Hubbell V6, V15 User Manual

OPERATING AND MAINTENANCE MANUAL FOR

ELECTRIC INDUSTRIAL PROCESS

WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ V6 and V15 ”

HUBBELL

ELECTRIC HEATER COMPANY

P.O. BOX 288

STRATFORD, CT 06615

PHONE: [phone]
FAX: [phone]

INTERNET: http://www.hubbellheaters.com/

-- IMPORTANT --

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

WARNING / CAUTION

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

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

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

4. The refractory material used in heating elements may absorb some moisture during transit,
periods of storage, or when subjected to a humid environment. This moisture absorption results
in a cold insulation resistance of less than twenty (20) megohms. If this heater has been
subjected to the above condition, each heating element must be checked for insulation
resistance before energizing. A low megohm condition can be corrected by removing the
terminal hardware and baking the element in an oven at 350°F -700°F for several hours or until
the proper megohm reading is obtained.

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

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

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

2

TABLE OF CONTENTS

SECTION TITLE PAGE #

I GENERAL DESCRIPTION AND CONSTRUCTION 5

II INSTALLATION 10

III SCHEDULED MAINTENANCE AND OPERATION 17

IV TROUBLESHOOTING 19

V SERVICING & REPLACEMENT OF PARTS 21

VI MISCELLANEOUS CHARTS AND FORMULAS 27

3

4 5

SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This booklet describes an electric water heater designed for use in an industrial or commercial
application. The complete assembly consists of the storage tank, immersion electric heating element(s),
thermostat, safety relief valve, safety high temperature cut out, magnetic contactor(s), and any other
required electrical operating control. Optional equipment may be supplied with your unit. Please
consult the product drawing for details specific to your assembly. The unit is factory assembled,
insulated, jacketed, wired, tested, and ready for electrical and plumbing service connections.

CONSTRUCTION

TANK

The storage tank is constructed of type 316L stainless steel for maximum tank longevity. The tank is
formed by all welded construction and is designed for a maximum allowable working pressure of 150
psi (300 psi TP).

TANK CONNECTIONS

The heater is supplied with separate connections for the cold water inlet and the hot water outlet. Water
entering the cold water inlet is deflected by means of a baffle 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
incoloy or copper sheathed elements that are brazed into a brass flange. Each assembly is fastened to a
corresponding tank flange using a gasket and four (4) 3/8-16 x 1-inch long hex head steel bolts and
nuts. See drawing for voltage and power ratings.

CONTROL THERMOSTAT

The water heater is supplied with a single stage immersion thermostatic
switch that is installed and wired at the factory. The thermostat can be
adjusted through a range of 100° - 195° F, (an optional low range, 30° ­110° F, is available), and is adjustable with a flat tip screwdriver. Other
thermostatic controls are available, see Options below.

TEMPERATURE HIGH LIMIT SWITCH

As a safety device, either a surface mounted high temperature cut-off switch with manual reset, factory
set at 205° F, or an optional immersion high temperature cut-off switch with manual reset, adjustable
through a range of 100° - 240° F, is provided. In the event of an over-temperature condition, the
thermostat will disengage the power from the system. The high limit must be manually reset thereafter
to restart the heater.

Manual Reset

Surface Mounted High
Temperature Cut-Off Switch Immersion High Temperature Cut-Off Switch

MAGNETIC CONTACTOR

The magnetic contactor(s) is a heavy-duty resistive load type
rated for 100,000 cycles. The contactor supplies power to the
heating element(s) based on the resistive load (non-inductive) of
the heater only when the thermostatic switch is engaged, 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.

6

OUTER SHELL, INSULATION, AND SUPPORTS

The tank is encapsulated in 2-inches of high-density fiberglass insulation. The protective shell is
constructed of galvaneel and is coated with a durable silver hammertone finish. NSF approved
adjustable plastic legs are provided for support.

FUSED LOW VOLTAGE TRANSFORMER

A fused low voltage transformer is supplied with all models rated
for 480-volts. This component is used to step down the 480-volt
power supply to 240-volts for safety when working with control
circuits. As an option, a transformer may be installed on any unit
to step down the voltage to 120-volts.

ON/OFF SWITCH

An illuminated on/off switch is provided for positive verification heater status.

OPTIONS

The following optional features may be included in your water heater. Reference included drawing
specific to your heater for further details.

Low Water Cut-Off

Used as a safety device, the electronic low water cut-off is
used to detect a low water situation and disengage the
operating coils in the magnetic contactor(s). Once the
condition is remedied, the low water cut-off switch is
automatically reset.

Stainless Steel Outer Jacket

An optional stainless steel outer jacket may replace the standard galvaneel jacket.

7

Dial Temperature and Pressure Gauge

A combination temperature (70° - 250° F) and pressure
(0 – 200 psi) gauge with 2½-inch dial may be supplied
for in-line installation (shipped loose).

Vacuum Relief Valve

A vacuum relief valve may be provided with the unit to reduce the risk of back siphonage and back pressure of the system. The valve will be shipped loose for in-line installation. Instructions for installation are provided with the valve.

Individually Fused Elements

To prevent the possibility of damage to control circuits and other elements in case of electrical
overloads, fuses may be supplied for each element. Two types of fuses may be used; a type NON for
voltages less than 250-volt or type JJS for voltage less than 600-volt.

Type JJS Type NON

Built-in Circuit Breaker

A built-in circuit breaker may be provided with or without shunt trip protection for protection from
circuit overload.

Building Management System (BMS)

A Building Management System control package may be supplied for remote operation and alarm
capabilities.

Pump Interlock Terminal Block
An optional pump interlock terminal block may be installed to prevent energizing when the pump is not
running.

8

Silicon Control Rectifier

A silicon control rectifier (SCR) “zero fired” power controller for 0-100% proportional control of
heaters may be supplied.

Digital Display

A 1/16 DIN electronic temperature control package may be
installed. A separate manufacturer’s operating manual will be
supplied with the unit.

Optional Connections

Flanged inlet and outlet connections (150#)
Threaded inlet and outlet connections (1 ½”, 2” MNPT)
Sanitary Connections

Special Customized Features

Please reference drawing for details.

9