Hubbell DF User Manual

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OPERATING AND MAINTENANCE MANUAL FOR POWER BURNER SERIES FORCED DRAFT COMMERCIAL WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ DF ”

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

¾Do not use or store gasoline or any other flammable vapors, liquids, or materials in the vicinity of this or any other appliance.

¾Due to the rigors of transportation, all connections should be checked for tightness before heater is placed in operation.

¾Safety relief valve must be installed in tapping provided.

¾KEEP 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.

¾Installation and service must be performed by a qualified installer, service agency or the gas supplier. City, state, and national codes governing installation of commercial water heaters must be followed and take precedence over recommendations in this manual.

¾The manufacturer’s warranty on this water heater is in effect only when the water heater is installed and operated in accordance with these instructions and local codes and ordinances or, in the absence of local codes and ordinances, the National Fuel Gas Code (the latest ANSI Z223.1). In Canada, installation should conform to the latest CAN/CGAB149 installation codes and/or local codes. The manufacturer of this water heater will not be held liable for any damage from failure to comply with these installation and operating instructions.

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FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

¾DO NOT try to light any appliance.

¾DO NOT touch any electrical switch.

¾DO NOT use any phone in the building.

¾Immediately 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.

¾WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

PRECAUTIONS

TANK LINING - DAMAGE PREVENTION

The water heater lining has been electronically inspected for continuity prior to final assembly. It was found to be free of defects. In order to protect the lining, do not apply heavy blows or weld to the exterior pressure vessel. Damage to the interior lining will void the warranty and ASME HLW stamp.

TANK MAINTENANCE - REMOVAL OF SEDIMENT AND SCALE

To keep the water heater efficient and in good working condition, inspect and clean two weeks after installation to remove any piping system debris that may have accumulated. Do not acidize this unit. Monthly inspections should be performed to determine a time span for removing any sediment within the unit. This should become the basis for a routine maintenance schedule. It is recommended that high-pressurewater be used to purge any accumulation of sediment through the drain valve opening or the hand hole.

ANODE MAINTENANCE

The water heating industry knows that many water heaters are installed in areas where the water supply can be abnormally corrosive due to low pH or an excessive amount of dissolved oxygen. Because of our commitment to provide clear water in all areas, an anode has been provided to help counteract the effects of these factors. Periodic inspection and, if necessary, replacement is required to assure the anodes effectiveness.

WATER QUALITY - pH LEVEL

Materials used in the water heater to prevent corrosion have been selected for their compatibility with most domestic water supplies. However, significantly alkaline water (pH 7.5 or higher) or acidic water (pH 6.5 or lower) can result in abnormal scale formation or seriously attack these materials and cause premature corrosion. If the pH of incoming supply water does not fall between 6.5 and 7.5, it must be treated to prevent damage to internal water heater surfaces and other building plumbing components.

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SAFETY TEMPERATURE AND PRESSURE RELIEF VALVE (T&P)

A listed and properly rated combination temperature and pressure relief valve shall be installed in the opening provided and marked for this purpose at the time of installation. Local codes shall govern installation of relief devices. The pressure rating of the relief valve must not exceed the working pressure shown on the rating plate affixed to the front of the water heater. The BTU/H rating of the relief valve must equal or exceed the water heater input shown on the rating plate. The relief valve discharge line must terminate 6 inches above the floor drain or externally to building. The discharge line must be able to withstand water temperature in excess of 210°F.

¾DO NOT install a valve between tank and the relief valve.

¾DO Install a discharge line directly to an adequate open drain. The discharge line must be shielded, secured and plumbed to an appropriate drain to prevent scald injury.

¾DO NOT install a reducing coupling or other restriction in the discharge line.

¾DO NOT install the discharge line where it may be subject to blocking, plugging or freezing.

¾DO NOT allow water from discharge line to contact any live electrical part.

Failure to install a listed and properly rated temperature and pressure relief valve could result in hazard to life, bodily injury or property damage and will release the manufacturer of this water heater from any claim which might result from excessive water temperature or pressure.

CAUTION

KEEP CLEAR OF DISCHARGE LINE OUTLET. It is hot enough to cause scald injury, is under pressure and may splash.

IMPORTANT

¾Periodically check combustion products to assure that carbon monoxide is kept below 0.02% (200 PPM) or that the CO2 is kept between 9 & 9 ½%.

¾Drain the water heater for 5 minutes every day to help prevent accumulation of sediment and scale. Periodically check for the presence of scale and sediment. If present, physically loosen and flush using high-pressurewater.

¾All startup, periodic tuning and service must be performed by a trained technician familiar with the water heater and forced draft burner. It is mandatory that the startup test report, contained in the burner installation and operation manual, be completed and a copy returned to the factory. It is also important that an operating log be maintained to provide a history of water heater performance.

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TABLE OF CONTENTS

 

SECTION

TITLE

PAGE #

I

GENERAL DESCRIPTION

9

II

INSTALLATION

10

III

START UP AND OPERATION

16

IV

SCHEDULED MAINTENANCE AND SERVICING

18

V

TROUBLESHOOTING

25

VI

MISCELLANEOUS CHARTS AND FORMULAS

26

5

6

8

SECTION I - GENERAL DESCRIPTION

GENERAL DESCRIPTION

This is a commercial storage water heater designed and constructed in accordance with UL and ASME requirements. Its thermal efficiency and standby loss exceed the levels established by ASHRAE 90.1 and incorporated by federal EPACT legislation. Given a reasonable amount of maintenance, this water heating product will perform reliably for many years. Its basic design is well proven over time, and operating components have been selected for their reliability and widespread use in the water heating industry. This philosophy also promotes availability of both parts and trained service personnel. It is essential that all aspects of installation, maintenance, routine servicing, troubleshooting and repair be planned with safety as the primary consideration. If the installer or service technician has any questions about this water heater's operation, the factory should be contacted immediately. It is also very important to properly maintain this water heater to obtain long life and maintain its high efficiency.

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SECTION II – INSTALLATION

WARNING / CAUTION

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.

The National Fuel Gas Code, (ANSI Z223.1 and Can 1 -Bl49.1 or Bl 49.2), expressly prohibits the following:

1.Installation of water heater in a bathroom, bedroom, or any occupied room normally kept closed.

2.Installation of a water heater in a garage unless the unit is installed so that the burner and ignition devices are at least eighteen (18) inches above floor level and protected to avoid damage by a moving vehicle.

If unit is painted or insulated on the job site, care should be taken not to paint or insulate over the A.S.M.E. nameplate. This plate should be accessible and legible at all times to inspectors, and information from this plate must be used when ordering parts from the factory.

HANDLING

Some models have been constructed with lifting lugs to permit lifting with a crane. Fork lift movement (rear access only) is also acceptable.

To lift with a crane, remove flue outlet adapter and connect a lifting cable to the two lifting lugs attached to the top tubesheet. Be sure lifting cable and crane can support the shipping weight as shown on Bill of Lading.

The skids are compatible with the forks of most fork lift equipment. When moving a heater into place, pick water heater up from rear (do not pick up from front or sides) with forks inside the skids. Picking up heater on outside of skids may allow forks to puncture bottom of combustion chamber.

INSPECTION

Inspect the water heater and burner for possible damage that may have occurred in shipping or during storage. Check rating plate on the water heater and burner for compliance with specifications. Be sure the electrical supply, gas and/or oil supply lines are adequate for the installation.

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LOCATION

NOTE: Do not run uninsulated water pipes in front of or directly above a fresh air opening. If an exhaust fan is installed in the mechanical room, the combustion air inlet must allow for the fan's exhaust air volume. An undersized opening may cause down drafts resulting in poor combustion, sooting and carbon monoxide.

1.Position the water heater in a clean and dry location as close as possible to the greatest use of hot water (and the oil storage tank if used). Minimum clearances for servicing are listed on a label near the burner. Greater clearances may be required by local code.

2.An adequate uncontaminated air supply for combustion is needed. If air is directly obtained from outdoors, a free area of 1 square foot per 1,000 CF/Hr1 of input is required. If air is obtained from an adjacent indoor area, 1 square inch per 1,000 BTU/Hr of input is required. Ifoil-fired,1 gallon per hour equals 140,000 BTU/Hr. Combustion air inlets should be located on an outside wall, away from prevailing winds, and be sized to accommodate all fuel burning equipment located in the mechanical room. Combustion air calculations should assume simultaneous operation of all fuel burning equipment in the equipment room.

3.The water heater should not be installed in an area where combustible liquids or vapors may be present that could be ignited by the burner. The installation area should not contain air contaminated with chlorinated hydrocarbons, perchlorethylene or any strong oxidizing agent. Combustion air containing these agents will seriously damage the burner and vessel parts thus voiding all warranties. If required, combustion air should be ducted from outside the building to avoid such contaminants. Burners require special construction for outside combustion air applications. Consult factory for details.

4.The water heater should be located on a pitched floor near a suitable drain, or other provisions must be made to prevent damage to areas of the building subject to water damage should the heater or plumbing leak. A drain is required for relief valve discharge as well as routine cleaning and flushing of the tank. The heater must be installed in a level position. Shim under skids if necessary.

WATER CONECTIONS

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.

Water connections are made to the cold water inlet and hot water outlet as shown on the supplied water heater drawing. Dielectric fittings are provided to minimize the formation of galvanic corrosion (some jurisdictions require the use of dielectric fittings). Shut-offvalves and unions should

1 1,000 CF/Hr of Gas = 1,000,000 BTU/Hr = 7.14 GPH of #2 fuel oil

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be installed so the heater may be disconnected for servicing if necessary. Hot water and return circulation lines should be insulated. The cold water supply line should be insulated if subjected to freezing temperatures. When a check valve is installed in the cold water line to the water heater, a diaphragm type expansion tank suitable for potable water shall be installed in the system.

PIPING MULTIPLE WATER HEATERS

A parallel connection, see the following diagram, allows heated water from multiple heaters to flow into the system to serve peak loads that can occur in a short time period. Pressure drop is reduced and total storage capacity is available for immediate use.

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ELECTRICAL CONNECTIONS

Electrical connections to the water heater should conform to the National Electrical Code or the code legally authorized in your locality. A fused disconnect switch should be used in the burner control circuit. The contractor shall run the properly sized electrical service to the terminals indicated on burner wiring diagram. Refer to burner manufacturer's manual for specific electrical requirements.

VENTING

This non-condensingwater heater is designed to exhaust into its own independent vent or into an existing vent system that serves other appliances. In all cases, a negative pressure must be maintained within the venting system to prevent the leakage of combustion products.

Several basic venting rules must always be followed.

1.The vent must be independently supported so its weight does not bear on the water heater's flue collector.

2.The vent must never be sized smaller than the flue collector outlet. It can be up to two sizes larger but, in all cases, must be sized in accordance with National Fuel Gas Code Requirements given the particular installations vent configuration and water heater input rate.

3.When a relatively high negative draft occurs in a vent, a draft regulator sized to the vent diameter should be installed and adjusted to begin opening at a negative draft of -0.1in. W.C. A draft regulator should be installed no further than two feet away from the water heater flue outlet.

4.A vent must never be welded to the flue collector outlet.

5.All vents must be constructed in accordance with the National Fuel Gas Code and terminated on the outside of the building using a UL listed vent cap. Horizontal venting through an outside wall is acceptable, but an induction blower may be needed to maintain a negative draft in the vent.

If the water heater is vented into an existing overhead vent (or breaching), it is recommended the vent be designed for positive pressure in case there is positive pressure in the overhead vent.

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GAS CONNECTION PIPING FOR GAS AND COMBINATION GAS/OIL BURNERS

WARNING / CAUTION

LP UNITS; liquefied petroleum (L.P.) gas is heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking L.P gas. Before operating the water heater, sniff at floor level. IF YOU SMELL GAS, follow applicable instructions on cover page.DO NOT OPERATE APPLIANCE

UNTIL LEAKAGE IS CORRECTED AND AREA IS PURGED OF ANY GAS ACCUMULATION.

Be sure gas supply lines have been cleaned of all debris which could enter the regulators or the burner system and cause malfunctions or unsafe conditions. Pipe connection compounds must be used AT ALL TIMES. DO NOT use Teflon tape as a thread sealant.

1.The gas supply line must be sized, considering pressure drop, to furnish gas at a pressure necessary for the burner to develop rated capacity and the CFH to handle all fuel burning equipment attached to the line. A drip leg should be installed ahead of the burner piping connection. See burner manufacturer's manual for piping detail.

2.Piping or tubing from regulator vents shall be routed outside the building and must be the same diameter as the regulator venting ports. Provide no traps in the vent lines and terminate away from all doors, windows and air intakes serving HVAC equipment. Vent termination shall face downward with a screen mesh cover to prevent insects and debris from entering. If regulator vents are combined, use tubing or pipe equal to the total cross sectional area of the individual vents. Normally open vent valves must be separately vented.

NOTE: High and low gas pressure switches must be vented separately from those of the main and pilot regulators. Termination of vents shall be the same as for regulators.

3.Before gas is turned on, be sure the gas line has been checked for leaks. Check to see that there are no open fittings and that the burner main manual valve and pilot manual valve are closed.

OIL TANK AND PIPING

1.Tank construction and installation must meet all local codes and should meet the specifications recommended by Underwriters Laboratories.

2.REFER TO YOUR BURNER STARTUP MANUAL FOR OIL PUMPING AND PIPING DETAILS.

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3.A Rule of Thumb to determine total suction for suction line sizing is to add 10% to suction determined from the burner manufacturer's instruction manual.

4.It is good practice to size the oil pump return-line(to the tank) the same size as the selected suction line.

PRESSURE AND TEMPERATURE SAFETY RELIEF VALVE

1.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

2.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.

15

SECTION III – START UP AND OPERATION

WARNING / CAUTION

Temperatures above 130ºF (54º C) can cause scalding. Scalding temperatures are especially hazardous to young children, aged or handicapped persons. A serious or disabling injury can occur. Note that a mixing valve installed at the hot water outlet can reduce the risk of scalding at such points of use as lavatories, sinks and bathing facilities

Excessively hot water may suggest that the upper operating thermostat has failed. If you determine an operating control thermostat has failed, it should be replaced IMMEDIATELY by a qualified service technician.

If the burner turns on and off every 3 to 4 minutes on a regular basis, the lower control thermostat setting may have to be decreased. Such a "short cycling" condition accelerates wear of burner components which can lead to early failure.

IMPORTANT

THE MANUFACTURER'S START UP REPORT MUST BE COMPLETED AND RETURNED. FAILURE TO DO SO WILL VOID THE WARRANTY.

ALWAYS CONTACT A TRAINED SERVICE TECHNICIAN TO PERFORM START UP. SHOULD FACTORY ASSISTANCE BE REQUIRED, PLEASE HAVE THE WATER HEATER SERIAL NUMBER AVAILABLE.

Combination gas/oil burners require a supply of oil for oil pump lubrication even when operating on gas.

Some oil burners require a supply of either natural or L.P gas to operate the pilot. Check burner construction for the presence of gas pilot tubing and a pilot gas pressure regulator.

START UP

1.Fill water heater and drain to remove any residue that may have accumulated during the installation process. Remove hand hole cover and remove any material not flushed through drain. Reinstall hand hole cover, fill with water and open a nearby hot water faucet to bleed out any entrapped air. Be sure all tank connections are tight. Leaking water causes corrosion and insulation damage.

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2.The burner manufacturer's installation and operation manual, included with this manual, contains a detailed start up procedure that should be studied and followed precisely.

NOTE: Rated gas input for this water heater can be established by adjusting manifold gas pressure to the value listed on the burner data plate. Rated oil input can be established by adjusting oil pressure to the burner at 300 psi (pressure may have to be slightly reduced to obtain clean, smokefree combustion).

TEMPERATURE ADJUSTMENT

The upper operating control thermostat shuts off the burner when its temperature setting is reached. The lower operating control thermostat can be adjusted to vary the temperature that activates the burner. The unit is also equipped with a high limit safety control preset at 180°F. For energy efficient operation of your water heater, the recommended upper temperature setting is approximately 130°F. Facilities with small children or invalids may require a 120°F or lower temperature setting to reduce the risk of scald injury. Some states require a lower temperature setting. Check with your gas supplier for local requirements governing the temperature setting.

Remember that no water heating system will provide an exact temperature at all times. Allow a few days of operation to determine the correct temperature setting consistent with your needs.

A lower temperature setting can cause condensation, but that does not mean your tank is leaking. Many reported tank leaks on installation are proven to be condensation. To avoid unnecessary inconvenience and expense, make sure the tank is leaking before calling a service person.

17

SECTION IV - SCHEDULED MAINTENANCE AND SERVICING

WARNING / CAUTION

Before performing any maintenance procedure, turn off the water heater main disconnect switch before performing any cleaning or service. Also close both the pilot and main manual shutoff valves.

Keep the equipment room clean. Clean the burner at regular intervals. The blower inlet can collect dust and debris from the air during operation. Clean blower wheel and flame scanner when necessary. The burner should be cleaned each year according to the burner manufacturer's recommended procedures. A DIRTY BLOWER WHEEL WILL REDUCE EFFICIENCY AND

MAY CAUSE POOR COMBUSTION, SOOTING OR THE PRODUCTION OF CARBON MONOXIDE.

IMPORTANT

A preventive maintenance program should be established to help assure a long, trouble-freewater heater life.AN ANNUAL INSPECTION SHOULD BE PERFORMED AND DOCUMENTED.

A COPY OF THE INSPECTION REPORT MUST BE FORWARDED TO THE MANUFACTURER. FAILURE TO DO SO WILL VOID THE WARRANTY.

18

RECOMMENDED PERIODIC INSPECTION

DAILY

1.Inspect area around water heater for moisture. If present, determine if cause is condensation or leakage.

a.If cause is condensation - May be due to very cold incoming water. Consider installation of intra-tankcirculator; contact manufacturer for details.

b.If cause is leakage - May be due to leaking fitting; repair as soon as possible. If tank leak is suspected, contact manufacturer.

2.Inspect vent for corrosion. If present, replace corroded vent section as soon as possible. Determine if cause is low temperature of combustion products (less than 280º F net flue temperature), or the presence of contaminated combustion air. Correct either condition immediately.

MONTHLY

1.Drain heater, remove hand hole cover and inspect for sediment accumulation. Remove any sediment and inspect more frequently to determine an appropriate schedule for sediment removal. NOTE: FAILURE OF THE WATER HEATER DUE TO SEDIMENT OR

SCALE ACCUMULATION IS NOT COVERED BY THE WARRANTY.

2.Test combustion products for the presence of carbon monoxide (CO) above a 200 ppm concentration. If necessary, adjust burner to reduce CO concentration.

19

RECOMMENDED PERIODIC TESTING

TESTING

HOW

COMPLETED

 

ITEM

OFTEN

BY

REMARKS

Gauges, monitors and operating log

Daily

Operator

Make visual inspection and record readings

Instrument and equipment settings

Daily

Operator

Make visual check against recommended

 

 

 

specifications

Firing rate

Weekly

Operator

Verify factory settings

 

Semiannually

Service Tech

Verify factory settings

 

Annually

Service Tech

Check with combustion test

Flue, vent, stack or outlet dampers

Monthly

Operator

Make visual inspection of linkage; check for

 

 

 

proper operation

Igniter

Weekly

Operator

Make visual inspection, check flame signal

 

 

 

strength if meter-fitted(see "Combustion Safety

 

 

 

Controls")

Fuel valves: pilot and main

Weekly

Operator

Operate burner. Using a manometer or pressure

(primary and secondary)

 

 

gauge, check pressure to the burner as required

 

 

 

on rating label.

Pilot and main gas or oil train

Annually

Service Tech

Perform leakage tests - refer to instructions

Combustion safety controls (flame

Weekly

Operator

Close manual fuel supply for the pilot and main

failure)

 

 

fuel valve(s); check safety shutdown timing; log

 

 

 

result.

Flame signal strength

Weekly

Operator

With flame signal meter installed, read and log

 

 

 

for both pilot and main flames. Notify service

 

 

 

organization if readings are very high, very low

 

 

 

or fluctuating. Refer to instructions for nominal

 

 

 

values

Pilot turndown test

As required /

Service Tech

Required after any adjustment to flame scanner

 

annually

 

mount or pilot burner; verify annually - refer to

 

 

 

instructions.

Low-waterfuel cutoff and alarm

Daily/weekly

Operator

Refer to instructions and perform a slow drain

 

Semiannually

 

test.

High limit safety thermostat control

Annually

Service Tech

Refer to instructions

Operating thermostat control

Annually

Service Tech

Refer to instructions

Vent draft fan, and air pressure

Monthly

Operator

Refer to instructions

switches

 

 

 

High and low gas pressure interlocks

Monthly

Operator

Refer to instructions

High and low oil pressure interlocks

Monthly

Operator

Refer to instructions

Fuel valve interlock switch

Annually

Operator

Refer to instructions

Low fire start interlock

Annually

Operator

Refer to instructions

Automatic changeover control (dual

At least

Service Tech

Under supervision of gas utility

fuel)

annually

 

 

T&P valves

As required

Operator

In accordance with procedure in Section VI

 

 

 

ASME Boiler and Pressure Vessel Code,

 

 

 

Recommended Rules for Care and Operation of

 

 

 

Heating Boilers.

Inspect Burner Components

Semiannually

Operator

Refer to burner instructions

20