Hatco C-7-208-3 Compact 7.0 kW Insulated Booster Water Heater User Manual

C-7-208-3 Compact 7.0 kW Insulated Booster Water Heater
User Manualhatcocorp.com
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C-7-208-3 Compact 7.0 kW Insulated Booster Water Heater

Electric Booster Water Heaters
Imperial, Compact, and Mini-Compact Series
Installation and Operating Manual

WARNING
Do not operate this equipment unless you have read and understood the contents of this manual! Failure to follow the instructions contained in this manual may result in serious injury or death. This manual contains important safety information concerning the maintenance, use, and operation of this product. If you’re unable to understand the contents of this manual, please bring it to the attention of your supervisor. Keep this manual in a safe location for future reference.

IMPORTANT OWNER INFORMATION

Record the model number, serial number, voltage, and purchasedate of the unit in the spaces below (specification label located on the unit). Please have this information available when callingHatco for service assistance.
Model No.
Serial No.
Voltage ____
Date of Purchase __
Register your unit!
Completing online warranty registration will prevent delay in obtaining warranty coverage. Access the Hatco website at www.hatcocorp.com, select the Support pull-down menu, and click on “Warranty”.

Business Hours:
7:00 am to 5:00 pm Monday–Friday,Central Time (CT)
(Summer Hours — June to September: 7:00 am to 5:00 pm Monday–Thursday 7:00 am to 4:00 pm Friday)
Telephone: 800-558-0607; 414-671-6350
E-mail: support@hatcocorp.com
24 Hour 7 Day Parts and Service
Assistance available in the United States and Canada by calling 800-558-0607.
Additional information can be found by visiting our web site at www.hatcocorp.com.

INTRODUCTION

Hatco Electric Booster Water Heaters are designed for use with commercial dish machines to boost the temperature of the regularly available hot water, usually 115°–150°F (46°–66°C) up to 180°F (82°C). Water at 180°F (82°C) can be used as sanitizing rinse water in commercial dish machines in accordance with Health Codes, NSF Standard #5 and plumbing codes.
All Hatco Booster Heaters are ready for electrical and plumbing service connections, with an adjustable ambient compensated immersion thermostat(s) and a high temperature limit switch.
The service area is accessible from the front of the unit, permitting easy access.
Hatco Electric Booster Water Heaters are products of extensive research and field testing. The materials used were selected for maximum durability, attractive appearance, and optimum performance. Every unit is inspected and tested thoroughly prior to shipment.
This manual provides the installation, safety, and operating instructions for the Hatco Electric Booster Water Heaters. Hatco recommends all installation, operating, and safety instructions appearing in this manual be read prior to installation or operation of the unit.
Safety information that appears in this manual is identified by he following signal word panels:
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
** Read the following important safety information before using this equipment to avoid serious injury or death and to avoid damage to equipment or property.
WARNING
ELECTRIC SHOCK HAZARD:**

• Unit must be installed by qualified, trained installers. Installation must conform to all local electrical and plumbing codes. Installation by unqualified personnel will void the unit warranty and may lead to electric shock or burn, as well as damage to unit and/or its surroundings. Check with local plumbing and electrical inspectors for proper procedures and codes.
• Turn OFF power at fused disconnect switch/circuit breaker and allow unit to cool before performing any cleaning, adjustments, or maintenance.
• Consult a licensed electrical contractor for proper electrical installation conforming to local electrical codes and the National Electrical Code (N.E.C.).
• Unit is not weatherproof. Locate unit indoors where ambient air temperature is a minimum of 70°F (21°C).
• Do not place aftermarket covers on or over booster heater. Doing so can cause temperature and moisture build-up resulting in premature failure and electrical shock.
• This unit must be serviced by qualified personnel only. Service by unqualified personnel may lead to electric shock or burn.
• Use only Genuine Hatco Replacement Parts when service is required. Failure to use Genuine Hatco Replacement Parts will void all warranties and may subject operators of the equipment to hazardous electrical voltage, resulting in electrical shock or burn. Genuine Hatco Replacement Parts are specified to operate safely in the environments in which they are used. Some aftermarket or generic replacement parts do not have the characteristics that will allow them to operate safely in Hatco equipment.

Valves supplied by Hatco are designed for high-temperature commercial operation. Do not substitute Hatco valves with valves designed for domestic water heaters.
Temperature/pressure protective equipment should not be less than a combination temperature/pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of this equipment and meets the requirements for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22-1979. The temperature/pressure relief valve must be marked with a minimum set pressure not to exceed the marked hydrostatic test pressure of the
booster heater as noted on the unit specifications.
EXPLOSION HAZARD: Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
WARNING
FOR INSTALLING PRESSURE AND TEMPERATURE RELIEF VALVES IN ACCORDANCE WITH AMERICAN NATIONAL STD. Z21.22-1979. Combination pressure and temperature relief valves with extension thermostats must be installed so that the temperature-sensing element is immersed in the water within the top 6″ (152 mm) of the tank. They must be installed directly in a tank tapping. Combination pressure and temperature relief valves that do not have extension elements must be mounted directly in a tank tapping located within the top 6″ (152 mm) of the tank, and shall be adequately insulated and located so as to assure isolation from ambient conditions that are not indicative of stored water temperature. TO AVOID WATER DAMAGE OR SCALDING DUE TO VALVE OPERATION, DRAIN PIPE MUST BE CONNECTED TO VALVE OUTLET AND RUN TO A SAFE PLACE OF DISPOSAL. Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length. Drain line must pitch downward from the valve and must terminate between 1-1/2″ (38 mm) and 6″ (152 mm) above the floor drain where any discharge will be clearly  visible. The drain line shall terminate plain, not threaded, with material serviceable for temperatures up to 250°F (121°C) or greater. Excessive length, over 30′ (9.1 m), or use of more than four elbows can cause a restriction and reduce the discharge capacity of the valve. No shut-off valve shall be installed between the relief valve and tank, or in the drain line. Valve lever must be tripped periodically to assure that waterways are clear. This device is designated for emergency safety relief and shall not be used as an operating control. The valves are set to relieve at 150 psi (1034 kPa) or when water temperature reaches 210°F (99°C). Read tag on valve for additional information. Use only copper plumbing material. Non-copper plumbing material may create an unsafe condition.
Units are equipped with a high temperature limit safety switch that will shut off the power if the unit overheats. Contact an Authorized Hatco Service Agent if the high temperature limit safety switch cannot be reset or continues to trip.
Install booster water heater in a horizontal position with the base parallel to the floor and the inlet connection at the lowest point. Improper installation could create an unsafe condition.
Do not connect booster water heaters to domestic (consumer) dish machines or other domestic utilized equipment. This booster may damage domestic equipment.
WARNING
This product contains fiberglass, a product known to the state of California to cause cancer, birth defects, or other reproductive harm.
Install booster water heater as close as possible to a commercial dish machine. Employ re-circulation if distance between water heater and dish machine exceeds National Sanitation Foundation (NSF) specifications of five (5) linear feet (1524 mm).
Follow standard welding safety and operational procedures when attaching sliderails to bottom of dishtable. Make sure the dishtable is strong enough to support the weight of the heater AND water when installing with slide mounting brackets.
Refer to the BOOSTER HEATER SIZING CHART in this manual to ensure proper sizing and avoid personal injury and/or damage to the booster heater.
It is essential to recognize that even though a water heater may be properly installed initially and approved, there always exists the possibility that unknowing individuals might alter or change the installation in a manner that would render it unsafe. Therefore, it is important that all safety programs provide some mechanism to assure that these installations are inspected periodically.
This unit has no “user-serviceable” parts. If service is required on this unit, contact an Authorized Hatco Service Agent or contact the Hatco Service Department at 800-558-0607 or 414-671-6350.
vCAUTION
BURN HAZARD:

• Water in unit is very hot. Wear protective gloves and proper attire when operating to avoid injury.
• Valves supplied by Hatco are designed for high temperature commercial operation. Do not substitute Hatco valves with valves designed for domestic water heaters.

Do not use anti-siphon valves on incoming water line. Check valves on incoming water line is not recommended. Damages caused by the use of check valves on unit will not be covered by warranty.
Do not connect booster heater directly to a boiler or furnace coil or any other uncontrolled temperature source.
The booster heater thermostat could be damaged causing unit to overheat.
Incoming water temperature should be minimum of 85°F (29°C). Damage to the heater can occur if water is cooler than 85°F (29°C).
**CAUTION
Hatco requires that two temperature/pressure gauges (Hatco P/N 03.01.003.00) be installed to ensure proper operation. Install one in the supply line before the pressure
reducing valve and one in the outlet line as close to the booster heater as possible. This provides a visual check of the water temperature and pressure before and after the
water heater.
If water supply pressure to the booster inlet is over 20 psi (138 kPa) during flow, install pressure reducing valve with built-in bypass (Hatco P/N 03.02.004.00) for
proper operation of dish machine rinse nozzles.
NOTE: The pressure reducing valve must be the type equipped with a high pressure bypass, as supplied by Hatco.
DO NOT turn on power to the booster heater until tank has been filled with water and all air has been vented through the dish machine rinse nozzles. Heating elements will burn out in seconds if operated when not immersed in water.
NOTICE**
Always drain booster heater with power to the unit off or element burnout could occur.
Use dielectric couplings when connecting dissimilar metals, such as galvanized to copper. This will prevent electrolysis or premature plumbing damage.
Do not turn or adjust outlet water connection on all Large Compact Series units (C-24 to C-57).
Do not turn or adjust inlet or outlet water connection on Compact Series Booster Heaters or internal water flow will change and the unit will not produce a consistent outlet
temperature.
Do not back out or loosen any pipe fittings or leaks may occur.
Do not lay unit on the side with the control panel or inlet  and outlet pipes. Damage to the unit could occur.
Incoming water in excess of 3 grains of hardness per gallon (GPG) (0.75 grains of hardness per liter [GPL]) must be treated and softened before being supplied to booster heater(s). Water containing over 3 GPG (0.75 GPL) will decrease efficiency, increase energy use, and reduce the operating life of the unit through increased lime build-up.
Product failure caused by liming or sediment buildup is not covered under warranty.
Do not use deionized water. Deionized water will shorten the life of water reservoir and heating element. Units are voltage-specific. Refer to specification label for electrical requirements before beginning installation.
Connecting unit to incorrect power supply will void product warranty and may damage unit.

MODEL DESCRIPTION

All Models
Hatco Electric Water Booster Heaters are available in three models: Imperial, Compact, and Mini-Compact. All standard models include a booster heater with low-water cut-off system, temperature/pressure relief valve, pressure reducing valve with built-in high pressure bypass, two temperature/pressure gauges, and a high temperature limit safety switch.
Imperial Models “S” Series
Hatco Imperial models feature a Castone® tank with a 10 year limited tank warranty, a Power I/O (on/off) switch, an indicator light, and 6″ (152 mm) legs. Imperial units have a capacity of 16 gallons (61 liters) and provide up to 572 gallons per hour (GPH) (2169 liters per hour [LPH]) of sanitizing rinse water based on a 40°F (22°C) temperature rise. Compact Models “C” Series
Hatco Compact models feature a Castone® tank with a 10 year limited tank warranty, a Power I/O (on/off) switch, an indicator light, and either 6″ (152 mm) legs or slide mounting brackets for mounting under a dish table. Compact units have a capacity of 6 gallons (23 liters) and provide up to 573 GPH (2169 LPH) of sanitizing rinse water based on a 40°F (22°C) temperature rise. Mini-Compact Models “MC” Series
Hatco Mini-Compact models feature a stainless steel tank with a 10 year limited tank warranty and 6″ (152 mm) legs. MiniCompact units have a capacity of 3.2 gallons (12 liters) and provide up to 172 GPH (655 LPH) of sanitizing rinse water based on a 40°F (22°C) temperature rise. Ideal for either hot water sanitizing or point-of-use hot water dispensing.
NOTE: Mini-Compact models can be configured with an optional Power I/O (on/off) switch.

SPECIFICATIONS

Booster Heater Sizing Chart
Use the table below or the “Booster Heater Sizing Formula” to determine what Booster Heater kW rating is needed with your dishmachine.

1. Determine the water temperature rise.
   a. Subtract the lowest incoming water temperature supplied to the Booster Heater from the desired output water temperature of the Booster Heater. The difference is the Water Temperature Rise. Typically 145°F (63°C) is a low temperature chemical sanitizing application and 185°F (85°C) is a high temperature heated water sanitizing application.

2. Follow the appropriate “Water Temperature Rise” column down and locate the Gallons Per Hour (GPH) of the dishmachine’s rinse cycle (round up to the next size if exact GPH isn’t listed).
   NOTE: The primary water heater must be able to supply the Booster Heater with the incoming water temperature at the GPH usage of the dishmachine. Failure of the primary water heater to supply a continuous temperature will result in an inadequate output temperature of the Booster Heater.

3. Follow the GPH row to either of the “Booster Heater kW” columns for the appropriate Booster Heater kW rating.

Example: An incoming water temperature of 115°F (46°C) with a desired output temperature of 185°F (85°C) would be a 70°F (39°C) water temperature rise.
A 70°F (39°C) water temperature rise with a dishmachine capable of 185 GPH usage will require a minimum of a 36 kW Booster Heater.
NOTE: When incoming water temperatures are less than 85°F (29°C), consult factory for suitable Booster Heater.

Booster Heater kW| Water Temperature Rise| __Booster Heater kW
---|---|---
30°F| 40°F| 50°F| 60°F| 70°F| 80°F| 90°F| 100°F
GPH| GPH| GPH| GPH| GPH| GPH| GPH| GPH
4| 54| 40| 32| 27| 23| 20| 18| 16| 4
5| 67| 50| 40| 33| 29| 25| 22| 20| 5
6| 80| 60| 48| 40| 34| 30| 27| 24| 6
7| 94| 70| 56| 47| 40| 35| 31| 28| 7
9| 120| 90| 72| 60| 52| 45| 40| 36| 9
9.9| 132| 99| 79| 66| 57| 50| 44| 40| 9.9
10.5| 140| 105| 84| 70| 60| 53| 47| 42| 10.5
11.4| 153| 114| 92| 76| 65| 57| 51| 46| 11.4
12| 161| 120| 96| 80| 69| 60| 54| 48| 12
13.5| 181| 135| 108| 90| 77| 68| 60| 54| 13.5
15| 201| 151| 120| 100| 86| 75| 67| 60| 15
17.25| 231| 173| 139| 115| 99| 87| 77| 69| 17.25
18| 241| 181| 145| 120| 103| 90| 80| 72| 18
24| 321| 241| 193| 161| 138| 120| 107| 96| 24
27| 361| 271| 217| 181| 155| 135| 120| 108| 27
30| 401| 301| 241| 201| 172| 151| 134| 120| 30
36| 482| 361| 289| 241| 206| 181| 161| 145| 36
39| 522| 391| 313| 261| 224| 196| 174| 157| 39
40.5| 542| 407| 325| 271| 232| 203| 181| 163| 40.5
45| 602| 452| 361| 301| 258| 226| 201| 181| 45
54| 723| 542| 434| 361| 310| 271| 241| 217| 54
57| 763| 573| 458| 381| 326| 286| 254| 229| 57

Booster Heater Sizing Formula
LPH x Water Temp. Rise
840 = kW
NOTE: Refer to the “Water Temperature Rise” table in the French section of this manual for the metric (Celsius and liters) version of this table.

Circuit Breaker and Fused Disconnect Switch Sizes — 4 to 12 kW

kW| Volts| Phase| Amp Draw| Breaker or Fuse Size| Copper Wire Size| Conduit Size
---|---|---|---|---|---|---
L1| L2| L3
4| 208| 1| 19| 19| —| 30| 10| 1/2″ (13 mm)
240| 1| 17| 17| —| 30| 10| 1/2″ (13 mm)
480| 1| 8| 8| —| 15| 14| 1/2″ (13 mm)
5| 208| 1| 24| 24| —| 30| 10| 1/2″ (13 mm)
240| 1| 21| 21| —| 30| 10| 1/2″ (13 mm)
480| 1| 10| 10| —| 15| 14| 1/2″ (13 mm)
6| 208| 1| 29| 29| —| 40| 8| 1/2″ (13 mm)
208| 3| 14| 25| 14| 40| 8| 1/2″ (13 mm)
240| 1| 25| 25| —| 40| 8| 1/2″ (13 mm)
240| 3| 13| 22| 13| 30| 10| 1/2″ (13 mm)
380| 3| 9.2| 9.2| 9.2| 15| 14| 1/2″ (13 mm)
480| 3| 6| 11| 6| 15| 14| 1/2″ (13 mm)
600| 3| 5.7| 5.7| 5.7| 15| 14| 1/2″ (13 mm)
7| 208| 1| 34| 34| —| 50| 8| 1/2″ (13 mm)
208| 3| 17| 29| 17| 40| 8| 3/4″ (19 mm)
240| 1| 29| 29| —| 40| 8| 1/2″ (13 mm)
240| 3| 15| 25| 15| 40| 8| 1/2″ (13 mm)
380| 3| 11.4| 11.4| 11.4| 15| 14| 1/2″ (13 mm)
480| 3| 7| 13| 7| 20| 12| 1/2″ (13 mm)
600| 3| 6.7| 6.7| 6.7| 15| 14| 1/2″ (13 mm)
9| 208| 1| 43| 43| —| 60| 6| 1/2″ (13 mm)
208| 3| 22| 38| 22| 50| 8| 1/2″ (13 mm)
240| 1| 38| 38| —| 50| 8| 1/2″ (13 mm)
240| 3| 19| 33| 19| 50| 8| 1/2″ (13 mm)
380| 3| 13.3| 13.3| 13.3| 20| 12| 1/2″ (13 mm)
480| 3| 9| 16.3| 9| 30| 12| 1/2″ (13 mm)
600| 3| 8.7| 8.7| 8.7| 15| 14| 1/2″ (13 mm)
9.9| 208| 1| 47.5| 47.5| —| 60| 6| 1/2″ (13 mm)
208| 3| 27.5| 27.5| 27.5| 40| 8| 1/2″ (13 mm)
10.4| 208| 3| 28.8| 28.8| 28.8| 40| 8| 1/2″ (13 mm)
10.5| 208| 1| 51| 51| —| 70| 4| 3/4″ (19 mm)
208| 3| 29| 29| 29| 40| 8| 1/2″ (13 mm)
240| 1| 44| 44| —| 60| 6| 1/2″ (13 mm)
240| 3| 25.3| 25.3| 25.3| 40| 8| 1/2″ (13 mm)
480| 3| 12.6| 12.6| 12.6| 20| 12| 1/2″ (13 mm)
600| 3| 10| 10| 10| 15| 14| 1/2″ (13 mm)
11.4| 240| 1| 47.5| 47.5| —| 60| 6| 1/2″ (13 mm)
240| 3| 27.5| 27.5| 27.5| 40| 8| 1/2″ (13 mm)
480| 3| 13.7| 13.7| 13.7| 20| 12| 1/2″ (13 mm)
12| 208| 1| 58| 58| —| 90| 3| 1″ (25 mm)
208| 3| 33| 33| 33| 50| 8| 1/2″ (13 mm)
240| 1| 50| 50| —| 70| 4| 3/4″ (19 mm)
240| 3| 29| 29| 29| 40| 8| 1/2″ (13 mm)
380| 3| 19.1| 19.1| 19.1| 30| 10| 1/2″ (13 mm)
480| 3| 14.5| 14.5| 14.5| 20| 12| 1/2″ (13 mm)
600| 3| 11.6| 11.6| 11.6| 15| 14| 1/2″ (13 mm)

The shaded area contains electrical information for International models only.
NOTE: 250 kcmil maximum wire size for terminal block.
Circuit Breaker and Fused Disconnect Switch Sizes — 13.5 to 30 kW

kW| Volts| Phase| Amp Draw| Breaker or Fuse Size| Copper Wire Size| Conduit Size
---|---|---|---|---|---|---
L1| L2| L3
13.5| 208| 1| 65| 65| —| 90| 3| 1″ (25 mm)
208| 1| 38| 38| 38| 50| 8| 1/2″ (13 mm)
240| 1| 56.3| 56.3| —| 90| 3| 1″ (25 mm)
240| 1| 33| 33| 33| 50| 8| 1/2″ (13 mm)
480| 1| 16.3| 16.3| 16.3| 30| 10| 1/2″ (13 mm)
600| 1| 13| 13| 13| 20| 12| 1/2″ (13 mm)
15| 208| 1| 72| 72| —| 90| 3| 1″ (25 mm)
208| 3| 41.7| 41.7| 41.7| 60| 6| 3/4″ (19 mm)
240| 1| 62.5| 62.5| —| 90| 3| 1″ (25 mm)
240| 3| 36.1| 36.1| 36.1| 50| 8| 1/2″ (13 mm)
380| 3| 23.0| 23.0| 23.0| 30| 10| 1/2″ (13 mm)
480| 3| 18.1| 18.1| 18.1| 30| 10| 1/2″ (13 mm)
600| 3| 14.5| 14.5| 14.5| 20| 12| 1/2″ (13 mm)
17.25| 208| 3| 47.9| 47.9| 47.9| 60| 6| 3/4″ (19 mm)
18| 208| 1| 86.5| 86.5| —| 125| 1| 1-1/4″ (32 mm)
208| 3| 50| 50| 50| 70| 4| 1″ (25 mm)
240| 1| 75| 75| —| 100| 3| 1″ (25 mm)
240| 3| 43.4| 43.4| 43.4| 60| 6| 3/4″ (19 mm)
380| 3| 27.3| 27.3| 27.3| 40| 8| 1/2″ (13 mm)
480| 3| 21.7| 21.7| 21.7| 30| 10| 1/2″ (13 mm)
600| 3| 17| 17| 17| 30| 10| 1/2″ (13 mm)
24| 208| 1| 115.4| 115.4| —| 150| 1/0| 1-1/4″ (32 mm)
208| 3| 66.7| 66.7| 66.7| 90| 3| 1″ (25 mm)
240| 1| 100| 100| —| 125| 1| 1-1/4″ (32 mm)
240| 3| 57.8| 57.8| 57.8| 90| 3| 1-1/4″ (32 mm)
380| 3| 38.0| 38.0| 38.0| 50| 8| 1/2″ (13 mm)
480| 3| 29.9| 29.9| 29.9| 40| 8| 1/2″ (13 mm)
600| 3| 23| 23| 23| 30| 10| 1/2″ (13 mm)
27| 208| 1| 129.8| 129.8| —| 175| 2/0| 1-1/4″ (32 mm)
208| 3| 75| 75| 75| 100| 3| 1″ (25 mm)
240| 1| 112.5| 112.5| —| 150| 1/0| 1-1/4″ (32 mm)
240| 3| 65| 65| 65| 90| 3| 1″ (25 mm)
380| 3| 38.1| 38.1| 38.1| 50| 8| 1/2″ (13 mm)
480| 3| 32.5| 32.5| 32.5| 50| 8| 1/2″ (13 mm)
600| 3| 26| 26| 26| 40| 8| 1/2″ (13 mm)
30| 208| 1| 144| 144| —| 200| 3/0| 1-1/2″ (38 mm)
208| 3| 83.3| 83.3| 83.3| 125| 1| 1-1/4″ (32 mm)
240| 1| 125| 125| —| 175| 2/0| 1-1/2″ (38 mm)
240| 3| 72.3| 72.3| 72.3| 100| 3| 1″ (25 mm)
380| 3| 45.7| 45.7| 45.7| 60| 6| 3/4″ (19 mm)
480| 3| 36| 36| 36| 50| 8| 1/2″ (13 mm)
600| 3| 28.9| 28.9| 28.9| 40| 8| 1/2″ (13 mm)

Wire size is based on THHN insulated, copper wire for branch circuit protection at 0.91 derate factor. Circuit breakers and fused disconnects are to be mounted remote and wired by contractor. Sizes are based on the 2002 NEC table 310-16. Conduit size based on conductors plus ground wire sizing per Table C1 from Appendix C.
Only 6, 7, and 9 kW models can be field converted to single or three phase (open delta on 3 phase). Check wiring diagram supplied with the unit when converting the phase of the unit. Larger branch circuit required than for balanced 3 phase of equal kW. Balanced 3 phase available, consult factory.
Circuit Breaker and Fused Disconnect Switch Sizes — 36 to 57 kW

kW| Volts| Phase| Amp Draw| Breaker or Fuse Size| Copper Wire Size| **Conduit Size
---|---|---|---|---|---|---
L1| L2| L3**
36| 208| 1| 173| 173| —| 225| 4/0| 1-1/2″ (38 mm)
208| 3| 100| 100| 100| 125| 1| 1-1/4″ (32 mm)
240| 1| 150| 150| —| 200| 3/0| 1-1/2″ (38 mm)
240| 3| 86.7| 86.7| 86.7| 125| 1| 1-1/4″ (32 mm)
380| 3| 54.7| 54.7| 54.7| 70| 4| 1″ (25 mm)
480| 3| 43.3| 43.3| 43.3| 60| 6| 3/4″ (19 mm)
600| 3| 34.7| 34.7| 34.7| 50| 8| 1/2″ (13 mm)
39| 208| 1| 187.5| 187.5| —| 250| 250 kcmil| 2″ (51 mm)
208| 3| 108| 108| 108| 150| 1/0| 1-1/4″ (32 mm)
240| 1| 163.5| 163.5| —| 225| 4/0| 2″ (51 mm)
240| 3| 94| 94| 94| 125| 1| 1-1/4″ (32 mm)
380| 3| 59.3| 59.3| 59.3| 90| 3| 1″ (25 mm)
480| 3| 47| 47| 47| 60| 6| 3/4″ (19 mm)
600| 3| 37.6| 37.6| 37.6| 50| 8| 1/2″ (13 mm)
40| 208| 3| 61.6| 61.6| 61.6| 90| 3| 1″ (25 mm)
40.5| 208| 3| 112.5| 112.5| 112.5| 150| 1/0| 1-1/4″ (32 mm)
240| 3| 97.5| 97.5| 97.5| 125| 1| 1-1/4″ (32 mm)
480| 3| 48.8| 48.8| 48.8| 70| 4| 1″ (25 mm)
600| 3| 39| 39| 39| 50| 8| 3/4″ (19 mm)
45| 208| 3| 125| 125| 125| 175| 2/0| 1-1/2″ (38 mm)
240| 1| 188| 188| —| 250| 250 kcmil| 2″ (51 mm)
240| 3| 108| 108| 108| 150| 1/0| 1-1/4″ (32 mm)
380| 3| 68.6| 68.6| 68.6| 90| 3| 1″ (25 mm)
480| 3| 54| 54| 54| 70| 4| 1″ (25 mm)
600| 3| 43.4| 43.4| 43.4| 60| 6| 3/4″ (19 mm)
54| 208| 3| 150| 150| 150| 200| 3/0| 2″ (51 mm)
240| 3| 130| 130| 130| 175| 2/0| 1-1/2″ (38 mm)
380| 3| 82| 82| 82| 125| 1| 1-1/4″ (32 mm)
480| 3| 65| 65| 65| 90| 3| 1″ (25 mm)
600| 3| 52| 52| 52| 70| 4| 1″ (25 mm)
57| 208| 3| 158.4| 158.4| 158.4| 200| 3/0| 2″ (51 mm)
240| 3| 137.3| 137.3| 137.3| 175| 2/0| 1-1/2″ (38 mm)
380| 3| 86.7| 86.7| 86.7| 125| 1| 1-1/4″ (32 mm)
480| 3| 68.6| 68.6| 68.6| 90| 3| 1″ (25 mm)
600| 3| 54.9| 54.9| 54.9| 70| 4| 1″ (25 mm)

The shaded area contains electrical information for International models only.
Wire size is based on THHN insulated, copper wire for branch circuit protection at 0.91 derate factor. Circuit breakers and fused disconnects are to be mounted remote and wired by contractor. Sizes are based on the 2002 NEC table 310-16. Conduit size based on conductors plus ground wire sizing per Table C1 from Appendix C.
NOTE: 250 kcmil maximum wire size for terminal block.
WARNING
ELECTRIC SHOCK HAZARD: Consult a licensed electrical contractor for proper electrical installation conforming to local electrical codes and the National Electrical Code (N.E.C.).
Dimensions — Imperial “S” Series Dimensions — Compact “C” Series 4 to 18 kW Dimensions — Compact “C” Series 24 to 57 kW ![Hatco C-7-208-3 Compact 7.0 kW Insulated Booster Water Heater

• fig 6](https://manuals.plus/wp- content/uploads/2023/02/Hatco-C-7-208-3-Compact-7.0-kW-Insulated-Booster- Water-Heater-fig-6.png)Dimensions — Mini-Compact “MC” Series

Shipping Weights —S Models

Shipping Weights — C Models

Shipping Weights— MC Models

INSTALLATION

General
Booster Heaters are shipped with most components preassembled. Care should be taken when unpacking shipping carton to avoid damage to unit and components enclosed.
Components are shipped with the heater unit.
WARNING
ELECTRIC SHOCK HAZARD:

• Unit must be installed by qualified, trained installers.  Installation must conform to all local electrical and  plumbing codes. Installation by unqualified personnel will void the unit warranty and may lead to electric shock or burn, as well as damage to unit and/or its surroundings. Check with local plumbing and electrical inspectors for proper procedures and codes.
• Unit is not weatherproof. Locate unit indoors where ambient air temperature is a minimum of 70°F (21°C).
• Do not place aftermarket covers on or over booster heater. Doing so can cause temperature and moisture build-up resulting in premature failure and electrical shock.

EXPLOSION HAZARD: Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
Install booster water heater as close as possible to a commercial dish machine. Employ re-circulation if distance between water heater and dish machine exceeds National Sanitation Foundation (NSF) specifications of five (5) linear feet (1524 mm).
Install booster water heater in a horizontal position with the base parallel to the floor and the inlet connection at the lowest point. Improper installation could create an unsafe condition.

1. Remove the unit from the box.
   NOTE: To prevent delay in obtaining warranty coverage, complete online warranty registration. See the IMPORTANT OWNER INFORMATION section for details.

2. Remove tape and protective packaging from all surfaces of unit.

3. If unit is equipped with legs, carefully lay unit on its side and install the four legs. NOTICE
   Do not lay unit on the side with the control panel or inlet and outlet pipes. Damage to the unit could occur.
   NOTE: If unit is not level, use an adjustable wrench to adjust the foot of each leg until unit is level. Each leg is adjustable from 6″ (152 mm) to 7″ (178 mm).

4. Place the unit in the appropriate location.
   • The location must have a solid foundation along with being clean and dry.
   • Adequate front clearance is required to allow for accessibility to the control compartment. Hatco recommends the side clearance be at least 2″ (51 mm).
   • Location must have adequate clearance to allow for inspection, testing or replacement of pressure and/or temperature relief valve.
   • Install the booster heater as close as possible to the commercial dish machine for efficient operation.
   WARNING
   Make sure the dishtable is strong enough to support the weight of the booster heater and water when installing with slide mounting brackets.
   Follow standard welding safety and operational procedures when attaching sliderails to bottom of dishtable.

5. Install unit under dishtable using mounting slide brackets, if applicable (Compact Series only).
   a. Weld slide rails to bottom of dishtable.
   b. Using Hatco slide brackets as a template, drill 1/8″ (3 mm) holes into the sides of the heater jacket.
   c. Attach slide brackets to sides of heater with supplied screws.
   d. Slide heater onto slide rails under dishtable.

Plumbing Installation
WARNING
Do not connect booster water heaters to domestic (consumer) dish machines or other domestic utilized equipment. This booster may damage domestic equipment. Use only copper plumbing material. Non-copper plumbing material may create an unsafe condition. Refer to the BOOSTER HEATER SIZING CHART in this manual to ensure proper sizing and avoid personal injury and/or damage to the booster heater.
CAUTION
Do not connect booster heater directly to a boiler or furnace coil or any other uncontrolled temperature source. The booster heater thermostat could be damaged causing
unit to overheat.
NOTICE
Use dielectric couplings when connecting dissimilar metals, such as galvanized to copper. This will prevent electrolysis or premature plumbing damage. Do not turn or adjust inlet or outlet water connection on Compact Series Booster Heaters or internal water flow will change and the unit will not produce a consistent outlet temperature.
Do not back out or loosen any pipe fittings. Doing so may cause leaks.
Do not lay unit on the side with the control panel or inlet and outlet pipes. Damage to the unit could occur. Incoming water in excess of 3 grains of hardness per gallon (GPG) (0.75 grains of hardness per liter [GPL]) must be treated and softened before being supplied to booster heater(s). Water containing over 3 GPG (0.75 GPL) will decrease efficiency, increase energy use, and reduce the operating life of the unit through increased lime build- up. Product failure caused by liming or sediment buildup is
not covered under warranty. Do not use deionized water. Deionized water will shorten the life of water reservoir and heating element.
NOTE: Product failure caused by liming or sediment buildup is not covered under warranty.
NOTE: A 3/4″ union and a drain valve are required for easy servicing.
NOTE: An optional flow restrictor (P/N 03.02.074.00) is available for installation on the water inlet line.
NOTE: Some dish machines require two booster heaters to be plumbed in series (not parallel) to meet the demand.
To ensure proper operation, a 29°F (16°C) temperature differential must be maintained between the inlet and outlet of each booster heater.
Inlet
Use the following procedure to install the inlet assembly. Refer to the appropriate “Plumbing Connections” diagram in this section for more information.

1. Connect the booster water inlet to a copper hot water supply line from a normal water heater.
   • Water temperature from the water heater should be 115°–145°F (46°–63°C) and should not exceed 155°F (68°C). Minimum temperature differential between inlet and outlet should never be less than 29°F (16°C).
   NOTE: Refer to BOOSTER HEATER SIZING CHART for application information.
   NOTE: The red mark on the inlet and outlet water pipes of Compact series units must remain in the top most position.

2. Install a shut-off valve (a full opening gate or ball type).

3. Install one of the temperature/pressure gauges.
   • When installing the temperature/pressure gauge, the temperature sensing element must be in the water stream and the gauge must be mounted upright (see illustration below).
   NOTE: Tighten gauge during installation by turning the 1/2″ brass nut only. DO NOT turn the face of the gauge. Turning the face will cause inaccurate measurements.
   CAUTION
   Hatco requires that two temperature/pressure gauges (Hatco P/N 03.01.003.00) be installed to ensure proper operation. Install one in the supply line before the pressure
   reducing valve and one in the outlet line as close to the booster heater as possible. This provides a visual check of the water temperature and pressure before and after the water heater. NOTE: If a check valve or back flow prevention is installed and cannot be removed, install a back pressure relief valve (P/N 03.02.039.00) preset at 125 psi (862 kPa) on the  incoming line between the pressure reducing valve and the inlet to the booster heater. Any discharge must be directed to an open site drain.
   NOTE: If the back pressure relief valve is not acceptable, a high temperature thermal expansion tank may be substituted. The thermal expansion tank must be installed on the inlet side of the booster. The appropriate size and rating of the thermal expansion tank must be determined by qualified personnel, assuming a minimum 212°F (100°C) thermal, and 150 psi (1034 kPa) rating to match the built in safety devices on the booster.

4. Install the pressure reducing valve if water pressure available to the booster heater inlet is over 25 psi (172 kPa).
   • Set pressure reducing valve at 20 psi (138 kPa) flow pressure.
   NOTE: Be sure water flows through the pressure reducing valve in the proper direction. Check directional arrow. Valve will reduce pressure only during flow conditions.
   CAUTION
   If water supply pressure to the booster inlet is over 138 kPa (20 psi) during flow, install standard pressure reducing valve with built-in bypass (Hatco P/N 03.02.004.00) for proper operation of dish machine rinse nozzles.
   NOTE: The pressure reducing valve must be the type equipped with a high pressure bypass, as supplied by Hatco.
   NOTE: Optional brass pressure reducing valve with built-in bypass (Hatco P/N 03.02.015.00) also available.

5. Install the temperature/pressure relief valve directly into the marked fitting on the rear or side of the unit.
   • Mini-Compact Series: P/N 03.02.020.00
   • Compact and Imperial Series: P/N 03.02.022.00

WARNING
Temperature/pressure protective equipment should not be less than a combination temperature/pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of this equipment and meets the requirements for Relief Valves and Automatic Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22-1979. The temperature/pressure relief valve must be marked with a minimum set pressure not to exceed the marked hydrostatic test pressure of the
booster heater as noted on the unit specifications.
FOR INSTALLING PRESSURE AND TEMPERATURE RELIEF VALVES IN ACCORDANCE WITH AMERICAN NATIONAL STD. Z21.22-1979. Combination pressure and temperature relief valves with extension thermostats must be installed so that the temperature-sensing element is immersed in the water within the top 6″ (152 mm) of the tank. They must be installed directly in a tank tapping. Combination pressure and temperature relief valves that do not have extension elements must be mounted directly in a tank tapping located within the top 6″ (152 mm) of the tank, and shall be adequately insulated and located so as to assure isolation from ambient conditions that are not indicative of stored water temperature. TO AVOID WATER DAMAGE OR SCALDING DUE TO VALVE OPERATION, DRAIN PIPE MUST BE CONNECTED TO VALVE OUTLET AND RUN TO A SAFE PLACE OF DISPOSAL. Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length. Drain line must pitch downward from the valve and must terminate between 1-1/2″ (38 mm) and 6″ (152 mm) above the floor drain where any discharge will be clearly visible. The drain line shall terminate plain, not threaded, with material serviceable for temperatures up to 250°F (121°C) or greater. Excessive length, over 30′ (9.1 m), or use of more than four elbows can cause a restriction and reduce the discharge capacity of the valve. No shut-off valve shall be installed between the relief valve and tank, or in the drain line. Valve lever must be tripped periodically to assure that waterways are clear. This device is designated for emergency safety relief and shall not be used as an operating control. The valves are set to relieve at 150 psi (1034 kPa) or when water temperature reaches 210°F (99°C). Read tag on valve for additional information.
CAUTION
BURN HAZARD: Valves supplied by Hatco are designed for high temperature commercial operation. Do not substitute Hatco valves with valves designed for domestic water heaters.
Do not use an anti-siphon or check valves on incoming water line.
Plumbing Connections † Not supplied, but is available as an option/accessory.
‡ Not supplied with booster heater.
WARNING
Valves, gauges, and unions must be installed per diagram  to ensure proper operation, servicing, and warrantycoverage.
Plumbing Connections

† Not supplied, but is available as an option/accessory.
‡ Not supplied with booster heater.
WARNING
Valves, gauges, and unions must be installed per diagram to ensure proper operation, servicing, and warranty coverage.
Outlet

1. Flush the water supply line to remove any pipe compound and foreign matter.

2. Connect the booster heater water outlet to the commercial dish machine sanitizing rinse pipe connection using a 3/4″ union and copper piping.
   WARNING
   DO NOT turn or adjust water outlet connection on Large Compact Series units (C-24 to C-57).
   NOTE: Red marks on water inlet and outlet pipe for C-24 to C-57 series units must remain in the top most position.
   NOTE: Be certain the connection is made to the final rinse and not to the wash tank.

3. Install a temperature/pressure gauge in the outlet line. The temperature sensing element must be in the water stream and the gauge must be mounted upright.

• Water temperature at the outlet should be 185°–190°F (85°–88°C).
NOTE: Some dish machines require two booster heaters to be plumbed in series (not parallel) to meet the demand.
To ensure proper operation, a 29°F (16°C) temperature differential must be maintained between the inlet and outlet of each booster heater.
NOTE: Hatco recommends installing an optional shock absorber (P/N 03.04.057.00) in the outlet line as close as possible to the commercial dish machine solenoid rinse valve. The shock absorber softens the water hammer caused by automatic dish machine valves.
Plumbing Installation Inspection

1. Close the drain valve and fill the booster heater with water.
2. Check all pipe connections for leaks.
3. Make sure the temperature/pressure relief valve discharge is not blocked.
4. Vent air from the tank before operating by opening the temperature/pressure relief valve or venting through the dish machine rinse nozzles.

vWARNING
DO NOT turn on power to the booster heater until tank has been filled with water and all air has been vented through the dish machine rinse nozzle. The heating elements
will burn out in seconds if operated when they are not immersed in water. WARNING
Hatco has always endorsed the use of safety equipment when using a booster water heater or storage-type water heater. Hatco booster heaters are shipped with a temperature/pressure relief valve at no extra charge. This valve must be installed into the marked opening provided in the tank. Valves supplied by Hatco are designed for high temperature commercial operation. Do not substitute Hatco supplied valves with valves designed for domestic operation.
It is essential to recognize that even though a water heater may be properly installed initially and approved, there always exists the possibility that unknowing individuals might alter or change the installation in a manner that would render it unsafe. Therefore, it is important that all safety programs provide some mechanism to assure that these installations are inspected periodically.
Electrical — All Sizes and Voltages
General
Hatco Electric Booster Water Heaters are available for operation on standard power systems. Check the specification label for the proper power supply.
All internal electrical connections have been made at the factory. See the “Circuit Breaker and Fused Disconnect Switch” chart in the SPECIFICATIONS section for supply wire size, fuse, breaker, and conduit recommendations. Consult local codes for verification and compliance.
WARNING
ELECTRIC SHOCK HAZARD:

• Unit must be installed by qualified, trained installers. Installation must conform to all local electrical and plumbing codes. Installation by unqualified personnel will void the unit warranty and may lead to electric shock or burn, as well as damage to unit and/or its surroundings. Check with local plumbing and electrical inspectors for proper procedures and codes.
• Turn OFF power at fused disconnect switch/circuit breaker and allow unit to cool before performing any cleaning, adjustments, or maintenance.
• Consult a licensed electrical contractor for proper electrical installation conforming to local electrical codes and the National Electrical Code (N.E.C.).

NOTICE
Units are voltage-specific. Refer to specification label for electrical requirements before beginning installation. Connecting unit to incorrect power supply will void product warranty and may damage unit.
Electrical Connections

1. Remove the front jacket cover screws, pull the cover forward and remove the cover.
   NOTE: On Imperial models, there is a hinged access panel under the front jacket cover. Remove the bottom screw and lift the panel up to expose the fuse blocks.
   • On Mini-Compact models, remove front cover screws. Ease cover forward and upward.
   • On Compact models, the control box is under the front hinged jacket cover.

2. Locate the terminal or fuse block(s) inside the unit.
   NOTE: See “Circuit Breaker and Fused Disconnect Switch” chart in the SPECIFICATIONS section for proper connections and wire size.
   NOTE: Only 6, 7, and 9 kW models, in 208 or 240 volt, can be converted to single or three phase in the field. Refer to the wiring diagram for proper wiring connections at the terminal block.

3. Bring power leads from a properly sized disconnect switch or circuit breaker through the knockout provided on the unit. Connect leads to the terminal or fuse block(s).
   USE COPPER WIRE ONLY. TIGHTEN CONNECTIONS PROPERLY TO A MINIMUM OF 40 INCH POUNDS.
   NOTE: Due to the rigors of transportation all connections should be checked for tightness before heater is put into operation.

4. Properly connect an equipment grounding connector to the grounding lug (located near the supply terminals).
   CAUTION
   DO NOT turn on power to the booster heater until tank has been filled with water and all air has been vented through the dish machine rinse nozzles. Heating elements will burn out in seconds if operated when not immersed in water.

5. Replace and secure cover(s).

OPERATION

General
Use the following procedures to operate Hatco Electric Booster Water Heaters.
CAUTION
BURN HAZARD: Water in unit is very hot. Wear protective gloves and proper attire when operating to avoid injury.
Controls
The following is a list of the available controls for electric booster water heaters.
Power I/O (on/off) Switch —Turns power on and off to the heating elements.
Reset Icon —Indicates the Power I/O switch also is the reset switch.
The high limit switch trips when the unit exceeds the high temperature limit.
Use the Power I/O (on/off) switch to reset the unit when the Error Indicator Light is illuminated.
Power Indicator Light —Illuminates when power is on, shuts off when power is off.
Error Indicator Light —Illuminates/flashes when the unit is malfunctioning.
• Flashing Light = Probe is defective or low water error
• Solid Light = High Limit tripped

Startup

1. Close the drain valve.

2. Open the shutoff valve to the primary water supply line.
   The water temperature at inlet should be 115° to 145°F (46° to 63°C) and should not exceed 155°F (68°C).
   NOTE: Minimum temperature differential between inlet and outlet should never be less than 29°F (16°C).

3. Vent all the air from the tank through the dish machine rinse nozzles and the temperature/pressure relief valve when the tank is filled with water.
   CAUTION
   DO NOT turn on power to the booster heater until tank has been filled with water and all air has been vented through the dish machine rinse nozzles. Heating elements will burn out in seconds if operated when not immersed in water.

4. Check all plumbing connections for leaks.

5. Check the temperature/pressure relief valve discharge opening to be sure it is not blocked and no scale or other foreign matter has reduced the size of the opening.

6. Turn on the booster water heater.
   • For models with a Power I/O (on/off) switch, move the Power I/O (on/off) switch on the control panel to the I (on) position.
   • For models without a Power I/O (on/off) switch, turn on power at the fused disconnect switch/circuit breaker.
   NOTE: The power indicator light will illuminate when the unit turns on. Some units are equipped with an error indicator light that will illuminate when the unit needs to be serviced.
   NOTE: All models can be configured with or without a Power I/O (on/off) switch.

7. When the booster water heater has had sufficient heating time, operate the rinse cycle and check the water temperature and pressure readings on the gauges.
   • Water temperature at the booster outlet should be 185°–190°F (85°–88°C) and flow pressure should be 20 psi (138 kPa) maximum.

NOTE: Outlet water temperatures can be adjusted for Low-Temperature Dish Machine applications. See the MAINTENANCE section for thermostat adjustment procedure.
WARNING
Units are equipped with a high temperature limit safety switch that will shut off the power if the unit overheats. Contact an Authorized Hatco Service Agent if the high temperature limit safety switch cannot be reset or continues to trip. Shutdown
Under normal and regular operation, Hatco recommends that the unit be turned on at all times.
If the booster heater will not be used for an extended period of time or will be exposed to freezing conditions, it should be drained to prevent damage to the unit.

1. Move the Power I/O (on/off) switch to the O (off) position, and turn off power at the fused disconnect switch/circuit breaker.
2. Close the shutoff valve to the primary water supply line.
3. Open the drain valve and drain the water from the booster heater tank.

NOTICE
Always drain booster heater with power to the unit off or element burnout could occur.

MAINTENANCE

General
Electric Booster Water Heaters are designed for maximum durability and performance with minimum maintenance.
WARNING
ELECTRIC SHOCK HAZARD:

• Turn OFF power at fused disconnect switch/circuit breaker and allow unit to cool before performing any cleaning, adjustments, or maintenance.
• This unit must be serviced by qualified personnel only. Service by unqualified personnel may lead to electric shock or burn.
• Use only Genuine Hatco Replacement Parts when service is required. Failure to use Genuine Hatco Replacement Parts will void all warranties and may subject operators of the equipment to hazardous electrical voltage, resulting in electrical shock or burn. Genuine Hatco Replacement Parts are specified to operate safely in the environments in which they are used. Some aftermarket or generic replacement parts do not have the characteristics that will allow them to operate safely in Hatco equipment.

This unit has no “user-serviceable” parts. If service is required on this unit, contact an Authorized Hatco Service Agent or contact the Hatco Service Department at 800-558-0607 or 414-671-6350.
Thermostat Adjustment
The thermostat is factory calibrated at 185°–190°F (85°–88°C).
If adjustment or recalibration is required due to the rigors of transportation, use the appropriate procedure based on the control on the unit.
NOTE: Low temperature dish machines require the thermostat(s) to be adjusted to 140°–150°F (60°–66°C).
Electronic Controls
Contact an Authorized Hatco Service Agent or contact the Hatco Service Department at 800-558-0607 or 414-671-6350.
Mechanical Controls

1. Move the Power I/O (on/off) switch to the O (off) position, and/or turn off power at the fused disconnect switch/circuit breaker.
2. Remove the access cover.
3. Adjust the temperature setpoint to the desired temperature.

• To lower the temperature setpoint, turn the outer screw counterclockwise.
• To raise the temperature setpoint, turn the outer screw clockwise.

NOTE: 1/6 turn of the outer screw equals 12°F (6.7°C).
NOTE: If recalibration is necessary, with the outer screw at high stop, turn the inner screw clockwise to raise the set point.
NOTE: 1/6 turn of the inner screw equals 8°F (4.4°C).
High Temperature Limit Safety Switch
All Hatco Electric Booster Water Heaters are equipped with a manually reset high temperature limit safety switch. If the temperature of the water in the heater exceeds 210°F (99°C) the safety switch will shut off the power. The switch must be manually reset.
If the high temperature limit safety switch needs to be reset use the following procedure:
Electronic Controls
The error indicator light will illuminate if the unit needs to be reset.

1. Move the Power I/O (on/off) switch to the O (off) position, and/or turn off power at the fused disconnect switch/circuit breaker.
2. Allow unit to cool.
3. Move the Power I/O (on/off) switch to the I (on) position, and/or turn on power at the fused disconnect switch/circuit breaker.
4. If tripping repeats, call an Authorized Service Agent. DO NOT attempt to adjust the High Temperature Limit Safety Switch.

Mechanical Controls

1. Move the Power I/O (on/off) switch to the O (off) position, and/or turn off power at the fused disconnect switch/circuit breaker.
2. Remove the access cover.
3. Push the red reset button.
4. If tripping repeats, call an Authorized Service Agent. DO NOT attempt to adjust the High Temperature Limit Safety Switch.

Mechanical Control Thermostat Adjustment and High Temperature Limit Safety Switch (Imperial “S” Model Shown)

TROUBLESHOOTING GUIDE

IMPORTANT! Read Before Using the Troubleshooting Guide
Many times when a booster heater does not appear to be functioning properly, the fault is not with the booster heater itself but with factors outside the heater.
WARNING
ELECTRIC SHOCK HAZARD:

• Turn OFF power at fused disconnect switch/circuit breaker and allow unit to cool before performing any cleaning, adjustments, or maintenance.
• This unit must be serviced by qualified personnel only. Service by unqualified personnel may lead to electric shock or burn.

Before proceeding with the “Troubleshooting Guide” to diagnose an issue, check ALL of the following outside factors.
Water Temperature

• Check the temperature of the water feeding into the booster tank. It must be 115° to 145°F (46° to 63°C), depending on the heating capability of the unit. The inlet water supply must be of sufficient quantity to hold its temperature throughout the dishwashing operation.
• If the wash tank of the dish machine is filled through the booster heater, this will use up all of the 180°F (82°C) water in storage. Sufficient time must be allowed to reheat the water in storage before starting the dish machine.
• Primary water heater temperature should not exceed 155°F (68°C).

Water Pressure

• Water pressure at the inlet to the booster heater must be adequate for proper operation of the rinse cycle of the dish machine, not to exceed 20 psi (138 kPa). Check with dish machine manufacture for specific details.
• If incoming water exceeds 20 psi (138 kPa), a pressure reducing valve must be installed.

Electrical Connections

• Booster heater voltage must be correct for voltage available. Check the specification label on the booster heater for full information.
• The breakers or fuses MUST be properly sized.

Plumbing Connections

• The temperature/pressure relief valve must be properly installed and be supplied by Hatco.
• A check valve should not be installed ahead of the booster.

NOTE: If a check valve is installed and cannot be removed, install a back pressure relief valve (P/N 03.02.039.00) set at 125 psi (862 kPa) on the incoming line between the pressure reducing valve and the inlet to the booster heater. Discharge must be to open site drain.
If the unit does not function properly after performing these checks, continue to the “Troubleshooting Guide” in this section.

WARNING
This unit must be serviced by qualified personnel only. Service by unqualified personnel may lead to electric shock or burn.
WARNING
ELECTRIC SHOCK HAZARD: Turn OFF power at fused disconnect switch/circuit breaker and allow unit to cool before performing any cleaning, adjustments, or maintenance.

Symptom| Probable Cause|

Corrective Action

---|---|---
Water reaches 180°F (82°C) but does not last through the entire dish machine operation.| Low incoming water temperature.| Incoming water temperature must be adequate for booster size. Increase incoming water temperature.
Incoming water temperature drops.| Primary water supply is not adequate to provide correct temperature in sufficient quantities. Increase supply of primary hot water.
Flow pressure is too high.| Higher pressure uses an excessive quantity of hot water. Adjust flow pressure to 20 psi (138 kPa).
Booster heater may be undersized.| Booster heater must be properly sized for incoming water temperature and rinse requirements of the dish machine.
Incorrect voltage.| Check voltage on heater serial plate and make sure supplied voltage matches. A 240V booster heater operating on 208V reduces wattage to 76% efficiency.
The booster heater does not heat at all or only delivers water at 120°- 150°F (49°-66°C).
The error indicator light is illuminated.| Unit may have been energized without water (dry fired) causing the element(s) to burn out quickly.| Replace the element(s).
Fuses may be blown or circuit breaker tripped.| Check for proper fuse sizing. Replace fuses. Check/reset circuit breaker.
Over-current fuses may be blown.| Check for shorted elements, bad fuse block or short in wiring.
Temperature setting out of calibration or inoperable.| Temperature setting should be maximum of 190°F (88°C).
Contactors do not pull in.| Test for voltage at coils. If coils are open or shorted, replace contactors.
High limit switch may be tripped or defective.| Reset switch, refer to “High Temperature Limit Safety Switch” in the MAINTENANCE section. If switch continues to trip or cannot be reset contact an Authorized Service Agent.
Transformer not working properly.| Check secondary voltage, it should be the same as the control circuit voltage. If not, replace the transformer.
Low water cutoff inoperable, contacts do not close.| Remove probe wire and touch it to the tank. If contacts close, probe is fouled and must be cleaned or replaced.

Relay on circuit board maybe defective. Jumper terminals 6 and 7. If unit energizes, circuit board is defective and should be replaced.

Water   at   dish   machine is not at the proper temperature.| Gauge(s) not working properly.| Check temperature of water with a thermometer to be certain gauges are working correctly. If not, replace gauge(s).
Thermostat set too low.| Adjust or recalibrate, refer to “Thermostat Adjustment” in the MAINTENANCE section. If thermostat will not recalibrate properly, replace it.
Booster heater has more than five (5) linear feet (1524 mm) of water pipe to the dish machine, causing the water to cool off inside the pipe.| If located    farther    than    five     (5)     linear     feet (1524 mm), pipes should be wrapped in insulation, and/or a recirculating system installed.
Relief valve dribbles.| No pressure reducing valve installed or incorrect valve installed causing pressure build-up inside booster tank.| A pressure reducing valve with high pressure bypass must be installed in the incoming water line to allow water to expand back into the feed line.
---|---|---
Bypass in pressure reducing valve may be blocked.| Clean bypass or replace with new valve with built in bypass.
Check valve or anti-siphon valve installed in the feed line.| Remove check valve or anti-siphon valve to allow for water expansion or install a back pressure relief valve (P/N 03.02.039.00) on the incoming water line.
Relief valve opens.| Unit is overheating.| Thermostat may be set too high or is sticking. Recalibrate or replace the thermostat.
Contactor may be sticking in closed position not allowing unit to cycle off.| Replace contactor(s).
High temperature limit safety switch trips.

The error indicator light is illuminated.

| Temperature limit safety switch is defective.| If booster heater is not overheating, replace High Limit Safety Switch.
Thermostat set too high.| Adjust or recalibrate, refer to “Thermostat Adjustment” in the MAINTENANCE section.
Incoming water temperature too high causing nuisance tripping of high temperature limit switch.| Incoming water temperature should not be higher than 160°F (71°C).
Chattering contactor or low water cutoff circuit board| Loose connections or wire connection has insulation under crimp.| Tighten all connections and check crimps
Low voltage.| Check control circuit voltage or secondary voltage with transformer.
Probe may be fouled.| Bypass probe by removing wire from low water cutoff probe and grounding to tank. Clean or replace probe if chattering stops.
Contactor(s) may be bad.| Test contactor coils and replace if needed.
Heating element(s) burn out.| Tank inadvertently drained leaving element(s) in a dry condition.| Replace element(s), and make sure tank is full of water at all times. Check low water cut-off system for proper operation.
Lime buildup in tank causing element(s) to split and burn out.| Replace element(s), and clean or delime tanks periodically. A water softener or blended phosphate treatment system may be required.

Troubleshooting Questions?
If you continue to have problems resolving an issue, please contact the nearest Authorized Hatco Service Agency or Hatco for
assistance. To locate the nearest Service Agency, log onto the Hatco website at www.hatcocorp.com, select the Support pulldown menu, and click on “Find
A Service Agent”; or contact the  Hatco Parts and Service Team at: Telephone: 800-558-0607 or 414-671-6350
e-mail: support@hatcocorp.com

OPTIONS AND ACCESSORIES

Stainless Steel Adjustable Legs
Stainless steel adjustable legs (P/N 05.30.070.00) are available as accessories for all models.
Use the following procedure to install legs:

1. Carefully place unit on its side.
   NOTICE
   Do not lay unit on the side with the control panel or inlet and outlet pipes. Damage to the unit could occur.

2. Thread the adjustable legs into the existing leg holes on the bottom of the unit.

3. After all legs are secure, return the unit to the upright position.

NOTE: If unit is not level, use an adjustable wrench to adjust the foot of each leg until unit is level. Each leg is adjustable from 6″ (152 mm) to 7″ (178 mm).

Floor Mounting Legs
Stainless steel adjustable legs with deck mounting flanges secure the booster heater to the floor are available options for Compact and Imperial models only.
Mounting Slide Brackets
A set of optional mounting slide brackets is available for Compact models only. (P/N R04.20.030.00)
Plumbing Accessories
A shock absorber, a brass pressure reducing valve, and a back pressure relief valve are available as accessories.

Blended Phosphate Water Treatment System
The optional Blended Phosphate Water Treatment System (P/N 03.05.061.00) dispenses a small amount of polyphosphate into the water. The polyphosphate prevents the buildup of mineral molecules.
The optional blended phosphate water treatment system is installed with unions on the incoming 3/4″ water supply line after the pressure reducing valve and before the booster heater.
Replacing a Phosphate Cartridge (P/N 03.05.061A.00)
Cartridges supplied have a usage rating of 100,000 gallons (378,541 liters) of water. To ensure proper operation, the cartridges must be replaced when the compound is near the bottom of the cartridge.
Use the following procedure for replacement:

1. Move the ON/OFF (I/O) switch to the OFF (O) position.

2. Shut off water supply and open the drain valve to remove water in piping.

3. Loosen the canister using the attached wrench.

4. Remove canister and discard depleted cartridge.

5. Using a clean damp cloth, wipe the interior of the canister clean.
   NOTE: Make sure the O-ring seal is placed properly in the canister.

6. Reverse the above procedure to reinstall.
   NOTE: Product failure caused by liming or sediment buildup is not covered under warranty.

Stainless Body and Base
An optional stainless body and base is available for all models.
Stainless Tank
An optional stainless tank is available for compact models.
Security Package
A security package is a factory-installed option for Compact and Imperial models only. A security package contains Torx ® screws and a control cover.

LIMITED WARRANTY

WARRANTY, EXCLUSIVE REMEDY:
Hatco Corporation (Seller) warrants that the products it manufactures (Products) will be free from defects in materials and workmanship under normal use and service and  when stored, maintained, and installed in strict accordance with factory recommendations. Seller’s sole obligation to the person or entity buying the Products directly from Seller (Customer) under this warranty is the repair or replacement by Seller or a Seller-authorized service agency, at Seller’s option, of any Product or any part thereof deemed defective upon Seller’s examination, for a period of: (i) the Warranty Duration from the date of shipment by Seller or (ii) the Warranty Duration from the date of Product registration in accordance with Seller’s written instructions, whichever is later. The “Warranty Duration” shall mean the specific periods set forth below for specific Product
components, or, to the extent not listed below, eighteen (18) months. Credit for Products or parts returned with the prior written permission of Seller will be subject to the terms shown on Seller’s material return authorization form. PRODUCTS OR PARTS RETURNED WITHOUT PRIOR WRITTEN PERMISSION OF SELLER WILL NOT BE ACCEPTED FOR CREDIT. Expenses incurred by Customer in returning, replacing, or removing the Products will not be reimbursed by Seller. If the defect comes under the terms of the limited warranty, the Products will be repaired or replaced and returned to the Customer and the cost of return freight will be paid by Seller. The remedy of repair or replacement provided for herein is Customer’s exclusive remedy. Any improper use, alteration, repairs, tampering, misapplication, improper  installation, application of improper voltage, or any other action or inaction by Customer or others (including the use of any unauthorized service agency) that in Seller’s sole judgment adversely affects the Product shall void this warranty. The warranty expressly provided herein may only be asserted by Customer and may not be asserted by Customer’s customers or other users of the Products; provided, however, that if Customer is an authorized equipment dealer of Seller, Customer may assign the warranty herein to Customer’s customers, subject to all of the limitations of these Terms, and in such case, the warranty shall be exclusively controlled by Seller in accordance with
these Terms . THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF NONINFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE EXPRESSLY DISCLAIMED.
Notwithstanding anything herein to the contrary, the limited warranty herein will not cover components in Seller’s sole discretion such as, but not limited to, the following: coated incandescent light bulbs, fluorescent lights, heat lamp bulbs, coated halogen light bulbs, halogen heat lamp bulbs, xenon light bulbs, LED light tubes, glass  components, and fuses;
Product failure in booster tank, fin tube heat exchanger, or other water heating equipment caused by liming, sediment buildup, chemical attack, or freezing.
WARRANTY REGISTRATION INSTRUCTIONS:
Product registration must be submitted within 90 days from the date of shipment from our factory to qualify for additional coverage. Registration may be submitted through the form on Seller’s website, through the form accessible through the QR code on the Product (where available), or by calling Customer Service with the required information at: 800-558-0607 or 414-671-6350.
LIMITATION OF LIABILITY:
SELLER WILL NOT BE LIABLE FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY, OR SPECIAL DAMAGES,  INCLUDING WITHOUT LIMITATION ANY LOST PROFITS, COSTS OF SUBSTITUTE PRODUCTS, OR LABOR COSTS ARISING FROM THE SALE, USE, OR INSTALLATION OF THE PRODUCTS, FROM THE PRODUCTS BEING INCORPORATED INTO OR BECOMING A COMPONENT OF ANOTHER PRODUCT, OR FROM ANY OTHER CAUSE WHATSOEVER, WHETHER BASED ON WARRANTY (EXPRESSED OR IMPLIED) OR OTHERWISE BASED ON CONTRACT, TORT, OR ANY OTHER THEORY OF LIABILITY, AND REGARDLESS OF ANY ADVICE OR REPRESENTATIONS THAT MAY HAVE  BEEN RENDERED BY SELLER CONCERNING THE SALE, USE, OR INSTALLATION OF THE PRODUCTS, EVEN IF SELLER IS AWARE OF THE POSSIBILITY OF SUCH DAMAGES. IN NO EVENT WILL SELLER’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT EXCEED THE TOTAL AMOUNTS PAID TO SELLER BY CUSTOMER FOR THE PRODUCTS WITHIN THE THREE (3) MONTH PERIOD IMMEDIATELY PRECEDING THE EVENT GIVING RISE TO CUSTOMER’S CLAIM. THE LIMITATIONS SET FORTH HEREIN REGARDING SELLER’S LIABILITY SHALL BE VALID AND ENFORCEABLE NOTWITHSTANDING A FAILURE OF ESSENTIAL PURPOSE OF THE LIMITED REMEDY SPECIFIED IN THESE TERMS.
Seller reserves the right to update these Terms at any time, at its sole discretion, which become binding upon the date of publishing. For the most current version of our full Terms of Sale, see our website at: https://www.hatcocorp.com/terms-of-sale

One (1) Year Parts and Labor PLUS One (1) Additional Year Parts-Only Warranty:
Conveyor Toaster Elements (metal sheathed)
Drawer Warmer Elements (metal sheathed)
Drawer Warmer Drawer Rollers and Slides
Food Warmer Elements (metal sheathed)
Display Warmer Elements (metal sheathed air heating)
Holding Cabinet Elements (metal sheathed air heating)
Heated Well Elements — HW, HWB, and HWBI Series (metal sheathed)
Two (2) Year Parts and Labor Warranty:
Induction Ranges
Induction Warmers
One (1) Year Replacement Warranty:
TPT Pop-Up Toasters
One (1) Year Parts and Labor PLUS Four (4) Years Parts-Only Warranty:
3CS and FR Tanks
One (1) Year Parts and Labor PLUS Nine (9) Years Parts-Only Warranty:
Electric Booster Heater Tanks
Gas Booster Heater Tanks
Ninety (90) Day Parts-Only Warranty:
Replacement Parts

AUTHORIZED PARTS DISTRIBUTORS

ALABAMA
Jones McLeod Appl. Svc.
Birmingham 205-251-0159
ARIZONA
Tech 24 Phoenix 602-234-2443
Byassee Equipment Co.
Phoenix 602-252-0402
CALIFORNIA
Industrial Electric
Commercial Parts & Service, Inc.
Huntington Beach
714-379-7100
Chapman Appl. Service
San Diego 619-298-7106
P & D Appliance
Commercial Parts & Service, Inc.
S. San Francisco
650-635-1900
COLORADO
Hawkins Commercial Appliance
Englewood 303-781-5548
FLORIDA
Whaley Foodservice Repair
Jacksonville 904-725-7800
Whaley Foodservice Repair
Orlando 407-757-0851
B.G.S.I./Heritage
Pompano Beach
954-971-0456
Comm. Appliance Service
Tampa 813-663-0313
GEORGIA
Heritage Service Group
Norcross 866-388-9837
HAWAII
Burney’s Comm. Service, Inc.
Honolulu 808-848-1466
Food Equip Parts & Service
Honolulu 808-847-4871
ILLINOIS
Parts Town
Addison 708-865-7278
Eichenauer Elec. Service
Decatur 217-429-4229
Midwest Elec. Appl. Service
Elmhurst 630-279-8000
Cone’s Repair Service
Moline 309-797-5323
IOWA
Goodwin Tucker Group
Des Moines 515-262-9308| KENTUCKY
Tech 24
Lexington 859-254-8854
Tech 24
Louisville 502-451-5411
LOUISIANA
Chandlers Parts & Service
Baton Rouge 225-272-6620
MARYLAND
Electric Motor Service
Baltimore 410-467-8080
MASSACHUSETTS
Ace Service Co., Inc.
Needham 781-449-4220
MICHIGAN
Bildons Appliance Service
Detroit 248-478-3320
Commercial Kitchen Service
Bay City 989-893-4561
Midwest Food Equip. Service
Grandville 616-261-2000
MISSOURI
General Parts
Kansas City 816-421-5400
Commercial Kitchen Services
St. Louis 314-890-0700
Kaemmerlen Parts & Service
St. Louis 314-535-2222
NEBRASKA
Anderson Electric
Omaha 402-341-1414
NEVADA
Burney’s Commercial
Las Vegas 702-736-0006
Hi. Tech Commercial Service
N. Las Vegas
702-649-4616
NEW JERSEY
Jay Hill Repair
Fairfield 973-575-9145
Service Plus Flanders 973-691-6300
NEW YORK
Alpro Service Co.
Maspeth 718-386-2515
Duffy’s – AIS
Buffalo 716-884-7425
3Wire Plattsburgh 800-634-5005
Duffy’s – AIS
Sauquoit 800-836-1014
J.B. Brady, Inc. Syracuse 315-422-9271
---|---
NORTH CAROLINA
Authorized Appliance
Charlotte 704-377-4501
OHIO
Akron/Canton Comm. Svc. Inc.
Akron 330-753-6634
Tech 24 Cincinnati 513-772-6600
Commercial Parts and Service
Columbus 614-221-0057
Electrical Appl. Repair Service
Brooklyn Heights 216-459-8700
E. A. Wichman Co. Toledo 419-385-9121
OKLAHOMA
Hagar Rest. Service, Inc.
Oklahoma City 405-235-2184
OREGON
General Parts Group
Portland 503-624-0890
PENNSYLVANIA
Elmer Schultz Services
Philadelphia 215-627-5401
FAST Comm. Appl. Service
Philadelphia 215-288-4800
AIS Commercial Parts and Service
Pittsburgh 412-809-0244
K & D Service Co.
Harrisburg 717-236-9039
Electric Repair Co.
Reading 610-376-5444
RHODE ISLAND
Marshall Electric Co.
Providence 401-331-1163
SOUTH CAROLINA
Whaley Foodservice Repair
Lexington 803-996-9900
TENNESSEE
Camp Electric
Memphis 901-527-7543
TEXAS
Armstrong Repair Service
Houston 713-666-7100
Cooking Equipment Specialist
Mesquite 972-686-6666
Commercial Kitchen Repair Co.
San Antonio 210-735-2811| UTAH
La Monica’s Rest. Equip. Service
Murray 801-263-3221
VIRGINIA
Daubers
Norfolk 757-855-4097
Daubers
Springfield 703-866-3600
WASHINGTON
3Wire
Seattle 800-207-3146
WISCONSIN
A.S.C., Inc.
Madison 608-246-3160
A.S.C., Inc.
Milwaukee 414-543-6460
CANADA
ALBERTA
Key Food Equipment Service
Edmonton 780-438-1690
BRITISH COLUMBIA
Key Food Equipment Service
Vancouver 604-433-4484
Key Food Equipment Service
Victoria 250-920-4888
MANITOBA
Air Rite, Inc.
Winnipeg 204-895-2300
NEW BRUNSWICK
EMR Services, Ltd.
Moncton 506-855-4228
ONTARIO
R.G. Henderson Ltd.
Toronto 416-422-5580
Choquette – CKS, Inc.
Ottawa 613-739-8458
QUÉBEC
Choquette – CKS, Inc.
Montreal 514-722-2000
Choquette – CKS, Inc.
Québec City
418-681-3944

UNITED KINGDOM
Marren Group
Northants +44(0)1933 665313
HATCO CORPORATION
P.O. Box 340500
Milwaukee, WI 53234-0500 U.S.A.
800-558-0607 414-671-6350
support@hatcocorp.com
www.hatcocorp.com
Register your unit online!
See IMPORTANT OWNER INFORMATION section for details.

References

• Commercial Foodservice & Restaurant Equipment | Hatco
• Commercial Foodservice & Restaurant Equipment | Hatco
• hatcocorp.com/terms-of-sale

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