Page 1
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL FOR
ELECTRIC INDUSTRIAL
PROCESS WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ V ”
2014 Edition Rev. A
UM ANSI/NSF5
Page 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 m
4. The refractory material used in heating elem
transit, periods of storage, or when subjected to a hum
absorption results in a cold insulation resistance of less than twenty
ust be
installed in tapping provided.
ents may absorb some mo
id environment. This mo
isture during
isture
(20) megohm
s. If this
heater has been subjected to the above condition, each heating element must be checked
for insulation resistance before energizing. C
ontact the factory for a replacement element.
5. KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS.
Do not perform
any maintenance, make any adjustments, or replace any com
ponents
inside the control panel with the high voltage power supply turned on. Under certain
circum
stances, 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 perform
ing any maintenance or adjustme
nt 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 in
stallations. A qualified installer is a person
who has licensed training and a working knowledge of the applicable codes, tools,
equipm
ent, 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 wa
ter 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 treatm
operating and m
ent to reduce potential corrosi
aintenance costs and will reduce product longevity. Chlorides mu
on. Excessive GPG will result in higher
st
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-lim
ing the heater as well as reducing me
tallic
corrosion. Product failure caused by these conditions is not covered under warranty.
See warranty for complete details.
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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
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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This book describes a packaged 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), 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
V32.9 3 2.9 20 15 12 10 V161 16 1 6 5 4 3
V35.7 3 5.7 39 29 23 19 V161.5 16 1.5 10 7 6 5
V39.9 3 9.9 68 51 41 34 V162 16 2 13 10 8 6
V310.4 3 10.4 71 53 43 36 V163 16 3 20 15 12 10
V311.4 3 11.4 78 58 47 39 V164 16 4 27 20 16 13
V411 4 11.4 78 58 47 39 V166 16 6 41 30 24 20
V415 4 15 103 77 62 51 V167 16 7 47 35 28 23
V427 4 27 185 138 111 92 V169 16 9 61 46 36 30
V61.5 6 1.5 10 8 6 5 V1613 16 13.5 92 69 55 46
V610 6 10.5 72 54 43 36 V1640 16 40.5 276 207 166 138
V612 6 12 82 62 49 41 V1645 16 45 307 230 184 153
V613 6 13.5 92 69 55 46 V1654 16 54 369 276 221 184
V615 6 15 103 77 62 51 V1658 16 58.5 399 299 239 199
V618 6 18 123 92 74 62 V1664 16 64 437 328 262 218
V624 6 24 164 123 98 82 V1666 16 66 451 338 270 225
V627 6 27 185 138 111 92 V1668 16 68 464 348 278 232
V630 6 30 205 154 123 103 V1679 16 79 539 404 323 269
V636 6 36 246 185 148 123 V1681 16 81 553 415 332 276
V639 6 39 267 200 160 133 V1685 16 85 580 435 348 290
V640 6 40.5 277 208 166 138 V1686 16 86 587 440 352 293
V645 6 45 308 231 185 154 V1688 16 88 601 451 360 300
V654 6 54 369 277 221 185 V1690 16 90 615 461 369 307
V658 6 58.5 400 300 240 200
Capacity
(gallons)
V61617543 V1612 16 12 82 61 49 41
V62 6 2 14 10 8 7 V1615 16 15 102 76 61 51
V63 6 3 21 15 12 10 V1618 16 18 123 92 73 61
V64 6 4 27 21 16 14 V1624 16 24 164 123 98 82
V65 6 5 34 26 21 17 V1627 16 27 184 138 110 92
V66 6 6 41 31 25 21 V1630 16 30 205 153 123 102
V67 6 7 48 36 29 24 V1636 16 36 246 184 147 123
V69 6 9 62 46 37 31 V1639 16 39 266 199 159 133
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)
If the required temperature rise is not listed above, the following formula may be used to
determine the maximum flow rate:
Flow Rate (GPH) = kW * 410 / Temperature Rise (°F)
Required kW = Temperature Rise (°F) * Flow Rate (GPH) * 0.00244
120°F
Rise
(GPH)
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5
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6
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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 and fabricated by all
welded construction and is designed for a maximum allowable working pressure of 150 psi
(225 psi test pressure).
TANK CONNECTIONS
The heater is supplied with separate connections for the cold/warm 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 corrosion resistant sheathed elements that are
fitted into a 1½-12UNF brass screw plug with a 1⅞”
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 V3 model element is a 1” NPS thread with a 1½” hex.
MAGNETIC CONTACTOR
Load switching is done by a heavy-duty resistive (non-inductive)
load type definite purpose magnetic contactor. The contactor
supplies power to the heating element(s) 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 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.
OPTIONAL EQUIPMENT
Dielectric Unions
Dielectric unions are provided for the inlet and outlet nipples to isolate stray
ground currents to reduce the possibility of galvanic corrosion.
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Page 8
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.
Slide Brackets
Available for the V6 Model only, these brackets allow for mounting the water heater under a
counter. See slide bracket diagram on page 9 for details.
Shock Absorber
The optional shock absorber can be installed between the heater
and the process to reduce the harmful pressures resulting from
quick closing 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
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 cold water stream before the
heater. The in-line system includes a clear cartridge housing to
allow an operator to view an operator to view the cartridge and
determine when it needs replacement without the need to open the
system.
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 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. See page 13 for
installation details. (Only available with r23 or later software).
Protective Shrouds (V6 and V16 only)
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.
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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
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 V6 models up to
18kW and 22” for V6
models 24 to 58.5kW.
V16 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
NOTES:
• No check valve may be installed in the supply line to the heater.
• 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.
• It is recommended that dielectric unions be installed on the inlet and outlet of the
heater.
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Page 10
1. Connect the cold water inlet and hot water outlet to the appropriate connections as
shown; refer to the specifications for location and sizes.
IMPORTANT (applies to V6 Models only) – Do not turn the entering cold 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 V6 Models only) – Do not apply heat directly to the
entering cold water or exiting hot water nipples. If sweat connections are to be used,
sweat tubing to the adapter before threading the adapter to the nipple on the heater.
Any heat applied to the heater nipple will damage the internal plastic diffuser and
affect performance.
2. Install 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.
4. Install the dial temperature and pressure gauge (if supplied) in the inlet and/or outlet
line. The temperature sensing element must be in the hot water stream and the gauge
must be mounted upright.
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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 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
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 heater and the inlet piping past the dielectric union (on the building
side, not the heater 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 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 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.
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.
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FOR REMOTE ON/OFF CONTROL
ying
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.
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
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 (V6 and V16 models in 6, 7, and 9 kW and 208 and 240 volts and
V411 models only)
1. For V6 and V16 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.
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2. For V411 models:
a. Re-wire the unit to desired configuration as indicated below.
Single-Phase 3-Phase
TO CONTACTOR
TO CONTACTOR
P1
T1
P4
WIRING DIAGRAM SHOWN IS FOR MODEL V411RS (SINGLE PHASE).
TO FIELD CONVERT TO 3-PHASE, REMOVE WIRE P2 AND RECONNECT
IT BETWEEN TERMINALS T6 AND THE CONTACTOR AND REMOVE WIRE
P5 AND RECONNECT IT BETWEEN TERMINALS T2 AND T5.
T2
T3 T4
P3
T5
P5
P2
T6
P6
T1
P4
WIRING DIAGRAM SHOWN IS FOR MODEL V411R (3-PHASE).
TO FIELD CONVERT TO SINGLE PHASE, REMOVE WIRE P2 AND
RECONNECT IT BETWEEN TERMINALS T3 AND T5 AND REMOVE
WIRE P5 AND RECONNECT IT BETWEEN TERMINALS T2 AND T4.
P1 P2
T2
T3 T4
P3
P5
T5
P6
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
T6
terminal JX3 of the XB1) 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
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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V6 and V16 Wiring Chart
Unit
kW Volt Ph
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 19.8 19.8 6.1 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)
4
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)
5
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
6
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 33.2 33.2 7.2 45 12 12 8 ½" 4
7
240 3 19.2 19.2 14.4 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
9
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
10.5
13.5
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
12
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 12.0 12.0 57.7 20 12 12 12 ½" 14
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
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Page 15
kW Volt Ph
15
18
24
27
30
36
39
V6 and V16 Wiring Chart (cont.)
Unit
Amp
Draw
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 16.0 16.0 43.3 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 24.0 24.0 28.8 30 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 33.2 33.2 21.7 45 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
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
15
Page 16
V6 and V16 Wiring Chart (cont.)
Unit
kW Volt Ph
208 1 196.8 65.6 1.1 250 8 10 250 2" 6A
208 3 113.8 56.9 2.1 145 8 10 1/0 1¼" 12(NCB)
240 1 168.8 56.3 1.4 215 8 10 250 1½" 6A
40.5
58.5
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)
45
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
54
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
68
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
81
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
88
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)
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
V6 and V16 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.
16
Page 17
V3 Wiring Chart
Unit
kW Volt Ph
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
9.9
208 3 27.5 8.7 35 12 12 8 ½" 10 (NT)
10.4
11.4
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
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
V3 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.
V4 Wiring Chart
kW Volt Ph
11.3
12.6
13.8
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
15
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)
27
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)
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
V4 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.
Page 18
1(WT)
1(NT)
L1
10(WT)
L2
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
L1 L2
Control
Module &
Display
J8
J2
J5
J3
J7
Control, Low Water,
& Hi-Limit Probe
Leak Detection
J8
Control
J2
J5
J7
Module &
J3
Display
Probe
10(NT)
L1 L3L2
Control, Low Water,
& Hi-Limit Probe
17
J5
J7
Leak Detection
Probe
L1 L3L2
Control
Module &
Display
J8
J2
J5
J3
J7
J8
Control
J2
Module &
J3
Display
Control, Low Water,
& Hi-Limit Probe
Leak
Detection
Probe
L1 L2 L3
Control, Low
Water, & Hi-Limit
Probe
Control
Module &
Display
J8
J4
J1
J5J3J2
J7
Leak
Detection
Probe
JX5
JX4JX
XB1
6
Page 19
6A
L1 L2
Control
Module &
Display
J5
J7
J3
3A
J8
J2
L1 L2
J8
J2
J5
J7
Control
Module &
J3
Display
12 (WT)
12
Control, Low
Water, & Hi-Limit
Probe
L1 L2 L3
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
L1 L2 L3
Leak
Detection
Probe
J5
J7
Control, Low Water,
& Hi-Limit Probe
Leak Detection
Probe
13 (NT)
L1 L3L2
J8
J2
Control
Module &
J3
Display
13(WT)
Control, Low Water,
& Hi-Limit Probe
Leak Detection Probe
J8
Control
J2
J5
Module &
J3
J7
Display
Control, Low Water,
& Hi-Limit Probe
J5
J7
Leak
Detection
Probe
Control
Module &
Display
J8
J2
J3
L1 L3L2
Control, Low Water,
& Hi-Limit Probe
J5
J7
Leak
Detection
Probe
J8
Control
J2
Module &
J3
Display
Page 20
20
Page 21
21
Page 22
Typical V6 Plumbing Connections
(Rear View)
Typical V16 Plumbing Connections
(Front View)
22
Page 23
Typical V4 Plumbing Connections
(Rear View)
Typical V3 Plumbing Connections
(Front View)
23
Page 24
SECTION III – SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before perform
ing 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: r
14, H r S, l2 3, 4 5 6; 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.
With the controller turned OFF, to enter the configuration menu, press and
ho
ld 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).
With XB1 installed ## can be 01 through 06.
ii. Low water detection – sets the low water detection on or off.
24
Page 25
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.
viii. XB1 Temperature Setpoint – sets the setpoint for the operation of the
XB1 relay operation.
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 heater.
b. The decimal points on the display, as shown below, indicate that the controller
is calling for a contactor to pull in. If three or more contactors are installed, the
third decimal is used for all remaining contactors.
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.
25
Page 26
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.
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 removed 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.
26
Page 27
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.
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
1. 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.
2. Note that before replacing the control board, display, or probe, it is recommended that
the power supply to the heater be turned off at the main circuit breaker disconnect to
the 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.
27
Page 28
GENERAL TROUBLESHOOTING
Symptom Probable Cause Corrective Action
Water reaches setpoint
temperature but does
Low incoming water
temperature.
not last through the
entire process cycle.
Incoming water
temperature is dropping.
Heater may be
undersized.
Incorrect voltage. Voltage available at the heater must be
If two magnetic
contactors are utilized,
one is not energizing.
One or more elements
are not energizing.
Water at the outlet is
not the proper
Gauge(s) not reading
correctly.
temperature.
Temperature setpoint
too low.
Water heater piping to
point of use is not
insulated.
Bypass valve (if
installed) is open or
allowing water to pass
when closed.
Incoming water temperature must be
adequate for the heater size. Increase the
incoming water temperature.
Primary water supply is not adequate to
continually provide correct temperature in
sufficient quantities. Increase the supply of
primary cold water.
The heater must be properly sized for the
incoming water and rinse requirements of
the process. If required, replace with a
properly sized unit.
correct for unit. Verify voltage on all
phases matches nameplate on the heater.
Verify that both magnetic contactors are
operating. If not, see the ‘Magnetic
Contactor Troubleshooting’ section.
Verify that each element is drawing the
correct amperage. Replace elements as
required.
Check the temperature of the water with a
thermometer to verify the gauges are
working properly. Replace gauges, if
required.
Adjust the temperature setpoint.
If there is more than 5 linear feet of piping
between the heater and the process, the
piping should be wrapped in insulation or a
recirculating system should be installed.
Verify that the bypass valve between the
hot and cold water lines is closed. If
condition continues, replace the bypass
valve.
28
Page 29
Symptom Probable Cause Corrective Action
Temperature and
pressure relief valve
seeps
Anti-siphon valve or
check valve installed in
the cold/warm water
Remove the anti-siphon valve or the check
valve to allow for the expansion of the water
or install a back pressure relief valve.
inlet line.
Temperature and
pressure relief valve
opens and/or high
limit temperature
error occurs.
Water heater does
not heat at all.
Unit is overheating due
See the ‘P65 Probe Troubleshooting’ section.
to improper P65 probe
calibration.
Unit is overheating due
to the magnetic
See the ‘Magnetic Contactor Troubleshooting’
section.
contactor staying in the
closed position.
Main supply circuit
Check and/or reset the circuit breaker.
breaker tripped.
Water heater circuit
breaker tripped.
If unit is supplied with a circuit breaker, check
and/or reset the circuit breaker.
Heater 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 the heater is full of water. If error is
still present see the ‘P65 Probe
Troubleshooting’ section.
Magnetic contactor
does not energize.
No power to control
board (T1000) or
display (TD1000) not
lit.
See the ‘Magnetic Contactor Troubleshooting’
section.
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.
Incorrect Configuration
Settings
Verify and correct configuration settings as
required.
29
Page 30
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 heater nameplate.
If voltage is incorrect, check main supply wiring or replace unit with proper 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).
Probe Ground (J7) Display Cable Leak Detection Wire (J2)
Expansion (J1)
Ground Wire (J8)
(D1)
Probe Cable
(J3)
Alarm Relay
(J4)
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 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 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
on the T1000 control board. If no voltage is present, replace the control board (T1000). If
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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
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
80°F
90°F
100°F
110°F
120°F
130°F
140°F
150°F
160°F
170°F
180°F
190°F
11883Ω
9299Ω
7334Ω
5828Ω
4664Ω
3758Ω
3048Ω
2488Ω
2043Ω
1687Ω
1400Ω
1169Ω
980Ω
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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.
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) and probe
ground (J7), leak detection wire (J2), ground wire (J8), 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.
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Probe Ground (J7) Display Cable Leak Detection Wire (J2)
Expansion (J1)
Ground Wire (J8)
(D1)
Probe Cable
(J3)
Alarm Relay
(J4)
Power Wire (Common, White) Connector (J5)
Power Wire (Black) Wire to #1 Contactor (yellow)
Wire to #2 Contactor (red)
Note: Probe connector J3 comes filled with a dielectric gel that should remain in the
connector.
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 J3 and the probe ground from J7 on the T1000
control board.
Probe Ground (J7)
Probe
Connection
(J3)
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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.
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.
rn on power to the unit. If display shows “ E rr, N o , P r b ”, 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 o-ring 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.
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SECTION VI – SERVICE PARTS LIST
Category Description Volts Ohms Hubbell P/N
Accessories 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 58 kw) 100XL .75 150LB
Relief Valve (64-90 kw) 40XL-4 1 150LB
Slide Brackets (V6 models only, 2 per set) J6 SLIDE BRACKET
V6, 3 Element Plastic Protective Shroud (1 to 18 kW) J6-3 SHROUD
V6, 6 Element Plastic Protective Shroud (24 to 58.5 kW) J6-6 SHROUD
V16 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 Inductive, 208/240 VAC Coil C25DNF315B
40 Amp Resistive, 30 Amp Inductive, 208/240 VAC Coil C25DNF330B
50 Amp Resistive, 40 Amp Inductive, 208/240 VAC Coil C25DNF340B
65 Amp Resistive, 50 Amp Inductive, 208/240 VAC Coil C25DNF350B
75 Amp Resistive, 60 Amp Inductive, 208/240 VAC Coil C25FNF360B
90 Amp Resistive, 75 Amp Inductive, 208/240 VAC Coil C25FNF375B
Elements
V4, V6, and V16
(Note: Each element
is supplied with an
O-Ring)
Elements 1900 Watts 120 7.6 C1315-39
V3 3300 Watts 208 13.1 C1315-40
(Note: Each element 3460 Watts 208 17.6 C1315-36
is supplied with an 3800 Watts 240 15.2 C1315-37
O-Ring) 3800 Watts 277 20.2 C1315-38
2000 Watts 208 21.6 C1315-2
4000 Watts 208 10.8 C1315-3
5000 Watts 208 8.7 C1315-4
6000 Watts 208 7.2 C1315-5
6500 Watts 208 6.7 C2315-6
7150 Watts 208 6.1 C2315-7
9000 Watts 208 4.8 N2375-9
9600 Watts 208 4.5 N2375-10
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 N2375-20
9750 Watts 240 5.9 N2375-21
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 N1375-32
9750 Watts 480 23.6 N1375-33
6750 Watts 480 34.1 C1315-35
Extra O Ring (#220 Buna-N) O RING J MODEL
3800 Watts 346 31.5 C1315-41
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SERVICE PARTS LIST (cont.)
Category Description Volts Ohms Hubbell P/N
Misc. Electrical
Vessel V6 Vessel with 3 Element Openings J6-3 TANK KIT
(includes insualtion V6 Vessel with 6 Element Openings J6-6 TANK KIT
and o-rings) V16 Vessel with 3 Element Openings J16-3 TANK KIT
Stainless Steel V6, 3 Element Base J6-3 BASE
Enclosure Parts V6, 3 Element Top Enclosure J6-3 JACKET
Control Board T1000
Digital Display Module (with overlay and V16 Extension) TD1000
V16 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,50 VA B050-3299-3
Transformer 600-195V,50 VA B050-3350-3
Transformer 380-185V,50 VA B050-3351-3
Transformer 480-208V,100 VA B100-3299-3
Transformer 600-195V,100 VA B100-3350-3
Transformer 380-185V,100 VA B100-3351-3
Transformer 480-208V (V3 and V4 only) TRAN 480-208 25VA
Transformer 380-208V (V3 only) TRAN 380-208 25VA
Transformer 277-208V (V3 only) TRAN 277-208 25VA
Transformer 600-208V (V3 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
Remote 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
V16 Vessel with 6 Element Openings J16-6 TANK KIT
V16 Vessel with 9 Element Openings J16-9 TANK KIT
V3 Vessel J3 TANK KIT
V4 Vessel J4 TANK KIT
V6, 3 Element Front Cover J6-3 FRONT COVER
V6, 6 Element Base J6-6 BASE
V6, 6 Element Top Enclosure J6-6 JACKET
V6, 6 Element Front Cover J6-6 FRONT COVER
V16 Base J16 BASE
V16 Top Enclosure J16 JACKET
V16 Front Cover J16 FRONT COVER
V3 Base J3 BASE
V3 Top Enclosure J3 JACKET
V3 Front Cover J3 FRONT COVER
V4 Base J4 BASE
V4 Top Enclosure J4 JACKET
V4 Front Cover J4 FRONT COVER
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SECTION VII – TORQUE VALUES
Part P/N Wire Size
Element to
Tank
Wire to
Element
Probe to Tank All N/A 300 25
Wire to Ground
Lug
Wire to Circuit
Breaker
Transformer All All 15 1.25
Wire to Control
Board
C25DNF315B
C25DNF330B
Wire to
Contactor
Wire to Power
Distribution
Block
Control Board
to Panel
Display to Base All N/A 10 0.83
All Other
Components to
Panel
C25DNF340B
C25DNF350B
C25FNF360B
C25FNF375B
All N/A 600 50
All All 15 1.25
KA8C All 25 2.08
KA4C All 45 3.75
#14-#10 35 2.92
All
All All 3.5 0.29
Line All 275 22.92
16023-3
16023-2
63133
63132
All N/A 10 0.83
All N/A 20 1.67
Load
Line
Load
#8 40 3.33
#6-#4 45 3.75
#14-#12 15 1.25
#10 25 2.08
#8 40 3.33
#6-#4 45 3.75
#14-#10 40 3.33
#8 45 3.75
#6-#4 50 4.17
#14-
#10
#8 25 2.08
#6-#4 35 2.92
#14-#8 50 4.17
#6-2/0 120 10
#14-
#10
#8 25 2.08
#6-#4 35 2.92
Torque
(in•lbs)
20 1.67
20 1.67
Torque
(ft•lbs)
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SECTION VIII – WARRANTY INFORMATION
LIMITED WARRANTY
1. PRODUCT WARRANTY. Hubbell warrants the water 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: 90 days parts and labor
ELECTRICAL COMPONENTS: One (1) year, parts only
TANK ONLY: Three (3) 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.
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NOTES
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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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