Hubbell ME User manual

OPERATING AND MAINTENANCE MANUAL FOR
MARINE ELECTRIC WATER HEATER
ELECTRIC HEATER COMPANY
BASE MODEL “ ME ”

2
HUBBELL
ELECTRIC HEATER COMPANY
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. Safety relief valve must be installed in tapping provided.
4. 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. A low megohm condition can be corrected by
removing the terminalhardware and baking the element in an oven at 350°F -700°F for
several hours or until the proper megohm reading is obtained.
5. KEEP AWAY FROM LIVE ELECTRICAL CIRCUITS.
Do not perform any maintenance, make any adjustments, or replace any components
inside the control panel 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.
6. The unit is designed to operate at pressure not more than 100 psi.
7. 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 regulation,
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.

3
SECTION TITLE PAGE No.
I GENERAL DESCRIPTION AND CONSTRUCTION 4
II INSTALLATION 6
III SCHEDULED MAINTENANCE AND OPERATION 8
IV TROUBLESHOOTING 9
V SERVICING AND REPLACEMENT OF PARTS 10
VI MISCELANEOUS CHARTS AND FORMULAS 18
VII ABS TYPE APPROVAL PROGRAM 20

SECTION I -GENERAL DESCRIPTION AND CONSTRUCTION
GENERAL DESCRIPTION
This book describes a packaged electric water heater, approved by ABS Americas (A Division
of the American Bureau of Shipping) and the USCG (United States Coast Guard), which is a
stationary, self contained unit and is designed and constructed specifically for marine
applications on board a surface vessel. The complete assembly consists of the storage tank,
immersion electric heating element(s), thermostat, safety relief valve, safety high temperature
cut out, and any other required electrical operating control. Optional equipment may be
supplied with your unit. Please consult the product drawing for details specific to your
assembly. The unit is factory assembled, insulated, jacketed, wired, tested, and ready for
electrical and plumbing service connections.
CONSTRUCTION
TANK
Standard Tank Construction:
The standard storage tank is constructed of steel and internally lined with specially formulated
Hydrastone cement to a ½-inch minimum thickness. The tank is designed for a maximum
allowable working pressure of 100 psi (150 psi TP).
Optional Tank Construction:
Optionally, the storage tank may be constructed of all welded solid copper-silicon alloy (ASTM
B-96) or type 316L stainless steel for maximum tank longevity. No internal lining is required
due to the non-ferrous materials used in the construction of the pressure vessel. The tank is
designed for a maximum allowable working pressure of 100 psi (150psi TP).
TANK CONNECTIONS
The heater is supplied with separate cold water and hot water connections. Water entering the
cold water inlet is deflected by means of a baffle within the tank. The hot water outlet includes a
built in heat trap to prevent hot water from radiating out from the heater. A ¾-inch FNPT
connection is located on the side of the heater for mounting a combination safety temperature
and pressure relief valve. An overflow line should be utilized from the relief valve outlet to a
floor drain. A ¾-inch GHT connection is supplied for draining. See drawing for locations and
sizes.
HEATING ELEMENT
The water heater is supplied with an
electric immersion heating element
assembly(s), composed of a copper
sheathed element(s) that are brazed into a brass flange. Each assembly is fastened to a
corresponding tank flange using a gasket and four (4) 3/8-16 x 1-inch long hex head steel bolts
and nuts. See drawing for voltage and power ratings.
CONTROL THERMOSTAT
The water heater is supplied with either a surface mounted or immersion thermostatic switch
that is installed and wired at the factory. See drawing for specific details. The surface mounted
thermostat can be adjusted through a range of 110° - 170° F. The immersion thermostat can be
adjusted through a range of 100° - 190° F. Both thermostats are adjustable with a flat tip
screwdriver.
4
Surface Mounted Thermostat
Immersion Thermostat

5
TEMPERATURE HIGH LIMIT SWITCH
As a safety device, either a surface mounted high temperature cut-off switch with manual reset,
factory set at 190° F, or an immersion high temperature cut-off switch with manual reset,
factory set at 180° F, is provided. In the event of an over-temperature condition, the thermostat
will disengage the power from the system. The high limit must be manually reset thereafter to
restart the heater.
ManualReset
Surface Mounted High
Temperature Cut-Off Switch Immersion High Temperature Cut-Off Switch
OUTER SHELL AND INSULATION
The tank is encapsulated in 2-inch thick polyurethane foam insulation. The insulation is
protected by a high impact non-corroding colorized composite protective jacket.
OPTIONS
The following optional features may be included in your water heater. Reference included
drawing specific to your heater for further details.
Low Water Cut-Off
Used as a safety device, the electronic low water cut-off is used to
detect a low water situation and disengage the operating coils in
the magnetic contactor(s). Once the condition is remedied, the low
water cut-off switch is automatically reset.
Dial Temperature and Pressure Gauge
A combination temperature (70° - 250° F) and pressure (0 – 200
psi) gauge with 2½-inch dial may be supplied for in-line installation
(shipped loose) or factory installed in the tank.
Vacuum Relief Valve
A vacuum relief valve may be provided with the unit to reduce the risk of
back siphonage and back pressure of the system. The valve will be shipped
loose for in-line installation. Instructions for installation are provided with the
valve.
Electro-Mechanical Timer
An electro-mechanical 7-day time clock with battery back-up may be
supplied for specific timing operations. A set of instructions will be
supplied with the timer.

SECTION II – INSTALLATION
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.
For protection against excessive pressures and temperatures, local codes require the
installation of a temperature-and-pressure (T&P) relief valve certified by a nationally
recognized laboratory that maintains periodic inspection of production of listed equipment of
materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff for Hot
Water Supply Systems. ANSI Z21.22-1971. THE CUSTOMER IS RESPONSIBLE TO
PROTECT PROPERTY AND PERSONNEL FROM HARM WHEN THE VALVE
FUNCTIONS.
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 PROPERTY.
WATER HEATER PLACEMENT
1. Place the heater on a solid foundation in a clean, dry location nearest to the point of
most frequent hot water use.
2. The water heater should be protected from freezing and waterlines insulated to reduce
energy and water waste.
3. Leave a minimum of 18” clearance for element withdrawal, if necessary.
4. Do not install in an area where flammable liquids or combustible vapors are present.
SECURING OF HEATER
1. The heater is supported by four 2-inch x 2-inch x ¼-inch thick angle iron legs each with
a 3-inch x 3-inch x ¼-inch thick steel base pad. Each leg is provided with one 9/16-inch
diameter bolt hole for one ½-inch bolt which should be used to secure heater to the deck.
2. In addition to the leg supports, two 3-inch x 3-inch x ¼-inch thick brackets with 7/8-inch
diameter mounting holes are attached to the upper portion of the heater. These brackets
should be attached to bulkhead secured tie-rods thus insuring further support of the
heater for shipboard installation.
6

7
Mounting Dimensions
Tank
Diameter
“A”
Overall
Diameter
“B”
Bolt
Circle
“C”
Bulkhead
Mounting
Dimension
“D”
Gallon
Capacity
16 20 12 None 10
16 20 12 None 20
16 20 12 None 30
16 20 12 12 40
18 3/4 22 3/4 16 12 50
22 26 16 12 65
22 26 16 12 80
24 28 18 12 100
24 28 18 12 120
PIPING INSTALLATION
NOTE: The most effective means for preventing deterioration from accelerated corrosion
due to galvanic and stray current is the installation of dielectric fittings/unions. The
installation of these fittings is the responsibility of the installing contractor.
1. Connect the cold water inlet and hot water outlet to the appropriate connections as
shown; refer to the drawing for location and sizes.
2. Install in-line vacuum breaker, if supplied.
3. Install in-line pressure and temperature gauge, if supplied.
4. Install the combination temperature and pressure safety relief valve in the tapping
provided. Note that this is required by law for safety considerations.
Outlettofloordrain Installintoprovidedtapping
Manual Release
Lever
Temperature Probe
Temperature and Pressure Relief Valve
5. Install a relief valve overflow pipe to a nearby floor drain. CAUTION: No valve of
any type should be installed between the relief valve and tank or in the drain line.
FILLING THE HEATER
1. Completely close the drain valve.
2. Open the highest hot water faucet to allow all air to escape from piping.
3. Open the valve to the cold water inlet and allow the heater and piping system to
completely fill, as indicated by a steady flow of water from the open faucet.
ELECTRICAL INSTALLATION
1. Enter junction box with properly sized feeder leads. Single-phase installations require
two (2) leads; three phase installations require three (3) leads.
2. Connect these power leads to wires enclosed in junction box with wire nuts.
3. All other electrical connections are made at the factory; therefore, no other electrical
connections are necessary.

8
FINAL CHECKS
1. Check all connections for tightness.
2. Ensure that all the above steps are completed
3. After the water is heated for the first time, monitor the water temperature as described
in Section III, Quarterly Inspection.
SECTION III -SCHEDULED MAINTENANCE AND OPERATION
WARNING / CAUTION
Before performing any maintenance procedure,make certain power supply is 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 thermostat. 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.
QUARTERLY INSPECTION
1. Monitor thermostat
a. Let water heater completely heat to a designated thermostat setting.
b. After thermostat satisfies (that is, when the thermostat actually clicks off), draw water
from heater.
c. Compare water temperature of drawn water to the temperature setting of the
thermostat 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 gauge, replace the thermostat.
2. Lift test lever on relief valve and let water run through valve for a period of
approximately 10 seconds. This will help flush away any sediment that might build up in
water passageways.
3. Inspect element flange for leakage as follows:
a. Shut off Power Supply.
b. Remove element housing cover.
c. Visually inspect heating element gasket for evidence of leaks.
d. Rub finger around gasket that is between the heating element and tank flange for any
evidence of moisture. If moisture is present or a water drip is observed, follow
procedure outlined in Section V.
4. Check for loose electrical connections. Tighten as necessary.
ANNUAL INSPECTION
1. Flush tank as follows
a. Shut off power supply.
b. Close valve on hot water outlet piping.
c. Open valve on drain piping.
d. Cold water inlet line pressure will be strong enough to flush sediment from the bottom
of the tank out through the drain. Let water run for 3-4 minutes.
e. Close drain valve.
f. Open hot water valve.
g. Turn power supply ON.

9
SECTION IV – TROUBLESHOOTING
Symptom Probable Cause Corrective Action / Remedy
No hot water Circuit breaker tripped at
source. Reset circuit breaker.
High limit switch tripped. Reset high limit switch.
Loose wires. Tighten wires. Torque screws per
torque chart included in Section VI.
Heating element inoperable. Check heating element operation by
clamping an Amprobe around each
wire to the element. The ampere
reading should agree with the
nameplate ‘AMP’ figure.
Low line voltage. Have source electrical system
checked by an electrician.
Faulty thermostat. Move thermostat dial through full
range. A definite ‘click’ should be
heard. If not, replace thermostat.
Faulty low water cut-off, if
installed. Check to see if tank is full of water. If not, fill tank. If problem continues
and tank is full, check for continuity
between the common and normally
open contact of the relay board. If
continuity is not observed, replace
low water cut-off.
Water temperature
below settings at
all times
Faulty thermostat. Check thermostat adjustment.
Monitor thermostat as described in
Section III, Quarterly Inspection.
Replace if necessary.
Heating element not
working on all phases Check to see that heating element is working on all phases, by checking
the resistance (ohms) value for each
element and comparing with the
chart included in Section VI.
Heater improperly sized Verify heater is properly sized for the
flow rate and temperature rise of your
system. See formulas included in
Section VI. Replace elements with
proper size as necessary.
Relief valve
discharges
continuously
Excessive temperature or
pressure in tank Temperature and pressure relief valves are made to operate if the
water temperature exceeds 210°F or
water pressure exceeds the pressure
rating of the safety relief valve. If
trouble is excessive temperature, then
thermostat is not shutting off at the
right setting and thermostat must be
replaced.

SECTION V -SERVICING & REPLACEMENT OF PARTS
WARNING / CAUTION
Before servicing or replacing any part make sure to turn the power supply switch to the OFF
position.
SURFACE TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover.
3. Disconnect the four (4) 14 gauge wires or three (3) 14 gauge wires and a jumper, as
required.
Control Wires
4. Remove the two (2) mounting screws or disconnect from thermostat, as required.
5. Replace control and install new high limit switch by performing above steps in reverse
order.
10
IMMERSION TEMPERATURE HIGH LIMIT CUT-OFF
1. Disconnect power from unit.
2. Remove access cover
3. Remove high limit cover screw and cover.
Cover
Cover Screw
Mounting Screws

11
Reset Switch
4. Disconnect the two (2) 14 gauge wires.
Wires
Capillary Tubes
5. Remove capillary tube and bulb from thermowell
6. Remove two (2) mounting screws.
Mounting Screws
7. Remove control and install new high limit switch by performing above steps in
reverse order. (Note: Be sure to place capillary tube into slot in base prior to installing
cover.)
HEATING ELEMENT
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Attach hose to drain connection.
4. Lift manual release lever on relief valve to let air into system or break union on
outgoing water line.
5. Drain water from tank.
6. Disconnect the wires from the heating element terminals.

Tank Flange
Wires
12
7. Remove the 3/8-16 nuts.
8. Withdraw element assembly and remove gasket.
Gasket
Element Assembly
Nuts
9. Install new gasket and insert new heating element.
10.Rewire element according to type of unit as shown below.
11.Fill tank and check around gasket for any leaks.

13
2
L1 L2 L3
L1 L2
Single Element Operation
3ØOpenDeltaWiringforSimultaneousOperation
4
3
2
1
1 3
24
1
1
2
31
24
1
2

L1 L2 L1 L2
14
2
1
4
4
3
2
2
1
1
2
1
4
4
3
2
1
2
1
Interlocked for Non-Simultaneous Operation Non-Interlocked for Simultaneous
Operation

15
SURFACE MOUNTED THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Disconnect the two (2) or three (3) 14 gauge wires and jumpers, as required.
Control Wires
4. Remove two (2) mounting screws and disconnect from high limit cut-off, if required.
Mounting Screws
5. Replace thermostat using the reverse procedure.
IMMERSION THERMOSTAT
1. Disconnect power from unit.
2. Remove access cover and locate thermostat.
3. Remove high limit cover screw and cover.
Cover
Cover Screw

4. Disconnect the two (2) or three (3)
14 gauge wires, as required.
Wires
Capillary Tube
5. Remove capillary tube and bulb from
thermowell.
6. Remove two (2) mounting screws.
Mounting Screws
7. Replace thermostat using reverse procedure. (Note: Be sure to place capillary tube
into slot in base prior to installing cover.)
16

17
RELIEF VALVE
1. Disconnect power from unit.
2. Shut off incoming water supply.
3. Lift test lever on relief valve to relieve pressure in tank.
4. Disconnect overflow piping.
5. Unscrew relief valve, remove assembly and replace with new one.
6. Connect overflow piping.
7. Turn on incoming water supply and check for leaks.
8. Turn safety switch to ON position.
Test Lever
Overflow Piping Outlet
Tank Connection
Temperature Probe

SECTION VI –MISCELLANEOUS CHARTS AND FORMULAS
ELEMENT CHART
Element Part #
Power (Watts) Immersion
Length
Element
Resistance
(Ohms)120V 208V 240V 277V 480V
CH-FO-358 ---- 3500 ---- ---- ---- 11 3/8" 12.36
CH-FO-408 ---- 4000 ---- ---- ---- 11 3/8" 10.82
CH-FO-508 ---- 5000 ---- ---- ---- 13 1/4" 8.65
CH-FO-608 2000 6000 ---- ---- ---- 13 3/8" 7.21
CH-FO-304 ---- ---- 3000 4000 ---- 9 3/4" 19.20
CH-FO-354 ---- 2500 3500 ---- ---- 9 3/4" 16.46
CH-FO-404 ---- 3000 4000 ---- ---- 11 1/2" 14.40
CH-FO-454 ---- ---- 4500 ---- ---- 11 1/2" 12.80
CH-FO-504 ---- ---- 5000 ---- ---- 11 1/2" 11.52
CH-FO-604 1500 4500 6000 ---- ---- 13 1/2" 9.60
TGB-1203-480 ---- ---- ---- ---- 2000 7 5/8" 83.23
TGB-1353-480 ---- 500 ---- 1000 3500 12 1/2" 47.56
TGB-2257L 2500 ---- ---- ---- ---- 9 5/8" 5.76
TGB-1207-240 500 1500 2000 2500 ---- 13 3/8" 28.80
TGB-1303-480 ---- ---- 990 3000 10 1/2" 55.49
TGB-1403-480 ---- ---- 1000 1350 4000 13 5/8" 41.62
TGB-2257-240 ---- 2000 2500 3500 ---- 10 5/8" 23.04
TGB-2257-480 ---- ---- ---- ---- 2500 13 1/4" 66.59
TGB-2457-277 ---- ---- ---- 4500 ---- 13 1/8" 17.05
TGB-2457-480 ---- ---- ---- 1500 4500 13 1/4" 36.99
TGB-2503-480 ---- 1000 ---- ---- 5000 9 3/4" 33.29
TGB-2507-277 ---- ---- ---- 5000 ---- 15" 15.35
TGB-2603-277 ---- ---- ---- 6000 ---- 15 1/2" 12.79
TGB-2603-480 ---- ---- 1500 2000 6000 15 1/2" 27.74
*Red wattage indicates the stamped element rating
18
FORMULAS

19
TORQUE VALUES
BOLT SIZE 18-8 S/S
IN.-LBS.
BRASS
IN.-LBS.
SILICON
BRONZE
IN.-LBS.
ALUMINUM
2024-T4
IN.-LBS.
316 S/S
IN.-LBS.
MONEL
IN.-LBS.
4-40 5.2 4.3 4.8 2.9 5.5 5.3
4-48 6.6 5.4 6.1 3.6 6.9 6.7
5-40 7.7 6.3 7.1 4.2 8.1 7.8
5-44 9.4 7.7 8.7 5.1 9.8 9.6
6-32 9.6 7.9 8.9 5.3 10.1 9.8
6-40 12.1 9.9 11.2 6.6 12.7 12.3
8-32 19.8 16.2 18.4 10.8 20.7 20.2
8-36 22.0 18.0 20.4 12.0 23.0 22.4
10-24 22.8 18.6 21.2 13.8 23.8 25.9
10-32 31.7 25.9 29.3 19.2 33.1 34.9
1/4-20 75.2 61.5 68.8 45.6 78.8 85.3
1/4-28 94.0 77.0 87.0 57.0 99.0 106.0
5/16-18 132 107 123 80 138 149
5/16-24 142 116 131 86 147 160
3/8-16 236 192 219 143 247 266
3/8-24 259 212 240 157 271 294
7/16-14 376 317 349 228 393 427
7/16-20 400 327 371 242 418 451
1/2-13 517 422 480 313 542 584
1/2-20 541 443 502 328 565 613
9/16-12 682 558 632 413 713 774
9/16-18 752 615 697 456 787 855
5/8-11 1110 907 1030 715 1160 1330
5/8-18 1244 1016 1154 798 1301 1482
3/4-10 1530 1249 1416 980 1582 1832
3/4-16 1490 1220 1382 958 1558 1790
7/8-9 2328 1905 2140 1495 2430 2775
7/8-14 2318 1895 2130 1490 2420 2755
1-8 3440 2815 3185 2205 3595 4130
1-14 3110 2545 2885 1995 3250 3730

SECTION VII –ABS TYPE APPROVAL PROGRAM
20