Electric Booster Water Heaters Imperial "S" Compact "C" Mini-Compact "MC" Series Installation & Operating Manual I&W #07.05.001.00 This manual contains important safety information concerning the maintenance, use and operation of this product. Failure to follow the instructions contained in this manual may result in serious injury. If you're unable to understand the contents of this manual, please bring it to the attention of your supervisor. Do not operate this equipment unless you have read and understood the contents of this manual. Este manual contiene importante información sobre seguridad concerniente al mantenimiento, uso y operación de este producto. Cualquier falla en el seguimiento de las instrucciones contenidas en este manual puede resultar en un serio daño. Si usted no puede entender el contenido de este manual por favor pregunte a su supervisor. No opere este equipo al menos que haya leído y comprendido el contenido de este manual. CONTENTS Important Owner Information...............................i Introduction ...........................................................i Important Safety Information ..............................1 Model Description ................................................4 All Models........................................................4 Imperial Models "S" Series..............................4 Compact Models "C" Series ............................4 Mini-Compact Models "MC" Series .................4 Specifications .......................................................5 Circuit Breaker & Fused Disconnect Switch Sizes ....................................................5 Sizing Chart for Low-Temp Dishmachines ......8 Booster Heater Sizing Chart .........................10 Capacity Charts.............................................14 Dimensions....................................................15 Installation ..........................................................16 Location.........................................................16 All Models......................................................17 Pressure & Temperature Relief Valves .........19 Pressure Reducing Valve..............................20 Temperature/Pressure Gauges .....................20 Blended Phosphate Water Treatment System (Optional) ........................20 Plumbing Connections ..................................20 Electrical-All Sizes and Voltages...................25 Operation ............................................................26 System Start-up.............................................26 Shut Down.....................................................24 Maintenance .......................................................26 General..........................................................27 Accessories ........................................................29 Troubleshooting .................................................30 Hatco Limited Warranty.....................................34 Authorized Parts Distributors ............Back Cover IMPORTANT OWNER INFORMATION Record the model number, serial number (identification decal located on the unit), voltage and purchase date of your Electric Booster Water Heater in the spaces below. Please have this information available when calling Hatco for service assistance. Model No. ________________________________ Serial No. ________________________________ Voltage __________________________________ Date of Purchase __________________________ Business Hours: 8:00 a.m. to 5:00 p.m. Central Standard Time (Summer Hours: June to September ­ 8:00 a.m. to 5:00 p.m. C.D.T. Monday through Thursday 8:00 a.m. to 2:30 p.m. C.D.T. Friday) Telephone: (800) 558-0607; (414) 671-6350 Fax: (800) 690-2966 (Parts & Service) (414) 671-3976 (International) 24-Hour 7-Day Parts & Service Assistance available in the United States and Canada by calling (800) 558-0607. Additional information can be found by visiting our web site at www.hatcocorp.com INTRODUCTION Hatco Electric Booster Water Heaters are designed for use with commercial dishwashers to boost the temperature of the regularly available hot water, usually 110°-150°F (43°-66°C) up to 180°F (82°C). Water at 180°F (82°C) can be used as sanitizing rinse water in commercial dishwashers in accordance with Health Codes, NSF Standard #5 and plumbing codes. All Hatco Booster Heaters are ready for electrical and plumbing service connections, with a pre-set ambient compensated immersion thermostat(s) and a high temperature limit switch. The service area is accessible from the front of the unit, permitting easy installation. This manual provides the installation, safety and operating instructions for the Booster Heaters. We recommend all installation, operating and safety Form No. EBOOSTERM-0406 i instructions appearing in this manual be read prior to installation or operation of your Booster Heaters. Safety instructions that appear in this manual after a warning symbol and the words WARNING or CAUTION printed in bold face are very important. WARNING means there is the possibility of serious personal injury or death to yourself or others. CAUTION means there is the possibility of minor or moderate injury. CAUTION without the symbol signifies the possibility of equipment or property damage only. Hatco Electric Booster Water Heaters are a product of extensive research and field testing. The materials used were selected for maximum durability, attractive appearance and optimum performance. Every unit is thoroughly inspected and tested prior to shipment. IMPORTANT SAFETY INFORMATION IMPORTANT! Read the following important safety instructions to avoid personal injury or death, and to avoid damage to the equipment or property. WARNINGS WARNINGS To avoid personal injury or damage to equipment, the booster heater must be installed by qualified, trained installers. Installation must conform to all local electrical and plumbing codes. Check with your local plumbing and electrical inspectors for proper procedures and codes. To avoid any injury or damage to the booster heater turn the power OFF at the disconnect switch/circuit breaker and allow to cool before performing any maintenance or adjustments. For proper electrical installation conforming to local electrical codes and the National Electrical Code (N.E.C.), consult a licensed electrical contractor. To avoid injury or damage to dishwashing equipment do not connect Hatco Electric Booster Water Heaters to domestic (consumer) dishmachines or other domestic utilized equipment. To avoid any injury or damage to equipment and to assure proper operation do not connect an expansion tank of any type to booster heater water lines. To avoid personal injury or damage to the Hatco Electric Booster Water Heater, only use plumbing material suitable for a minimum water temperature of 200°F (93°C). Materials used must meet National Sanitation Foundation (NSF) specifications and all local plumbing codes and regulations. To avoid personal injury or damage to the unit aftermarket covers must not be placed on or over the booster heater. Doing so can cause temperature and moisture build-up resulting in premature failure and electrical shock. It is essential to recognize that even though a water heater may be properly installed initially and approved, there always exists the possibility that unknowing individuals might alter or change the installation in a manner that would render it unsafe. Therefore, it is important that all safety programs provide some mechanism to assure that these installations are inspected periodically. 1 Hatco has always endorsed the use of safety equipment when using a booster water heater or storage-type water heater. Hatco booster heaters are shipped with a temperature/pressure relief valve at no extra charge. This valve must be installed into the marked opening provided in the tank. Valves supplied by Hatco are designed for high temperature commercial operation. Do not substitute Hatco supplied valves with valves designed for domestic operation. Temperature/pressure protective equipment should not be less than a combination temperature/pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of this equipment and meets the requirements for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22-1979. The temperature/pressure relief valve must be marked with a minimum set pressure not to exceed the marked hydrostatic test pressure of the booster heater as noted on the unit specifications. To avoid personal injury or damage to the equipment make sure the dishtable is strong enough to support the weight of the booster heater and water when installing with slide mounting brackets. To avoid personal injury or damage to the equipment, follow standard welding procedures when attaching sliderails to bottom of dishtable. Water in the unit is very hot. Wear protective gloves and proper attire when operating to avoid injury. To assure proper operation and avoid a possible unsafe condition, the booster heater must be installed in a horizontal position with the base parallel to the floor and the inlet connection at the lowest point. This product contains fiberglass, a product known to the state of California to cause cancer, birth defects or other reproductive harm. To avoid any injury or damage do not install the unit in an area where flammable liquids or combustible vapors are present. Form No. EBOOSTERM-0406 IMPORTANT SAFETY INFORMATION IMPORTANT! Read the following important safety instructions to avoid personal injury or death, and to avoid damage to the equipment or property. WARNINGS (CONTINUED) WARNINGS FOR INSTALLING PRESSURE AND TEMPERATURE RELIEF VALVES IN ACCORDANCE WITH AMERICAN NATIONAL STD. Z21.22-1979. Combination pressure and temperature relief valves with extension thermostats must be installed so that the temperature-sensing element is immersed in the water within the top 6" (152 mm) of the tank. They must be installed either in the hot outlet service line or directly in a tank tapping. Combination pressure and temperature relief valves that do not have extension elements must be mounted directly in a tank tapping located within the top 6" (152 mm) of the tank, and shall be adequately insulated and located so as to assure isolation from the flue gas heat or other ambient conditions that are not indicative of stored water temperature. TO AVOID WATER DAMAGE OR SCALDING DUE TO VALVE OPERATION, DRAIN PIPE MUST BE CONNECTED TO VALVE OUTLET AND RUN TO A SAFE PLACE OF DISPOSAL. Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length. Drain line must pitch downward from the valve and must terminate between 1-1/2" (38 mm) and 6" (152 mm) above the floor drain where any discharge will be clearly visible. The drain line shall terminate plain, not threaded, with material serviceable for temperatures up to 250°F (121°C) or greater. Excessive length, over 30' (9144 mm), or use of more than four elbows can cause a restriction and reduce the discharge capacity of the valve. No shut-off valve shall be installed between the relief valve and tank, or in the drain line. Valve lever must be tripped periodically to assure that waterways are clear. This device is designated for emergency safety relief and shall not be used as an operating control. The valves are set to relieve at 150 psi (1034 kPa) or when water temperature reaches 210°F (99°C). Read tag on valve for additional information. To avoid any injury or damage, the booster heater must only be serviced by qualified personnel. Valves supplied by Hatco are designed for high temperature commercial operation. Do not substitute Hatco valves with valves designed for domestic water heaters. Units are equipped with a High Temperature Limit Safety Switch that will shut the power off if the unit overheats. To avoid any injury to personnel or damage to the unit, contact an Authorized Hatco Service Agent if the High Temperature Limit Safety Switch cannot be reset or continues to trip. To avoid personal injury and to assure safe operation install the booster heater as close as possible to the commercial dishwasher. Employ recirculation if distance between booster and commercial dishwasher exceeds National Sanitation Foundation (NSF) specifications of five (5) linear feet (1524 mm). To avoid personal injury and avoid damage to the booster heater refer to BOOSTER HEATER SIZING CHART in this manual. If service is required on this unit, contact your Authorized Hatco Service Agent, or contact the Hatco Service Department at 800-558-0607 or 414-671-6350; fax 800-6902966 or International fax 414-671-3976. This product has no "user" serviceable parts. To avoid damage to the unit or injury to personnel, use only Authorized Hatco Service Agents and Genuine Hatco Replacement Parts when s ...