Hubbell Electric Heater HD161 Installation Manual

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL FOR

ELECTRIC DEIONIZED / RO

WATER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ HD ”

UM ANSI/NSF5

2015 Edition

HUBBELL

ELECTRIC HEATER COMPANY

45 SEYMOUR STREET

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) m egohms. 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.

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TABLE OF CONTENTS

SECTION TITLE PAGE No.

I GENERAL DESCRIPTION AND CONSTRUCTION 4

II INSTALLATION AND START-UP 8
III SCHEDULED MAINTENANCE AND OPERATION 20
IV TROUBLESHOOTING 23

V SERVICING AND REPLACEMENT OF PARTS 28
VI SERVICE PARTS LIST 32

VII TORQUE VALUES 34

VIII WARRANTY INFORMATION 35

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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This book describes a packaged electric water heater designed for use in deionized (DI) or
reverse osmosis (RO) water applications. 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 drawing supplied with the unit for details
specific to your assembly. The unit is factory assembled, insulated, jacketed, wired, tested, and
ready for electrical and plumbing service connections.

CAPACITY

Storage

Model

HD61617543 HD16416427201613

HD61.5 6 1.5 10 8 6 5 HD166 16 6 41 30 24 20

HD62 6 21410 8 7 HD16716 747352823
HD63 6 321151210 HD16916 961463630
HD64 6 4 27 21 16 14 HD1612 16 12 82 61 49 41
HD65 6 5 34 26 21 17 HD1613 16 13.5 92 69 55 46
HD66 6 6 41 31 25 21 HD1615 16 15 102 76 61 51
HD67 6 7 48 36 29 24 HD1618 16 18 123 92 73 61

HD69 6 9 62 46 37 31 HD1624 16 24 164 123 98 82
HD610 6 10.5 72 54 43 36 HD1627 16 27 184 138 110 92
HD612 6 12 82 62 49 41 HD1630 16 30 205 153 123 102
HD613 6 13.5 92 69 55 46 HD1636 16 36 246 184 147 123
HD615 6 15 103 77 62 51 HD1639 16 39 266 199 159 133
HD618 6 18 123 92 74 62 HD1640 16 40.5 276 207 166 138
HD624 6 24 164 123 98 82 HD1645 16 45 307 230 184 153
HD627 6 27 185 138 111 92 HD1654 16 54 369 276 221 184
HD630 6 30 205 154 123 103 HD1658 16 58.5 399 299 239 199
HD636 6 36 246 185 148 123 HD1664 16 64 437 328 262 218
HD639 6 39 267 200 160 133 HD1666 16 66 451 338 270 225
HD640 6 40.5 277 208 166 138 HD1668 16 68 464 348 278 232
HD645 6 45 308 231 185 154 HD1679 16 79 539 404 323 269
HD654 6 54 369 277 221 185 HD1681 16 81 553 415 332 276
HD658 6 58.5 400 300 240 200 HD1685 16 85 580 435 348 290
HD1611616543 HD1686 16 86 587 440 352 293

HD161.5 16 1.5 10 7 6 5 HD1688 16 88 601 451 360 300

HD162 16 2 13 10 8 6 HD1690 16 90 615 461 369 307
HD16316 320151210

Capacity

(gallons)

kW

60°F

Rise

(GPH)

80°F

Rise

(GPH)

100°F

Rise

(GPH)

120°F

Rise

(GPH)

Model

Storage

Capacity

(gallons)

kW

60°F

Rise

(GPH)

80°F

Rise

(GPH)

100°F

Rise

(GPH)

120°F

Rise

(GPH)

If the required tem

perature rise is not listed above, the following formula may be used to

determine the maximum flow rate:
To determine power (kW) requirement
____GPM × ____ °F ΔT × 0.1465 = ____ kW

To determine temperature rise
____ kW × 6.824 ÷ ____ GPM = ____°F ΔT

To determine flow rate
____ kW × 6.824 ÷ ____ °FΔT = ____ GPM

4

567

CONSTRUCTION

TANK

The storage tank is designed, manufactured, and stamped in accordance with ASME Section
VIII Division 1. The tank is constructed of type 316L stainless steel and fabricated by all
welded construction and is designed for a maximum allowable working pressure of 150 psi
(225 psi test pressure). As an option, the rear head may be a bolted flange connection that can
be removed to facilitate internal inspection and cleaning of interior tank surfaces.

TANK CONNECTIONS

The heater is supplied with separate connections for the cold inlet and the hot water outlet.
Water entering the cold 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
316L stainless steel sheathed elements that are fitted into a 316L stainless steel 1½-12UNF
screw plug with 1-7/8” hex. The element wetted surfaces are passivated and electropolished.
Each assembly is threaded into the tank and sealed with #220 Viton o-ring gaskets. See drawing
for voltage and power ratings.

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 functions 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 CFC/HCFC free closed cell 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.

LOW WATER CUTOUT

A float type 316L stainless steel low water cutout is included for low water detection.

OPTIONAL EQUIPMENT

Slide Brackets
Available for the HD6 Model only, these brackets allow for mounting the water heater under a
counter. See slide bracket diagram on page 9 for details.
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
Alternate Voltage
Other voltages are available, including 277V single-phase, and 380V, 415V, and 440V three­phase. Consult the factory for details.
XB1 Expansion Board
An optional expansion board to the control board can be used to for additional circuit firing
when more than two circuits are required and/or as an auxiliary high or low temperature
alarm/relay. On models with three contactors the XB1 is supplied as standard.
Remote Alarm Plug Adapter
An optional plug adapter is available to provide a remote fault alarm
signal through the J4 connector on the control board. See page 11 for

installation details.
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. See page 11 for
installation details. (Only available with r23 or later software).

Protective Shrouds
An optional durable protective plastic shroud is
available to prevent damage to the heater due to
water intrusion. The cover fits snugly over the entire
heater 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.

8

• 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

1. Place the heater on a solid, level foundation in a clean, dry location.

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 table. Spacing
should be 17” for HD6
models up to 18kW and
22” for HD6 models 24
to 58.5kW. HD16
models are not designed
for use with slide
brackets.

2. Attach slide bracket angles to heater with #8 sheet metal screws. It will be necessary

to drill 1/8” holes into heater jacket for screw pilot holes.

3. Slide heater onto slide rails under table.

PIPING INSTALLATION – See Diagrams

1. Connect the cold water inlet and hot water outlet to the appropriate connections as

shown; refer to the specifications for location and sizes.

2. 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

3. 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) and 6-inches above the drain.
b. Maximum 30-feet.
c. Maximum four (4) elbows.
d. No reduction in line size.
e. No valve of any type to be installed between the relief valve and tank or in the

drain line.

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 process outlet.

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

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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.

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 EXPANSION BOARD (used for temperature alarm / 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 water heater.

2. If the XB1 is not factory installed, mount the XB1 to the control panel and connect the

XB1 to the T1000 control board with the factory supplied cable between JX4 on the
XB1 and J1 and J4 on the T1000 and connect the ground between JX6 on the XB1
and J8 on the T1000.

3. 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 C ommon
(C) and the LED will flash green. When the tem perature is above the XB1 setpoint the
relay is closed between NO and C and the LED will be solid green. Use NO and C f or
low temperature interlock or high temperature alarm. Use Normally Closed (NC) and C
for low temperature alarm. A red LED indicates an error.

Note: Alarm Rating (resistive):
Max.: 5A @ 120VAC
5A @ 24VDC

(JX5 L1) Power Wire
(Common, White)

(JX5 L2)Power Wire
(Black)

(JX5) (4) Connections
for Additional Circuit
Firing

(JX2) Low Temp.
Relay Terminal Block

(JX6) Ground

(JX4) Connection to
T1000

(JX3) To be used as
T1000 J1 Connection

(JX1) To be used as
T1000 J4 Connection

LED

Note: Once the XB1 is connected to the T1000 control board, an additional menu option will
be available to set the low temperature setpoint. See Section III.

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
heater ON when energizing the relay coil or to turn
the heater OFF when de-energizing the relay coil.
Use a NO (Normally Open) relay to turn the heater
OFF when energizing the relay coil or to turn the
heater ON when de-energizing the relay coil.

10

OPTIONAL REMOTE ALARM CONTACTS

ying

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

Current: 3A

PLUG ADAPTER J4

(NO)
(NC)

Note: That when the XB1 expansion board is used, the J4 PLUG ADAPTER should plug
into the JX1 connection on the XB1.

OPTIONAL FIELD CONVERSION FROM SINGLE TO THREE PHASE OR THREE
TO SINGLE PHASE (HD6 and HD16 models in 6, 7, and 9 kW and 208 and 240 volts
only)

1. Find the appropriate diagram for the unit to be converted in the following chart titled

“Wiring Chart”.

2. Re-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.

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

proper identification.

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

T1000 control board (note: if the XB1 expansion board is used, plug the adapter into
terminal JX3 of the XB1) and verify that the configuration is set to “ H

on”, 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

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.

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