Super Hot 304B User manual

PN6510930
INSTALLATION AND SERVICE MANUAL
4 kW to 54 kW, 208 Vac to 600 Vac, Single or Three Phase
180ºF instantaneous hot water for commercial dishwashers
Suitable for installation with all “name-brand” dishwashers
SPACESAVER ELECTRIC BOOSTER
HOT WATER HEATERS
Manufactured by
Allied Engineering Company
Division of E-Z-Rect Manufacturing Ltd.
Manufacturers of Gas and Electric Boilers, Heat Exchangers, Electric Boosters, Indirect Tanks
94 Riverside Drive, North Vancouver, B.C. V7H 2M6  Telephone [phone]  www.alliedboilers.com
Branches: Calgary  Edmonton  Toronto  Denver
WARNING
RISK OF ELECTRIC SHOCK - This unit may be connected to more than
one electrical circuit. Turn off all electrical supply circuits before
servicing.
Failure to follow the information in this manual exactly may result in
property damage, personal injury or loss of life. Read all instructions
provided in this manual and all other information supplied with the
booster before installing. This manual must be used by a qualified
heating installer or service technician only.
IMPORTANT
 The booster heater must be installed in accordance with all applicable
national, provincial/state, and local codes, laws, regulations, and
ordinances.
 Carefully read this manual. This manual must be left with the owner and
should be located adjacent to the booster for reference.
 Ensure booster heater is full of water before turning on electricity.
Elements will burn out immediately without water in the booster heater.
 Booster heater voltage must be correct for voltage available. Check
nameplate on the booster heater for full information.
 Overcurrent protection between the power supply and the booster heater
must be provided in accordance with the national and/or local codes.
 Always ensure power switch is turned off before servicing.
 Under no circumstances should any electrical wiring or internal controls be
touched, except by a qualified electrician or any heating system be
adjusted, except by a qualified service technician.
SAVE THESE INSTRUCTIONS.
DATE OF INSTALLATION :
INSTALLED BY :
PHONE :

Electric Booster– Installation, Operating and Maintenance Instructions
2
Dimensions, Piping Diagram and Specifications Section 1
1.1 DIMENSIONS AND PIPING DIAGRAM
Figure 1 – Dimensions and Piping Diagram
1.2 TECHNICAL SPECIFICATIONS
Maximum Operating Pressure 130 p.s.i.
Maximum Operating Water Temperature 210ºF
Water Capacity in booster – 4-18kW 4.27 US Gallons
Water Capacity in booster – 24-54kW 5.80 US Gallons
Inlet and Outlet Pipe Size 3/4” NPT

Electric Booster– Installation, Operating and Maintenance Instructions
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TABLE 1. Super Hot Electric Booster Heater Specifications (Flange Type Elements)
BOOSTER MODEL NUMBERS, kW RATINGS AND MAX. AMPERAGE DRAW
Model
Number kW Btu/Hr
Tank
Capacity
U.S. Gal
U.S. Gal./Hr
40ºF Rise
Maximum Amperage Draw Approx.
Shipping
Weight
Single Phase Three Phase
208 240 208 240 480 600
304B 4 13,649 4.27 41 19.2 16.7 -- -- -- -- 60 LBS
305B 5 17.062 4.27 52 24.0 20.8 -- -- -- -- 60 LBS
306B 6 20,474 4.27 62 28.8 25.0 16.6 14.4 7.2 5.8 60 LBS
309B 9 30,711 4.27 93 43.3 37.5 25.0 21.6 10.8 8.7 60 LBS
312B 12 40,948 4.27 124 57.7 50.0 33.3 28.8 14.4 11.5 65 LBS
315B 15 51,185 4.27 156 72.1 62.5 46.4* 40.2* 20.1* 16.1* 65 LBS
318B 18 61,422 4.27 187 86.5 75.0 54.6* 47.3* 23.7* 18.9* 70 LBS
424B 24 81,895 5.80 249 115 100 66.5 57.7 28.8 23.1 70 LBS
430B 30 102,369 5.80 311 144 125 83.2 72.1 36.0 28.8 75 LBS
436B 36 122,843 5.80 373 173 150 100 86.5 43.3 34.6 75 LBS
545B 45 153,554 5.80 467 216 188 125 108 54.1 43.3 90 LBS
554B 54 184,264 5.80 560 260 225 150 130 64.9 51.9 90 LBS
SPECIFY MODEL NUMBER, VOLTAGE AND EITHER 1 OR 3 PHASE WHEN ORDERING
* Delta connection (unbalanced load): Leg with highest value of line current is indicated.
1.3 WATER TEMPERATURE RECOVERY
Booster Heater water recovery formulas:
G.P.H. (U.S.) = 415 x kW L.P.H. = 874 x kW
Temp. Rise (ºF) Temp. Rise (ºC)
TABLE 2. Water Temperature Recovery in GPH (LPH)
Model kW 30ºF (17ºC) 40ºF (22ºC) 50ºF (28ºC) 60ºF (33ºC) 70ºF (39ºC) 80ºF (44ºC) 90ºF (50ºC)
304B 4 55 (208) 41 (155) 33 (125) 28 (106) 24 (91) 21 (79) 18 (68)
305B 5 69 (261) 52 (197) 41 (155) 34 (129) 29 (110) 26 (98) 23 (87)
306B 6 83 (314) 62 (235) 50 (189) 41 (155) 35 (132) 31 (117) 27 (102)
309B 9 124 (469) 93 (352) 75 (284) 62 (235) 53 (200) 47 (178) 41 (155)
312B 12 166 (628) 124 (469) 100 (379) 83 (314) 71 (269) 62 (235) 55 (208)
315B 15 208 (787) 156 (590) 125 (473) 104 (394) 89 (337) 78 (295) 69 (261)
318B 18 249 (942) 187 (708) 149 (564) 125 (473) 107 (405) 93 (352) 83 (314)
424B 24 332 (1256) 249 (942) 199 (753) 166 (628) 142 (537) 125 (473) 111 (420)
430B 30 415 (1571) 311 (1177) 249 (942) 207 (783) 178 (673) 156 (590) 138 (522)
436B 36 498 (1885) 373 (1412) 299 (1132) 249 (942) 213 (806) 187 (708) 166 (628)
545B 45 622 (2354) 467 (1767) 373 (1412) 311 (1177) 267 (1010) 233 (882) 207 (783)
554B 54 747 (2827) 560 (2120) 448 (1695) 373 (1412) 320 (1211) 280 (1060) 249 (942)

Electric Booster– Installation, Operating and Maintenance Instructions
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Installation Instructions Section 2
2.1 RECEIVING
INSPECT SHIPMENT FOR POSSIBLE DAMAGE. All goods are carefully manufactured, inspected,
checked and packed by experienced workers. The manufacturer's responsibility ceases upon delivery of
goods to the carrier in good condition. Any claims for damage and/or shortage in shipment or non-delivery
must be filed immediately against the carrier by the consignee.
Use care when receiving and unpacking the tank. Dropping the booster heater may cause damage and
prevent safe and proper operation.
2.2 INTRODUCTION
Super Hot Electric Boosters are designed to produce 180ºF rinse water for commercial dishwashers to use
in cleaning and sanitizing dishware. The high efficiency and powerful rinse output of the booster heater
should result in significant savings on detergent and rinse additives. Compared with other methods of
sanitizing, the Super Hot Electric Booster is the economical choice and provides exceptional quality and
reliability.
2.3 INSTALLATION CODES AND REQUIREMENTS
All applicable national, provincial/state, and local codes, laws, regulations, and ordinances must be
followed. They expand on and take precedence over any recommendations in this booklet. Authorities
having jurisdiction shall be consulted before installations are made.
If an external electrical source is utilized, the booster heater, when installed, must be electrically grounded
in accordance with local codes or, in the absence of local codes, with the National Electrical Code,
ANSI/NFPA 70 (current edition) and/or the Canadian Electrical Code, CSA C22.1 Part 1 (current edition).
If there is any conflict in the above requirements, the more stringent requirement applies.
The installation and service must also conform to the additional requirements in this manual. If there is any
conflict with a requirement in this manual and a code requirement, the code requirement must be followed.

Electric Booster– Installation, Operating and Maintenance Instructions
5
2.4 BOOSTER HEATER LOCATION
DANGER – RISK OF EXPLOSION
Do not use or store gasoline or other flammable fuels or chemicals which have flammable vapors
near the booster. The vapors may be ignited by the heat or electronic components of the booster.
WARNING
The booster must be located in an area where water leakage of the booster or its connections will
not result in damage to the area adjacent to the appliance or to the lower floors of the structure.
When such locations cannot be avoided, a suitable drain pan must be installed under the appliance
and the drain pan must be connected to a drain of adequate capacity.
Failure to comply with the above could result in severe personal injury, death or substantial
property damage.
CAUTION
This booster must be installed such that any electronic components are protected from water
(dripping, spraying, rain, etc.) during appliance operation and service.
The space saving, compact booster heater can be installed almost
anywhere. The booster heater may be installed in an enclosed
space and attached directly to a combustible surface, however,
allow ample space for connecting, disconnecting and servicing the
unit. Locate booster heater as close to dishwasher as possible.
Dimensions are shown in Figure 1.
Sturdy plated steel legs are standard, but stainless steel hanging
brackets for under counter suspension are also available (specify
when ordering), see Figure 2.
2.5 PIPING
The recommended piping arrangement is shown in Figure 1. Use copper tubing only. Install the pressure
reducing valve (preset for 20 psi). Install the temperature and pressure relief valve on the booster heater
and plumb discharge in accordance with local codes. The temperature and pressure gauge attaches to a
tee on the inlet between reducing valve and booster heater. It is mandatory that a shock arrestor expansion
tank be installed on the line between booster heater and dishwasher (as close to dishwasher as possible).
It should be mounted in a vertical position above the pipe. In addition, it is recommended that the inlet and
outlet lines be insulated to prevent heat loss and that unions be used for piping connections to ease service.
All Super Hot booster heaters have 3/4" NPT inlet and outlet pipe size. Dielectric couplings should be used
in connecting dissimilar metals, such as galvanized to copper, to prevent electrolysis. A check valve should
not be installed in the supply line to the booster heater. All shut-off valves must be gate or ball valves, not
globe valves.
Figure 2 – Optional Hanging

Electric Booster– Installation, Operating and Maintenance Instructions
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2.6 T&P RELIEF VALVE PIPING
DANGER – RISK OF EXPLOSION
A T&P (temperature and pressure) relief valve must be installed to protect against excessive
temperature and pressure. Do not plug T&P relief valve or discharge piping. Plugging T&P relief
valve or discharge piping can cause excessive pressure, resulting in severe personal injury,
death or substantial property damage.
WARNING
The T&P valve may discharge pressurized hot water and/or steam. Steam exiting the discharge
outlet can explosively expand in any direction. Always maintain a safe distance from the
discharge pipe outlet in order to avoid potential contact with exiting hot water or steam.
Temperature and pressure settings of the T&P relief valve are factory set and are not adjustable. The T&P
valve must be of sized capacity to handle the maximum power of booster heater and not greater than the
operating restrictions stated on the rating plate of the booster heater and in this manual. Furthermore, the
service pressure should be at least 25 psi less than the setting stamped on the T&P relief valve.
Install the T&P relief valve directly into the T&P valve connection provided on the booster heater so that the
temperature sensing element is immersed in the water. No valve, reducing coupling or other restriction is
to be placed between the T&P relief valve and the booster heater connection. No valve, reducing coupling,
pipe plug, pipe cap or other restriction is to be placed in the discharge piping. Improper placement or piping
of the T&P relief valve can cause severe personal injury, death or substantial property damage.
The discharge line shall be installed to allow the complete drainage of both the valve and the line. It shall
be independently supported or arranged so as to avoid undue stress on the valve. Do not pipe in any area
where freezing may occur.
The termination of the T&P relief valve discharge line shall be downward and not directly connected to a
sewer line. The outlet of the discharge line shall terminate in the vicinity of a point of drainage within 6” of
the floor to eliminate potential risk of scalding and should terminate freely to atmosphere where any
discharge will be clearly visible and is at no risk of freezing.
2.7 WATER HAMMER
Water hammer is a damaging pressure shock wave created when the flow of water is suddenly stopped or
reduced (possibly induced by fast-closing faucet, reducing valve, or solenoid valve in a clothes/dishwashing
machine). This condition is commonly associated with hammering noises and vibrations; however, lack of
noise does not assure that water hammer is not present. Risers or air chambers do not provide protection.
To prevent damage to piping and the water heater: (1) install properly-sized water hammer arrestors at all
required locations and (2) adequately size pipes to ensure a maximum water velocity less than 5 ft/s.
2.8 FUNCTION OF PIPING ACCESSORIES
Shock Arrestor Expansion Tank:
Quick closing solenoid valves on the dishwasher will produce a shock pressure exceedingly high – up to
800 lbs. This may cause leaks in the plumbing and damage equipment such as relief valves, gauges, tank,
etc. The Shock Arrestor Expansion Tank provided with the booster heater must be installed.
Temperature and Pressure Indicating Gauge:
This gauge indicates the temperature and pressure and is useful when determining incoming water
temperature or adjusting the pressure reducing valve. It should be installed between the pressure reducing
valve and booster heater.
When a dishwasher is not equipped with a temperature gauge, a second gauge should be installed as close
to dishwasher as possible to verify 180ºF rinse temperature.

Electric Booster– Installation, Operating and Maintenance Instructions
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Temperature and Pressure Relief Valve:
The relief valve protects the tank from becoming overheated and/or over-pressurized. It opens and releases
water if the temperature exceeds 210ºF or if the pressure exceeds 125 psi (satisfies most local codes).
This device must be installed directly on the booster heater.
Pressure Reducing Valve with By-Pass:
When the supply pressure exceeds the final rinse pressure requirements, a pressure reducing valve with
built-in by-pass should be installed in the supply line to the booster heater. A pressure reducing valve
without a by-pass should not be installed as water expansion due to heating will cause the relief valve to
open.
Optional Extra Low Water Cut-Off:
A number of service calls are caused by energizing the heating elements in a “dry” tank. Even momentary
testing of the installation when the tank is dry will appreciably shorten the life of the element or burn it out
and affect the calibration of the aquastat.
The low water cut-off will protect the heating elements from damage by sensing if the tank is completely
filled with water before allowing the elements to operate.
2.9 WATER QUALITY
Always use good quality water to prolong the life of the booster. Water that is safe to drink and even city
water is not necessarily good quality water for the booster. The use of water treatment and filters can
prevent corrosion and reduce sediment in the booster. Water hardness, pH, and chlorides must be
controlled to normal levels.
 PH levels must be between 6.0 and 8.0
 Chlorine, chlorides or aggressive sulfates concentrations must be below 100 parts per
million.
If you are unsure, use a water softening system or consult a qualified water treatment expert.
NOTE: All improper use as detailed above could void the warranty of the booster.
Wiring and Controls Instructions Section 3
3.1 WIRING
WARNING
Turn off all the electric power before any wiring or service. All circuit breakers ahead of or related
to the booster operation must be switched off.
All electrical wiring is to be done in accordance with the Canadian Electrical Code, CSA C22.2 part 1, and/or
any local regulations and codes in Canada, or the National Electrical Code, ANSI/NFPA 70 (latest edition)
and/or any local regulations and codes in U.S.A. Verify the nameplate rating and check the related codes
to properly size conductors, switches and over-current protection. Check the voltage at the feeder panel,
compare to the values shown in Table 1, and supply the correct voltage power to the power supply block
on the booster heater. For wire connections, refer to the wiring diagram sticker on the back of the booster
heater front cover.
CAUTION
AC ONLY, USE COPPER WIRE ONLY. DO NOT USE ALUMINUM.

Electric Booster– Installation, Operating and Maintenance Instructions
8
3.2 CONTROLS
A “rapid response” aquastat provides temperature control and ensures safe operation. The aquastat switch
incorporates a magnetic contactor to complete the power circuit to the heating elements and control the
water temperature. By use of an adjustable dial the operating aquastat can control the water to the desired
temperature.
The electrical controls come pre-wired on the right-hand side of each booster heater where it is protected
from high ambient temperatures.
An indicator light visible on the front panel indicates that there is power to the heating elements when the
booster heater is in operation.
The low water cut-off (optional) uses a resistance-sensing probe to determine if the booster heater is filled
with water. If the booster heater is filled with water, the relay coil will close and allow the element to turn
on. Sensing resistance is dial-adjustable, turn dial clockwise to increase sensitivity.
Start-up Instructions Section 4
4.1 START-UP
WARNING
 The following instructions are intended as a guide for qualified persons.
 Before filling the booster, make sure that the T&P relief valve is installed and that the unit is
properly grounded.
 Before switching power on, fill system with water and vent air. Check for and repair any
leaks in water piping.
Perform the following procedure to check for proper booster heater operation:
1. Ensure power to the booster heater is turned OFF.
2. Set operating aquastat to give desired water temperature for dishwasher (usually 180ºF).
3. The operating aquastat setting should be at least 20ºF less than the temperature setting of T&P relief
valve (210ºF).
4. Run water through the booster heater for 5 minutes (or longer, if necessary) to ensure it is purged of
air and completely filled with water.
5. Check flow pressure with water flowing through the booster heater and, if necessary, readjust the
pressure reducing valve to 20 psi or to pressure recommended by dishwasher manufacturer.
6. Switch power to the booster heater ON.
7. The pilot lamp indicates that power is on when booster heater is operating.
8. Run a test cycle of dishwashing to confirm proper operation.
Maintenance Instructions Section 5
5.1 IMPORTANT
Many times when a booster heater does not appear to be functioning properly, the fault lies not with the
booster heater itself but with factors outside of the heater. Therefore, before becoming involved in corrective
work on the booster heater, the following steps should be followed:
 Check the temperature of the water feeding into the booster heater tank. It must be 140ºF or
the temperature designed and must be in sufficient quantity to hold its temperature throughout
the dishwashing operation.
 Incoming water temperature to the booster heater should not exceed 170ºF.
 If incoming water exceeds 20 psi, a pressure reducing valve must be installed.

Electric Booster– Installation, Operating and Maintenance Instructions
9
 If the wash tank of the dishwasher is filled through the booster heater, this will use up all the
180ºF water in storage. Sufficient time must be allowed to reheat the water in storage before
starting the dishwasher.
 Water pressure at the inlet to the booster heater must be adequate for proper operation of the
rinse cycle of the dishwasher.
 Be sure that the relief valve is one supplied by Allied Engineering Company.
 A check valve should not be installed ahead of the booster heater. Remove if present.
REPLACEMENT PARTS Section 6
6.1 ORDERING
Replacement parts or a replacement booster heater may be purchased through any Allied Engineering
Company distributor – call us if you need help locating a distributor near your area. If you require any
technical assistance or have any comments about our product, please write or phone us at:
Service Department
Allied Engineering Company
94 Riverside Drive
North Vancouver, B.C. CANADA
V7H 2M6
Tel [phone] Fax [phone]
Email: [email protected]
NOTE: To supply the correct part it is important that you state the model number and serial number.
Figure 3 – Replacement Parts

Electric Booster– Installation, Operating and Maintenance Instructions
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Troubleshooting Section 7
7.1 TROUBLESHOOTING
Problem Possible Cause Solution
Temperature too low or too
high. (Read rinse thermometer
on dishwasher)
Incorrect thermostat setting Remove booster heater front panel.
Adjust thermostat to correct setting
and check thermometer during rinse
cycle.
If machine cold, run rinse cycle twice
before checking proper reading.
Temperature should reach 180ºF –
185ºF (82ºC –85ºC).
Thermostat defective Check and replace, if necessary.
Rinse water temperature still
too low during continuous use.
Water supply to booster
heater below 140ºF (60ºC).
Read incoming water temperature by
combination gauge. Incoming
temperature should be 140ºF (60ºC)
(unless booster heater is specifically
designed for lower supply
temperature).
Increase incoming water temperature
to 140ºF (60ºC) at hot water supply
tank.
Pressure setting of pressure
reducing valve too high.
Read pressure on combination gauge
during rinse cycle.
Pressure reducing valve “PRV” should
be adjusted to dishwasher
specifications usually between 20 – 25
p.s.i.
Thermometer on dishwasher
not functioning properly.
Tap thermometer gauge with finger
during rinse cycle. If needle does not
move freely, contact dishwasher
manufacturer.
Booster heater too far from
dishwasher (more than 3 ft.)
Insulate pipe from booster heater to
dishwasher.
Relocate booster heater closer to
dishwasher.
Heating element(s) burned
out, faulty contactor or loose
wires
Turn off electricity to the booster
heater. Check elements, contactor and
wiring for continuity.

Electric Booster– Installation, Operating and Maintenance Instructions
11
Problem Possible Cause Solution
Temperature & pressure relief
valve discharges water
Thermostat set too high
above 185ºF (85ºC)
Remove front cover. Adjust thermostat
to a lower setting.
Pressure increases to 125
p.s.i. during booster heater
heating cycle because:
A. Pressure reducing
valve is an incorrect
style (without relief by-
pass). Letter “B”
should be in model
number.
Replace with correct pressure reducing
valve.
B. By-pass in pressure
reducing valve plugged
or inoperative.
While unit in heating cycle, tap pressure-
reducing valve with wood hammer or
screwdriver handle. If pressure gauge
does not show drop in pressure, replace
pressure-reducing valve.
Temperature & pressure relief
valve discharges water (after
checking above).
Relief valve not reseating
properly.
Quickly lift and release manual
discharge lever on relief valve to assist
proper reseating. If this fails, replace
temperature and pressure relief valve.
Water leaking from booster
heater.
Element and thermostat
threads may be leaking.
Turn off electricity to booster heater and
tighten elements.
Turn off water, drain, remove and apply
sealant if necessary. (Be sure to turn off
electricity before draining or elements
will burn out).
Plumbing connections may
be leaking.
Tighten incoming pipes, heating
elements, and temperature & pressure
relief valve. Turn off water, drain and
remove and apply sealant if necessary.
(Be sure to turn off electricity before
draining or elements will burn out).

Electric Booster– Installation, Operating and Maintenance Instructions
12
Index Section 8
Section Page
1 Dimensions, Piping Diagram and Specifications ....................................................................... 2
1.1 Dimensions and Piping Diagram ...................................................................................................... 2
1.2 Technical Specifications................................................................................................................... 2
1.3 Water Temperature Recovery .......................................................................................................... 3
2 Installation Instructions................................................................................................................. 4
2.1 Receiving ......................................................................................................................................... 4
2.2 Introduction ...................................................................................................................................... 4
2.3 Installation Codes and Requirements .............................................................................................. 4
2.4 Booster Heater Location .................................................................................................................. 5
2.5 Piping ............................................................................................................................................... 5
2.6 T&P Relief Valve Piping ................................................................................................................... 6
2.7 Water Hammer ................................................................................................................................. 6
2.8 Function of Piping Accessories ........................................................................................................ 6
2.9 Water Quality ................................................................................................................................... 7
3 Wiring and Controls Instructions ................................................................................................. 7
3.1 Wiring ............................................................................................................................................... 7
3.2 Controls ............................................................................................................................................ 8
4 Start-up Instructions ...................................................................................................................... 8
4.1 Start-up............................................................................................................................................. 8
5 Maintenance Instructions .............................................................................................................. 8
5.1 Important .......................................................................................................................................... 8
6 Replacement Parts ......................................................................................................................... 9
6.1 Ordering ........................................................................................................................................... 9
7 Troubleshooting ........................................................................................................................... 10
7.1 Troubleshooting ............................................................................................................................. 10
8 Index .............................................................................................................................................. 12