Keltech HL Series Installation Instruction Download | Manualshive

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729 S. Grove St., Delton, MI 49046
TEL: 269-623-6395 • 800-999-4320 FAX: 269-623-6398
[email protected] • www.keltech-inc.com

Installation

215-1823 Rev. A; ECN 150023

© 2015 Keltech

Page 1 of 20

11/24/2015

HL-Series

Tankless Heater Models

HL05
HL06
HL10 & L10
HL12
HL15 & L15
HL18 & L18

Voltage options:
208V Single and Three Phase
240V Single and Three Phase
277V Single Phase
380V Single and Three Phase
415V Single and Three Phase
480V Single and Three Phase

Table of Contents

Pre-Installation Information   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 2-3
Storage Instructions  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 3
Mounting Heater .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 4
Plumbing Installation   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 5-6
Electric Installation  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7
Start Up Check List   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 8
Start Up   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9
Digital Controller Operation   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10-11
Operational Tests   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 12-13
Product Options   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 13
Maintenance .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 14
Troubleshooting   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 15-16
Special Installation & Operating Instructions   .  .  .  .  .  .  .  .  .  . 17-20

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Summary of Contents for HL Series

Page 1: ... Single and Three Phase 240V Single and Three Phase 277V Single Phase 380V Single and Three Phase 415V Single and Three Phase 480V Single and Three Phase Table of Contents Pre Installation Information 2 3 Storage Instructions 3 Mounting Heater 4 Plumbing Installation 5 6 Electric Installation 7 Start Up Check List 8 Start Up 9 Digital Controller Operation 10 11 Operational Tests 12 13 Product Opti...

Page 2: ...water supply lines have been flushed and then completely turned off before beginning installation Debris in supply lines can cause valves to malfunction CAUTION Hot pipes Do not touch May cause minor burns NOTICE These heaters do not provide protection from supply or outlet pipe freezing Consult local building and plumbing codes prior to installation Should these codes differ from the information ...

Page 3: ...imize performance of the heater For use in a recirculation loop the incoming loop temperature should not exceed 140 F 60 C For applications utilizing quick close valves or solenoid valves it is important to install a hammer arrestor or surge tank close to the point of use to absorb pressure spikes Installation Considerations Maximum operating pressure 150psi Standard flow activation 0 5 gpm Certif...

Page 4: ...r plumbing for service maintenance Side View Wall Mounting Holes NEMA 1 A Set heater in a vertical upright position with the water inlet and outlet located at top Depending on the application the unit may also be installed rotated clockwise 90 with the inlet and outlet to the right B Mount heater to the wall using the 4 mounting brackets on the back of the enclosure Bolt the heater to the vertical...

Page 5: ... not perform any brazing or sweat soldering inside the enclosure NOTICE Failure to install proper filtration may result in a flow switch malfunction NOTICE To avoid water damage install a drain pipe from the pressure relief valve to an unrestricted drain per local code requirements If end use fixture is not at the highest point in the plumbing loop then an automatic air vent valve must be added at...

Page 6: ...015 Keltech 215 1823 Rev A ECN 150023 Plumbing Installation cont 2 25 1 2 648 3 4 Female NPT Outlet 11 279 3 4 Female NPT Inlet 2 5 16 59 2 51 24 610 14 1 2 368 16 406 7 178 N4 8 3 4 222 N4X Dimensions Plumbing and Electrical Configurations NEMA 4 4X ...

Page 7: ...ce with National Electric Code NEC for the full load amperage listed on the nameplate rating for each heater WARNING Failure to properly ground the unit s per the National Electric Code could result in injury or death ELECTRICAL SPECIFICATIONS FOR HEATER Single Phase Model Voltage Amps kWatts Min Wire Size HL060 480D 480 13 6 12 AWG HL120 480D 480 25 12 8 AWG HL180 480D 480 38 18 6 AWG HL060 415D ...

Page 8: ...and temperature relief valve on outlet if required by local or national plumbing codes If the hot water process is not at the highest point in the plumbing loop then an automatic air vent valve must be added at the highest point in the system plumbing loop to eliminate trapped air Electrical Verify supply voltage matches the indicated voltage on the Serial Tag Serial Tag is located within the heat...

Page 9: ... sure that plumbing and electrical are complete per Start Up Check List WARNING Make sure the breaker for the heater is OFF H When startup is complete leave the two or three pole switch or circuit breaker in the ON position The digital display should read ambient temperature and OFF G Turn on the connected process observe output temperature rise to setpoint On NEMA 1 controller set point and outpu...

Page 10: ...int Temperature Right Side Display Displays Setpoint Percent Power Temperature units F or C Menu prompt name Alarm code Output Temperature Left Side Display Displays Actual process temp of outgoing water Prompt parameter value Error code Output Temp Output Indicators Setpoint Temp Infinity Key Advance Key Setpoint Up Setpoint Down Output Temp Setpoint Temp Output Temp No Flow The pre programmed di...

Page 11: ...meters Output Indicators 1 5 Output 1 2 3 4 or 5 are active and operating if these LEDs are illuminated Setpoint Temperature Lower Display Displays Setpoint Percent Power Temperature units F or C Menu prompt name Alarm code Output Temperature Upper Display Displays Actual process temp of outgoing water Prompt parameter value Error code Output Indicators Output Temp Output Temp Output Temp No Flow ...

Page 12: ...pending on the hot water demand Digital temperature controller shows water temperature Additional programming is not necessary Heater will not energize heating elements if the inlet water temperature is equal to or greater than the temperature set on the digital controller If the water flow exceeds maximum heating capacity of the heater the temperature of water at the outlet may be lower than the ...

Page 13: ...ck Out Temperature lock out at specific F or C Low Flow L25 L15 Options include 0 25 GPM and 015 GPM for heating water at a lower flow as required D1 Control Interface Provides 4 20ma communication interface with temperature controller TE2 Corrosive Fluid Protection The TE2 option is a single layer of Xylan Fluoropolymeric coated heat exchanger with bright annealed stainless steel elements FDA App...

Page 14: ...ry 6 months or more often in areas where hard water sediment is present in the water To clean the Y Strainer 1 Turn the power off at the circuit breaker panel 2 Shut off the installer supplied cold water isolation valve to the heater 3 Relieve pressure in the plumbing lines 4 Position a bucket under the cold water inlet to catch any water that may still be in the pipe 5 Loosen the plumbing connect...

Page 15: ...ed due to excessive heat exchanger temperature or faulty sensor Turn power off Check for loose or disconnected wires Check the incoming service connection Voltage must match name plate rated voltage Labels are located on the upper left of back plate Serial Number Label Alarms do not occur Make sure alarm set points are correct Make sure alarm is not latched Make sure alarm side settings are correc...

Page 16: ...ower source A load voltage reading is also helpful If the above steps do not solve the problem some additional checks may be performed Follow the schematic to perform the following continuity checks High temperature bimetals Manual Reset Safeties Optional ground fault breaker must be in the closed position for the unit to work All internal breakers must be in the ON position for the unit to work F...

Page 17: ...EXP2 Installation Notes 1 Any tubing conduit or fittings connected to the Pressurized Enclosure PE must conform to local codes for flammability ratings 2 All egress into PE must be plugged and properly sealed to minimize leakage of purge air Use hazardous location sealing fittings suitable for Class I locations within 18 of enclosure 3 The EXP2 purge system option is a continuous flow purge system...

Page 18: ...osure and the protective gas supply The alarm actuator shall be mechanical pneumatic or electrical Electrical alarms and electrical alarm actuators shall be approved for the location in which they are installed No valves shall be permitted between the alarm actuator and the enclosure Intrinsically Safe IS Installation 1 Electrical equipment connected to associated apparatus should not use or gener...

Page 19: ...6 requirements No valves may be fitted between the Expo Technologies system and the alarm switch WARNING Never turn on the power without purging first unless you have proved the interior of the PE is gas free and checked that the Pressurized indicator is green Commissioning Test Commissioning Continuous Flow Purge Keltech Option EXP2 System 1 Open the air or gas supply shutoff valve 2 Adjust the F...

Page 20: ...larms function correctly Check the Relief Valve and any other Spark Arrestors Remove any debris or corrosion or replace the Spark Arrestor Check the condition of the air supply filter element Clean or replace it as necessary Periodic Maintenance Every 18 24 months At least every two years the following additional checks are recommended Apparatus Heater Purge Systems Alarms etc is suitable for the ...

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