Hubbell CE110 User Manual

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OPERATING AND MAINTENANCE MANUAL FOR COMMERCIAL ELECTRIC WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ CE110 ”

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.

The following information should be noted at time of installation and retained for future reference. Serial No.:

Date Installed:

Dealer's Name:

Address:

City and State:

2

WARNING / CAUTION

1.Please read all instructions prior to installing water heater.

2.Tank is to be completely filled with water and all air is to be vented before energizing.

3.Due to the rigors of transportation, all connections should be checked for tightness before heater is placed in operation.

4.Safety relief valve must be installed in tapping provided.

5.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°Ffor several hours or until the proper megohm reading is obtained.

6.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.

7.This appliance is designed to store water heated only by the electrical elements provided, at temperature of not more then 125°F and pressures of not more than 150 psi. Heat input from any external or additional source will void the warranty.

8.The design anticipates the proper installation and care in use of the product. There is a risk of property damage and personal injury inherent in these of any hot water system. The Company cannot supervise the installation and therefore make it a specific condition of the warranty that the customer will supervise the installation and use of this product to be sure they are performed in accordance with safe guidelines and proper local or national codes. 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.

3

 

TABLE OF CONTENTS

 

SECTION

TITLE

PAGE #

I

GENERAL INFORMATION

6

II

INSTALLATION GUIDELINES

8

III

SCHEDULED MAINTENANCE AND OPERATION

14

IV

TROUBLESHOOTING

16

V

SERVICING AND REPLACEMENT OF PARTS

17

VI

WARRANTY

21

4

PARTS LOCATION DIAGRAM

High Limit

Access Cover

High Limit Safety Switch - Manual reset switch designed to shut off all electrical circuits if water reaches 190°F

Thermostat - For constant temperature control. Factory set at 125°F.

Thermostat and Heating

Element Access Cover

Long-LifeHeating Element -

Waste is reduced with immersed heating element because all available heat passes directly into the water. Low watt density element assures longer life - and reduces mineral build up.

Electrical Junction

Box Cover

Hot Water

Outlet - (Cold water inlet not shown on bottom).

 

 

Temperature &

Jacket and Insulation -

 

Pressure Safety

Durable & easy-to-clean,

 

Relief Valve

jacket is heavy -gauge

 

 

 

 

steel, finished with high

 

 

gloss enamel. Insulation

 

 

consists of high-density

 

 

fiberglass blankets.

 

 

 

 

 

5

SECTION I - GENERAL INFORMATION

GENERAL DESCRIPTION

This book describes a packaged electric water heater that is a stationary, self-containedunit. 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, painted, wired, tested, and ready for electrical and plumbing service connections.

CONSTRUCTION
TANK

The one-gallonstorage tank is constructed of stainless steel and is designed for a maximum allowable working pressure of 150 psi (300 psi TP).

TANK CONNECTIONS

The heater is supplied with separate ¼” MNPT cold water and hot water connections. A ¾-inchFNPT 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. See drawing for locations and sizes.

HEATING ELEMENT

The water heater is supplied with either a 1000 watt or a 450-wattelectric immersion heating element assembly, rated for 120 volts, and composed of a copper sheathed element that is brazed into a 1” NPT brass plug.

TEMPERATURE HIGH LIMIT SWITCH

As a safety device, a surface mounted high temperature cut-offswitch with manual reset, factory set at 190° F, is provided. In the event of anover-temperaturecondition, the thermostat will disengage the power from the system. If this switch operates, do not attempt to reset. A dangerous situation is indicated and a qualified service person should be called to find the source before the unit is operated again.

Manual Reset

6

CONTROL THERMOSTAT

The temperature of the water in the heater is regulated by the adjustable, automatic, immersion thermostat located behind the jacket front cover. This automatic control is set at the factory to maintain a water temperature of 125°F to reduce the risk of scald injury. The thermostat dial is graduated with markings form 1 to 10 with 10 being the hottest.

Capillary Tube and Bulb

OUTER SHELL AND INSULATION

The tank is encapsulated in 1-inchthick fiberglass insulation. The tank and insulation is protected by a painted steel protective jacket.

TEMPERING VALVE (Optional)

An optional tempering valve may be supplied to increase the amount of available hot water. The ½” NPT valve is adjustable from 100° - 130° F and is typically used when supplying hot water to multiple lavatories from a single CE110.

WALL BRACKET (Optional)

An optional wall bracket is available for easy mounting of the heater.

7

SECTION II – INSTALLATION GUIDELINES

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. ANSIZ21.22-1971.A relief valve is designed to discharge excessively hot water. 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.

The warranty provided assures replacement within its terms, but specifically does not warrant against consequential damage caused by failure to follow these instructions.

UNPACKING AND INSPECTING THE HEATER

1.Remove the model CE110 from the shipping carton and visually inspect for any sign of damage. A damaged unit should not be installed, but returned to the factory for replacement.

WATER HEATER PLACEMENT

1.Locate the heater in a clean, dry location nearest to the point of most frequent hot water use.

2.Secure the water heater. Optional wall mounting brackets may be utilized, if supplied.

3.The water heater should be protected from freezing and waterlines insulated to reduce energy and water waste.

4.Leave sufficient room to service the heater.

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

8

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 installation diagram.

2.Provide a shut off valve in the cold water line. Mark for future emergency use

3.If pressure reducers or any other restrictions are put in the cold water line, special precautions should be taken. Consult you local plumbing inspector

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.

9

ELECTRICAL INSTALLATION

1.Enter the electrical service entrance with properly sized feeder leads, conforming to the voltage stamped on the rating plate. Note: A separate fused branch circuit, conforming to local or National Electric Codes, must be provided by a qualified electrician.

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

CAUTION: There is a risk of electric shock in an ungrounded service. It is critical that this unit be wired with a power supply that has a service ground wire available. Be sure to connect the ground wire to the green ground wire provided in the junction box.

3.Mark the electrical shut off clearly for future emergency use.

4.Field connections with aluminum conductors must use connectors approved for copper to aluminum connection.

5.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.Complete following checklist to ensure that all the above steps are completed:

a.Unit unpacked and checked for damage.

b.Heater properly located.

c.Heater properly secured to wall.

d.Cold water line connected to cold water inlet on tank.

e.Shut-offvalve installed on cold water line.

f.Hot water line connected to hot water outlet on tank.

g.Temperature and pressure relief valve installed.

h.Relief valve overflow line installed.

i.Water heater filled with water.

j.Power leads connected inside electrical enclosure from separate fused circuit.

k.Ground wire connected.

3.After the water is heated for the first time, monitor the water temperature as described in Section III, Quarterly Inspection.

10

Ground L1

L2

High Limit Cutout

1 2

3 4

Thermostat

Capillary Tube

Heating Element

WIRING DIAGRAM

11

INSTALLATION WITHOUT TEMPERING VALVE

Piping to Hot

Water

Support Bracket –

(bottom bracket

not shown) Temperature & Pressure

Relief Valve

Relief Valve

Discharge Pipe

Drain Valve

Piping from

Cold Water

Air Gap

Floor Drain

12

INSTALLATION WITH TEMPERING VALVE

Piping to

 

Tempering

Hot Water

 

Valve

 

 

 

Support Bracket – (bottom bracket not

shown) Piping from Cold Water

Temperature & Pressure

Relief Valve

Drain Valve

Air Gap

Relief Valve

Discharge Pipe

Floor Drain

13

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.

Exposure to 125°F or hotter water can cause scalding injuries. Appropriate caution must be taken when using hot water. Special supervision must be given to those who cannot react quickly such as children, invalids, or elderly persons.

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.Water temperature regulation.

a.Let water heater completely heat to a designated thermostat setting.

b.After thermostat satisfies (i.e., when the thermostat actually clicks off), draw water from heater.

c.Measure the maximum temperature with an accurate thermometer.

d.If the temperature is above the safe limits for your circumstances call a service man to adjust or replace the control.

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 for evidence of leaks.

d.Rub finger around heating element and check 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.

14

ANNUAL INSPECTION

1.Flush tank as follows

a.Shut off power supply.

b.Attach a hose to the drain valve installed in the cold water piping.

c.Close valve on the cold water line to the heater.

d.Open the drain valve and direct the water to a drain.

e.Open hot water faucet to admit air into the tank.

f.Close drain valve and hot water faucet.

g.Open valve on the cold water line to the heater.

h.Turn power supply ON.

LONG TERM SHUT DOWN

1.If the water heater is to remain idle for an extended period of time, the power and water to the heater should be turned off to conserve energy.

2.The water heater and piping should be drained, if they might be subjected to freezing temperatures.

3.After a long shutdown period, the heater's operations and controls should be checked by qualified service personnel.

4.Make certain the water heater is filled before placing it in operation.

EMERGENCY

1.Should the heater be subject to flood, fire, or other damaging conditions, turn off the power and water to the heater.

2.DO NOT place water heater in operation again until it has been thoroughly checked by qualified service personnel.

15

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 ‘AMP’ 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.

Water temperature

Faulty thermostat.

Check thermostat adjustment. Monitor

below settings at all

 

thermostat as described in Section III,

times

 

Quarterly Inspection. Replace if necessary.

Relief valve

Excessive temperature or

Temperature and pressure relief valves are

discharges

pressure in tank

made to operate if the water temperature

continuously

 

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.

16

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; refer to wiring diagram in Section II. Torque screws per chart in back

17

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.Remove access cover.

7.Disconnect the wires from the heating element terminals.

Thermowell

Wires

8.Unscrew heating element.

9.Withdraw element assembly.

Tank Coupling

Element Assembly

10.Install Teflon tape and insert new heating element. Thermowell must be above the heating element, in the 12 o’clock position.

11.Rewire element; refer to wiring diagram in Section II. Torque screws per chart in back.

12.Reinstall access cover.

13.Fill tank and check around element for any leaks.

18

THERMOSTAT

1.Disconnect power from unit.

2.Remove access cover and locate thermostat.

3.Disconnect the two (2) control wires.

Wires

Capillary Tube

4.Remove capillary tube and bulb from thermowell in element. See previous page.

5.Remove mounting screw and knob.

6.Remove thermostat by sliding out from behind mounting bracket.

Mounting Bracket

Mounting Screw

7. Replace thermostat using the reverse procedure; refer to wiring diagram in Section II.

19

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

20