Hubbell NX800, NX200 User Manual

Download

ELECTRIC HEATER COMPANY

OPERATING AND MAINTENANCE

MANUAL FOR

HUBBELL MODEL NX

COMMERCIAL GAS WATER

HEATING SYSTEM

Edition 2020

Hubbell NX

Model Numbers: NX200 - NX800 Version Date: 2020-10-26

INSTALLATION AND OPERATION INSTRUCTIONS

HUBBELL NX WATER HEATER

TABLE OF CONTENTS

1.0 INTRODUCTION ..................................................................................................................... 3

2.0 SPECIFICATION ...................................................................................................................... 6

3.0 WATER HEATER LOCATION ................................................................................................. 7

4.0 GENERAL VENTING ............................................................................................................... 12

5.0 VENT AND AIR-INTAKE TERMINATION CLEARANCES .............................................. 27

6.0 CONDENSATE DRAIN ............................................................................................................ 30

7.0 INSTALLING GAS PIPING ....................................................................................................... 31

8.0 LIGHTING THE WATER HEATER ................................................................................................ 33

9.0 GAS VALVE AND BURNER SET-UP ......................................................................................... 35

10.0 WATER HEATER PIPING ........................................................................................................ 42

11.0 LEAD LAG INSTRUCTIONS ............................................................................................... 51

12.0 FIELD WIRING ..................................................................................................................... 54

13.0 WIRING SCHEMATICS ........................................................................................................ 60

14.0 INSTALLATION CHECKLIST ............................................................................................ 64

15.0 ANNUAL MAINTENANCE AND INSPECTION ................................................................ 65

16.0 PARTS LIST ........................................................................................................................... 67

17.0 TROUBLESHOOTING ......................................................................................................... 79

HAZARD SYMBOLS AND DEFINITIONS

Danger Sign: Indicates a hazardous situation which, if not avoided, will result in serious injury or death.

Warning Sign: Indicates a hazardous situation which, if not avoided, could result in serious injury or death.

Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in property damage.

Notice Sign: Indicates a hazardous situation which, if not avoided, could result in property damage.

This Water Heater must be installed by a licensed and trained Heating Technician or the Warranty is Void. Failure to properly install this unit may result in property damage, serious injury to occupants, or possibly death.



Hubbell NX │Installation and Operation Instructions NX Series

Read Before Proceeding

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death.



FOR YOUR SAFETY, READ BEFORE OPERATING



A) This water heater does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

B) BEFORE OPERATING smell all around the water heater area for gas. Be sure to smell next to the floor

because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric 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.

C) Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or

turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D) Do not use this water heater if any part has been under water. Immediately call a qualified service

technician to inspect the

water heater and to replace any part of the control system and any gas control

which has been under water.



OPERATING INSTRUCTIONS

1. STOP! Read the safety information above very carefully.

2. Set the thermostat to lowest setting. Turn off all electric power to the water heater.

3. This water heater does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

4. Turn the manual gas valve to the OFF position. Remove front access panel.

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas.

7. Replace the front access panel.

8. Set thermostat to highest setting. Turn on all electric power to the water heater.

9. Ignition sequence is automatic. Combustion will occur after a brief fan purge.

10. If ignition does not occur, follow the instructions “To Turn Off Gas To Water heater” and call your service

technician or gas supplier.



TO TURN OFF GAS TO THE WATER HEATER



1. STOP! Read the safety information above very carefully.

2. Turn off all electric power to the water heater

3. Turn the manual gas valve to the OFF position

Crystalline Silica - Certain components confined in the combustion chamber may

contain this poteal carcinogen. Improper installation, adjustment, alteration, service or main-

tenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to Section

15.0 for information on handling instructions and recommended personal protective equipment. Installation and must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the instructions before installing, servicing, or removing this water heater. This water heater contains materials been identified as carcinogenic, or possibly carcinogenic, to humans).

Void Warranty - This Water heater must have water flowing through it whenever the burner is on or it will damage the unit and void the warranty. Failure to follow these instructions may result in serious injury or death.



service

supplied

that have



Installation and Operation Instructions │Hubbell NXNX Series

1.0 INTRODUCTION

General Installation Requirements

The installation of your Hubbell NX water heater must conform to the requirements of this manual, your local authority, and the National Fuel Gas Code ANSI Z223.1 and or CAN/CGA B149 Installation Codes. Where required by the Authority, the installation must conform to the standard for Controls and Safety Devices for Automatically Fired Water heaters ANSI/ASME CSD-1.

This document pertains to the correct installation and operation of Hubbell water heater models NX200, NX300, NX400, NX500, NX600, NX700 and NX800. The instructions detailed in this document supersede any and all previous instructions provided by Hubbell, written or otherwise. Each unit is provided with the following:

1. Installation and Operating Instructions,

2. Appendix A – Controller and Touchscreen Display Instructions,

3. Hubbell User’s Manual, and

4. Natural Gas to LP Conversion Kit*

Models NX600-NX800 are not approved for operation with Propane (LP Gas). Operating these models with Propane will result in property damage, serious injury or death.

Read and understand this entire document prior to proceeding with the installation of the Hubbell NX. Failure to follow the instructions outlined in this document will result in property damage, serious injury or death.

User Responsibilities This water heater must be installed and serviced by a qualified installer or service technician. This water heater

must be serviced and inspected annually. Demanding applications or extreme conditions may require more frequent service and inspection. As the User/Owner of this equipment, you are responsible for ensuring the maintenance is performed at the required intervals (see Section 15 – Annual Maintenance and Inspection).

Failure to have the water heater properly serviced and inspected on a regular basis by a qualified

service technician may result in property damage, serious injury or death.

Failure to keep the Vent and Combustion Air-inlet clear of ice, snow, and other debris may result in property damage, serious injury, or death.

Installer Responsibilities A qualified installer is a licensed person who has appropriate training and a working knowledge of the applicable

codes, regulations, tools, equipment and methods necessary to install a water heater. The Installer assumes all responsibility for a safe installation and that it meets the requirements of the water heater instruction manuals, as well as National and local installation codes. It is also the installer’s responsibility to inform the User/Owner of their obligation with respect to the description under “User Responsibilities”. Failure to follow this warning could result in fire, serious injury, or death.

Failure to use the appropriate Natural to LP Conversion Kit and Orifice when operating

the Hubbell NX with Propane will result in extremely dangerous burner operation leading to property damage, serious injury or death. Refer to section titled ATTENTION: LIQUEFIED PETROLEUM (LP) PROPANE for applicable conversion

kit and LP orifice numbers.



Hubbell NX │Installation and Operation Instructions NX Series

Water heater Vent / Air-Inlet Piping

The Hubbell NX is certified as a “Category IV” water heater, and requires a “Special Venting System” designed for pressurized venting. The exhaust gases must be piped directly to the outdoors using the vent materials and rules outlined in these instructions. Failure to follow these instructions will result in serious injury or death.



Installation and Operation Instructions │Hubbell NXNX Series

IN THE STATE OF MASSACHUSETTS ONLY

(a) For all horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or

in part for residential purposes, including those owned and operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed and on each additional level of the dwelling, building or structure served by the equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision cannot be met at the time of completion of

installation, the owner shall have a period of 30 days to comply with the above requirements; provided, however, that during said 30 day period a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the

horizontally vented gas fueled heating water heater or equipment. The sign shall read, in print size no less than onehalf (1/2) inch in size,

(plate included with water heater).

“

GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS

4. INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

”

(b) EXEMPTIONS

: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED:

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the water heater or equipment installation instructions; and

2. The “special venting system” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

all venting instructions, all parts list for venting instructions, and/or all venting design instructions shall remain with the water heater or equipment at the completion of the installation.

When the



(

2.0 SPECIFICATION

Table 2-1 General Specification



NX200

Installation and Operation Instructions │Hubbell NXNX Series

NX700

NX300

NX400

NX500

NX600

NX800

Gas Connection

1∕2"(Female)

3∕4"(Female)

1" (Male)

(inches, NPT) Water Connections

1" (Female)

1-1/4" (Female)

2" (Female)

inches, NPT)

Exhaust Vent

Connection (inches) Air-inlet connection

inches)

Cabinet Height

29.5

inches)

Cabinet Width

(inches)

Cabinet Depth

18.5

21.5

32.5

47.5

(inches)

Approximate Weight

125

180

225

320

380

with Water (lbs)

Water Content

1.2

2.1

2.4

3.3

(gallons) Electrical Rating

Table 2-2(a) Water Heater Performance Specification

Description

CSA Input



Modulation (MBH)

Recovery Rating at 100⁰F Rise (GPH)

Thermal Efficiency

(%)

Notes:

NX200

NX300

25 - 199

1,2

229

55 - 275

317

120V / 1 Phase / 60 Hz / 12A

NX400

75 - 399

460

NX500

100 - 500

576

NX600

120 - 600

691

NX700

160 - 700

806

1. Listed Input and Output ratings are at minimum vent lengths at Sea Level. Numbers will be lower with longer venting and/or altitudes greater than 2000 feet.

2. Based on standard test procedures prescribed by the U.S. Department of Energy. Ratings have been confirmed by AHRI.

63.5

475

5.2

NX800

160 - 800

922

High Altitude Operation The Hubbell NX is designed to operate at its maximum listed capacity in installations less than or equal to 2000 ft

above Sea Level. Since the density of air decreases as elevation increases, maximum specified capacity should be de-rated for elevations above 2000 ft in accordance with Table 2-3.

Table 2-3 De-rate % for High Altitudes

Elevations

In Canada

In USA

Notes:

Canada: Altitudes between 2000-4500 ft [610-1372 m], de-rate by 10%. Consult local authorities for de-rating capacities for

altitudes above 4500 ft [1372 m].

USA: De-rate capacity by 4% for every 1000 ft [305 m], if altitude is over 2000 ft [610 m].

2000 ft [610 m]

de-rate by 10%

3000 ft [914 m] 4000 ft [1219 m] 4500 ft [1372 m] 5000 ft [1524 m]

de-rate by 10%

de-rate by 12%

de-rate by 10%

de-rate by 16%

de-rate by 10% de-ra te % m ay vary

de-rate by 18%

de-rate by 20%

Combustion – At elevations above 2000 feet, the combustion of the water heater must be checked with a calibrated combustion analyzer to ensure safe and reliable operation.

It is the Installers responsibility to check the combustion and to adjust the combustion in accordance to Section 9.0. Failure to follow these instructions may result in property

damage, serious injury, or death.



Hubbell NX │Installation and Operation Instructions

3.0 WATER HEATER LOCATION

NX Series

In all cases, the Hubbell NX must be installed indoors in a dry location where the ambient temperature must be maintained above freezing and below 100F [38C]. Gas components must be protected from dripping, spraying water, or rain during operation and servicing. Consider the proximity of system piping, gas and electrical supply, condensate disposal drain, and proximity to vent termination when determining the best water heater location.

Water or flood damaged components must be replaced immediately with new factory approved components as failure to do so may result in fire, serious injury, or death.

Floor Mounting The Hubbell NX can be mounted directly on combustible flooring, with the exception of carpeting. Installing the

water heater on carpeting is not permissible. Ensure the water heater is mounted above any anticipated flood level. Models NX200-NX400 come equipped with stationary, low profile legs. Models NX500-NX800 include factory supplied/field installed leveling legs. Once the unit is removed from the pallet, thread the leveling legs into the allocated threaded inserts in the bottom of the unit.

Water heater Area Ventilation Air Openings

Direct Vent – If water heater area clearances are less than the recommended clearances specified in Table 3-1, the

water heater area must be ventilated. (Exception: if the water heater area/room has a volume of 150 ft3or greater, ventiation of the water heater room is not required). Each ventiation air opening must meet the minimum requirements of 1 in2per 1000 Btu/hr, but not less than 100 in2. The lower ventilation opening must

be located within 6" of the floor while the upper opening must be located 6" from the top of the space.

If the “Water heater Area” does not meet the recommended clearances listed in Table 3-1, and if the water heater area has a volume less than 150 ft3, it is considered a Closet or Alcove.

PVC vent pipe and fittings shall not be used within the closet or alcove; only approved CPVC, Polypropylene or Stainless Steel vent pipe and fittings can be used. See Table 4-3 for a list of approved materials.

Indoor Combustion Air – When using Indoor Combustion Air in lieu of Direct Vent air-inlet piping (an option

for models NX500-NX800), provisions for combustion and ventiation air, in accordance with section “Air for

Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (U.S.), or Clause

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1 (Canada), or applicable

provisions of the local building codes, must be adhered to.

Closet Installations

For closet installations, it is necessary to provide two ventilation air openings as shown in Figure 3-1(a), (b) and (c), each providing a minimum area equal to 1 in2per 1000 Btu/hr, but not less than 100 in2and within 6" of the top and bottom of the closet door. See Table 3-1for minimum recommended clearances.

Alcove Installations Alcove installations have the same minimum clearances as closet installations, except the front must be

completely open to the room at a distance no greater than 18" [457 mm] from the front of the water heater and the room is at least three (3) times the size of the alcove. Provided these conditions are met, the water heater requires no extra ventilation air openings to the space. See Table 3-1for minimum recommended clearances.

Wall Mounting Installations (Optional)

NX200-NX400 models are shipped with wall mounting brackets to provide installers with the option of wall mounting the water heater. NX500-NX800 models are not available as a wall mountable unit. Refer to Figures 3-3(a) and 3-3(b) for instructions and illustrations on wall mounting applicable models.



NX Series

Installation and Operation Instructions │

Hubbell NX

Closet/alcove installations in US and Canada require approved

CPVC

vent and air-inlet

pipe, fittings, cements and primers (Table 4-3).



Hubbell NX

│Installation and Operation Instructions

NX Series

Table 3-1 Minimum Clearances for Installation and Service

Model No.

Clearances

Front

NX200

NX300 & NX400

NX500-NX800

Minimum

Recommended

Minimum

Recommended

Minimum

Recommended



Flue Pipe

Dimensions - inches

Top

Left Side Right Side Rear



Installation and Operation Instructions │Hubbell NXNX Series

Notes:

1. 6"

if surface is removable allowing 36" clearance (i.e. closet installation). See Ventilation Air Opening dimensions in Figure

3-1.

Clearances can be as low as 12" if the right side has a clearance of 24"

For models NX500-NX800, ensure rear of unit is accessible for wiring and flue gas testing.

4. Code requires all wall mounted instantaneous water heaters to be installed with suitable wall protection extending the full length and width of the water heater. Check with local authorities regarding acceptable protection materials.



Hubbell NX

│Installation and Operation Instructions NX Series

1. Remove the uppe

back of the water heater.

Secure the upper wall mount bracket to a solid wall using field supplied lag screws (anchors when mounting on a concrete wall) that are adequate to support the weight of the water heater. Ensure the bracket is mounted in the level position. Refer to Table 2-1 Specifications for water heater weight.

Mount the water heater to the bracket by aligning the slots in the back of the water heater with the hooks protruding from the wall bracket. The top of the slots must rest at the bottom of the groove in the hooks of the wall mount bracket.

Pull the bottom of the unit away from the wall to allow the installation of the lower wall mount bracket (included with water heater). The bracket will snap into place using the slots provided in the bottom of the unit (ensure the snaps lock into place, once installed the bracket should not be easily removed).

wall mount bracket from the

Failure to follow instructions may result in fire, serious injury, or death.

This unit requires two people to lift it or damage and injury may result.

Code requires all wall mounted instantaneous water heaters to be installed with suitable wall protection extending the full length and width of the water heater. Check with local authorities regarding acceptable protection materials.



NX Series

While leaving the upper bracket intact (A), remove the wall mount bracket attached to the bottom-back of the water heater (B). Save the mounting hardware for Step 4.

Secure the wall mount bracket, removed from the bottom of the water heater in Step 1, to a solid wall using field supplied lag screws (anchors when mounting to a concrete wall) that are adequate to support the weight of the water heater (refer to Table 2-1 Specifications). Ensure the wall mount bracket is mounted level and flush to the wall with mounting holes on the bottom, flange pointed upward and angled away from the wall.

Mount the water heater to the wall by aligning the upper bracket (A) with the wall mount bracket (B). Slide the upper bracket down over the wall mount bracket until it hooks.

Once the water heater is resting securely on the

upper bracket, secure the bottom bracket to the underside of the water heater using the mounting hardware removed in Step 1; then, anchor the bottom bracket to the wall as shown.

Installation and Operation Instructions │

Failure to follow instructions may result in fire, serious injury, or death.

This unit requires two people to lift it or damage and injury may result.

Hubbell NX



Hubbell NX │Installation and Operation Instructions NX Series

4.0 GENERAL VENTING

The Hubbell NX is certified as a “Category IV” water heater requiring a “Special Venting System” designed for pressurized venting. The Exhaust Vent must be piped to the outdoors, using the vent materials and rules outlined in this section. Under no conditions may this unit vent gases into a masonry chimney, unless it is vacant, and utilizes the approved venting material and rules described in this section.

Vent and Air-inlet are to be piped separately. The Hubbell NX cannot share a common vent or air-inlet with multiple appliances. Failure to comply will result in serious injury or

death.

Removing an Existing Water heater from Common Venting System

Do not install the Hubbell NX into a common venting system with any other appliances. Failure to comply with this warning will cause flue gas spillage and leech carbon monoxide emissions into the surrounding air resulting in serious injury or death.

When an existing water heater is removed from a common venting system, the common

venting system is likely to be too large for proper venting of the remaining appliances connected

to it.



NX Series

Direct Vent Installation

Installation and Operation Instructions │

(Mandatory for models NX200-NX400)

Hubbell NX

When installed as a Direct Vent water heater the combustion air-inlet must also be piped directly to the outdoors using the methods described in this section and in accordance with the National Fuel Gas Code, ANSI Z223.1 (U.S.) or CSA B149.1 (Canada) and local requirements.

Indoor Combustion Air

(Optional for models NX500-NX800)

When the installation uses Indoor Combustion Air (i.e. piping is not directly connecting the water heater air-inlet fitting to the outdoors), provisions for combustion and ventilation air, in accordance with section “Air for Combustion and Ventilation,” of the

Natural Gas and Propane Installation C ode, CAN/CS A B149.1

8.4 of

National Fuel Gas Code, ANSI Z223.1/NFPA 54

(Canada), or applicable provisions of the local

(U.S.), or Clause 8.2, 8.3 or

building codes, must be adhered to.

The water heater shall be located so as not to interfere with proper circulation of

combustion, ventilation, and dilution air.

Make up air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements. Failure to ensure adequate make up air to all appliances may result in personal injury or death.

Controller RPM Adjustments

– To avoid the potential water heater lockouts due to wind and static pressure differences, the Lightoff and Minimum Modulation RPM Rates must be adjusted as per Figures 4-11 and 4-21 in Appendix A when using indoor combustion air.

Air Filter Kit (P/N HUB-84093) –

When using indoor combustion air (non-Direct Vent), it is highly recommended to use the optional Air Filter Kit (P/N HUB- 84093) to limit the amount of dust that enters the combustion system. The Air Filter Kit (P/N HUB- 84093) can be installed on water heater models NX500-NX800, as illustrated in Figure 4-1 (comprehensive installation instructions are provided with the Filter Kit).

Venting Limitation

maximum equivalent exhaust vent length is limited to 30 ft. with 4" piping, or 90 ft.

with 6

piping; see warning below Table 4-5.

Figure 4-1 Installation of Optional Air Filter Kit (P/N HUB-84093)

– When using the Air Filter Kit on models NX500 & NX600, the

air-inlet adapter; keep screws from installation of filter kit



2.Secure filter kit using factory

screws removed in step 1. Reuse the factory gasket.

3.Secure the filter in place

with the brackets and knurled screws provided in the filter kit.



Hubbell NX │Installation and Operation Instructions NX Series

Combustion Air-inlet Contamination

Be careful not to locate the Air-inlet termination in an area where contaminants can be drawn in and used for combustion. Combustion air containing dust, debris or air-borne contaminants will drastically increase the required maintenance and may cause a corrosive reaction in the Heat Exchanger which could result in premature failure, fire, serious injury, or death. See Table 4-1 for a list of areas to avoid when terminating air-intake piping:

Table 4-1 Corrosive Products and Contaminant Sources

Products to Avoid

Antistatic fabric softeners, bleaches, detergents, cleaners

Perchloroethylene (PCE), hydrocarbon based cleaners

Chemical fertilizer, herbicides/pesticides, dust, methane gas

Paint or varnish removers, cements or glues, sawdust

Water chlorination chemicals (chloride, fluoride)

Solvents, cutting oils, fiberglass, cleaning solvents

Refrigerant charge with CFC or HCFC

Permanent wave solutions

Fixer, hydrochloric acid (muriatic acid), bromide, iodine

Cement powder, crack fill dust, cellulose, fiber based insulation

Contaminated Sources to Avoid

Laundry facilities

Dry cleaning facilities

Farms or areas with livestock and manure

Wood working or furniture refinishing shops

Swimming pools, hot tubs

Auto body or metal working shops

Refrigerant repair shops

Beauty shops

Photo labs, chemical / plastics processing plants

Concrete plant or construction site

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Failure to follow instructions may result in serious injury or death.

It is BEST PRACTICE to pipe the combustion air-inlet directly to the outdoors (Direct Vent installation) to avoid contamination often contained in indoor air.

Flammable Solvents and Plastic Piping Due to the extremely flammable characteristics of most glues, cements, solvents and primers used in the process of

joining plastic vent and air-inlet pipe, explosive solvent vapors must be evacuated from the vent and air-intake prior to start-up. Avoid using excess cement or primer that may lead to pooling inside the pipe assembly. Freshly assembled piping assembly should be allowed to cure for a minimum of 8 hours before applying power to the gas fired appliance. Refer to Mandatory Pre-commissioning Procedure for Plastic Venting in this section.

Flammable Cements and Primers–It is the installers’responsibility to familiarize themselves with the hazards associated with explosive solvents and to take all precautions to reduce these risks. Failure to follow these instructions can cause explosions, property damage, injury or death.

Mandatory Pre-commissioning Procedure for Plastic Venting (PVC or CPVC)

Do not apply power to the water heater prior to Step 4 in the Mandatory Pre-commissioning

Procedure for Plastic Venting.

Spark Igniter Cable - Maintain a minimum 2" separation between spark igniter circuit and

conductors. Failure to follow instructions may result in component failure, injury or death.

1) Working with the power turned off to the water heater, completely install the vent and air-inlet system, securely cementing joints together. If possible, allow primers/cements to cure for 8 hours before firing the burner. If curing time is less than 8 hours, proceed with Steps 2 through 6.

2) Maintain the water heater gas supply shut-off valve in the off position.

3) Disconnect electrical leads to the Hot Surface or Spark Igniter. Ensure the cables are placed in a fashion where they will not arc to ground or other conductor. Refer to warning regarding Spark Igniter Cable.

4) Turn power on to the water heater and apply a heat demand.

5) Allow for 3 complete trials for ignition, consisting of pre and post purge of the combustion blower, until an ignition lockout occurs. Repeat the process two more times (i.e. 9 complete ignition sequences in total).

6) Turn power off and reconnect the electrical leads to the Igniter.



Hubbell NX │Installation and Operation Instructions NX Series

Near Water Heater Vent/Air Piping

Each Hubbell NX is equipped with a short piece of approved CPVC vent pipe (see Table 4-2 CPVC Vent Pipe Transition Piece). Insert one end into the water heater flue outlet adapter and cement the other to field venting (see Table 4-4 for approved venting material). The CPVC vent pipe should extend fully into the water heater flue outlet adapter (see Table 4-2). Ensure that the venting system does not apply a load or strain on the water heater flue outlet adapter. The manufacturer recommends using two elbows to create a “swing joint” to reduce potential strain on vent piping and cemented joints; see Figures 4-2 through 4-5.

Gasket Seating - Improper seating can cause leakage and eventual failure of the sealing gasket. Failure to follow these instructions may result in serious injury or death.

PVC Exhaust Venting – DO NOT insert PVC pipe directly into the water heater exhaust adapter, as it can deform from the clamping force of the gear clamp. Failure to follow these instructions may result in gasket failure and/or the dislodging of the exhaust pipe water heater adapter, resulting in property damage, serious injury or death.

Table 4-2 CPVC Vent Pipe Transition Piece

Model No.

CPVC Vent Pipe Size CPVC Transition Vent Pipe Length

NX200

NX300-NX600

NX700 & NX800

Polypropylene or Stainless Steel Venting – When using Polypropylene or Stainless Steel piping, the appropriate water heater adapters must be used to transition the water heater vent

connections to accept the respective Polypropylene or Stainless Steel venting. See Table 4-3 for a list of approved adapters. Failure to use the correct adapter will result in flue gas leakage resulting in property damage, serious injury or death.

Table 4-3 Water heater Adapters for Polypropylene and Stainless Steel Venting

Model No.

NX200

NX300-NX600

NX700 & NX800

Notes: 1 Listed water heater adapters are only approved for use with the respective venting brand; i.e. a PolyPro water heater

adapter shall not be used with InnoFlue venting.

PolyPro and FasNSeal water heater adapters are available from DuraVent (1-800-835-4429 or www.duravent.com); Inno-

Flue water heater adapters are available from Centrotherm Eco Systems (1-877-434-3432 or www.centrotherm.us.com).

Vent Material

Polypropylene

Stainless Steel

Polypropylene

Stainless Steel

Polypropylene

Stainless Steel

Exhaust venting must be supported to reduce strain on piping joints. Failure to follow these instructions may result in result in damage, serious injury or death.

(used when venting with PVC)

Minimum 5"[127 mm]

Minimum 4" [100 mm]

Minimum 6" [152 mm]

Centrotherm - InnoFlue

Venting Brand

DuraVent – PolyPro

DuraVent – FasNSeal

DuraVent – PolyPro

DuraVent – FasNSeal

DuraVent – PolyPro

DuraVent – FasNSeal

Full Insertion Depth

2-7/8" [73 mm]

1-7/8" [48 mm]

2-1/2" [63 mm]

Adapter Part No.

300150

ISANY0303

300715

300151

ISAA0404

303631

810004281

ISAA0606

810005231

from the

1,2

In Canada, the first 3 ft (915 mm) of vent piping must be readily accessible for inspection.



NX Series



Installation and Operation Instructions │Hubbell NX

Figure4-

2(a) Near Water Heater Venting (CPVC)

Air Inlet

3" Pipe *

Coupling

3" Removable (field supplied)

Figure 4-3(a) Near Water Heater Venting (CPVC)

Models NX300 & NX400

Exhaust Vent

4"/6" CPVC

0o elbow typical, or tee and rain cap option for easy cleanouts

Model NX200

Exhaust Vent

3" CPVC

Flue Outlet

Stainless Steel Adapter (factory supplied)

Swing Joint

to attain slope in horizontal runs

Flue Outlet

Stainless Steel Adapter (factory supplied)

Coupling

4"Removable (factory supplied)

Swing Joint

to attain slope in horizontal runs

Air-Inlet

4" Pipe *

Figure 4-2(b) Near Water Heater Venting (PVC)

Air Inlet

3" Pipe *

Coupling

3" Removable (field supplied)

Figure 4-3(b) Near Water Heater Venting (PVC)

Mandatory Vent Pipe Transition Piece

See Table 4-2. horizontal runs

Exhaust Vent

4"/6"PVC (check local codes and Table 4-3)

Transition Piece

4" CPVC, minimum 4" long (factory supplied)

90o elbow typical, or tee and drain cap option for easy cleanouts

Model NX200

Models NX300 & NX400

Swing Joint

to attain slope in horizontal runs

Exhaust Vent

(check local codes and Ta 4-3)

Coupling

Transition Piece

3" CPVC, minimum 5" l (factory supplied)

Flue Outlet

Stainless Steel Adapter (factory supplied)

Mandatory Vent Pipe

Transition Piece

See Table 4-2.

- 3" PVC,

3" PVC

Swing Joint

to attain slope in

Coupling

4"/6"x4" PVC

Flue Outlet

Stainless Steel Adapter (factory supplied)

Coupling

4" Removable

(factory supplied)

Air-Inlet

4" Pipe *

ble

ong

* Air-Inlet- check with applicable local codes for acceptable pipe material



Air-

Hubbell NX │Installation and Operation Instructions NX Series

Figure 4-4(a) NearWaterHeater Venting(CPVC/PVC)

Swing Joint

to attain slope in horizontal runs

Exhaust Vent

4" CPVC

Exhaust Vent

4" PVC (check local codes and Table 4-3)

Flue Outlet 4"

stainless steel (factory supplied)

Transition

4" CPVC

Mandatory Vent Pipe Transition Piece

4" CPVC (factory supplied). See Table 4-2.

Figure 4-5(a) Near Water Heater Venting (CPVC)

Models NX700 & NX800

Models NX500 & NX600

InletAdapter

4” stainless steel (factory supplied

Air-Inlet

4" Pipe *

)

90o elbow typical, or tee and drain cap option for easy cleanouts

Figure 4-5(b) Near Water Heater Venting (PVC)

Models NX700 & NX800

Exhaust Vent

6" CPVC

Flue Outlet

6" stainless steel elbow (factory supplied)

90o elbow typical, or tee and drain cap option for easy cleanouts

Swing Joint to

attain slope in horizontal runs

Air-Inlet

Air-Inlet Adapter

4" stainless steel (factory supplied

4" Pipe *

Mand atory Vent Pi pe Transition Piece

6" CPVC (factory supplied). See Table 4-2.

Swing Joint

to attain slope in horizontal runs

Exhaust Vent

6" PVC (check local codes and

)

Table 4-3)

Coupling 6"

PVC, length 4"

Transition

6" CPVC

Flue Outlet 6"

stainless steel elbow (factory supplied)

90o elbow typical, or tee and drain cap option for

Air-Inlet

4” stainless steel (factory supplied

4/6" Pipe *

Inlet Adapter

)

*Air-Inlet - check with applicable local codes for acceptable pipe material.



NX Series

Installation and Operation Instructions │Hubbell NX

Vent/Air-inlet Pipe Material

Table 4-4 Acceptable Vent and Air-inlet Pipe Material

Items

Materials

2, 3

United States

Vent Piping and Fittings

Pipe Cement

Primers

Notes:

Refer to Table 4-5 for Allowable Vent and Air-inlet Pipe Sizes and Lengths. PVC venting (exhaust and air-intake) is not permitted within the Closet/alcove of a Closet/alcove installation. The Air-Intake does not require high temperature pipe material. Check applicable local codes for acceptable materials. ULC S636 PVC is approved for flue gas temperatures up to 149oF (65oC) and must only be used for low temperature

PVC - DWV

PVC Schedule 40

CPVC Schedule 40 ANSI/ASTM F441

AL29-4C

Polypropylene (PP) -

PVC

CPVC

PVC / CPVC

ANSI/ASTM D2265

ANSI/ASTM D1785

UL-1738

ANSI/ASTMD2564

ANSI/ASTMF493

ANSI/ASTM F656

applications. High temperature applications requiring water heater supply water temperatures greater than 140oF (60oC) must use ULC S636 CPVC, PP or AL29-4C.

Installation Standards

All venting material in

ULC S636 approved.

See Note 4 below for appropriate temperature

Canada

Canada must be

applications.

All Vent and Air-inlet materials installed on gas fired appliances in CAN/US must meet the Standards listed in Table 4-4. Failure to comply could result in fire, serious injury or death.

The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in the exhaust venting system is prohibited. Failure to follow these instructions may result in property damage, personal injury or death.

Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. Failure to follow these instructions may result in property damage, personal injury or death.



Hubbell NX │Installation and Operation Instructions NX Series

Vent and Air-inlet Pipe Length Determination

Use Table 4-5 to determine the maximum pipe length that can be used. The table calculates sweep, 90º elbows, and 45º elbows at 5 equivalent feet each. Note: model NX200 has limitations when operating with Propane Gas (LP).

Example: An NX200 can be installed with 105 equivalent feet of air-inlet piping and 105 equivalent feet of exhaust

vent piping when operating with Natural Gas. When operating with Propane Gas (LP), the maximum length of each the exhaust vent and air-inlet pipe is limited to 50 equivalent feet (3" diameter pipe).

The length of one vent pipe (air-inlet or exhaust) may not exceed the length of the other vent pipe by more than 20 equivalent feet.

Table 4-5 Allowable Vent and Air-Intake Pipe Size and Lengths

Model

Pipe Size

Gas

Length

ft.

Number of Elbows (90’s or 45’s) and Equivalent Feet

1 2 3 4 5

40 35

30 25 20 15

NX200

NX300& NX400

NX500

NX600

4" or 6"

4" or 6

4"or 6

NG & LP

105

100 95 90

105

100 95 90

100

90 85

100

90 85

100

90 85

85 80 75 70 65

80 75

80 75 70 65

70 65

8 9

60 55

NX700 &

NX800

Notes:

Only 6" exhaust vent is permissible for models NX700-800. Air-inlet pipe can be 4" or 6" (6" is highly recommended).

Models NX600-NX800 operate with Natural Gas only.

Models NX500 & NX600 are limited to 30 ft. of 4" or 90 ft. of 6" exhaust venting when using the Air Filter Kit

(P/N HUB-84093).

100

90 85

80 75 70 65

Air Filter Kit venting restrictions - Models NX500 & NX600 are limited to 30 equiva-

lent feet of 4" (or 90 equivalent feet of 6") exhaust vent when using the optional Air Filter Kit. When transitioning from 4" to 6", the 4” venting used must be counted 3 times to convert to an equivalent length in 6".

Example: An application uses one 90º elbow and 5 feet of 4" venting before converting to 6"; therefore, the 4"

venting has an equivalent length of 30’ [(5'+5') x 3] of 6" venting; thus allowing an additional 60' equivalent of 6"venting (Note: Example is only true with NX500-600 models using the optional Indoor Combustion Air Kit).

60 55



NX Series

Installation and Operation Instructions │Hubbell NX

Termination Options – Direct Vent Installation

The venting system of the Hubbell NX may be terminated using field supplied piping to construct a “Two-Pipe” termination, see Figures 4-6(b), 4-7(a), 4-7(b) and 4-8(a); alternatively the venting may be terminated using a factory kit selected from Table 4-6.

Kits certified with the Hubbell NX are listed in Table 4-6 and available from IPEX, DuraVent, Centrotherm, and/ or Hubbell. For more information on System 636 Vent Kits or wholesaler locations contact IPEX directly USA: 1-800-463-9572 or www.IPEXamerica.com

│ CAN: 1-866-473-9462 or www.ipexinc.com. For more information

on PolyPro Vent Kits or wholesaler locations contact DuraVent directly 1-800-835-4429 or www.duravent.com. For more information on InnoFlue Vent Kits or wholesaler locations contact Centrotherm directly at 1-877-434-3432 or

www.centrotherm.us.com.

Table 4-6 Optional Vent Termination Kits

Vent

Description

IPEX Low Profile (Flush Mount)

IPEX Concentric (Wall/Roof)

5,6,7,8

Size



DuraVent - Poly Pro Concentric (Wall)

DuraVent - Poly Pro Concentric (Roof)

Centrotherm – InnoFlue

(Flush Mount)

Centrotherm – InnoFlue Concentric (Wall)

Centrotherm – InnoFlue Concentric (Roof)



Models NX300-NX800 are not approved for use with any of the 3" vent termination kits; only 4" vent termination kits, listed in Table 4-6, are acceptable.

Supplier P/N

196985 (Hubbell P/N 84357)

196986 (Hubbell P/N 84358)

196116 (Hubbell P/N 82666)

196021 (Hubbell P/N 84355)

3PPS-HK

4PPS-HK

3PPS-VK

4PPS-VK

ISLPT0303

ICWS3513 & ICTC0335

ICWS4639 & ICTC0446

ICRT3539 & ICTC0335

ICRT4679 & ICTC0446

Figure

4-9(b), 4-10(b)

4-9(d)

4-10(c)

4-9(d)

4-10(c)

4-9

Vent Material Compatibility

PVC/CPVC

PVC/CPVC/PP



Vent Option

✘

✔ ✔

✘

✔

✘

PVC/CPVC/PP

✘

✔

Wall

✔

✘

✔

✘

PVC In Canada - Authorities in some jurisdictions may not allow the use of any PVC venting materials with condensing water heaters; check with the local safety inspector to verify compliance prior to installing a PVC Concentric Vent Kit with a Hubbell NX.



Hubbell NX │Installation and Operation Instructions NX Series

Sidewall Termination - Due to potential moisture loading (build-up) along the exterior

wall, sidewall venting may not be the preferred venting option. Refer to Figures 4-8 and

Sidewall Termination Examples – Direct Vent Installation

Figure

4-6(a) Concentric Sidewall Termination

4-10 for roof top venting options.

(NX200 Illustrated)

Figure 4-6(b) Two-Pipe Sidewall Termination

(NX200Illustrated)

Figure 4-7(a) Two-Pipe Sidewall Termination

(NX800 Illustrated)

Figure 4-7(b) Two-Pipe Sidewall Termination

(NX400 Illustrated)



NX Series

Installation and Operation Instructions │Hubbell NX

Extra precaution must be taken to adequately support the weight of the Vent/Air-inlet piping in applications using roof-top terminations. Failure to follow these instructions may result in venting or water heater component failure resulting in flue gas spillage leading to property damage, serious injury or death.

Roof Termination Examples – Direct Vent Installation

Figure 4-8(a) Two-Pipe Roof Termination

(NX200 Illustrated)

Figure 4-8(b) Concentric Roof Termination

(NX200 Illustrated)



Air-

Hubbell NX

│Installation and Operation Instructions NX Series

Sidewall Termination Details – Direct Vent Installation

Horizontal 4-12" or greater than 36"

ertical

Min. 18"

ent Screen

Min. 12" above grade or snow level

ent pipe piece to

retain vent screen

Min. 12" above grade or snow

inletaround

perimeter (1-2" from wall)

Exhaust through center

ent Screen

ent pipe piece to

retain vent screen

Air-inlet around

Min. 12" above grade or snow level

Air-inlet bottom

Exhaust center



NX Series

Installation and Operation Instructions │Hubbell NX

Roof Termination Details – Direct Vent Installation

Two-Pipe Termination (Roof)

Figure 4-10(a)

Exhaust

Vent Screen

Vent pipe piece to retain vent screen

Air-inlet

Min. 12" above grade or snow level

Flashing

Vertical

Min. 18"

Horizontal

4-12" or greater

than 36"

Figure 4-10(b)

IPEX Concentric Termination (Roof)

Refer to documentation included with termination kit for co plete installation instructions.

Exhaust center

Vent pipe piece to retain vent screen

Vent Screen

Air-inlet around

perimeter

Min. 12" above grade or snow level

Flashing

Figure 4-10(c)

PolyPro / InnoFlue Termination (Roof)

Refer to documentation included with termination kit for complete installation instructions.

Min. 12"

above grade or

snow level

Air-inlet

Flashing

Exhaust

Figure 4-10(d)

Exhaust only Termination (Roof)

Figure illustrates two options for exhaust termination only; neither vent pipe illustrated is for combustion air-inlet.

Vent pipe piece to retain vent screen

Vent Screen

Exhaust Option 1

Min. 12" above grade or snow

Exhaust Option 2

level

Flashing



Hubbell NX │Installation and Operation Instructions NX Series

Venting Rules and Guidelines

1. Prevailing Winds: Ensure the vent is located where it will not be exposed to normal prevailing winds.

2. Combustion Air-inlet Contamination: Air for combustion must be drawn from an area free of dust and

contaminants. Combustion air containing chemicals such as chloride, fluoride, bromine or iodine or dust and debris will cause corrosion damage of the heat exchanger voiding your Hubbell warranty. Refer to Table 4-1 for a list of corrosive products and contaminants sources to avoid.

3. Vertical Separation: The exhaust must be a minimum of 18 in. above the air inlet, and the air inlet must always

be a minimum of 12 in. plus snow allowance above any surface that will support snow. (Two feet plus snow allowance is highly recommended). Consult your weather office for the maximum typical snowfall for your region.

4. Horizontal Separation: The horizontal distance between the inlet and exhaust must be a minimum of 4" center to

center.

5. Wall Flashing: Under normal operating conditions this water heater will produce a plume of white gases, and

should be taken into consideration when selecting an adequate location. A 36 in. diameter stainless, plastic, or vinyl shield can be used to flash the exterior of the building.

6. Flue Gas Hazard: Position the vent termination where vapors cannot make accidental contact with people and

pets or damage nearby shrubs and plants.

7. Elbow Extensions: Elbows on outside of wall must be no more than 1∕2 in. away from the wall.

8. Vent Sloping: All indoor exhaust piping must be on a slope back to the water heater a minimum of 1∕4 in.

per linear foot of vent. For applications where excessive condensation is possible 1∕2 in. per linear foot is recommended.

9. Vent Supports: Where required Vent and Air-inlet piping shall be secured to the wall for more rigidity.

All interior vent pipe shall be supported a minimum of every 36 in..

10. Roof Exhaust: In all roof applications the discharge must point away from the pitch of the roof.

11. Roof Flashing: Install adequate flashing where the pipe enters the roof, to prevent water leakage.

12. Rain Cap: Install and seal a rain cap over existing chimney openings, in vacant chimney applications.

13. Venting Below Grade: For installations that exit the wall below grade refer to Figure 4-11.

14. Vent Screens: Install factory supplied vent screens on the outside of the last elbow for both the inlet and exhaust

vent terminal elbows. Install the screen into the female opening of the elbow, and then cut a small piece of pipe to sandwich the screen into the elbow. NOTE: ensure the small piece of pipe cut, does not extend past the end of the elbow. Two screens are provided in the package. See Figures 4-9 and 4-10.

15. Condensate Hazard: Do not locate vent over public walkways, driveways or parking lots. Condensate

could drip and freeze resulting in a slip hazard or damage to vehicles and machinery.

16. Warning Plate: For Sidewall Venting, install the warning plate “Gas Vent Directly Below”, directly above

(within 4 ft. vertically) the location of the air-inlet pipe, so it is visible from at least 8 ft away.

See Figure 4-9.

17. Wall Thickness: Direct vent terminations are designed to work with any standard wall thickness.

Installation guidelines for min/max wall thickness are as follows: Min. = 1 in., Max. = 60 in..

18. Venting Options: Due to potential moisture loading (build-up) along the exterior wall, sidewall venting

may not be the preferred venting option. Refer to Figures 4-8 and 4-10 for roof top venting options.

The vent for this water heater shall not terminate over public walkways; or near soffit vents or crawl space vents or other area where condensate of vapor could create a nuisance or hazard or cause property damage; or where condensate or vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.



Hubbell NX │Installation and Operation Instructions NX Series

For installations that exit the wall below grade:

Excavate site to a point below where the pipes

are

to exit as shown.

Ensure the wall is fully sealed where the pipes

penetrate.

The Vent/Air-inlet piping MUST be secured to

3. the side of the building above grade, as shown, to provide rigidity.

Optional mounting bracket P/N. HUB-82075 for

securing the exhaust pipes (only applicable for 3 in. PVC/CPVC venting).

Ensure that the Vent/Air-inlet clearances are

5. maintained, see Section 5.0 fo

details.

Vent piping outside the building is permitted under the following conditions:

1. The maximum length outside the building is 20 ft. Note that outdoor length must be included in the overall vent length calculation.

2. All normal termination clearances are maintained.

3. The pipe is supported every 24 in..

4. The exhaust and inlet are sloped back to the water heater 1∕2 in. elevation for every linear foot.

Wall Brackets

Gas Vent Directly Below

Keep Free of Obstructions

Supports every 24 in.

Exhaust Vent

Air-Inlet

Maximum of 20 ft. is permitted for piping outside a building.

12 in. plus snow allowance above grade

Figure 4-13 Existing Chimney Chase Way

It is permissible to use an existing chimney as a chase way to run the Vent/Air-inlet piping as long as:

1. The chimney is not being used by any other water

heater.

2. Flue gases do not enter the vacant chimney.

3. Only Hubbell NX certified venting materials are used, see Table 4-4.

4. Vent lengths are within the maximums specified.

5. The top of the chimney is capped and the Vent/ Air-inlet pipes are flashed to prevent leakage into the vacant chimney.

Chimney Cap

Existing Chimney (used as a chase way)

Under no circumstances may an existing chimney or chase-way be used to vent or



Exhaust Vent

Air-Inlet

Exhaust Vent Min. 18 in. above air-inlet Min. 12 in. above roof

Air-Inlet and snow level

Hubbell NX │Installation and Operation Instructions NX Series



provide combustion intake air to a Hubbell NX. Failure to follow these instructions will result in fire, property damage, serious injury or death.



5.0 VENT AND AIR-INTAKE TERMINATION CLEARANCES

The quick reference table below is to be read in conjunction with the numbered notes as

indicated, Figures 5-1 through 5-6, and the Venting Rules and Guidelines in Section 4.0. The instructions detailed in this section are a combination of Hubbell NX specific and National Gas Code restrictions. Compliance alone doesn’t insure a satisfactory installation as good common sense must also be applied. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Table 5-1 Termination Clearances Quick Reference Table

Clearances

Above grade/roofline and snow level

Above roof line - Concentric Vent

To exhaust vent from any other water heater

to Air-Inlet Termination

Clearances to Exhaust Vent Termination

Above

rade/roofline and snow level

Minimum vertical separation above air inlet

Minimum horizontal separation from air inlet

Window or door that may be opened, or other building opening

To combustion air inlet of any other appliance

Non-mechanical air supply inlet to building

Mechanical air supply inlet to building

Soffit, overhang, eave or parapet

Soffit vent or vent opening in an overhang, eave or parapet

Outside corner

Inside corner of an L-shaped structure (including walls and fences)

Service regulator / vent outlet

Each side of center line above or below meter / regulator assembly

Above a paved sidewalk, driveway, or parking lot on public property if adjacent

Above a public walkway

Above a sidewalk or paved driveway that is locatedbetween two single family

dwellings and services both dwellings

Under a concrete veranda, porch, deck, or balcony

Above, under or near exterior stairs

Into a canopy or carport

6, 11, 13

Notes: 1 - Canadian installations must comply with the current CSA B149.1 Natural Gas and Propane Installation Code and local building codes. 2 - US installations must comply with current ANSI Z223.1/ NFPA 54 National Fuel Gas Code and local building codes. 3 - Horizontal separation center-to-center (c.c.) 4"-12" (102-305 mm). 4 - For US installations, an exhaust vent must be 3 ft above a mechanical air supply inlet if within 10 ft. horizontally. 5 - Horizontal clearance must be observed up to a height of 15 ft. [4.6 m] above/below the meter, regulator, or relief devices. 6 - Concentric Vent must protrude from the roof precisely 24"[610 mm] measuring from the terminal end-cap vanes. 7 - Permitted if veranda, porch, deck, or balcony is made of concrete and a minimum of two sides are fully open beneath. 8 - 24" is the recommended snow level allowance above grade/roofline or any surface that will support snow, debris, or ice (i.e. for roof venting clearances - roofline and snow level). If living in a snowfall region, consult your local weather office for the maximum typical snowfall for your area. 9 - Note that the vent must maintain a minimum vertical distance above the air-inlet. Example: Vent height = 18" (457 mm) above

air inlet + 12" (305 mm) for air inlet above grade/roof line and snow level = 30" (762 mm) above grade and snow level. 10 - Clearances to an outside corner to be in accordance with local installation codes. 11 - In Canada, concentric vent materials are subject to approval by local inspectors. See Termination Kits in Section 4.0. 12 - Above public walkways, driveways or parking lots if adjacent to it and condensate cannot drip, freeze, or create a hazard.

13 - Contact Hubbell for special exemptions relating to multiple water heater installations using concentric vents.

USA

Canada

Min. Distance Min. Distance

12 in. 305 mm

24 in. 610 mm 12 in. 305 mm

Min. Distance

12 in.

305 mm

18 in.

457 mm

4 in. 102 mm

12 in. 305 mm 12 in. 305 mm 12 in. 305 mm

915mm

3 ft.

24 in.

610mm

6 ft. 1.83 m

36 in. 915 mm

36 in. 36 in.

7 ft.

24 in. 610 mm

915mm

X X

2.13 m

Min. Distance



12 in.

24 in.

36 in.

12 in. 18 in.

4 in. 36 in. 36 in. 36 in.

6 ft.

24 in.

6 ft.

36 in.

36 in. 36 in.

7 ft.

24 in.



Hubbell NX | Installation and Operation Instructions

Figure 5-1 Termination Clearances Quick Reference Diagram

---'

(}".

(}". _J

I-

W W

(:1

!=1

(I)

---'

NX Series

!=1

I-

(}". >-

I-

(}".

I-

_J L

(}'.'.

::>::

Cl'.'.

I-

W O

1- Z

I-

::<:

(}'.'.

I-

(}'.'. ;s

W L:

(l".

1- W

D I-

<§



NX Series

Installation and Operation Instructions │

Hubbell NX

G – Letter represents a specific Termination Position. Refer to Table 5-1 for corresponding termination clearances.



Hubbell NX

│Installation and Operation Instructions NX Series

6.1 CONDENSATE DRAIN

This unit produces liquid condensate in the heat exchanger and venting system as a product of combustion. Steps must be taken to ensure that condensate does not collect in the venting system; therefore, all exhaust

slope back to the water heater a minimum 1/4

per linear foot of vent. Condensate must be drained from the unit into a

piping must

household drain.

Check with your municipality, or local gas company to determine if the disposal of combustion condensate is permitted in your area (e.g. in the

State of Massachusetts

the

condensate must be neutralized prior to entering a drain).

The following are important notes that must be taken into consideration when constructing the condensate drain system (See Figure 6-1 for further details):

 DO NOT

install condensate lines outside. A frozen or blocked drain will cause the condensate to fill the combustion chamber. This will result in a no heat condition, as the unit will shut down, and damage to the flame sensor, and components can occur.

 NEVER

use copper, steel, or galvanized piping in the construction of the condensate disposal system as

condensate is very corrosive and will corrode most metallic drains and sewer pipes.

 When a condensate pump is used or required, select a pump that is designed for residential furnaces.

If the combustion chamber has been flooded due to the condensate drain backing up, or

for any other reason, the combustion chamber door must be removed and the inside of the water heater must be inspected for component damage, e.g. the internal insulation at the front and back of the chamber. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Figure 6-1 All Models

Condensate Drain Piping

Drain Vent Do not block or install piping into the top branch of the condensate drain tee.

Drain Pipe Connection to the bottom of the condensate drain tee must be made using 1/2" Schedule 40 PVC pipe. Secure using appropriate PVC cement. All piping must be below the level where the condensate leaves the water heater.

Floor Drain Check with your local authorities regarding disposal of condensate (regulation may require the use of a neutralizer).



Hubbell NX │Installation and Operation Instructions NX Series

7.1 INSTALLING GAS PIPING

The Hubbell NX is factory equipped to operate with Natural Gas, the installation of a

conversion kit is required prior to operating with Propane Gas.The Natural to LP Conversion Kit (see Table 7-1) must be installed prior to installing the gas piping to the water heater. Failure to properly convert the unit to operate with Propane may result in property damage, serious injury or death.

Liquefied Petroleum (LP) propane gas is heavier than air. Do not install the water heater

in a pit or similar location that will permit heavier than air gas to collect. Check with Local

as they may require appliances fueled with LP gas to be provided with an approved means of removing

unburned gases

from the room. Failure to follow these instructions may result in serious injury or death.

Table 7-1 Natural Gas to LP Propane Conversion Kit

Model Number

NX200

NX300

NX400

NX500

Notes:

mation on adjusting the throttle screw convert water heater to LP.

only.

No LP orifice is used with model NX500, see conversion kit instructions for infor-

Models NX600-NX800 cannot be operated with LP – Propane. Use Natural Gas

LP Conversion Kit Number

HUB-82650-1

HUB-83017-1

HUB-84386-1

LP Orifice

No Orifice

Installation Refer to the current National Fuel Gas Code ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 installation codes,

and local codes for gas piping requirements and sizing. Pipe size running to the unit depends on:

 Length of pipe.  Number of fittings.  Type of gas.  Maximum input requirement of all gas appliances.

Codes

Ensure that:

 The gas line connection to the water heater does not apply any weight to the gas valve. Hubbell recommends

using approved flexible gas piping (if acceptable by local codes) to connect the water heater to the gas supply (See Figure 7-1 for details).

 You plan the installation so that the piping does not interfere with the vent pipe, or the removal of the valve,

burner, and serviceable components.

 The water heater shall be installed such that the gas ignition system components are protected from water

(dripping, spraying, rain etc.) during installation and servicing.

 The gas piping is large enough for all the appliances. No appreciable drop in line pressure

should occur when any unit (or combination of units) lights or runs. Use common gas-line sizing practices.

 Always use a pipe-threading compound that is resistant to propane (LP) gas solvent action. Apply sparingly to

all male threads, starting at two threads from the end. Over doping or applying dope to the female end, can result in a blocked gas line.

 DO NOT TIGHTEN FITTINGS WITHOUT SUPPORTING THE GAS VALVE as damage to the gas valve or

combustion blower can occur.

 Install a manual “Equipment Shut-Off Valve” as shown in Figure 7-1. Valve must be listed by a nationally

recognized testing lab.

 The gas line piping can safely be removed from the water heater for servicing, by strategically placing the gas

line shutoff and union; see example in Figure 7-1.

 All gas piping, including gas components in the water heater, are checked for leaks using a “Bubble Test”, prior

to operating the water heater.



Installation and Operation Instructions │Hubbell NXNX Series

Manual Shutoff Valve

Union

Flexible Gas Line Piping

Recommended to eliminate strain on the appliance gas components (only use if acceptable by local codes).

Drip Leg

Strain on the gas valve and fittings may result in vibration, premature component failure and leakage and may result in a fire, explosion, property damage, serious injury or death.

Flexible gas piping cannot be used within the water heater cabinet and cannot pass through the cabinet wall, use rigid piping as shown in Figure 7-1. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Do not use an open flame to test for gas leaks. Failure to follow these instructions may result in fire, property damage, serious injury or death.

When performing a pressure test on the gas line piping, be sure the water heater is disconnected or isolated if the test pressure is expected to exceed 1/2 PSI (14" w.c.), as damage to the valve could occur resulting in fire, property damage, serious injury or death.

Figure 7-1 Gas Line Connection (Typical)

Model NX200 Illustrated

Rigid Gas Line Piping

Use only rigid gas line piping within the appliance cabinet. Rigid piping must protrude beyond the outside of the cabinet wall.

Manual Shutoff Valve

overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.

- Should



Hubbell NX

│Installation and Operation Instructions NX Series

8.0 LIGHTING THE WATER HEATER

Before Start-up refer to Mandatory Pre-commissioning Procedure for Plastic Venting in

Section 4.0. Failure to follow these instructions can result in explosions, injury or death.

Prior to turning the gas supply on and lighting the water heater, ensure all aspects of the

installation are complete and in conformance with the instructions provided in this manual, including the Vent/Air-Intake, Condensate Drain, and System Water Piping. Failure to precisely follow these instructions will cause a fire or explosion resulting in property damage, serious injury or death.

Do not store or use gasoline or other flammable vapors & liquids in the vicinity of this or any other appliance. Failure to follow instructions could result in explosion causing property damage, serious injury or death.

If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, serious injury or death.

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the water heater. Failure to follow instructions could result in explosion causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING

A) This water heater does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

B) BEFORE OPERATING smell all around the water heater area for gas. Be sure to smell next to the floor

because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any water heater.

• Do not touch any electric switch.

• Do not use any phone in your building.

• Immediately call your gas supplier from an outside phone. Follow the gas supplier’s instructions.

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

C) Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or

turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D) Do not use this water heater if any part has been under water. Immediately call a qualified service

technician to inspect the which has been under water.



1. STOP! Read the safety information above very carefully.

2. Set the thermostat to lowest setting. Turn off all electric power to the water heater.

3. This water heater does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

4. Turn the manual gas valve to the OFF position. Remove front access panel.

water heater and to replace any part of the

control system and any gas control

OPERATING INSTRUCTIONS

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas.

7. Replace the front access panel.

8. Set thermostat to highest setting. Turn on all electric power to the water heater.

9. Ignition sequence is automatic. Combustion will occur after a brief fan purge.

10. If ignition does not occur, follow the instructions “To Turn Off Gas To Water heater” and call your service

technician or gas supplier.



TO TURN OFF GAS TO THE WATER HEATER



1. STOP! Read the safety information above very carefully.

2. Turn off all electric power to the water heater.

3. Turn the manual gas valve to the OFF position.



Installation and Operation Instructions │Hubbell NXNX Series

The initial lighting of the water heater must be performed by a licensed Gas Technician. Failure to follow instructions may result in property damage, serious injury or death.

 Ensure the water heater is wired in accordance with this manual.  Ensure the gas shut-off valve is turned on, and that the gas system has been fully tested for leaks. •  Ensure the system is completely filled with water, and that ALL the air is purged out.

Allow primers/cements to cure for 8 hours prior to Start-up. If curing time is less than 8 hours, first perform Steps 2 through 6 of Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosion, serious injury or death.

Initial Start-Up

1. Turn on power to the Hubbell NX and turn-up the Thermostat(s). The water heater should run through a purge, and combustion should occur. (The control system has a built in ignition retry, allowing the system to try at least three times, before locking-out.)

2. With the unit operating at full capacity, verify that the gas line pressure is 5.5-10.5 inches w.c. for Natural gas, and 9-13 inches w.c. for Propane (See Section 9.0 for details).

3. Using an appropriate Oxygen or Carbon Dioxide analyzer, take a sample of the flue gas. The sample must fall within the acceptable ranges for Carbon Dioxide, which is 8.8% - 9.8% for Natural gas, and 9.8%-10.8% for propane (See Section 9.0 for details).

4. Perform at least three lights in succession to ensure proper operation.

5. After the three successive lights, unplug the flame probe, and allow the unit to cycle again. Ensure that it tries to light, and locks out on safety reset. Once you have successfully activated the flame safety system, replace the wire on the flame sensor, and reconfirm proper lighting.

If the unit fails to light consistently and smoothly, contact Hubbell for technical assistance

at 1-800-647-3165. Never allow the water heater to operate if the ignition or operation of the burner is rough or erratic. Failure to follow these instructions may result in serious injury or death.

The flame probe uses a single electrode located in the burner door at the 6 O’clock positionDO NOT remove the wire from the dual electrode located in the burner door at the 3 O’clock position; this device is used for spark igniting and delivers a high voltage potential which would result in an EXTREME ELECTRICAL SHOCK possibly causing serious injury or death.

Re-lighting Unit

1. Stop and read these instructions very carefully.

2. Set the thermostat to the lowest setting, and then turn off all power to the water heater.

3. This water heater does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do not try to light the burner by hand.

4. Turn the gas shut-off valve to the off position, and then remove the front cover.

5. Wait five (5) minutes to clear out any gas. Then check for gas, including near the floor. If you smell gas “Stop” and follow “B” above. If you don’t detect any gas proceed to the next step.

6. Turn the gas shut-off valve to the on position, wait an addition five (5) minutes and check for gas.

7. Replace the front cover.

8. Set the thermostat to the highest setting, and then turn on all power to the water heater.

9. Ignition sequence is automatic, combustion will occur after a brief fan purge. Ignition will retry 3 times.

10. If ignition does not occur, “Turn off the gas and electricity to the water heater” and contact a professional service technician, or gas supplier.

Turning Off The Water heater

1. Set the thermostat to the lowest setting, and then turn off all power to the water heater.

2. Turn the gas shut-off valve to the off position.



Hubbell NX │Installation and Operation Instructions NX Series

9.0 GAS VALVE AND BURNER SET-UP

The Hubbell NX gas valve must be set-up by a licensed Gas Technician. Improper set-up may result in incorrect operation, damage to components or property, injury or death.

Gas Line Pressure

The water heater gas valve is equipped with a line pressure test port; see Figures 9-1 through 9-3. Use the following procedure to measure the gas line pressure to the water heater to ensure if falls within the range given in Table 9-1:

1. Turn the supply of gas to the water heater off.

2. Open the bleed screw of the line pressure test port approximately 1-1/2 turns (NX200-NX500 models).

This port is directly connected to the gas line feeding the water heater. For NX600-NX800 models, replace 1/8" NPT plug in the inlet flange of the gas valve with a hose barb fitting suitable for manometer tubing used. See Figures 9-1 through 9-4.

3. Force 1/4" ID tubing over the housing of the line pressure test port; install the other end of the tubing to an appropriate line pressure test gauge or manometer. Ensure both ends of the tubing make a tight connection.

4. Open the supply of gas to the water heater and check for gas leaks.

5. Observe the line pressure under static conditions and compare it to Table 9-1. The pressure will be greatest under static conditions.

6. With all other gas appliances in the applications running, operate the burner to the maximum firing rate (see Table 9-2) and compare the observed line pressure with Table 9-1. The pressure will be lowest during the maximum flow of gas.

7. Adjust the gas line pressure to ensure the parameters in Table 9-1 are attained under all conditions. If possible adjust the line pressure to the “Nominal/Desired” value listed in Table 9-1, while the unit is

operating at the

maximum modulation rate, see Table 9-2.

8. Continue observing the gas line pressure until the completion of the combustion analyses, incase adjustments need to be made.

9. Upon completion of the line pressure testing, return the bleed screw of the Line Pressure Test Port to the closed position. For the NX600-800 models, replace the installed hose barb fitting with the factory 1/8" NPT plug; use NG/LP approved thread sealant.

The line pressure is a function of the gas supply and is affected solely by field provided param eters such as line size and regulator settings. Under no circumstances can the water heater gas valve influence or be used to adjust the gas line pressure.

Failure to close the bleed screw of the Line Pressure Test Port will cause a severe leakage of gas, resulting in a fire or explosion causing property damage, serious injury or death.

Table 9-1 Line Pressure and Combustion Parameters

Gas

 

Natural

Propane

Notes:

It is permissible to have higher CO values with the burner operating at the minimum modulation rate.

The minimum permissible line pressure when operating with Natural Gas is 5.5 inches wc for model NX500.

Table 9-2 Minimum and Maximum Modulation Rates

Modulation Rates (rpm)

Minimum

Maximum

NX200

925

5950

Line Pressure (inches wc)



NX300

1250

5850

Min.

NX400

1550

7250

 

Max.

10.5

NX500

NX600

1400

6400

1050

4350

CO (%)

Min. Max.

8.8

9.8



NX700

1250

4300



Carbon Monoxide - Never leave the water heater operating if emitting Carbon Monoxide (CO) concentrations in excess of 175ppm. Failure to comply may result in injury of death.

Manifold Pressure - DO NOT adjust or measure the Manifold Pressure of the water heater.

9.8

10.8

NX800

1250

5300

CO (ppm)

Max.

175



Correct manifold pressure is factory set. Field adjustment could result in improper burner

Installation and Operation Instructions │Hubbell NXNX Series

operation resulting in fire, explosion, property damage or death.



Hubbell NX

NX300 Assembly Orientation

Rotated Clockwise 90

Manifold Pressure Test Port

NX200

Orientation Illustrated

Gas Valve

Line Pressure Test Port

│Installation and Operation Instructions NX Series

NX200 Orientation Illustrated

Gas In

Venturi

Air-inlet

Throttle/Input Adjustment Screw

Orifice Location (See Kit HUB-82650-1)

Figure 9-2 Gas Valve and Venturi Assembly (NX400)

Orifice Location

(See Kit HUB-83017-1)

Manifold Pressure Test Port

Venturi

Throttle/Input Adjustment Screw

Line Pressure

Test Port

Gas In

Gas Valve

Air Inlet



Air

Figure 9-3 Gas Valve and Venturi Assembly (NX500)

-inlet



Hubbell NX

Adjustment

Input Screw Adjustments -

│Installation and Operation Instructions NX Series

The water heater is equipped with a Throttle/Input Adjustment Screw, located on the Gas Valve and Venturi Assembly. The Throttle screw is used to adjust the flow of gas leaving the gas valve, entering the Venturi and hence entering the combustion air stream. By turning the adjustment screw in, clockwise, the flow of gas is reduced and the combustion becomes leaner, thus reducing the concentration of CO in the flue gases. To increase the CO the Throttle screw must be adjusted out, counterclockwise, thus increasing

the flow of gas from the gas valve to the combustion air stream. See Figure 9-5 for screw direction.

NX200 & NX300 Adjustments -

The throttle screw for models NX200 & NX300 is a multiple turn valve. Typical adjustment required for Natural Gas is 0-1 full turns in or out from the factory setting. Typical adjustment for LP Gas is 0-3 full turns in or out from the factory setting upon inserting the LP orifice as per the applicable Propane conversion instructions. See Figure 9-1 for throttle screw location.

NX400 Adjustments -

The throttle screw for the NX400 is a geared valve with a 4:1 ratio. Adjusting the throttle screw 4 complete turns will return the valve to the original location, 2 turns from fully open will completely close the valve. Typical adjustment required is 0-1/4 turn in or out from the factory setting. See Figure 92 for throttle screw location.

NX500 Adjustments –

The throttle screw for the NX500 is a multiple turn valve. Typical adjustment required for Natural Gas is 0-1 full turns in or out from the factory setting. To adjust combustion for Propane Gas, turn the throttle screw all the way in (clockwise until it stops), then turn the throttle screw out (counterclockwise) 4-1/2 turns and set with a combustion analyzer. See Figure 9-3 for throttle screw location.

NX600-NX800 Adjustments -

Remove the cap and adjust the input screw by turning it clockwise to decrease gas flow and counter-clockwise to increase gas flow. Typical adjustment required is 0-1/8 turns in or out. See Figure 9-4 for throttle screw location.

Figure 9-5 Throttle/Input Adjustment Screw (All Models)

Decrease Gas -

Turn Clockwise

Increase Gas -

Turn Counter Clockwise

Adjustments to the Throttle screw may only be made by a qualified gas technician, while us ing a calibrated combustion analyzer capable of measuring CO

these instructions may result in serious injury or death.

Adjustments to the Throttle screw may only be performed if the gas line pressure is maintained

above minimum levels throughout the duration of the test; see Table 9-1. these instructions may result in serious injury or death.

Combustion Calibration

combustion analyzer capable of measuring CO and CO from Natural and Propane Gas burning appliances:

- To calibrate burner operation, perform the following procedure using a calibrated

1. Operate the unit at the maximum modulation rate, see Table 9-2.

2. Ensure the gas line pressure is maintained within tolerance, see Table 9-1.

3. While at the maximum modulation rate, measure the CO and CO; adjust as necessary, using the Throttle Screw,

to be within the limits listed in Table 9-1.

4. Operate the unit at the minimum modulation rate (Table 9-2). Ensure the combustion remains smooth and CO and CO remain within the limits (Table 9-1). If not, do not adjust further, contact Hubbell for assistance.

and CO. Failure to follow

Failure to follow



Flue Gas Analysis and Adjustment

Each Hubbell NX is factory set to operate with Natural Gas, for water heaters field converted to operate with Propane Gas, a flue gas analysis and adjustment is mandatory. See Table 7-1 and propane conversion instructions.

Models NX200-NX400 require the installation of an LP orifice prior to operating with Propane Gas, see Propane conversion instructions for more details. To convert the NX500 to operate with Propane Gas requires field calibration of the throttle/input screw; see “NX500 Adjust ments” in Section 9.0 and Propane conversion instructions. Models NX 600-NX800 only oper ate with Natural Gas; conversion to Propane is not an option. Failure to follow these instruc tions will result in property damage, personal injury or death.

Failure to perform the flue gas analysis and adjustment detailed in this section may result in erratic and unreliable burner operation, leading to reduced efficiency, increased fuel consumption, reduced component life, heat exchanger combustion deposits, and general unsafe operation. Failure to follow these instructions may result in serious injury or death.

Analysis

- Hubbell NX flue gas test ports are located in the flue outlet adapter assembly. Test port access is either from inside the water heater cabinet (NX200 Figure 9-6) or from outside the water heater cabinet (NX300NX800 Figures 9-7 and 9-8). Remove the test port plug, perform flue gas analysis, and adjust throttle/input screw as required until CO and CO levels are within acceptable limits, see Table 9-1 Line Pressure and Combus-

tion Parameters

Once flue gas sampling is completed, re-install test port plug. For model with a threaded plug,

seal threads with Teflon tape before reinstalling plug.

Failure to re-install the test port plug will result in damage to the unit, property damage, fire, explosion, serious injury or death.



Hubbell NX

│Installation and Operation Instructions NX Series

Combustion

Figure 9-7 Flue Gas Sampling Using Test Port (NX300 & NX400)

Combustion



jury or

FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis. Re-install plug once sampling is completed to prevent flue gas leakage during appliance operation.

Failure to comply with these instructions

will result in serious in

death.

Combustion

port



Hubbell NX │Installation and Operation Instructions NX Series

10.1 WATER HEATER PIPING

The heat exchanger of the Hubbell water heater is designed to attain the highest level of heat transfer in a compact design. To accomplish this, the heating water flows through a series of fin shaped tubes, designed to maximize the heat transfer area. To maintain the efficient and reliable operation of the heat exchanger, and to avoid heat exchanger failure, it is critical to ensure the rules and guidelines in this section are followed.

Failure to follow the instructions provided in this section will void the Hubbell warranty and may result in property damage, fire, serious injury or death.

Water Heater System Preparation Prior to connecting plumbing to the water heater, flush the entire system to ensure it is free of sediment, flux, solder,

scale, debris or other impurities that may be harmful to the system and water heater. During the assembly of the piping system, it is important to keep the inside of the piping free of any debris including construction and copper dust, sand and dirt. Toxic chemicals, such as used for water heater treatment, shall not be introduced into the potable water system.

Water Chemistry – The installer of the Hubbell NX water heater must consider the condition of the

potable water. Ensure the water condition falls within the following recommended parameters to avoid scale build-up and aggressive PH levels that can result in corrosive reactions and damage to the heat exchanger and system components:

 Conductivity – TDS 80 to 200 ppm or Total Hardness 5 to 12 grains/gal.

Water heater water that falls outside of the parameters listed above must only be conditioned or treated with products approved for potable hot water systems. Toxic chemicals, such as used for water heater treatment must not be introduced

into the potable water system.

Potable Water Systems

This water heater is suitable for water (potable) heating. The water heater can be configured for “water (potable) heating only” and is subject to the following requirements:

1) Piping and components connected to the water heater for use with water (potable) heating applications shall be suitable for use with potable water.

2) Toxic chemicals, such as used for water heater treatment, shall not be introduced into the potable water system.

3) This water heater which will be used to supply potable water shall not be connected to any heating system or component(s) previously used with a non-potable water heating appliance.

Definition of Potable Water Systems

Each potable water system described below is meant to be used with a storage tank (refer to Table 10-1):

 Water (Potable) Heating Only - refers to an open potable water system dedicated to providing domestic

hot water and is not intended for space heating.

 Storage Tank (Vessel) - refers to a tank used to store hot water that is heated indirectly by a water heater external

to the tank or a container provided for storage of hot water under pressure.



Safe Temperatures for Potable Water

Two factors used to determine safe hot water temperatures are Legionella and scalding. Potable water needs to be stored at temperatures hot enough to limit the growth of Legionella, yet be cool enough to prevent scalding. Since both hazards present a potential risk to the user, they must be monitored and controlled. Table 10-1 indicates how water temperature affects Legionella bacteria and contributes to scald injury. Use of a thermostatic mixing valve in the water heater plumbing system can help protect against both of these hazards. By storing potable water at higher temperatures, bacteria growth is controlled, while still providing high temperature water for dishwasher applications and low temperature water for bathing. Before proceeding, read the following carefully and take all necessary pre-cautions to avoid potential illness and/or injury that can result from Legionella or scalding hazards.

Legionella Hazard - This bacteria is naturally occurring in surface water and ponds. It can

also be found in man-made water systems around the world such as water storage tanks, water distribution systems, fountains, hot tubs, humidification systems, refrigeration systems and grocery produce misters. Health authorities agree that Legionella bacteria most often enter the lungs due to aspiration when contaminated water spray is breathed in as opposed to ingesting drinking water contaminated with the bacteria. Typical illnesses attributed to Legionella include fl like symptoms (Pontiac Fever) and a potentially fatal type of pneumonia (Legionnaires’ disease). Failure to follow instructions may result in illness or death.

Contributing Factors to Legionella - Experts acknowledge that Legionella is an identified risk in most water systems. Although eradicating Legionella is improbable, pre-cautions can be taken to control and monitor conditions that promote bacteria growth. According to the World Health Organization (WHO); American Society of Heating, Refrigeration, and Air-conditioning Engineers (ASHRAE); Canada Safety Council

(CSC); and Centers for Disease Control (CDC), contributing factors to the growth of Legionella in potable water systems include:

 Minerals and nutrients present in the source water and systems materials  Stagnation or low flow characteristic of dead ends in distribution piping systems and storage tanks  Scale, corrosion, and bio film  Tepid water in cold water lines  Water storage temperatures optimal for bacteria growth  Chlorine concentration

Scald Hazard - Hotter water increases the risk of scald injury. There is a hot water scald potential if the storage tank thermostat is set too high. Before changing the temperature setting on the tank thermostat, refer to the thermostat manufacturers recommended settings. Failure to follow these instructions may result in serious injury or death.

A scald injury can occur when hot steam or liquid makes contact with one or more layers of skin. Scald severity (degree of burn) is directly impacted by exposure time and temperature. Refer to Table 10-1. The following basic precautions are common sense:

 Young children and elderly adults burn more quickly and should use cooler water.  Never leave a child alone while drawing water in a bathtub.  Test the water temperature before bathing or showering.  Turn cold water on first, then add hot water until the temperature is comfortable.



Hubbell NX │Installation and Operation Instructions NX Series

Thermostatic Mixing Valve - When the system requires water at temperatures higher than

required for other uses, such as high temperature applications typically greater than 115oF, a

means such as a thermostatic mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential. Anit-scald devices such as a thermostaic mixing valve allows potable water to be stored at a higher temperature to limit bacteria growth, and allows water at the tap to be delivered at a lower temperature to prevent scalds. Failure to follow these instructions may result in serious injury or death.

Water stored at temperatures between 68-113ºF is ideal for bacteria growth (see Table 10-1);

therefore consuming water from a Water Heater is not recommended. Consuming water from a

Water Heater may cause illness or death.

Legislation and Guidelines - At the time this document was written, standards and guidelines regulating the prevention of Legionella in the United States and Canada were mostly voluntary. The American Society of Heating, Refrigerating and Air-Conditioning Engineers,

Inc. (ASHRAE) is currently in the process of converting its guideline entitled “Minimizing the Risk of Legionellosis Associated with Building Water Systems” (ASHRAE Guide line 12-2000) into an official standard. Consult with your local authorities as to

recommended guidelines for controlling Legionella in potable water systems.

General Guidelines - In the absence of a National standard or local codes, the following are general guidelines

for “good practice” on maintaining, monitoring and operating your potable water system:

 Store hot water at temperatures > 140oF for “water (potable) heating only” applications.  Store hot water at temperatures > 176oF for “combined space heating” applications.  Store and distribute cold water at temperatures below 68oF.  System supply for uses other than high temperature applications typically greater than 115oF shall be equipped

with a thermostatic mixing valve on the hot water outlet to reduce potential scald hazards.

 Clean aerators and nozzles on water fixtures on a regular basis to reduce scale build-up.  Clean storage tanks and remove sediment. Flush storage tanks and piping systems regularly for 10-30

minutes at high water temperatures (depending on guidelines used) to rid the system of sediment and scale that develops, typically in the bottom of storage tanks where water temperature is coolest and piping runs where water can stagnate.

 Abandoned water lines should be capped off at the distribution main, not at the most convenient place.  Avoid dead-ends in piping system. If unavoidable, provide a drainage port in these areas at the lowest point to flush

out stagnant water regularity.

 Insulate DHW recirculation lines and keep pipe runs as short as possible.  Recommend annual water testing of water in your tank and piping system(s) to monitor water conditions.

 Keep a maintenance record of when your water heater and storage tank were cleaned, piping systems

flushed and who did the service work.

Water Temperature

158-176oF

140-149oF

122-131oF

68-113oF

below 68oF

Notes:

Published by Chartered Institute of Plumbing and Heating Engineering, Databyte series,“Safe Hot Water Temperatures”.

The elderly and small children are susceptible to bad burns at shorter exposure times than listed in this table.

A thermostatic mixing valve should be installed on DHW storage tanks when outlet temperatures exceed 115oF.

Typical water temperature for bathing or showering range between 98-113oF.

Temperature-Time-Burn Chart published by John Hopkins University, excluding notes.

Legionella Bacteria

Disinfection range

Bacteria die within minutes

Bacteria die within hours

Bacteria thrive and multiply

Bacteria is dormant

Water Temperature

Table 10-1 How Water Temperature relates to Legionella and Scald Hazard

158oF

140oF

131oF

122oF

111oF

Exposure Time vs Burn

1 second - 2ndor 3rddegree burn

5 seconds - 2ndor 3rddegree burn

5 seconds - 1stdegree burn

1 minute - 1stdegree burn

5 hours - 1stdegree burn

3,4



NX Series Installation and Operation Instructions │Hubbell NX

Near Water Heater Plumbing Pressure Relief Valve - A Pressure Relief Valve is factory supplied with each unit and must be field installed at the

water heater outlet in the vertical position, as shown in Figures 10-1(a) and (b), with the drain pipe outlet exiting the side of the pressure relief valve horizontally and elbowing down. NX200-NX400 models come with a 125 psi relief valve, while NX500-NX800 models come with a 150 psi relief valve. The maximum allowable working pressure (MAWP) varies with water heater model, see Table 10-2; alternate relief valves may be used, so long as they are ASME certified and meet the requirements for the respective water heater.

If installed with the incorrect orientation (horizontally with drain pipe out the bottom) the relief valve may not function properly resulting in property damage or personal injury.

Ensure the discharge of the pressure relief is piped to a location where the steam or water will not cause property damage or serious injury.

Pressure Gauge – Hubbell NX units come with a factory supplied Pressure Gauge. The pressure gauge must be in-

stalled at the water heater outlet, prior to any circulators, and in the vicinity of the pressure relief valve. See Figures 10-1(a) and (b).

Table 10-2 Pressure Relief Valve Specification

Water heater Model

NX200

NX300

NX400

NX500

NX600

NX700

NX800

Maximum Pressure Relief Valve Setting

/ Water heater MAWP (psi)

145

160

145

160



160



Minimum Pressure Relief

Valve Capacity (MBH)

200

300

400

500

600

700

800



Hubbell NX

Safety Flow Switch

Pressure Gauge

│Installation and Operation Instructions NX Series

Figure 10-1(a) Near Water Heater Piping(NX200-NX400)

Trim-able paddle

Near Water Heater tees and fittings

Pressure Relief Valve discharge

to floor drain

Inlet

Outlet

Pressure Relief Valve

Figure 10-1(b) Near Water heater Piping (NX500-NX800)

Inlet

Outlet



Installation and Operation Instructions │Hubbell NXNX Series

Safety Flow Switch - A safety flow switch is required by code to ensure a sufficient rate of water supply is

available for proper operation of the water heater. Hubbell models NX500-NX800 come factory equipped with a safety flow switch installed; for models NX200-NX400, a safety flow switch must be field supplied and installed. Locate the flow switch in series with the water heater and in accordance with the instructions provided with the safety flow switch. Hubbell recommends a safety flow switch with an activation point no lower than the flow rate specified in Table 10-3.

Table 10-3 Flow Switch Installation Requirements

Model

NX200

NX300

NX400

Activation Point

(no lower than)

6 gpm

9 gpm

12 gpm

Line Size for

Flow Switch

1-1/4"

IMPORTANT: After the flo switch, increase pipe diameter to the size specifie in Table 10-5. Refer to Section

12.0 for instructions on wiring the safety flo switch.

The Safety Flow Switch must be installed on the water heater outlet fitting (see Figure 10-1) in accordance with the instructions provided with the flow switch. Install the flow switch in a 1" diameter line for model NX200, and a 1-1/4" diameter line for models NX300 & NX400.

Models NX500-NX800 come equipped with a factory installed flow switch installed in a 2" diameter line. The flow switch is pre-plumbed with a Nema 4 rated enclosure and prewired via liquid-tight conduit.

The Safety Flow Switch must be wired as per the instructions provided in this manual. Refer to Section 12.0 for wiring instructions.

Water Heater System Plumbing The Hubbell water heater uses a low mass heat exchanger that requires a minimum rate of forced water circulation

any time the burner is operating (See Table 10-5 for minimum flow rates). To ensure the minimum flow rate is attained, the water heater must be installed with a safety flow switch (see Figure 10-2 for suggested plumbing diagram). A properly installed system will as a minimum include the major components in Table 10-4.

Table 10-4 System Major Component Checklist

Factory Supplied Components

□

Pressure Relief Valve

□

Pressure Gauge (160PSI)

□

Flow Switch (NX500-800 only) □



Notes:

Field Supplied Components

□

Bronze/Stainless Steel Water Heater Circulator (Pump B in Figure 10-2)

□

System Backflow Preventer (check if required by

DHW/Potable Water Expansion Tank (check if required by local codes)

□

DHW Storage Tank

□

Tank Temperature and Pressure Relief Valve

□

Tank Thermostat (aquastat)

□

Thermostatic (Anti-Scald) Mixing Valve

□

Safety Flow Switch

1 Refer to Table 10-2 for minimum Pressure Relief Valve specifications 2 Expansion Tank is mandatory if using a System Backflow preventer

local codes)



Hubbell NX │Installation and Operation Instructions NX Series

Water Heater Circulator - The NX water heater is equipped with three 120VAC pump outputs (Pump A, B and C).

Use only Pump Output B for the Water Heater Circulator. Note that bronze or stainless steel circulators are required for potable water systems. Ensure that circulators (pumps) are oriented as per the pump manufacturers’ instructions. See Section 12.0 for wiring details.

Circulators responsible for forcing the water flow rate through the water heater must be sized according to Table 10-5, see Figure 10-2 for details.

Failure to ensure the minimum water flow rate through the water heater when the burner is on will not only reduce the operating efficiency of the water heater, but may also cause premature failure, overheating and void the warranty. Failure to follow instructions may result in fire, property damage, serious injury or death.

Table 10-5 Minimum Water Heater Circulator and Pipe Sizes

Model

200 16' at 16 GPM

Restriction

Head Loss

300 16' at 24 GPM

400 20' at 32 GPM

500 25' at 40 GPM

600 23' at 48 GPM

700 19' at 56 GPM

800 25' at 64 GPM

Notes:

Pump models listed are for bronze or stainless steel circulators only; cast iron pumps are n ot permitted.

Maximum Current Load 1-1/2hp @ 120VAC or 3hp @ 240VAC.

Armstrong pumps E10.2B-E13.2B, and Taco pump 2400-40S are not recommended.

Armstrong pump E15.2B-E17.2B not recommended.

Armstrong pump E23.2B-E33.2B not recommended.

Armstrong pumps E22.2B and E24.2B also recommended.

Min. Pipe Size

1-1/4"

1-1/2"

2-1/2"

Min.

Flow (GPM)

Max. Temp. Rise

Maximum

Current Load

B&G

Grundfos

23F 5 A or 2/5 hp PL-36B UP 26-99 BF

23F 5 A or 2/5 hp PL-36B

UPS 26-150

23F 5 A or 2/5 hp PL-55B UPS 26-150

23F

See Note

PDB-37

PDB-37 TP 32-160

PDB-38 TP 40-160

TP 32-160

Minimum Pump Size

Armstrong T

E8.2B 0013-

E14.2B / E9.2B

E24.2B

E22.2B

E33.2B



MSSF



2400

-30S

2400-50S

1935B

System Backflo Preventer - Check if a backflow preventer is required by local codes. This manufacturer and most

plumbing codes require a thermal expansion control device be installed if a backflow preventer, pressure

reducing valve or check valve is installed on a domestic supply line. Installing an expansiontank approvedfor

usewith potablewateris mandatory in applications using a System Backflow Preventer device.



DHW/Potable Water Expansion Tank - Check if an expansion tank is required by local codes. If required, the

expansion tank must be suitable for use with potable water and be sized in accordance with the water volume of the system as well as the firing rate of the appliance. The expansion tank must be installed downstream of any backflow prevention device used to control system thermal expansion. See example in Figure 10-2.

Ensure the expansion tank cannot become isolated from the water heater anytime the system is operating. Failure to follow these instructions may result in discharge of the Pressure Relief Valve, resulting in property damage or personal injury.

The DHW storage tank should be located in an area where leakage or connections will not

result in damage to the area adjacent to the appliance 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 appliance. This manufacturer is not responsible for any water damage that may occur in connection with the storage tank

or any of its components.



Installation and Operation Instructions │Hubbell NXNX Series

Tank Temperature and Pressure Relief Valve - The storage tank will require a temperature and pressure relief

valve sized to ASME specifications and that complies with the Standard for Relief Valves for Hot Water

Supply Systems, ANSI Z21.22•CSA 4.4. The relief valve is to be installed on the storage tank in accordance with Figure 10-2 and must be accessible for servicing or replacement. No valve is to be place between the T&P Relief

Valve and the storage tank. Check if local codes require storage tanks to have any additional valves.

Ensure the discharge of the temperature and pressure relief valve is piped to a drain or a location where steam or water will not cause property damage, serious injury or death.

Tank Thermostat (Aquastat) - The aquastat is intended to allow the water heater to monitor and control tank

temperature, improve response time, and prevent short cycles of operation. Check that the aquastat will mate with the tapping on the storage tank prior to commencing installation. Install the aquastat in the storage tank as per the manufactures’ instructions. Refer to Section 12.0 Field Wiring for details.

Tank Sensor – In lieu of a Tank Thermostat, the NX water heater control can monitor a tank sensor installed in the

storage tank. When a tank sensor is used, the tank temperature is set via the NX control; burner demands are generated directly by the NX controller based on controller settings.

Tank sensor MUST be used in conjunction with a DHW temperature safety shutoff switch. Hubbell recommends using P/N HUB-84632 (Tank Sensor w/integrated safety switch). Failure to provide such a switch may result in property damage, serious injury to occupants, or possibly death.

Thermostatic (AntiScald) Mixing Valve - An anti-scald mixing valve is recommended when storing domestic hot

water above 115°F and should be used on branches supplying low temperature water to endpoint plumbing fixtures. A mixing valve is optional on high temperature water applications, including but not limited to process water, clothes washers, dishwashers or sanitizers, depending on the temperature desired at the appliance and water storage temperature.

When the system requires water at temperatures higher than required for other uses, a

means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential. Failure to follow these instructions may result in serious injury or death.

Figure 10-2: Stand Alone Water Heater Applications - This piping diagram demonstrates an application with both

low temperature requirements, such as bathing, and high temperature requirements, such as commercial process water heating or laundry. When the system requires water at temperatures higher than required for other uses, a thermostatic (anti-scald) mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential, see Table 10-1. An optional DHW Recirculation Return may be used on long plumbing runs to prevent wait times for hot water on both low and high temperature water applications. Refer to Section 12.0 for field wiring instructions.

The Water Heater Circulator (Pump B) must be sized according to Table 10-5 to provide

adequate circulation through the water heater.

Figure 10-2 illustrates a typical piping system. The Water Heater Plumbing Schematic does

not illustrate all of the required concepts and components required to have a proper installation. Concepts not shown include: prevention of thermal-siphoning (i.e. heat traps), isolation valves, drain and purge valves, etc. It is the responsibility of the installing contractor and system designer to consider all aspects of a proper system design including compliance with local codes. Contractor modifications to these instructions may be required, based upon existing piping and system design.

Energy Efficiency - Although the Hubbell NX Water Heater is an energy efficient appliance, insulating long pipe

runs can improve the overall system efficiency by conserving energy and reducing standby losses.



Hubbell NX

│Installation and Operation Instructions NX Series

Figure 10-2 All Models

Stand Alone Water Heater Plumbing Configuration

Storage Tank



11.0 LEAD LAG INSTRUCTIONS

Installation and Operation Instructions │Hubbell NXNX Series

Multiple Water Heater Applications The NX controller has the internal capacity to stage or Lead-Lag up to 8 water heaters configured in a cascade. This

Lead-Lag capability allows a designated “Master” water heater to communicate with and effectively control each water heater in a multiple water heater system. This function is accomplished by “Daisy Chaining” a 3-wire cable between each of the water heaters and enabling the Master parameter in the water heater of your choice. The water heater with the Master parameter enabled becomes the single point of contact for settings and control wiring. Use the

instructions detailed in this section to set-up and install the cascade water heater system; reference Appendix A – Con- troller and Touchscreen Display Instructions for details on more advanced settings and for assistance with navigating

the touchscreen display.

Lead Lag Instructions Plumbing – install as many as 8 NX water heaters in a parallel plumbing configuration as illustrated in Figure 11-

1. Size common piping as per Table 11-1.

Water Heater Pump – each water heater must have its own circulator (see Figure 11-1) which is controlled by its

PUMP B output; see Field Wiring Figures and Tables 12-1(a) and 12-1(b). The water heater pump must be sized

according to Table 10-5.

Communication Wiring – using 3-wire cable, daisy-chain terminals LL DATA +, LL DATA – and SENSOR COM

of each water heater in parallel; see Field Wiring Tables 12-2(a) and 12-2(b) and Figure 12-2.

System Sensor – NOT USED. The master water heater sensor input should be set to Unconfigured as follows:

Configure – Sensor Configuration – S10 (J10-7) sensor [S5 (J8-11) sensor for NX500-NX800 models] – UNCON-

FIGURED

Modbus Address – assign a unique MB2 Modbus Address to each water heater in the cascade. Access the MB2

Modbus Address setting via the System Identification & Access menu as follows:

Configure – System Identification & Access – MB2 Modbus Address

Master Enable – choose one (and only one) water heater in the cascade to be the Master, this water heater will receive

all control wiring and will be used for setting control parameters (see steps below). On this one water heater, set

Master enable equal to Enabled via the Lead Lag Master Configuration menu, accessed as follows:

Configure – Lead Lag Master Configuration – Master enable

Tank Thermostat – connect to SENSOR COM and DHW of the Master water heater; see Field Wiring Tables 12-2(a)

and 12-2(b) and Figure 12-2. Switch must be an isolated end switch (dry contact).

DHW Setpoint – at the Master water heater only, set the DHW setpoint via the Lead Lag Master Configuration

menu, accessed as follows:

Configure – Lead Lag Master Configuration – DHW setpoint

DHW switch (Lead Lag) – at the Master water heater only, set DHW switch equal to DHW (S 6) sensor shorted

via the Lead Lag Master Configuration menu, accessed as follows:

Configure – Lead Lag Master Configuration – Advanced Settings – Domestic Hot Water – DHW switch

DHW enable (Local) – at the Master water heater only, set DHW enab le equal to Disabled via the Domestic Hot

Water Configuration menu, accessed as follows:

Configure – Domestic Hot Water Configuration – DHW enable



Hubbell NX │Installation and Operation Instructions NX Series

Tank Sensor – when operating in a cascade system, the water heater controls do not sup-

Table 11-1 Minimum Pipe Sizes for Multiple Water Heater Applications

# of

Units

NX200

2-1/2"

port the use of a tank sensor; a tank thermostat (switch) must be used.

NX300

NX400

2-1/2"

NX500

NX600

5”

All Water Heater piping in Multiple Water Heater Applications must be sized based on Table 11-1 in accordance with the number of units the piping supports.

All water heater circulators (Pump B) must be sized according to Table 10-5.

NX700

NX800



Hubbell NX │Installation and Operation Instructions NX Series

Multiple Water Heater Lead-Lag Plumbing Configuration

Figure 11-1 All Models

Storage

ank T

Hubbell



Hubbell NX │Installation and Operation Instructions NX Series

12.0 FIELD WIRING

The water heater must be electrically grounded in accordance with the National Electrical Code ANSI/NFPA 70, local codes, and/or the Canadian Electrical Code CSA C22.1.

Avoid Shocks - To Avoid Electrical Shock, turn off electrical power to the water heater prior opening any electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions may result in com

ponent failure, serious injury or death.

Field Wiring - Wire grommets must be used to secure wiring and prevent chafing when passing wiring through the cabinet wall. Failure to follow instructions may damage unit.

Line Voltage Connections Electrical rating for the Hubbell NX is 120V / 1 Phase / 60 Hz / 12A. The Hubbell NX line voltage junction box

is located in the lower right corner of the water heater cabinet on NX200 models and can be accessed by removing the front door of the water heater, followed by the removal of the line voltage junction box cover. On NX300 & NX400 models, the line voltage junction box is located at the top of the water heater cabinet on the right hand side and can be accessed by removing the top front cover of the water heater. On NX500-NX800 models, the line voltage junction box is located at the back of the water heater cabinet on the power switch side. Remove the top back cover of the water heater to access the three holes / knockouts needed for routing field wiring into the line voltage junction box. Line voltage field connections are to be installed in accordance with Figures and Tables 12-1(a) and 12-1(b).

Fuses (120VAC) – The Hubbell NX is equipped with either one or two 7 Amp fuses to protect 120VAC system

components. The fast-acting fuses are located on the front of the control panel box and can be easily accessed from the outside of the control panel.

NX200-NX400 Control Panel:

 Fuse A: Protects the blower, spark generator and PUMP B output circuits.  Fuse B: Protects PUMP A and PUMP C output circuits.

NX500-NX800 Control Panel:

 Fuse A: Protects the 120VAC circuits within the water heater.

Pump Relays (NX500-NX800) – In lieu of the 120VAC pump outputs, the NX500-NX800 incorporates

three non-powered isolation relay contacts for switching high capacity pumps. Contact Secondary Maximum rating is 1.5HP @ 120V, 3.0HP @ 240V, or 30A. Refer to Figure 12-2(b) for Field Wiring requirements.

Wire Protection - When passing any wiring through the cabinet of the water heater, the installer must use wire grommets suitable for securing the wiring and preventing chafing. Failure to follow instructions may result in component failure, serious injury or death.

Power Supply - The Hubbell NX is designed to be powered using a single phase 120VAC power supply that is fused (or protected via a circuit breaker) to allow a maximum of 15 Amps. Failure to follow instructions may result in component failure, serious injury or death.

Labeling - Label all wires prior to disconnecting them when servicing controls. Wiring errors

can cause improper and dangerous operation. Failure to follow instructions may result in

property damage or personal injury.

Continuity - Before connecting the line voltage wiring, perform a continuity check be-

tween all wires and ground to make sure that there are no electrical leaks that could blow a fuse or damage electrical components. Also check the polarity of the line and neutral wires. Line must measure 120VAC to ground; neutral must measure zero. Failure to follow instructions may damage the unit.

Max Load – NX200-NX400 circulator outputs are each limited to operating a circulator

with a maximum current load of 5 Amps or a maximum 2/5 hp motor. See Table 12-1.



NX Series

Table 12-1 Line Voltage Field Connections

Connection Location

(120VAC)

120VAC Hot

codes require the installatio n of a service switch to b reak line voltage to the appliance.

Installation and Operation Instructions │

120VAC SUPPLY

Line Neutral Gnd

- Location for connecting line voltage of the power supply. Note most installation

Description

Hubbell NX

PUMP B

Black

White Green



PUMP A

PUMP B

PUMP C

(Neutral)

Ground

No Conn.



Not used.

DHW Demand

Not used.

120VAC Common

120VAC Ground

- Output to the Water Heater Circulator, powered during tank demand.

- Location for connecting neutral of the power supply and circulator.

- Location for connecting ground of the power supply and circulator.



Factory Wiring

from this location.

- This terminal is used only for factory wiring. Do not add or remove wires



Hubbell NX

│Installation and Operation Instructions NX Series



L1 (120VAC)

L2 (Neutral Ground)



PUMP A

PUMP B

PUMP C

Location

120VAC Hot

installation codes require the installation of a service switch to break line voltage to the appliance.

120VAC Common

120VAC Ground

Not used.

DHW Demand

demands.

Not used.

- Location for connecting line voltage of the power supply. Note most

- Location for connecting neutral of the power supply and circulator.

- Location for connecting ground of the power supply and circulator.

- Dry Contact for Water Heater circulator; Coil B powered during tank

Description



Installation and Operation Instructions │Hubbell NXNX Series

Low Voltage Connections

The Hubbell NX low voltage junction box is located in the lower left corner of the water heater cabinet on NX200 models and can be accessed by removing the front door of the water heater, followed by the removal of the low voltage junction box cover. On NX300 & NX400 models, the low voltage junction box is located at the top of the water heater cabinet on the left hand side and can be accessed by removing the top front cover of the water heater. On NX500-NX800 models, the low voltage junction box is located at the back of the water heater cabinet and can be accessed by removing the top back cover of the water heater. Each water heater is provided with one hole and two knockouts for routing field wiring into the low voltage junction box. Low voltage field connections identified in Tables 12-2(a) and 12-2(b) are to be read in conjunction with Figure 12-2.

Table 12-2(a) Low Voltage Field Connections (NX200-NX400)

Connection

Location

Description

COM (24VAC)

R (24VAC)

LIM

CH1 *

CH2 (LL) *



DHW

OD SENSOR *

SYSTEM *

SENSOR COM

4 -20mA



LL DATA+

LL DATA-

BMS D+

BMS D-

24VAC Common

24VAC Hot

External Limit

operate. Comes factory equipped with a jum per to the R terminal. Remove the factory

installed jumper and install the normally open isolated contacts of the field supplied Safety Flow Switch.

NOT USED.

DHW Tank Demand

for DHW. Switch made via isolated end switch (dry contact) from the storage tank thermostat (Aquastat). Or optional Tank Sensor (P/N 84632), see Appendix A.

NOTICE:

not support the use of a tank sensor: a tank thermostat (switch) must be used.

NOT USED.

System Common

External Modulation Control

directly modulate the burner firing rate or adjust the active set point. This can be useful for applications using external staging controls or Building Automation Systems.

Lead-Lag

Terminals 13, 14 and 10 (common) can be “daisy-chained” to multiple water heaters (up to 8 in total) for the purpose of staging.

Building Management System (BMS)

Modbus communication port. Terminals 15, 16 and 10 (common) can be connected to a Gateway for communication to a BMS or other device.

– Neutral for the 24VAC power supply within the water heater.

- Power supply for inputs LIM, CH1, and CH2 (LL).

– Input requiring 24VAC from terminal R to permit the burner to

– Input requiring closure of terminals 7 and 10 to initiate a demand

Tank Sensor – when operating in a casc ade system, the water heater controls do

– Common port for field inputs DHW, OD Sensor and System Sensor.

– Using a 4-20m Asignal, an external control can be used to

– Connects internally to the controller’s MB2 Modbus communication port.

– Connects internally to the display’s COM2,



ALARM

Normally Open Alarm Contacts

condition. May be connected to a BMS, maximum capacity of 0.63Amps at 24VAC.

– Contacts close during a lockout or other alarm



Hubbell NX │Installation and Operation Instructions NX Series

Table 12-2(b) Low Voltage Field Connections (NX500-NX800)

Connection Location

COM (24VAC)

R1/R2 (24VAC)

EXT. LIM

24VAC Common

24VAC Hot

External Limit

– Neutral for the 24VAC power supply within the water heater.

- Power supply for inputs EXT. LIM

– Input requiring 24VAC from terminals R1/R2 to permit the burner to

operate. Comes factory equipped with a jumper to the R2 terminal. For installations

requiring the use of an additional safety switch, such as a LWCO or auxiliary temperature limit, remove the factory installed jumper and install the normally open isolated contacts of the field supplied additional limit in place of jumper. Flow Switch factory installed and prewired in series with EXT LIMIT jumper.

GAS LO PR.

Gas Low Pressure Switch (Optional)

applications requiring a Low Gas Pressure Switch, remove jumper and connect normally open isolated contacts of the Gas Low Pressure Switch. Switch must be installed external to unit (24VAC circuit). For preapproved High Gas Pressure Switch, see Note 1 below.

AUX. PROOF

CH1 *

CH2 (LL) *



DHW

Auxiliary Proof

Combustion Air (NX500-800 only), remove jumper and replace with field supplied end switch incorporated with motorized damper/louver control.

NOT USED.

DHW Tank Demand

for DHW. Switch made via isolated end switch (dry contact) from the storage tank

– Comes factory equipped with a jumper. For applications using Indoor

– Input requiring closure of terminals 11 and 14 to initiate a demand

thermostat (Aquastat). Or optional Tank Sensor (P/N HUB-84632); see Appendix A.

OD / SYS SENSOR *

TOD

NOT USED.

Time of Day (Night Time Setback)

initiate TOD setback setting. Switch is made using an isolated end switch (dry contact) using a timer, BAS or other device.

SENSOR COM

System Common

– Common port for field inputs DHW

Description

– Comes factory equipped with a jumper. For

– Input requiring closure of terminals 13 and 14 to



20mA / +)

LL DATA+

External Modulation Control

directly modulate the burner firing rate or adjust the active set point.

Lead-Lag

– Connects internally to the controller’s MB2, Modbus communication port.

– Using a 4-20mA signal, an external control can be used to

Terminals 17, 18 and 14 (common) can be “daisy-chained” to multiple water heaters (up to

LL DATA-

BMS D+

BMS D-

ALARM (A & B)

Notes

8 in total) for the purpose of staging.

Building Management System (BMS)

Modbus communication port. Terminals 19, 20 and 14 (common) can be connected to a Gateway for communication to a BMS or other device.

Normally Open Alarm Contacts

condition. May be connected to a BMS, maximum capacity of 0.63Amps at 24VAC.

– Connects internally to the display’s COM2,

– Contacts close during a lockout or other alarm

1 For applications requiring a High Gas Pressure Switch, see supplemental instructions included with Hubbell High Gas Pressure Switch Kit, P/N HUB-84094. Note: this is the only High Gas Pressure Switch that has been tested with the unit and preapproved for field installation within the appliance cabinet.

Asterisk indicates connection not used or applicable for water heater applications.



NX Series Installation and Operation Instructions │

Low Voltage Terminals

transformer. Do not connect power from these terminals to any other terminal other than

terminal 4. Failure to follow these instructions may damage the unit.

Fuse (24VAC)

2 Amp fuse to protect the internal transformer located within the slide-out control panel box.

- Hubbell NX200-NX400 models are equipped with a “blade style”

- Terminals 2 and 3 (R) have 24VAC potential from the internal

Hubbell NX

Figure 12-2 Low Voltage Field Wiring (All Models)

NX200-NX400 Illustrated

DHW Demand

Switch/Sensor

Lead Lag Wiring for up to

8 NX Water Heaters

Flow

Switch

BMS/

Gateway



13.1 WIRING SCHEMATICS

Figure 13-1(a) Connection Diagram (NX200-NX400)



60



NX Series Installation and Operation Instructions I Hubbell NX



14.0 INSTALLATION CHECKLIST

Installation

□

1. If operating on Propane Gas, convert water heater using appropriate Kit number. See Table 7-1.

□

2. Locate the water heater in accordance with Section 3.0 of this manual.

□

3. Install the Vent/Air-inlet piping in accordance with Sections 4.0 and 5.0 of this manual. Ensure all joints are secured and cemented properly. Perform the Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0.

□

4. Connect the condensate drain in accordance with Section 6.0 of this manual.

□

5. Connect the gas supply in accordance with Section 7.0 of this manual.

□

6. Install the plumbing in accordance with the appropriate this Manual. Flush/cleanse the internals of the

piping system.

□

7. Connect field wiring in accordance with Section 12.0 of this manual.

□

8. Advise building owner of their responsibilities with respect to maintaining the water heater.

The building owner is responsible for keeping the Vent/Air-inlet termination free of snow, ice, or other potential blockages, and for scheduling routine maintenance on the water heater (see Section 15.0). Failure to properly maintain the water heater may result in serious injury or death.

Start-up

□

1. Turn gas shut-off valve to the ON position.

□

2. Turn Power on to water heater.

□

3. Set Controller to the desired settings.

□

4. Turn thermostat up, Ignition will occur.

Operational Checklist

□

1. System is free of gas leaks.

□

2. System is free of water leaks.

□

3. Water pressure is maintained above 15 PSI.

□

4. All air is purged from the system piping.

□

5. Ensure proper water flow rate; unit must not kettle, bang, hiss or flash the water to steam.

□

6. Ensure gas line pressure is in accordance with Section 9.0.

□

7. System is free of combustion leaks.

□

8. Unit must operate smoothly.

□

9. Ensure the flue gas combustion readings are within the tolerances listed in Table 9-1.

□

10. Each ignition must be smooth.

□

11. Verify that all condensate lines are clean and drain freely.

Before Leaving

□

1. Remove line pressure gauge from gas valve, tighten bleed screw, test screw for leaks. See Section 9.0.

□

2. Install plug into the flue gas test port and test for leaks, see Section 9.0.

□

3. Allow the water heater to complete at least one heating cycle, or to operate for at least 15 minutes.

□

4. Always verify proper operation after servicing.

Instructions to Installing Contractor

□

1. Ensure that the customer receives the Warranty Documentation included with the installation manual.

□

2. Leave the manual with the customer so they know when to call for annual maintenance and inspection.

This water heater must have water flowing through it whenever the burner is firing. Failure to comply may damage the unit, void the warranty, and cause serious injury or death.

Allowing the water heater to operate with a dirty combustion chamber will adversely affect its operation and void the warranty. Failure to clean the heat exchanger on a frequency that matches the need of the application may result in fire, property damage, or death.



NX Series Installation and Operation Instructions │Hubbell NX

15.0 ANNUAL MAINTENANCE AND INSPECTION

This unit must be inspected at the beginning of every heating season by a Qualified Technician.

Annual Inspection Checklist

□

1. Lighting is smooth and consistent, and the combustion fan is noise & vibration free.

□

2. The condensate freely flows from the unit, and is cleaned of sediment.

□

3. Relief Valve and air vents are not weeping.

□

4. Low water cut off is flushed (if applicable)

□

5. Examine all venting for evidence of leaks. Ensure vent screens are cleaned and clear of debris.

□

6. Check the burner plate for signs of leaking.

□

7. The combustion chamber must be inspected and cleaned.

□

8. Listen for water flow noises indicating a drop in water flow rate. The heat exchanger may need to be flushed to eliminate hard water scale

Combustion Chamber Cleaning Procedure Units operating with LP Gas or in an industrial environment will have to be cleaned a minimum of once per year.

Other applications will require the combustion chamber to be cleaned after the first year of operation, with subsequent cleanings scheduled based on the condition of the combustion chamber at the time. Unless a step is identified as model specific, the following combustion chamber cleaning procedure is the same for all models.

Crystalline Silica - Read carefully the warnings and handling instructions pertaining to Refractory Ceramic Fibers before commencing any service work in the combustion chamber. Take all necessary precautions and use recommended personal protective equipment as required.

Cleaning Checklist

□

1. Initiate a post-purge cycle to clear any gas from the combustion chamber, then turn gas valve off.

□

2. Danger Explosion Hazard (NX300-NX800): To disconnect the fuel-air metallic tubing between the blower and the high-vent pressure switch, loosen the compression fitting at the high-vent pressure switch with a 1/2" wrench. At the blower end, support the brass fitting body with a 1/2" wrench to keep it from rotating while loosening the compression fitting nut with a 9/16" wrench. Remove tubing assembly from blower.

□

3. Access the combustion chamber by removing the aluminum burner door assembly of the water heater.

□

4. Remove (or cover) the insulation disc located in the back of the combustion chamber to avoid damaging it during the cleaning process. The disc is held in place with a 3/32" “Allen-head” screw.

□

5. Use a vacuum with a high efficiency filter to remove any loose debris or dust.

□

6. Wet the inside of the combustion chamber with water. Use a garden hose with a trigger nozzle to direct

pressurized water through the gaps between the heat exchanger tubes. The water should pass in-between the heat exchanger tubes and exit via the condensate drain. This process may require the use of some dry rags or plastic to protect electrical components from being damaged by dripping or spraying water.

□

7. Use a nylon or other non-metallic brush to loosen the incrustations and any other contaminates that have remained stuck on and in-between the tubes.

□

8. Repeat steps 6 and 7 until the heat exchanger is clean and water from the condensate drain runs clear.

□

9. Re-install the insulation disc to the back of the combustion chamber (see Table 16-1, Item 31 for part #).

□

10. Inspect the insulation disc located on the back-side of the burner door. Replace if damaged (see Table 161, Item 33 for part # by applicable model).

□

11. Re-install the burner door, gas-supply and Air-inlet pipe, check for gas leaks.

□

12. NX300-NX800: Reconnect the fuel-air metallic tubing between the blower and the high-vent pressure switch. Ensure the brass fitting body at the blower remains stationary and does not rotate during reconnection.

□

13. Perform the Operational Check List detailed in Section 14.0.

Explosion Hazard (NX300-NX800) - The fuel-air metallic tubing connecting the blower and

the high-vent pressure switch contains a mixture of fuel and air. Refer to Combustion Chamber Cleaning Procedure for instructions on connecting and disconnecting the metallic

tubing. Failure to follow these instructions will result in serious injury or death.

Replace any gaskets or insulation discs that show any signs of damage and do not re-use. Failure to follow these instructions may result in fire, property damage or death.



Hubbell NX │Installation and Operation Instructions NX Series

Refractory Ceramic Fibers (RFC)

Personal Protective Equipment Recommended - Read the following warnings and

handling instructions carefully before commencing any service work in the combustion chamber. The insulating material on the inside of the burner door and at the back of the combustion

chamber contains Refractory Ceramic Fibers and should not be handled without person

al protective equipment.

Potential Carcinogen - Use of Refractory Ceramic Fibers in high temperature appli-

cations (above 1000oC) can result in the formation of Crystalline Silica (cristobalite), a respirable silica dust. Repeated airborne exposure to crystalline silica dust may result in chronic lung infections, acute respiratory illness, or death. Crystalline silica is listed as a (po tential) occupational carcinogen by the following regulatory organizations: International

Agency for Research on Cancer (IARC), Canadian Centre for Occupational Health and Safe

ty (CCOHS), Occupational Safety and Health Administration (OSHA), and National Institute for Occupational Safety and Health (NIOSH). Failure to comply with handling instructions in Table 15-1 may result in serious injury or death.

Crystalline Silica - Certain components confined in the combustion chamber may contain this poteal carcinogen. Improper installation, adjustment, alteration, service or maintenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to Table 15-1 for handling instruction and recommended personal protective equipment. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this water heater. This water heater contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

Table 15-1 Handling Instructions for Refractory Ceramic Fibers (RCF)

Reduce the Risk of Exposure

Avoid contact with skin and eyes

Avoid breathing in silica dust

Avoid transferring contamination

First Aid Measures

Notes:

Consult your local regulatory authority regarding current requirements for respirators, personal protective equipment, handling, and disposal of RCFs.

Respirator recommendations based on CCOHS and OSHA requirements at the time this document was written.

Precautions and Recommended Personal Protective Equipment

 Wear long-sleeved clothing, gloves, and safety goggles or glasses.

 Wear a respirator with a N95-rated filter efficiency or better. 1

airborne dust levels when cleaning the combustion chamber. Do not dry sweep s ilica dust. Pre-wet or use a vacuum with a high efficiency filter.

 When installing or removing RFCs, place the material in a sealable plastic bag.  Remove contaminated clothing after use. Store in sealable container until cleaned.  Wash contaminated clothing separately from other laundry.

If irritation persists after implementing first aid measures consult a physician.

 Skin  Eyes  Inhalation

- Wash with soap and water.

- Do not rub eyes; flush with water immediately. – Breathe in fresh air; drink water, sneeze or cough to clear irritated

passage ways.

For more information on Refractory Ceramic Fibers, the risks, recommended handling procedures and acceptable disposal practices contact the organization(s) listed below:

United States (OSHA): Telephone directory listing under Government Blue Pages Canada—Health and Safety—Canadian Centre for Occupational Health and Safety; or website http://www.ccohs.ca.

Canada (CCOHS): Telephone directory listing under United States Government—Department of Labor— Occupational Safety and Health website http://www.osha.gov.

Use water to reduce

Administration; or



NX Series

16.0 PARTS LIST

Installation and Operation Instructions │

Hubbell NX

For a list of parts that corresponds to the item numbers in the bubbles, refer to Table 16-1. Note that that some item numbers may appear more than once in the parts list depending on which model number is being referenced.

Building Owners

- Replacement parts are available from your local manufacturer's representative. Contact your local

installer or representative for assistance with parts.

Installers -

Contact your local representative or Hubbell Heaters Inc. directly if technical assistance is required, (203)

378-2659.



NX Series

Installation and Operation Instructions │

Hubbell NX



NX Series

Installation and Operation Instructions │

Hubbell NX

114

105

106

View

Reverse

Angle



(NX500-NX800)



NX500-600

Flue Adapte

bs) a

(c/w T

NX500-600

101

100



Installation and Operation Instructions │Hubbell NXNX Series

Figure 16-7 Heat Exchanger, Gas Valve, Blower and Burner Assembly (NX500)

114



NX Series Installation and Operation Instructions

Figure 16-8 Heat Exchanger, Gas Valve, Blower and Burner Assembly (NX600-NX800)

Hubbell NX



Hubbell NX

│Installation and Operation Instructions NX Series

Table 16-1 Parts List: Hubbell NX

Item Part #

1 1 1 1 1 1 2 2 3 3 3 4 4 5 5 5 5 5 6 6 6 7

HUB-82657 HUB-82658 200 HUB-84207 300 HUB-83338 400, 500 HUB-84383 600 HUB-84134 700, 800 HUB-82761 200–500 HUB-84133 600–800 HUB-82771 200 HUB-83195 300–500 HUB-84132 600, 700, 800 HUB-82766 200–500 HUB-84026 600–800 HUB-82052 200 HUB-82661 200, 300 HUB-82994 400 HUB-84322 500 HUB-84006 600–800 HUB-82054-2 200, 300 HUB-83106 400 HUB-84084 600–800 HUB-82054-1 200

Models

200

Description

Premixburner135.8 (NX200) Premixburner, 200.6 (NX200) Premixburner, (NX300) Premixburner(NX400-500) Premixburner(NX600) Premixburner(NX700-800) Premix BurnerGasket (NX200-500) Premix BurnerGasket (NX600-800) ExtendedAirTube (NX200) ExtendedAirTube(NX300-500) Conical Air-Gas Inlet Pipe/Stabilor(NX600-800) BlowerGasket (NX200-500) BlowerGasket (NX600-800) EBM BlowerRG130 (NX200) EBM BlowerRG148/1200-3633(NX200-300) EBM BlowerRG148/Enhanced(NX400) EBM Blowe EBM BlowerG1G170 (NX600-800) CVI Venturi Gasket (NX200-300) O-ring, Venturi to Blower(NX400) O-ring, Venturi to Blower(NX600-800) CVI Venturi 01 (NX200)

RG137 (NX500)



)

Installation and Operation Instructions │Hubbell NXNX Series

  

Item Part #

7 7 7 8 8 8 8 9 9 9 9 10 10 11 12 13 13 13 14 14 14 14 15 16 17 17

18 19 20 20 21 22 23

HUB-81994 300 HUB-82990 400 HUB-84013 600–800 HUB-82650 200 HUB-84157 300 HUB-82993 400 (NG) HUB-83017 400 (LP) HUB-82054 200–300 HUB-82989 400 HUB-84318 500 HUB-84012 600–800 HUB-83870 200–500 HUB-84154 600–800 HUB-82774 All Models HUB-82600 200, 300 HUB-83883 200, 300

HUB-83194 400 HUB-84138 600–800 HUB-82065 200, 300 HUB-82991 400 HUB-84321 500 HUB-84035 600–800 HUB-83606 All Models HUB-83223-1 200, 300, 400 HUB-83462 200 HUB-82698 300, 400

HUB-83007 All Models HUB-82539 All Models HUB-83608 200, 300, 400 HUB-84039 500–800 HUB-82765 200 HUB-82763 200 HUB-82764 200

HUB-83605 All Models

HUB-83706 200, 300, 400

HUB-84075 500–800

RESERVED

HUB-83396 200

HUB-84022 300

HUB-82926 400

HUB-84311 500

HUB-84312 600

HUB-84005 700, 800

HUB-83042 200

HUB-83721 All Models

HUB-83720 All Models

HUB-83715 200

HUB-83907 300, 400

HUB-84313 500, 600

Models

Description

CVI Venturi 51 (NX300) CVI Venturi (NX400) CVI Venturi (NX600-800) CVI 5.20mm Orifice #45.900.444.107B (NX200) CVI 6.20mm Orifice (NX300) Gas ValveOrifice, 8.0mm,NG (NX400) Gas ValveOrifice, 6.2mm, LP (NX400) Gas Valve(CVI) VK8115F1134B(Valve Only) (NX200-300) Gas ValveVR8615VB 1044B (NX400) Gas ValveGB-ND 057 (NX500) Gas ValveV8730C 1023B (NX600-800) Ignition Electrode, Dual–c/w gasket (NX200-500) Ignition Electrode, Dual(NX600-800) Flame Probe Gasket Gas Valve RegulatorVent Adapter(NX200-300) CVI Gas ValveInlet O-ring Gasket (NX200-300) Gas Valve ConnectorO-ring, Large (NX400) Gas ValveInlet O-ring (NX600-800) Gas Valve(CV1) 1/2”NPT elbow #45.900.400-132B (NX200-300) Gas ValveAdapter45900400-138B, 3/4”NPT (NX400) Gas ValveAdapter253-517, 3/4”NPT, c/w screws and O-ring (NX500) Gas ValveAdapter, 1”NPT (NX600-800) Outlet Sensor, Dual Low WaterPressure Switch, 1/4”NPT (NX200-400) Street Tee, Brass, 1/4” (NX200) 1/4”NPT Brass Tee (NX300-400)

1/4”x 1/8” Bushing Brass Automatic AirVent 1/8” Flue Sensor, Dual (NX200-400) Flue Sensor, Dual Composite Flue Outlet Gasket (NX200) Composite Flue Box (NX200) Hubbell Flue Box to Heat ExchangerGasket (NX200) Inlet Sensor, Single Plug, Brass, 1/4”NPT (NX200-400) Plug, Brass, 1/2”NPT

Heat Exchanger-ASME(NX200 Heat Exchanger-ASME(NX300) Heat Exchanger-ASME (NX400) Heat Exchanger-ASME(NX500) Heat Exchanger-ASME (NX600) Heat Exchanger-ASME (NX700-800) Y-DrainFitting 5/8”, White (NX200) Tee, PVC, 1/2”, Sch.40, White Elbow,Street, PVC, 1/2”, Sch.40, White Condensate Drain Tube(NX200) Condensate Drain Tube (NX300-400) Condensate Drain Tube (NX500-600)



Installation and Operation Instructions │Hubbell NXNX Series

Item Part #

30 31 32 32 33 33 33 34 34 34 35 36 36 37 37 38 39 39

Models

HUB-83996 700, 800

HUB-83112 All Models

HUB-82770 200–500

HUB-84136 600–800

HUB-83808 200, 500

HUB-83950 300, 400

HUB-84137 600–800

HUB-83885 200, 500

HUB-83949 300, 400

HUB-84135 600–800

HUB-83934 300, 400

HUB-82762 200–500

HUB-84155 600–800

HUB-82099 200, 300

HUB-83951 400

HUB-83425 200

RESERVED

HUB-83426-2 200

39(a) HUB-84208 300 39(b) HUB-84209 300 39

HUB-83952 400

HUB-83425-1 200

HUB-83712 200

HUB-83213 300, 400

HUB-84387 500, 600

HUB-84052 700, 800

HUB-82882 300, 400

HUB-84051 500–800

HUB-83477 200

HUB-83712-1 200

HUB-84054 300–800

HUB-83873 200

HUB-83953 300, 400

HUB-83505 200, 300

HUB-83923 400

HUB-83506 600–800

HUB-83506 200

HUB-83924 300, 400

HUB-84097 500–800

HUB-83874 200

HUB-83954 300, 400

HUB-84139 600–800

HUB-82662 All Models

HUB-83875 200

HUB-83955 300, 400

51 51 52 52 52

RESERVED

HUB-84622 All Models

RESERVED

HUB-84653 All Models

Description

Condensate Drain Tube (NX700-800) Hubbell DividerPlate Insulation c/w Washer & Scr ew BurnerDoorVitonGasket (NX200-500) BurnerDoorVitonGasket (NX600-800) BurnerDoorCeramic Disc (NX200,500) BurnerDoorCeramic Disc (NX300-400) BurnerDoorCeramic Disc (NX600-800) Cast Alum BurnerDoor(NX200,500) Cast Alum BurnerDoor(NX300-400) Cast Alum BurnerDoor(NX600-800)

ipple, 1/4” x 6”, Brass 113-B6 (NX300-400) Flame Rod(NX200-500) Flame Rod(NX600-800) 1-1/2” MJ Coupling (NX200-300)

2” GearClamp Assembly (NX400)

Elbow, Street 90, PVC Sys 15,1-1/2” (NX200)

1-1/2” PVC Pipe, Sys 15, 4.5” Long (NX200) 1-1/2” AirMetering Assembly (NX300) 2” PVC AirInlet Assembly (NX300) AirInlet Assembly (NX400) AirMetering Elbow (NX200) Flue OutletAdapter(HubbellNX3”PVC), c/w plug (NX200) Flue OutletAdapter(NX300-400) Flue OutletAdapterc/w Tabs(NX500-600) Flue OutletAdapter(NX700-800)

Coupling, Rubber, 4”,Fernco (NX300-400) AirInlet AdapterSS Bushing, PVC Sch. 40, 3”x1.5” (NX200) 3/8” Stainless Steel Plug (NX200) Exhaust Test Plug (NX300-800) TiS WallMount Bracket 2 (NX200) WallMounting Clip (NX300-400) Grommet, Vinyl, 1/2” IPS (NX200-300) Grommet, Vinyl, 3/4” IPS (NX400) Grommet, Vinyl, 1” IPS (1030) (NX600-800) Grommet, Vinyl, 1-3/8” OD Grommet, Vinyl, 2” OD (NX300-400) Grommet, Vinyl, 2 1/2” IPS (3125) TiS AirSwitch Support Clip II (NX200) AirSwitch Bracket (NX300-400) AirSwitch Bracket (NX600-800) AirSwitch Huba 604.E021180 set @ .15” w.c. TiS WallStand-Off - Bottom (NX200) WallMounting Support, Bottom (NX300-400)

Display Molding

Display S7999D, Blac



Hubbell NX │Installation and Operation Instructions NX Series

Item Part #

HUB-83876 200

HUB-83872 All Models

HUB-83877 200

HUB-83707 All Models

HUB-83724 All Models

HUB-82250 All Models

HUB-83592-1 All Models

HUB-83190 200, 300, 400

HUB-84047 500–800

HUB-83589 200, 300, 400

HUB-84034 500–800

HUB-83878 200, 300, 400

HUB-84140 500–800

HUB-83879 200, 300, 400

HUB-84141 500–800

HUB-83880 200

HUB-83871 200, 300, 400

HUB-84065 500–800

HUB-83876-1 200

HUB-83517 200, 300, 400

HUB-84192 All Models

HUB-83837 All Models

HUB-83882 All Models 71 72 72

72 72 73 73 73 73 73 73 74 74 74 74 74 74 74 74 75 75 75 75 75 75 76

RESERVED

HUB-83886 200

HUB-83956 300, 400

HUB-84372 500

HUB-84142 600–800

HUB-83887 200

HUB-84210 300

HUB-83957 400

HUB-84373 500

HUB-84374 600

HUB-84143 700, 800

RESERVED

HUB-83888-2 200

HUB-84211 300

HUB-83958 400

HUB-84375 500

HUB-84376 600

HUB-84144 700, 800

HUB-83889 200

HUB-84212 300

HUB-82959 400

HUB-84377 500

HUB-84378 600

HUB-84145 700, 800

HUB-83890 200

Models

Description

Electrical J-box CoverR1, Left (NX200) BarrierStrip, Line Voltage Electrical J-box, Line Voltage (NX200) Ignition Coil Q652B1006/B SparkIgniterWire, 12” SNAP BUSHING, 1” PowerSupply–TouchScreen Transformer, 24V, 40VA(NX200-400) Transformer, 24V, 75VA ICP Honeywell Sola ControllerR7910B1015/B (NX200-400) ICP Honeywell Sola ControllerR7910A1001 DrawerCover(NX200-400) Control Panel Cove Drawer(NX200-400) Control Panel Electrical J-box, Low Voltage (NX200) BarrierStrip, Low Voltage (NX200-400) BarrierStrip, Low Voltage

X150-200 Electrical J-box CoverR1 (Right) (NX200) Fuse, Matrix/NX, 2 Amp (NX200-400) Fuse Holder, 20 Amp at 250VAC Max Fuse, Littlefuse 7A, 250VAC, Fast Blow TouchScreen Display Support

Front Cover(NX200) Front Cover(NX300-400)

Front Cover(NX500) Front Cover(NX600-800) Right Side (NX200) Right Side (NX300) Right Side R1 (NX400) Right Side (NX500) Right Side (NX600) Right Side (NX700-800)



Left Side (NX200) Left Side (NX300) Left Side (NX400) Left Side (NX500) Left Side (NX600) Left Side (NX700-800) Front Top(NX200) Front Top(NX300) Front Top(NX400) Top(NX500) Top(NX600) Front Top (NX700-800) TopPanel BackR1 (NX200)



Installation and Operation Instructions │Hubbell NXNX Series

Item Part #

76 77 77 77 78 78 78 79 80 81 82 83 84 85 86 86 87 87 88 88 89 89 89 90 91 92

93 94 94 95 96 97 98

100 HUB-83923

101 HUB-84346

101 HUB-84011

102 HUB-84056

103 HUB-84043

104 HUB-84130

105 HUB-82064

105 HUB-83016 400

105 HUB-84319 500

106 HUB-84392

114 HUB-84993 300-800

Models

HUB-84146 700, 800 HUB-83961 300, 400 HUB-84379 500 HUB-84147 600–800 HUB-83915 300, 400 HUB-84380 500 HUB-84053 600–800 HUB-83962 400 HUB-84057 500–800 HUB-84010 All Models HUB-84087 600–800 HUB-84045 600–800 HUB-84148 600–800 HUB-84044 600–800 HUB-84388 500 HUB-84061 700, 800 HUB-84389 500 HUB-84063 600–800 HUB-84347 500 HUB-84025 600–800 HUB-84390 500 HUB-84351 600 HUB-84062 700, 800 HUB-84064 700, 800 HUB-84102 500–800 HUB-84099 500–800

HUB-84058 500–800 HUB-84381 600 HUB-84149 700, 800 HUB-84095 500–800 HUB-84069 600–800 HUB-84072 All Models HUB-84073 500–800

HUB-84150

500–800

500

600–800

500–800

200-300

300–800

Description

RearTop(NX700-800) Fuel-AirMetallic Tubing with Ends (NX300-400) Fuel-AirMetallic Tubing with Ends (NX500) Fuel-AirMetallic Tubing with Ends (NX600-800) High-VentPressure Switch, AFS460-367 (NX300-400) High -Vent Pressure Switch, ANA124-406 (NX500) High -Vent Pressure Switch,ANA124-381 (NX600-800) Gas ValveOrifice O-ring, Large(NX400) Coupling, 2”, Brass System Sensor, Pipe SensorTSA00A4 Gasket, Cork(NX600-800) Cross, Brass, M5 Thread To Barb (NX600-800) AirMetering Tube(NX600-800) Elbow, Brass, M5 to Barb (NX600-800)

ipple, 3/4” x 5”, BlackIron (NX500)

ipple, 1” x 6”, BlackIron (NX700-800) Elbow, 3/4”, 90 deg., Street, BlackIron (NX500) Elbow,1”,90deg.,Street,BlackIron (NX600-800) Manual Shutoff Valve, 3/4”NPT (NX500) Manual Shutoff Valve, 1” NPT (NX600-800)

ipple, 3/4” x 2-1/2”, BlackIron (NX500)

ipple, 1” x Close, BlackIron (NX600)

ipple, 1” x 3-1/2”, BlackIron (NX700-800) Elbow, 1”, 90 deg., BlackIron (NX700-800) Flow switch, FS8-W, Paddles–2-1/2” Bushing, 2” x 1”, Brass

Tee, 2” x 2” x 2”, Brass Gas Valve RegulatorSensing Tube (NX600) Gas ValveRegulatorSensing Tube(NX700-800) Plug, 7/8” BlackDome Clamp, U-bolt, 1” IPS (NX600-800) Leg Leveler, 3/8-16 x 1/5” Leg LevelerHex Base Cap

Flow Switch Wiring Conduit

Grommet, Vinyl, 3/4” IPS (1020)

Grommet, Vinyl (3375), Air-inlet (NX500)

Gasket, Air-inlet 3/16” (NX600-800)

Relay, Omron

Rocker Switch, Black

FlowSwitch Wiring Conduit Fitting

Gas Valve Harness, CVI (NX200-300)

Gas ValveHarness (NX400)

Gas ValveHarness, Dungs (NX500)

Thermal Fuse, Heat Exchanger Exterior (NX300-800)

M5 Reset Safety Switch (NX300-800)



Hubbell NX │Installation and Operation Instructions NX Series

17.1 TROUBLESHOOTING

Observe the following precautions when servicing the water heater. Failure to comply with these may result in fire, property damage, serious injury or death.

Servicing the Water heater

 Disconnect or shut off all energy sources to the water heater: 120VAC power, water and gas.  Identify and mark wires before disconnecting or removing them.  Never bypass electrical fuses or limit devices except temporarily for testing.  Use proper personal protective equipment (PPE) i.e. eye protection, safety footwear.

These procedures should only be performed by qualified service personnel, when abnormal operation of the water heater is suspected. The water heater incorporates a sophisticated microprocessor based control which normally responds appropriately to varying conditions. If the water heater operation appears to be incorrect, or it is not responding at all to a demand for heat, the following is suggested to determine and correct the problem.

Before undertaking any troubleshooting procedures it is highly recommended to have available a digital multimeter(s) capable of measuring AC and DC volts, Amperes, Resistance (ohms) and Continuity.

Check 120VAC and 24VAC at the Water heater

First, verify the following:

 There is 120V being supplied to the water heater:

The circuit breaker in the electrical panel supplying power to the water heater is not tripped.

The service switch (if applicable) is in the ON position.

To check for the presence of 120VAC and 24VAC at the water heater follow this procedure:

 Remove the water heater front cover.  120VAC

Remove the Line Voltage junction box cover. First remove the #10 pan-head Phillips screw securing the

cover to the junction box. Lift the cover to release it from the water heater base and withdraw the cover from the water heater cabinet. This will expose the Line Voltage barrier strip.

With an AC voltmeter set on the appropriate scale, measure the voltage across the L1 and L2 terminals

(terminals 1 and 5).

If 120VAC is not detected, check the electrical service as suggested above. If the service is verified, inspect the circuit wiring from the panel to the water heater for broken or disconnected conductors.

 24VAC (only check if 120VAC supply is verified).

Remove the Low Voltage junction box cover. First remove the #10 pan-head Phillips screw securing the

cover to the junction box. Lift the cover to release it from the water heater base and withdraw the cover from the water heater cabinet. This will expose the Low Voltage barrier strip.

With an AC voltmeter set on the appropriate scale, measure the voltage across the R and C terminals

(terminals 3 and 1).

If 24VAC is not detected, check Fuse “C” (see below).



Fuse “C” ATO 2A 32V Auto Blade Type

Figure 17-1(a) NX200-NX400

Control Panel Fuse Locations

Installation and Operation Instructions │Hubbell NXNX Series

Fuse “A” 3AG 7A 250V Fast-Acting

Fuse “B” 3AG

7A 250V

Fast-Acting

Figure 17-1(b) NX500-NX800

Control Panel Fuse Location

Fuse “A” 3AG 7A 250V Fast-Acting

Fuses There are three (3) fuses associated with the Hubbell NX200-NX400 controller but only one (1) with the NX500-

NX800 controller. Check these fuses before replacing the controller or any other electrical component; if the fuse is blown, it will prevent the protected device(s) from functioning.

To check, and if necessary replace, the fuses:

 Remove all 120VAC power from the water heater. Be careful to check that the unit is not powered from more

than one source e.g. a UPS (uninterruptible power supply).

 Remove the front cover.  On models NX200-NX400 the control panel is located below the heat exchanger. Fuses “A” and “B” are

accessible by removing the spring-loaded knurled knob of their respective holders. Push the knob toward the panel, and twist approximately 1/4 turn counter-clockwise.

 To access Fuse “C”, remove the two #10 pan-head Phillips screws and lift the top cover from the panel. The auto

blade type fuse is installed in an “inline” style fuse holder.

 On models NX500-NX800, the control panel is located above the heat exchanger toward the back of the unit.

Fuse “A” is accessible by removing the spring-loaded knurled knob from its holder. Push the knob toward the panel, and twist approximately 1/4 turn counter-clockwise.

After inspecting and if necessary replacing fuses, replace the panel cover and front cover. Restore power to the water heater and confirm proper operation.

Only replace fuses with identical parts, see Figures 17-1(a) and (b). Failure to follow this warning may result in component failure, fire, property damage, serious injury or death.



Hubbell NX │Installation and Operation Instructions NX Series

User Interface (Touch-screen Display)

A blank screen does not necessarily indicate a problem; the display may be configured to automatically blank the screen after a pre-set interval. Simply touch the screen to activate it. Confirm that 120V power is being supplied to the water heater. If the screen does not become active, perform the following procedure:

Blank Screen

1. Remove the front cover from the water heater.

2. Remove the control panel cover and check Fuse “C” (Auto Blade Type); if faulty check for shorts in the thermostat wiring, correct, then replace fuse (see Figure 17-1).

3. Ensure the “2 by 2” Molex connector, located behind the display at the top, is connected and that the wires are fully inserted (see Figure 17-2). Verify that 24VAC is present between the Blue and Red wires; if not trace wiring back to 24VAC transformer; correct wiring and/or replace transformer [see applicable Figure 13-1(a) or 10-2(a)].

4. Remove the display assembly from the control panel and check the 24VAC wiring connection on the back of the display; Blue to terminal 7 [24VAC (COM)], Red to terminal 8 [24VAC].

System Disconnected If the Touch-screen Display is not blank, but is displaying “System Disconnected!” in the middle of the screen,

ensure the 4 by 1 Molex connector, located behind the display at the top, is connected and that the wires are fully inserted (see Figure 17-2). If the connector appears to be fine, check the wiring connections on the back of the touchscreen display; Green, Red and Black go to terminals 1, 2 and 3 respectfully.

Figure 17-2 Touch-screen Display Electrical Disconnects

Power Supply Connector (2 by 2)

Communication Connector

Blue (White on bottom)

Red

Black

Red

Blue

Red

White

Black

Red

Green

(4 by 1)

Green

DO NOT drop the plastic housing or allow it to swing down freely, it may be damaged by forceful impact.



Installation and Operation Instructions │Hubbell NXNX Series

Summary and Diagnostics Display – The Hubbell NX controller and Touchscreen display provides detailed

operational and diagnostic information for aid in troubleshooting. When power is applied to the water heater the initial page displayed is the Summary page. Information presented on the Summary page includes Demand source, Burner state, status of sensors and pumps, and so forth. Any current Alert or Lockout condition is also displayed. Accessible from the Summary page are the Diagnostics pages. Refer to the controller manual for more information.

Lockout and Alert History – The controller maintains a record of the fifteen (15) most recent events for both

Lockouts and Alerts. To display the logs, touch the History button on the Summary page (refer to Section 7.0 in

Appendix A - Co ntroller and Touchscreen Display Instructions). In any situation where malfunction is

suspected, always check the Alerts and Lockouts history. Entries recorded in the history provide useful information for determining the cause of the malfunction.

Table 17-1 Troubleshooting Chart



Display shows “System Disconnected” constantly

Burner not operating

PROBLEM

POSSIBLE CAUSE

Communication wire disconnected

Faulty Sola controller

Heat demand satisfied; no call for heat

CORRECTIVE ACTION

See, “System Disconnected!” above.

If 24VAC present at control ler terminals J8 1 & 2, check Power LED on controller. Verify that connector J8 is securely plugged into the controller. Recycle power to water heater, if controller does not operate, replace the controller.

Check Demand and Set points via Touchscreen. Check DHW aquastat setting.

Lockout 2 – Waiting for safety data verification

Lockout 9 – Flame bias out of range

Hold 27 – Flame rod shorted to ground detected

Hold 61 – Anti short-cycle

Hold 62 – Fan speed not proved

Water heater outlet temperature exceeds “Setpoint - On Hysteresis”

Hold delay or Lockout

Burner switch off

Safety parameter(s) has been adjusted

4-20mA input being overdriven.

Control malfunction

A flame circuit shorted to ground may show up as a flame circuit timeout. Zero-ohm shorts can display as Hold

27.

Demand off

Normal Operation (Drive to Lightoff)

Blown fuse

Wiring defect

- Faulty Sola controller

- Faulty Blower

Check outlet temperature, setpoint and hysteresis settings via Touchscreen.

Check Summary page on Touchscreen for code.

Check Summary page, if Demand indicates “Burner switch off” go to diagnostics burner test page and switch on.

Changing settings that are considered safety parameters require “Safety data verification”. Refer to Appendix A.

If using 4-20mA input, check to ensure current is not greater than 21mA.

Cycle power, if problem returns replace control.

Check to ensure condensate drain is not blocked. Check to ensure no voltage applied to R & T terminals. If using 4-20mA input, check to ensure current is not greater than 21mA.

Check demand. Delay is to prevent rapid cycling of burner.

Hold 62 is momentarily displayed prior to burner ignition during the Drive to Lightoff.

Check Fuse “A”, blown fuse prevents blower from operating.

Inspect blower wiring, ensure connectors at Sola controller and blower are securely attached.

If Hold 62 persists for 15 seconds or more, while the blower is running, check “Fan speed” indicated on display. If “LOW RPM”, “HIGH

RPM displayed, try connecting another Sola controller. If problem remains, replace blower.

”, “0”

or rapidly changing RPM value is



Hubbell NX │Installation and Operation Instructions NX Series

Table 17-1 Troubleshooting Chart



RESERVED

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION



Lockout or Hold 65 – Interrupted Air Switch OFF

No problem, normal operation

Blown fuse

Faulty blower

Blocked venting

Blocked air inlet

Disconnected, damaged or blocked tubing

Incorrect air switch setting

Faulty air proving switch

Hold 65 will normally be displayed momentarily during the drive to light-off.

Check Fuse “A”, blown fuse prevents blower from operating.

If Fuse “A” is good and blower remains off, check 120VAC supply to blower, if present replace blower. If blower is on proceed to next step.

Check for blockage of the exhaust vent.

Check for blockage of the air inlet.

Inspect the clear vinyl tubing connecting the air switch + and – ports to the air metering elbow. Condensation or other foreign matter may be obstructing the tubing, preventing the switch from sensing differential pressure caused by air flow through the metering elbow.

Contact Hubbell technical support.

If venting and air inlet are clear, temporarily jumper the air switch. If the unit lights and operates smoothly – replace air switch. If the unit fails to light or lights but runs rough or abruptly shuts down – check water heater internals for blockage. Only jumper the air switch for diagnosing purposes.

Hold 66 – Interrupted air switch ON (and blower is off)

Hold 66 – Interrupted air switch ON (and blower is on)

Tripped High Vent Pressure Switch (NX300-400 only)

Tripped Thermal Fuse (NX300-400 only)

Tripped Door Reset Safety Switch (NX300-800 only)

Incorrect air switch wiring

Incorrect air switch setting

Incorrect air switch wiring

Faulty air switch

- Blower problem

- Faulty controller

The high vent pressure switch will trip when the combustion chamber is blocked. Clean combustion chamber and reset switch.

Check Thermal Fuse on the back of the heat exchanger (accessed from the rear of the cabinet). If tripped contact Hubbell.

The Door Reset Safety Switch will trip with the combustion chamber gets dirty or the door insulation fails. Clean the combustion chamber, inspect the door insulation and reset the switch.

Check that the red and orange wires are connected to quick connect tabs 3 and 1 respectively.

Contact Hubbell technical support.

Check that the red and orange wires are connected to quick connect tabs 3 and 1 respectively.

Disconnect red and orange wires from air switch and check for open circuit between terminals 1 &

3. If continuity detected, replace air switch.

Check low voltage wiring from blower to controller. Check VDC signal from red–green and black-green; if not 28-32VDC and 0 VDC respectfully – replace controller. If signal is correct – replace blower.



Table 17-1 Troubleshooting Chart



Lockout or Hold 67 – ILK OFF

Lockout or Hold 79 – Outlet High Limit

Lockout or Hold 81 – Delta T limit OR

Water heater making banging or hissing sounds

PROBLEM

Installation and Operation Instructions │Hubbell NXNX Series

POSSIBLE CAUSE

Insufficient water pressure (NX200-400 only)

External Limit Tripped

Insufficient flow for Flow Switch (NX500-800 only)

Tripped Thermal Fuse (NX500-800 only)

Tripped High Vent Pressure Switch (NX500-800 only)

DHW settings

DHW pump problem

Incorrect “Outlet high limit” setting Increase “Outlet high limit” setting; maximum

Incorrect “Outlet high limit response” setting (NX200-400 water heater applications only)

Insufficient water flow

CORRECTIVE ACTION

Ensure at least 15PSI at water heater outlet. Refer to Supplementary Documentation section 2.0 System Piping.

Indication that an external limit (wired to “LIM”) is open. Not a problem with water heater, check external limit.

Check plumbing, ensure circulator is operating.

Check Thermal Fuse on the back of the heat exchanger (accessed from the rear of the cabinet). If tripped contact Hubbell.

The high vent pressure switch will trip when the combustion chamber is blocked or venting is too restrictive. Check venting and clean combustion chamber.

Check if DHW setpoint temperature plus off hysteresis exceed “High limit” setpoint – factory setting = 210°F (99°C).

See “Inoperative DHW pump” below.

setting = 210°F (99°C).

Unless deemed unacceptable by local installation codes, the “Outlet high limit response” should be set to “recycle and hold” to prevent lockout.

 Check Fuse “A”   Ensure plumbing is correct. Refer to

Supplementary Documentation section 2.0 System Piping. Check that water pressure is at least 15PSI.

 Water heater heat transfer surfaces may be fouled

with scale or magnetite. Clean with Fernox DS-40 Descaler and Cleanser. See Table 10-1.

Check water heater pump.

Lockout 82 – Stack limit

Lockout or Hold 85 – Inlet/Outlet Inversion Limit

Lockout or Hold 88 – Outlet T Rise limit



Dirty heat exchanger

Incorrect “Stack limit setpoint”

Faulty sensor

Pump flowing in the wrong direction

Incorrect factory sensor wiring

Insufficient water flow

Inspect and if required clean the combustion chamber and/or heat exchanger. Refer to 14.0 Annual Maintenance and Inspection and Supplementary Documentation section 2.0 System Piping.

Unless installed in Canada with PVC exhaust venting, set “Stack limit setpoint” to maximum setting of 220ºF (104ºC). In Canada PVC exhaust venting is limited to 149ºF (65ºC).

Check resistance of stack sensor and compare to thermistor resistance chart, see Table 17-2.

Ensure water circulation is flowing into the water heater at the fitting closest to the wall.

Disconnect flue sensor cable; screen should display “Hold 95 – Stack sensor fault”; if not contact Hubbell.

See Lockout or Hold 81.



Hubbell NX │Installation and Operation Instructions NX Series

Table 17-1 Troubleshooting Chart



Hold 91– Inlet sensor fault

Hold 92 – Outlet sensor fault Sensor disconnected

Hold 95 – Stack sensor fault

Lockout 109 – Ignition failure occurred (NX500-800 only)

PROBLEM

Hold 110 – Ignition failure occurred, failure to prove flame after 3 ignition attempts (NX200-400 only)

Lockout 113 – Flame circuit timeout

POSSIBLE CAUSE

Sensor disconnected

Faulty sensor

Sensor disconnected

Faulty sensor

Spark cable disconnected

Insufficient gas line pressure

Flame rod disconnected

No 120VAC to Spark Generator

Faulty Spark Generator

No 24VAC to Gas Valve

Faulty Gas Valve

A flame circuit shorted to ground may show up as a flame circuit timeout. High resistance shorts can display as Lockout 113.

CORRECTIVE ACTION

 Verify that 2-position Molex connector on

wiring harness is securely attached to mating connector on inlet sensor.

 Inspect sensor wiring.

Check resistance of sensor and compare to thermistor resistance chart, see Table 17-2.

 Verify that 4-position Molex connector on

wiring harness is securely attached to mating connector on outlet sensor.

 Inspect sensor wiring.

Check resistance of sensor and compare to thermistor resistance chart, see Table 17-2.

 Verify that 4-position Molex connector on

wiring harness is securely attached to mating connector on stack sensor.

 Inspect sensor wiring.

Check resistance of sensor and compare to thermistor resistance chart, see Table 17-2.

Ensure that the high voltage spark cable is securely connected to the spark generator and the igniter electrode. Check that the green ground wire is securely attached to the 1∕4" quick connect tab on the igniter electrode.

Ensure the manual gas shutoff valve is open. Refer to manual section 9.0 GAS VALVE AND BURNER SETUP.

Verify that the flame rod signal wire is securely attached to the flame rod, which is located bottom center of the burner door.

Check wiring from controller to spark generator. With an AC voltmeter measure voltage across J5-

6 and ground (the controller chassis is connected to the 120VAC supply ground) during trial for ignition.

During trial for ignition check for arc on spark electrode via the observation port located next to the spark electrode in the burner door. If the spark generator is receiving 120VAC and no spark is observed, replace the spark generator.

Check the wiring harness for loose or interrupted connections of the gas valve wiring. With an AC voltmeter, measure the voltage from controller terminals J5-2 to J4-10. There should be 24VAC present during trial for ignition.

The gas valve emits an audible click when it switches on or off. If the controller is providing 24VAC to the gas valve, and the wiring is intact, it should be possible to detect if the valve is responding.

Check to ensure condensate drain is not blocked. Check to ensure no voltage applied to R & CH terminals. If using 4-20mA input, check to ensure current is not greater than 21mA.



Table 17-1 Troubleshooting Chart



Lockout 122 – Lightoff rate proving failed

PROBLEM

Installation and Operation Instructions │Hubbell NXNX Series

POSSIBLE CAUSE

Blower is not turning on

Missing or incorrect blower feedback signal

Blower is a lways on

CORRECTIVE ACTION

See “Blower not operating” below.

See Hold 62 above.

See “Blower operating at high speed while burner is off” below.

Alert 128 - Modulation rate was limited due to IAS was open (Air switch open while burner firing)

Lockout 173 - Pilot relay feedback incorrect

Lockout 174 – Safety relay feedback incorrect

Inoperative DHW pump

RESERVED

Blocked venting

Blocked air inlet

External Electrical Noise

Failing Limit Switch in ILK circuit Check operation of internal LWCO, and/or ex-

Hardware failure of Sola controller Reset power, If problem persists replace Sola

Check for blockage of the exhaust vent.

Check for blockage of the air inlet.

Look for sources of electrical noise, i.e. a large motor or multiple pieces of equipment starting at the same time.

ternal limit (i.e. devise connected between “R” and “LIM”); replace as necessary

controller.



Alert 311 – Run was terminated due to interrupted air flow switch was off

Inoperative CH and/or DHW pump



Blocked venting

Blocked air inlet

Disconnected, damaged or blocked tubing

Incorrect air switch setting

Blown fuse

Faulty controller

Faulty pump

Check for blockage of the exhaust vent.

Check for blockage of the air inlet.

Contact Hubbell technical support.

Check Fuse “A”.

Check Fuse “B”.

If Fuse “B” not blown , and controller is operating, navigate to pump diagnostic on display. Manually switch pump on, check for 120VAC at pump connection terminal on line voltage barrier strip. If 120VAC not detected, replace controller.

If 120VAC supplied to pump, and pump does not operate, replace pump.



Hubbell NX │Installation and Operation Instructions NX Series

Table 17-1 Troubleshooting Chart



PROBLEM

Blower operating at high speed while burner off

POSSIBLE CAUSE

Blower signal cable disconnected

CORRECTIVE ACTION

 Verify that the 5-position Molex connector on

the wiring harness is securely connected to its mating connector on the blower.

 Check that the 4-position Molex connector on

wiring harness is securely connected to its

Blower operating at high speed while burner off

No 24VAC to controller

mating connector on the controller.

 Check Power LED on controller.  Check Fuse “C”.  With an AC voltmeter measure voltage at

term inals J8 1 & 2, 24VAC should be present.

Blower not operating

Blower power disconnected

Verify that the 3-position Molex connector on the wiring harness is securely connected to its mating

Blown fuse

connector on the blower.

Check Fuse “A” using the procedure described above. Fuse “A” protects the blower as well as the ignition spark generator and water heater pump.

Faulty blower

Measure voltage across pins 1 & 2 (black and white wires) of 3-position connector on wiring harness. If 120VAC detected, replace power connector and remove 5-position signal connector.

Blower should rotate at high speed. If blower does not rotate, replace blower.

Table 17-2 Thermistor Resistance vs. Temperature

Temp °F

Table 17-3 Hold and Lockout Codes

-22

-4

104

113

Code Description

None

Unconfigured safety data

Waiting for safety data verification

Internal fault: Hardware fault

Internal fault: Safety Relay key feedback error

Internal fault: Unstable power (DCDC) output

Internal fault: Invalid processor clock

Internal fault: Safety relay drive error

Resistance Ohms (Ω) Temp °F

176,133

96,761

55,218

32,650

25,390

19,900

15,710

12,490

10,000

8,057

6,531

5,327

4,369

122

131

140

149

158

167

176

185

194

203

212

230

Resistance Ohms (Ω)

3,603

2,986

2,488

2,083

1,752

1,481

1,258

1,072

918

789

680

506

Note

Hold / No lock out Lockout

Lockout

Hold



Table 17-3 Hold and Lockout Codes

Code Description

Internal fault: Zero crossing not detected

Internal fault: Flame bias out of range

Internal fault: Invalid Burner control state

Internal fault: Invalid Burner control state flag

Internal fault: Safety relay drive cap short

Internal fault: PII shorted to ILK

Internal fault: HFS shorted to LCI

Internal fault: Safety relay test failed due to feedback ON

Internal fault: Safety relay test failed due to safety relay OFF

Internal fault: Safety relay test failed due to safety relay not OFF

Internal fault: Safety relay test failed due to feedback not ON

Internal fault: Safety RAM write

Internal fault: Flame ripple and overflow

Internal fault: Flame number of sample mismatch

Internal fault: Flame bias out of range

Internal fault: Bias changed since heating cycle starts

Internal fault: Spark voltage stuck low or high

Internal fault: Spark voltage changed too much during flame sensing time

Internal fault: Static flame ripple

Internal fault: Flame rod shorted to ground detected

Internal fault: A/D linearity test fails

Internal fault: Flame bias cannot be set in range

Internal fault: Flame bias shorted to adjacent pin

Internal fault: SLO electronics unknown error

Internal fault: Safety Key 0

Internal fault: Safety Key 1

Internal fault: Safety Key 2

Internal fault: Safety Key 3

Internal fault: Safety Key 4

Internal fault: Safety Key 5

Internal fault: Safety Key 6

Internal fault: Safety Key 7

Internal fault: Safety Key 8

Internal fault: Safety Key 9

Internal fault: Safety Key 10

Internal fault: Safety Key 11

Internal fault: Safety Key 12

Internal fault: Safety Key 13

Internal fault: Safety Key 14

Flame rod to ground leakage

Static flame (not flickering)

24VAC voltage low/high

Modulation fault

Pump fault

Motor tachometer fault

AC inputs phase reversed

Safety GVT model ID doesn’t match application’s model ID

Application configuration data block CRC errors

56-57 RESERVED

Installation and Operation Instructions │Hubbell NXNX Series

Note

Hold

Lockout

Hold

Hold / Lockout

Lockout

Hold

Lockout

Hold

Lockout



Hubbell NX │Installation and Operation Instructions NX Series

Table 17-3 Hold and Lockout Codes

Code Description

Internal fault: HFS shorted to IAS

Internal fault: Mux pin shorted

Internal fault: HFS shorted to LFS

Anti short cycle

Fan speed not proved

LCI OFF

PII OFF

Interrupted Airflow Switch OFF

Interrupted Airflow Switch ON

ILK OFF

ILK ON

Pilot test hold

Wait for leakage test completion

Input power frequency mismatch

72-77 RESERVED

Demand lost in run

Outlet high limit

DHW high limit

Delta T limit

Stack limit

Delta T exchanger/outlet limit

Delta T inlet/exchanger limit

Inlet/Outlet inversion limit (See Table 17-1)

Exchanger/outlet inversion limit

100 Pressure sensor fault

101 Exchanger sensor fault

102-104 RESERVED

105 Flame detected out of sequence

106 Flame lost in MFEP

107 Flame lost early in run

108 Flame lost in run

109 Ignition failed

110 Ignition failure occurred

111 Flame current lower than WEAK threshold

112 Pilot test flame timeout

113 Flame circuit timeout

Inlet/exchanger inversion limit

Outlet T-Rise limit (See Table 17-1)

Exchanger T-rise limit

Heat exchanger high limit

Inlet sensor fault

Outlet sensor fault

DHW sensor fault

Header sensor fault

Stack sensor fault

RESERVED

Internal fault: A2D mismatch

Internal fault: Exceeded VSNSR voltage tolerance

Internal fault: Exceeded 28V voltage tolerance



Note

Lockout

Hold

N/A

Hold

N/A

Hold

Lockout



Hold

Disabled

Hold / Lockout

Lockout

Disabled

Hold

Disabled

Lockout

Disabled

Hold



Lockout

Hold

Disabled



Hold / Lockout

Lockout

Hold

Lockout



Table 17-3 Hold and Lockout Codes

Code Description

114-115 RESERVED

116 Wait for OK to Run

117 Flap valve condensate fault

118 Controller interaction system fault

119 Controller interaction communications fault

120 Flap valve backflow fault

121 Flap valve fault

122 Light off rate proving failed

123 Purge rate proving failed

124

High fire switch OFF

125

High fire switch stuck ON

126

Low fire switch OFF

127

Low fire switch stuck ON

128 Fan speed failed during pre-purge

129 Fan speed failed during pre-ignition

130 Fan speed failed during ignition

131 Fan movement detected during standby

132 Fan speed failed during run

133-135 RESERVED

136 Interrupted Airflow Switch failed to close

137 ILK failed to close

138 Flame too low

139-142 RESERVED

143 Internal fault: Flame bias out of range 1

144 Internal fault: Flame bias out of range 2

145 Internal fault: Flame bias out of range 3

146 Internal fault: Flame bias out of range 4

147 Internal fault: Flame bias out of range 5

148 Internal fault: Flame bias out of range 6

149 Flame detected

150 Flame not detected

151

High fire switch ON

152 Combustion pressure ON

153 Combustion pressure OFF

154 Purge fan switch ON

155 Purge fan switch OFF

156 Combustion pressure and Flame ON

157 Combustion pressure and Flame OFF

158 Main valve ON

159 Main valve OFF

160 Ignition ON

161 Ignition OFF

162 Pilot valve ON

163 Pilot valve OFF

164 Block intake ON

165 Block intake OFF

166-168 RESERVED

169 Safety opto bad in test state

170 Safety relay opto feedback incorrect



Installation and Operation Instructions │Hubbell NXNX Series

Note



Disabled

Hold

Disabled

Lockout

Hold

Hold / Lockout

Hold



Hold

Lockout



Lockout

Hold / Lockout

Hold

Hold / Lockout

Lockout



Lockout



Hubbell NX │Installation and Operation Instructions NX Series

Table 17-3 Hold and Lockout Codes

Code Description

171 Safety relay feedback incorrect in run

172 Main relay feedback incorrect

173 Pilot relay feedback incorrect

174 Safety relay feedback incorrect

175 Safety relay open

176 Main relay ON at safe start check

177 Pilot relay ON at safe start check

178 Safety relay ON at safe start check

179-180 RESERVED

181 Invalid Blocked condensate enable setting

182 Invalid J7-1 configuration, both LFS and Blocked condensate

183 Invalid J7-2 configuration, both HFS and Flap valve

184 Invalid BLOWER/HSI output setting

185 Invalid Delta T limit enable setting

186 Invalid Delta T limit response setting

187 Invalid DHW high limit enable setting

188 Invalid DHW high limit response setting

189 Invalid Flame sensor type setting

190 Invalid interrupted air switch enable setting

191 Invalid interrupted air switch start check enable setting

192 Invalid Igniter on during setting

193 Invalid Ignite failure delay setting

194 Invalid Ignite failure response setting

195 Invalid Ignite failure retries setting

196 Invalid Ignition source setting

197 Invalid Interlock open response setting

198 Invalid Interlock start check setting

199 Invalid LCI enable setting

200 Invalid light off rate setting

201 Invalid Light off rate proving setting

202 Invalid Main Flame Establishing Period time setting

203 Invalid MFEP flame failure response setting

204 Invalid NTC sensor type setting

205 Invalid Outlet high limit response setting

206 Invalid Pilot Flame Establishing Period setting

207 Invalid PII enable setting

208 Invalid pilot test hold setting

209 Invalid Pilot type setting

210 Invalid Post-purge time setting

211 Invalid Power up with lockout setting

212 Invalid Pre-ignition time setting

213 Invalid Pre-purge rate setting

214 Invalid Pre-purge time setting

215 Invalid Purge rate proving setting

216 Invalid Run flame failure response setting

217 Invalid Run stabilization time setting

218 Invalid Stack limit enable setting

219 Invalid Stack limit response setting

220 Unconfigured Delta T limit set point setting



Note

Lockout

Disabled

Lockout



Table 17-3 Hold and Lockout Codes

Code Description

221 Unconfigured DHW high limit set point setting

222 Unconfigured Outlet high limit set point setting

223 Unconfigured Stack limit set point setting

224 Invalid DHW demand source setting

225 Invalid Flame threshold setting

226 Invalid Outlet high limit set point setting

227 Invalid DHW high limit set point setting

228 Invalid Stack limit set point setting

229 Invalid Modulation output setting

230 Invalid CH demand source setting

231 Invalid Delta T limit delay setting

232 Invalid Pressure sensor type setting

233 Invalid IAS closed response setting

234 Invalid Outlet high limit enable setting

235 Invalid Outlet connector type setting

236 Invalid Inlet connector type setting

237 Invalid DHW connector type setting

238 Invalid Stack connector type setting

239 Invalid Header connector type setting

240 RESERVED

241 Exchanger sensor not allowed with stack connector setting

242 Invalid DHW auto detect configuration

243

244

Invalid UV with spark interference not compatible with Igniter on throughout

PFEP Internal fault: Safety relay test invalid state

245 Invalid Outlet connector type setting for T-rise

246 4-20mA cannot be used for both modulation and setpoint control

247 Invalid ILK bounce detection enable

248 Invalid forced recycle interval

249 STAT cannot be demand source when Remote Stat is enabled

250 Invalid Fan speed error response

251 Lead drop-stage on error setting does not match drop method configuration

252 Invalid Line frequency setting

253 Lead Lag modulation sensor not valid with setpoint source

254 Lead Lag modulation sensor not valid with local setpoint source

255 Lead Lag modulation sensor not valid with local modulation source

256 Selected Controller interaction enable setting is not allowed

257 Controller interaction enable does not match neighbor stack fault setting

258 Controller ID must be non-zero if controller interaction is enabled

259 Modulation output must be fan if controller interaction is enabled

260

Asymmetrical paired (no flap) is set but flap switch input is energized

261 Neighbor burner control blower fault detected

262

Blower fault detected during flap test

263 Invalid DHW demand temperature setting

264 Invalid preferred outlet high limit setting

265 Invalid preferred lightoff rate setting

266 Invalid preferred stack limit rate setting

Installation and Operation Instructions │Hubbell NXNX Series

Note



Lockout



Hubbell NX │Installation and Operation Instructions NX Series

Code Description

None (No alert)

Alert PCB was restored from factory defaults

Safety configuration parameters were restored from factory defaults

Configuration parameters were restored from factory defaults

Invalid Factory Invisibility PCB was detected

Invalid Factory Range PCB was detected

Invalid range PCB record has been dropped

EEPROM lockout history was initialized

Switched application annunciation data blocks

Switched application configuration datablocks

Configuration was restored from factory defaults

Backup configuration settings was restored from active configuration

Annunciation configuration was restored from factory defaults

Annunciation configuration was restored frombackup

Safety group verification table was restored from factory defaults

Safety group verification table was updated

Invalid Parameter PCB w as detected

Invalid Range PCB was detected

Alarm silence time exceeded maximum

Invalid safety group verification table was detected

Backdoor password could not be determined

Invalid safety group verification table was not accepted

CRC errors were found in application configuration datablocks

Backup Alert PCB was restored from active one

RESERVED

Lead Lag operation switch was turned OFF

Lead Lag operation switch was turned ON

Safety processor was reset

Application processor was reset

Burner switch was turned OFF

Burner switch was turned ON

Program Module (PM) was inserted into socket

Program Module (PM) was removed from socket

Alert PCB was configured

Parameter PCB was configured

Range PCB was configured

Program Module (PM) incompatible withproduct was inserted into socket

Program Module application parameter revision differs fromapplicationprocessor

Program Module safety parameter revision differs from safetyprocessor

PCB incompatible with product contained in Program Module

Parameter PCB in Program Module is too large forproduct

Range PCB in Program Module was too large fo

Alert PCB in Program Module was too large forproduct

IAS start check was forced on due to IAS enabled

Low voltage was detected in safety processor

High line frequency occurred

Low line frequency occurred

Invalid subsystem reset request occurred

Write large enumerated Modbus register value was not allowed

roduct



Hubbell NX800, NX200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual