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BOX 288 STRATFORD, CT 06615 PHONE: (203) 378-2659 FAX: (203) 378-3593 INTERNET: -- IMPORTANT -- Always reference the full model number and serial number when calling the factory. WARNING / CAUTION 1. Tank is to be completely filled with water and all air is to be vented before energizing. 2. Due to the rigors of transportation, all connections should be checked for tightness before heater is placed in operation. 3. Safety relief valve must be installed in tapping provided. 4. The refractory material used in heating elements may absorb some moisture during transit, periods of storage, or when subjected to a humid environment. This moisture absorption results in a cold insulation resistance of less than twenty(20) megohms. If this heater has been subjected to the above condition, each heating element must be checked for insulation resistance before energizing. A low megohm condition can be corrected by removing the terminal hardware and baking the element in an oven at 350°F -700°F for several hours or until the proper megohm reading is obtained. 5. KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS. Do not perform any maintenance, make any adjustments, or replace any components inside the control panel with the high voltage power supply turned on. Under certain circumstances, dangerous potentials may exist even when the power supply is off. To avoid casualties, always turn the power supply safety switch to off, turn the charge or ground the circuit before performing any maintenance or adjustment procedure. 6. The unit is designed to operate at pressure not more than 150 psi. 7. Generalized instructions and procedures cannot anticipate all situations. For this reason, only qualified installers should perform the installations. A qualified installer is a person who has licensed training and a working knowledge of the applicable codes regulation, tools, equipment, and methods necessary for safe installation of an electric resistance water heater. If questions regarding installation arise, check your local plumbing and electrical inspectors for proper procedures and codes. If you cannot obtain the required information, contact the company. TABLE OF CONTENTS SECTION TITLE PAGE # I GENERAL DESCRIPTION AND CONSTRUCTION 5 II INSTALLATION 9 III SCHEDULED MAINTENANCE AND OPERATION 15 IV TROUBLESHOOTING 17 V SERVICING & REPLACEMENT OF PARTS 19 VI MISCELLANEOUS CHARTS AND FORMULAS 24 SECTION I -GENERAL DESCRIPTION AND CONSTRUCTION GENERAL DESCRIPTION This book describes a packaged electric booster heater that is typically used to provide 180°F sanitizing rinse water. 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/warm inlet and the hot water outlet. Water entering the cold water inlet is deflected by means of a baffle within the tank. A .-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. CONTROL THERMOSTAT The water heater is supplied with an immersion thermostatic switch that is installed and wired at the factory. The thermostat can be adjusted through a range of 100° - 195° F and is adjustable with a flat tip screwdriver. TEMPERATURE HIGH LIMIT SWITCH A surface mounted high temperature cut-off switch with manual reset, factory set at 205° F is provided. In the event of an over-temperature condition, the thermostat will disengage the operating coils in the magnetic contactor(s). The high limit must be manually reset thereafter to restart the heater. 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 ...