Installation
CLE Series
Tankless Heater Models
CLE18, CLE25
Voltage options:
600V 3-phase
480V 3-phase
415V 3-phase
400V 3-phase
380V 3-phase
Table of Contents
Pre-Installation Information .........................2–3
Storage Instructions .................................3
Mounting Heater....................................4
Plumbing Installation ................................5
Electric Installation ..................................6
Start Up Check List .................................7
Start Up ..........................................8
Digital Controller Operation ...........................9
Operational Tests ...............................10–11
Product Options ...................................11
Maintenance......................................12
Troubleshooting ................................12–13
Special Installation & Operating Instructions ..........14–17
215-1822 Rev. A; ECN 140011
© 2015 Keltech
Page 1 of 17 10/2/2015
729 S. Grove St., Delton, MI 49046
TEL: 269-623-6395 • 800-999-4320 FAX: 269-623-6398
sales@keltech-inc.com • www.keltech-inc.com
CLE Series Tankless Heater Installation
DANGER
Tip over hazard. System can crush you resulting in serious injury or death. Read and follow precautions in this
installation manual that accompanied the heater for instructions on how to safely transport and anchor heater.
Do not transport with the heater in the vertical position. This heater is top heavy and should not be placed in
the vertical position until the site is prepared to anchor the heater to the wall or the legs to the floor.
WARNING
Read this manual BEFORE using this equipment. Failure to read and follow all safety and user information
could result in death, serious personal injury, minor burns, property damage, or damage to the equipment.
Keep this Manual for future reference. Failure to comply with proper installation and maintenance instructions
could contribute to the heater’s failure.
A qualified plumber or electrician should install and service this system. Install system according to these
instructions and in compliance with national and local codes.
ASSE standard 1071 listed devices should be used at fixtures to prevent possible injury. Severe bodily injury
including scalding, chilling, and/or death may result depending upon system water pressure changes and/or
supply water temperature changes.
For safe operation of the heater, observe all warning labels as indicated.
Water heater system under pressure. Do not open enclosure while in operation.
These heaters should never be used to provide “anti-scald” or “anti-chill” service.
Hazardous voltage inside enclosure may result in serious burns or death. Disconnect power supply before
performing any work in the enclosure.
Failure to ground this system may result in death or serious injury.
Make sure that all water supply lines have been flushed and then completely turned off before beginning
installation. Debris in supply lines can cause valves to malfunction.
CAUTION
Hot pipes! Do not touch. May cause minor burns.
NOTICE
These heaters do not provide protection from supply or outlet pipe freezing.
Consult local building and plumbing codes prior to installation. Should these codes differ from the information
in the Manual, follow the local codes. Inquire with governing authorities for additional local requirements.
Regular checking and cleaning of the heater’s internal components and check stops is necessary for maximum
life and proper product function. Periodic inspection and yearly maintenance by a licensed contractor is
required. Corrosive water conditions, and/or unauthorized adjustments or repairs could render the heater
ineffective for its intended service. Frequency of cleaning and inspection depends upon local water
conditions. For heaters with adjustable output temperatures, check and adjust as needed at initial installation
and on a quarterly basis.
IMPORTANT
Read this entire installation manual to ensure proper installation. When finished with the installation, file this
manual with the owner or maintenance department. Compliance and conformity to local codes and ordinances
is the responsibility of the installer. Product warranties may be found under “Products” on our Web site at
www.keltech-inc.com.
Separate parts from packaging and make sure all parts are accounted for before discarding any packaging
material. If any parts are missing, do not begin installation until you obtain the missing parts.
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
Installation CLE Series Tankless Heater
Pre-Installation Information
General Information
The Keltech Tankless Water Heater provides instant and precise temperature-controlled hot water. To insure proper performance,
install the heater according to the following installation instructions and in compliance with applicable national and local codes.
Keltech can supply heaters for most commercial and industrial hot water applications. Flow rates and temperature figures are
important for proper sizing. If needed to meet certain temperature demands, flow control devices are readily available. See
Temperature Rise Specifications chart. Contact KELTECH, INC. for further information on available flow control devices.
Operation and Setup
CLE Series heaters supply an unlimited amount of hot water with specific flow and temperature rise capabilities.
These heaters are energy efficient, reliable, and provide optimum performance in the most demanding applications.
Application Specific Requirements
The CLE Series can be used in many different applications that require tepid water intended to supply safety fixtures.
For applications utilizing quick close valves or solenoid valves, it is important to install a hammer arrestor or surge
tank close to the point of use to absorb pressure spikes.
Installation Considerations
Maximum operating pressure: 150 psi.
Minimum flow activation: 0.75 gpm
Certifications
Keltech Electric Tankless Water Heaters are certified by ETL to UL499, UL50E, CSA22.2 No 88 and NFPA 496.
Heaters are compliant to NEC/NFPA 70 and Canadian Electrical Code C22.1.
WARNING For safe operation of the heater, observe all the warning labels as indicated.
Storage Instructions
NOTICE! Keep Keltech Electric Tankless Water Heaters stored in original packaging until installation.
Recommended storage criteria:
Store Keltech Electric Tankless Water Heaters where temperatures exceed 35°F (2°C) at all times.
Indoor storage is recommended.
Minimize excessive on-site transport to reduce risk of shock and impact damage.
Alternate storage:
If in the original crate, Keltech Electric Tankless Water Heaters will withstand outside storage for approximately 1
month in most climates. Crate may not be capable of protecting the heater if left outside longer than this time frame.
If the Keltech Electric Tankless Water Heater is stored in an outdoor environment, care should be taken to protect the
heaters from:
• Rain or other falling precipitation via tarp or other waterproof media.
• Runoff and accumulation of groundwater from any source that may exceed 1 inch.
NOTICE! For heaters with ENHT freeze protection option: If the heater is stored where the temperature
could fall below 45°F(7°C), the heater must be powered immediately after hydro testing to insure
internal freeze protection components are activated. Once the heater is installed and the on-site
plumbing has been hydro tested, the power supply must remain constant until the risk of freeze is
eliminated. If this is not possible, the heater must be drained of water. Freezing of the heater can
cause serious damage. Follow notes in Start Up Check List section following electrical lockout/
tagout procedure.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
3
CLE Series Tankless Heater Installation
Packaging
Crates are constructed from 3/4" OSB.
Crate dimensions approx: 44" x 28" x 12" (1118mm x 711mm x 305mm)
Crates should not be stacked more than 2 high.
All crates must be stacked evenly and horizontally.
Safety issues related to packaging:
• Product should be transported with the care associated to packages labeled “FRAGILE” even if packaging is not
marked accordingly.
• Standard safety procedures for forklift transport and large items less than 1000lbs should be followed at all times.
• When stored, crate must be supported in entirety of its length and width.
1
Mounting Heater
WARNING HIGH VOLTAGE SHOCK. Disconnect power supply before performing any work inside
the heater enclosure.
Installation should be performed by a qualified plumber or electrician.
If heater is installed where freezing can occur, specify Keltech's ENHT Freeze Protection option. Keltech's
ENHT option must be purchased at the time of order. Do not install in areas where freezing can occur
without the ENHT option listed in the model number.
For best results, install heater as close as possible to the point of use.
Long pipe runs are not recommended. A heat loss of 1°F for every 10ft (3 meters) of uninsulated
pipe can occur.
When determining a mounting location, give consideration to the location of the main electrical panel
and ensure accessibility of the cabinet enclosure door and other plumbing for service/maintenance.
36" minimum in front of the cabinet enclosure is required.
Set heater in a vertical, upright position
A
with the water outlet located at top.
Standard Wall Mount
Mount heater to the wall using the (4)
mounting brackets on the back of the
enclosure. Bolt the heater to the vertical
surface. Vertical surface must support 150
B
pounds or more.
Optional Leg Kit
Use the floor mounting template on the
side of the crate to help with alignment.
Secure heater by bolting each leg to the
floor using 3/8" anchor bolts.
8"
(102mm)
(203mm)
4"
20"
(508mm)
12¼"
(311mm)
6¼"
(159mm)
4"
(102mm)
Install the pressure and temperature relief
valve on hot water outlet immediately
C
following the union.
NOTICE! Valve must empty into a drain.
Rectangle outlines on template is not
actual size of heater.
Template may require cutting to fit into
tight areas.
Holes are for alignment purposes and may
not represent actual drill size for mounting
hardware.
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
⁷⁄₁₆" x ¾" Slot
(6 Places)
Installation CLE Series Tankless Heater
2
Plumbing Installation
Components Needed:
• (2) Union 3/4"
• Shutoff Valve
• Pressure and Temperature Relief Valve (150 psi)
• Y-Strainer (100 mesh) or Inline Filter (150 microns)
• (2) Gate or Ball Type Valves
• Drain pipe
• Water hammer arrestor (recommended)
• Elbows, nipples and fittings as needed
CAUTION! To avoid damage to the electronics
or internal wiring, do not perform any
brazing or sweat soldering inside the
enclosure.
NOTICE! Failure to install proper filtration may
result in a flow switch malfunction.
NOTICE! To avoid water damage, install a drain
pipe from the pressure relief valve to an
unrestricted drain.
If end use fixture is not at the highest point in
the plumbing loop, then an automatic air vent
valve must be added at the highest point in the
system or at any drop to eliminate trapped air.
Dimensions, Plumbing and
Electrical Configurations
¾" Female
NPT Outlet
2"
(51)
6"
(152)
¾" Female
NPT Inlet
A
B
C
P&T Relief
Valve
3⁷⁄₁₆"
(87)
Install shutoff valve above (upstream of) the
heater inlet.
Install one union on the water inlet side of
the heater. Install one 100 Mesh (150 micron)
Y-strainer above (upstream of) union.
Install one union on the water outlet side of the
heater. Install one P & T Relief Valve above
union.
Install the pressure relief valve (150 psi) and
outlet plumbing of heater per code requirements
and route relief valve discharge to drain. Make
sure no shutoff valve is between the water heater
outlet and the relief valve, as well as no shutoff
valve between the relief discharge and drain.
Install hammer arrestor. Ensure plumbing is
secure and not subject to vibrations.
Use 3/4" hard copper tubing or pipe as needed.
Outlet
Inlet
18kW
25kW
Ball or Gate
Shutoff Valves
Y-Strainer with
100 Mesh Screen
Recommended
Threaded
Unions
Dim. "A" Dim. "B"
31-1/2" (800) 30" (762)
37-1/2" (953) 36" (914)
Disconnect
A
B
18½" (470)
20" (508)
Suggested Location For Power Entrance.
Entrance Holes To Be Provided By Installer.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
Optional
Fused
(203)
10.95"
(278)
To Drain
8"
Suggested Installation Configuration
Components provided by installer unless
otherwise specified. Reference the product
options sections or contact your local Bradley
Representative for product options.
5
CLE Series Tankless Heater Installation
3
Electric Installation
WARNING Install product to rated line voltage in accordance to current local and national codes and
regulations.
WARNING All Keltech heaters must be fused in accordance with National Electric Code (NEC) for the
full load amperage listed on the nameplate rating for each heater.
WARNING Failure to properly ground the unit(s) per the National Electric Code could result in injury
or death.
Open enclosure door.
A
NOTICE! Any option that requires field wiring
must be done with 600V cable per
the schematic that was shipped with
the heater.
NOTICE! Use a 4-core cable or multi-stranded
machine tool wire from an approved
isolating 3-pole switch or circuit
breaker.
NOTICE! Make sure the electrical cable is the
correct size to carry 100% of the full
load current. See table for proper
wire sizes.
ELECTRICAL SPECIFICATIONS FOR HEATER (3 PHASE)
Model Voltage Amps kWatts
CLE183/600D 600 18 18 10 AWG*
CLE253/600D 600 24 25 10 AWG*
CLE183/480D 480 22 18 10 AWG*
CLE253/480D 480 30 25 8 AWG*
CLE183/415D 415 18 13 10 AWG*
CLE253/415D 415 26 19 8 AWG*
CLE183/400D 400 17 12 12 AWG*
CLE253/400D 400 24 17 10 AWG*
CLE183/380D 380 17 11 12 AWG*
CLE253/380D 380 24 15 10 AWG*
* Based on the NEC Table 310.15 for 75°C insulated copper wire @ 30°C
Ambient. Aluminum wire requires larger gauges.
Min Wire
Size
Using a hole punch, cut a hole the proper
size for conduit connection; large enough
for the wire size for each heater. The
B
connectors need to be rated NEMA4/4X
to ensure proper sealing of the enclosure.
Run wires through the appropriate size
C
conduit.
Connect wires to the system terminal
block or fused disconnect inside the
D
enclosure.
Connect the ground wire to the stud
E
provided with the “Ground” label beneath it.
Not all available (optional) voltages are listed in table.
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Installation CLE Series Tankless Heater
4
Start Up Check List
Plumbing
System is set in a vertical, level, and upright position with the outlet located at the top. System is mounted to the
wall using the (4) mounting brackets on the back of the enclosure or bolted to the floor with the optional leg kit.
Confirm installation of shutoff valve above (upstream of) the union on the inlet connection. Confirm installation of
a Y-strainer (100 mesh screen) or inline filter (150 micron) between the inlet shutoff valve and the heater.
Pressure and temperature relief valve is installed on tepid water outlet immediately following the union. No valve
or restriction is between the relief valve and the system or the relief valve and drain. Shutoff valve is installed
after pressure and temperature relief valve on outlet if required by local or national plumbing codes.
If the tepid water process is not at the highest point in the plumbing loop, then an automatic air vent valve must
be added at the highest point in the system plumbing loop to eliminate trapped air.
Electrical
Verify supply voltage matches the indicated voltage on the Serial Tag. Serial Tag is located within the heater
enclosure on the upper left corner of the back plate (mounting plate).
Appropriate conduit is installed properly, secured and sealed to unit enclosure per NEC and hazard
location requirements.
Appropriate conductors for unit routed through conduit and secured to power block inside the enclosure. All
electrical is installed in accordance with national and local electrical codes, including fuse size and rating.
Appropriate earth ground is installed to the lug provided on enclosure backplate.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
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CLE Series Tankless Heater Installation
5
Start Up
WARNING Make sure the breaker for the heater is OFF.
Be sure that plumbing and electrical are complete per Start Up Check List.
Slowly turn on water supply to the unit
with the enclosure door open and the
A
breaker in the off position.
Slowly turn on the water outlet valve,
activate the connected process requiring
heater water (eyewash, etc.), then flush
the system for 5 minutes to ensure all air is
B
purged from the system.
NOTICE! Failure to bleed air properly
will damage elements and
cause heater malfunction.
Turn off the connected process and
check the entire system to verify leak-free
C
installation.
Energize the electrical service to the unit
F
by switching on the breaker.
Unit is now in the ready state.
G
Turn on the connected process; observe
output temperature rise to setpoint.
NOTE: Top portion of temperature
H
controller displays output temperature,
bottom displays setpoint temperature.
When startup is complete, leave circuit
breaker in the ON position. The Green
I
power light should be illuminated.
Close enclosure door and secure.
D
If your heater has the EXP2 option and
is located in a Class I Division 2 area,
please review Special Instructions &
Operation Instructions section for all
proper electrical connections and sealing
to ensure the installation will provide the
E
proper protection. Proceed to Step F once
you have completed the steps in the Special
Instructions & Operation Instructions or if you
do not have this option.
NOTICE! If your heater is mounted in an area where freezing temperatures are possible, an ENHT
Freeze Protection Option should be specified. Heaters must be powered at all times to be
Freeze Protected. If continuous power is not possible, do not allow the heater to remain full of
water. Freezing of the heater can cause serious damage.
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
Installation CLE Series Tankless Heater
6
Digital Controller Operation
The preprogrammed digital controller is mounted through the bezel on the enclosure door. The digital
controller will be powered but the bottom display will read OFF until water is flowing through the heater.
The bottom display will then display the setpoint temperature (See Digital Controller Operation section for
more information).
Description Upper Display Lower Display Function
EZ Key Toggles output on/off (disabled on CLE models)
Setpoint Up Button Increases output temperature (disabled on CLE
models)
Setpoint Down Button Decreases output temperature (disabled on
CLE models)
Infinity Key Back to Home page
Advance Key Advances through parameter prompts
Auto, Man, Off C.r71 Turns Control Loop On/Manual/Off (disabled on
CLE models)
XX.X% h.Pr1 Heater Power % (disabled on CLE models)
no AUt1 Autotune (Contact Factory) (disabled on CLE
models)
C or F C_F1 Change Temperature Units from F to C
Output Indicators (1-5) Output 1,2,3,4 or 5 are active and operating if
these LEDs are illuminated.
Setpoint Temperature
(Lower Display)
Output Temperature
(Upper Display)
Displays:
Displays:
• Setpoint
• Percent Power
• Temperature units F or C
• Menu prompt name
• Alarm code
• Actual process temp. of outgoing water
• Prompt parameter value
• Error code (feature disabled)
Layout Diagram ON - Heating OFF - No Flow
EZ Key
Output Indicators
1
2
Output Temp.
3
4
Setpoint Temp.
5
Setpoint Up
Setpoint Down
1
Output
2
Temp.
3
4
Setpoint
5
Temp.
1
2
Output
3
Temp.
4
No Flow
5
Advance KeyInfinity Key
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
9
CLE Series Tankless Heater Installation
6
Perform Operational Test No. 1
Ensure the enclosure door is closed
prior to performing operation test.
Set the 3-pole switch or circuit breaker to the
A
ON position.
Start the water flow through the heater by
starting the process or fixture this heater is
B
connected to in order to activate heater.
When flow rate reaches approximately
0.75gpm, the flow switch activates and begins
the heating process.
When the flow switch activates:
• Phase indicator lights illuminate on the front
C
bezel verifying power supply connection to the
heating elements via the solid-state relays.
• Element load lights may be solid or flash
in unison as heating elements modulate
depending on the hot water demand.
• Lower display on controller goes from off to
setpoint temperature.
The controller displays the temperature of
D
water measured at the outlet.
Located on the panel is a (18kW or 25kW)
green ready light. When illuminated, the
safety circuit is engaged and ready for use.
Test water temperature and stability at
outlet by viewing the display. Controller
E
displays (in red) the temperature of water
exiting the heater.
Heater will not energize heating elements if the
inlet water temperature is equal to or greater than
the temperature set on the digital controller .
7
Perform Operational Test No. 2
Each model has precise specifications for temperature rise capabilities.
Turn on hot water faucet/fixture/process (min
flow rate of 0.75gpm). The heater should
A
activate immediately.
If the water flow exceeds maximum heating capacity of the heater, the temperature of water at the outlet
may be lower than the temperature selected on the controller. See table below to determine maximum
temperature rise capabilities.
Models 480/600V kW
CLE18 18 122 61 41 31 25 20 17 15 13 12
CLE25 25 160 85 57 43 34 28 24 21 19 17
Models 480/600V kW
CLE18 18 68 34 32 17 14 11 9 8 7 7
CLE25 25 89 47 14 24 19 16 13 12 11 9
1 gpm
ΔT °F
3.8 lpm
ΔT °C
Temperature Rise (GPM & F°)
2 gpm
ΔT °F
7.6 lpm
ΔT °C
3 gpm
ΔT °F
Temperature Rise (lpm & C°)
11.4 lpm
ΔT °C
4 gpm
ΔT °F
*May exceed the maximum temperature setting of the heater
15.1 lpm
ΔT °C
B
5 gpm
ΔT °F
18.9 lpm
ΔT °C
Turn off hot water faucet/fixture/process.
The flow switch will deactivate and shut
off power to the heater.
6 gpm
ΔT °F
22.7 lpm
ΔT °C
7 gpm
ΔT °F
26.5 lpm
ΔT °C
8 gpm
ΔT °F
30.2 lpm
ΔT °C
9 gpm
ΔT °F
34.1 lpm
ΔT °C
10 gpm
ΔT °F
37.8 lpm
ΔT °C
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
Installation CLE Series Tankless Heater
Output heating capacity is reduced if these heaters are installed on 415V, 400V or 380V 3-ph.
Contact the factory to supply this information.
Satisfactory performance of the heater is dependent upon a specific flow rate vs temperature rise capability. If the
desired temperature is not achieved, please verify the following:
1. Circuit breaker is on and rated for the maximum power draw.
2. Heater is drawing the proper current for the supply voltage on all 3 phases.
3. All 3 phase indicator lights are lit (not flashing) indicating maximum power draw and maximum
amperage is being drawn.
4. Flow rate and temperature rise in the water heating process are compatible with the heater specifications.
5. Verify there is no additional supply of cold water entering the line downstream of the heater.
Product Options
AL3 & AL3-SL Alarms: The AL3 option provides dry contacts that open to signal flow >1.5 gpm has activated the
heater. The AL3-SL option provides these dry contacts and additionally activates a local audible and visual alarm on
the heater.
GF (Ground Fault): Detects electrical leakage from external sources to protect equipment, electronics, and the heat
exchanger from being damaged in the event of a power fault. After turning on water, then power, test ground fault:
1. Press GF Test button.
2. Watch for ground fault light to illuminate and Bank Ready light(s) to shut off. The Ground Fault system is active
and in working order.
3. Press the GF Reset button, hold for 2 seconds and release to reset ground fault.
NOTE: If a trip occurs under normal operation DO NOT RESET Ground Fault without evaluation and service.
NOTE: Normal state is Ground Fault light OFF, Bank Ready lights ON.
ENHT Freeze Protection (ENHT): ENHT offers protection to -20°F (-28°C). This level of protection utilizes the normal
heater supply voltage. No additional dedicated circuit to the unit is required during field installation. Freeze protection
(ENHT option) includes an internally insulated NEMA 4/4X enclosure and thermostatically controlled forced air heater to
maintain internal temperatures above freezing. The ENHT option also includes a connection point for DCS monitoring.
In the event of a power interruption or ENHT system failure when internal enclosure temperatures reach 40°F (4.4°C)
or lower, the unit will notify a facilities control/monitoring system that the unit is unable to maintain freeze protection.
Regardless of state of power to the unit, this warning notifies maintenance personnel and provides an opportunity to
correct the condition before any damage occurs to the unit.
NOTICE! With this option, three phase power must be continuously applied to the heater for the internal
freeze protection heater to operate properly and provide protection. If three phase power cannot
be continuously applied, the heat exchanger must be completely drained of water and electrically
locked out or damage from freezing may occur. Use Start Up procedure to restart this equipment.
This option does not require a separate electrical circuit.
ENHT is rated to -20° (-28°C) and EXP2 is rated to -4°F (-20°C). When both ENHT and EXP2 are selected,
the unit is rated to -4°F (-20°C).
NOTICE! Failure to install these options properly, to maintain power at all times or to connect the contacts
provided on ENHT heaters correctly to the BMS may result in damage to the heater and void
the warranty. Please utilize the temperature sensor contacts (N.O.) that can provide a signal to
a remote device when temperature inside the cabinet drops below 40°F (4°C) and be aware of
freezing conditions in your area (Reference Schematic). The contacts will open and notify you that
the operations of the system should be verified.
EXP2 (Explosion Proof Purge System): Keltech's EXP2 option makes heaters compliant for classified areas;
Class I Division 2, Groups A, B, C, D, Temp Code: T5. The Purge System requires a supply of clean instrument air or
inert gas (provided by installer). This supply maintains a positive internal pressure and prevents the enclosure from
filling with flammable gases, dusts or vapors from the ambient environment. The externally mounted purge system is
rated to -4°F (-20°C). Complete installation provided in this manual.
FDS Fused Disconnect: Internal fused disconnect interlocks with enclosure door when energized, prohibiting access
to a live cabinet. Select the FDS option for an additional level of safety and convenience at the heater location.
N4X (NEMA 4X Enclosure): Corrosion resistant enclosure made of stainless steel and idea for harsh environments.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
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CLE Series Tankless Heater Installation
Maintenance
Preventative maintenance is important for optimal performance of the heater. To ensure the heater works properly,
always keep the inside of the enclosure dry. Moisture inside an enclosure increases the humidity, which condenses
on cooler surfaces. This can cause electrical problems and reduce the efficiency of enclosure insulation. To prevent
problems perform the following:
• Verify the interior of the enclosure is dry.
• Verify there are no leaks in seals of enclosure and that in high humidity environments all enclosure egresses are
properly sealed.
• Monitor eyewash heater performance at each routine safety eyewash inspection.
• Ensure plugs are in place on back side of enclosure.
• Check seals monthly during temperatures above 32°F (0°C) and weekly during temperatures below 32°F(0°C).
Check internal freeze protection system(ENHT) prior to first seasonal freeze for proper performance. The external
heater and internal thermostat are factory set at 55°F(13°C). Check weekly during temperatures below 32°F (0°C).
See Information in Product Options section for additional information on freeze protection.
• Bimetal manual reset safeties mounted to the heat exchangers may trip at temperatures below 32°F on heaters
equipped with ENHT. The bimetal manual resets are set to trip at 100°F(38°C). Heat trace installed on piping can
heat water to temperatures above 100°F(38°C), causing the manual reset safeties to trip. Reset bimetal manual
safeties and lower heat trace temperature to below 100°F.
• All heaters require filtration of 150 microns or smaller to ensure proper operation. Y-strainers or additional filtration
should be verified and cleaned at least every 6 months or more often in areas where hard water sediment is
present in the water.
To clean the Y-Strainer:
1. Turn the power off at the circuit breaker panel.
2. Shut off the installer supplied cold water isolation valve to the heater.
3. Relieve pressure in the plumbing lines.
4. Position a bucket under the cold water inlet to catch any water that may still be in the pipe.
5. Loosen the plumbing connection on the Y-strainer to get to the screen.
6. Remove screen and clean out debris. Use a wire brush to clean smaller particles from the screen.
7. Once the screen is clean, put it back into the Y-strainer housing and secure the plumbing connection.
8. Before switching the power back on, bleed the air out of the lines by turning heater water supply back on and
the plumbing fixture or process farthest from the heater.
9. With the air purged, turn on all circuit breakers supplying the water heater.
• At the same time the Y-strainer or additional filtration is cleaned, it is a good practice to also check all valves
connected to the system. With no water flow through the heater, work both the inlet ball valves and the outlet gate
valves open and shut to break up any calcium deposits that may have formed from the valve being open for an
extended period of time. Power to the heater does not need to be turned off to do this.
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Installation CLE Series Tankless Heater
Troubleshooting for Controller
Problem Solution
No Power Verify power is on.
Check the incoming service connection. Voltage must
match name plate rated voltage. Labels are located on
upper left of back plate (serial number label).
Turn power off. Check continuity of all internal fuses in
control transformer, heating elements or optional fused
disconnect circuits.
Check all field service circuit breakers or fuses.
Check the safety interlock door switch to make sure
that lack of power is not due to misadjustment or open
enclosure door.
Check system temperature limit control to make sure
it has not activated due to excessive heat exchanger
temperature or faulty sensor.
Turn power off. Check for loose or disconnected wires.
Basic Troubleshooting
Problem Solution
The heater does not work or works intermittently. 1. Heater is wired with the proper breaker and wire size.
Refer to Electrical Specifications Table in Step 3 for
proper requirements.
2. Unit is receiving voltage from all 3 phases of the
power source. A load voltage reading is also helpful.
3. Verify the functionality of the flow switch.
4. At the wires from the flow switch, read Open without
flow and Closed with flow.
5. Water flow through the heater is adequate to activate
the flow switch at 0.75 gpm (standard).
IMPORTANT: Turn power OFF before recording any Ohm readings.
If the above steps do not solve the problem, some additional checks may be performed. Follow the
schematic to perform the following continuity checks:
High temperature bimetals (Manual Reset Safeties).
Optional ground fault breaker must be in the closed position for the unit to work.
All internal breakers must be in the ON position for the unit to work.
For additional information on Troubleshooting or other information, please call Keltech Inc. technical support at
1-800-999-4320. Please have Model No. and Serial No. available when seeking technical assistance. Serial No.
tag is located in the enclosure on the upper left hand corner of the back plate. Please record and maintain this
information at all times:
CLE Model No.
Serial No.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
13
CLE Series Tankless Heater Installation
Special Installation and Operating Instructions
Tankless Water Heaters With Optional Class I Division 2 Purge EXP2 Option
General Information
All Keltech Tankless Water Heaters with a model number suffix of – EXP2 have been fitted with a Z purge system to
pressurize the enclosure suitable for use in Class I Division 2 Hazardous Locations.
A Continuous Flow (Model CF) Mini-Z Pressurizing System has been fitted to the bottom of the enclosure.
Suggested region for power
1
Purge System
R
1
2
3
4
5
supplied by others
2
4
5
1
5" (127mm)
Relief Valve
Conduit Hub
Class 1 Div. 2
18" (458mm)
Max
entrance. Entrance hole and
components to be provided by
installer.
2
Purge Control Panel
Class 1 Division 2
3
All installation egress from
panel must be sealed (electrical
conduit) for proper explosion proof
installation.
Spark arrestor with calibration orifice
4
is located behind the purge control
unit and through the bottom of the
enclosure.
Purge gas/compressed air inlet
5
fitting here.
Explosion proof
sealing fitting
supplied by others
EXP2 Installation Notes
1. Any tubing, conduit or fittings connected to the Pressurized Enclosure (PE) must conform to local codes for
flammability ratings.
2. All egress into PE must be plugged and properly sealed to minimize leakage of purge air. Use hazardous
location sealing fittings suitable for Class I locations within 18" of enclosure.
3. The EXP2 purge system option is a continuous flow purge system and is calibrated to flow at 0.9 SCFM. To minimize
waste, plug and seal all openings and conduit. The externally mounted purge system is rated to -4°F (-20°C).
4. The system is designed for use primarily with compressed air. The source of the compressed air must be
from a non-classified area (see Purge Gas Supply Notes). Purge air must be clean, dry and free of flammable
gases. When inert compressed gases are used (Nitrogen, for example) the installer and facility manager must
take suitable precautions on-site so that buildup of the inert gas does not present a health hazard. Where risk
of asphyxiation exists, a warning label must be fitted to the Pressurized Enclosure (PE).
5. Adjustment of Purge System is not necessary. System is fully calibrated.
6. Connect to Purge System where indicated. Connection port is 1/4" NPT female. Supply pressure must be
regulated to 60–115 PSI.
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
Installation CLE Series Tankless Heater
Purge Gas Supply Notes
An alarm shall be provided to indicate failure of the protective gas supply to maintain the required pressure. Piping for
the protective gas shall be protected against mechanical damage.
Where the compressor intake line passes through a classified location, it shall be constructed of noncombustible
material, designed to prevent leakage of flammable gases, vapors, or dusts into the protective gas, and protected
against mechanical damage and corrosion.
The electrical power for the protective gas supply (blower, compressor, etc.) shall be supplied either from a separate
power source or from the protected enclosure power supply prior to any service disconnects of the protected
enclosure. Any protected enclosure that can be isolated from the protective gas supply shall be equipped with an
alarm. Where an alarm is used to indicate the loss of pressure in the cabinet:
• The alarm shall be located at a constantly attended location.
• The alarm actuator shall take its signal from the protected enclosure and shall not be installed between the
enclosure and the protective gas supply.
• The alarm actuator shall be mechanical, pneumatic, or electrical.
• Electrical alarms and electrical alarm actuators shall be approved for the location in which they are installed.
• No valves shall be permitted between the alarm actuator and the enclosure.
Intrinsically Safe (IS) Installation
Hazardous Location
Class I , Division 2
Groups A, B, C, D
T5 Hazardous (classified) Areas
Simple apparatus
device
MiniPurge: Option Code /IS
Vmax = 30v
Imax = 350mA
Ci = 0 Li = 0
1. Electrical equipment connected to associated apparatus should not use or generate more than 250 volts.
2. Installation shall be in accordance with the manufacturer's instructions and the National Electrical Code (NFPA 70).
3. For guidance on Installation see ANSI/ISA RP12.6 (Installation of IS Instrument System in Class I
Hazardous Locations).
4. Voc or Vt of associated apparatus is less than Vmax
Isc or IT of associated apparatus is less than Imax
Ci plus capacitance of interconnecting cabling is less than Ca of the associated apparatus
Li plus inductance of interconnecting cabling is less than La fo the associated apparatus
5. "Simple Apparatus" is a device that will not generate or store more than 1.2V, 0,1A, 25mW or 20uJ
Non- Hazardous Location
(or suitably protected enclosure)
Intrinsically Safe
Interface Unit
Power Supply
Outputs to relays or
power contactors
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
15
CLE Series Tankless Heater Installation
IS Installation continued…
All quarter turn latches in the door of the PE must be fully latched for proper operation. Power to the PE must be
turned off before opening the enclosure.
WARNING This Pressurized Enclosure shall not be opened unless the area is known to be free of
flammable materials or unless all devices within have been de-energized.
Power shall not be restored after the enclosure has been opened until the enclosure has been purged for allotted
time (see table below). Time begins when pressure indicator turns green after the door of the enclosure has been
closed and fully latched.
WARNING Ignition of potentially explosive gas/air mixtures may result if power is turned on before the
allotted purge time!
Expo Technologies CF systems have a Minimum Pressure Sensor set to a pressure of at lease 0.1" WC (0.25bars). When
the PE pressure is above this set point the sensor produces a positive Pressurized signal. This is displayed on the Red/
Green indicator located on the Purge System. This signal can be used to operate an electrical contact for a remote Alarm.
This signal may be supplied to the pressure operated switch suitable for Intrinsically Safe circuit in accordance. When the
enclosure pressure falls below the set point of the sensor, the Pressurized signal is removed, and the Alarm conditions
occurs. This Alarm must be located where it can be readily observed according to NFPA496 requirements. No valves may
be fitted between the Expo Technologies system and the alarm switch.
WARNING Never turn on the power without purging first, unless you have proved the interior of the PE is gas
free and checked that the “Pressurized” indicator is green!
Commissioning Test
Commissioning Continuous Flow Keltech Options EXP2 System:
1. Open the air or gas supply shutoff valve.
2. Adjust the Flow Control Valve (FCV) so that the enclosure pressure rises to the point where the "Pressurized"
indicator turns green.
3. Lower the PE pressure until the Pressurized indicator turns Red.
4. Open the FCV again and set the PE pressure to a level somewhere between the Minimum Pressure Sensor
set point and the RLV opening pressures. This working pressure is not critical. Enough pressure to keep
the“Pressurized” indicator Green is sufficient.
5. On EXP2 Purge System the timing function if performed by the user. The user must ensure that the time delay
between the indicator turning Yellow and the application of power to the PE is not less than the minimum time
required to purge the PE as shown in the table below.
Normal Operation: Turn the air supply valve ON to start or OFF to stop the system. The user must close the Power
Switch only after the enclosure has been pressurized and purged sufficiently to ensure that the interior of the enclosure
is gas free. It is the operator’s responsibility to shut off the power as soon as possible after a pressure failure.
PURGE TIME CHART - EXP2 Option
for use with EXPO Mini Z Purge 1ZCF/bp/IS
Model/Enclosure
Group Size
CLE18 2.78 11.12 0.9 #2 13
CLE25 3.33 13.32 0.9 #2 15
Cubic
Feet
Volume
Exchanges
X 4
Orifice
Size
Orifice
No.
Purge
Time
(Minutes)
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10/2/2015 Keltech • 215-1822 Rev. A; ECN 140011
Installation CLE Series Tankless Heater
Special Installation Maintenance
Routine Maintenance of the System (Every 6 months)
Recommended maintenance of the systems is as follows:
Repeat Commissioning test at least every six months. The test includes checking the opening pressure of the Relief
Valve, setting of the Minimum Pressure Sensor, the “Normal Working Pressure” of the enclosure. Test that the interlock
and alarms function correctly.
Check the Relief Valve and any other Spark Arrestors. Remove any debris or corrosion, or replace the Spark Arrestor.
Check the condition of the air supply filter element. Clean or replace it as necessary.
Periodic Maintenance (Every 18-24 months)
At least every two years, the following additional checks are recommended:
Apparatus (Heater, Purge Systems, Alarms etc.) is suitable for the Hazardous Location.
There are not unauthorized modifications.
The source of air is uncontaminated.
The interlock and alarms function correctly.
Approval labels are legible and undamaged.
Adequate spare parts are carried.
The action of pressure failure is correct.
Keltech • 215-1822 Rev. A; ECN 140011 10/2/2015
17
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