OPERATING AND MAINTENANCE
MANUAL FOR
ELECTRIC BOOSTER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ J ”
ASME ANSI/NSF5
2010 Edition
2
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) megohm s. 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-line treatment). 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 with de-liming the 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.
3
TABLE OF CONTENTS
SECTION TITLE PAGE No.
I GENERAL DESCRIPTION AND CONSTRUCTION 4
II INSTALLATION AND START-UP 9
III SCHEDULED MAINTENANCE AND OPERATION 24
IV TROUBLESHOOTING 26
V SERVICING AND REPLACEMENT OF PARTS 32
VI SERVICE PARTS LIST 35
VII TORQUE VALUES 37
VIII WARRANTY INFORMATION 38
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
(gallons)
kW
40°F
Rise
(GPH)
70°F
Rise
(GPH)
Model
Storage
Capacity
(gallons)
kW
40°F
Rise
(GPH)
70°F
Rise
(GPH)
J32.9 3 2.9 30 17 J161 16 1 10 5
J35.7 3 5.7 58 33 J161.5 16 1.5 15 8
J39.9 3 9.9 101 58 J162 16 2 20 11
J310.4 3 10.4 107 61 J163 16 3 30 17
J311.4 3 11.4 117 67 J164 16 4 41 23
J411 4 11.4 117 67 J166 16 6 62 35
J415 4 15 154 88 J167 16 7 72 41
J427 4 27 277 158 J169 16 9 92 53
J61 6 1 10 5 J1612 16 12 123 70
J61.5 6 1.5 15 8 J1613 16 13.5 138 79
J62 6 2 20 11 J1615 16 15 154 88
J63 6 3 30 17 J1618 16 18 185 105
J64 6 4 41 23 J1624 16 24 246 141
J65 6 5 51 29 J1627 16 27 277 158
J66 6 6 62 35 J1630 16 30 308 176
J67 6 7 72 41 J1636 16 36 369 211
J69 6 9 92 53 J1639 16 39 400 228
J610 6 10.5 108 62 J1640 16 40.5 415 237
J612 6 12 123 70 J1645 16 45 461 264
J613 6 13.5 138 79 J1654 16 54 554 316
J615 6 15 154 88 J1658 16 58.5 600 343
J618 6 18 185 105 J1664 16 64 656 375
J624 6 24 246 141 J1666 16 66 677 387
J627 6 27 277 158 J1668 16 68 697 398
J630 6 30 308 176 J1679 16 79 810 463
J636 6 36 369 211 J1681 16 81 830 474
J639 6 39 400 228 J1685 16 85 871 498
J640 6 40.5 415 237 J1686 16 86 882 504
J645 6 45 461 264 J1688 16 88 902 515
J654 6 54 554 316 J1690 16 90 923 527
J658 6 58.5 600 343
4
5
6
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-inch FNPT 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 1½-12UNF screw plug with 1-7/8” hex. Each
assembly is threaded into the tank and sealed with an o-ring gasket. See drawing for voltage and
power ratings. Note that the J3 model element is a 1” NPS thread with a 1 ½” hex.
MAGNETIC CONTACTOR
The definite purpose magnetic contactor(s) is a heavy-duty resistive
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, hilimit cut-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, 380, or 277) to 208/240volts for 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 foam insulation meeting the requirements for UL 94
HF-1 rating. The protective shell is constructed of type 304 brushed stainless steel. NSF
approved adjustable plastic legs are provided for support. Plastic legs for the J3 and J4 models
are optional.
DIAL TEMPERATURE AND PRESSURE GAUGE
A combination temperature (30°-240° F / 0°-120°C) and pressure (0–200
psi / 0-1400 kPa) gauge with 3-inch dial is supplied with the unit for in-line
installation (shipped loose). The connection is ½” NPT with a 2” long
sensing probe. Dial temperature and pressure gauges for the J3 and J4
models are optional.
7
PRESSURE REDUCING VALVE
A bronze pressure reducing valve with built-in bypass is supplied with the
unit. This valve is shipped separately for in-line installation. The ¾” NPT
valve is adjustable from 25-psi to 75-psi. The inlet connection is supplied with
a ¾” union by sweat connection. The outlet connection is ¾” female NPT.
The set screw located at the top of the diaphragm adjusts the pressure, turn
clockwise to decrease
the pressure and counter-clockwise to increase the
pressure. Pressure reducing valves for the J3 and J4 models are optional.
DIELECTRIC UNIONS
Dielectric unions are provided for the inlet and outlet nipples to isolate stray
ground currents to reduce the possibility of galvanic corrosion. (Optional on
the J3 and J4 Models).
OPTIONAL EQUIPMENT
Slide Brackets
8
Available for the J6 Model only, these brackets allow for mounting the booster heater under a
counter. See slide bracket diagram on page 9 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, die-cast nickel plated, and
floor mount stainless steel. All optional
legs are adjustable height type. 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 277V single-phase, and 380V, 415V, and 440V threephase. 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 heater. The
in-line system 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-line control 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 12 for
installation details.
24-Volt Heater Interlock Adapter
An optional plug adapter is available to interlock the heater via a 24-volt
signal through the J1 connector on the control board. The 24-volt heater
interlock adapter is supplied standard on the J3 model. See page 13 for
installation details. (Only available with r23 or later software).
Protective Shrouds (J6 and J16 only)
An optional durable protective plastic shroud is
available to prevent damage to the booster due to
water intrusion. The cover fits snugly over the
entire booster and can be easily removed for
cleaning and service.
SECTION II – INSTALLATION AND START-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. ANSI Z21.22-1971. THE CUSTOMER
IS RESPONSIBLE TO PROTECT PROPERTY AND PERSONNEL FROM HARM
WHEN THE VALVE FUNCTIONS.
• All water heaters have a risk of leakage at some unpredictable time. IT IS THE
CUSTOMER'S RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER
ADEQUATE MEANS, SO THAT THE RESULTANT FLOW OF WATER WILL
NOT DAMAGE 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 up to
18kW and 22” for J6
models 24 to 58.5kW.
J16 models are not
designed for use with
slide brackets.
9
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:
• No check valve may be installed in the supply line to the booster.
• All shut-off valves 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. Install the factory supplied dielectric unions on the inlet and outlet piping.
2. 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.
3. Install water pressure regulator in the entering cold/warm water inlet line 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-pass arrangement 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 25 to 75 psi. The set screw located at the top of the diaphragm adjusts the pressure,
turn clockwise
to increase the pressure and counter-clockwise to decrease the pressure.
4. Install the factory supplied in-line pressure and temperature gauge in the entering
cold/warm water line. NOTE: The temperature sensing element must be in the water
stream.
5. 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
6. 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
10
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-inches above the drain
7. A shock absorber is recommended in the hot water outlet line to soften the water
hammer caused by automatic dishwasher solenoid valves.
8. If supplied, install the optional second 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 cut KO’s with properly sized feeder leads, See
Wiring Chart. Single-phase installations require two (2) leads. All Hubbell 3-phase
heaters are intended for use with a 3-wire delta system plus ground. No neutral is
required. For a 4-wire plus 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. Connect incoming ground wire to ground lug supplied.
4. Check for proper grounding. Check for AC millivolts (mV) between the ground
connection at the booster and the inlet piping past the dielectric union (on the building
side, not the booster side). There should be zero potential/millivolts (mV). If not
zero, then the piping should be re-grounded.
5. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
6. 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.
11
3. To set the XB1 setpoint, turn the potentiometer clockwise for a higher setpoint and
counter-clockwise for a lower setpoint. The range is adjustable between 150°F and
180°F.
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.
LED
Relay
Terminal Block
12
Temperature Adjustment Potentiometer
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 whe
de-energizing the relay coil.
n
Use a NO (Normally Open) relay to turn the booster OFF when energizing the relay coil or
to turn the booster ON when de-energizing the relay coil.
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
Note: Rating (resistive)
Max. Switching Power:
60W, 62.5VA
Max. Switching Voltage:
220VDC, 250VAC
Max. Switching Current: 2A
Max. Carr
y
ing Current: 3A
PLUG ADAPTER J4
Wiring by
Customer
Remote Relay by Customer
1
2
3
4
Controller J5 Connector
Red Wire to
Contactor #2
Wiring from Contactor,
Power Distribution Block,
or Transformer
Yellow Wire to
Contactor #1
Note: Rating (resistive):
Max.: 5A @ 120VAC
5A @ 24VDC
(NO)
(NC)
OPTIONAL FIELD CONVERSION FROM SINGLE TO THREE PHASE OR
THREE TO SINGLE PHASE (J6 and J16 models in 6, 7, and 9 kW and 208 and 240
volts and J411 models only)
1. For J6 and J16 models:
a. Find the appropriate diagram for the unit to be converted in the following chart
titled “Wiring Chart”.
b. Re-wire the unit according to the diagram.
NOTE: The wire to be used for internal wiring must conform to SEW-2 or
PTFE (200°C) and must match the wire size currently in use. Contact the
factory for assistance, if required.
c. Contact the factory for correct labels. The factory will need the serial number
for proper identification.
2. For J411 models:
a. Re-wire the unit to desired configuration as indicated below.
Single-Phase 3-Phase
OPTIONAL 24-VOLT HEATER INTERLOCK ADAPTER
1. If desired, the heater can be wired to operate only when supplied with a 24-volt signal
through the heater interlock adapter. When no 24-volt signal is supplied through the
heater interlock adapter the heater is interlocked and will not energize. When
interlocked the display will show “HLd”. The heater will resume normal operation
when a 24-volt signal is re-applied through the heater interlock adapter.
2. To utilize this feature, plug the 24-volt heater interlock adapter into terminal J1 of the
control board and verify that the configuration is set to “Hon”, see the controller
operation section for further detail. The signal can be either AC or DC. However, if a
DC signal is utilized and the interlock feature does not operate, switch the two 24-volt
supply wires at the heater interlock adapter.
J1
13
To J1
To 24-Volt Signal
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed.
3. Remove the protective outer plastic covering from the sheet metal shell.
4. After the water is heated for the first time, monitor the water temperature as described
in Section III, Annual Inspection.
J6 and J16 Wiring Chart
kW Volt Ph
Unit
Amp
Draw
Branch
Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min.
Feed
Breaker
or Fuse
Size
Internal
Power
Wire
Size
Element
Jumper
Wire
Size
Copper
Power Feed
Wire Size
Conduit
Size
Diagram
1 120 1 8.3 8.3 14.4 15 12 N/A 14 ½" 1(NT)
1.5 120 1 12.5 12.5 9.6 20 12 N/A 14 ½" 1(NT)
2 120 1 16.7 16.7 7.2 25 12 N/A 12 ½" 1(NT)
3 120 1 25.0 25.0 4.8 35 12 12 10 ½" 1(NT)
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)
380 1 10.7 10.7 36.1 15 12 N/A 12 ½" 1(WT)
480 1 8.3 8.3 57.6 15 12 N/A 14 ½" 1(WT)
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)
380 1 13.2 13.2 28.9 20 12 N/A 12 ½" 1(WT)
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)
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)
380 3 8.6 8.6 48.1 15 12 12 14 ½" 10(WT)
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)
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)
380 3 10.0 10.0 41.3 15 12 12 12 ½" 10(WT)
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)
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)
380 3 14.3 14.3 32.1 20 12 12 12 ½" 10(WT)
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)
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)
380 3 17.1 17.1 27.5 25 12 12 10 ½" 10(WT)
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)
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)
380 3 18.6 18.6 24.1 25 12 12 10 ½" 10(WT)
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)
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)
380 3 21.4 21.4 21.4 30 12 12 10 ½" 10(WT)
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
4
5
6
7
9
10.5
12
13.5
14
J6 and J16 Wiring Chart (cont.)
kW Volt Ph
Unit
Amp
Draw
Branch
Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min.
Feed
Breaker
or Fuse
Size
Internal
Power
Wire
Size
Element
Jumper
Wire
Size
Copper
Power Feed
Wire Size
Conduit
Size
Diagram
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)
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)
380 3 22.9 22.9 19.3 30 12 12 8 ½" 10(WT)
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)
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)
380 3 27.9 27.9 16.0 35 12 12 8 ½" 10(WT)
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
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)
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)
380 3 37.1 37.1 12.0 50 10 12 6 ¾" 13(WT)
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)
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)
380 3 42.9 42.9 10.7 55 10 12 6 ¾" 13(WT)
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)
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)
380 3 45.7 45.7 9.6 60 10 12 4 1" 13(WT)
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)
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)
380 3 55.7 55.7 8.0 70 8 10 3 1" 13(WT)
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)
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)
380 3 60.8 60.8 7.4 80 8 10 3 1" 13(WT)
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
15
18
24
27
30
36
39
15
J6 and J16 Wiring Chart (cont.)
kW Volt Ph
Unit
Amp
Draw
Branch
Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min.
Feed
Breaker
or Fuse
Size
Internal
Power
Wire
Size
Element
Jumper
Wire
Size
Copper
Power Feed
Wire Size
Conduit
Size
Diagram
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)
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)
380 3 60.8 60.8 7.1 80 8 10 3 1" 13(WT)
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)
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)
380 3 68.6 34.3 6.4 90 12 12 2 1" 12(WT)
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
240 3 129.9 65.0 2.1 165 8 10 2/0 1½" 12
380 3 80.0 40.0 5.3 100 10 12 1 1" 12(WT)
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
240 3 140.7 70.4 2.0 180 6 8 2/0 1½" 12
380 3 91.4 45.7 4.9 115 10 12 1 1" 12(WT)
480 3 70.4 35.2 7.9 90 12 12 3 1" 12(WT)
600 3 54.3 54.3 12.3 70 8 10 4 1" 15
64 208 3 178.6 59.5 1.4 225 8 10 4/0 1½" 17
66 600 3 63.4 63.4 10.9 80 8 10 4 ¾" 18
240 3 162.4 54.1 1.7 205 8 10 4/0 1½" 17
380 3 102.8 34.3 4.2 130 12 12 1/0 1¼" 16(WT)
480 3 81.2 27.1 6.8 105 12 12 2 1" 16(WT)
79 380 3 120.0 40.0 3.7 150 10 12 2/0 1¼" 16(WT)
208 3 224.8 74.9 1.1 285 6 8 300 2" 17
240 3 194.9 65.0 1.4 245 8 10 250 2" 17
480 3 105.5 35.2 5.7 135 12 12 1 1" 16(WT)
85 600 3 81.5 81.5 8.5 105 6 8 2 1" 18
86 208 3 239.8 79.9 1.0 300 6 8 350 2" 17
240 3 211.1 70.4 1.3 265 6 8 300 2" 17
480 3 105.5 35.2 5.2 135 12 12 1/0 1¼" 16(WT)
90 380 3 137.1 45.7 3.2 175 10 12 2/0 1½" 16(CBWT)
88
58.5
40.5
45
54
68
81
J6 and J16 Wiring Chart 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-2 or PTFE wiring in a raceway
with an ambient temperature up to 60°C.
3. For information on 277V, 415V, or 440V models reference the supplied drawing
or contact the factory.
4. Normal phase-to-phase resistance tolerance is ±5%.
5. 380, 480, and 600-volt phase-to-phase resistance values are shown with the transformer
disconnected.
6. For 575V models, multiply the kW rating of the 600V model by a de-rating factor 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.
16
J3 Wiring Chart
kW Volt Ph
Unit
Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min.
Feed
Breaker
or Fuse
Size
Internal
Power
Wire
Size
Element
Jumper
Wire
Size
Copper
Power Feed
Wire Size
Conduit
Size
Diagram
2.9 120 1 23.8 5.0 30 12 12 10 ½" 4
5.7 120 1 47.5 2.5 60 10 12 6 ¾" 4
208 1 47.6 4.4 60 10 12 6 ¾" 4
208 3 27.5 8.7 35 12 12 8 ½" 10 (NT)
208 1 51.9 4.2 65 10 12 6 ¾" 4
208 3 28.8 8.3 40 12 12 8 ½" 10 (NT)
240 1 47.5 5.1 60 10 12 6 ¾" 4
240 3 27.4 10.1 35 12 12 8 ½" 10 (NT)
277 1 41.2 6.7 55 10 12 6 ¾" 4 (WT)
380 3 16.8 25.3 25 12 12 12 ½" 14
415 3 15.9 30.2 20 12 12 12 ½" 14
480 3 13.7 40.4 20 12 12 14 ½" 14
600 3 11.0 63.2 15 12 12 14 ½" 14
9.9
10.4
11.4
J3 Wiring Chart 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-2 or PTFE wiring in a raceway
with an ambient temperature up to 60°C.
3. Normal phase-to-phase resistance tolerance is ±5%.
4. 277, 380,415, 480, and 600-volt phase-to-phase resistance values are shown with the
transformer disconnected.
J4 Wiring Chart
kW Volt Ph
Unit
Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min.
Feed
Breaker
or Fuse
Size
Internal
Power
Wire
Size
Element
Jumper
Wire
Size
Copper
Power Feed
Wire Size
Conduit
Size
Diagram
208 1 54.1 3.8 70 8 8 4 1" 4
208 3 31.2 7.7 40 8 8 8 ½" 10 (NT)
220 1 57.3 3.8 75 8 8 4 1" 4
220 3 33.1 7.7 45 8 8 8 ½" 10 (NT)
230 1 59.8 3.8 75 8 8 4 1" 4
230 3 34.5 7.7 45 8 8 8 ½" 10 (NT)
240 1 62.5 3.8 80 8 8 4 1" 4
240 3 36.1 7.7 50 8 8 8 ½" 10 (NT)
480 3 18.0 30.7 25 12 12 10 ½" 10 (WT)
208 3 75.0 3.2 95 6 8 3 1" 10 (NT)
240 3 65.0 4.3 85 8 10 4 1" 10 (NT)
480 3 32.5 17.1 45 12 12 8 ½" 10 (WT)
13.8
11.3
12.6
15
27
J4 Wiring Chart 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-2 or PTFE wiring in a raceway
with an ambient temperature up to 60°C.
3. Normal phase-to-phase resistance tolerance is ±5%.
4. 480-volt phase-to-phase resistance values are shown with the transformer disconnected.
Note: Wiring diagrams 3, 5, 6, 7 (NT), 7 (WT), and 11 are obsolete.
1(WT)
L1
L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
Control
Module &
Display
1(NT)
L1 L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection
Probe
Control
Module &
Display
J7
J7
L1 L2 L3
J5J3J2
J7
17
Control
Module &
Display
Control, Low
Water, & Hi-Limit
Probe
Leak
Detection
Probe
10(WT)
L1 L3L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection
Probe
Control
Module &
Display
10(NT)
L1 L3L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak
Detection
Probe
Control
Module &
Display
J7
J7
6A
L1 L2
J5
J3
J2
Control, Low
Water, & Hi-Limit
Probe
Leak
Detection
Probe
Control
Module &
Display
J7
3A
L1 L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection
Probe
Control
Module &
Display
J7
13 (NT)
L1 L3L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
Control
Module &
Display
J7
12 (WT)
L1 L2 L3
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
Control
Module &
Display
J7
12
L1 L2 L3
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak
Detection
Probe
Control
Module &
Display
J7
13(WT)
L1 L3L2
J5
J3
J2
Control, Low Water,
& Hi-Limit Probe
Leak
Detection
Probe
Control
Module &
Display
J7
20
21
Typical J6 Plumbing Connections
(Rear View)
Typical J16 Plumbing Connections
(Front View)
22
Typical J4 Plumbing Connections
(Rear View, shown with optional legs)
Typical J3 Plumbing Connections
(Front View, shown with optional legs)
23
24
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).
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.
vii. Heater Interlock – sets the heater interlock mode to on or off. (Only
available with r23 or later software).
1. HoF, to disable the 24-volt interlock feature. (Factory Default)
2. Hon, to enable the 24-volt interlock feature.
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.
ANNUAL 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 as close as possible heater outlet and measure the
temperature.
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-reading gauge,
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:
a. Shut off power supply.
25
26
b. Remove front cover.
c. Visually inspect around heating element for evidence of leaks.
d. Rub around the heating element with a rag. Check for any evidence of
moisture. If moisture is present or a water drip is observed, follow procedure
outlined in Section V.
CAUTION: The area around the heating element may be hot.
4. Scale and mineral build-up on heating elements is a normal condition. It is
recommended that the heating element be removed for examination and if scaled,
should be cleaned. In an area of known hard or poor water conditions, the elements
may need to be checked more frequently. This will improve the efficiency of the
heater and increase the element life.
NOTE: Failure of the elements due to scale and mineral build-up is not covered under
warranty. See warranty for complete details.
a. Shut off power supply.
b. Drain the tank.
c. Remove front cover.
d. Disconnect the element wiring. It is recommended that one element at a time
is removed to simplify re-wiring.
e. Unscrew element.
f. Lime scale removal
i. Place limed ends of the heating element in a de-limer solution, designed
for potable water applications, and allow lime to dissolve. Do not allow
de-limer to contact heating element terminals.
g. Other scale removal
i. Silicates, sulfates, and aluminates must be rem oved by scraping or other
mechanical means. De-limers will not dissolve these types of scale.
h. Flush the cleaned ends of the elements with clean water.
i. Re-install element with new o-ring.
j. Re-attach element wires.
k. Continue until all heating elements are cleaned.
l. Fill the heater following the filling instructions provided in Section II and check
around the elements for leaks.
m. Re-apply power.
5. Check for loose electrical connections. Tighten as necessary.
SECTION IV – TROUBLESHOOTING
ERROR MESSAGES
1. Err, No, Prb
a. This message will flash when the controller does not detect that the probe is
connected to the control board. To clear this error reinsert the probe connector
and press RESET.
2. Err, too, hot, ### (where ### is the actual temperature of the water.)
a. This message will display if the temperature of the water exceeds the high limit
temperature setpoint. To clear this error, wait until the temperature is below the
operating setpoint and press RESET. Note that the unit will not reset until the
indicated temperature is below 195°F. If this message continually occurs, follow
the troubleshooting flow chart for continuous over-temperature condition.
3. Err, No, H2O
a. This message will display when the water level in the tank has dropped below
the sensor probe. To clear this message, refill the tank. If the low water reset is
set for automatic, the error will clear. If the low water reset is set for manual,
when the tank is full press RESET. Check the heater and the piping for leaks.
27
Check for mineral buildup on the probe and clean as required. Check for
continuity between the yellow wire and ground. See diagram 2 on the following
page.
4. Err, H2O, LEA
a. This message displays if the leak detection sensor determines there is water in
the base of the heater shell. To clear this message, remove the water from the
leak detection sensor. Check the unit and piping for leaks.
5. CC
a. This message displays if the display cable is installed into the control board
backwards. To clear this message, remove and correctly install the display cable.
6. 255
a. This message indicates that the probe is likely out of calibration. To clear this
message, it is recommended that the probe be removed and replaced.
7. HLd
a. This message indicates that the 24-volt interlock feature is enabled, there is no
24-volt signal present, and the heater is in standby mode. If it is not the intention
to operate the heater with the 24-volt interlock feature, this feature should be
disabled as shown in the controller operation section. (Only available with r23 or
later software).
CONTACTOR CARE
1. A chattering or humming from the contactor is due to dust or debris on the contact points
that prevents the contactor from making proper contact. The debris can be removed by
utilizing a can of antistatic cleaning and dusting spray (pressurized air) and spraying
through the side of the contactor to remove the debris.
DISPLAY BUTTONS
1. If the display randomly changes or does not respond when the buttons are pressed,
loosen the four (4) screws holding the display to the base, reseat the display in the
center of the opening, and re-tighten the screws.
MISCELLANEOUS
2. If the display flashes when the unit is first turned on or turned on after maintenance,
check that the J5 terminal on the controller is engaging all four pins on the board.
3. Note that before replacing the control board, display, or probe, it is recommended that
the power supply to the booster heater be turned off at the main circuit breaker
disconnect to the booster heater to reset and clear the electronic controller.
CAUTION: Do not use plumber’s tape/Teflon tape/pipe dope when installing the probe.
Tape will prevent the low water detection system from operating properly and will cause
false low water errors. Lubricate O-ring prior to installation.
28
GENERAL TROUBLESHOOTING
Symptom Probable Cause Corrective Action
Water reaches setpoint
temperature but does
not last through the
entire dishwasher
cycle.
Low incoming water
temperature.
Incoming water temperature must be
adequate for the booster size. Increase the
incoming water temperature.
Incoming water
temperature is dropping.
Primary water supply is not adequate to
continually provide correct temperature in
sufficient quantities. Increase the supply of
primary warm water.
Water pressure is too
high.
Higher water pressure uses an excessive
supply of hot water. Verify a pressure
reducing valve is installed and adjust the
water pressure to 20 psi.
Booster heater may be
undersized.
The booster heater must be properly sized
for the incoming water and rinse
requirements of the dishwasher. If required,
replace with a properly sized unit.
Incorrect voltage. Voltage available at the booster heater must
be correct for unit. Verify voltage on all
phases matches nameplate on the booster
heater.
If two magnetic
contactors are utilized,
one is not energizing.
Verify that both magnetic contactors are
operating. If not, see the ‘Magnetic
Contactor Troubleshooting’ section.
One or more elements
are not energizing.
Verify that each element is drawing the
correct amperage. Replace elements as
required.
Water at the
dishwasher is not the
proper temperature.
Gauge(s) not reading
correctly.
Check the temperature of the water with a
thermometer to verify the gauges are
working properly. Replace gauges, if
required.
Temperature setpoint
too low.
Adjust the temperature setpoint.
Booster heater piping to
the dishwasher is not
insulated.
If there is more than 5 linear feet of piping
between the booster heater and the
dishwasher the piping should be wrapped
in insulation or a recirculating system
should be installed.
Bypass valve is open or
allowing water to pass
when closed.
Verify that the bypass valve between the
hot and warm water lines is closed. If
condition continues, replace the bypass
valve.
29
Symptom Probable Cause Corrective Action
Temperature and
pressure relief valve
seeps
No pressure reducing
valve or wrong valve
installed causing
excessive pressure in
the unit.
The proper pressure reducing valve with high
pressure bypass must be installed in the inlet
water line to allow for the expansion of water.
Pressure reducing valve
bypass is blocked.
Clean the bypass or install a new valve with a
built-in bypass.
Anti-siphon valve or
check valve installed in
the warm water inlet
line.
Remove the anti-siphon valve or the check
valve to allow for the expansion of the water
or install a back pressure relief valve.
Temperature and
pressure relief valve
opens and/or high
limit temperature
error occurs.
Unit is overheating due
to improper P65 probe
calibration.
See the ‘P65 Probe Troubleshooting’ section.
Unit is overheating due
to the magnetic
contactor staying in the
closed position.
See the ‘Magnetic Contactor Troubleshooting’
section.
Booster heater does
not heat at all.
Main supply circuit
breaker tripped.
Check and/or reset the circuit breaker.
Booster heater circuit
breaker tripped.
If unit is supplied with a circuit breaker, check
and/or reset the circuit breaker.
Booster in high limit. If a high limit error occurs, allow water to cool
and press the reset button. If error continues
see symptom “Temperature and pressure relief
valve opens and/or high limit temperature
error occurs”.
Low water error. Verify that booster heater is full of water. If
error is still present see the ‘P65 Probe
Troubleshooting’ section.
Magnetic contactor
does not energize.
See the ‘Magnetic Contactor Troubleshooting’
section.
No power to control
board (T1000) or
display (TD1000) not
lit.
Reseat the display (TD1000) ribbon cable in
the control board (T1000) connector. If the
display is still not lit, see the ‘Control Board
(T1000) / Display (TD1000) Troubleshooting’
section.
Element Failure Disconnect the wires from each element and
verify that the resistance (ohms) value for each
element is correct. Replace elements as
required.
CONTROL BOARD (T1000) / DISPLAY (TD1000) TROUBLESHOOTING
1. Verify proper power supply voltage between each phase (L1 to L2, L2 to L3, and L1 to
L3). The power supply voltage should match the voltage listed on the booster nameplate.
If voltage is incorrect, check main supply wiring or replace unit with proper booster
heater.
2. Check for 208/240VAC between pin 1 (white wire) and pin 2 (black wire) of the J5
connector on the T1000 control board. If no voltage is present, skip to step 4.
3. If 240VAC is present, check for 24VDC between D1 and ground. If 24VDC is present
replace the display (TD1000). If 24VDC is not present replace the control board (T1000).
Ground Wire (J7) Display Cable Leak Detection Wire (J2) Probe Cable (J3)
(D1)
Power Wire (Common, White) Connector (J5)
Power Wire (Black) Wire to #1 Contactor (yellow)
Wire to #2 Contactor (red)
4. If a transformer is installed, verify proper power supply voltage to the primary side of the
transformer and verify approximately 240VAC on the secondary side of the transformer.
If voltage is present of the primary side but not on the secondary side, replace the
transformer.
5. If circuit breakers are installed, verify that the circuit breaker is ON. Verify proper power
supply voltage between each phase (L1 to L2, L2 to L3, and L1 to L3) to the line side of
each circuit breaker and to the load side of each circuit breaker. If voltage is present of
the line side but not on the load side, replace the circuit breaker.
6. Verify that the booster heater is wired according to the proper wiring schematic for the
unit. Correct as required. If unit still does not operate, contact the factory.
MAGNETIC CONTACTOR TROUBLESHOOTING
1. With the unit ON and calling for heat, check for lit decimal points on the display. If the
unit has a single contactor, the first decimal to the right of the display should be lit. If two
decimals are lit, verify that the configuration is set for one contactor. If the unit has two
contactors, verify that two decimals are lit. If only one decimal is lit, verify that the
configuration is set for two contactors. If no decimals are lit, continue to the ‘P65 Probe
Troubleshooting’ section.
2. With the unit ON and calling for heat and one decimal lit, check for 240VAC between
pin 1 (white wire) and pin 4 (yellow wire) of the J5 connector on the T1000 control
board. If no voltage is present, replace the control board (T1000). If voltage is present,
check for voltage across the contactor coil. If voltage is present at the contactor coil,
replace the magnetic contactor. If no voltage is present, verify that the booster heater is
wired according to the proper wiring schematic for the unit.
3. If the unit has two contactors, with the unit ON and calling for heat and two decimals lit,
check for 240VAC between pin 1 (white wire) and pin 3 (red wire) of the J5 connector
30
on the T1000 control board. If no voltage is present, replace the control board (T1000). If
voltage is present, check for voltage across the contactor coil. If voltage is present at the
contactor coil, replace the magnetic contactor. If no voltage is present, verify that the
booster heater is wired according to the proper wiring schematic for the unit.
P65 PROBE TROUBLESHOOTING
1. Unplug and reseat the P65 probe wire in the jack on the T1000 control board. Note that
the error message “Err, No, Prb” will be displayed and the reset button must be pressed
to clear the message.
2. If problem persists, unplug the P65 probe from the control board and plug into the RJ45
pigtail (not supplied).
3. If the problem is with temperature control or high limit:
a. Change the configuration to ‘dSt’ to display the actual water temperature.
b. Check the temperature of the water with a thermometer and compare that with the
temperature on the display. If the two temperatures coincide, replace the T1000
control board. If the two temperatures do not coincide, continue to the next step.
c. Unplug the P65 probe from the control board and plug into the RJ45 pigtail (not
supplied). Check the resistance value (ohms) between the blue wire of the pigtail
(#1) and the red wire of the pigtail (#4). Compare the resistance value measure
with the chart below at the measured temperature of the water. If the two values
coincide, replace the T1000 control board. If the two values do not coincide,
replace the P65 sensor
4. If the problem is with low water:
a. Verify that the unit is filled with water.
b. Check for continuity between the yellow wire of the pigtail (#2) and ground. If
continuity exists, replace the T1000 control board. If no continuity exists, replace
the P65 sensor probe.
Thermistor Resistance vs. Temperature
Water Temperature Resistance (±3%)
70°F
11883Ω
80°F
9299Ω
90°F
7334Ω
100°F
5828Ω
110°F
4664Ω
120°F
3758Ω
130°F
3048Ω
140°F
2488Ω
150°F
2043Ω
160°F
1687Ω
170°F
1400Ω
180°F
1169Ω
190°F
980Ω
31
SECTION V – SERVICING AND REPLACEMENT OF PARTS
WARNING / CAUTION
Before servicing or replacing any part, make sure to turn the power supply to the unit OFF.
HEATING ELEMENT
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on
outgoing water line.
5. Drain water from tank.
6. Disconnect the wires from the heating element terminals.
7. Unscrew element with a 1-7/8” 6-point socket with no bevel.
O-Ring Groove O-Ring Terminal Connections #220 Buna-N O-Ring
8. Install new #220 Buna-N o-ring gasket and install new heating element. NOTE:
Hubbell recommends lubricating the o-ring with Parker O-Lube prior to installation.
9. Rewire element according to the wiring diagram as shown in the Section II.
10. Fill tank and check around element for any leaks.
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MAGNETIC CONTACTOR
1. Disconnect power from unit.
2. Disconnect line and load wires to contactor.
3. Disconnect the control circuit wires.
Control Wires
Line Wires
Load Wires
Mounting Screws
4. Loosen holding screws and remove contactor.
5. Replace with new contactor using reverse procedure.
CONTROL BOARD
1. Disconnect power from unit.
2. Disconnect display cable, probe cable (J3), leak detection wire (J2), ground wire (J7),
and terminal block (J5) from the control board. NOTE: The terminal block (J5) is
removable from the control board. Grasp the terminal block on the ends and pull
straight away from the board.
Ground Wire (J7) Display Cable Leak Detection Wire (J2) Probe Cable (J3)
Power Wire (Common, White) Connector (J5)
Power Wire (Black) Wire to #1 Contactor (yellow)
Wire to #2 Contactor (red)
3. Remove four (4) screws securing control board to panel.
4. Remove and replace control board.
5. Reconnect wires disconnected in step 2. NOTE: When reconnecting the ribbon cable,
be sure to have the key on the cable align with the slot in the connector.
6. Connect power to unit.
RELIEF VALVE
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on
outgoing water line.
5. Drain water from tank.
6. Disconnect overflow piping.
7. Unscrew relief valve, remove assembly and replace with new one.
8. Connect overflow piping.
9. Turn on incoming water supply and check for leaks.
10. Connect power to unit.
P65 SENSOR PROBE
1. Disconnect power from the unit.
2. Unplug the P65 probe connector from the T1000 control board.
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Probe connection (J3)
3. Twist the cord and shrink-wrap end of the P65 probe (or cut the shrink-wrap with a
sharp knife) to loosen the P65 sensor assembly from the P65 thermowell.
4. Remove the old P65 sensor assembly by pulling on the cord coming out of the P65
thermowell.
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Note: It is unnecessary to unscrew the
thermowell from the vessel to replace the P65 sensor.
Cord P65 Sensor
Shrink-Wrap Cap
5. Insert the new P65 sensor assembly into the P65 thermowell. Be sure to insert the
sensor until the shrink-wrap cap engages the threads on the end of the thermowell.
Note: The new sensor and cord assembly is push-fit onto the end of the thermowell
threads. Do not twist the new sensor and cord assembly into the thermowell. The
thermal conductive heat transfer paste inside the thermowell is sufficient for
replacement sensors. Adding additional paste is not required.
6. Plug P65 probe connector into the T1000 control board.
7. Turn on power to the unit. If display shows “Err, No, Prb”, press the reset button.
P65 THERMOWELL
1. Follow steps 1-4 for removing the P65 Sensor Probe above.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on
outgoing water line.
5. Drain water from tank.
6. Remove the thermowell from tank using a 13/16” socket.
7. Install new #115 Buna-N o-ring gasket
and install new thermowell. NOTE:
Hubbell recommends lubricating the oring with Parker O-Lube prior to
installation. WARNING: Do not remove
the jam nut.
Thermowell
8. Reinstall or install a replacement P65 sensor
probe in accordance with steps 5 and 6 above.
9. Refill tank.
10. Check for leaks. Retighten as required.
11. Turn on power to the unit.
12. Note that to resume operation the controller will need to be reset by pressing the
‘RESET’ button on the display.
CAUTION: Do not use plumber’s tape/Teflon tape/pipe dope when installing the P65
Thermowell. Tape will prevent the low water detection system from operating properly and
will cause false low water errors. Lubricate O-ring prior to installation.
Tighten probe at the brass hex flats only.
SECTION VI – SERVICE PARTS LIST
Category Description Volts Ohms Hubbell P/N
Accessories Bronze Pressure Reducing Valve N45BU
Plastic Legs (Price each, 4 Req'd.) AP61-4003-C
Nickel Plated Legs (Price each, 4 Req'd.) AE61-4002-C
Stainless steel adjustable legs (Price each) A50-5048-C
Floor Mount Legs S/S (Price each, 4 Req'd.) A50-9939-C
Temp. and Pressure Gauge T405
Dielectirc Union, 3/4" DIELECTRIC UNION
Relief Valve (up to 27 kw) 100XL .75 150LB
Relief Valve (30-58 kw) 40XL-5 .75 150LB
Relief Valve (64-90 kw) 40XL-4 1 150LB
Slide Brackets (J6 models only, 2 per set) J6 SLIDE BRACKET
J6, 3 Element Plastic Protective Shroud (1 to 18 kW) J6-3 SHROUD
J6, 6 Element Plastic Protective Shroud (24 to 58.5 kW) J6-6 SHROUD
J16 Element Plastic Protective Shroud J16 SHROUD
Water Treatment System (blended phosphate) HBW-CLEAR
Replacement cartridge for water treatment RSC-10
Circuit Breakers 60 amp CB 60 AMP
70 amp CB 70 AMP
80 amp CB 80 AMP
90 amp CB 90 AMP
100 amp CB 100 AMP
Contactors 20 Amp Resistive, 15 Amp Indu ctiv e, 208/240 VAC Coil C25DNF315B
40 Amp Resistive, 30 Amp Indu ctive, 208/240 VAC Coil C25DNF330B
50 Amp Resistive, 40 Amp Indu ctive, 208/240 VAC Coil C25DNF340B
65 Amp Resistive, 50 Amp Indu ctive, 208/240 VAC Coil C25DNF350B
75 Amp Resistive, 60 Amp Indu ctive, 208/240 VAC Coil C25FNF360B
90 Amp Resistive, 75 Amp Indu ctive, 208/240 VAC Coil C25FNF375B
Elements
2000 Watts 208 21.6 C1315-2
J4, J6, and J16
4000 Watts 208 10.8 C1315-3
(Note: Each element
5000 Watts 208 8.7 C1315-4
is supplied wi th an
6000 Watts 208 7.2 C1315-5
O-Ring)
6500 Watts 208 6.7 C2315-6
7150 Watts 208 6.1 C2315-7
9000 Watts 208 4.8 C2315-9
9600 Watts 208 4.5 C2315-10
2000 Watts 240 28.8 C1315-11
3000 Watts 240 19.2 C1315-12
3500 Watts 240 16.5 C1315-13
4000 Watts 240 14.4 C1315-14
4500 Watts 240 12.8 C1315-15
5000 Watts 240 11.5 C1315-16
6000 Watts 240 9.6 C1315-17
6500 Watts 240 8.9 C1315-18
6750 Watts 240 8.5 C1315-34
7500 Watts 240 7.7 C2315-19
9000 Watts 240 6.4 C2315-20
9750 Watts 240 5.9 C2315-21
2000 Watts 480 115.2 C1315-22
2333 Watts 480 98.8 C1315-23
3000 Watts 480 76.8 C1315-24
3500 Watts 480 65.8 C1315-25
4000 Watts 480 57.6 C1315-26
4500 Watts 480 51.2 C1315-27
5000 Watts 480 46.1 C1315-28
6000 Watts 480 38.4 C1315-29
6500 Watts 480 35.4 C1315-30
7500 Watts 480 30.7 C1315-31
9000 Watts 480 25.6 C1315-32
9750 Watts 480 23.6 C1315-33
6750 Watts 480 34.1 C1315-35
Extra O Ring (#220 Buna-N) O RING J MODEL
Elements 1900 Watts 120 7.6 SGB-2197
J3 3300 Watts 208 13.1 SGB-2337
(Note: Each element 3460 Watts 208 17.6 SGB-2347
is supplied with an 3200 Watts 220 15.1 SGB-2327V
O-Ring) 3800 Watts 240 15.2 SGB-2387
3800 Watts 277 20.2 SGB-2387V
3800 Watts 346 31.5 SGB-2388V
35
SERVICE PARTS LIST (cont.)
Category Description Volts Ohms Hubbell P/N
Misc. Electrical
Control Board T1000
Digital Display Module (with overlay and J16 Extension) TD1000
J16 Ribbon Cable Extension RIBBON CABLE J16
Display Overlay OVERLAY J MODEL
Probe Sensor P65
Probe Thermowell (includes #115 Buna-N O- Ring) P65 WELL
Transformer 480-208V B050-3299-3
Transformer 600-195V B050-3350-3
Transformer 380-185V B050-3351-3
Transformer 480-208V (J3 and J4 only) TRAN 480-208 25VA
Transformer 380-208V (J3 only) TRAN 380-208 25VA
Transformer 277-208V (J3 only) TRAN 277-208 25VA
Transformer 600-208V (J3 only) TRAN 600-208 25VA
Power Distribution Block 175 amp 2 pole 16220-2
Power Distribution Block 175 amp 3 pole 16220-3
Power Distribution Block 310 amp 3 pole 16023-3
Diffuser Assembly with Nipple J6 DIFFUSER
RJ45 Pigtail for P65 Probe Testing P65-RJ45 TESTER
Low Temperature Interlock XB1
24-Volt Interlock Adapter
PLUG ADAPTER J1
Remo
te Alarm Plug Adapter PLUG ADAPTER J4
Wire #18 200C (black,white,red,yellow) Tefzel 750 WIRE #18 200C "COLOR"
Wire #12 200C (blue or red) Tefzel 750 WIRE #12 200C "COLOR"
Wire #10 200C (blue or red) Tefzel 750 WIRE #10 200C "COLOR"
Wire #8 200C (blue or red) Tefzel 750 WIRE #8 200C "COLOR"
Wire #6 200C (black) Tefzel 750 WIRE #6 200C BLACK
Vessel J6 Vessel with 3 Element Openings J6-3 TANK KIT
(includes insualtion J6 Vessel with 6 Element Openings J6-6 TANK KIT
and o-rings) J16 Vessel with 3 Element Openings J16-3 TANK KIT
J16 Vessel with 6 Element Openings J16-6 TANK KIT
J16 Vessel with 9 Element Openings J16-9 TANK KIT
J3 Vessel J3 TANK KIT
J4 Vessel J4 TANK KIT
Stainless Steel J6, 3 Element Base J6-3 BASE
Enclosure Parts J6, 3 Element Top Enclosure J6-3 JACKET
J6, 3 Element Front Cover J6-3 FRONT COVER
J6, 6 Element Base J6-6 BASE
J6, 6 Element Top Enclosure J6-6 JACKET
J6, 6 Element Front Cover J6-6 FRONT COVER
J16 Base J16 BAS E
J16 Top Enclosure J16 JACKET
J16 Front Cover J16 FRONT COVER
J3 Base J3 BASE
J3 Top Enclosure J3 JACKET
J3 Front Cover J3 FRONT COVER
J4 Base J4 BASE
J4 Top Enclosure J4 JACKET
J4 Front Cover J4 FRONT COVER
36
37
SECTION VII – TORQUE VALUES
Part P/N Wire Size
Torque
(in•lbs)
Torque
(ft•lbs)
Element to
Tank
All N/A 600 50
Wire to
Element
All All 15 1.25
Probe to Tank All N/A 300 25
Wire to Ground
Lug
KA8C All 25 2.08
KA4C All 45 3.75
Wire to Circuit
Breaker
All
#14-#10 35 2.92
#8 40 3.33
#6-#4 45 3.75
Transformer All All 15 1.25
Wire to Control
Board
All All 3.5 0.29
Wire to
Contactor
C25DNF315B
C25DNF330B
C25DNF340B
C25DNF350B
#14-#12 15 1.25
#10 25 2.08
#8 40 3.33
#6-#4 45 3.75
C25FNF360B
C25FNF375B
#14-#10 40 3.33
#8 45 3.75
#6-#4 50 4.17
Wire to Power
Distribution
Block
16023-3
16023-2
Line All 275 22.92
Load
#14-
#10
20 1.67
#8 25 2.08
#6-#4 35 2.92
63133
63132
Line
#14-#8 50 4.17
#6-2/0 120 10
Load
#14-
#10
20 1.67
#8 25 2.08
#6-#4 35 2.92
Control Board
to Panel
All N/A 10 0.83
Display to Base All N/A 10 0.83
All Other
Components to
Panel
All N/A 20 1.67
38
SECTION VIII – WARRANTY INFORMATION
LIMITED WARRANTY
1. PRODUCT WARRANTY. Hubbell warrants the booster heater it manufactures and its
components (the "Product") to be free from defects in materials and workmanship, under
normal use and service for the period of time identified below beginning from the date of
installation, provided that the product is installed within three (3) months of date of shipment
from Hubbell and when the Product is installed and maintained in accordance with Hubbell's
written instructions (see operators manual for details). Owner must establish the Product's
purchase date by means satisfactory to Hubbell in its sole discretion.
TANK and COMPONENTS: One (1) year parts and labor
TANK ONLY: Ten (10) years Non Pro-Rated
REPLACEMENT PARTS: Thirty (30) days parts only, no labor, from date of purchase
SUCH WARRANTIES DO NOT COVER:
• Product failure (including but not limited to the tank and/or heating elements) caused
by liming, sediment buildup, chemical corrosion, chlorine corrosion, or freezing.
• Temperature setting adjustments, pressure reducing valve adjustments, resets, and
plumbing leaks.
• Product misuse, tampering or misapplication, accidental damage, improper installation
or the application of improper voltage.
• Costs incurred for shipping, delivery, handling, and/or administrative charges.
• For the tank warranty after the first year, all labor, shipping, installation costs, and
components (other than the tank) are the responsibility of the owner.
• With respect to labor warranty within the first year, overtime, holiday, weekend or any
other non-standard labor rate.
• Excessive and unreasonable labor rates and/or travel expenses as determined by
Hubbell in its sole discretion.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ANY OTHER
WARRANTY, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE OR PATENT OR OTHER INTELLECTUAL PROPERTY RIGHT
INFRINGEMENT.
2. LIMITATION OF REMEDIES AND DAMAGES. Hubbell's liability and Buyer's
exclusive remedy hereunder will be limited solely, at Hubbell's option, to repair or
replacement by a Hubbell authorized service agency (other than where Buyer is located
outside of the United States or Canada, in which case Hubbell's liability and Buyer's
exclusive remedy hereunder will be limited solely to replacement of part under warranty)
with respect to any claim made within the applicable warranty period referred to above.
Without limiting the generality of the foregoing, all warranty items shall be returned by
Buyer, at its sole expense, to the nearest Hubbell-authorized service agency or to the Hubbell
factory (45 Seymour Street Stratford, CT 06615) for replacement or repair. Hubbell reserves
the right to accept or reject any such claim in whole or in part. Hubbell will not accept the
return of any product without prior written approval from Hubbell, and all such approved
returns shall be made at Buyer's sole expense. HUBBELL WILL NOT BE LIABLE,
UNDER ANY CIRCUMSTANCES, FOR CONSEQUENTIAL OR INCIDENTAL
DAMAGES, INCLUDING BUT NOT LIMITED TO LABOR COSTS OR LOST PROFITS
RESULTING FROM THE USE OR INABILITY TO USE THE PRODUCTS OR FROM
THE USE OF OR INABILITY TO USE THE PRODUCTS OR FROM THE PRODUCTS
BEING INCORPORATED IN OR BECOMING A COMPONENT OF ANY OTHER
PRODUCT OR GOODS.
39
NOTES
P.O. BOX 288
STRATFORD, CT 06615-0288
PHONE: (203) 378-2659
FAX: (203) 378-3593
INTERNET: http://www.hubbellheaters.com/
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