OPERATING AND MAINTENANCE MANUAL FOR
INSTANTANEOUS ELECTRIC
CIRCULATION HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ CR ”
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
SECTION TITLE
PAGE #
I
II
GENERAL DESCRIPTION AND CONSTRUCTION
INSTALLATION
5
12
14
15
17
22
III
IV
V
SCHEDULED MAINTENANCE AND OPERATION
TROUBLESHOOTING
SERVICING & REPLACEMENT OF PARTS
MISCELLANEOUS CHARTS AND FORMULAS
VI
3
Download from Www.Somanuals.com. All Manuals Search And Download.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This book describes a packaged electric heater that is a stationary, self-contained unit. The complete
assembly consists of the pressure vessel, immersion electric heating element, thermostat, safety relief
valve, safety high temperature cut out, magnetic contactor(s), power circuit fusing, fused low voltage
control circuit transformer, 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
PRESSURE VESSEL
Standard Vessel Construction:
The standard pressure vessel is constructed of all welded carbon steel, then hot dip galvanized for
added corrosion resistance. Units over 58 kW are designed and built in accordance with ASME Section
IV and stamped, certified, and registered with the National Board of Boiler and Pressure Vessel
Inspectors. The maximum allowable working pressure is stamped on the nameplate. The standard
working pressure is 150 psi (225 psi TP).
Optional Non-Ferrous Vessel Materials:
1. Copper-Silicon – A copper-silicon alloy offers tremendous longevity due to its ability to
withstand the cycling effects induced from changes in water temperature and pressure. This
material is suitable for storage of hot potable water in a variety of commercial and industrial
applications.
2. 90/10 Copper-Nickel – A 90% copper and 10% nickel alloy similar to copper-silicon, but with
added strength and corrosion resistance. Typically used in applications with corrosive
environments (salt water) or critical applications.
3. Stainless Steel – Stainless steel (type 304, 316, or 316L) is well suited for high purity
applications requiring a corrosion resistant tank with minimal leaching of impurities into the
water. Well suited for process, RO, and DI water systems in the pharmaceutical, food, and
electronic industries.
4. Other materials are available upon request.
Optional Working Pressures:
The pressure vessel may be supplied with optional working pressures (standard working pressure is 150
psi). See drawing for details.
VESSEL CONNECTIONS
The heater is supplied with separate cold water and hot water connections. A 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.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
OUTER SHELL, INSULATION, AND SUPPORTS
The pressure vessel 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. The horizontal
configuration is supported on heavy-duty steel I-beam supports. Also available in a vertical
configuration or wall hung for off the floor installation.
HEATING ELEMENT
The heater is supplied with a flanged electric immersion heating element assembly, composed of
copper, incoloy, or stainless steel sheathed elements that are brazed or welded into a ANSI steel flange.
The heating element is fastened to a corresponding tank flange using a gasket and hex head steel bolts
and nuts. Specialized heating element construction may be included. These options include: special
watt density ratings, passivation, electropolishing, or special materials. See drawing for voltage, power
ratings, and special options.
ELECTRICAL ENCLOSURE
A louvered control panel available in various sizes and with assorted types of handles is supplied. The
standard cabinet is rated NEMA 1, but other NEMA rated enclosures are available, consult drawing for
further information. A list of NEMA ratings are available in Section VI. An optional explosion-proof
enclosure is available for hazardous locations.
FLOW SWITCH
The heater is supplied with a factory installed and wired
safety flow switch. This device will allow the immersion
heating element to energize only when there is sufficient flow
through the unit.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
CONTROL THERMOSTAT
The control panel is supplied standard with a single-stage immersion thermostatic switch. As an
optional any of the following may be supplied; a four-stage immersion thermostatic switch, a solid-state
staging controller with thermistor, or a digital 1/16 DIN temperature controller with thermocouple. See
drawing for specific details. The single-stage immersion thermostat can be adjusted through a range of
100° - 190° F. A low range, (30° - 110° F), operating thermostat is also available in the single-stage
version. The four-stage immersion thermostat can be adjusted through a range of 100° - 250° F and is
capable of switching four circuits. The solid-state staging controller automatically brings on-line the
required number of heating steps in order to meet the hot water demand and will also operate each
circuit in a circular mode to allow for equal usage of all heating circuits. The thermostat is adjustable to
the desired temperature by turning the dial on the pot switch. A 1/16 DIN electronic temperature
control package may be installed. A separate manufacturer’s operating manual will be supplied with all
units except the single-stage immersion thermostat.
Single-Stage Immersion Thermostat
Four-Stage Immersion Thermostat
1/16 DIN Digital Display
Solid State Staging Controller
7
Download from Www.Somanuals.com. All Manuals Search And Download.
TEMPERATURE HIGH LIMIT SWITCH
As a safety device, an immersion high temperature cut-off switch with manual reset, adjustable through
a range of 100° - 240° F, is provided. The high limit must be manually reset thereafter to restart the
heater. Optionally a 1/16 DIN digital controller may be used as a high-limit.
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.
FUSED LOW VOLTAGE TRANSFORMER
A fused low voltage transformer may be supplied. This option
is used to step down higher voltages to 120-volt for safety
when working with control circuits.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
INDIVIDUALLY FUSED ELEMENTS
To prevent the possibility of damage to control circuits and other elements in case of electrical
overloads, fuses may be supplied for each element. Two types of fuses may be used; a type NON for
voltages less than 250-volt or type JJS for voltage less than 600-volt.
Type JJS
Type NON
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.
Conductive Type Low Water Cut-Off Relay
OPTIONS
The following optional features may be included in your water heater. Reference included drawing
specific to your heater for further details.
Stainless Steel Jacket
An optional stainless steel outer jacket may replace the standard galvaneel covering. This optional
jacket may be painted.
9
Download from Www.Somanuals.com. All Manuals Search And Download.
On / Off Control Switch
A built-in non-fused On/Off disconnect switch may be supplied with the control panel to decrease the
risk of injury when working with the control panel.
Built-In Circuit Breaker
A built-in circuit breaker may be provided with or without shunt
trip protection for protection from circuit overload.
Audible Alarm
An audible alarm may be installed on the outside of the control panel to give warning of an over-
temperature condition.
Building Management System (BMS)
A Building Management System control package may be supplied for remote operation and alarm
capabilities.
Status Indicating Lamp(s)
Optional status indicating lamps may be installed to show when the unit is on, when the heating
element is energized, or if there is an alarm condition.
10
Download from Www.Somanuals.com. All Manuals Search And Download.
Silicon Control Rectifier
An SCR “zero fired” power controller for 0-100% proportional control of heaters may be supplied.
Dial Temperature and Pressure Gauge
A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge with 2½-inch dial may be
supplied for in-line installation (shipped loose) or factory installed in the tank.
Special Customized Features
Please reference drawing for details.
11
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
HEATER PLACEMENT
1. Place the heater on a solid foundation in a clean, dry location nearest to the point of most
frequent hot water use.
2. The heater should be protected from freezing and waterlines insulated to reduce energy and
water waste.
3. Leave sufficient clearance for element withdrawal, if necessary.
4. Do not install in an area where flammable liquids or combustible vapors are present.
PIPING INSTALLATION
NOTE: The most effective means for preventing deterioration from accelerated corrosion due to
galvanic and stray current is the installation of dielectric fittings/unions. The installation of these
fittings is the responsibility of the installing contractor.
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 in-line vacuum breaker and in-line pressure and temperature gauge, if supplied.
3. Install the combination temperature and pressure safety relief valve in the tapping provided.
Note that this is required by law for safety considerations.
12
Download from Www.Somanuals.com. All Manuals Search And Download.
Outlet to floor drain
Install into provided tapping
Manual Release
Lever
Temperature Probe
Temperature and Pressure Relief Valve
4. Install a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of any type
should be installed between the relief valve and tank or in the drain line.
FILLING THE HEATER
1. Completely close the drain valve and open the highest hot water valve to allow all air to
escape from piping.
2. 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 from the open faucet.
ELECTRICAL INSTALLATION
1. Enter electric enclosure with properly sized feeder leads (use 60° C copper wire for water
heaters rated less than 100 amps; otherwise use 75°C copper wire). Single-phase installations
require two (2) leads; three phase installations require three (3) leads.
2. Install these power leads into the box lugs on the terminal block or magnetic contactor.
3. Torque screws per torque chart included in Section VI.
4. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed.
3. After the water is heated for the first time, monitor the water temperature as described in
Section III, Quarterly Inspection.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION III - SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before performing any maintenance procedure, make certain power supply is OFF and cannot
accidentally be turned on.
MAINTENANCE AND OPERATION
The heater is automatic in its operation. It will maintain water at the temperature setting of the
thermostat. The heater should not be turned on without first making sure that the vessel is full of
water and that all air has been released.
FREEZING
The vessel should be fully drained in the event the electricity has been turned off and if there is
danger of freezing.
QUARTERLY INSPECTION
1. Monitor thermostat
a. Let water heater completely heat to a designated thermostat setting.
b. After thermostat satisfies (that is, when the thermostat actually clicks off), draw water from
heater.
c. Compare water temperature of drawn water to the temperature setting of the thermostat 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 thermostat.
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 flange for leakage as follows:
a. Shut off Power Supply.
b. Remove element housing cover.
c. Visually inspect heating element gasket for evidence of leaks.
d. Rub finger around gasket that is between the heating element and tank flange for any
evidence of moisture. If moisture is present or a water drip is observed, follow procedure
outlined in Section V.
4. Check for loose electrical connections. Tighten as necessary.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION IV – TROUBLESHOOTING
Symptom
No hot water
Probable Cause
Circuit breaker tripped at
source.
On/Off switch in ‘OFF’
position, if installed.
Circuit breaker at control
cabinet tripped, if installed.
Blown fuse in element fuse
block, if installed.
Corrective Action / Remedy
Reset circuit breaker.
Turn switch to ‘ON’ position.
Reset circuit breaker.
Replace fuse.
Blown fuse in transformer, if
installed.
Replace fuse.
High limit switch tripped.
Reset high limit switch.
Loose wires.
Tighten wires. Torque screws per
torque chart included in Section
VI.
Heating element inoperable.
Check heating element operation
by clamping an Amprobe around
each wire to the element. The
ampere reading should agree with
the nameplate ‘AMP’ figure.
Have source electrical system
checked by an electrician.
Move thermostat dial through full
range. A definite ‘click’ should be
heard. If not, replace thermostat.
Check to see if tank is full of
water. If not, fill tank. If problem
continues and tank is full, check
for continuity between the
Low line voltage.
Faulty thermostat.
Faulty low water cut-off, if
installed.
common and normally open
contact of the relay board. If
continuity is not observed, replace
low water cut-off.
Magnetic contactor does not
energize.
Replace complete magnetic
contactor. Because of the design
of this particular contactor, it is
more desirable to replace complete
control rather than rebuilding coil,
contacts and springs, etc.
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Water temperature below
settings at all times
Faulty thermostat.
Check thermostat adjustment.
Monitor thermostat as described in
Section III, Quarterly Inspection.
Replace if necessary.
Blown fuse in element fuse
block, if installed.
Replace fuse.
Heating element not working
on all phases
Check to see that heating element
is working on all phases, by
checking the resistance (ohms)
value for each element and
comparing with the chart included
in Section VI.
Heater improperly sized
Verify heater is properly sized for
the flow rate and temperature rise
of your system. See formulas
included in Section VI. Replace
elements with proper size as
necessary.
Relief valve discharges
continuously
Excessive temperature or
pressure in tank
Temperature and pressure relief
valves are made to operate if the
water temperature exceeds 210°F
or water pressure exceeds the
pressure rating of the safety relief
valve. If trouble is excessive
temperature, then thermostat is not
shutting off at the right setting and
thermostat must be replaced.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION V - SERVICING & REPLACEMENT OF PARTS
WARNING / CAUTION
Before servicing or replacing any part make sure to turn the power supply switch to the OFF position.
MAGNETIC CONTACTOR
1. Disconnect power from unit.
2. Disconnect line and load wires to contactor.
3. Disconnect two (2) 14 gauge control circuit wires.
Control Wires
Line Wires
Load Wires
4. Loosen two (2) holding screws and remove contactor.
Mounting Screws
(Bottom screw not shown)
5. Replace with new contactor using reverse
procedure.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
IMMERSION TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover.
3. Remove high limit cover screw and cover.
Cover
Cover Screw
Reset Switch
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tube
5. Remove capillary tube and bulb from thermowell
6. Remove two (2) mounting screws.
Mounting Screws
7. Remove control and install new high limit switch by performing
above steps in reverse order. (Note: Be sure to place capillary tube into
slot in base prior to installing cover.)
18
Download from Www.Somanuals.com. All Manuals Search And Download.
IMMERSION THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Remove high limit cover screw and cover.
Cover
Cover Screw
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tube
5. Remove capillary tube and bulb from thermowell.
6. Remove two (2) mounting screws.
Mounting Screws
7. Replace thermostat using reverse procedure. (Note: Be sure to
place capillary tube into slot in base prior to installing cover.)
19
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Remove element housing cover
7. Disconnect the wires from the heating element terminals.
8. Disconnect conduit from coupling.
Conduit Coupling
Element Housing Cover
9. Remove nuts and bolts from flanges.
10. Withdraw element assembly and remove gasket.
Vessel Flange
Gasket
Flanged Element Assembly
11. Install new gasket and insert new
heating element.
12. Rewire element according to the voltage
and phase rating of the unit as shown
below.
13. Fill tank and check around gasket for any leaks.
20
Download from Www.Somanuals.com. All Manuals Search And Download.
RELIEF VALVE
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Lift test lever on relief valve to relieve pressure in tank.
4. Disconnect overflow piping.
5. Unscrew relief valve, remove assembly and replace with new one.
6. Connect overflow piping.
7. Turn on incoming water supply and check for leaks.
8. Turn safety switch to ON position.
Test Lever
Overflow Piping Outlet
Tank Connection
Temperature Probe
21
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS
NEMA ENCLOSURES
22
Download from Www.Somanuals.com. All Manuals Search And Download.
ELECTRICAL DATA
23
Download from Www.Somanuals.com. All Manuals Search And Download.
FORMULAS
24
Download from Www.Somanuals.com. All Manuals Search And Download.
TORQUE VALUES
SILICON ALUMINUM
18-8 S/S
IN.-LBS. IN.-LBS.
BRASS
316 S/S MONEL
IN.-LBS. IN.-LBS.
BOLT SIZE
BRONZE
IN.-LBS.
4.8
2024-T4
IN.-LBS.
2.9
4-40
4-48
5.2
6.6
4.3
5.4
5.5
6.9
5.3
6.7
6.1
3.6
5-40
7.7
6.3
7.1
4.2
8.1
7.8
5-44
9.4
7.7
8.7
5.1
9.8
9.6
6-32
6-40
8-32
8-36
9.6
7.9
9.9
8.9
5.3
6.6
10.1
12.7
20.7
23.0
23.8
33.1
78.8
99.0
138
147
247
271
393
9.8
12.1
19.8
22.0
22.8
31.7
75.2
94.0
132
142
236
259
376
11.2
18.4
20.4
21.2
29.3
68.8
87.0
123
131
219
240
349
12.3
20.2
22.4
25.9
34.9
85.3
106.0
149
160
266
294
427
16.2
18.0
18.6
25.9
61.5
77.0
107
116
192
212
317
327
422
443
558
615
907
1016
1249
1220
1905
1895
2815
2545
10.8
12.0
13.8
19.2
45.6
57.0
80
86
143
157
228
242
313
328
413
456
715
798
980
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
400
517
541
682
371
480
502
632
418
542
565
713
451
584
613
774
752
697
787
855
1110
1244
1530
1490
2328
2318
3440
3110
1030
1154
1416
1382
2140
2130
3185
2885
1160
1301
1582
1558
2430
2420
3595
3250
1330
1482
1832
1790
2775
2755
4130
3730
958
1495
1490
2205
1995
7/8-14
1-8
1-14
25
Download from Www.Somanuals.com. All Manuals Search And Download.
|