Hubbell Heaters A64, A65, A66, A67, A68 Maintenance Manual

OPERATING AND MAINTENANCE MANUAL FOR

ELECTRIC BOOSTER HEATER

ELECTRIC HEATER COMPANY

BASE MODEL “ A ”

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.

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TABLE OF CONTENTS

SECTION TITLE PAGE #

I GENERAL DESCRIPTION AND CONSTRUCTION 5

II INSTALLATION 9

III SCHEDULED MAINTENANCE AND OPERATION 16

IV TROUBLESHOOTING 18

V SERVICING & REPLACEMENT OF PARTS 20

VI MISCELLANEOUS CHARTS AND FORMULAS 25

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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION

GENERAL DESCRIPTION

This book describes a packaged electric booster heater that is typically used to provide 180°F sanitizing
rinse water. The complete assembly consists of the storage tank, immersion electric heating element(s),
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/warm 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.

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CONTROL THERMOSTAT

The water heater is supplied with an immersion thermostatic switch
that is installed and wired at the factory. The thermostat can be adjusted
through a range of 100° - 195° F and is adjustable with a flat tip
screwdriver.

TEMPERATURE HIGH LIMIT SWITCH

A surface mounted high temperature cut-off switch with manual reset, factory set at 205° F is provided.
In the event of an over-temperature condition, the thermostat will disengage the operating coils in the
magnetic contactor(s). The high limit must be manually reset thereafter to restart the heater.

Manual Reset

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.

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.

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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.

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.

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 in­line installation (shipped loose).

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Pressure Reducing Valve

An optional pressure reducing valve with
built-in bypass may be supplied. This valve is
shipped separately for in-line installation.

Stainless Steel Outer Jacket

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

Stainless Steel Legs

As an option, 6-inch adjustable stainless steel legs may be supplied.

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SECTION II – INSTALLATION

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.

WATER HEATER PLACEMENT

1. Place the heater on a solid foundation in a clean, dry location as near as possible to the dish
washing machine.

2. The water heater should be protected from freezing and waterlines insulated to reduce energy
and water waste.

3. Leave a minimum of 18” clearance for element withdrawal, if necessary.

4. Do not install in an area where flammable liquids or combustible vapors are present.

PIPING INSTALLATION

NOTE:

galvanic and stray current is the installation of dielectric fittings/unions. The installation of these
fittings is the responsibility of the installing contractor.

The most effective means for preventing deterioration from accelerated corrosion due to

1. Connect the cold water inlet and hot water outlet to the appropriate connections as shown;
refer to the drawing for location and sizes.

2. Install water pressure regulator, if supplied, and adjust to the pressure recommended by the
dishwasher manufacturer. WHEN A STANDARD PRESSURE REGULATOR IS USED,
(other than that purchased with the booster), it acts as a check valve and it is possible that
thermal expansion will cause the relief valve to drip or occasionally blow off a small amount

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