Hubbell JSK Series Operating instructions

1
OPERATING AND MAINTENANCE
MANUAL FOR
ELECTRIC HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “JSK/JFR”
2019Edition

2
HUBBELL
ELECTRIC HEATER COMPANY
45 SEYMOUR STREET
P.O. BOX 288
STRATFORD, CT 06615
PHONE: [phone]
FAX: [phone]
INTERNET: http://www.hubbellheaters.com
-- IMPORTANT --
Always reference the full model number and serial number when calling the factory.
WARNING / CAUTION
1. Tank is to be completely filled with water and all air is to be vented before energizing.
2. Due to the rigors of transportation, all connections should be checked for tightness before
heater is placed in operation.
3. The refractory material used in heating elements may absorb some moisture during
transit, periods of storage, or when subjected to a humid environment. This moisture
absorption results in a cold insulation resistance of less than twenty (20) megohms. If this
heater has been subjected to the above condition, each heating element must be checked
for insulation resistance before energizing. Contact the factory for a replacement element.
4. KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS.
Do not perform any maintenance, make any adjustments, or replace any components
inside the unit with the high voltage power supply turned on. Under certain
circumstances, dangerous potentials may exist even when the power supply is off. To
avoid casualties, always turn the power supply safety switch to off, turn the charge or
ground the circuit before performing any maintenance or adjustment procedure.
5. The unit is designed to operate at atmospheric pressure.
6. Generalized instructions and procedures cannot anticipate all situations. For this reason,
only qualified installers should perform the installations. A qualified installer is a person
who has licensed training and a working knowledge of the applicable codes, tools,
equipment, and methods necessary for safe installation of an electric resistance water
heater. If questions regarding installation arise, check your local plumbing and electrical
inspectors for proper procedures and codes. If you cannot obtain the required
information, contact the company.
7. Water Quality Requirements – Recommended water hardness is 0 to 3 grains of
hardness per gallon (GPG). Water hardness above 3 GPG should be treated by a water
conditioner (water softener or in-line treatment). 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 heater as well as reducing metallic
corrosion. Product failure caused by these conditions is not covered under warranty.
See warranty for complete details.
8. The water temperatures in the sink or holding vessel and drain water may reach
temperatures above 190°F. 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.
9. The unit is not weatherproof and should be located indoors where the ambient air
temperature is a minimum of 70°F (21°C).
10. The unit is not “jet-proof” construction. DO NOT use jet-clean spra to clean this unit.

3
11. DO NOT submerge or saturate with water. The unit is not waterproof. Do not operate if
the unit has been submerged or saturated with water.
12. Install the unit with a minimum of 3 ½” of space from the bottom of the unit to all
combustible surfaces to prevent combustion.
13. Discontinue use if power cord is frayed or worn.
14. DO NOT use harsh chemicals such as bleach (or cleaners containing bleach), oven
cleaners, or flammable cleaning solutions to clean this unit.
15. Make sure all operators have been instructed on the safe and proper use of the unit.
16. This unit is not intended for use by children or persons with reduced physical, sensory,
or mental capabilities. Ensure proper supervision of children and keep them away from
the unit.
17. DO NOT use extension pipes on the inlet and outlet connections on water heater units.
Poor performance or unsafe conditions may occur.
18. This unit is intended for commercial use only – NOT for household use.
19. Do not use excessive force when tightening unions or nuts. Over-tightening and
excessive force may cause leaks.
20. Use only delimers that are non-corrosive to aluminum, brass, and stainless steel.
Damage to unit caused by corrosive materials is not covered under warranty.
NSF CRITERIA
NSF Standard 4 has recently added performance requirements for food rethermalizing. The
requirements mirror the requirements for food rethermalizing in the FDA Food Code. The basic
requirement is that food reach a temperature of 165°F (74°C) in a time period of two hours or
less.
Appliances that are manufactured for the purpose of rethermalizing food will need to meet these
performance requirements in order to be listed to NSF Standard 4.
The JFR Series heating unit is specifically made for food rethermalizing, however, the heating
unit is designed to be incorporated into a hot water bath rethermalizer. Hubbell does not supply
the vessel that contains the water, nor the sytem which determines how food is placed and held
in the vessel. The JFR unit attaches to the bottom of the vessel and supplies hot water to the
vessel.
Hubbell does supply sizing recommendations to enable the appliance manufacturer to correctly
size the JFR unit to the vessel. However, there are variables in the way that the vessel is
manufactured that affect its ability to pass the NSF performance requirements. The JFR unit is
listed with NSF for construction only. Due to the fact that the JFR is only a portion of a larger
system, it is impossible to do performance testing intil the JFR unit is incorporated onto the
water vessel.
It is the responsibility of the vessel manufacturer to have the entire rethermalizing appliance
tested and listed in accordance with NSF Standard 4. Simply hanging an NSF listed JFR unit on
the appliance does not transfer NSF listing to the entire appliance.

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TABLE OF CONTENTS
SECTION TITLE PAGE No.
I GENERAL DESCRIPTION AND CONSTRUCTION 5
II INSTALLATION AND START-UP 8
III SCHEDULED MAINTENANCE AND OPERATION 16
IV TROUBLESHOOTING 20
V SERVICING AND REPLACEMENT OF PARTS 25
VI SERVICE PARTS LIST 28
VII TORQUE VALUES 29
VIII WARRANTY INFORMATION 30

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SECTION I -GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This manual describes a packaged Sink Sanitizing heater (Hubbell Model JSK) that is typically
used to provide 180°F sanitizing rinse water and Food Rethermalizing/Bain Marie heater
(Hubbell Model JFR) that is used to heat foods to temperatures of between 140°F and 190°F.
The complete assembly is designed to directly mount under a sink or holding vessel and
consists of the storage tank, immersion electric heating element(s), electronic control module,
enclosure, magnetic contactor(s), and any other required electrical operating control. Optional
equipment may be supplied with your unit. Please consult the product packing list for details
specific to your assembly. The unit is factory assembled, wired, tested, and ready for electrical
and plumbing service connections.
Note: This electric water heater has an efficiency rating of 98%, which is in compliance with
national energy requirements.
MODEL SPECIFICATIONS
Model* Watts Volts Amps Phase Model* Watts Volts Amps Phase
XXX-3RS 3000 208 14.4 1 XXX-3T 3000 240 7.2 3
XXX-4RS 4500 208 21.7 1 XXX-4T 4500 240 10.8 3
XXX-6RS 6000 208 28.9 1 XXX-6T 6000 240 14.4 3
XXX-9RS 9000 208 43.3 1 XXX-9T 9000 240 21.7 3
XXX-3S 3000 240 12.5 1 XXX-3T5 3000 440 3.9 3
XXX-4S 4500 240 18.8 1 XXX-4T5 4500 440 5.9 3
XXX-6S 6000 240 25.0 1 XXX-6T5 6000 440 7.9 3
XXX-9S 9000 240 37.5 1 XXX-9T5 9000 440 11.8 3
XXX-3S 3000 220 11.5 1 XXX-3T4 3000 480 3.6 3
XXX-4S 4500 220 17.2 1 XXX-4T4 4500 480 5.4 3
XXX-6S 6000 220 22.9 1 XXX-6T4 6000 480 7.2 3
XXX-9S 9000 220 34.4 1 XXX-9T4 9000 480 10.8 3
XXX-3S 3000 230 12.0 1 XXX-3T6 3000 600 3.0 3
XXX-4S 4500 230 18.0 1 XXX-4T6 4500 600 4.5 3
XXX-6S 6000 230 24.0 1 XXX-6T6 6000 600 6.0 3
XXX-9S 9000 230 35.9 1 XXX-9T6 9000 600 9.0 3
XXX-3W 3000 277 9.6 1 XXX-3T3 3000 380 4.3 3
XXX-4W 4500 277 14.4 1 XXX-4T3 4500 380 5.7 3
XXX-6W 6000 277 19.2 1 XXX-6T3 6000 380 8.6 3
XXX-9W 9000 277 28.9 1 XXX-9T3 9000 380 11.5 3
XXX-3T4S 3000 480 6.3 1 XXX-3T7 3000 415 4.7 3
XXX-4T4S 4500 480 9.4 1 XXX-4T7 4500 415 6.2 3
XXX-6T4S 6000 480 12.5 1 XXX-6T7 6000 415 9.4 3
XXX-9T4S 9000 480 18.8 1 XXX-9T7 9000 415 12.5 3
XXX-3R 3000 208 9.4 3 XXX-3T7 3000 400 4.5 3
XXX-4R 4500 208 12.5 3 XXX-4T7 4500 400 6.0 3
XXX-6R 6000 208 16.7 3 XXX-6T7 6000 400 9.0 3
XXX-9R 9000 208 25.0 3 XXX-9T7 9000 400 12.1 3
*XXX is JSK for the Sink Sanitation Unit and JFR for the Food Rethermalizer/Bain Marie Unit

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SIZING INFORMATION
1) For JSK models in a sink heater application use a minimum of 2000 watts per square
foot of vessel top.
2) For JFR models in a food rethermalizer application use a minimum of 2000 watts per
square foot of vessel top.
3) For JFR models in a Bain-Marie or steam table application use a minimum of 750
watts per square foot of vessel top.
NOTE: Use one heater for a Bain-Marie up to 6’ long. Units over 6’ require a minimum
of two heaters.
CONSTRUCTION
TANK
Each tank is a single vessel constructed with two distinct chambers, a sediment collection
chamber and a heating chamber. Water, flowing directly from the sink or holding vessel by
means of convection flow, enters the first, or sediment collection chamber. The unique design
of this chamber causes sediment entrapped within the flowing water to separate from the water
flow and to collect in the bottom of the chamber. The collected debris can then be easily flushed
from the system when the sump drain valve is opened. The water then travels on to the second,
or heating chamber where it is heated, flowing upward and returning to the sink or holding
vessel. The tank is fabricated of type 304 stainless steel all welded construction for maximum
tank longevity and is designed for use at atmospheric pressure.
RIGHT SIDE VIEW
BOTTOM VIEW

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TANK CONNECTIONS
The heater is supplied with two standard 1 ½” sink connections intended to be connected to the
bottom of a sanitation sink or holding vessel. See drawing for locations and sizes.
HEATING ELEMENT
The water heater is supplied with an electric
immersion heating element composed of corrosion
resistant sheathed elements that are fitted into a 1”
NPS brass screw plug. Each assembly is threaded
into the tank and sealed with an o-ring gasket. See drawing for voltage and power ratings.
MAGNETIC CONTACTOR
Load switching is done by a heavy-duty resistive (non-inductive)
load type definite purpose magnetic contactor. The contactor supplies
power to the heating element(s) when the relay on the control board
is closed, thereby pulling in the contacts until the desired temperature
is reached. At this point, the contacts will drop out, which in turn
disconnects power from the elements. Units with multiple contactors
will turn on and off in stages. This contactor is rated for 200,000 cycles.
ELECTRONIC CONTROL BOARD, PROBE, AND DISPLAY
The control board supplies all the
necessary functions for heater
operation. These include control
temperature, hi-limit cut-out, low water
detection, and leak detection.
LOW VOLTAGE CONTROL TRANSFORMER
A control circuit transformer is supplied with all models rated
greater than 240-volts. This component is used to step down the
primary power supply (600, 480, 440, 415, 380, or 277) to 208/240-
volts for safety when working with control.
OUTER SHELL
The tank and all electrical and components are encapsulated in a protective shell constructed of
type 304 brushed stainless steel.
OPTIONAL EQUIPMENT
Security Package
For prison and other secure facilities a tamper resistant package is available. All external screws are
spader type requiring a spader wrench for removal.
Cord and Plug and Receptacle
Some JFR units can be supplied with an electrical cord and plug installed and shipped with the
mating receptacle. Plugs and receptacles can be supplied for the following applications only. 208V
and 240V JFR units at 3kW supplied with a NEMA 6-20P and 208V and 240V JFR units at 4.5
kW supplied with a NEMA 6-30P.
Flush Hose Kit
The flush hose kit is available for JSK and JFR models and is used to power flush the unit to keep
it working at peak efficiency. The kit consists of a drain stopper and a hose with adapter.

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SECTION II –INSTALLATION AND START-UP
WARNING / CAUTION
•DO NOT TURN ON THE ELECTRIC POWER SUPPLY to this equipment until
heater is completely filled with water and all air has been released. If the heater is
NOT filled with water when the power is turned on, the heating elements will burn
out.
•All water heaters have a risk of leakage at some unpredictable time. IT IS THE
CUSTOMER'S RESPONSIBILITY TO PROVIDE A CATCH PAN OR OTHER
ADEQUATE MEANS, SO THAT THE RESULTANT FLOW OF WATER WILL
NOT DAMAGE FURNISHINGS OR PROPERTY.
•Installation or service of this unit requires ability equal to that of a licensed tradesman
in the field.
•The installation must conform to these instructions and any local authority having
jurisdiction. Grounding and electrical wiring connected to the unit must also conform
to the latest version of the National Electric Code NFPA-70.
•Water and waste piping and connections must comply with the International Plumbing
Code 2003, International Code Council (ICC), or to the Uniform Plumbing Code
2003, International Association of Plumbing and Mechanical Officaials (IAPMO).
WATER HEATER PLACEMENT
1. The water heater should be protected from freezing and waterlines insulated to reduce
energy and water waste.
2. Leave a minimum of 12” clearance for element withdrawal and control access.
3. Do not install in an area where flammable liquids or combustible vapors are present.
UNIT INSTALLATION
NOTE: JFR Models should be installed with a perforated water baffle (not supplied with
unit) to distribute the heated water properly. The baffle should be ¾” high with a divider
wall between the inlet and outlet. The baffle should also have ¾” holes around the periphery
every 6”.
NOTE: Front edge of unit should be flush
with the front edge of the sink or holding
vessel.
NOTE: JFR models should be situated
with a maximum of 3’ on either side of
the sink or holding vessel.
1. Drill (1) ¾” pilot hole 4 ½” from
the front of the sink or holding
vessel and (1) ¾” pilot hole 8 ½”
from the first pilot hole.
2. Cut (2) 2” diameter holes at the
pilot holes using a knockout hole
punch.
3. Make a 3” diameter offset, which is
1/8” deep, centered around the 2”
diameter holes.
4. Unscrew the drain spud assembly
from the welded pipe on the heater.
5. Unscrew the locknut from the drain
spud assembly and slide off all of
the washers except the rubber
washer.

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6. With only the rubber washer attached to the drain spud, slide the drain spud through
the sink hole from above.
7. Secure the drain spud
assembly to the sink or
holding vessel.
a. From under the
sink, slide the fiber
washer onto the
drain spud.
b. Screw the locknut
(flat side up), with plastic gasket between locknut and drain spud, onto the drain
spud.
8. Repeat steps 4-7 for the other spud assembly.
9. Secure the unit to the sink or
holding vessel. Two people
may be required for this
step.
a. Position the unit under
the two spud
assemblies.
NOTE: Make sure the washers
are positioned properly inside the
union nuts and are not crimped.
b. Screw the union nut to
the threaded drain
spud assembly.
10. Tighten the union nuts and
locknuts securely.
11. Confirm sump drain valve
handle is closed (vertical)
position.
12. Fill the sink or holding
vessel with water and check for leaks.
NOTE: A ¾” hose or pipe may be connected to the sump drain and run to an open sight
drain. The sump drain should not be permanently connected to the sanitary drain system.
Check local plumbing code for drain installation.
FILLING THE HEATER
1. With the heater connected to bottom of the sink or holding vessel, fill the sink or
holding vessel with warm water to normal operating level and allow the heater to
completely fill with water.
ELECTRICAL INSTALLATION
1. Enter the base through the factory cut KO’s with properly sized feeder leads, See
Wiring Chart. Single-phase installations require two (2) leads plus ground. All
Hubbell 3-phase heaters are intended for use with a 3-wire delta system plus ground.
No neutral is required. For a 4-wire plus ground system, install 3 legs of power plus
the ground and terminate the neutral leg.
2. Install these power leads into the box lugs on the power distribution block.
3. Connect incoming ground wire to ground lug supplied.
4. Check for proper grounding.
5. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.
6. Check all connections, including factory connections, for tightness.
7. For cord connected units, wire receptacle as required and plug in unit.

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START-UP
1. Check that the fused disconnect switch or circuit breaker is on, or if equipped with
power cord and plug make sure the unit is plugged into a properly grounded receptacle
of the correct voltage, size, and plug configuration.
2. Make sure that the drain cap is securely tightened to heating chamber drain.
3. Close the sump drain by moving the drain handle toward the front of the unit until it
stops in the vertical position.
4. Fill the sink or holding vessel with hot tap water to the normal operating level.
5. Press the Power ON/OFF button to turn the unit ON.
6. On JFR models, set the water temperature control to the desired temperature.
7. Wait until the water reaches the desired temperature.
OPTIONAL FIELD CONVERSION FROM SINGLE TO THREE PHASE OR
THREE TO SINGLE PHASE (JSK and JFR models in 6 and 9 kW at 208, 240, and
480 volts only)
1. Re-wire the unit to desired configuration as indicated below.
NOTE: The wire to be used for internal wiring must conform to THHN (90°C) and
must match the wire size currently in use. Contact the factory for assistance, if
required.
2. Contact the factory for correct labels. The factory will need the serial number for
proper identification.
Single-Phase 3-Phase
P5 P4
P6
SINGLE PHASE
WIRING DIAGRAM SHOWN IS FOR MODEL JSK/JFR (SINGLE PHASE).
TO FIELD CONVERT TO 3-PHASE, DISCONNECT WIRE P2 FROM
TERMINAL T5 AND RECONNECT IT TO THE CENTER POLE OF THE
CONTACTOR AND DISCONNECT WIRE P4 FROM TERMINAL T4 AND
RECONNECT IT TO TERMINAL T3.
T1 T2
T3 T4
T5 T6
P1 P3
TO CONTACTOR
P2
P4 P5
P6
3-PHASE
WIRING DIAGRAM SHOWN IS FOR MODEL JSK/JFR (3-PHASE).
TO FIELD CONVERT TO SINGLE PHASE, DISCONNECT WIRE P2
FROM THECONTACTOR AND RECONNECTIT TO TERMINAL T5
ANDDISCONNECT WIREP4 FROM TERMINAL T3 AND
RECONNECT IT TO TERMINAL T4.
T1 T2
T3 T4
T5 T6
P1 P2 P3
TO CONTACTOR
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed.
3. Remove the protective outer plastic covering from the sheet metal shell.
4. After the water is heated for the first time, monitor the water temperature as described
in Section III, Annual Inspection.

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JSK and JFR Wiring Charts
kW Volts Ph Unit Amp
Draw
Phase-
Phase
Resistance
(Ohms)
Min. Feed
Breaker or
Fuse Size
Internal
Power
Wire
Size
Copper
Power
Feed Wire
Size
Conduit
Size Wiring Diagram
3
208 1 14.4 14.4 20 12 12 ¾” 1(NT)
208 3 9.4 28.8 15 12 14 ¾” 3(NT)
220 1 11.5 19.1 15 12 14 ¾” 1(NT)
230 1 12.0 19.2 20 12 14 ¾” 1(NT)
240 1 12.5 19.2 20 12 12 ¾” 1(NT)
240 3 7.2 38.4 15 12 14 ¾” 3(NT)
277 1 9.6 28.9 15 12 14 ¾” 1(WT)
380 3 4.3 96.3 15 12 14 ¾” 3(WT)
400 3 4.5 106.7 15 12 14 ¾” 3(WT)
415 3 4.7 114.8 15 12 14 ¾” 3(WT)
440 3 3.9 129.1 15 12 14 ¾” 3(WT)
480 1 6.3 76.2 15 12 14 ¾” 1(WT)
480 3 3.6 153.6 15 12 14 ¾” 3(WT)
600 3 3.0 240.0 15 12 14 ¾” 4
4.5
208 1 21.7 9.6 30 10 10 ¾” 2(NT)
208 3 12.5 19.2 20 12 12 ¾” 3(NT)
220 1 17.2 12.8 30 12 10 ¾” 2(NT)
230 1 18.0 12.8 30 12 10 ¾” 2(NT)
240 1 18.8 12.8 30 12 10 ¾” 2(NT)
240 3 10.8 25.6 15 12 14 ¾” 3(NT)
277 1 14.4 19.2 20 12 12 ¾” 2(WT)
380 3 5.7 64.2 15 12 14 ¾” 3(WT)
400 3 6.0 71.1 15 12 14 ¾” 3(WT)
415 3 6.2 76.5 15 12 14 ¾” 3(WT)
440 3 5.9 86.0 15 12 14 ¾” 3(WT)
480 1 9.4 51.1 15 12 14 ¾” 2(WT)
480 3 5.4 102.4 15 12 14 ¾” 3(WT)
600 3 4.5 160.0 15 12 14 ¾” 4
6
208 1 28.9 7.2 40 10 8 ¾” 5(NT)
208 3 16.7 14.4 30 12 10 ¾” 3(NT)
220 1 22.9 9.6 30 10 10 ¾” 1(NT)
230 1 24.0 9.6 40 10 10 ¾” 1(NT)
240 1 25.0 9.6 40 10 8 ¾” 5(NT)
240 3 14.4 19.2 20 12 12 ¾” 3(NT)
277 1 19.2 14.4 30 12 10 ¾” 1(WT)
380 3 8.6 48.1 15 12 14 ¾” 3(WT)
400 3 9.0 53.3 15 12 14 ¾” 3(WT)
415 3 9.4 57.4 15 12 14 ¾” 3(WT)
440 3 7.9 64.5 15 12 14 ¾” 3(WT)
480 1 12.5 38.4 20 12 12 ¾” 5(WT)
480 3 5.4 76.8 15 12 14 ¾” 3(WT)
600 3 6.0 120.0 15 12 14 ¾” 4
9
208 1 43.3 4.8 60 8 4 ¾” 5(NT)
208 3 25.0 9.6 40 10 8 ¾” 3(NT)
220 1 34.4 6.4 50 8 6 ¾” 2(NT)
230 1 35.9 6.4 50 8 6 ¾” 2(NT)
240 1 37.5 6.4 50 8 6 ¾” 5(NT)
240 3 21.7 12.8 30 10 10 ¾” 3(NT)
277 1 28.9 9.6 40 10 8 ¾” 2(WT)
380 3 11.5 32.1 15 12 14 ¾” 3(WT)
400 3 12.1 35.6 20 12 12 ¾” 3(WT)
415 3 12.5 38.3 20 12 12 ¾” 3(WT)
440 3 11.8 43.0 15 12 14 ¾” 3(WT)
480 1 18.8 26.7 30 12 10 ¾” 5(WT)
480 3 10.8 51.2 15 12 14 ¾” 3(WT)
600 3 9.0 80.0 15 12 14 ¾” 4

12
JSK and JFR Wiring Chart Notes:
1. Power feed wire sizing is based on using 75°C Cu THHN wire with feeder branch
protection rated at 125%.
2. Internal wire sizing is based on using 90°C Cu THHN wiring in a raceway with an
ambient temperature up to 60°C.
3. For information on 277V, 415V, or 440V models reference the supplied drawing
or contact the factory.
4. Normal phase-to-phase resistance tolerance is ±5%.
5. 380, 480, and 600-volt phase-to-phase resistance values are shown with the transformer
disconnected.

13
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J1
J4
TO
DISPLAY
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TOBACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
BLANK
COVER
CONTROL
THERMISTOR
1(NT)
JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TOBACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
BLANK
COVER
CONTROL
THERMISTOR
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
1(WT)
J1J1 JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TO BACK
PANEL
LEAK
DETECTION
WIRE CONTROL
THERMISTOR
POWER
DISTRIBUTION
BLOCK
2(NT)
J1J1 JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TOBACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
CONTROL
THERMISTOR
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
2(WT)
J1J1 JP3

14
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
L1L2
L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TO BACK
PANEL
LEAK
DETECTION
WIRE CONTROL
THERMISTOR
POWER
DISTRIBUTION
BLOCK
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
3(NT)
J1J1 JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TOBACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
CONTROL
THERMISTOR
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
3(WT)
J1J1 JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TOBACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
CONTROL
THERMISTOR
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
4
J1J1 JP3

15
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TO BACK
PANEL
LEAK
DETECTION
WIRE CONTROL
THERMISTOR
POWER
DISTRIBUTION
BLOCK
5(NT)
J1J1 JP3
T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4 T1250
CONTROL
BOARD
J7
J8
J5
J3 J2 JP1
J4
TO
DISPLAY
L1L2L3
T1T2T3
CONTACTOR
P65
PROBE
GROUND
TO BACK
PANEL
LEAK
DETECTION
WIRE
POWER
DISTRIBUTION
BLOCK
CONTROL
THERMISTOR
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
TRANSFORMER
H2
--
--
H1
X1
--
--
X2
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
ELEMENT
HEATING
5(WT)
J1J1 JP3

16
SECTION III – SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before performing any maintenance procedure,make certain the power supply is turned OFF
and cannot accidentally be turned on.
MAINTENANCE AND OPERATION
The water heater is automatic in its operation. It will maintain a full tank of water at the
temperature setting of the controller. The water heater should not be turned on without first
making sure that the tank is full of water and that all air has been released.
FREEZING
The tank should be fully drained in the event the electricity has been turned off and if there
is danger of freezing.
CONTROLLER OPERATION
NOTE: All controller variables come preset from the factory to include a preset temperature
of 185°F.
1. To turn unit on or off:
a. Press the ON/OFF button on the display module.
b. Note that the controller will resume its last mode of operation if power is
disconnected.
2. To change setpoint temperature (the temperature is fully adjustable from 32° to 194°F
(0°-90°C):
a. Press the UP and DOWN arrows simultaneously to enter setpoint change mode.
b. Press the UP or DOWN button to change the setpoint temperature.
c. Pressing and holding the UP or DOWN button will scroll through the setpoint
temperature.
d. To leave setpoint change mode
i. Wait 5 seconds without pushing any buttons or press the UP and DOWN
buttons simultaneously.
3. To view the number of operational hours (the number of hours when a contactor is
pulled in) and software version:
a. Press the UP and DOWN arrows simultaneously to enter setpoint change mode.
b. Press the ON/OFF button.
c. Display will flash the software version (e.g. R14), HRS, followed by the hours
in thousands of hours, followed by the hours.
i. Example: r 14, H r S, l2 3, 4 5 6; indicates software version R1.4 and
123,456 hours.
d. To leave operational hours mode
i. Wait 5 seconds without pushing any buttons or press the UP and DOWN
buttons simultaneously.
4. Configuration Menu. (NOTE: Configuration menu change should only be made by
qualified personnel).
a. With the controller turned OFF, to enter the configuration menu, press and hold
the UP, DOWN, and ON/OFF buttons simultaneously for 5 seconds.
b. To scroll through menu settings, press the ON/OFF button.
c. To make a change to a menu setting use either the UP or DOWN arrow.
d. Settings:
i. Relays – sets the number of magnetic contactors used in the heater.
1. r##, where ## is the number of magnetic contactors (01).
ii. Low water detection – sets the low water detection on or off.

17
1. LOn, for low water on. (Factory Default)
2. LOF, for low water off.
iii. Low water reset – sets the low water reset for either automatic or manual
1. LAU, for low water automatic reset. (Factory Default)
2. LAn, for low water manual reset.
iv. Temperature units – sets the temperature units to either degrees
Fahrenheit or Celsius.
1. DEF, for degrees Fahrenheit. (Factory Default)
2. DEC, for degrees Celsius.
v. Differential – sets the number of degrees below setpoint that the heater
will resume heating after it has achieved setpoint.
1. d##, where ## is the differential in degrees (1 to 20). (Factory set
at 02)
vi. Display – sets the display to either setpoint or actual temperature.
1. dSS, for display setpoint temperature. (Factory Default)
2. dSt, for display actual temperature.
vii. Heater Interlock – sets the heater interlock mode to on or off. (Only
available with r23 or later software).
1. HoF, to disable the 24-volt interlock feature. (Factory Default)
2. Hon, to enable the 24-volt interlock feature.
e. To leave the configuration menu, wait 5 seconds without pushing any buttons or
press the UP and DOWN buttons simultaneously.
5. To reset any high-limit, no probe, or low water (when in manual reset mode) fault
condition, press the RESET button.
6. Display
a. By default the display will show the setpoint of the heater.
b. The decimal points on the display, as shown below, indicate that the controller
is calling for a contactor to pull in. If three or more contactors are installed, the
third decimal point is used for all remaining contactors.
RECOMMENDED CLEANING SCHEDULE
•On a daily basis.
•Whenever food accumulates in the tank.
•Whenever a non-food spill occurs.
•Whenever the unit is to be stored or shipped, especially in freezing temperatures.
DAILY CLEANING
1. Make sure the power supply is turned OFF and allow the unit and water to cool down.
2. Connect a drain hose to the sump drain and make sure the other end is in a bucket or
open sight drain following the local plumbing codes.
3. Place a rubber stopper on the inlet strainer connection.
4. Turn the handle of the sump drain valve to the horizontal position to allow water to
flow to the drain hose.

18
5. Attach the flush hose with adapter that is connected to a fresh water supply and place
the adapter in the outlet strainer connection. Flush until the sump drain is clear.
6. Close the sump drain valve by moving the handle into the vertical position.
7. Remove the rubber stop from the inlet strainer connection and place it in the inlet
strainer connection and place the flush hose and adapter in the inlet strainer
connection.
8. Place a bucket under the heating chamber drain and remove the pipe cap.
9. Flush the unit with water until the heat compartment is clear.
10. Turn the water supply OFF and allow the unit to finish draining.
11. Place the pipe cap back on the heating chamber drain and tighten.
12. Remove the flush hose and rubber stop from the inlet and outlet connections.
DRAINING HEATER FOR SERVICE PROTECTION
Use the following procedure when shutting down the unit for long periods of time.
1. Press the Power ON/OFF button to turn the unit OFF.
2. Perform the entire cleaning procedure in this section.
3. Turn off the electrical power supply to the heater.
4. Make sure the water has been completely drained from the unit and the sink or holding
vessel.
ANNUAL INSPECTION
1. Monitor water temperature
a. Let water heater completely heat to a designated temperature setting.
b. After controller satisfies (that is, when the magnetic contactor actually clicks
off), measure the temperature of the water in the sanitizing sink or holding
vessel.
c. Compare the water temperature of outlet water to the temperature setting of
the display when it satisfies. Normal variation between the two points is
approximately + 5°F.
d. If these two readings do not coincide within acceptable tolerances and
verification has been made of the accuracy of the temperature-reading device,
replace the control board and/or the sensor probe.
2. Inspect element for leakage as follows:
a. Shut off power supply.
b. Remove front cover.
c. Visually inspect around heating element for evidence of leaks.
d. Rub around the heating element with a rag. Check for any evidence of
moisture. If moisture is present or a water drip is observed, follow procedure
outlined in Section V.
CAUTION: The area around the heating element may be hot.
3. Scale and mineral build-up on heating elements is a normal condition. It is
recommended that the heating element be removed for examination and if scaled,
should be cleaned. In an area of known hard or poor water conditions, the elements
may need to be checked more frequently. This will improve the efficiency of the
heater and increase the element life.
NOTE: Failure of the elements due to scale and mineral build-up is not covered under
warranty. See warranty for complete details.
a. Shut off power supply.
b. Drain the tank.
c. Remove upper front cover.
d. Disconnect the element wiring. It is recommended that one element at a time
is removed to simplify re-wiring.
e. Unscrew element.
f. Lime scale removal

19
i. Place limed ends of the heating element in a de-limer solution, designed
for potable water applications, and allow lime to dissolve. Do not allow
de-limer to contact heating element terminals.
g. Other scale removal
i. Silicates, sulfates, and aluminates must be removed by scraping or other
mechanical means. De-limers will not dissolve these types of scale.
h. Flush the cleaned ends of the elements with clean water.
i. Re-install element with new o-ring.
j. Re-attach element wires.
k. Continue until all heating elements are cleaned.
l. Fill the heater following the filling instructions provided in Section II and check
around the elements for leaks.
m. Re-apply power.
4. Check for loose electrical connections. Tighten as necessary.

20
SECTION IV – TROUBLESHOOTING
ERROR MESSAGES
1. Err, No, Prb
a. This message will flash when the controller does not detect that the P65 probe or
control thermistor is connected to the control board. To clear this error reinsert
the probe connector and press RESET.
2. Err, too, hot, ### (where ### is the actual temperature of the water.)
a. This message will display if the temperature of the water exceeds the high limit
temperature setpoint. To clear this error, wait until the temperature is below the
operating setpoint and press RESET. Note that the unit will not reset until the
indicated temperature is below 195°F. If this message continually occurs, follow
the troubleshooting flow chart for continuous over-temperature condition.
3. Err, No, H2O
a. This message will display when the water level in the tank has dropped below
the sensor probe. To clear this message, refill the tank. If the low water reset is
set for automatic, the error will clear. If the low water reset is set for manual,
when the tank is full press RESET. Check the heater and the piping for leaks.
Check for mineral buildup on the probe and clean as required. Check for
continuity between the yellow wire and ground.
4. Err, H2O, LEA
a. This message displays if the leak detection sensor determines there is water in
the base of the heater shell. To clear this message, remove the water from the
leak detection sensor. Check the unit and piping for leaks.
5. CC
a. This message displays if the display cable is installed into the control board
backwards. To clear this message, remove and correctly install the display cable.
6. 255
a. This message indicates that the probe is likely out of calibration. To clear this
message, it is recommended that the probe be removed and replaced.
7. HLd
a. This message indicates that the 24-volt interlock feature is enabled, there is no
24-volt signal present, and the heater is in standby mode. If it is not the intention
to operate the heater with the 24-volt interlock feature, this feature should be
disabled as shown in the controller operation section. (Only available with r23 or
later software).
CONTACTOR CARE
1. A chattering or humming from the contactor is due to dust or debris on the contact points
that prevents the contactor from making proper contact. The debris can be removed by
utilizing a can of antistatic cleaning and dusting spray (pressurized air) and spraying
through the side of the contactor to remove the debris.
DISPLAY BUTTONS
1. If the display randomly changes or does not respond when the buttons are pressed,
loosen the four (4) screws holding the display to the base, reseat the display in the
center of the opening, leaving the screws loose.