POWERMITE® GAS BOOSTER HEATER INSTALLATION, OPERATING, SERVICE AND PARTS MANUAL MODEL: PMG-60 58,000 BTU I&W #07.05.053.00 WATER HEATERS FOR OTHER THAN RECREATIONAL VEHICLE INSTALLATION ONLY CHAUFFE-EAU POUR INSTALLATION AUTRE QUE DANS DES VÉHICULES DE LOISIR UNIQUEMENT WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. AVERTISSEMENT: Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d'incendie ou d'explosion ou pour éviter out dommage matériel, toute blessure ou la mort. - Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil. - QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: · Ne pas tenter d'allumer d'appareil. · Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment. · Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur. · Si vous ne pouvez rejoindre le fournisseur, appelez le service des incendies. - L'installation et l'entretien doivent être assurés par un installateur ou un service d'entretien qualifié ou par le fournisseur de gaz. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. - WHAT TO DO IF YOU SMELL GAS: · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. · If you cannot reach your gas supplier, call the fire department. - Installation and service must be performed by a qualified installer, service agency or the gas supplier. CONTENTS Important Safety Instructions ............Front Cover Important Owner Information...............................i Introduction ...........................................................i Model Description ................................................1 System Overview .................................................1 Specifications .......................................................2 Dimensions......................................................3 Booster Heater Sizing Chart ...........................4 Installation ............................................................5 General............................................................5 Plumbing .........................................................8 Gas................................................................13 Electrical........................................................16 Operation ............................................................17 Start-Up Procedures......................................17 Maintenance .......................................................19 Accessories ........................................................23 Replacement Parts List .....................................24 Wiring Diagram...................................................26 Hatco Limited Warranty.....................................27 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 Powermite® Gas Booster 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 Powermite Gas Booster Heaters are instantaneous fin tube type heaters designed to boost the temperature of regularly available hot water, usually 110°F to 150°F (43°C to 66°C) to a minimum of 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 and National Sanitation Foundation Standard #5. The Hatco Gas Booster Heater is design certified by CSA International and tested under the requirements of the American National Standard, ANS Z21.10.3*CSA 4.3, Current Edition. All Hatco Gas Booster Heaters are factory preplumbed and pre-wired to allow for easy installation. The control compartment area is accessible from the front, which permits easy installation, even when near other equipment. Hatco Gas Booster Heaters are quality built for long life and rugged dependability. Dependability of the booster heater is preserved through proper, safe installation and operation. Form No. PMG-60M-0705 i This manual provides the installation, safety and operating instructions for the Powermite Gas Booster Heater. We recommend all installation, operating and safety instructions appearing in this manual be read prior to installation or operation of your Hatco PMG-60 Gas Booster Heater. Safety instructions that appear in this manual after a and the words WARNING or warning symbol CAUTION printed in bold face are very important. WARNING means there is the possibility of serious 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 Gas Booster 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. MODEL DESCRIPTION ALL MODELS Water enters the booster heater at the inlet water connection and flows into the stainless steel tank. It then is pumped through the finned tube heat exchanger where it is heated to the proper temperature. The heated water then returns back to the top half of the stainless steel tank for supply to the dishwashing machine. Water that is not immediately used by the dishwashing machine is recirculated through the heat exchanger. This system is designed to assure the availability of the proper temperature water at the heater outlet. All Hatco booster heaters are warranted to be free of defects in material and workmanship under normal use and service, and when installed in accordance with factory recommendations. NOTE: Hatco Booster Water Heaters are approved for use with commercial dishwashers only. SYSTEM OVERVIEW The Hatco Powermite Gas Booster Heater is designed to maintain a minimum temperature of 180°F (82°C) water required for the rinse cycle of a commercial dishwasher. An inlet water temperature of at least 110°F (43°C) will produce optimum results (See Capacity Chart and Booster Heater Sizing Chart in SPECIFICATIONS). After the necessary power, water and gas connections are completed, start the unit by turning on the toggle switch located on the lower front base. The water circulating pump will start at this time. After 20 seconds, providing the operating and safety controls are satisfied, the ignition module will energize the spark igniter and turn on the gas for the pilot. The igniter will spark for about 90 seconds or until proof of fire. If there is a confirmed pilot fire, and the water temperature is below the setpoint, the unit will go into full burn. The unit will stay in full burn until the desired setpoint temperature is met, then the burner will shut off. During standby periods of limited use, the burner will cycle on only to replace standby water temperature loss. If for some reason the unit did not ignite there is an automatic 5 minute delay before the unit attempts to ignite again. If the unit overheats above the setpoint temperature, the safety high limit will open, shutting down the burner, locking out the controller, and turning on the alarm pilot light. In order to reset the unit, turn the unit off and depress the reset button on the appropriate high limit switch. The heat exchange high limit is located on the left hand side of the heat exchanger or the tank high limit on the lower front of the control box. This switch will not reset until the temperature has dropped to a safe level. This unit must remain off for at least 10 seconds before it can be restarted. NOTE: The operating thermostat control is factory preset at 190°F (88°C). NOTE: The circulator pump will stay on as long as the toggle switch is in the ON position. 1 Form No. PMG-60M-0705 SPECIFICATIONS Type: Capacity: Fuel: Operating Water Pressure: Power: Ignition: Gas-fired, instantaneous recirculating booster heater with accumulator for use with door type dishwashers. Unit is unvented and floor mounted. Input 58,000 BTUs/Hour. Output 46,000 BTUs/Hour = 13.4 kW Natural gas @ 5 iwc or Propane @ 11 iwc ­ minimum inlet gas pressure. 150 PSI max. Relief valve set at 150 PSI, 210°F (99°C). Supply 120 VAC, 15 amp service (unit uses 1.75 amps @ 120 volts). Electronic spark pilot with flame proofing by rectification. Temperature Control: Electronic, temperature control probe/microprocessor based. Factory preset at 190°F (88°C). Safety Systems: Energy cut off devices include manual reset flame rollout and heat exchanger high limits, and manually reset tank high limit. Redundant gas solenoid valve with integral regulator. Temperature/Pressure relief valve on tank. Direct ­ combustion air enters bottom, flue gases exit sides at top of unit. Recirculating with bronze housing. Gas ­ 1/2" NPT, Water ­ 3/4" NPT, Electric ­ 120 VAC, 15 Amp. 108 pounds (49 kg), dry. Fluing: Pump: Connections: Weight: WATER TEMPERATURE RECOVERY TABLE ­ FAHRENHEIT INPUT MBH Gallons per Hour (GPH) at Indicated Temperature Rise (F°) MODEL PMG-60 (1,000 BTU/HR) 58 30° 181 40° 135 50° 108 60° 90 70° 77 NOTE: Capacity is reduced @ altitudes above 2000 feet (610 m). See HIGH ALTITUDE INSTALLATION & OPERATION section for sizing considerations. Form No. PMG-60M-0705 2 SPECIFICATIONS DIMENSIONS NOTE: Overall Dimensions 20-3/8"W x 24-1/2"D x 24-5/8"H (518 x 622 x 625 mm) Figure 1. Dimensional Drawings 3 Form No. PMG-60M-0705 SPECIFICATIONS BOOSTER HEATER SIZING CHART GAS POWERMITE® BOOSTER Temperature Rise 40°F (22°C) Blakeslee Champion Dishwasher Model Number 70°F (39°C) UC-21, D-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60 U-H1, UH-200, UH-200B, U-HB, UL-150 . . . . . . . . . . . . . . . . . . . .PMG-60 UH-150, UH-150B, UH-100B, DHB-VS . . . . . . . . . . . . . . . . . . . . .PMG-60 D-H1, D-HB, D-H1T, D-HBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 PP-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 D-H1C, D-H1TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 66 WSPW, 44-WS, 66WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 LXiC, LXiGC, LX-18C, LX-30C, LX-40C . . . . . . . . . . . . . . . . . . . . .PMG-60 LX-30, SR24, SR24H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 LX-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 AM-14T, AM-14F, AM-14TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 AM-12, AM-12C*, AM-14, AM-14C . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 AM-15, AM-15F, AM-15T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 Opti-RinSe C44AW, CRS-66AW, CCS-66AW, CPW-80AW . . . . . .PMG-60 . . . . . . . .PMG-60 . . . . . . . .PMG-60 . . . . . . . .PMG-60 . . . . . . . .PMG-60 . . . . . . . . . . .--. . . . . . . . . . .--. . . . . . . .PMG-60 . . . . . . . .PMG-60 . . . . . . . . . . .--. . . . . . . .PMG-60 . . . . . . . . . . .--. . . . . . . .PMG-60 . . . . . . . . . . .--- Hobart Insinger Jackson Commander 18-5, 18-5H, Ensign 40-2 . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . . . . .--JP-24, JP-24B, JP-24F, JP-24BF . . . . . . . . . . . . . . . . . . . . . . . . . .PMG-60 . . . . . . . .PMG-60 24B Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . .PMG-60 10AB, 10APRB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . .PMG-60 200 . . . . . . . . . . . . . . . . . . . . . . . . . . ...