, Current Edition.

All Hatco Gas Booster Heaters are factory preplumbed and pre-wired to allow for easy installation. The control compartment area is accessible from the front, which permits easy installation, even when near other equipment.

Hatco Gas Booster Heaters are quality built for long life and rugged dependability. Dependability of the booster heater is preserved through proper, safe installation and operation.

This manual provides the installation, safety and operating instructions for the Powermite Gas Booster Heater. We recommend all installation, operating and safety instructions appearing in this manual be read prior to installation or operation of your Hatco PMG-60 Gas Booster 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.

Hatco Gas Booster 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.

Important Safety Instructions............Front Cover

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

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

Model Description................................................1

System Overview .................................................1

Specifications.......................................................2

Dimensions......................................................3

Booster Heater Sizing Chart...........................4

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

General............................................................5

Plumbing .........................................................8

Gas................................................................13

Electrical........................................................16

Operation............................................................17

Start-Up Procedures......................................17

Maintenance .......................................................19

Accessories........................................................23

Replacement Parts List.....................................24

Wiring Diagram...................................................26

Hatco Limited Warranty.....................................27

Authorized Parts Distributors............Back Cover

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 Powermite

Gas Booster Heater in the spaces below. Please have this information available when calling Hatco for service assistance.

Model No. ________________________________ Serial No. ________________________________ Voltage __________________________________ Date of Purchase __________________________

Business 8:00 a.m. to 5:00 p.m. Hours: Central Standard Time

(Summer Hours: June to September – 8:00 a.m. to 5:00 p.m. C.D.T. Monday through Thursday

8:00 a.m. to 2:30 p.m. C.D.T. Friday) Telephone: (800) 558-0607; (414) 671-6350 Fax: (800) 690-2966 (Parts & Service)

(414) 671-3976 (International)

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

24-Hour 7-Day Parts & Service Assistance available in the United States and Canada by calling (800) 558-0607.

Form No. PMG-60M-0705

MODEL DESCRIPTION

The Hatco Powermite Gas Booster Heater is designed to maintain a minimum temperature of 180°F (82°C) water required for the rinse cycle of a commercial dishwasher. An inlet water temperature of at least 110°F (43°C) will produce optimum results (See Capacity Chart and Booster Heater Sizing Chart in SPECIFICATIONS).

After the necessary power, water and gas connections are completed, start the unit by turning on the toggle switch located on the lower front base. The water circulating pump will start at this time. After 20 seconds, providing the operating and safety controls are satisfied, the ignition module will energize the spark igniter and turn on the gas for the pilot. The igniter will spark for about 90 seconds or until proof of fire. If there is a confirmed pilot fire, and the water temperature is below the setpoint, the unit will go into full burn. The unit will stay in full burn until the desired setpoint temperature is met, then the burner will shut off. During standby periods of limited use, the burner will cycle on only to replace standby water temperature loss. If for some reason the unit did not ignite there is an automatic 5 minute delay before the unit attempts to ignite again.

If the unit overheats above the setpoint temperature, the safety high limit will open, shutting down the burner, locking out the controller, and turning on the alarm pilot light. In order to reset the unit, turn the unit off and depress the reset button on the appropriate high limit switch. The heat exchange high limit is located on the left hand side of the heat exchanger or the tank high limit on the lower front of the control box. This switch will not reset until the temperature has dropped to a safe level. This unit must remain off for at least 10 seconds before it can be restarted.

NOTE: The operating thermostat control is factory preset at 190°F (88°C).

NOTE: The circulator pump will stay on as long as the toggle switch is in the ON position.

SYSTEM OVERVIEW

ALL MODELS

Water enters the booster heater at the inlet water connection and flows into the stainless steel tank. It then is pumped through the finned tube heat exchanger where it is heated to the proper temperature. The heated water then returns back to the top half of the stainless steel tank for supply to the dishwashing machine. Water that is not immediately used by the dishwashing machine is recirculated through the heat exchanger.

This system is designed to assure the availability of the proper temperature water at the heater outlet.

All Hatco booster heaters are warranted to be free of defects in material and workmanship under normal use and service, and when installed in accordance with factory recommendations.

NOTE: Hatco Booster Water Heaters are approved for use with commercial dishwashers only.

Form No. PMG-60M-0705

SPECIFICATIONS

Type: Gas-fired, instantaneous recirculating booster heater with accumulator for use with

door type dishwashers. Unit is unvented and floor mounted.

Capacity: Input 58,000 BTUs/Hour. Output 46,000 BTUs/Hour = 13.4 kW Fuel: Natural gas @ 5 iwc or Propane @ 11 iwc – minimum inlet gas pressure. Operating

Water Pressure: 150 PSI max. Relief valve set at 150 PSI, 210°F (99°C). Power: Supply 120 VAC, 15 amp service (unit uses 1.75 amps @ 120 volts). Ignition: Electronic spark pilot with flame proofing by rectification. Temperature Control: Electronic, temperature control probe/microprocessor based. Factory preset at

190°F (88°C).

Safety Systems: Energy cut off devices include manual reset flame rollout and heat exchanger high

limits, and manually reset tank high limit. Redundant gas solenoid valve with integral regulator. Temperature/Pressure relief valve on tank.

Fluing: Direct – combustion air enters bottom, flue gases exit sides at top of unit. Pump: Recirculating with bronze housing. Connections: Gas – 1/2" NPT, Water – 3/4" NPT, Electric – 120 VAC, 15 Amp. Weight: 108 pounds (49 kg), dry.

NOTE: Capacity is reduced @ altitudes above 2000 feet (610 m). See HIGH ALTITUDE INSTALLATION & OPERATION section for sizing considerations.

WATER TEMPERATURE RECOVERY TABLE – FAHRENHEIT

INPUT MBH Gallons per Hour (GPH) at Indicated Temperature Rise (F°)

MODEL (1,000 BTU/HR) 30° 40° 50° 60° 70° PMG-60 58 181 135 108 90 77

Form No. PMG-60M-0705

SPECIFICATIONS

DIMENSIONS

Figure 1. Dimensional Drawings

NOTE: Overall Dimensions 20-3/8"W x 24-1/2"D x 24-5/8"H (518 x 622 x 625 mm)

Form No. PMG-60M-0705

SPECIFICATIONS

BOOSTER HEATER SIZING CHART

GAS

POWERMITE

BOOSTER†

Dishwasher Model Number Temperature Rise

40°F (22°C) 70°F (39°C)

Blakeslee UC-21, D-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

Champion U-H1, UH-200, UH-200B, U-HB, UL-150 . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

UH-150, UH-150B, UH-100B, DHB-VS . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

D-H1, D-HB, D-H1T, D-HBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

PP-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

D-H1C, D-H1TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

66 WSPW, 44-WS, 66WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

Hobart LXiC, LXiGC, LX-18C, LX-30C, LX-40C . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

LX-30, SR24, SR24H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

LX-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

AM-14T, AM-14F, AM-14TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

AM-12, AM-12C

, AM-14, AM-14C . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

AM-15, AM-15F, AM-15T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

Opti-RinSe C44AW, CRS-66AW, CCS-66AW, CPW-80AW . . . . . .PMG-60 . . . . . . . . . . .---

Insinger Commander 18-5, 18-5H, Ensign 40-2 . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

Jackson JP-24, JP-24B, JP-24F, JP-24BF . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

24B Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . .PMG-60

10AB, 10APRB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . .PMG-60

200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

200B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . .PMG-60

Knight Equipment

LTD. KLE-112 HL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60

Metalwash/

Intedge FW4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

Stero SCT-44-10-LW, SCT-44-LW, SCT-66S-LW, SCT-76S-LW,

SCT-76SC-LW, SCT-90S-LW . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

SF-1RA, SC20-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

SF-2RA, SF-2DRA, SD-2RA, SDRA, SDRA-PACK . . . . . . . . . . . .PMG-60 . . . . . . . . . . .---

* Hobart Model AM-12 with serial no. 12-067-357 or below and model AM-12C with serial no. 12-067-537 or

below require slightly larger booster than listed. Or C Models with serial no. 85-1041605 or greater use Opti-RinSe.

† Powermite installations above 2,000 ft. (610 m) will reduce the above capacities and may require change of

pressure and/or orifices in certain models at time of install to meet IAS safety compliance. These modifications are the responsibility of the installer. Consult “Installation and Operating Manual” for sizing adjustments and orifice changes.

This selector chart is based on 40°F (22°C) and 70°F (39°C) temperature rises, 20 psi flow pressure, and minimum rinse cycle timer setting in NSF listing.

All booster heaters are rated at 100% of the capacity of the dishwashers as recommended by the National Sanitation Foundation. Where make-up water for wash tank is provided from final rinse supply, chart recommendations are based upon this additional demand (not over 2 GPM) as required by NSF.

All sizings shown are that of the dishwasher manufacturers. Hatco Corporation is not responsible for incorrect sizing applications.

Form No. PMG-60M-0705

INSTALLATION

WARNING To assure proper operation and avoid a possible unsafe condition, the booster heater must be installed in a horizontal position with the base parallel to the floor and the inlet connection at the lowest point.

The Booster Heater must not be installed directly on carpeting, but on top of a metal, wood (or equivalent) panel extending beyond the full width and depth of the booster heater by at least 3" (76 mm) in any direction or, if the heater is installed in an alcove or closet, the entire floor must be covered by the panel. The panel must be strong enough to carry the weight of the heater when full of water.

Adequate front clearance is required to allow for accessibility to the control compartment.

The booster heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the booster heater . The p an must not restrict combustion air flow.

CAUTION

Unit is not weatherproof. For safe and proper operation the unit must be located indoors where the ambient air temperature is constant and is a minimum of 70°F (21°C).

GENERAL

Code Requirements

Installation must be in accordance with local codes, or in the absence of local codes, with the latest edition of the National Fuel Gas Code, ANSI Z223.1, the National Electrical Code, ANSI/NFPA 70. Canadian installations should conform with CSAB149.1 Natural Gas and Propane Installation Code, and CSA-C22.1 Electrical Code, and/or local installation codes. {Les installations canadiennes

doivent se conformer aux CODES D’INSTALLATION CSA-B149.1, Natural Gas and Propane Installation Code, et CSA-C22.1 Electrical Code, et/ou aux codes locaux d’installation.}

NOTE: In the Commonwealth of Massachusetts, Hatco Booster Heaters shall be installed by a licensed plumber and gasfitter.

NOTE: The Commonwealth of Massachusetts requires that if a water treatment system is installed in line with the Hatco Booster Heaters, a water backflow protector shall also be installed.

NOTE: If a check valve or water backflow protector is installed and cannot be removed install a back pressure relief valve, Hatco part number

03.02.039.00, set at 125 psi (862 kPa) on the incoming line between the pressure reducing valve and the inlet to the booster heater. Discharge must be to open site drain.

For the most effective operation, install the Hatco Gas Booster Heater as close as possible to the dishwashing machine.

NOTE: Employ external recirculation if distance between booster and dishwasher exceeds the National Sanitation Foundation specifications of five (5) feet (1.5 m).

Form No. PMG-60M-0705

INSTALLATION

Combustion/Ventilation Air

The booster heater must be located in an area which allows for an adequate supply of air for proper combustion and ventilation in accordance with Section 5.3 and 7.2.2 of the National Fuel Gas Code NFPA54/ANSI Z223.1 (a portion of the 1996 code is excerpted below) or applicable provisions of the local building codes. Only a single booster appliance may be installed in this manner.

Installations under the jurisdiction of Canadian CSA-B149.1, Natural Gas and Propane Installation Code require a gas interlock tied into the ventilation hood system. {Les installations

sous la juridiction des CODES D’INSTALLATION canadiens CSA-B149.1, Natural Gas and Propane Installation code nécessitent un verrouillage réciproque de gaz raccordé au système de capot de ventilation.}

EXCERPT FROM ANSIZ223.1/NFPA #54

7.2.1 Connection To Venting Systems. Excerpt as

permitted in 7.2.2 through 7.2.6, all gas utilization equipment shall be connected to venting systems.

7.2.2 Equipment Not Required To Be Vented.

A single booster-type [automatic instantaneous] water heater, when designed and used solely for the sanitizing rinse requirements of a dishwashing machine, provided that the equipment is installed, with the draft hood in place and unaltered, if a draft hood is required in a commercial kitchen having a mechanical exhaust system. Where installed in this manner, the draft hood shall not be less than 36 inches (91 cm) vertically and 6 inches (15 cm) horizontally from any surface other than the equipment.

Where any or all of this equipment is installed so the aggregate input rating exceeds 20 Btu per hour per cubic foot (207 watts per m

) of room space in which it is installed, one or more shall be provided with venting systems or other approved means for removing the vent gases to the outside atmosphere so the aggregate input rating of the remaining unvented equipment does not exceed the 20 Btu per hour per cubic foot (207 watts per m

) figure. Where the room or space in which the equipment is installed is directly connected to another room or space by a doorway, archway or other opening of comparable size that cannot be closed, the volume of adjacent room or space shall be permitted to be included in the calculation.

Form No. PMG-60M-0705

INSTALLATION

WARNING/CAUTION The flow of air to the heater for combustion and ventilation must not

be obstructed. Air

vents on the bottom and side of the unit

should never be blocked.

WARNING/CAUTION

This unit is designed to vent directly into the room and is intended for commercial food service water heating only. IT IS NOT FOR RESIDENTIAL USE.

WARNING/CAUTION

Flue gases exit top sides of this unit and must not be obstructed, specified clearances must be maintained for safe operation.

While the gas booster heater is designed and approved to vent directly into the room, an alternative venting method is available through our accessory diverter hood. See the ACCESSORIES section of this manual.

High

Altitude Installation and Operation

Atmospheric conditions at elevations above 2000 ft. (610 m) have an effect on the performance of most gas fired products. For this reason, historical models for altitude de-rating were developed for gas appliances with atmospheric burners. The National Fuel Gas Code, ANSI Z223.1 is an accepted model which requires a de-rating of 4% per 1000 ft. (305 m) elevation when no testing to the contrary exists for that product. This could require modifying the equipment and adjusting settings in the field to achieve de-rating. Testing has shown this to be a very conservative approach.

Manufacturers discourage unnecessary field adjustments in order to maintain a level of performance and quality designed into the product. For these and other reasons, testing was underwritten through CSA International to verify an improved satisfactory performance with little or no modification to effect input rate or control. The following text and charts are a result of this testing and should be used during application sizing and installation.

• The PMG-60 can operate with less de-rating than ANSI Z223.1 with sea level manifold pressure settings and orifices. Anatural gas unit will require an orifice change over 5000 ft. (1525 m). No change is needed for a liquid propane gas unit. This is true up to 8500 ft. (2593 m) elevation where a slight decrease in manifold pressure may be needed to meet the approved BTU rate. Also note that the GPH capacity will be reduced and a guideline is given as to the percent of sea level capacity expected.

Orifice Kits for altitude installations may be ordered through Hatco Customer Service. For PMG-60 order P/N ORIF60.

For Canadian installations between 2000-4500 feet (610-1370 m) de-rate unit by 10% to 52,000.

{Pour les installations au Canada entre 610 et 1370 m (2000 et 4500 pi) reclassifier l’appareil de 10% à 52,000 BTU.}

Minimum Clearance Requirements: {Exigences quant au dégagement minimum:}

Floor Top Left Side Right Side Front Back

{Sol} {Dessus} {Côté gauche} {Côté droit} {Devant} {Derrierè}

6"* (152 mm) 5" (127 mm) 6" (152 mm) 6" (152 mm) 20" (508 mm) 2" (51 mm)

*Includes legs supplied with booster heater {Comrend pieds fournis avec appareil de chauffage auxiliare}.

Form No. PMG-60M-0705

INSTALLATION

SUPPLIED WITH UNIT OPTIONAL WITH UNIT SUPPLIED BY INSTALLER

• Temperature/Pressure • Back Pressure • 3/4" Gate or Ball Valve Relief Valve Relief Valve • Drain Valve

• Blended Phosphate Water Treatment System • 3/4" Unions

• Temperature/Pressure Gauges (2) • 3/4" Piping

• Shock Absorber

• 3/4" Plug (installed)

• 3/4" Inlet Tee

Altitude:

Ft. Above Sea Level 0-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-8500 8501-9500 9501-10500 (Meters) (0-610) (610-915) (915-1220) (1220-1525) (1525-1830) (1830-2135) (2135-2440) (2440-2593) (2593-2898) (2898-3203)

PMG-60 LPG

Approved Input Rate* 58000 57154 56308 55461 54615 53769 52923 52500 50400 48300

Suggested Orifice Size† #68DMS GPH Capacity Derate• 1 0.99 0.97 0.96 0.94 0.93 0.91 0.91 0.87 0.83

Altitude:

PMG-60

Approved Input Rate* 58000 56154 54308 52462 50615 48769 46923 46000 44160 42320

Suggested Orifice Size† #55DMS #56DMS GPH Capacity Derate• 1 0.97 0.94 0.90 0.87 0.84 0.81 0.79 0.76 0.73

LIQUID PROPANE GAS

Altitude Summary Publication Data for PMG Boosters

NATURAL GAS

Notes:

* This is the maximum allowable btu rate certified by CSA. These are to be verified by the qualified gas

installer on site. Check Heat Value with local Gas Utility

† The first orifice size is the factory built unit.

The next sizes are shown at the altitudes where a change is required to allow pressure adjustments to the approved input rates.

• This is a de-rate multiplier to use when sizing a gas booster for a given application. Take this value and multiply it by the GPH found on the Hatco sizing chart to ensure it will provide the capacity you need. You can also use this value by dividing it into your capacity needs and take the resulting adjusted GPH to the sizing chart to select a gas booster.

PLUMBING

Components

+ 22 hidden pages

Hatco PMG-60M-0705-7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual