HYDRO-HEATER Sanitizing Sink Heaters Food Rethermalizers/Bain-Marie Heaters Installation & Operating Manual I&W #07.05.133.00 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 are 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 Instructions .....................................1 Model Descriptions .......................................................3 All Models ..............................................................3 3CS2 Models...........................................................3 FR2 Models.............................................................3 Specifications.................................................................3 Plug Configurations ................................................3 Electrical Rating Chart - 3CS2 Models ..................4 Electrical Rating Chart - FR2 Models ....................5 Sizing Information ..................................................6 Dimensions..............................................................6 Electrical .................................................................6 Installation.....................................................................7 Plumbing .................................................................7 Operation.......................................................................9 Start-Up Procedures ................................................9 Minutes to Heat Table ...........................................11 Maintenance ................................................................12 General ..................................................................12 Draining & Cleaning All Models..........................12 Optional Power Flush Cleaning............................13 Deliming Instructions............................................14 Hatco Limited Warranty............................................16 Authorized Parts Distributors....................Back Cover IMPORTANT OWNER INFORMATION Record the model number, serial number (identification plate located on the lower right hand side, front corner of the unit), voltage, and purchase date of your HydroHeater 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 3CS2 Hydro-Heater Sanitizing Sink Heaters and FR2 Hydro-Heater Food Rethermalizers/Bain-Marie Heaters are designed to supply temperature-controlled water to a holding vessel (sink or tank) located above the heater. Water flows by natural convection from the holding vessel directly into a tubular water chamber with heating elements uniquely wrapped on the outside of the flow tube. The heating elements do not come in direct contact with the water reducing sediment and lime buildup on the element, resulting in longer life. The heated water flows upward and returns to the holding vessel. A special electronic controller maintains the setpoint temperature assuring a responsive and efficient operation. The unit electrical and plumbing connections are factory-assembled and ready for installation. This manual provides the installation, safety and operating instructions for the Hydro-Heater Form No. HHM-1103 i Sanitizing Sink Heaters and Food Rethermalizers/BainMarie Heaters. We recommend all installation, operating and safety instructions appearing in this manual be read prior to installation or operation of your Hatco HydroHeater. Safety instructions that appear in this manual and the words WARNING after a warning symbol or CAUTION printed in bold face are very important. WARNING means there is the possibility of serious CAUTION injury or death to yourself or others. minor or moderate means there is the possibility of injury. CAUTION without the symbol signifies the possibility of equipment or property damage only. Hatco Hydro-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 INSTRUCTIONS IMPORTANT! Read the following important safety instructions to avoid personal injury or death, and to avoid damage to the equipment or property. WARNINGS Hatco 3CS2 and FR2 series units are designed for commercial use only by properly trained personnel! To avoid any injury or damage to the unit read and follow the instructions contained in this manual. Do not operate this equipment unless you have read and completely understood the contents of this manual. To avoid any electrical shock hazard, or physical burns turn the power OFF at the fuse disconnect switch/circuit breaker or unplug the unit from the power source and allow to cool completely before performing any maintenance or cleaning. For proper electrical installation conforming to local electrical codes consult a licensed electrical contractor. Improper electrical connections may cause a serious electrical shock injury or may damage the unit. For proper plumbing installation conforming to local plumbing codes consult a licensed plumbing contractor. Units equipped with a power cord and plug should be plugged into an electrical outlet of the correct voltage, size and plug configuration. If the plug and receptacle do not match, contact a qualified electrician to determine the proper voltage and size and install the proper electrical outlet. To prevent any injury or damage to the unit do not pull unit by power cord. To prevent any injury, discontinue use if power cord is frayed or worn. Units are designed to heat water up to 190ºF (88ºC). DO NOT set temperature controls to a setting higher than 190ºF (88ºC). Water over 190°F (88°C) is very active and could splash onto operator causing serious burns or injury. To avoid any injury or damage to the unit use only Authorized Hatco Service Agents to perform any temperature display changes. 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 800-690-2966 or International fax 414-671-3976. 1 Form No. HHM-1103 WARNINGS 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 Parts when service is required. Genuine Hatco Replacement Parts are specified to operate safely in the environments in which they are used. Some aftermarket or generic replacement parts do not have the characteristics that will allow them to operate safely in Hatco equipment. It is essential to use Hatco Replacement Parts when repairing Hatco equipment. Failure to use Hatco Replacement Parts may subject operators of the equipment to hazardous electrical voltage, resulting in electrical shock or burn. CAUTIONS Water in the unit and holding vessel is very hot. Wear protective gloves and proper attire when operating to avoid injury. Do not use extension pipes on the inlet and outlet connections on heater units. Poor performance or unsafe conditions may occur. Unit is not weatherproof. For safe and proper operation locate the unit indoors where the ambient air temperature is constant and is a minimum of 70°F (21°C). IMPORTANT SAFETY INSTRUCTIONS IMPORTANT! Read the following important safety instructions to avoid personal injury or death, and to avoid damage to the equipment or property. CAUTIONS CAUTIONS Do not overtighten unions or nuts. Overtightening may cause leaks. Do not turn the electrical current to the unit on until the holding vessel has been filled with water or element burnout may occur. Inspect daily for lime and sediment buildup inside unit. Excessive amounts can affect unit performance and reduce the operating life of the unit. To avoid any damage to the heater unit use only delimers that are non-corrosive to aluminum, brass and stainless steel. Damage caused by corrosive material or solutions is not covered under warranty. Drain holding vessel with power to the unit off, or element burnout may occur. Water Quality Requirements - Incoming water in excess of 3.0 grains of hardness per gallon (GPG) (.75 grains of hardness per liter) must be treated and softened before being supplied to a Hydro-Heater. To maintain efficiency and to extend the operating life "regular deliming and cleaning" must be performed when water supplied contains over 3.0 GPG (.75 GPL). To avoid any damage to units with Auto-fill, do not exceed the following: Incoming Water Temperature: 140°F (60°C) Incoming Water Pressure: 80 PSI (550 kPa) Form No. HHM-1103 2 MODEL DESCRIPTIONS ALL MODELS The Hydro-Heater mounts to the underside of a holding vessel, leaving the entire vessel area free. Units are shipped ready to install with all gaskets and fittings. Hydro-Heaters include a stainless steel front, powder coated body, a low-water cut-off system and a convenient drain outlet. 3CS2 MODELS The Hatco 3CS2 model heaters are designed for use with any manual dishwashing operation. The 3CS2 heater maintains sanitizing rinse water of 180ºF (82ºC) by using a special electronic temperature controller and "free flow" technology, assuring a responsive and efficient operation. Figure 1. Hydro-Heater FR2 MODELS The Hatco FR2 model heaters are designed to be used with a Bain-Marie or Food Rethermalizer to heat or hold foods at temperatures between 140ºF and 190ºF (60° - 88ºC). The desired holding temperature is maintained by a special electronic controller and "free flow" technology, assuring a responsive and efficient operation. Figure 2. Hydro-Heater with Auto-Fill SPECIFICATIONS PLUG CONFIGURATIONS WARNING Units equipped with a power cord and plug should be plugged into an electrical outlet of the correct voltage, size and plug configuration. If the plug and receptacle do not match, contact a qualified electrician to determine the proper voltage and size and install the proper electrical outlet. Model FR2-3 FR2-4 208 Volt NEMA 6-20P NEMA 6-30P 240 Volt NEMA 6-20P NEMA 6-30P NEMA 6-20P NEMA 6-30P Figure 3. Plug Configurations 3 Form No. HHM-1103 SPECIFICATIONS ELECTRICAL RATING CHART ­ 3CS2 MODELS Model 3CS2-3 3CS2-4 3CS2-6 3CS2-3 3CS2-4 3CS2-6 3CS2-3B 3CS2-4B 3CS2-6B 3CS2-3B 3CS2-4B 3CS2-6B 3CS2-8 3CS2-8 3CS2-9B 3CS2-9B 3CS2-12B 3CS2-12B Voltage 208 208 208 240 240 240 208 208 208 240 240 240 208 240 208 240 208 240 Kilowatts (kW) 3 4 6 3 4 6 3 4 6 3 4 6 8 8 9 9 12 12 Phase 1 1 1 1 1 1 3 3 3 3 3 3 1 1 3 3 3 3 Amps 14.5 19.2 28.8 12.5 16.7 25.0 8.4 11.2 16.7 7.3 9.6 14.5 38.4 33.3 25.0 21.7 33.4 29.0 Wire Sizing AWG* 12 12 10 12 12 10 14 14 12 14 14 12 8 8 10 10 8 10 Fuse or Circuit Breaker* 20 30 40 20 30 40 15 15 30 15 15 20 50 50 40 30 50 40 Shipping Weight 24 lbs. (11 kg) 24 lbs. (11 kg) 27 lbs. (12 kg) 24 lbs. (11 kg) 24 lbs. (11 kg) 27 lbs. (12 kg) 24 lbs. (11 kg) 24 lbs. (11 kg) 27 lbs. (12 kg) 24 lbs. (11 kg) 24 lbs. (11 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) 27 lbs. (12 kg) * Based upon NEC 2002 Code Based upon THHN wire rated 90ºC. Form No. HHM-1103 4 SPECIFICATIONS ELECTRICAL RATING CHART ­ FR2 MODELS Model FR2-3 FR2-4 FR2-6 FR2-3 FR2-4 FR2-6 FR2-3B FR2-4B FR2-6B FR2-3B FR2-4B FR2-6B FR2-8 FR2-8 FR2-9B FR2-9B FR2-12B FR2-12B Voltage 208 208 208 240 240 240 208 208 208 240 240 240 208 240 208 240 208 240 Kilowatts (kW) 3 4 6 3 4 6 3 4 6 3 4 6 8 8 9 9 12 12 Phase 1 ...