Hubbell CR manual

OPERATING AND MAINTENANCE MANUAL FOR INSTANTANEOUS ELECTRIC CIRCULATION HEATER ELECTRIC HEATER COMPANY BASE MODEL “ CR ”[...]

2 HUBBELL ELECTRIC HEATER COMPANY P.O. BOX 288 STRATFORD, CT 06615 PHONE: (203) 378-2659 FAX: (203) 378-3593 INTERNET: http://www.hubbellheaters.com/ -- IMPORTANT -- Always reference the f ull model num ber and serial number when calling the factory. WARNING / CAUTION 1. Tank is to be complete ly fille d with water and a ll air is to be vente d bef[...]

3 TABLE OF CONTENTS SECTION TITLE PAG E # I GENERAL DESCRI P TI ON AND CONSTRUCTION 5 II INSTAL LATI ON 12 III S C H E D U LE D M A IN TE NANC E AND OPERATION 14 I V TROUBL ES HOOTI NG 15 V S E R V I C I N G & R E P L A C E M E N T O F P A R T S 1 7 VI MI SCELL ANEOUS C HARTS AND FORMULAS 22[...]

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5 SECTION I - GENERAL DESCRIPTION AND CONST RUCTION GENERAL DESCRIPTION This book describes a packaged electric heater that is a stationary , self-contained unit. The complete assembly consists of the pressur e vessel, imme rsion ele ctric heating eleme nt, thermostat, saf ety relief valve, safety high temperature cut out, magnetic contactor(s), po[...]

6 OUTER SHELL, INSULATION, AND SUPP ORTS The pressure vessel is encapsulated in 2-inches of high-density fiberg lass 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 configur[...]

7 CONTROL THERMOS TAT The control pane l is supplied standard with a single- stage immersion thermosta tic switch. As an optional any of the following may be supplied; a four- stage immersion thermosta tic switch, a solid-state staging controller with thermistor, or a digital 1/16 DI N temperature controller with thermocouple. See drawing for speci[...]

8 TEMPERATURE HIGH LIMIT SWIT CH As a safety device, an immersion high temper ature cut-off switch with manua l reset, adjustable throug h a range of 100° - 240° F, is provided. The high limit must be manually reset thereafter to restart the heater. Optionally a 1/16 DI N digital controlle r may be used as a hig h-limit. Manual Reset MAGNETIC CON[...]

9 INDIVID UALLY FUSED ELEM ENTS To prevent the possibility of damage to c ontrol circuits a nd other eleme nts in case of electrica l overloads, fuses may be suppl ied for each element. Two types of fuses may be used; a ty pe NON for voltages less than 250-volt or ty pe JJ S for voltage less than 600-volt. Ty pe JJ S Ty pe NON LOW WATER CUT-OFF Use[...]

10 On / Off Control Switc h 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 c ontrol panel. Buil t-In Circui t Breaker A built-in circuit breaker may be provided with or without shunt trip protection for protection from circuit overload. Audible Alar m An audi[...]

11 Silicon Control Re ctifier An SCR “zero fired” power controller for 0-100% proportional control of heaters may be supplied. Dial Temperature an d 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 [...]

12 SECTION II – INSTALLATION WARNING / CAUTION DO NOT TURN ON THE ELECTRI C POWER SUPPL Y to this equipment until heate r is completely filled with water and all air has been re leased. If the heater is NOT fille d with water when the power is turned on, the heating elements will burn out. For protection against excessive pressures and temperatur[...]

13 Outlet to floor drain I nstall into provided tapping Manual Release Lev e r Temperature and Pressure Relief Valve 4. I nstall a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of any ty pe should be installed between the relief valve and tank or in the drain line. FILLING THE HEATER 1. Completely close the drain valve and o[...]

14 SECTION III - SCHEDULED MAINTE NANCE AND OPERATION WARNING / CAUTION Before performing any maintenance procedure, make certain power supply is OF F 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[...]

15 SECTION IV – TROUBLESHOOTING Symptom Probable Cause Corrective Action / Remedy Circuit breaker tripped at source. Reset circ uit breaker. On/Off switch in ‘OF F’ position, if installed. Turn switch to ‘ON’ position. Circuit breaker at control cabinet trippe d, if installed. Reset circ uit breaker. Blown fuse in element fuse block, if i[...]

16 Faulty thermostat. Chec k thermostat adjustment. Monitor thermostat as described in S e ct i o n III, Q u a rt e r l y In s p e c t i on. Replace if necessary. Blown fuse in element fuse block, if installed. Replace fuse. Heating element not worki ng on all phases Check to see th at heating element is working on all phases, by checking the resis[...]

17 SECTION V - SERVICING & REPLACEMENT OF PARTS WARNING / CAUTION Before servicing or replacing any part make sure to turn the power supply switch to the OF F position. MAGNETIC CONTACTOR 1. Disconnect power from unit. 2. Disconnect line and load wires to contactor. 3. Disconnect two (2) 14 gaug e control circuit wires. Control Wires Line Wires[...]

18 IMMERSION TEMPERATURE HIGH L IMIT CUT-OFF 1. Disconnect power from unit. 2. Remove access cover. 3. Remove high limit c over screw and cover. Cover Cover Screw Reset Switch 4. Disconnect the two (2) 14 gauge wires. Wires Capillary Tube 5. Remove capilla ry tube a nd bulb from thermowell 6. Remove two (2) mounting screws. Mounting Screws 7. Remov[...]

19 IMMERSION THE RMOSTAT 1. Disconnect power from unit. 2. Remove access cover and locate t hermostat. 3. Remove high limit c over screw and cover. Cover Cover Screw 4. Disconnect the two (2) 14 gauge wires. Wires Capillary Tube 5. Remove capilla ry tube a nd bulb from thermowell. 6. Remove two (2) mounting screws. Mounting Screws 7. Replace thermo[...]

20 HEATING ELEM ENT 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 sy stem or break union on outgoing water line. 5. Drain water from tank. 6. Remove element housing cover 7. Disconnect the wires from the heating elem ent terminal s.[...]

21 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 assemb ly and repl ace with new one. 6. Connect overflow piping. 7. Turn on incoming water supply and check for leaks. 8. Turn safety switch[...]

22 SECTION VI – MISCELL ANEOUS CHARTS AND FORMULAS NEMA ENCLOSURE S[...]

23 ELECTRICAL D ATA[...]

24 FORMULAS[...]

25 TORQUE VALUE S BOLT SIZE 18-8 S/S IN. - LB S . BRASS IN. - LB S . SI LI CON BRONZE IN. - LB S . ALUMI NUM 2024-T4 IN. - LB S . 316 S/S IN. - LB S . MONEL IN. - LB S . 4-40 5.2 4.3 4.8 2.9 5.5 5.3 4-48 6.6 5.4 6.1 3.6 6.9 6.7 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 9.6 7.9 8.9 5.3 10.1 9.8 6-40 12.1 9.9 11.2 6.6 12.7 12.3 8[...]