Hubbell PBX, PBX50SL, PBX40SL, PBX80SL, PBX120SL Installation, Operation And Maintenance Manual
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INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL FOR
HYBRID ELECTRIC HEAT PUMP
WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ PBX ”
2015
HUBBELL
ELECTRIC HEATER COMPANY
P.O. BOX 288
STRATFORD, CT 06615
PHONE: (203) 378-2659
FAX: (203) 378-3593
INTERNET: http://www.hubbellheaters.com/
-- IMPORTANT --
Always reference the full mo del num ber a nd seri al numbe r whe n callin g the factory.
WARNING / CAUTION
1. Tank is to be comple tely fi lle d wit h wa te r an d al l ai r is to be ve nte d be fo re e ne rgiz ing .
Do not turn on water heater if cold water supply shut off valve is closed.
2. Due to the rigors of transportation, all connections should be checked for tightness
before heater is plac ed i n opera tion .
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 o f stora ge, or w hen sub jected to a humid environment. This moisture
absorption results in a cold insulation resistance of less than twenty (20) megohms. If this
heater has been subjected to the above condition, each heating element must be checked
for insulation resistance before energizing. A low megohm condition can be corrected by
removing the terminal hardware and baking the element in an oven at 350°F -700°F for
several hours or until the proper megohm reading is obtained.
5. KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS.
Do not perform any maintenance, make any adjustments, or replace any components
inside the control panel with the high voltage power supply turned on. Under certain
circumstance s, da nge rou s p ote nt ia ls m ay e xi s t e ven w he n t he pow er su ppl y i s 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 opera te at press ure not more tha n 150 psi .
7. Generalized instructions and procedures cannot anticipate all situations. For this reason,
only qualified installers should perform the installations. A qualified installer is a person
who has licensed training and a working knowledge of the applicable codes regulation,
tools, equipment, and methods necessary for safe installation of an electr ic re sista nce
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. In the event of overheating, fire, flood, or physica l damage, turn off all power to your
water heater. Do not power the heater until it be en examined by a trained professional.
9. Do not store or use gasoline or other flammable vapors and li quids, such as adhesives
or paint thinner, in the vicinity of this wat er heater. If such flammable materials must
be used near the unit, open nearby doors and windows to allow for ventilation
2
Safety Information and Precautions:
SECTION
PAGE No.
Operating Principle, Specifications, and Performance
4
Installation
8
Controller Operation
9
Data Logger Configuration and Operation
18
Scheduled Maintenance
22
Troubleshooting
23
Servicing and Replacement of Parts
26
Warranty
29
Please read the following safety information before proceeding:
• Water temperature over 125°F can cause severe burns instantly or
death from scalds.
• Children, disabled and elderly are at the highest risk of being scalded.
• See instructi on manual before setting temperature at the water heater.
• Feel water before bathing or showering.
• Temperature limiting valves are available, see manual.
The temperature of the water in the hea ter is regul at ed by an a djustable ,
automatic, temperature control whi ch use s sur fa c e mount ed t hermistors
located behind the jacket access panels. These automatic controls are set at the factory to
maintain a water temperature of 120°F. Although these controls are designed to industry
standards, they can fail to control temperature properly without any notice, and therefore
should be tested periodically for your protection.
To perform the test: Turn on the hot water fauc et and measure the maximum temperature wi th an accurate thermometer. If the temperature is above the safe limits for your circumstances call a service technician to adjust or replace the control.
DANGER: IF YOU DISCOVER EXTREME HOT WATER COMING FROM THE
F AUCET , IMMEDIA TELY SHUT OFF THE ELECTRICITY AT THE MAIN SWITCH
AND CALL COMPETENT SERVICE PERSONNEL. ANY OVERHEATED WATER
HEATER IS A POTENTIAL HAZARD TO LIFE AND PROPERTY. DO NOT
OPERATE UNTIL THE SOURCE OF THE PROBLEM HAS BEEN DETERMINED
AND ELIMINATED.
3
OPERATING PRINCIPLE, SPECIFICATIONS, AND PERFORMANCE
How the Hubbell Heat Pump Water Heater Works
The Hubbell Model PBX Heat Pump Water Heater uses a small amount of electricity to
transfer heat from the air to water. In comparison, traditional electric water heaters use
resistive heating elements to directly heat the water. A benefit of a the heat pump water heater
is that it uses less than half the electricity of a traditional electric water heater to produce the
same amount of hot water and therefore the Hubbell Model PBX is significantly more energy
efficient compared to a conventional electric water heater.
In principle, a heat pumps works like a refrigerator in reverse. A refrige rator moves hea t from
inside the refrigerator and transfers that heat energy to the surrounding room. A heat pump
water heater on the other hand pulls free and essentially unlimited heat from the surrounding
air and transfers that heat to the water stored in the t ank.
The Hubbell Model PBX Heat Pump Water Heater can pull heat out of air as cool as 40°F,
and if it cannot provide enough heating capacity to meet demand, the water heater includes
back-up resistive heating elements to ensure the unit provi des sufficient hot water. In addit ion,
the heat pump process of removing heat from the air and transferring it to the water results in
the exhaust of cooler dryer air, with as m uch as 0.4 gallons per hour of “free” dehumidification
provided by the heat pump while the unit is heating water.
Heat Pump Functions with Operational Diagram:
1. T he bui lt in fa n draw s room air into t he he at pum p
compartment and across an evaporator coil, and exhausts
cooler and slightly dryer (dehumidified) air.
2. T he e vap ora to r c oi l ca pt ure s hea t e ner gy in the ai r a nd
transfers that ener gy to a s pecia lly form ula ted CFC free
refrigerant c o nta ine d w it hi n th e e va pora t or.
3. The refrigerant changes from a liquid to a gas as it gets
warmer.
4. The refrigera nt, now as a warm gas, exits the eva porator
and passes into a compressor.
5. The warm gas is c ompressed, causing it to become a
superheated h ot gas an d the n fl ows to the he at exc ha nge r.
6. T he hea t exc hange r tr ans fer s heat e ner gy from the
superheated hot gas to the cold water from the tank.
7. The p ump c irc ula te s col d wa te r from t he tank through the
heat exchanger resulting in a continuous transfer of heat
energy from the superheated gas to the water.
8. Ho t wat er e xi ts the hea t e xcha ng er a nd i s st ore d in the
tank.
9. T he supe rhe ate d gas conde nse s bac k to a li qui d and the
process is repeated.
4
Outline Dimensions
Dimensions (Inches)
Floor to Relief
“C”
PBX40SL
40
28
49
26
9
270
PBX50SL
50
25
66
43
9
325
PBX65SL
65
28
63
40
9
365
PBX80SL
80
28
73 ½
50
9
440
PBX120SL
120
30
84
61
9
525
Model Specific Dimensional Data
Base Model
Number
Storage
Capacity
(Gallons)
Overall
Diameter
“A”
Options
•
1 ½” Male NPT inlet and outlet water connections.
Corrosion-Resistant (Copper-Alloy, Type 304L or Type 316L stainless steel) storage tank
•
for maximum lif e.
ASME tank construction.
•
Tank installed heat exchanger for use with solar or radiant heating systems.
•
Alternate single and 3 phase voltages, alternate wattages or 50 Hz available.
•
Condensate removal pump (120V plug-in) to remove and lift condensate to drain.
•
Overall
Height
“B”
Valve & Hot
Water Outlet
Floor to Cold
Water Inlet
“D”
Shipping
Weight
(lbs.)
5
Specifications
Tank:
Hydrastone Cement Lined Steel
Hi-Limit:
190°F Manual Reset
Pressure Rating:
150 psi WP, 300 psi TP
First Hour Rating:
(Gallons)
Storage:
40, 50, 65, 80, 119 Gallons
PBX40SL
46
Orientation:
Vertical
PBX50SL
61
Voltages:
208-240 Volt AC
PBX65SL
70
Phase:
Single
PBX80SL
82
Frequency:
60 Hz
PBX120SL
120
Inlet Size:
¾” Female NPT
Standby Heat Loss:
(°F/hr)
Outlet Size:
¾” Male NPT
PBX40SL
0.45
Drain Size:
¾” GHT
PBX50SL
0.36
Condensate Size:
⅜” Tube
PBX65SL
0.35
Relief Valve Size:
¾” Female NPT
PBX80SL
0.28
Relief Valve Type:
T&P, 210°F, 150 psi
PBX120SL
0.28
Heat Pump:
Energy Factor:
2.33
Refrigerant:
R426A (CFC Free)
COP:
2.36
ODP:
0
Average Power Consumption :
GWP:
1349
High Fan:
680 Watts
Over Pressure Safety:
Manual Reset
Low Fan:
614 Watts
Field Chargeable:
No
Electric Elements:
Incoloy Sheathed
Ambient Air:
3800W @ 240V
Air Flow (High Fan) :
450 CFM
Insulation:
3” Polyurethane Foam
Air Flow (Low Fa n):
250 CFM
Sound Level:
62db Average @ 3 Feet
Air Filtration:
Washable / Removabl e
Warranty:
Temperature Range:
40-110°F
Tank:
10 Years
Thermostat Range:
50-160°F (°F or °C) ±3°F
Parts:
6 Years
Error Indication:
Visual and Audible
Approvals:
cULus, ENERGY STAR
Demand Response
Qualified
Capable:
Yes
Jacket:
High Impact Colorized
Child Lock Capable:
Yes Composite
Color:
White with Black Trim
240V
2.6
15.8
15.8 (3800 Watts)
18.4
220V
2.8
14.5
14.5 (3200 Watts)
17.3
208V
3.0
13.7
13.7 (2850 Watts)
16.7
Electrical
Amperage Rating Chart (Amps)
Supply Voltage
Economy Hybrid Electric Super
Total Maximum Amp Draw in Various Operating Modes
Overcurrent circuit protection rated 25 amp minimum is required. Reference local, state, and
national codes.
6
Performance
Economy
Hybrid
Electric
Super
80°F
∆T
50°F
Ambien
Temp
50°F
3,240
12,965
12,965
16,205
70°F
5,400
12,965
12,965
18,365
90°F
7,020
12,965
12,965
19,985
These units are designed to meet or exceed ANSI (American National Standards Institute)
requirements and have been tested according to D.O.E. test procedures and meet or exceed the
energy efficiency requirements of NAECA, ASHRAE standard 90, ICC Code and all state
energy efficienc y pe r form ance cri te ria for e ne rgy c on sum ing a ppl ia nce s.
Ambient Air Temperature (°F)
Energy Consumption Chart
Annual Energy Consumption (EST)
Annual Energy Consumption and Operating Cost in Various Operating Modes
Ambient Air
Temperature
50°F
70°F
90°F
Energy
Factor (EF)
1.39 1.42 3159 $336 3159 $336 4671 $497 4368 $465
2.33 2.36 1884 $201 1884 $201 4671 $497 3851 $410
3.07 3.07 1430 $152 1430 $152 4671 $497 3527 $376
Coefficient of
Performance
(COP)
kW·hrs
Operating
Cost $
kW·hrs
Operating
Cost $
kW·hrs
Operating
Cost $
kW·hrs
Operating
Cost $
Energy Factor and Average Annual Operating Costs based on 2007 D.O.E. (Department of Energy) test
procedures. D.O.E. national average fuel rate electricity 10.65¢/kW·hr. Energy Factor (EF) based upon
heater operating in Hybrid mode.
Recover Rating Chart
Continuous Recovery Rating (GPH)
Ambien
t Air
Temp
70°F
90°F
Economy Hybrid Electric Super
60°F ∆T 70°F ∆T 80°F ∆T 60°F ∆T 70°F ∆T 80°F ∆T 60°F ∆T 70°F ∆T 80°F ∆T 60°F ∆T 70°F ∆T
6.5 5.6 4.9 25.9 22.2 19.4 25.9 22.2 19.4 32.4 27.8 24.3
10.9 9.4 8.2 25.9 22.2 19.4 25.9 22.2 19.4 36.8 31.6 27.6
14.2 12.2 10.6 25.9 22.2 19.4 25.9 22.2 19.4 40.1 34.4 30.0
Continuous Recovery Rating (GPH) in Various Operating Modes
Continuous Recovery rating based upon 240V power supplied to heater and fan operating in high speed
mode. ∆T represents the °F temperature rise for hot water.
Heating Capacity Chart
Heating Capacity Chart (BTU/Hr)
t Air
Economy Hybrid Electric Super
BTU/Hr Rating in Various Operating Modes
Heating Capacity based upon 240V power supplied to heater and fan operating in high speed mode.
7
INSTALLATION
WARNING / CAUTION
DO NOT TURN ON THE ELECTRIC POWER S UPPLY 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 element s 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 Z 21.22. 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 unpredic table 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.
Water Heater Placement
1. Place the heater on a solid foundation in a clean, dry location neare s t t o the poi nt of
most frequent hot water use. If the heater is to be raised off the floor, the entire bottom
of the heater should be supported by a solid surface.
2. The water h eat er must be installed with the minimum clearances as shown on page 5.
3. Do not install in an area where flammable liquids or combustible vapors are present.
4. The water heater should be protected from freezing and waterlines insula t ed to reduce
energy and water waste.
5. The space that the water heater is installed must be no less than 10’ x 10’ x 7’ high
(700 cubic feet). If a smaller space is used, there must be louvers installed in the space
that will allow for 450 CFM air flow.
6. The installation location must not be cooler than 40°F. Locations with warmer
ambient air (ex. furnace rooms) are more advantageous as they provide abundant
“free” heat.
7. The heat pump dehumidifies the air and as a result produces condensate which must be
piped to a drain or outdoors.
Piping Installation
NOTE: The most effective means for preventing deterioration from accelerated corrosion
due to galvanic and stray current is the installation of dielectric fittings/unions. The installation
of these fittings is the responsibility of the installing contractor.
1. Connect the cold water inlet and hot water outlet to the appropriate connections as
shown; refer to the drawing for location and sizes.
NOTE: Certain models are supplied with a flow measuring device (flowmeter) and
temperature measuring device (thermistor) to be installed on the cold water supply
side. These items are shipped pre-wired into the uni t and stored in the heat pump
compartment. The flowmeter should be installed in-line with the cold water supply
piping with the arrow pointing toward the water heater. The thermistor should be
secured to the outside of the cold water piping and covered with insulation.
2. Install the combinatio n tempe ratu re and p ress ure sa fety re lief val ve in t he tap ping
provided. Note that this is required by law for safety considerations.
3. Install a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of
any type should be installed between t he rel i ef valve and tank or in the drain line.
8
Filling the Water Heater
1. Completely close the drain valve.
2. Open the highest hot water faucet to allow all air to escape from piping.
3. Open the valve to the cold water inlet and allow the heater and piping system to
completely fill, as indicated by a stea dy fl ow of water from the open faucet.
4. Close the faucets.
5. Lift the top cover of the heat pump unit.
6. Carefully open the Air Purge Valve at the top of the heat pump unit to let air escape.
See the Outline Dimensions illustration for the location.
7. Fully tighten Air Purge Valve.
Electrical Installation
1. Enter junction box with properly sized feeder leads. Note that overcurrent circuit
protection is required. For the standard model t he overcurrent protection must be rated
25 amp minimum.
2. Connect these power leads to wires enclosed in junction box with wire nuts.
3. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
Final Checks
1. Check all connections for tightness.
2. Ensure that all the above steps are completed.
3. After the water is heated for the first time, monitor the water temperature as described
in the Scheduled Maintenance section.
CONTROLLER OPERATION
About the Controller
The Hubbell Heat Pump Water Heater Controller provides the user with the ability to control
and customize the operation of their heat pump water heater. The 4-digit display shows the
current status of the water heater, and can display useful information such as current
temperature conditions inside the tank, error notifications, and more. It allows basic
customization, such as mode and temperature set point, as well as more advanced options,
such as temperature differential, and display options. Once the setu p is complete the water
heater is automatic in operation and will maintain a full tank of water at the temperature setting
of the controller.
Powering up your Heat Pump Water Heater for the first time
When the unit is first powered up, the default home screen i s shown, see diagram below. This
screen consists of two alternating displays; one shows the current mode (e.g., hibr), and the
other shows the temperature set point (e.g., S120). These displays will switc h every 5 seconds.
By default, the Hubbell Hot Water Heat Pump comes programmed with a temperature
setpoint of 120°F and set to hybrid mode (“hibr”).
The Home Screen
The home screen provides a quick reference to the current status of the water heater and can
be modified to fit the user’s preference. If desired, the temperature readouts can be displayed
in Celsius (see “Changing the Temperature Scale”) and the user has the option to display
9
either the temperature set point, denoted by a capita l “S” preceding t he set point, or the current
Standby: Used for taking the water heater in and out of standby mode. When the
Also serves as an execute button in certain me nus .
Mode: Used for changing modes. Serves as a cancel button in certain menus.
Used for navigating the options menu.
Up: Used for increasing numeric settings. Also scrolls up when changing
options. Can be held for auto scroll.
Down: Used for decreasing numeric settings. A l s o scrolls down when changing
options. Can be held for auto scroll.
Away: Used for entering / exiting vacation override. Also used to set / unset
child lock.
temperature conditions inside the tank, denoted by “t” and “b” preceding the top and bottom
temperatures, respectively (see “Changing the Home Screen”).
If an error condition is detecte d, the e rror code is displayed unt il the error condition is resolved.
There are several error conditions which ma y result in this behavior (see “Maintenance Alerts
and Procedures”).
As shown in the above diagram, the home screen also has two indicators; power and cool
down. The power indicator denotes whether active heating of the water is taking place. If the
power indicator light is not visible, the water in the tank has reached the desired temperature,
and thus no active heating is taking place. A blinking powe r indicator light m eans that the unit
has not yet reached the temperature set point, and that current is being drawn to power the
heating elements. A solid power indic a tor light mea ns that the u nit is ca lli ng for powe r, but is
not detecting the proper amp draw to the elements. This may indicate a problem with the
elements or that only the heat pump is running (normal for Hybrid and Economy modes). Set
the tank to Electric or Super mode to check operation of both elements.
When the compressor is running, pressure builds up within the heat pump module. The cool
down indicator shows whether or not the heat pump has had sufficient time to allow the
pressure within the system to stabilize. The duration of this cool down period is 10 minutes
and starts from t he time when the compressor tur ns off. If the cool down indicator light is not
visible, either the cool down period is complete, or the unit does not currently require the use
of the compressor. A solid cool down indic at or light indicates that the unit requires the use of
the compressor, and is currently within the cool down period.
Button Overlay
The button overlay provides the user with a means to alter the configuration settings and
control the operation of the water he ater. A brie f description o f the basic functionali ty of each
button is provided below. Detailed descriptions of how to use these buttons to perform certain
functions is provided throughout this manual.
unit is in standby, “STBY” will be displayed. This is not considered OFF
because the tank will come on at very low tem peratures to prevent freezing.
Max Heat: Used for entering / exiting max heat overri de.
Fan Off: Used for entering / exiting fan off and fan speed overrides.
Operating Modes
The Hubbell Heat Pump Water Heater is equipped with four operating modes and four
temporary settings. A brief overview of each mode and setting is listed below:
10
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