OPERATING AND MAINTENANCE MANUAL
FOR PACKAGED ELECTRIC TEPID
WATER HEATING SYSTEM
ELECTRIC HEATER COMPANY
BASE MODEL “ EMV ”
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 7
III SCHEDULED MAINTENANCE AND OPERATION 9
IV TROUBLESHOOTING 12
V SERVICING & REPLACEMENT OF PARTS 13
VI ELEMENT CHARTS 22
3
4
SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This manual describes a packaged electric water heater system designed to meet the requirements of ANSI
Z358.1-1998 for tepid water delivery to an emergency drench system. The complete assembly consists of the
storage tank, immersion electric heating element(s), thermostat(s), safety relief valve, safety high temperature
cut out, mixing valve, 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 standard storage tank is constructed of steel and internally lined with specially formulated Hydrastone
cement to a ½-inch minimum thickness. The tank is designed for a maximum allowable working pressure of 150
psi (300 psi TP).
TANK CONNECTIONS
The heater is supplied with separate cold water and tepid water connections. A 1-½ inch FNPT connection is
supplied for the cold water inlet. The cold water is deflected by means of a baffle within the tank. A 1-¼ inch
FNPT union connection is supplied at the mixing valve for tepid water. A ¾ inch FNPT 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. A ¾ inch GHT connection is supplied for
draining. See drawing for locations.
HEATING ELEMENT
The water heater is supplied with an
electric immersion heating element
assembly(s), composed of a copper
sheathed element(s) 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 1inch long hex head steel bolts and nuts.
See drawing for voltage and power ratings.
CONTROL THERMOSTAT
The water heater is supplied with an immersion thermostat factory
preset at 170°. The immersion thermostat can be adjusted through a
range of 100° - 180° F and is adjustable with a flat tip screwdriver.
5
TEMPERATURE HIGH LIMIT SWITCH
As a safety device, a surface mounted high temperature cut-off switch with manual reset is supplied. As an
option, an immersion high temperature cut-off switch with manual reset may be provided. Either high
temperature cut-out switch is factory preset at 190°F. 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 Immersion High Temperature Cut-Off Switch
Temperature Cut-Off Switch (Optional)
(Standard)
MIXING VALVE
The mixing valve is a triple redundant, thermostatic pressure balanced
valve specifically designed for emergency safety shower/face/eyewash
application. The valve is factory mounted and piped to the water heater.
The mixing valve meets OSHA and ANSI requirements and is capable of
providing 85°F output regardless of inlet pressure and temperature
variations, and the temperature setting is tamper proof and can not be
inadvertently adjusted in the field. Alternate mixing valve tepid water set
temperatures of 70°, 75°, 80°, and 90°F are available.
AUTOMATIC AIR VENT VALVE
An automatic air vent valve is supplied in the highest point of the
system to allow trapped air in the system to escape.
DUAL TEMPERRATURE AND PRESSURE GAUGE
A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge
with 3-inch dial is installed in the tank.
OUTER SHELL AND INSULATION
The tank is encapsulated in 3-inch thick polyurethane foam insulation. The insulation is protected by a high
impact non-corroding colorized composite protective jacket.
6
OPTIONS
The following optional features may be included in your water heater. Reference included drawing specific to
your heater for further details.
Low Temperature Alarm Dry Contacts
A low temperature thermostat is available with dry contacts to remotely alarm when the tank water temperature
falls below a specified setpoint. The low temperature thermostat is adjustable from 30-110°F.
High Temperature Alarm Dry Contacts
High temperature alarm dry contacts are available with the optional immersion high limit cut-out switch to
remotely alarm when the tank water temperature rises above the high limit setpoint.
Outdoor Weather Package
The optional outdoor weather package includes a 304 stainless steel outer protective jacket, a weather resistant
electrical housing, and 6” high tank legs to raise the entire unit off the floor.
Flow Alarm
An optional flow alarm may be included to signal that there is tepid water flow.
Explosion Proof Construction
The system may be constructed for installation in a hazardous location.
Mixing Valve Enclosure
An optional fiberglass enclosure provides added protection for the mixing valve in outdoor environments.
Multiple Units
Multiple units may be piped together to meet the needs of larger demand systems.
Alternate Heat Sources
An optional heat exchanger may be factory installed to utilize steam or boiler water as the heating source.
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 PROPERTY.
WATER HEATER PLACEMENT
1. Place the heater on a solid foundation in a clean, dry location nearest to the point of most frequent
tepid 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.
4. Do not install in an area where flammable liquids or combustible vapors are present, except when
installed with the explosion proof option.
7
PIPING INSTALLATION
NOTE:
and stray current is the installation of dielectric fittings/unions. The installation of these fittings is the
responsibility of the installing contractor.
The most effective means for preventing deterioration from accelerated corrosion due to galvanic
1. Connect the cold water inlet and tepid water outlet to the appropriate connections as shown below;
refer to the drawing for location and sizes.
2. Install the combination temperature and pressure safety relief valve in the tapping provided. Note that
this is required by law for safety considerations.
Install into provided tapping Manual Release Lever
Temperature Probe
Outlet to floor drain
Temperature and Pressure Relief Valve
3. 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.
4. On startup, thermal expansion will cause the water to expand. Hubbell recommends that a thermal
expansion tank or supplementary pressure relief device be installed in the hot water outlet to allow
for this expansion.
8
FILLING THE HEATER
1. Completely close the drain valve.
2. Open the highest tepid water outlet to allow all air to escape from piping.
3. The black plastic knob on the air vent valve must be opened two turns to allow air to escape from the
system.
4. 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 outlet.
ELECTRICAL INSTALLATION
1. Enter junction box with properly sized feeder leads.
2. Connect these power leads to wires enclosed in junction box with wire nuts.
3. 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. 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.
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.
MONTHLY INSPECTION – MIXING VALVE
NOTE: The mixing valve should be tested in conjunction with regular OSHA required shower/eyewash
testing. These tests confirm that the equipment is safe and operational and also serve to purge potential
bacteria laden water from the system.
1. Monitor temperature
a. Record all information on the Mixing Valve Inspection and Test Log, see page 11.
b. Using an accurate thermometer, turn on the shower/eyewash and record the maximum start-up spike
c. After a few minutes of running, record the normal temperature.
d. If the temperature does not match required temperature (±3°F), recalibrate the mixing valve. See
2. Monitor flow rate
a. OHSA/ANSI recommends a potable water system maintain a pressure of 30-psig minimum with a flow
b. One simple method of testing is to collect the water in a 5-gallon container. At the required flow rate,
temperature of the water.
Section V, Service and Replacement of Parts, Re-Calibrate Mixing Valve.
rate of 20-GPM minimum to a shower head and 3-GPM minimum to an eye/face wash fixture.
the shower head will fill the container in approximately 15 seconds and the eye/face wash will fill the
container in approximately 15 seconds.
9
QUARTERLY INSPECTION
3. 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 the relief
valve.
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 +
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.
4. 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.
5. 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.
6. Check for loose electrical connections. Tighten as necessary.
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.
7°F.
10
MIXING VALVE INSPECTION AND TEST LOG
COMPANY:
HEATER SERIAL NUMBER:
DATE START-UP
SPIKE
OUTPUT
TEMPERATURE
COMMENTS TESTED BY
11
SECTION IV – TROUBLESHOOTING
Symptom Probable Cause Corrective Action / Remedy
No hot water in tank
Water temperature in
tank below settings at
all times
Relief valve discharges
continuously
Tepid water
temperature too hot
Tepid water
temperature too cold
Circuit breaker tripped at source. Reset circuit breaker.
High limit switch tripped. Reset high limit switch.
Loose wires. Torque screws holding wires.
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.
Faulty thermostat. Check thermostat adjustment. Monitor
thermostat as described in Section III,
Quarterly Inspection. Replace if necessary.
Heating element not working on all
phases
Heater improperly sized Verify heater is properly sized for the flow rate
Excessive temperature or pressure
in tank
Blockage in cold water inlet to
mixing valve
Mixing valve out of calibration Re-calibrate mixing valve as described in
Blockage in hot water inlet to
mixing valve
Mixing valve out of calibration Re-calibrate mixing valve as described in
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.
and temperature rise of your system. 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.
Disconnect mixing valve and clean out cold
water inlet pipe.
Section V, Service and Replacement of Parts,
Re-Calibrate Mixing Valve.
Disconnect mixing valve and clean out hot
water inlet pipe.
Section V, Service and Replacement of Parts,
Re-Calibrate Mixing Valve.
12
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.
5. Replace control and install new high limit switch by performing above steps in reverse order.
See wiring diagram included with drawing for assistance.
Mounting Screws
13
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 Capillary Tube
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.)
14
SINGLE PHASE 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.
Tank Flange
Wires
7. Remove the 3/8-16 nuts.
8. Withdraw element assembly and remove gasket.
Gasket
Element Assembly
Nuts
9. Install new gasket and insert new heating element.
10. Rewire element according to type of unit as shown
in your drawing.
11. Fill tank and check around gasket for any leaks.
15
3-PHASE 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.
Tank Flange
Element Terminals
Nuts
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 drawing and in
accordance with the jumper configuration as
shown below for your heater.
11. Fill tank and check around gasket for any leaks.
16
3-PHASE ELEMENT JUMPER CONFIGURATION
17
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
Capillary Tube
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.)
18
MAGNETIC CONTACTOR (3-PHASE ONLY)
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.
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
MIXING 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. Drain tank.
5. Disconnect unions on both sides of the mixing valve.
6. Remove mixing valve.
7. Replace mixing valve.
8. Fill system in accordance with procedures on page 9.
Acorn Nut Cap
Hot Water Inlet Cold Water Inlet
Union Union
Tepid Water Outlet
RE-CALIBRATE MIXING VALVE
1. Remove small domed acorn nut cap on top of the diaphragm actuator.
2. Without turning the adjustment screw, loosen the locknut securing the adjustment screw.
3. Turn on the water at the shower or eye/face wash and monitor the water temperature during
calibration.
4. Using a 1/8” allen wrench, turn the adjustment screw counter-clockwise to raise the outlet water
temperature or clockwise to lower the outlet water temperature.
5. Start by turning the adjustment screw only one full turn, then observe the water temperature and the
shower or eye/face wash fixture.
6. If needed, turn the adjustment screw an additional ½ turn at a time until the desired water
temperature is reached.
7. Turn off the water at the shower or eye/face wash fixture.
8. Lock the adjustment screw with the locknut.
9. Replace the domed acorn nut cap over the adjustment screw.
10. Re-check the outlet water temperature as described in Section III, Scheduled Maintenance and
Operation, Monthly Inspection – Mixing Valve.
21
SECTION VI – ELEMENT CHARTS
SINGLE PHASE ELEMENT CHART
Element Part #
CH-FO-358 ---- 3500 ---- ---- ---- 11 3/8" 12.36
CH-FO-408 ---- 4000 ---- ---- ---- 11 3/8" 10.82
CH-FO-508 ---- 5000 ---- ---- ---- 13 1/4" 8.65
CH-FO-608 2000 6000 ---- ---- ---- 13 3/8" 7.21
CH-FO-304 ---- ---- 3000 4000 ---- 9 3/4" 19.20
CH-FO-354 ---- 2500 3500 ---- ---- 9 3/4" 16.46
CH-FO-404 ---- 3000 4000 ---- ---- 11 1/2" 14.40
CH-FO-454 ---- ---- 4500 ---- ---- 11 1/2" 12.80
CH-FO-504 ---- ---- 5000 ---- ---- 11 1/2" 11.52
CH-FO-604 1500 4500 6000 ---- ---- 13 1/2" 9.60
TGB-1203-480 ---- ---- ---- ---- 2000 7 5/8" 83.23
TGB-1353-480 ---- 500 ---- 1000 3500 12 1/2" 47.56
TGB-2257L 2500 ---- ---- ---- ---- 9 5/8" 5.76
TGB-1207-240 500 1500 2000 2500 ---- 13 3/8" 28.80
TGB-1303-480 ---- ---- 990 3000 10 1/2" 55.49
TGB-1403-480 ---- ---- 1000 1350 4000 13 5/8" 41.62
TGB-2257-240 ---- 2000 2500 3500 ---- 10 5/8" 23.04
TGB-2257-480 ---- ---- ---- ---- 2500 13 1/4" 66.59
TGB-2457-277 ---- ---- ---- 4500 ---- 13 1/8" 17.05
TGB-2457-480 ---- ---- ---- 1500 4500 13 1/4" 36.99
TGB-2503-480 ---- 1000 ---- ---- 5000 9 3/4" 33.29
TGB-2507-277 ---- ---- ---- 5000 ---- 15" 15.35
TGB-2603-277 ---- ---- ---- 6000 ---- 15 1/2" 12.79
TGB-2603-480 ---- ---- 1500 2000 6000 15 1/2" 27.74
*Red wattage indicates the stamped element rating
Note: Element part numbers, ratings, and lengths are subject to change without notice.
3-PHASE ELEMENT CHART
Element
Part #
2-38683N 13" 57.6 19.2 57.6 38.6
3-38683N 13" 43.2 14.4 43.2 28.9
4-38683N 13" 34.4 11.5 34.4 23.0
5-38683N 13" 27.9 9.3 27.9 18.7
6-38683N 13" 21.6 7.2 21.6 14.5
7-38683N 13" 17.1 5.7 17.1 11.5
8-38683N 13" 14.4 4.8 14.4 9.6
9-38683N 15" 12.1 4.0 12.1 8.1
10-38683N 15" 9.1 3.0 9.1 6.1
11-38683N 15" 7.5 2.5 7.5 5.0
120V 208V 240V 277V 480V
Immersion
Length
Hairpin
Power (Watts)
Resistance (Ohms)
1 Φ 3 Φ DELTA 3 Φ WYE
Immersion
Length
Element Resistance
(Ohms)
22
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