Hubbell J User Manual

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OPERATING AND MAINTENANCE MANUAL FOR

ELECTRIC BOOSTER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ J ”

ASME ANSI/NSF5

2007 Edition Rev. A

1

HUBBELL

ELECTRIC HEATER COMPANY

45 SEYMOUR STREET

P.O. BOX 288

STRATFORD, CT 06615

PHONE: (203) 378-2659

FAX: (203) 378-3593

INTERNET: http://www.hubbellheaters.com

--IMPORTANT--

Always reference the full model number and serial number when calling the factory.

WARNING / CAUTION

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

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

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

4.The refractory material used in heating elements may absorb some moisture during transit, periods of storage, or when subjected to a humid environment. This moisture absorption results in a cold insulation resistance of less than twenty (20) megohms. If this heater has been subjected to the above condition, each heating element must be checked for insulation resistance before energizing. Contact the factory for a replacement element.

5.KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS.

Do not perform any maintenance, make any adjustments, or replace any components inside the control panel with the high voltage power supply turned on. Under certain circumstances, dangerous potentials may exist even when the power supply is off. To avoid casualties, always turn the power supply safety switch to off, turn the charge or ground the circuit before performing any maintenance or adjustment procedure.

6.The unit is designed to operate at pressure not more than 150 psi.

7.Generalized instructions and procedures cannot anticipate all situations. For this reason, only qualified installers should perform the installations. A qualified installer is a person who has licensed training and a working knowledge of the applicable codes, tools, equipment, and methods necessary for safe installation of an electric resistance water heater. If questions regarding installation arise, check your local plumbing and electrical inspectors for proper procedures and codes. If you cannot obtain the required information, contact the company.

8.Water Quality Requirements – Recommended water hardness is 4 to 6 grains of hardness per gallon (GPG). Water hardness above 6 GPG should be treated by a water conditioner (water softener or in-linetreatment). Water hardness below 4 GPG also requires treatment to reduce potential corrosion. Excessive GPG will result in higher operating and maintenance costs and will reduce product longevity. Chlorides must not exceed 50 parts per million (ppm). Excessive chlorides will result in metallic corrosion and will reduce product longevity. Water treatment has been shown to reduce costs associated withde-limingthe booster as well as reducing metallic corrosion. Product failure caused by these conditions is not covered under warranty. See warranty for complete details.

9.This water heater is not intended for space heating applications.

10.The water heater is factory set at 185°F for booster water heating applications. This results in the possibility of a scalding water injury. A full thickness skin burn can occur in less than one second of exposure to water at this temperature.

2

 

TABLE OF CONTENTS

 

SECTION

TITLE

PAGE #

I

GENERAL DESCRIPTION AND CONSTRUCTION

4

II

INSTALLATION AND START-UP

8

III

SCHEDULED MAINTENANCE AND OPERATION

19

IV

TROUBLESHOOTING

21

V

SERVICING & REPLACEMENT OF PARTS

26

VI

SERVICE PARTS LIST

29

VII

TORQUE VALUES

30

VIII

WARRANTY INFORMATION

31

3

SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This book describes a packaged electric booster heater that is typically used to provide 180°F sanitizing rinse water. The complete assembly consists of the storage tank, immersion electric heating element(s), electronic control module, safety relief valve, magnetic contactor(s), and any other required electrical operating control. Optional equipment may be supplied with your unit. Please consult the product packing list for details specific to your assembly. The unit is factory assembled, insulated, jacketed, wired, tested, and ready for electrical and plumbing service connections.

CAPACITY

Model

Storage Capacity

kW

40° Rise

70° Rise

(gallons)

(GPH)

(GPH)

 

 

J61

6

1

10

5

J61.5

6

1.5

15

8

J62

6

2

20

11

J63

6

3

30

17

J64

6

4

41

23

J65

6

5

51

29

J66

6

6

62

35

J67

6

7

72

41

J69

6

9

92

53

J610

6

10.5

108

62

J612

6

12

123

70

J613

6

13.5

138

79

J615

6

15

154

88

J618

6

18

185

105

J624

6

24

246

141

J627

6

27

277

158

J630

6

30

308

176

J636

6

36

369

211

J639

6

39

400

228

J640

6

40.5

415

237

J645

6

45

461

264

J654

6

54

554

316

J658

6

58.5

600

343

 

 

 

 

 

J161

16

1

10

5

J161.5

16

1.5

15

8

J162

16

2

20

11

J163

16

3

30

17

J164

16

4

41

23

J165

16

5

51

29

J166

16

6

62

35

J167

16

7

72

41

J169

16

9

92

53

J1610

16

10.5

108

62

J1612

16

12

123

70

J1613

16

13.5

138

79

J1615

16

15

154

88

J1618

16

18

185

105

J1624

16

24

246

141

J1627

16

27

277

158

J1630

16

30

308

176

J1636

16

36

369

211

J1639

16

39

400

228

J1640

16

40.5

415

237

J1645

16

45

461

264

J1654

16

54

554

316

J1658

16

58.5

600

343

4

5

CONSTRUCTION

TANK

The storage tank is designed, manufactured, and stamped in accordance with ASME section VIII Division 1. The tank is constructed of type 304L stainless steel for maximum tank longevity and fabricated by all welded construction and is designed for a maximum allowable working pressure of 150 psi (225 psi TP).

TANK CONNECTIONS

The heater is supplied with separate connections for the cold/warm inlet and the hot water outlet. Water entering the warm water inlet and leaving through the hot water outlet is evenly circulated by means of a diffuser within the tank. A ¾-inchFNPT connection is provided for mounting a combination safety temperature and pressure relief valve. An overflow line should be utilized from the relief valve outlet to a floor drain. See drawing for locations and sizes.

HEATING ELEMENT

The water heater is supplied with an electric immersion heating element assembly(s), composed of copper sheathed elements that are fitted into a brass 1½-12UNFscrew plug with1-7/8”hex. Each assembly is threaded into the tank and sealed with ano-ringgasket. See drawing for voltage and power ratings.

MAGNETIC CONTACTOR

The definite purpose magnetic contactor(s) is a heavy-dutyresistive load type. The contactor supplies power to the heating element(s) based on the resistive load(non-inductive)of the heater only when the relay on the control board is closed, thereby pulling in the contacts until the desired temperature is reached. At this point, the contacts will drop out, which in turn disconnects power from the elements. Units with two contactors will turn on and off in stages.

CONTROL BOARD AND DISPLAY

The control board supplies all the necessary function for heater operation. These include control temperature, hi-limitcut-out,low water detection, and leak detection.

LOW VOLTAGE CONTROL TRANSFORMER

A control circuit transformer is supplied with all models rated greater than 240-volts.This component is used to step down the primary power supply (600, 480, 440, 415, or 380) to208/240-voltsfor safety when working with control circuits.

POWER CIRCUIT BREAKERS

When required by code, a magnetic power circuit breaker is supplied for circuit overload protection. The circuit breaker can be reset in the event of a current overload.

OUTER SHELL, INSULATION, AND SUPPORTS

The tank is encapsulated in high efficiency polyurethane foam insulation meeting the requirements for UL 94 HF-1rating. The protective shell is constructed of type 304 brushed stainless steel. NSF approved adjustable plastic legs are provided for support.

6

DIAL TEMPERATURE AND PRESSURE GAUGE

A combination temperature (30°-240°F /0°-120°C)and pressure(0–200psi / 0- 1400 kPa) gauge with3-inchdial is supplied with the unit forin-lineinstallation (shipped loose). The connection is ½” NPT with a 2” long sensing probe.

PRESSURE REDUCING VALVE

A bronze pressure reducing valve with built-inbypass is supplied with the unit. This valve is shipped separately forin-lineinstallation. The ¾” NPT valve is adjustable from25-psito75-psi.The inlet connection is supplied with a ¾” union by sweat connection. The outlet connection is ¾” female NPT.

OPTIONAL EQUIPMENT

Slide Brackets

Available for the J6 Model only, these brackets allow for mounting the booster heater under a counter. See slide bracket diagram on page 8 for details.

Shock Absorber

The optional shock absorber can be installed between the booster and the dishwasher to reduce the harmful pressures resulting from quick closing dishwasher solenoid valves.

Legs

In lieu of the standard black plastic legs, optional adjustable legs are available in stainless steel, diecast nickel plated, and floor mount stainless steel. All optional legs are adjustable height type.

S/S Floor Mount

Nickel Plated

Stainless Steel

Security Package

For prison and other secure facilities a tamper resistant package is available. All external screws are spader type requiring a spader wrench for removal.

Alternate Voltage

Other voltages are available, including 380V, 440V, and 415V. Consult the factory for details.

Water Treatment System

The optional water treatment system provides superior mineral scale prevention and corrosion control by feeding a special blend of scale control compounds into the warm water stream before the booster. The in-linesystem includes a clear cartridge housing to allow an operator to view the cartridge and determine when it needs replacement without the need to open the system.

XB1 Low Temperature Interlock

An optional in-linecontrol board with separate manual setpoint (range: 165°F – 194°F) monitors the temperature of the water through the P65 probe and will trip a SPDT relay for customers’ remote applications.

Remote Alarm Plug Adapter

An optional plug adapter is available to provide a remote fault alarm signal through the J4 connector on the control board. See page 11 for installation details.

7

SECTION II INSTALLATION ANDSTART-UP

WARNING / CAUTION

DO NOT TURN ON THE ELECTRIC POWER SUPPLY to this equipment until heater is completely filled with water and all air has been released. If the heater is NOT filled with water when the power is turned on, the heating elements will burn out.

For protection against excessive pressures and temperatures, local codes require the installation of a temperature-and-pressure(T&P) relief valve certified by a nationally recognized laboratory that maintains periodic inspection of production of listed equipment of materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff for Hot Water Supply Systems. ANSIZ21.22-1971.THE CUSTOMER IS RESPONSIBLE TO PROTECT PROPERTY AND PERSONNEL FROM HARM WHEN THE VALVE FUNCTIONS.

All water heaters have a risk of leakage at some unpredictable time. IT IS THE CUSTOMER'S RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER ADEQUATE MEANS, SO THAT THE RESULTANT FLOW OF WATER WILL NOT DAMAGE FURNISHINGS OR PROPERTY.

Installation or service of this unit requires ability equal to that of a licensed tradesman in the field.

The installation must conform to these instructions and any local authority having jurisdiction. Grounding and electrical wiring connected to the unit must also conform to the latest version of the National Electric Code NFPA-70.

WATER HEATER PLACEMENT

NOTE: For most effective operation, install the booster heater as close as possible to the dishwasher. If the distance between the booster and the dishwasher exceeds NSF requirements, recirculation methods must be employed.

1.Place the heater on a solid, level foundation in a clean, dry location as near as possible to the dish washing machine.

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

3.Leave a minimum of 18” clearance for element withdrawal and control access.

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

SLIDE BRACKETS FOR HANGING SUPPORT MOUNTING

1.Weld slide rails to bottom of dishtable. Spacing should be 17” for J6 models 4 to 18kW and 22” for J6 models 24 to 58.5kW. J16 models are not designed for use with slide brackets.

2.Attach slide bracket angles to heater with #8 sheet metal screws. It will be necessary to drill 1/8” holes into heater jacket for screw pilot holes.

3.Slide heater onto slide rails under dishtable.

PIPING INSTALLATION – See Diagrams

NOTES:

Dielectric couplings should be used in connecting dissimilar metals to prevent electrolysis.

No check valve may be installed in the supply line to the booster.

8

All shut-offvalves must be gate or ball valves – not globe valves.

To minimize heat loss and maximize efficiency, hot water piping should be insulated.

Teflon tape should be used on all NPT threaded pipe connections.

1.Connect the cold/warm water inlet and hot water outlet to the appropriate connections as shown; refer to the specifications for location and sizes.

IMPORTANT – Be certain to connect the outlet piping to the final rinse and not to the wash tank. IMPORTANT (applies to J6 Models only) – Do not turn the entering warm water or exiting hot water nipples from their factory installed positions. The internal diffusers are aligned at the factory and turning the nipple will change the diffuser position and affect performance. Hubbell recommends that the inlet and outlet pipes are insulated to prevent excessive heat loss.

IMPORTANT (applies to J6 Models only) – Do not apply heat directly to the entering warm water or exiting hot water nipples. If sweat connections are to be used, sweat tubing to the adapter before threading the adapter to the nipple on the heater. Any heat applied to the heater nipple will damage the internal plastic diffuser and affect performance.

2.Install water pressure regulator and adjust to the pressure recommended by the dishwasher manufacturer. WHEN A STANDARD PRESSURE REGULATOR IS USED, (other than that purchased with the booster), it acts as a check valve and it is possible that thermal expansion will cause the relief valve to drip or occasionally blow off a small amount of water. To overcome this condition, it is recommended that a 3/8” by-passarrangement with a horizontal check valve be installed around the pressure regulator. This will prevent annoyance caused by the relief valve dripping or blowing off. The pressure reducing valve is adjustable from 10 to 35 psi. The set screw located at the top of the diaphragm adjusts the pressure, turnclockwise toincrease the pressure andcounter-clockwise todecrease the pressure.

3.Install in-linepressure and temperature gauge(s).NOTE: The temperature sensing element must be in the water stream.

4.Install the combination temperature and pressure safety relief valve in the tapping provided. Note that this is required by law for safety considerations.

Install into provided tapping

Manual Release Lever

Temperature Probe

Outlet to floor drain

Temperature and Pressure Relief Valve

5.Install a relief valve overflow pipe to a nearby floor drain. NOTE: Relief valve discharge piping limitations:

a.Termination to be plain end (no threads)

b.Maximum 30-feet

c.Maximum four (4) elbows

d.No reduction in line size

e.No valve of any type to be installed between the relief valve and tank or in the drain line

f.Termination to be 6-inchesabove the drain

6.A shock absorber is recommended in the hot water outlet line to soften the water hammer caused by automatic dishwasher solenoid valves.

9

7.Install the dial temperature and pressure gauge in the outlet line. The temperature sensing element must be in the hot water stream and the gauge must be mounted upright.

FILLING THE HEATER

1.Open the valve to the cold water inlet and allow the heater and piping system to completely fill, as indicated by a steady flow of water through the dishwasher rinse nozzles.

NOTE: Flush the tank at full flow for 10 minutes prior to putting into service.

ELECTRICAL INSTALLATION

1.Enter the base through the factory punched KO’s with properly sized feeder leads, See Wiring Chart. Single-phaseinstallations require two (2) leads. All3-phaseheaters are intended for use with a 3- wire delta system plus ground. No neutral is required. For a4-wireplus ground system, install 3 legs of power plus the ground and terminate the neutral leg.

2.Install these power leads into the box lugs on the power distribution block or magnetic contactor, as required.

3.All other electrical connections are made at the factory; therefore, no other electrical connections are necessary.

4.Connect incoming ground wire to ground lug supplied.

5.Check all connections, including factory connections, for tightness.

OPTIONAL XB1 LOW TEMPERATURE INTERLOCK

1.If desired, the XB1 can be used as an alarm relay or a temperature interlock at a setpoint other than the water temperature setpoint on the booster heater.

2.If the XB1 is not factory installed, mount the XB1 to the control panel, plug the P65 probe into the XB1, and plug the XB1 into the T1000 control board.

3.To set the XB1 setpoint, turn the potentiometer clockwise for a higher setpoint and counterclockwise for a lower setpoint. The range is adjustable between 150°F and 180°F.

10

4.Make connections as required to the relay terminal block. When the temperature drops below the XB1 setpoint the relay is open between Normally Open (NO) and Common (C) and the LED will flash green. When the temperature is above the XB1 setpoint the relay is closed between NO and C and the LED will be solid green. Use NO and C for low temperature interlock or high temperature alarm. Use Normally Closed (NC) and C for low temperature alarm. A red LED indicates an error.

Relay Terminal Block

LED

 

Temperature Adjustment

Note: Rating (resistive):

Max.: 5A

@ 120VAC

Potentiometer

5A

@ 24VDC

OPTIONAL REMOTE ALARM CONTACTS

1.If desired, the control board can be wired to a remote alarm to indicate a reset fault condition. These fault conditions include over-temperature,no probe, and low water (when the configuration is set to manual reset).

2.This alarm can be wired to the J4 connector on the control board as shown below. To facilitate this installation, an optional adapter, Hubbell P/N PLUG ADAPTER J4, can be purchased to provide wire connections.

J4 Connector

Common

 

(NO)

 

(NC)

Note: Rating (resistive)

Max. Switching Power: 60W, 62.5VA

PLUG ADAPTER J4 Max. Switching Voltage: 220VDC, 250VAC

Max. Switching Current: 2A

Max. Carrying Current: 3A

OPTIONAL FIELD CONVERSION FROM SINGLE TO THREE PHASE OR THREE TO SINGLE PHASE (6, 7, and 9 kW models in 208 and 240 volts only)

1.Find the appropriate diagram for the unit to be converted in the following chart titled “Wiring Chart”.

2.Re-wirethe unit according to the diagram.

NOTE: The wire to be used for internal wiring must conform toSEW-2or PTFE (200°C) and must match the wire size currently in use. Contact the factory for assistance, if required.

3.Contact the factory for correct labels. The factory will need the serial number for proper identification.

11

FOR REMOTE ON/OFF CONTROL

To remotely control the On / Off operation of the heater, it is recommended that a DPST switch or relay (by others) be used to break both power legs (white and black wires) connected to the top two terminals of the J5 connector on the control board. See diagram at right.

Use a NC (Normally Closed) relay to turn the booster ON when energizing the relay coil or to turn the booster OFF when deenergizing the relay coil.

Use a NO (Normally Open) relay to turn the booster OFF when energizing the relay coil or to turn the booster ON when deenergizing the relay coil.

Wiring from Contactor, Power Distribution Block, or Transformer

FINAL CHECKS

Remote Relay by Customer

Wiring by

Customer

1

2

34

Controller J5 Connector

Red Wire to

Yellow Wire to

Contactor #2

Contactor #1

1.Check all connections for tightness.

2.Ensure that all the above steps are completed.

3.Remove the protective outer plastic covering from the sheetmetal shell.

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

12

Wiring Chart

 

 

 

Unit

Branch

Phase-Phase

Min. Feed

Internal

Element

Copper Power

Conduit

 

kW

Volt

Ph

Amp

Resistance

Breaker or

Power Wire

Jumper

Diagram

Amp Draw

Feed Wire Size

Size

 

 

 

Draw

(Ohms)

Fuse Size

Size

Wire Size

 

 

 

 

 

 

 

 

4

208

1

19.2

19.2

10.8

25

12

N/A

10

½"

1(NT)

240

1

16.7

16.7

14.4

25

12

N/A

12

½"

1(NT)

 

480

1

8.3

8.3

57.6

15

12

N/A

14

½"

1(WT)

5

208

1

24.0

24.0

8.7

30

12

N/A

10

½"

1(NT)

240

1

20.8

20.8

11.5

30

12

N/A

10

½"

1(NT)

 

480

1

10.4

10.4

46.1

15

12

N/A

14

½"

1(WT)

 

208

1

28.8

28.8

7.2

40

12

12

8

½"

4

 

208

3

16.7

16.7

14.4

25

12

12

10

½"

10(NT)

6

240

1

25.0

25.0

9.6

35

12

12

8

½"

4

240

3

14.4

14.4

19.2

20

12

12

12

½"

10(NT)

 

 

480

3

7.2

7.2

76.8

10

12

12

14

½"

10(WT)

 

600

3

6.0

6.0

114.8

10

12

12

14

½"

14

 

208

1

32.5

32.5

6.4

45

12

12

8

½"

4

 

208

3

18.7

18.7

12.4

25

12

12

10

½"

10(NT)

7

240

1

30.5

30.5

8.2

40

12

12

8

½"

4

240

3

17.6

17.6

16.5

25

12

12

10

½"

10(NT)

 

 

480

3

8.4

8.4

65.8

15

12

12

14

½"

10(WT)

 

600

3

6.8

6.8

102.0

10

12

12

14

½"

14

 

208

1

43.3

43.3

4.8

55

10

12

6

¾"

4

 

208

3

25.0

25.0

9.6

35

10

12

8

½"

10(NT)

9

240

1

37.5

37.5

6.4

50

10

12

8

½"

4

240

3

21.7

21.7

12.8

30

10

12

10

½"

10(NT)

 

 

480

3

10.8

10.8

51.2

15

12

12

14

½"

10(WT)

 

600

3

9.1

9.1

76.5

15

12

12

14

½"

14

 

208

1

48.8

48.8

4.3

65

8

10

6

¾"

4

 

208

3

29.1

29.1

8.2

40

12

12

8

½"

10(NT)

10.5

240

1

43.8

43.8

5.5

55

10

12

6

¾"

4

240

3

25.3

25.3

11.0

35

12

12

8

½"

10(NT)

 

 

480

3

12.6

12.6

43.9

20

12

12

12

½"

10(WT)

 

600

3

10.2

10.2

68.1

15

12

12

14

½"

14

 

208

1

57.7

57.7

3.6

75

8

10

4

1"

4

 

208

3

33.3

33.3

7.2

45

12

12

8

½"

10(NT)

12

240

1

50.0

50.0

4.8

65

8

10

6

¾"

4

240

3

28.9

28.9

9.6

40

12

12

8

½"

10(NT)

 

 

480

3

14.4

14.4

38.4

20

12

12

12

½"

10(WT)

 

600

3

11.3

11.3

61.2

15

12

12

14

½"

14

 

208

1

64.9

64.9

3.2

85

8

10

4

1"

4

 

208

3

37.5

37.5

6.4

50

10

12

8

½"

10(NT)

13.5

240

1

56.3

56.3

4.3

75

8

10

4

1"

4

240

3

32.5

32.5

8.5

45

12

12

8

½"

10(NT)

 

 

480

3

16.2

16.2

34.1

25

12

12

12

½"

10(WT)

 

600

3

13.6

13.6

51.0

20

12

12

12

½"

14

 

208

1

72.1

72.1

2.9

95

6

8

3

1"

4 (DB)

 

208

3

41.6

41.6

5.8

55

10

12

6

¾"

10(NT)

15

240

1

62.5

62.5

3.8

80

8

10

4

1"

4

240

3

36.1

36.1

7.7

50

10

12

8

½"

10(NT)

 

 

480

3

18.0

18.0

30.7

25

12

12

10

½"

10(WT)

 

600

3

14.7

14.7

47.1

20

12

12

12

½"

14

 

208

1

86.5

86.5

2.4

110

6

8

2

1"

4 (DB)

 

208

3

50.0

50.0

4.8

65

8

10

6

¾"

10(NT)

18

240

1

75.0

75.0

3.2

95

6

8

3

1"

4 (DB)

240

3

43.3

43.3

6.4

55

10

12

6

¾"

10(NT)

 

 

480

3

21.7

21.7

25.6

30

12

12

10

½"

10(WT)

 

600

3

18.1

18.1

38.3

25

12

12

12

½"

14

13

 

 

 

Unit

Branch

Phase-Phase

Min. Feed

Internal

Element

Copper Power

Conduit

 

kW

Volt

Ph

Amp

Resistance

Breaker or

Power Wire

Jumper

Diagram

Amp Draw

Feed Wire Size

Size

 

 

 

Draw

(Ohms)

Fuse Size

Size

Wire Size

 

 

 

 

 

 

 

 

 

208

1

115.4

38.5

1.8

145

10

12

1/0

1¼"

3A

 

208

3

66.6

66.6

3.6

85

8

10

4

1"

13(NT)

24

240

1

100.0

33.3

2.4

130

12

12

1

1¼"

3A

240

3

57.7

57.7

4.8

75

8

10

4

1"

13(NT)

 

 

480

3

28.9

28.9

19.2

40

12

12

8

½"

13(WT)

 

600

3

22.6

22.6

30.6

30

12

12

10

½"

15

 

208

1

130.0

43.3

1.6

165

10

12

2/0

1½"

6A

 

208

3

74.9

37.5

3.2

95

10

12

3

1"

12(NCB)

27

240

1

112.5

37.5

2.1

145

10

12

1/0

1¼"

3A

240

3

65.0

65.0

4.3

85

8

10

4

1"

13(NT)

 

 

480

3

32.5

32.5

17.1

45

12

12

8

½"

13(WT)

 

600

3

27.2

27.2

25.5

35

12

12

8

½"

15

 

208

1

144.2

48.1

1.4

185

8

10

3/0

1½"

6A

 

208

3

83.3

41.6

2.9

105

10

12

2

1"

12(NCB)

30

240

1

125.0

41.7

1.9

160

10

12

2/0

1½"

6A

240

3

72.2

36.1

3.8

95

10

12

3

1"

12(NCB)

 

 

480

3

36.1

36.1

15.4

50

10

12

8

½"

13(WT)

 

600

3

29.4

29.4

23.6

40

12

12

8

½"

15

 

208

1

173.1

57.7

1.2

220

8

10

4/0

2"

6A

 

208

3

99.9

50.0

2.4

125

8

10

1

1¼"

12(NCB)

36

240

1

150.0

50.0

1.6

190

8

10

3/0

1½"

6A

240

3

86.6

43.3

3.2

110

10

12

2

1"

12(NCB)

 

 

480

3

43.3

43.3

12.8

55

10

12

6

¾"

13(WT)

 

600

3

36.2

36.2

19.1

50

10

12

8

½"

15

 

208

1

187.5

62.5

1.1

235

8

10

250

2"

6A

 

208

3

108.3

54.1

2.2

140

8

10

1/0

1¼"

12(NCB)

39

240

1

162.5

54.2

1.5

205

8

10

4/0

1½"

6A

240

3

93.8

46.9

3.0

120

10

12

1

1"

12(NCB)

 

 

480

3

46.9

46.9

11.8

60

8

10

6

¾"

13(WT)

 

600

3

36.2

36.2

19.1

50

10

12

8

¾"

15

 

208

1

195.0

65.0

1.1

245

8

10

250

2"

6A

 

208

3

112.6

56.3

2.1

145

8

10

1/0

1¼"

12(NCB)

40.5

240

1

168.8

56.3

1.4

215

8

10

250

1½"

6A

240

3

97.4

48.7

2.8

125

10

12

1

1"

12(NCB)

 

 

480

3

48.7

48.7

11.4

65

8

10

4

¾"

13(WT)

 

600

3

36.2

36.2

19.1

50

10

12

8

¾"

15

 

208

3

119.1

59.5

1.9

150

8

10

2/0

1¼"

12(NCB)

45

240

1

187.5

62.5

1.3

235

8

10

250

2"

6A

240

3

108.3

54.1

2.6

140

8

10

1/0

1¼"

12(NCB)

 

480

3

54.1

54.1

10.2

70

8

10

4

¾"

13(WT)

 

600

3

42.2

42.2

16.4

55

10

12

6

¾"

15

 

208

3

149.9

74.9

1.6

190

6

8

3/0

1½"

12

54

240

3

129.9

65.0

2.1

165

8

10

2/0

1½"

12

480

3

65.0

65.0

8.5

85

8

10

4

1"

13(WT)

 

 

600

3

54.3

54.3

12.8

70

8

10

4

1"

15

 

208

3

159.9

79.9

1.5

200

6

8

4/0

1½"

12

58.5

240

3

140.7

70.4

2.0

180

6

8

2/0

1½"

12

480

3

70.4

35.2

7.9

90

12

12

3

1"

12(WT)

 

 

600

3

54.3

54.3

12.8

70

8

10

4

1"

15

Notes:

1.Power feed wire sizing is based on using 75°C Cu THHN wire with feeder branch protection rated at 125%.

2.Internal wire sizing is based on using 200°C SEW-2or PTFE wiring in a raceway with an ambient temperature up to 60°C.

3.For information on 380V, 415V, or 440V models reference the supplied drawing or contact the factory.

4.Normal phase-to-phaseresistance tolerance is ±5%.

5.480-voltand600-voltphase-to-phaseresistance values are shown with the transformer disconnected.

6.For 575V models, multiply the kW rating of the 600V model by a de-ratingfactor of 0.92 to get the actual rating for 575V.

7.For models manufactured prior to June 24, 2005, that utilize wiring diagrams 3, 5, 6, 7(NT), 7(WT), or 11 please contact the factory for wiring diagrams.

14

1(WT)

 

 

1(NT)

 

3A

 

 

 

L1

L2

L2

 

 

 

 

 

 

 

 

L1

 

L1

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Control

 

 

 

 

Module &

 

 

 

 

 

Display

 

 

 

 

 

J7

 

 

 

 

J5

J2

 

 

 

 

 

J3

 

 

 

 

Control, Low Water,

 

 

 

 

 

& Hi-LimitProbe

 

 

 

 

 

Leak Detection

 

 

 

J7

Probe

 

 

 

 

 

 

 

 

J5

J2

Control

 

J7

 

 

 

 

 

J3

Module &

J5

J2

Control

 

 

Display

 

J3

Module &

 

 

 

 

 

Display

Control, Low Water,

& Hi-LimitProbe

Leak Detection Probe

Control, Low Water,

& Hi-LimitProbe

 

Leak Detection

Probe

4

 

 

 

 

 

 

 

 

 

 

 

 

 

4 (DB)

 

 

 

 

6A L1 L2

 

 

 

 

 

L1

 

L2

 

L1

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Control

 

Control

 

Control

 

Module &

Module &

Module &

 

Display

 

Display

 

Display

 

 

 

 

 

 

J7

 

J7

 

J7

 

 

 

 

 

 

J5

J2

J5

J2

J5

J2

 

J3

 

J3

 

J3

 

 

 

 

 

 

 

Control, Low Water,

 

Control, Low Water,

 

 

 

 

& Hi-LimitProbe

 

 

 

& Hi-LimitProbe

 

 

 

 

 

 

 

 

 

Leak Detection

Leak Detection

 

 

Probe

 

 

 

Probe

 

 

 

 

 

 

 

 

 

 

 

 

Control, Low

Leak

 

 

 

Water, & Hi-Limit

Detection

 

 

 

Probe

Probe

15

12 (WT) L1 L2 L3

13 (NT)

 

L1 L2 L3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J7

 

 

J5 J2

Control

 

J3

Module &

 

 

Display

 

Control, Low Water,

 

 

& Hi-LimitProbe

 

 

Leak Detection Probe

 

10(WT)

10(NT)

 

L1 L2 L3

L1 L2 L3

Control

Module &

Display

J7

 

 

 

 

J5

J2

 

 

 

 

J3

 

 

J7

 

 

 

 

J5

 

J2 Control

 

 

 

 

J3

Module &

Control, Low Water,

 

 

 

Display

 

 

 

 

 

 

 

 

& Hi-LimitProbe

Leak

 

 

 

 

 

 

 

 

 

Detection

 

Control, Low Water,

 

 

 

Probe

 

& Hi-LimitProbe

 

 

 

 

 

Leak Detection

Probe

 

J7

J5

 

J2 Control

J3

Module &

 

 

Display

 

 

Control, Low Water,

& Hi-LimitProbe

Leak Detection Probe

13(WT)

L1 L2 L3

 

J7

J5

 

J2 Control

J3

Module &

 

 

Display

 

 

Control, Low Water,

& Hi-LimitProbe

Leak

Detection

Probe

16

12 (NCB) L1 L2 L3

12

L1 L2 L3

Control

Module &

Display

J7

J5 J2

J3

Control, Low Water,

& Hi-LimitProbe

Leak Detection Probe

14

 

 

 

L1

L2

L3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J7

J5

J3 J2

Control, Low Water,

& Hi-LimitProbe

Leak Detection Probe

Control

Module &

Display

J7

J5 J2

J3

Control, Low Water,

& Hi-LimitProbe

Leak

Detection

Probe

15 L1 L2 L3

Control

Module &

Display

J7

J5

J3 J2

Control, Low Water,

& Hi-LimitProbe

Leak Detection Probe

Note: Wiring diagrams 3, 5, 6, 7 (NT), 7 (WT), and 11 are obsolete.

17

J6 Plumbing Connections

(Rear View)

J16 Plumbing Connections

(Front View)

18

SECTION III - SCHEDULED MAINTENANCE AND OPERATION

WARNING / CAUTION

Before performing any maintenance procedure, make certain the power supply is turned OFF and cannot accidentally be turned on.

MAINTENANCE AND OPERATION

The water heater is automatic in its operation. It will maintain a full tank of water at the temperature setting of the controller. The water heater should not be turned on without first making sure that the tank is full of water and that all air has been released.

FREEZING

The tank should be fully drained in the event the electricity has been turned off and if there is danger of freezing.

CONTROLLER OPERATION

NOTE: All controller variables come preset from the factory to include a preset temperature of 185°F.

1.To turn unit on or off:

a.Press the ON/OFF button on the display module.

b.Note that the controller will resume its last mode of operation if power is disconnected.

2.To change setpoint temperature (the temperature is fully adjustable from 32° to 194°F (0°-90°C):

a.Press the UP and DOWN arrows simultaneously to enter setpoint change mode.

b.Press the UP or DOWN button to change the setpoint temperature.

c.Pressing and holding the UP or DOWN button will scroll through the setpoint temperature.

d.To leave setpoint change mode

i.Wait 5 seconds without pushing any buttons or press the UP and DOWN buttons simultaneously.

3.To view the number of operational hours (the number of hours when a contactor is pulled in) and software version:

a.Press the UP and DOWN arrows simultaneously to enter setpoint change mode.

b.Press the ON/OFF button.

c.Display will flash the software version (e.g. R14), HRS, followed by the hours in thousands of hours, followed by the hours.

i.Example: r14, HrS, 123, 456; indicates software version R1.4 and 123,456 hours.

d.To leave operational hours mode

i.Wait 5 seconds without pushing any buttons or press the UP and DOWN buttons simultaneously.

4.Configuration Menu. (NOTE: Configuration menu change should only be made by qualified personnel).

a.To enter the configuration menu, press and hold the UP, DOWN, and ON/OFF buttons simultaneously for 5 seconds.

b.To scroll through menu settings, press the ON/OFF button.

c.To make a change to a menu setting use either the UP or DOWN arrow.

d.Settings:

i.Relays – sets the number of magnetic contactors used in the heater.

1.r##, where## is the number of magnetic contactors (01 or 02).

19

ii.Low water detection – sets the low water detection on or off.

1.LOn, for low water on. (Factory Default)

2.LOF, for low water off.

iii.Low water reset – sets the low water reset for either automatic or manual

1.LAU, for low water automatic reset. (Factory Default)

2.LAn, for low water manual reset.

iv.Temperature units – sets the temperature units to either degrees Fahrenheit or Celsius.

1.DEF, for degrees Fahrenheit. (Factory Default)

2.DEC, for degrees Celsius.

v.Differential – sets the number of degrees below setpoint that the heater will resume heating after it has achieved setpoint.

1.d##, where## is the differential in degrees (1 to 20). (Factory set at 02)

vi.Display – sets the display to either setpoint or actual temperature.

1.dSS, for display setpoint temperature. (Factory Default)

2.dSt, for display actual temperature.

e.To leave the configuration menu, wait 5 seconds without pushing any buttons or press the UP and DOWN buttons simultaneously.

5.To reset any high-limit,no probe, or low water (when in manual reset mode) fault condition, press the RESET button.

6.Display

a.By default the display will show the setpoint of the booster heater.

b.The decimal points on the display, as shown below, indicate that the controller is calling for a contactor to pull in.

Setpoint

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2nd Contactor

 

 

1st Contactor

(if supplied)

 

 

 

 

 

 

 

QUARTERLY INSPECTION

1.Monitor water temperature

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

b.After controller satisfies (that is, when the magnetic contactor actually clicks off), draw water from heater outlet and measure the temperature as close as possible to the heater.

c.Compare the water temperature of outlet water to the temperature setting of the display when it satisfies. Normal variation between the two points is approximately + 5°F.

d.If these two readings do not coincide within acceptable tolerances and verification has been made of the accuracy of the temperature-readinggauge, replace the control board and/or the sensor probe.

2.Lift test lever on relief valve and let water run through valve for a period of approximately 10 seconds. This will help flush away any sediment that might build up in water passageways.

3.Inspect element for leakage as follows:

20