OPERATING AND MAINTENANCE MANUAL FOR
ELECTRIC INDUSTRIAL PROCESS
WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ V10 and V20 ”
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TABLE OF CONTENTS
SECTION TITLE
PAGE #
I
II
GENERAL DESCRIPTION AND CONSTRUCTION
INSTALLATION
5
10
16
18
20
26
III
IV
V
SCHEDULED MAINTENANCE AND OPERATION
TROUBLESHOOTING
SERVICING & REPLACEMENT OF PARTS
MISCELLANEOUS CHARTS AND FORMULAS
VI
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SECTION I - GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This booklet describes an electric water heater designed for use in an industrial or commercial
application. The complete assembly consists of the storage tank, immersion electric heating element(s),
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 water 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 a single stage immersion thermostatic
switch that is installed and wired at the factory. The thermostat can be
adjusted through a range of 100° - 195° F, (an optional low range, 30° -
110° F, is available), and is adjustable with a flat tip screwdriver. Other
thermostatic controls are available, see Options below.
TEMPERATURE HIGH LIMIT SWITCH
As a safety device, either a surface mounted high temperature cut-off switch with manual reset, factory
set at 205° F, or an optional immersion high temperature cut-off switch with manual reset, adjustable
through a range of 100° - 240° F, is provided. 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
Immersion High Temperature Cut-Off Switch
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.
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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. Heavy gauge steel
support legs are provided.
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.
Fused Low Voltage Transformer
A fused low voltage transformer may be supplied. This option
is standard only in 480-volt systems with low water cut-offs to
step down the voltage to 240-volt for safety when working with
control circuits. As an option, a transformer may be installed on
any unit to step down the voltage to 120-volts.
Stainless Steel Outer Jacket
An optional stainless steel outer jacket may replace the standard galvaneel jacket.
Watertight Jacket
The Jacket may be constructed in a watertight manner for wet/humid locations.
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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).
Vacuum Relief Valve
A vacuum relief valve may be provided with the unit to reduce the risk of back siphonage and back
pressure of the system. The valve will be shipped loose for in-line installation. Instructions for
installation are provided with the valve.
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
Built-in Circuit Breaker
A built-in circuit breaker may be provided with or without shunt trip protection for protection from
circuit overload.
NEMA 4X Electric Control Panel
A NEMA 4X control panel may be supplied to provide watertight construction for installation in “wet”
areas.
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Building Management System (BMS)
A Building Management System control package may be supplied for remote operation and alarm
capabilities.
Pump Interlock Terminal Block
An optional pump interlock terminal block may be installed to prevent energizing when the pump is not
running.
Silicon Control Rectifier
A silicon control rectifier (SCR) “zero fired” power controller for 0-100% proportional control of
heaters may be supplied.
Digital Display
A 1/16 DIN electronic temperature control package may
be installed. A separate manufacturer’s operating
manual will be supplied with the unit.
Optional Connections
Flanged inlet and outlet connections (150#)
Threaded inlet and outlet connections (1 ½”, 2” MNPT)
Sanitary Connections
Suspension Straps
For under counter, off the floor operation an optional suspension strap may be supplied in place of the
standard support legs.
Special Customized Features
Please reference drawing for details.
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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 nearest to the point of hot 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, 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 pressure and temperature gauge, if supplied.
3. Install in-line vacuum breaker, if supplied.
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4. Install the combination temperature and pressure safety relief valve in the tapping provided.
Note that this is required by law for safety considerations.
Outlet to floor drain
Install into provided tapping
Manual Release
Lever
Temperature Probe
Temperature and Pressure Relief Valve
5. 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. Open the pressure relief valve test lever to allow air to escape.
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 relief valve.
ELECTRICAL INSTALLATION
1. Enter electric enclosure with properly sized feeder leads. 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. See
wiring diagrams below.
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.
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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.
Outgoing Hot Water
Incoming Cold Water
1 – V Model Water Heater
2 – Pressure and Temperature Relief Valve (pipe overflow to floor drain or sink)
3 – Drain Valve
4 – Pressure/Temperature Gauge
5 – Shut-Off Valve
6 – Union
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1 – Terminal Block
2 – Magnetic Contactor
3 – Heating Element
4 – Low Water Cut-Off, if supplied
5 – Transformer, 480-Volt/240-Volt, installed on 480-Volt models with low water cut-off only
6 – High-Temperature Limit Switch
7 – Control Thermostat
13
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1 – Terminal Block
2 – Magnetic Contactor
3 – Heating Element
4 – Low Water Cut-Off, if supplied
5 – Transformer, 480-Volt/240-Volt,
installed on 480-Volt models
with low water cut-off only
6 – High-Temperature Limit Switch
7 – Control Thermostat
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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.
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.
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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.
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SECTION IV – TROUBLESHOOTING
Symptom
No hot water
Probable Cause
Circuit breaker tripped at source.
Blown fuse in transformer, if
installed.
Corrective Action / Remedy
Reset circuit breaker.
Replace fuse.
Circuit breaker at control cabinet
tripped, if installed.
Blown fuse in element fuse block,
if installed.
Reset circuit breaker.
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.
Low line voltage.
Faulty thermostat.
Faulty low water cut-off, if
installed.
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
common and normally open
contact of the relay board. If
continuity is not observed,
replace low water cut-off.
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.
Magnetic contactor does not
energize.
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Water temperature 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
phases
element is working on all
phases, by checking the
resistance (ohms) value for each
element and comparing with the
chart included in Section VI.
Replace fuse.
Blown fuse in element fuse block,
if installed.
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.
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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.
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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.)
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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 voltage and phase rating of the unit as shown below.
11. Fill tank and check around gasket for any leaks.
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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.)
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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.
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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
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SECTION VI – MISCELLANEOUS CHARTS AND FORMULAS
ELEMENT CHART
Resistance (Ohms)
Power (kW)
208V 240V 480V
Immersion
Length
Element
Part #
CH-FO 608
Hairpin
7.2
1 Φ
7.2
9.6
11.5
9.3
7.2
5.7
4.8
4.0
3.0
2.5
3 Φ DELTA 3 Φ WYE
---- ----
13 3/8"
13 3/8"
13"
13"
13"
13"
13"
15"
15"
----
----
----
----
6
CH-FO 604 4.5
6
5
----
6
9.6
4-38683N
5-38683N
6-38683N
7-38683N
8-38683N
9-38683N
10-38683N
4
5
6
34.4
27.9
21.6
17.1
14.4
12.1
9.1
34.4
27.9
21.6
17.1
14.4
12.1
9.1
23.0
18.7
14.5
11.5
9.6
8.1
6.1
5.0
6
8
8
10
12
15
20
----
8
10
12
15
20
10
12
15
11-38683N 17.3 ---- ----
15"
7.5
7.5
FORMULAS
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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
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