Hubbell Electric Heater Company Water Jtx Om

User Manual: Hubbell Electric Heater Company Electric Heater Electric Water Heater

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INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL FOR
THE HUBBELL MODEL JTX / JHX
TANKLESS BOOSTER HEATER
ELECTRIC HEATER COMPANY
* The Hubbell Model JTX is designed for use with conveyor and flight type dish
machines. This product is not intended for use with door style dish machines.
Edition 2016A
2
HUBBELL
ELECTRIC HEATER COMPANY
P.O. BOX 288
STRATFORD, CT 06615-0288
PHONE: (203) 378-2659
FAX: (203) 378-3593
INTERNET: http://www.hubbellheaters.com
Important Safety Information
1. You must read and follow all instructions. Serious bodily injury or death could occur
if you ignore this warning.
2. All circuit breakers and/or disconnect switches servicing the heater must be turned off
when installing, uninstalling, or repairing this booster heater.
3. The Hubbell Tankless Booster Heater must be grounded.
4. The unit must be installed by a licensed electrician and plumber.
5. The unit must be wired in accordance with the current version of the National
Electrical Code (US) or Canadian Electric Code (Canada).
6. This installation must comply with all national, state, and local plumbing and
electrical codes.
7. When the heater is not within sight of the electrical circuit breakers, an additional
local means of disconnection of all ungrounded conductors must be provided that is
within sight of the appliance or a circuit breaker lockout must be used. (Ref. NEC
422.31)
8. Water Quality Requirements Recommended water hardness is 4 to 6 grains of
hardness per gallon (GPG). Water hardness above 6 GPG should be treated by a
water conditioner (water softener or in-line treatment). Water hardness below 4 GPG
also requires treatment to reduce potential corrosion. Excessive GPG will result in
higher operating and maintenance costs and will reduce product longevity. Chlorides
must not exceed 50 parts per million (ppm). Excessive chlorides will result in
metallic corrosion and will reduce product longevity. Water treatment has been
shown to reduce costs associated with de-liming the booster as well as reducing
metallic corrosion. Product failure caused by these conditions is not covered under
warranty. See warranty for complete details.
9. The booster heater is factory set at 185°F for booster water heating applications. This
results in the possibility of a scalding water injury. A full thickness skin burn can
occur in less than one second of exposure to water at this temperature.
10. *Disclaimer: The Hubbell Model JTX is designed for use with conveyor and flight
type dish machines. This product is not intended for use with door style dish
machines.
3
TABLE OF CONTENTS
SECTION
TITLE
PAGE No.
I
TANKLESS BOOSTER HEATER OPERATING PRINCIPLE
4
II
GENERAL DESCRIPTION AND CONSTRUCTION
5
III
INSTALLATION
9
IV
OPERATION AND MAINTENANCE
26
V
TROUBLESHOOTING
32
VI
SERVICING & REPLACEMENT OF PARTS
39
VII
PARTS LIST
43
VIII
WARRANTY
44
4
SECTION I TANKLESS BOOSTER HEATER OPERATING PRINCIPLE
How the Hubbell Tankless Booster Heater Works:
For the most part, operating the new tankless booster heater is very similar to using any
traditional booster heater system. However, it is very important that all of the set-up
procedures and operating instructions are carefully read to ensure maximum performance
and energy savings from the new water heater.
The Hubbell Tankless Booster Heater does not store hot water like a conventional tank-type
booster heater. It contains high powered heating elements that are capable of heating water
instantly on-demand as needed. As soon as there is a hot water demand, a sophisticated flow
sensor within the heater recognizes the demand and initiates the heating process. This
sensor measures the water flow rate while two other sensors measure the incoming and
outgoing water temperature. This information is transmitted continually to the
microprocessor controller which determines the precise amount of power to send to the
heating elements to heat the water to the desired temperature. The Hubbell tankless booster
heater only uses as much power as is needed to meet the demand by fully modulating the
heating elements from 0 to 100%.
It is important to keep in mind that all tankless booster heaters are subject to a maximum
flow rate. If this flow rate is exceeded, the heater will not be capable of fully heating water.
The amount of water that can be heated by the tankless booster heater at any given time will
depend on the model selected and the incoming water temperature. See the charts in Section
II to determine the maximum flow rates.
Moreover, since a tankless booster heater eliminates the ongoing thermal losses caused by
storing hot water in a tank, there will be a significant energy savings compared to a
conventional tank type booster heater.
*Disclaimer: The Hubbell Model JTX is designed for use with conveyor and flight type
dish machines. This product is not intended for use with door style dish machines.
5
SECTION II GENERAL DESCRIPTION AND CONSTRUCTION
Technical Specifications Common to All Models:
Copper Exchanger /
Stainless Steel Casing
Plumbing
Connection:
Low
Flow
¾” Copper Sweat
98%
High
Flow
1” Copper Sweat
208-600 Volts
Operating Range:
5 150 psi
50 / 60 Hz
Protection:
Thermal Auto Reset
Product Overview:
Notes:
1. Power distribution blocks are only installed on single phase models.
2. Magnetic contactors are only installed on 3-phase models.
3. Transformers are only installed on 3-phase models over 240 volts.
4. 2-Element models will have a plug in the lowest element chamber and have only two hi-
limit switches and triacs installed.
Typical 2/3-Element Model
Heating Elements
Heating Chamber
Hi-Limit Switches
Inlet Thermistor
Outlet Thermistor
Element Switching
Devices (Triacs)
LED Digital Display
(with buttons)
Power Distribution Block
Ground Lug
Hot Water
Outlet
Warm
Water Inlet
Drain
Flow Meter
Magnetic
Contactor
Transformer
Control Fuse
Temperature
Controller
(TK2000)
6
Control Fuse
Notes:
1. Power distribution blocks are only installed on single phase models and 3-phase models
that require two magnetic contactors. Single phase models use a 2-pole power
distribution block.
2. Magnetic contactors are only installed on 3-phase models. One or two magnetic
contactors may be installed as required.
3. Transformers are only installed on 3-phase models over 240 volts.
Typical 6-Element Model
Heating Elements
Inlet Thermistor
(beneath triac
plate)
Outlet Thermistor
Element Switching
Devices (Triacs)
Temperature
Controller
(TK2250)
LED Digital Display
(with buttons)
Magnetic Contactor
Ground Lug
Hot Water
Outlet
Warm
Water Inlet
Drains
Flow Meter
Hi-Limit Switches
Heating Chamber
Transformer
Power
Distribution
Block
Control Fuse
7
Tankless Booster Heater Maximum Flow Rates:
5°F 10°F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 100°F 120°F 140°F
810.9 5.5 2.7 1.8 1.4 1.1 0.9 0.8 0.7 0.5 0.5 0.4
11 15.0 7.5 3.8 2.5 1.9 1.5 1.3 1.1 0.9 0.8 0.6 0.5
12 16.4 8.2 4.1 2.7 2.1 1.6 1.4 1.2 1.0 0.8 0.7 0.6
13 17.8 8.9 4.4 3.0 2.2 1.8 1.5 1.3 1.1 0.9 0.7 0.6
14 19.1 9.6 4.8 3.2 2.4 1.9 1.6 1.4 1.2 1.0 0.8 0.7
15 20.5 10.3 5.1 3.4 2.6 2.1 1.7 1.5 1.3 1.0 0.9 0.7
16 21.9 10.9 5.5 3.6 2.7 2.2 1.8 1.6 1.4 1.1 0.9 0.8
18 24.6 12.3 6.2 4.1 3.1 2.5 2.1 1.8 1.5 1.2 1.0 0.9
20 27.3 13.7 6.8 4.6 3.4 2.7 2.3 2.0 1.7 1.4 1.1 1.0
21 28.7 14.4 7.2 4.8 3.6 2.9 2.4 2.1 1.8 1.4 1.2 1.0
24 32.8 16.4 8.2 5.5 4.1 3.3 2.7 2.3 2.1 1.6 1.4 1.2
25 34.2 17.1 8.5 5.7 4.3 3.4 2.8 2.4 2.1 1.7 1.4 1.2
27 36.9 18.5 9.2 6.2 4.6 3.7 3.1 2.6 2.3 1.8 1.5 1.3
30 20.5 10.3 6.8 5.1 4.1 3.4 2.9 2.6 2.1 1.7 1.5
31 21.2 10.6 7.1 5.3 4.2 3.5 3.0 2.6 2.1 1.8 1.5
33 22.6 11.3 7.5 5.6 4.5 3.8 3.2 2.8 2.3 1.9 1.6
36 24.6 12.3 8.2 6.2 4.9 4.1 3.5 3.1 2.5 2.1 1.8
40 27.3 13.7 9.1 6.8 5.5 4.6 3.9 3.4 2.7 2.3 2.0
42 28.7 14.4 9.6 7.2 5.7 4.8 4.1 3.6 2.9 2.4 2.1
48 32.8 16.4 10.9 8.2 6.6 5.5 4.7 4.1 3.3 2.7 2.3
50 34.2 17.1 11.4 8.5 6.8 5.7 4.9 4.3 3.4 2.8 2.4
54 36.9 18.5 12.3 9.2 7.4 6.2 5.3 4.6 3.7 3.1 2.6
Maximum Flow Rate (GPM) at Temperature Rise (°FΔT)
Power (kW)
1. Shaded values indicate that a High Flow (JHX) unit is required.
2. Blank values indicate that the flow rate will exceed the flow capability of the flow meter.
3. For alternate power (kW) values, the maximum flow rate can be calculated using the
formulas on the following page.
Tankless Low Flow Pressure Drop Chart (JTX):
0
2
4
6
8
10
12
14
16
012345678
2-Element 3-Element 6 -Element
GPM
Pressure Drop (psi)
8
Tankless High Flow Pressure Drop Chart (JHX):
Wattage De-rating Formula:
Applied Voltage2
× Rated Wattage = Actual Wattage
Rated Voltage2
For example: If installing a 27 kW unit when actual voltage is 212 V,
2122
=
44,944
= 0.78 × 27,000 W = 21,060 W @ 212 V
2402
57,600
Amperage Formula:
Watts
= Amps (Single Phase)
Watts
÷1.73 = Amps (3-Phase)
Volts
Volts
Flow Rate Formulas:
To determine power (kW) requirement
____GPM × ____ °F T × 0.1465 = ____ kW
To determine temperature rise
____ kW × 6.824 ÷ ____ GPM = ___F T
To determine flow rate
____ kW × 6.824 ÷ ____ °FT = ____ GPM
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25 30 35 40
3-Element 6-Element
GPM
Pressure Drop (psi)
9
SECTION III INSTALLATION
WARNING: Serious bodily injury or death may occur if the following warnings are
ignored.
All circuit breakers and/or disconnect switches servicing this heater must be turned
off before installing, repairing or uninstalling this water heater.
Installation of this product is restricted to indoor locations.
Installation
MUST
be done by a licensed electrician and licensed plumber.
*Disclaimer:
The Hubbell Model JTX is designed for use with conveyor and flight
type dish machines. This product is not intended for use with door style dish
machines.
Locating and Mounting Instructions:
The Hubbell tankless booster heater can be installed just about anywhere. Due to the small
size of the water heater, it can be mounted in many small spaces. However, there are some
important guidelines to follow that will ensure that the installation is both safe and
convenient in the event that future servicing is required.
This product is designed to be installed indoors only. The unit may be installed in an
outdoor location as long as it is mounted in a suitable enclosure that protects it from rain,
direct sunlight, debris, and insects. This product should NOT be installed in a location where
it may be subjected to freezing temperatures. If the water inside the tankless booster heater
freezes, it can cause severe and permanent damage that is not covered under the warranty. If
you suspect that the tankless booster heater may have frozen, do not turn on the heater until
it has thawed and it has been inspected for leaks.
When selecting an installation location, give consideration to the existing plumbing
configuration, location of your main electrical panel, and location of the point of use. Try to
choose a location that does not require major plumbing alterations, that is close to the main
electrical panel (this will reduce the amount of wire needed to install), and that is physically
close to the dish machine. By locating the heater close to the dish machine, this will reduce
the amount of time it takes for the hot water to travel from the water heater to the point of
use. Consideration should also be given to future servicing. Do NOT locate the water heater
in a location that is difficult to access. Do NOT install above electrical boxes or junctions.
Mounting the unit:
Leave a minimum of 12” to both sides and 4” on the top and bottom of the unit.
Mount the booster heater securely to the wall by putting four (4) screws through the
mounting holes.
Install a ¼” diameter bead of sealing caulk around the entire perimeter of the heater
between the heater back panel and the wall. This prevents any moisture or debris
from accumulating.
10
11
Plumbing Installation Instructions:
IMPORTANT INFORMATION:
Ensure all fitting installations comply with local plumbing and building codes.
The booster heater does not require a temperature and pressure (T&P) relief valve. A
T&P relief valve may be installed if required by county, city or state plumbing code.
Installations in the Commonwealth of MASSACHUSETTS and KENTUCKY require
a
T&P
relief valve.
When connecting to a plumbing system that utilizes Flex or PVC, a
T&P
relief valve
should be used as added safety.
Do not connect the unit directly to CPVC pipe or PEX tubing. You must use at least
three feet of copper pipe prior to connecting to any CPVC or PEX connection.
WARNING:
Do not solder any pipes with the unit connected to the pipes. Doing so
will damage the flow meter and void your warranty.
Before energizing the heater, run water for a minimum of three (3) minutes and
verify that all air has been removed.
Installation of an air separator device is recommended for installations where air can
be easily introduced into the water system (i.e. Well water systems, lake pumps, and
other municipal systems).
A shut off valve MUST be installed on inlet side of unit. A shut off valve on the
outlet is recommended.
Typical JTX Plumbing Installation:
Piping:
Remove the sweat end of the dielectric fitting from the unit.
Sweat the pipe to the dielectric union.
Connect the union and pipe assembly to the unit.
IMPORTANT Be certain to connect the outlet piping to the final rinse and not to the
wash tank.
Install water pressure regulator in the entering cold/warm water inlet line and adjust to
the pressure recommended by the dishwasher manufacturer. The pressure reducing
valve is adjustable from 25 to 75 psi. The set screw located at the top of the diaphragm
adjusts the pressure, turn clockwise to increase the pressure and counter-clockwise to
decrease the pressure.
Install the factory supplied in-line pressure and temperature gauges in the entering
cold/warm and existing hot water lines. NOTE: The temperature sensing element
must be in the water stream as shown below.
A shock absorber is recommended in the hot water outlet line to soften the water
hammer caused by automatic dishwasher solenoid valves.
12
Flush the line:
Before connecting the union to the unit, it is extremely important to
flush the lines to eliminate all plumbing paste, residue, or debris in the lines
Checking for Leaks and Purging Air:
If unit has been wired, verify all circuit breakers supplying power to the unit are
turned off.
Open all valves supplied by the unit and inspect water connections for leaks.
With all valves still open, allow the water to run for a minimum of 3 minutes.
Inspect the outlets to ensure all air in the lines has been purged. This process purges
all the air from the water lines and MUST be performed prior to turning on the power
at the unit.
WARNING:
FAILURE TO FOLLOW THIS STEP CAN CAUSE
PERMANENT DAMAGE TO THE HEATING ELEMENTS.
Close all valves.
Electrical Installation Instructions:
IMPORTANT INFORMATION:
The unit must be wired in accordance with the current version of the National
Electrical Code (US) or Canadian Electric Code (Canada).
The unit must have its own independent circuits.
When the heater is not within sight of the electrical circuit breakers, an additional
local means of disconnection of all ungrounded conductors must be provided that is
within sight of the appliance or a circuit breaker lockout must be used. (Ref. NEC
422.31)
Wire entry must be through the electrical KO provided in the bottom of the unit.
For Canada, per Canadian Electric Code, C22.1-02, the unit must be wired by a single
feed installation with one (1) double-pole circuit breaker.
For US, the unit may be wired by a single feed installation with one (1) double-pole
circuit breaker or by a multiple feed installation with multiple double-pole circuit
breakers.
Wiring to the booster heater:
Connect the power wire from the main panel to the power distribution block or
magnetic contactor as applicable.
Connect the main ground wire to the ground lug in the heater.
Make sure the connections are securely tightened.
13
Electrical Specifications:
Listed below are the electrical specifications for each tankless booster heater model.
Tankless booster heaters are considered a non-continuous load.
If a multiple feed installation is used, it is acceptable to install up to two conductors in
one line side port. Additionally, when a power distribution block is supplied,
additional conductors may be installed in an open load side port of the power
distribution block.
Wiring sizing listed is for 75°C THHN. 60°C or 90°C wire may be used. Refer to
NEC table 310.16 for sizing.
Conductors should be sized to maintain a voltage drop of less than 3% under load.
Electrical specifications for the High Flow (JHX) models are the same as listed for the
Low Flow (JTX) models.
The Hubbell Model JTX is designed for use with conveyor and flight type dish
machines. This product is not intended for use with door style dish machines.
Where “Min. Breaker Size” is marked with a star (*), these models require a
supplemental protection assembly for installation.
For the following models, for installation in Canada per CSA requirements, a single
feed is required sized as follows:
o JTX036-6RS: 3/0
o JTX040-6RS: 4/0
o JTX042-6S: 3/0
o JTX048-6RS: 250
o JTX048-64S: 4/0
o JTX054-6S: 250
14
Model kW
Volts /
Phase
Amps
Min.
Breaker
Size
Wire
Size
Conduit
Size
Wiring
Diagram
Element
Amp
Draw
JTX008-2RS 8 208 / 1 38.5 45 8¾" 1 19.9
JTX011-3R 11 208 / 3 30.5 35 8¾" 3 16.3
JTX011-2S 11 240 / 1 45.8 50 8¾" 1 22.9
JTX011-3T3 11 380 / 3 16.7 20 8¾" 4 9.9
JTX012-2RS 12 208 / 1 57.7 70 6¾" 1 28.9
JTX012-3R 12 208 / 3 33.3 35 8¾" 3 19.9
JTX013-3T3 13 380 / 3 19.8 25 8¾" 4 11.5
JTX013-3T7 13 415 / 3 18.1 20 8¾" 4 10.8
JTX014-2RS 14 208 / 1 67.3 80 41" 1 32.5
JTX014-2S 14 240 / 1 58.3 70 6¾" 1 29.2
JTX014-3T 14 240 / 3 33.7 40 8¾" 3 18.8
JTX015-3T3 15 380 / 3 22.8 25 8¾" 4 13.2
JTX016-3RS 16 208 / 1 76.9 90 41" 2 25.3
JTX016-3R 16 208 / 3 44.4 50 8¾" 3 25.3
JTX016-2S 16 240 / 1 66.7 80 41" 1 33.3
JTX016-3T 16 240 / 3 38.5 45 8¾" 3 22.9
JTX016-3T7 16 415 / 3 22.3 25 8¾" 4 12.6
JTX018-3RS 18 208 / 1 86.5 90 31" 2 28.9
JTX018-3R 18 208 / 3 50.0 60 6¾" 3 28.9
JTX018-2S 18 240 / 1 75.0 80 41" 1 37.5
JTX018-3T3 18 380 / 3 27.3 30 8¾" 4 15.7
JTX018-3T7 18 415 / 3 25.0 30 8¾" 4 14.4
JTX018-3T4 18 480 / 3 21.7 25 8¾" 4 12.5
JTX020-3RS 20 208 / 1 96.2 110 21" 2 32.5
JTX020-3R 20 208 / 3 55.5 60 6¾" 3 32.5
JTX020-3T3 20 380 / 3 30.4 35 8¾" 4 17.7
JTX020-3T7 20 415 / 3 27.8 30 8¾" 4 16.2
JTX021-3S 21 240 / 1 87.5 90 31" 2 29.2
JTX021-3T 21 240 / 3 50.5 60 6¾" 3 29.2
JTX021-3T4 21 480 / 3 25.3 30 8¾" 4 14.6
JTX021-3T6 21 600 / 3 20.2 25 8¾" 5 20.2
JTX024-6RS 24 208 / 1 115.4 125* 12" 6 19.9
JTX024-6R 24 208 / 3 66.6 70 41" 7 19.9
JTX024-3S 24 240 / 1 100.0 110 21" 2 33.3
JTX024-3T 24 240 / 3 57.7 70 6¾" 3 33.3
JTX024-3T7 24 415 / 3 33.4 40 8¾" 4 19.3
JTX024-3T4 24 480 / 3 28.9 35 8¾" 4 16.7
JTX024-3T6 24 600 / 3 23.1 25 8¾" 5 23.1
JTX025-3T3 25 380 / 3 38.0 40 8¾" 4 22.2
JTX027-3S 27 240 / 1 112.5 125 12" 2 37.5
JTX027-3T 27 240 / 3 65.0 70 41" 3 37.5
JTX027-6T3 27 380 / 3 41.0 45 8¾" 9 11.5
JTX027-6T7 27 415 / 3 37.6 40 8¾" 9 10.8
JTX027-3T4 27 480 / 3 32.5 35 8¾" 4 18.8
15
Model kW
Volts /
Phase
Amps
Min.
Breaker
Size
Wire
Size
(Qty.)
Conduit
Size
Wiring
Diagram
Element
Amp
Draw
JTX027-3T6 27 600 / 3 26.0 30 8¾" 5 26.0
JTX030-6T3 30 380 / 3 45.6 50 8¾" 9 13.2
JTX031-6RS 31 208 / 1 149.0 175* 2/0 1 ½" 6 25.3
JTX031-6R 31 208 / 3 86.0 90 31" 7 25.3
JTX031-6T7 31 415 / 3 43.1 50 8¾" 9 12.6
JTX033-6S 33 240 / 1 137.5 150* 1/0 1 ¼" 6 22.9
JTX033-6T 33 240 / 3 79.4 90 41" 7 22.9
JTX036-6RS 36 208 / 1 173.1 200* 3(2) 1 ½" 6 28.9
JTX036-6R 36 208 / 3 99.9 110 21" 8 28.9
JTX036-6T3 36 380 / 3 54.7 60 6¾" 9 15.7
JTX036-6T7 36 415 / 3 50.1 60 6¾" 9 14.4
JTX036-6T4 36 480 / 3 43.3 50 8¾" 9 12.5
JTX040-6RS 40 208 / 1 192.3 225* 2(2) 2" 6 32.5
JTX040-6R 40 208 / 3 111.0 125 12" 8 32.5
JTX040-6T3 40 380 / 3 60.8 70 6¾" 9 17.7
JTX040-6T7 40 415 / 3 55.6 60 6¾" 9 16.2
JTX042-6S 42 240 / 1 175.0 200* 3(2) 1 ½" 6 29.2
JTX042-6T 42 240 / 3 101.0 110 21" 8 29.2
JTX042-6T4 42 480 / 3 50.5 60 6¾" 9 14.6
JTX042-6T6 42 600 / 3 40.4 45 8¾" 10 40.4
JTX048-6RS 48 208 / 1 230.8 250* 1(2) 2" 6 38.5
JTX048-6R 48 208 / 3 133.2 150* 1/0 1 ¼" 12 38.5
JTX048-6S 48 240 / 1 200.0 225* 2(2) 2" 6 33.3
JTX048-6T 48 240 / 3 115.5 125 12" 8 33.3
JTX048-6T7 48 415 / 3 66.8 80 41" 9 19.3
JTX048-6T4 48 480 / 3 57.7 70 6¾" 9 16.7
JTX048-6T6 48 600 / 3 46.2 50 8¾" 10 46.2
JTX050-6T3 50 380 / 3 76.0 80 41" 9 22.2
JTX054-6S 54 240 / 1 225.0 250* 1(2) 2" 6 37.5
JTX054-6T 54 240 / 3 129.9 150* 1/0 1 ¼" 12 37.5
JTX054-6T4 54 480 / 3 65.0 70 41" 9 18.8
JTX054-6T6 54 600 / 3 52.0 60 6¾" 10 52.0
16
Triac
Triac
Flow
Meter
Power
Distribution
Block
Temperature
Controller
Hi-Limit Hi-Limit
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Leak
Detection
Wire
Fuse
Tankless Wiring Diagram 1
Triac
Triac
Triac
Flow
Meter
Power
Distribution
Block
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Leak
Detection
Wire
Fuse
Tankless Wiring Diagram 2
17
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Leak
Detection
Wire
Fuse
Tankless Wiring Diagram 3
18
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Leak
Detection
Wire
Transformer
Fuse
Tankless Wiring Diagram 4
19
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Leak
Detection
Wire
Transformer
Fuse
Tankless Wiring Diagram 5
20
Triac
Triac
Triac
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Triac
Triac
Triac
Leak
Detection
Wire
Power
Distribution
Block
L1 L2 L1 L2
Flow
Meter
Fuse
Tankless Wiring Diagram 6
21
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Triac
Triac
Triac
Leak
Detection
Wire
Fuse
Tankless Wiring Diagram 7
22
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element
Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element
Heating
Element
Triac
Triac
Triac
Magnetic
Contactor
Power
Distribution
Block
Leak
Detection
Wire
Fuse
Tankless Wiring Diagram 8
23
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Triac
Triac
Triac
Leak
Detection
Wire
Transformer
Fuse
Tankless Wiring Diagram 9
24
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Triac
Triac
Triac
Leak
Detection
Wire
Transformer
Fuse
Tankless Wiring Diagram 10
25
Triac
Triac
Triac
Flow
Meter
Temperature
Controller
Hi-Limit Hi-Limit Hi-Limit
Heating
Element
Heating
Element Heating
Element
Outlet
Thermistor
Inlet
Thermistor
Magnetic
Contactor
L1 L2 L3
Hi-Limit Hi-Limit Hi-Limit
Heating
Element Heating
Element Heating
Element
Triac
Triac
Triac
Magnetic
Contactor
Leak
Detection
Wire
L1 L2 L3
Fuse
Tankless Wiring Diagram 12
26
SECTION IV OPERATION AND MAINTENANCE
First Use of your Hubbell Tankless Booster Heater:
Once the water supply is on and air has been purged from the system, power the unit on at
the main panel. The unit is now operating automatically. When water flows through the unit,
the heating elements turn on to heat the water to the displayed setpoint temperature. When
the water flow stops, the heating elements turn off.
You can adjust the setpoint upward or downward by pressing the UP or DOWN button.
Displaying Celsius or Fahrenheit degrees and adjusting other settings for the tankless booster
heater can be done via the configuration menu, described below.
Upper Button to
Increase Temperature
Digital Display Lower Button to
Decrease Temperature
Maintenance:
The Hubbell Tankless Booster Heater requires no maintenance other than to
periodically check around the outside of the unit for leaks. If a water leak is detected
from your water heater, turn off the water supply at the shut-off valve on the inlet side
of the water heater, turn off the power to the heater at the main electrical panel and
call a service technician or plumber for evaluation and repair.
When any maintenance is performed on the booster heater or the plumbing system
that may introduce air into the water supply pipes, it is important to turn the power off
to the water heater and purge the air out of the lines before restoring power to the unit.
See Checking for Leaks and Purging Air in Section III.
Temperature Controller User Interface Instructions:
1. To turn the unit OFF and ON:
a. To turn the unit OFF, press and hold the DOWN button until display shows OFF.
b. To turn the unit ON, press and hold the UP button until the setpoint temperature
is displayed.
c. Note that the display is always lit when power is applied to the unit.
d. Note that the controller will preserve all its settings during any power outage or
disconnect.
2. To change setpoint temperature (the temperature is fully adjustable in 1° increments).
a. Press the UP or DOWN button to change the setpoint temperature.
b. Pressing and holding either the UP or DOWN button will fast scroll.
3. Configuration Menu.
a. To enter configuration menu, press and hold the UP and DOWN buttons
simultaneously for 7 seconds. (Note that the display will change during the time
you are holding the buttons. You are in the configuration menu and can release
the buttons when the first character of the display is ‘P’).
b. To scroll through menu items, press the UP or DOWN button.
c. To leave the configuration menu, wait 7 seconds without pushing any buttons.
d. To make a change to a specific configuration menu item, simultaneously press
the UP and DOWN buttons. The menu item setting will now flash indicating it
can be changed.
e. To scroll through menu item settings, press the UP or DOWN key.
f. When the desired setting is displayed, simultaneously press the UP and DOWN
buttons to lock in the selection and return back to the configuration menu.
27
g. Configuration Menu Items:
i. Power Setting - Sets the total kW rating of booster heater.
1. P###, where ### is adjustable from 001 to 054 (Note
that the kW selection should equal the kW based upon
the actual voltage measured to the heater. Please see the nameplate
on the front cover of the heater for a listing of kW ratings at various
voltages).
ii. Temperature Range Sets the temperature adjustment range
1. r001, 60° to 140°F (15°-60°C)
2. r002, 32° to 194°F (0°-90°C) (Factory Default)
3. r003, 32° to 104°F (0°-40°C)
iii. Display units Sets the display units to either Fahrenheit/Gallons or
Celsius/Liters.
1. dEFF, for degrees Fahrenheit and Gallons. (Factory
Default)
2. dECC, for degrees Celsius and Liters.
iv. Normal Display Mode Sets the display to show various values.
1. dSP1, to display setpoint temperature only. (Factory
Default)
a. setpoint is displayed as ###
2. dSP2, to display measured inlet temperature intermittently with
setpoint temperature.
a. Inlet temperature is displayed as i###
3. dSP3, to display measured outlet temperature intermittently with
setpoint temperature.
a. Outlet temperature is displayed as o###
4. dSP4, to display measured flow rate intermittently with setpoint
temperature
a. Flow rate is displayed as F##.#, in tenths of a gallon or liter.
5. dSP5, to display inlet temp, outlet temp, flow rate and setpoint all
intermittently.
v. Power Limiting Factor Sets the % of heater output allowed by the
controller
1. L###, where ### is a percentage from 001 to 100
(Factory Default 100). This feature allows a user
to limit the kW rating of the unit by a specific percentage and
effectively lower the total amp draw of the unit.
vi. Heater Configuration Sets the controller to perform calculations based
on the heater configuration of the unit.
1. E001, for single-phase one heating element and
all 3-phase units
2. E002, for single-phase two heating elements
3. E003, for single-phase three or six heating elements
4. E004, for single-phase four heating elements
vii. Calibration Used to calibrate the heater. (For factory use only)
1. CA #, where ## equals the degrees of calibration
from -3 to 3. Default is 0.
viii. Low/High Flow Sets the unit as either a low flow or high flow unit.
1. LF, for low flow (Factory Default).
2. HF, for high flow.
ix. Remote Control Sets the operation of the remote control function (see
Priority and Remote Controls in this section).
1. iPOF, disables the remote control (Factory
Default).
28
2. iPHi, 24VDC signal or closed relay connected to P2 and P3 will
allow the heater to operate and loss of 24VDC signal or open relay
connected to P2 and P3 will inhibit the heater operation.
3. iPLo, 24VDC signal or closed relay connected to P2 and P3 will
inhibit the heater operation and loss of 24VDC signal or open relay
connected to P2 and P3 will allow the heater to operate.
4. When the remote control operation is inhibiting
the unit from operating, the display will show hLd.
x. Display Lock Allows the user to lock the heater
parameters. When the display is locked the temperature setpoint cannot be
changed and although the configuration menu will still be accessible, no
changes can be made to any parameters, except to change the display lock.
With the display lock on, attempting to change the temperature setpoint
will cause the display to show, Locd.
1. LcOn, to turn the display lock on.
2. LcOF, to turn the display lock off (Factory
Default).
xi. Software Version Displays the version number of the software
1. Sd##, where ## is the version of the display software.
2. Sb##, where ## is the version of the main board software.
h. After this menu item, the configuration menu cycles back to the first item.
4. Diagnostic Menu Display
a. To display common diagnostic data useful for troubleshooting,
when in normal display mode press and release the UP and
DOWN buttons simultaneously.
b. The display will intermittently display the following values: flow
rate (F##.#), measured inlet temp (i###), measured outlet temp
(o###), setpoint (###).
c. These values and settings will continue to display and scroll until
either the UP or DOWN button is pressed. The display then
returns to normal display mode.
5. Configuration Settings Display
a. To display all configuration settings, when in normal display mode press and
release the UP and DOWN buttons simultaneously twice.
b. The display will scroll through all configuration settings.
c. The display will continue to scroll until either the UP or DOWN button is pressed
and will then return to normal display mode.
6. Power Rate Display
a. The decimal point in the display’s rightmost digit is a visual indicator of how
much power is required to meet the demand. A blinking decimal
point indicates that the triac is being sent a signal to energize and
thus turn the element on. The decimal point light will
blink at a faster rate as the controller is calling for more
heat. When the unit is calling for full power the light is solid.
b. If the amount of power required exceeds the capacity of the heater, then the
entire display will intermittently flash. (Note that the display will only flash
when the display configuration is set to ‘dSP1’.)
7. Cost Calculator Allows the user to view the amount of power and hot water
consumed and the cost of operation.
a. To display the Cost Calculator values, when in normal display mode press and
release the UP and DOWN buttons simultaneously three times.
b. The display will scroll through the Cost Calculator Values since last reset
i. C###, where ### equals the total cost of operation
ii. ####, where #### equals the total number of kW∙Hrs consumed
POINT IS FLASHING
29
iii. H0##, where ## equals water usage up to the ten thousands place,
followed by h###, where ### equals water usage up to the hundreds
place. Example: H012, h345 equals 12,345 gallons of water used.
iv. To reset these values to 0, press and hold the UP and DOWN buttons
simultaneously for 5 seconds. When the display shows ‘0000’, the cost
calculator has been reset.
c. To enter a specific cost per kW∙Hr value, while displaying the Cost Calculator
values above press and release the UP and DOWN buttons simultaneously.
i. The display shows the cost per kW∙Hr as #.### (Factory Default 0.114)
ii. Press the UP or DOWN button to adjust the cost per kW∙Hr. Holding the
UP or DOWN buttons will fast scroll.
iii. Press the UP and DOWN buttons simultaneously to lock in the cost per
kW∙Hr.
iv. Press the UP or DOWN button to return to Cost Calculator values.
v. Press the UP or DOWN button to return to normal display mode.
8. Error Code
a. Err1, indicates a failure of element #1
b. Err2, indicates a failure of element #2
c. Err3, indicates a failure of element #3
d. Err4, indicates a failure of element #4
e. Err5, indicates a failure of the inlet thermistor
f. Err6, indicates a failure of the outlet thermistor
g. Err7, indicates a failure of the display unit to communicate with the main board
h. Err8, indicates that water has been detected in the case
Remote Display
An optional remote display may be supplied and connected to the TK2000 control board as
shown below.
Priority and Remote Controls:
Optionally, the tankless water heater may be connected to another electrical device (10A
@240VAC max.) that will give priority to the booster heater over that device to ensure that
both do not operate at the same time and/or the tankless booster heater may be wired to a
remote switch, relay, or provided with a 24VDC signal (such as from a building maintenance
system) to allow the tankless booster heater to be remotely controlled. The diagram and
description below provide details on how connections to the tankless booster heater control
board are to be made.
1. Priority Relay (10[email protected]240VAC max.)
a. When the unit is demanding power (calling for heat):
i. The connection between the terminals marked C and NO are closed and
will allow power to pass through.
ii. The connection between the terminals marked C and NC are open and will
not allow power to pass through.
b. When the unit is not demanding power (not calling for heat):
i. The connection between the terminals marked C and NO are open and will
not allow power to pass through.
ii. The connection between the terminals marked C and NC are closed and
will allow power to pass through.
2. Remote Control
a. When a 24VDC signal (5mA draw max.) is supplied between terminals P1 and
P2, the heater will either operate or be inhibited (displayed as hLd) as determined
by the Remote Control settings as shown above. Loss of 24VDC signal has the
opposite effect.
30
b. When wired to a volt-free contact (10A max.) between terminal P2 and P3 (output
signal 24VDC@5mA), opening or closing the contact will allow the heater to
either operate or inhibit (displayed as hLd) operation as
determined by the Remote Control settings as shown above.
TK2000 Control Board Wiring Detail
Power and Triac Wiring
Outlet
Thermistor
Inlet
Thermistor
Leak
Detection
F1 F2 F3
Flow
Meter
Remote
Display
Display
Auxiliary
P1(0VDC) P2(+24VDC) P3
Remote
Control
Priority
Relay
NC
NO
C
31
32
SECTION V TROUBLESHOOTING
Common Issues:
Symptom
Probable Cause
Corrective Action
Water reaches setpoint
temperature but does
not last through the
entire dishwasher
cycle.
Low incoming water
temperature.
Incoming water temperature must be
adequate for the booster size. Increase the
incoming water temperature.
Incoming water
temperature is
dropping.
Primary water supply is not adequate to
continually provide correct temperature in
sufficient quantities. Increase the supply
of primary warm water.
Water pressure is too
high.
Higher water pressure uses an excessive
supply of hot water. Verify a pressure
reducing valve is installed and adjust the
water pressure to the dish machine
specifications.
Booster heater may be
undersized.
The booster heater must be properly sized
for the incoming water and rinse
requirements of the dishwasher. If
required, replace with a properly sized
unit.
Incorrect voltage.
Voltage available at the booster heater
must be correct for unit. Verify voltage on
all phases matches nameplate on the
booster heater.
Gauge(s) not reading
correctly.
Check the temperature of the water with a
thermometer to verify the gauges are
working properly. Replace gauges, if
required.
Temperature setpoint
too low.
Adjust the temperature setpoint.
Water at the
dishwasher is not the
proper temperature.
Booster heater piping
to the dishwasher is not
insulated.
If there is more than 5 linear feet of
piping between the booster heater and the
dishwasher the piping should be wrapped
in insulation or a recirculating system
should be installed.
Bypass valve is open or
allowing water to pass
when closed.
Verify that the bypass valve between the
hot and warm water lines is closed. If
condition continues, replace the bypass
valve.
If none of the above addresses and solves the issue, proceed with the Initial Evaluation.
33
Initial Evaluation:
No Hot Water
or
Water is not hot
enough
Is display lit?
Is
circuit breaker or
disconnect
off?
Turn on circuit
breaker or
disconnect
No
Yes
Yes
Is
the temperature
setting too
low?
Adjust
temperature
setting
See Section III.
Is flow
too great for temp.
setting? See
Section II.
Reduce flow.
See Advanced
Troubleshooting
Yes
No
Yes
Is
there a plumbing
crossover? (See
note 1) Yes Consult a local
plumber for help
in correcting the
plumbing
crossover.
No
Turn off power supply to the unit.
Close installer supplied cold water
shut-off valve (if none installed,
install before proceeding).
Open all hot water taps supplied by
the unit.
Wait 5 minutes and check all taps.
Any water running is a sign of
plumbing crossover.
To check for a plumbing crossover:
No
NOTE 1
Is
an anti-scald or
tempering valve
installed?
No
No
An anti-scald or tempering valve
automatically mixes cold water even
when the faucet handle is turned to
full hot. These devices are usually
adjustable so the cold mix can be
turned off completely. Alternatively,
the temperature of the heater can be
increased if hotter water is needed.
Yes
For the final three steps,
set the unit to diagnostic
mode by pressing and
releasing the UP and
DOWN buttons
simultaneously.
Does
i### match the
actual inlet
temp.?
Does
o### match the
actual outlet
temp.?
With
water flowing, does
F##.# show
00.0?
Yes Yes
No
Go to step 6 of
Check the
Thermistor
Go to step 6 of
Check the
Thermistor
Go to step 4 of
Check the Flow
Meter
No No Yes
Is control fuse
open?
Replace Fuse See Advanced
Troubleshooting
Yes No
34
Advanced Troubleshooting:
WARNING: Serious bodily injury or death may occur if the following warnings are
ignored.
This following portion of this section is intended for use by a QUALIFIED
ELECTRICIAN.
All circuit breakers must be turned off at the main panel before the cover of the unit
is removed.
This troubleshooting section will cover all the points that need to be checked from an
electrical standpoint to ensure that the Hubbell tankless booster heater is working correctly
and to determine which component may need to be replaced.
Tools Required:
Phillips screwdriver
Clamp multi-meter able to read voltage and amperage (amperage readings require a
clamp type meter).
Thermometer
Pre-Operational Procedures:
1. With power to the unit turned ON, verify that the configuration settings are correct in
accordance with the Temperature Controller User Interface Instructions in Section IV.
2. TURN OFF POWER AT THE MAIN PANEL.
3. Remove the cover by unscrewing the screws located on all sides of the unit.
4. Verify that the main power feed is properly connected to the power distribution block
or magnetic contactor, as applicable.
5. Verify all connections are tight.
Check the Power Supply to the Unit:
1. Turn on power to the unit from the main panel.
2. Check the incoming voltage between each phase at the line side of the power
distribution block or magnetic contactor, as applicable.
3. If no voltage is present between all phases, verify that the breakers or disconnect on
the main panel have been turned on.
4. If the breakers are on and there is still no voltage present or if the incorrect voltage or
no voltage is present between any two phases, contact an electrician to troubleshoot
the feed.
5. If all voltage readings are acceptable, proceed to Check the Transformer.
Check the Transformer:
1. The transformer is utilized on units with supply voltages above 240 volts to supply a
reduced voltage capable of powering the temperature controller.
2. If the display is lit or the unit is not equipped with a transformer (208 and 240 volt
units), proceed to Check the Hi-Limit Thermostats.
3. Check the voltage on the primary side of the transformer.
4. If there is no voltage present, check the wiring and connections to the primary side of
the transformer from the power distribution block or magnetic contactor, as
applicable.
5. Check the voltage on the secondary side of the transformer.
6. If the secondary voltage does not conform to the table below, replace the transformer.
7. If all voltage readings are acceptable, proceed to Check the Hi-Limit Thermostats.
35
Primary Voltage
Secondary Voltage (±5%)
380
207
415
221
440
214
480
234
575
206
600
215
Note: The secondary voltage listed in the transformer is based on the transformer being used
at full capacity. Because there is essentially “no load” on the transformer, the secondary
voltage will be higher than the voltage listed on the transformer. This “regulation” varies
from 8.4% to 12% depending on the primary voltage and the transformer used.
Check the Hi-Limit Thermostats:
1. The unit is supplied with safety hi-limit thermostats mounted on the plate that holds
the heating chamber in place. In single phase units with no contactor, these
thermostats allow the power from one phase of the terminal block to flow to the
heating element. If the hi-limit thermostat fails it will not supply the heating element
with power and therefore the heating element will not turn on and produce heat. In
three-phase units or any unit with a magnetic contactor, the thermostats are wired in
series to a magnetic contactor coil. If any hi-limit thermostat fails it will not supply
power to the contactor coil and therefore no power will be supplied to any heating
elements.
2. For single-phase units, check the voltage between the left-hand metal connection point
of the thermostat and the metal plate. If shrink-wrap is present around the metal
connection point to the hi-limit thermostat, cut back the shrink-wrap with a knife to
expose the metal connection. A voltage reading around 120V should be indicated
since this component is being fed by one leg of the electrical power coming off the
terminal block. Perform this step on the left-hand connection of each hi-limit
thermostat then again on the right-hand connection of each hi-limit thermostat.
3. If there is no voltage at the bottom of any hi-limit thermostat, then check the wiring
and connections between that hi-limit thermostat and the power distribution block.
4. If correct voltage is present at the bottom of the hi-limit thermostat but no voltage is
present at the top of the thermostat, then that hi-limit thermostat needs to be replaced.
5. If correct voltage is present on the top and bottom continue to Check the Thermistor.
6. For three-phase units, if the magnetic contactor is pulled in, continue to Check the
Thermistor. Otherwise, starting at the left-hand connection of the lowest hi-limit
thermostat, check the voltage between the metal connection point of the thermostat
and the metal plate.
7. A voltage reading around 120V should be indicated. If no voltage is present at this
point, check the wiring and connections to this hi-limit thermostat from the magnetic
contactor or transformer, as applicable.
8. If correct voltage is present, check the voltage at the right-hand side of the thermostat,
then the left-hand side of the thermostat above and continue this pattern to the
uppermost thermostat.
36
9. If at any point there is voltage on the left-hand side and there is no voltage on the
right-hand side of the same thermostat, replace that hi-limit thermostat.
10. If at any point there is voltage on the right-hand side of a thermostat and there is no
voltage on the left-hand side of the thermostat above it, check the wiring and
connections.
11. If all voltage readings are good and the contactor is not pulled in, check the wiring and
connections between the right-hand side of the uppermost thermostat and the magnetic
contactor coil.
12. If the wiring and connections are good, replace the magnetic contactor.
Check the Thermistor:
1. The thermistor is a temperature sensing device that changes resistance with changes in
temperature. It is designed to register 150,000 at 77°F (25°C).
2. Set the unit to diagnostic mode by pressing and releasing the UP and DOWN buttons
simultaneously.
3. With a thermometer, measure the temperature of the cold water and hot water at a
fixture.
4. Compare the displayed inlet temperature (i###) to the measured cold water
temperature and the displayed outlet temperature (o###) to the measured hot water
temperature. If either of these readings is significantly different, continue with the
next step. Otherwise, proceed to
Check the Flow Meter.
5. At the right hand side of the temperature controller
are two terminal blocks. Disconnect the wires from
the uppermost terminal block (outlet thermistor).
Using the multi-meter probes with the setting at
OHMS or , place one probe on the end of one wire
and the other probe on the end of the other wire. An
ohms reading consistent with the chart below for the
approximate temperature of the water should be
indicated. NOTE: Alligator clips should be used.
Holding the wires in your hands will give a false
reading. Reconnect the wires.
Thermistor Chart (150,000 @ 77°F (25°C))
Temperature, °F (°C)
Ohms,
50 (10.0)
299,516
60 (15.6)
229,905
70 (21.1)
178,244
80 (26.7)
139,501
90 (32.2)
110,157
100 (37.8)
87,723
110 (43.3)
70,418
120 (48.9)
56,957
130 (54.4)
46,402
140 (60.0)
38,062
150 (65.6)
31,425
160 (71.1)
26,106
170 (76.7)
21,816
180 (82.2)
18,333
190 (87.8)
15,489
6. Repeat the above step with the lower terminal block (inlet thermistor).
Outlet
Thermistor
Inlet
Thermistor
0
50,000
100,000
150,000
200,000
250,000
300,000
350,000
50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
37
7. If either of these readings is not consistent with the chart (within ±10,000), replace
that thermistor.
8. If all ohms readings are acceptable, proceed to Check the Flow Meter.
Check the Flow Meter:
1. Set the unit to diagnostic mode by pressing and releasing the UP and DOWN buttons
simultaneously.
2. Turn on a hot water tap at a fixture that will ensure a good flow rate through the unit.
3. If the flow rate on the display reads ‘F00.0’ then continue with the next step.
Otherwise, proceed to Check the Temperature Controller.
4. Verify that the wiring from the flow switch is connected to the control board in the
order WHITE/GREEN/BROWN from left to right.
5. With no flow on the unit, using the multi-meter probes with the setting at Volts
Direct Current, place one probe on the terminal block where the WHITE wire is
connected (F1) and the other probe where the BROWN wire is connected (F3). A
voltage reading in the appropriate range (9V) should be indicated.
6. If the voltage reading is not in the appropriate range (9V), replace the temperature
controller.
7. Turn on a hot water tap at a fixture that will ensure a good flow rate through the unit
and using the multi-meter probes with the setting at Volts Direct Current, place one
probe on the terminal block where the WHITE wire is connected (F1) and the other
probe where the GREEN wire is connected (F2). A voltage reading in the appropriate
range (4.5V) should be indicated.
8. If the voltage reading is not in the appropriate range (4.5V), replace the flow meter.
9. If all voltage readings are acceptable, proceed to Check the Temperature Controller.
Check the Temperature Controller:
1. At the top of the temperature controller there are 4 sets of terminal blocks. Verify the
wiring is correct as indicated in the wiring diagram specific to the model.
2. Check the voltage between the terminal block where the BLACK wire is connected
(this will be the leftmost terminal) and the metal heater chamber cover. A voltage
reading in the appropriate range (120V) should be indicated.
3. If no voltage is present, verify that the BLACK wire in the terminal block is properly
tightened and verify that the opposite end, this will be a RED wire, is properly
connected to the power distribution block, magnetic contactor, or transformer, as
applicable.
4. Check the voltage between the terminal block where the BLACK wire is connected at
the second terminal from the left and the metal heating chamber cover. A voltage
reading in the appropriate range (120V) should be indicated. Repeat this step for each
of the wires connected to the terminal blocks.
5. If no voltage is present, verify that the BLACK wire in the terminal block is properly
tightened and verify that the opposite end, this will be a RED wire, is properly
connected to the power distribution block, magnetic contactor, or transformer, as
applicable.
6. If voltage is present where the black wires connect to the terminals and there is no
display, replace the temperature controller.
7. Check the voltage between each additional wire from left to right and the metal
heating chamber cover. A voltage reading in the appropriate range (one half of the
incoming power voltage, i.e. if the incoming power is 480V, then the reading should
be 240V) should be indicated.
8. If no voltage is present, verify that the BLACK wires in the terminal block are
properly tightened and verify that the opposite ends of the BLACK wires are properly
jumpered to the previous BLACK wire connection terminal or properly connected the
magnetic contactor, as applicable.
38
9. Turn on a hot water tap at a fixture that will ensure a good flow rate through the unit
and set the temperature at the highest setting so the unit calls for full power.
10. Check the voltage between the terminal block where the first YELLOW wire is
connected from left to right and the metal heating chamber cover. A voltage reading in
the appropriate range (one half of the incoming power voltage, i.e. if the incoming
power is 480V, then the reading should be 240V) should be indicated. Repeat this step
for each of the YELLOW wires.
11. If no voltage is present on any one of the YELLOW wires, replace the temperature
controller.
12. If all voltage readings are acceptable, proceed to Check the Triacs (Step 1).
Check the Triacs (Step 1):
1. The triacs are the switching mechanism for turning the
heating elements on and off.
2. Turn on a hot water tap at a fixture that will ensure a good
flow rate through the unit and set the temperature at the
highest setting so the unit calls for full power.
3. Check the voltage between the two wires that are connected
to the top of the heating element. A voltage reading in the
appropriate range (equal to the incoming line voltage) should
be indicated.
4. If no voltage is present on any heating element, the triac
connected to that element should be replaced.
5. If all voltage readings are acceptable, proceed to Check the Heating Elements.
Check the Heating Elements:
1. To check the heating element the amperage draw from each
heating element must be verified. To do this the unit must be
operating.
2. Turn on the hot water to ensure a good flow rate through the
unit and set the temperature at the highest setting.
3. Using a clamp-on multi-meter, clamp the meter around one
of the RED wires going to the lowest heating element. The
reading should be as indicated (±5%) based on the specific
model listed in the Electrical Specification table in the
Installation section.
4. Repeat for all the heating elements.
5. If any amp reading is not within the range as indicated in the
chart, that heating element should be replaced.
6. If all readings are within range continue to Check the Triacs (Step 2).
Check to Triacs (Step 2):
1. Turn off the flow of hot water.
2. Using a clamp-on multi-meter, clamp the meter around one of the RED wires going to
the lowest heating element (same as in step 3 of Check the Heating Elements). The
reading should be zero. Repeat for all the heating elements.
3. If any reading is not zero with the hot water turned off, then that triac should be
replaced.
Contact the Factory:
1. If you were unable to determine the problem from the above troubleshooting, please
have the electrician contact the factory.
39
SECTION VI SERVICING & REPLACEMENT OF PARTS
WARNING: Serious bodily injury or death may occur if the following warnings are
ignored.
This following portion of this section is intended for use by a QUALIFIED
ELECTRICIAN OR PLUMBER.
All circuit breakers must be turned off at the main panel before the cover of the unit
is removed.
When any maintenance is performed on the water heater that may introduce air into
the unit, it is important to purge the air out of the lines before allowing the unit to
power up. See Checking for Leaks and Purging Air in Section III.
Heating Element:
Disconnect power.
Shut off cold water inlet and hot water outlet valves.
Drain unit.
Remove cover.
Disconnect the RED power leads from the top of the
element to be replaced.
Unscrew the element from the heating chamber coupling.
Install the replacement heating element by screwing it into the
heating chamber coupling.
NOTE: Verify that the o-ring is installed onto the heating
element prior to installation.
Re-connect the power leads to the element terminals.
Re-install cover.
Open the cold water inlet and hot water outlet valves.
Bleed air from the unit. See Checking for Leaks and Purging
Air in Section III.
Turn on power.
Hi-Limit Switch:
Disconnect power.
Remove cover. Disconnect power.
Remove cover.
For single-phase models, disconnect the leads from the heating element and power
distribution block that connect to the hi-limit switch to be replaced. For three-phase
units, disconnect the wires from the hi-limit switch to be replaced.
NOTE: The replacement hi-limit switch comes with power leads attached. For single-
phase units, power leads should not be disconnected from the hi-limit switch. For
three-phase units, disconnect the attached power leads on the replacement piece.
Remove the two (2) screws securing the hi-limit switch to the heating chamber cover.
Remove the hi-limit switch.
Spread a pea sized amount of the conductive thermal paste included
with the replacement kit on the back of the hi-limit switch (the
portion to be installed against the heating chamber tube).
Install the hi-limit switch to the heating chamber cover with the two
(2) screws previously removed.
For single-phase units, connect the supplied power leads to the
heating element and the power distribution block. For three-phase
units, connect the wires previously disconnected in the prior step.
Re-install cover.
Turn on power.
40
Inlet Thermistor:
Disconnect power.
Remove cover.
Disconnect inlet thermistor wires from the controller.
Cut the tie-wrap securing the inlet thermistor to the
inlet pipe and remove the inlet thermistor.
Spread a pea sized amount of the conductive thermal
paste included with the replacement kit on the inlet
pipe where the replacement inlet thermistor is to be installed.
Secure the inlet thermistor to the inlet pipe with a new tie-wrap.
Connect the inlet thermistor wires to the controller.
Re-install cover.
Turn on power.
Outlet Thermistor:
Disconnect power.
Remove cover.
Disconnect outlet thermistor wires from the
controller.
Cut the tie-wrap securing the outlet thermistor
insulation.
NOTE: Save the insulation to cover the
replacement outlet thermistor.
Remove the aluminum tape securing the outlet
thermistor and remove the outlet thermistor.
Spread a pea sized amount of the conductive thermal paste included with the
replacement kit on the outlet pipe where the replacement outlet thermistor is to be
installed.
Secure the outlet thermistor to the outlet pipe with a new piece of aluminum tape.
Position the outlet thermistor such that the wires are facing towards the top.
Secure the outlet thermistor insulation around the outlet
thermistor with a new tie-wrap.
Connect the outlet thermistor wires to the controller.
Re-install cover.
Turn on power.
Temperature Controller:
Disconnect power.
Remove cover.
Mark the wires going to the controller so they can be re-connected in the same places
upon replacement.
Disconnect all the wires from the controller.
NOTE: The display may need to be removed to access the wires from the flow meter.
The display can be removed by removing the four (4) screws securing the display to the
controller standoffs and then pulling the display from the socket.
Remove the two (2) screws securing the temperature controller to the controller stand.
Install the replacement controller with the two (2) screws removed in the last step.
Re-connect the wires to the temperature controller in the same locations they were
previously disconnected from.
Re-install cover.
Turn on power.
Outlet
Thermistor
Inlet
Thermistor
Inlet
Thermistor
Temperature
Controller
41
Triac:
Disconnect power.
Remove cover.
Disconnect the wire from the heating element, the wire from the
power distribution block or magnetic contactor (as applicable), and
the wire from the controller for the triac to be replaced.
NOTE: Replacement triacs come with replacement wires attached.
Remove the two (2) nuts securing the triac to the heatsink and
remove the triac.
Spread a pea sized amount of the conductive thermal paste included with the
replacement kit on the back of the triac to be installed.
Install the replacement triac to the heatsink with the two (2) nuts removed previously.
Connect the RED wire to the heating element, the BLACK wire to the power
distribution block or magnetic contactor (as applicable), and the YELLOW wire to the
controller.
Re-install cover.
Turn on power.
Flow Meter:
Disconnect power.
Shut off cold water inlet and hot water outlet
valves.
Drain unit.
Remove cover.
Disconnect the flow meter wires from the
controller.
NOTE: The display may need to be removed to
access the wires from the flow meter. The
display can be removed by removing the four (4)
screws securing the display to the controller
standoffs and then pulling the display from the socket.
Disconnect the cold water supply pipe from the union fitting.
Unscrew the union connection and coupling assembly from the flow meter.
Unscrew the flow meter from the inlet pipe.
Screw the replacement flow meter into the inlet pipe.
NOTE: Pipe dope must be used to seal the connection.
NOTE: When installing flow meter make sure arrow is pointing in the direction of the
water flow (towards triac plate).
Screw the union connector and coupling assembly into the replacement flow meter.
NOTE: Pipe dope must be used to seal the connection
Re-connect the cold water inlet piping to the union connector.
Connect the flow meter wires to the controller. From left to right, WHITE / GREEN /
BROWN.
Re-install cover.
Open the cold water inlet and hot water outlet valves
Bleed air from the unit. See Checking for Leaks and Purging Air in Section III.
Turn on power.
42
Magnetic Contactor:
Disconnect power.
Remove cover.
Mark the wires going to the
magnetic contactor so they can be
re-connected in the same places
upon replacement.
Disconnect all the wires from the
magnetic contactor.
Remove the two (2) screws securing
the magnetic contactor to the base.
Install the replacement magnetic contactor with the two (2) screws removed in the last
step.
Re-connect the wires to the magnetic contactor in the same locations they were
previously disconnected from.
Re-install cover.
Turn on power.
Transformer:
Disconnect power.
Remove cover.
Mark the wires going to the transformer so
they can be re-connected in the same places
upon replacement.
Disconnect all the wires from the
transformer.
Remove the two (2) screws securing the
transformer to the base.
Install the replacement transformer with the
two (2) screws removed in the last step.
Re-connect the wires to the transformer in the same locations they were previously
disconnected from.
Re-install cover.
Turn on power.
Control Flow:
Disconnect power.
Remove cover.
Twist fuse and pull from fuse holder.
Insert new fuse in holder and twist to lock in place.
Reinstall cover.
Turn on power.
43
SECTION VII PARTS LIST
Category Description Hubbell P/N
Plumbing Dielectric Union- 3/4" Sweat x 3/4"FNPT DIELECTRIC UNION
Dielectric Union- 1" Sweat x 1"FNPT DIELECTRIC UNION 1"
Heating Chamber: 3 Element, Low Flow TK3-FM
Heating Chamber: 3 Element, High Flow TK3-FMHF
Heating Chamber: 6 Element, Low Flow TK6-FM
Heating Chamber: 6 Element, High Flow TK6-FMHF
Filter Screen for Inlet SCREEN TK
Bronze Pressure Reducing Valve N45BU
Temperature and Pressure Gauge T405
Water Treatment System (blended phosphate) HBW-CLEAR
Replacement Cartridge for Water Treatment RSC-10
Elements 4500 Watts @ 240 Volts, 8.5" long N1315-4500
(with O-ring) 5500 Watts @ 240 Volts, 8.5" long N1315-5500
7000 Watts @ 240 Volts, 12" long N1315-7000
8000 Watts @ 240 Volts, 12" long N1375-8000
9000 Watts @ 240 Volts, 12" long N1375-9000
6000 Watts @ 480 Volts, 12" long N1315-6000T4
7000 Watts @ 480 Volts, 12" long N1315-7000T4
8000 Watts @ 480 Volts, 12" long N1375-8000T4
9000 Watts @ 480 Volts, 12" long N1375-9000T4
7000 Watts @ 440 Volts, 12" long N1315-7000T5
8000 Watts @ 440 Volts, 12" long N1375-8000T5
9000 Watts @ 440 Volts, 12" long N1375-9000T5
7000 Watts @ 346 Volts, 12" long N1315-7000T6
8000 Watts @ 346 Volts, 12" long N1375-8000T6
9000 Watts @ 346 Volts, 12" long N1375-9000T6
8000 Watts @ 208 Volts, 12" long N1375-8000R
Extra O-Ring O RING SGB
Electrical Thermistor (with wire leads) USP9509
Auto Reset Hi-Limit 200°F (with wire leads) L93
Temperature Control Board TK2000
Digital Display TKD2000
Power Distribution Block: 3 Pole 16023-3
Power Distribution Block: 2 Pole 67512
Transformer, 50VA, 380V - 185V B050-3351-3
Transformer, 50VA, 480V - 208V B050-3299-3
Transformer, 50VA, 600V - 195V B050-3350-3
Magnetic Contactor, 40A (Res.), 208/240V Coil C25DNF330B
Magnetic Contactor, 50A (Res.), 208/240V Coil C25DNF340B
Magnetic Contactor, 65A (Res.), 208/240V Coil C25DNF350B
Magnetic Contactor, 75A (Res.), 208/240V Coil C25FNF360B
Magnetic Contactor, 90A (Res.), 208/240V Coil C25FNF375B
Triac, 600V (with wire leads) TG40E60
Triac, 800V (with wire leads) TG40E80
Flow Meter (1/2" NPT, 0.2-8 GPM) TK FLOW BR
Flow Meter (1" NPT, 0.5-40 GPM)
VT2511MSHNP000
Control Fuse
LGR-3
Miscellaneous Overlay cover for TKD2000 TANKLESS OVERLAY
44
SECTION VIII WARRANTY
MANUFACTURER’S LIMITED WARRANTY
1. PRODUCT WARRANTY: Hubbell warrants the Hubbell Tankless Booster Heater and
its components as manufactured by Hubbell (the "Product") to be free from defects in
materials and workmanship, under normal use and service for the period of time identified
below beginning from the date of installation, provided that the Product is (i) installed within
sixty (60) days from date of shipment from Hubbell and (ii) installed by a licensed
electrician and plumber (specific proof required) and maintained in accordance with
Hubbell's written instructions.
HEATING CHAMBER: Five (5) years
ELECTRICAL COMPONENTS: One (1) year
REPLACEMENT PARTS: Thirty (30) days
SUCH WARRANTIES DO NOT COVER:
Product failure caused by liming, sediment buildup, chemical corrosion,
chlorine/chloride corrosion, or freezing.
Product failure caused by the failure to remove air from system prior to or during
operation.
Product misuse, tampering or misapplication, accidental damage, improper installation
or the application of improper voltage.
Costs incurred for shipping, delivery, handling, and/or administrative charges.
Product failure due to lightening, flood or other natural or manmade calamities.
Labor charges of any kind.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ANY OTHER
WARRANTY, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE OR PATENT OR OTHER INTELLECTUAL PROPERTY RIGHT
INFRINGEMENT.
2. LIMITATION OF REMEDIES AND DAMAGES: Hubbell's liability and Buyer's
exclusive remedy hereunder will be limited solely, at Hubbell's option, to repair or
replacement by the Hubbell Service Center with respect to any claim made within the
applicable warranty period referred to above. Without limiting the generality of the
foregoing, all warranty items shall be returned by Buyer, at its sole expense, to the Hubbell
Service Center for replacement or repair. Hubbell reserves the right to accept or reject any
such claim in whole or in part. Hubbell will not accept the return of any product without
prior written approval from Hubbell, and all such approved returns shall be made at Buyer's
sole expense. HUBBELL WILL NOT BE LIABLE, UNDER ANY CIRCUMSTANCES,
FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING BUT NOT
LIMITED TO LABOR COSTS OR LOST PROFITS RESULTING FROM THE USE OF
(OR INABILITY TO USE) THE PRODUCTS OR FROM THE PRODUCTS BEING
INCORPORATED IN OR BECOMING A COMPONENT OF ANY OTHER PRODUCT
OR GOODS.
3. FURTHER LIMITATIONS AND EXCLUSIONS AFFECTING YOUR
WARRANTY: This warranty is void if the product is not installed in accordance with
relevant, local electrical and plumbing codes and in accordance with the installation
instructions specified by the manufacturer. Local codes will override manufacturer’s
instructions at the time of installation and if additional installation parts are required, the
costs will be the responsibility of Buyer. Product nameplate identifying the model and serial
number must be affixed to the unit and legible for the warranty to be exercised. Product
without the nameplate is excluded from warranty consideration. Buyer hereby accepts the
45
entire responsibility for ascertaining whether they have sufficient electrical power to operate
our Tankless Water heaters as indicated in our specifications which are readily available at
our website, in our brochures and contained in the shipping box for installers to read before
installation. If Buyer has purchased without first ascertaining the cost for installation or the
necessary power available for operation, Hubbell at its sole and complete discretion may
allow a return and grant a refund less freight and less 30% of the retail price as a restocking
fee. The refund will be conditioned upon a determination by Hubbell after inspection of the
Product being returned (either unopened or in the original shipping box and packing) that the
Product has not been damaged. This request and for this reason only must be made within 30
calendar days of receipt of the Product.
AFTER 30 CALENDAR DAYS FROM DATE OF PURCHASE THERE WILL BE NO
RETURNS WHATSOEVER. BUYER ACCEPTS ALL SALES AS FINAL. ANY
ALTERATION TO THE PRODUCT VOIDS ALL WARRANTIES. HUBBELL IS NOT
RESPONSIBLE FOR ANY OTHER CHARGE OR EXPENSE INCURRED OTHER
THAN THE ORIGINAL PURCHASE PRICE OF THE PRODUCT. Hubbell shall not be
liable for consequential, special, incidental or contingent expenses or damages arising
directly or indirectly from any defect in or use of the Product nor will Hubbell be liable for
any water damage arising directly or indirectly from the use of the Product or from the
failure of or defect in any component part or connecting plumbing. Hubbell and Buyer agree
to these and the above terms in their entirety and accept all sales as final without recourse to
a credit card company and hereby agree that this Manufacturer's Limited Warranty shall be
governed by the laws of the State of Connecticut any and all actions arising from or relating
to this Manufacturer’s Limited Warranty and any aspects of the Product shall be brought in a
court of competent jurisdiction in Fairfield County, Connecticut.
WARRANTY PROCEDURE
4. PARTS REPLACEMENT PROCEDURE (Under Warranty within 1 Year): Have
your licensed electrician determine the exact parts that are defective and require
replacement. Please note that technical support is available for qualified technicians only
(licensed electricians and/or plumbers). Technical support that involves potentially
dangerous electrical conditions is not available to an unqualified person.
When contacting Hubbell, please be sure that the technician has read the “Operation and
Maintenance Manual” and has written down all the data from the Advanced Troubleshooting
Section.
If, at the sole discretion of Hubbell, a component requires repair or replacement under the
terms of this Manufacturer’s Limited Warranty, the part must be purchased and paid for
under our “Bill and Credit” terms and will be shipped via standard ground delivery. All
shipping charges are not included and are the responsibility of the Buyer. If faster shipping
service is desired, the Buyer must select and pay for same.
The replacement part purchased under our “Bill and Credit” terms is purchased via credit
card and upon return of the defective parts Hubbell will determine the cause of failure, and if
under warranty will issue a full credit less shipping charges. The returned part must be
received by Hubbell within thirty (30) days of shipment of the replacement part. Hubbell
will evaluate the returned part within ten (10) days, and if determined to be defective and
covered under terms of this warranty, full credit for the part will be issued.
Return warranty parts to: Hubbell Electric Heater
ATTN: Tankless Warranty
45 Seymour Street
Stratford, CT 06615
46
NOTES
47
NOTES
48
P.O. BOX 288
STRATFORD, CT 06615-0288
PHONE: (203) 378-2659
FAX: (203) 378-3593
INTERNET: http://www.hubbellheaters.com

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