Hubbell Electric Heater Company Water Heater EMV User Manual

OPERATING AND MAINTENANCE MANUAL  
FOR PACKAGED ELECTRIC TEPID  
WATER HEATING SYSTEM  
ELECTRIC HEATER COMPANY  
BASE MODEL “ EMV ”  
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TABLE OF CONTENTS  
SECTION TITLE  
PAGE #  
I
II  
GENERAL DESCRIPTION AND CONSTRUCTION  
INSTALLATION  
5
7
III  
IV  
V
SCHEDULED MAINTENANCE AND OPERATION  
TROUBLESHOOTING  
9
12  
13  
22  
SERVICING & REPLACEMENT OF PARTS  
ELEMENT CHARTS  
VI  
3
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4
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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION  
GENERAL DESCRIPTION  
This manual describes a packaged electric water heater system designed to meet the requirements of ANSI  
Z358.1-1998 for tepid water delivery to an emergency drench system. The complete assembly consists of the  
storage tank, immersion electric heating element(s), thermostat(s), safety relief valve, safety high temperature  
cut out, mixing valve, 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 standard storage tank is constructed of steel and internally lined with specially formulated Hydrastone  
cement to a ½-inch minimum thickness. The tank is designed for a maximum allowable working pressure of 150  
psi (300 psi TP).  
TANK CONNECTIONS  
The heater is supplied with separate cold water and tepid water connections. A 1-½ inch FNPT connection is  
supplied for the cold water inlet. The cold water is deflected by means of a baffle within the tank. A 1-¼ inch  
FNPT union connection is supplied at the mixing valve for tepid water. A ¾ inch FNPT connection is located on  
the side of the heater 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. A ¾ inch GHT connection is supplied for  
draining. See drawing for locations.  
HEATING ELEMENT  
The water heater is supplied with an  
electric immersion heating element  
assembly(s), composed of a copper  
sheathed element(s) 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.  
CONTROL THERMOSTAT  
The water heater is supplied with an immersion thermostat factory  
preset at 170°. The immersion thermostat can be adjusted through a  
range of 100° - 180° F and is adjustable with a flat tip screwdriver.  
5
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TEMPERATURE HIGH LIMIT SWITCH  
As a safety device, a surface mounted high temperature cut-off switch with manual reset is supplied. As an  
option, an immersion high temperature cut-off switch with manual reset may be provided. Either high  
temperature cut-out switch is factory preset at 190°F. In the event of an over-temperature condition, the  
thermostat will disengage the power from the system. The high limit must be manually reset thereafter to restart  
the heater.  
Manual Reset  
Surface Mounted High  
Temperature Cut-Off Switch  
(Standard)  
Immersion High Temperature Cut-Off Switch  
(Optional)  
MIXING VALVE  
The mixing valve is a triple redundant, thermostatic pressure balanced  
valve specifically designed for emergency safety shower/face/eyewash  
application. The valve is factory mounted and piped to the water heater.  
The mixing valve meets OSHA and ANSI requirements and is capable of  
providing 85°F output regardless of inlet pressure and temperature  
variations, and the temperature setting is tamper proof and can not be  
inadvertently adjusted in the field. Alternate mixing valve tepid water set  
temperatures of 70°, 75°, 80°, and 90°F are available.  
AUTOMATIC AIR VENT VALVE  
An automatic air vent valve is supplied in the highest point of the  
system to allow trapped air in the system to escape.  
DUAL TEMPERRATURE AND PRESSURE GAUGE  
A combination temperature (70° - 250° F) and pressure (0 – 200 psi) gauge  
with 3-inch dial is installed in the tank.  
OUTER SHELL AND INSULATION  
The tank is encapsulated in 3-inch thick polyurethane foam insulation. The insulation is protected by a high  
impact non-corroding colorized composite protective jacket.  
6
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OPTIONS  
The following optional features may be included in your water heater. Reference included drawing specific to  
your heater for further details.  
Low Temperature Alarm Dry Contacts  
A low temperature thermostat is available with dry contacts to remotely alarm when the tank water temperature  
falls below a specified setpoint. The low temperature thermostat is adjustable from 30-110°F.  
High Temperature Alarm Dry Contacts  
High temperature alarm dry contacts are available with the optional immersion high limit cut-out switch to  
remotely alarm when the tank water temperature rises above the high limit setpoint.  
Outdoor Weather Package  
The optional outdoor weather package includes a 304 stainless steel outer protective jacket, a weather resistant  
electrical housing, and 6” high tank legs to raise the entire unit off the floor.  
Flow Alarm  
An optional flow alarm may be included to signal that there is tepid water flow.  
Explosion Proof Construction  
The system may be constructed for installation in a hazardous location.  
Mixing Valve Enclosure  
An optional fiberglass enclosure provides added protection for the mixing valve in outdoor environments.  
Multiple Units  
Multiple units may be piped together to meet the needs of larger demand systems.  
Alternate Heat Sources  
An optional heat exchanger may be factory installed to utilize steam or boiler water as the heating source.  
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 PROPERTY.  
WATER HEATER PLACEMENT  
1. Place the heater on a solid foundation in a clean, dry location nearest to the point of most frequent  
tepid water use  
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.  
4. Do not install in an area where flammable liquids or combustible vapors are present, except when  
installed with the explosion proof option.  
7
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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 tepid water outlet to the appropriate connections as shown below;  
refer to the drawing for location and sizes.  
2. Install the combination temperature and pressure safety relief valve in the tapping provided. Note that  
this is required by law for safety considerations.  
Install into provided tapping  
Temperature Probe  
Manual Release Lever  
Outlet to floor drain  
Temperature and Pressure Relief Valve  
3. 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.  
4. On startup, thermal expansion will cause the water to expand. Hubbell recommends that a thermal  
expansion tank or supplementary pressure relief device be installed in the hot water outlet to allow  
for this expansion.  
8
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FILLING THE HEATER  
1. Completely close the drain valve.  
2. Open the highest tepid water outlet to allow all air to escape from piping.  
3. The black plastic knob on the air vent valve must be opened two turns to allow air to escape from the  
system.  
4. 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 outlet.  
ELECTRICAL INSTALLATION  
1. Enter junction box with properly sized feeder leads.  
2. Connect these power leads to wires enclosed in junction box with wire nuts.  
3. 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.  
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 water heater is automatic in its operation. It will maintain a full tank of water at the temperature setting  
of the thermostat. 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.  
MONTHLY INSPECTION – MIXING VALVE  
NOTE: The mixing valve should be tested in conjunction with regular OSHA required shower/eyewash  
testing. These tests confirm that the equipment is safe and operational and also serve to purge potential  
bacteria laden water from the system.  
1. Monitor temperature  
a. Record all information on the Mixing Valve Inspection and Test Log, see page 11.  
b. Using an accurate thermometer, turn on the shower/eyewash and record the maximum start-up spike  
temperature of the water.  
c. After a few minutes of running, record the normal temperature.  
d. If the temperature does not match required temperature (±3°F), recalibrate the mixing valve. See  
Section V, Service and Replacement of Parts, Re-Calibrate Mixing Valve.  
2. Monitor flow rate  
a. OHSA/ANSI recommends a potable water system maintain a pressure of 30-psig minimum with a flow  
rate of 20-GPM minimum to a shower head and 3-GPM minimum to an eye/face wash fixture.  
b. One simple method of testing is to collect the water in a 5-gallon container. At the required flow rate,  
the shower head will fill the container in approximately 15 seconds and the eye/face wash will fill the  
container in approximately 15 seconds.  
9
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QUARTERLY INSPECTION  
3. 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 the relief  
valve.  
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 + 7°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.  
4. 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.  
5. 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.  
6. Check for loose electrical connections. Tighten as necessary.  
ANNUAL INSPECTION  
1. Flush tank as follows  
a. Shut off power supply.  
b. Close valve on hot water outlet piping.  
c. Open valve on drain piping.  
d. Cold water inlet line pressure will be strong enough to flush sediment from the bottom of the tank out  
through the drain. Let water run for 3-4 minutes.  
e. Close drain valve.  
f. Open hot water valve.  
g. Turn power supply ON.  
10  
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MIXING VALVE INSPECTION AND TEST LOG  
COMPANY:  
HEATER SERIAL NUMBER:  
DATE  
START-UP  
SPIKE  
OUTPUT  
TEMPERATURE  
COMMENTS  
TESTED BY  
11  
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SECTION IV – TROUBLESHOOTING  
Symptom  
No hot water in tank  
Probable Cause  
Circuit breaker tripped at source.  
High limit switch tripped.  
Loose wires.  
Corrective Action / Remedy  
Reset circuit breaker.  
Reset high limit switch.  
Torque screws holding wires.  
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.  
Low line voltage.  
Faulty thermostat.  
Have source electrical system checked by an  
electrician.  
Move thermostat dial through full range. A  
definite ‘click’ should be heard. If not, replace  
thermostat.  
Water temperature in  
tank below settings at  
all times  
Faulty thermostat.  
Check thermostat adjustment. Monitor  
thermostat as described in Section III,  
Quarterly Inspection. Replace if necessary.  
Heating element not working on all Check to see that heating element is working  
phases  
on all phases, by checking the resistance  
(ohms) value for each element and comparing  
with the chart included in Section VI.  
Verify heater is properly sized for the flow rate  
and temperature rise of your system. Replace  
elements with proper size as necessary.  
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.  
Heater improperly sized  
Relief valve discharges Excessive temperature or pressure  
continuously  
in tank  
Tepid water  
temperature too hot  
Blockage in cold water inlet to  
mixing valve  
Disconnect mixing valve and clean out cold  
water inlet pipe.  
Mixing valve out of calibration  
Re-calibrate mixing valve as described in  
Section V, Service and Replacement of Parts,  
Re-Calibrate Mixing Valve.  
Tepid water  
temperature too cold  
Blockage in hot water inlet to  
mixing valve  
Disconnect mixing valve and clean out hot  
water inlet pipe.  
Mixing valve out of calibration  
Re-calibrate mixing valve as described in  
Section V, Service and Replacement of Parts,  
Re-Calibrate Mixing Valve.  
12  
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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.  
SURFACE TEMPERATURE HIGH LIMIT CUT-OFF  
1. Disconnect power from unit.  
2. Remove access cover.  
3. Disconnect the four (4) 14 gauge wires.  
Control Wires  
4. Remove the two (2) mounting screws.  
Mounting Screws  
5. Replace control and install new high limit switch by performing above steps in reverse order.  
See wiring diagram included with drawing for assistance.  
13  
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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.)  
14  
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SINGLE PHASE 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.  
Tank Flange  
Wires  
7. Remove the 3/8-16 nuts.  
8. Withdraw element assembly and remove gasket.  
Gasket  
Element Assembly  
Nuts  
9. Install new gasket and insert new heating element.  
10. Rewire element according to type of unit as shown  
in your drawing.  
11. Fill tank and check around gasket for any leaks.  
15  
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3-PHASE 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. Remove the 3/8-16 nuts.  
Tank Flange  
Element Terminals  
Nuts  
8. Withdraw element assembly and remove gasket.  
Gasket  
Element Assembly  
9. Install new gasket and insert new heating  
element.  
10. Rewire element according to the drawing and in  
accordance with the jumper configuration as  
shown below for your heater.  
11. Fill tank and check around gasket for any leaks.  
16  
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3-PHASE ELEMENT JUMPER CONFIGURATION  
17  
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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.)  
18  
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MAGNETIC CONTACTOR (3-PHASE ONLY)  
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.  
19  
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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  
20  
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MIXING 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. Drain tank.  
5. Disconnect unions on both sides of the mixing valve.  
6. Remove mixing valve.  
7. Replace mixing valve.  
8. Fill system in accordance with procedures on page 9.  
Acorn Nut Cap  
Cold Water Inlet  
Hot Water Inlet  
Union  
Union  
Tepid Water Outlet  
RE-CALIBRATE MIXING VALVE  
1. Remove small domed acorn nut cap on top of the diaphragm actuator.  
2. Without turning the adjustment screw, loosen the locknut securing the adjustment screw.  
3. Turn on the water at the shower or eye/face wash and monitor the water temperature during  
calibration.  
4. Using a 1/8” allen wrench, turn the adjustment screw counter-clockwise to raise the outlet water  
temperature or clockwise to lower the outlet water temperature.  
5. Start by turning the adjustment screw only one full turn, then observe the water temperature and the  
shower or eye/face wash fixture.  
6. If needed, turn the adjustment screw an additional ½ turn at a time until the desired water  
temperature is reached.  
7. Turn off the water at the shower or eye/face wash fixture.  
8. Lock the adjustment screw with the locknut.  
9. Replace the domed acorn nut cap over the adjustment screw.  
10. Re-check the outlet water temperature as described in Section III, Scheduled Maintenance and  
Operation, Monthly Inspection – Mixing Valve.  
21  
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SECTION VI – ELEMENT CHARTS  
SINGLE PHASE ELEMENT CHART  
Power (Watts)  
240V  
----  
Immersion Element Resistance  
Element Part #  
CH-FO-358  
CH-FO-408  
CH-FO-508  
CH-FO-608  
CH-FO-304  
CH-FO-354  
CH-FO-404  
CH-FO-454  
CH-FO-504  
CH-FO-604  
TGB-1203-480  
TGB-1353-480  
TGB-2257L  
TGB-1207-240  
TGB-1303-480  
TGB-1403-480  
TGB-2257-240  
TGB-2257-480  
TGB-2457-277  
TGB-2457-480  
TGB-2503-480  
TGB-2507-277  
TGB-2603-277  
TGB-2603-480  
Length  
11 3/8"  
11 3/8"  
13 1/4"  
13 3/8"  
9 3/4"  
(Ohms)  
12.36  
10.82  
8.65  
120V  
----  
----  
----  
2000  
----  
----  
----  
----  
----  
1500  
----  
----  
2500  
500  
----  
----  
----  
----  
----  
208V  
3500  
4000  
5000  
6000  
----  
2500  
3000  
----  
----  
4500  
----  
500  
----  
1500  
----  
----  
2000  
----  
----  
----  
1000  
----  
----  
277V  
----  
----  
----  
----  
4000  
----  
----  
----  
----  
----  
----  
1000  
----  
2500  
990  
1350  
3500  
----  
4500  
1500  
----  
480V  
----  
----  
----  
----  
----  
----  
----  
----  
----  
----  
2000  
3500  
----  
----  
----  
----  
3000  
3500  
4000  
4500  
5000  
6000  
----  
7.21  
19.20  
16.46  
14.40  
12.80  
11.52  
9.60  
83.23  
47.56  
5.76  
9 3/4"  
11 1/2"  
11 1/2"  
11 1/2"  
13 1/2"  
7 5/8"  
----  
----  
2000  
12 1/2"  
9 5/8"  
----  
13 3/8"  
10 1/2"  
13 5/8"  
10 5/8"  
13 1/4"  
13 1/8"  
13 1/4"  
9 3/4"  
28.80  
55.49  
41.62  
23.04  
66.59  
17.05  
36.99  
33.29  
15.35  
12.79  
27.74  
3000  
4000  
----  
2500  
----  
4500  
5000  
----  
1000  
2500  
----  
----  
----  
----  
----  
----  
1500  
----  
----  
----  
----  
5000  
6000  
2000  
15"  
15 1/2"  
15 1/2"  
----  
6000  
----  
----  
*Red wattage indicates the stamped element rating  
Note: Element part numbers, ratings, and lengths are subject to change without notice.  
3-PHASE ELEMENT CHART  
Resistance (Ohms)  
Immersion  
Length  
Element  
Part #  
Hairpin  
57.6  
43.2  
34.4  
27.9  
21.6  
17.1  
14.4  
12.1  
9.1  
1 Φ  
19.2  
14.4  
11.5  
9.3  
7.2  
5.7  
4.8  
4.0  
3 Φ DELTA  
3 Φ WYE  
38.6  
28.9  
23.0  
18.7  
14.5  
11.5  
9.6  
2-38683N  
3-38683N  
4-38683N  
5-38683N  
6-38683N  
7-38683N  
8-38683N  
9-38683N  
10-38683N  
11-38683N  
13"  
13"  
13"  
13"  
13"  
13"  
13"  
15"  
15"  
15"  
57.6  
43.2  
34.4  
27.9  
21.6  
17.1  
14.4  
12.1  
9.1  
8.1  
6.1  
5.0  
3.0  
7.5  
2.5  
7.5  
22  
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