CONVERSION KIT INSTRUCTIONS
Contents
1. FOR INSTALLATION BY QUALIFIED SERVICE PERSONNEL ONLY CONVERSION KIT INSTRUCTIONS Commercial Electric Water Heaters ATTEMPTING ANY CONVERSION CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY mr PLEASE READ THOROUGHLY BEFORE 125 Southeast Parkway Franklin TN 37068 LISTED 1 800 433 2545 apcom inc com PRINTED IN U S A 1011 196679 003 FOREWORD The purpose of this manual is to explain how to change the voltage and wattage of your commercial electric water heater by changing the elements This manual is not intended to explain the rebuilding of commercial electric water heaters in the field Addition of heating elements or subtraction of heating elements in the field is not approved by Underwriters Laboratories Inc and therefore is not allowed and should not be attempted Please note the limitation that both the heater required and the heater to be converted must be found on the same page in this manual must be followed Before attempting any conversion read the detailed instructions contained on pages 8 9 10 and 11 SAFETY Be sure to disconnect appliance from electrical supply before working on or near the electrical system of the heater Never touch electrical components with wet hands or when standing in water REQUIRED ABILITY CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED ELECTRICAL TRADESM2. 36KW is normally supplied using six 6 000 watt elements It can however be supplied using nine 4 000 watt elements 7 B ELEMENT SIZE VERIFICATION All elements are marked with both wattage and voltage Verification be made by measuring the ohms resistance across the terminals of the elements Element must be disconnected from the circuit The following table gives resistance in ohms for all elements used in commercial electric water heaters OHMS RESISTANCE TABLE VOLTAGE WATTAGE 240 480 208 2000 21 63 28 80 11520 14 42 19 20 76 80 10 82 10 82 721 960 3840 Element ohms resistance should be within 5 of the above values Examples Elements with an ohm resistance of 14 ohms indicates that it is either a 3 000 watt 208 volt element and or a 4 000 watt 240 volt element dual rated type FULL LOAD CURRENT IN AMPERES Number KW Single 1 phase Three 3 Phase of Each Elements Elements 208V 240V 480V 208V 240V 480V l 1 2 CAUTION NEVER OPERATE THE HEATER WITHOUT FILLING WITH WATER PER THE FILLING INSTRUCTIONS FAILURE TO DO SO WILL DAMAGE INTERNAL PARTS Smart Parts 125 Southeast Parkway Franklin TN 37068 1 800 433 2545 apcom inc com
3. the conversion you have just completed Peel off the back of the label and paste over the existing rating plate as shown below COMMERCIAL STORAGE opie UL TANK WATER HEATER O LISTED ANSI NSF 5 22U1 MODEL NUMBER SERIAL NUMBER ITEM 1D PART NUMBER CITY OF NEW YORK DEPT OF BUILDINGS MEA CAPACITY US GAL STANDBY LOSS MAX WORKING ATT RATED MEASURED PRESSURE SAMPLE RATING PLATE WITH CONVERSION LABEL C Peel off back of caution label and attach label to upper right hand corner of control panel door D CRATE IDENTIFICATION Using a black magic marker cross out heater identification on crate as appropriate bold letters write new electrical specifications in crate matching those on the revised rating plate E SHIPPING CRATE Close and tape the plastic flap on front of crate CHECK LIST O All affected parts have been installed properly and have been checked for tightness All affected wires have been checked for tightness New elements have been wired per wiring diagram label on the unit New elements have been tightened properly New elements have been leak checked I Oo D Oo New rating plate overlay has been installed properly over the existing rating plate Vill MISCELLANEOUS INFORMATION A NON STANDARD CONSTRUCTION At 480 and 240 volts 18KW is normally supplied using three 6 000 watt elements They can however be constructed using six 3 000 watt elements At 480 volts and 240 volts
4. AN TABLE OF CONTENTS Page Page Foreword 2 KW Conversion Element Replacement 4 Conversion 5 2 Voltage Conversion c EL 4 5 C ion Guideli 3 Phase Conversion 5 6 en 6 Conversion Instructions Final Assembly 6 7 IRITOQUCTOR An 4 Check 5 7 Heater Preparation 4 Miscellaneous Information 7 8 CONVERSION MATERIALS 1 Screw Plug Element Remover Part no 9000429015 or 1 1 2 deep well socket and ratchet 2 Screwdrivers Two required one 2 phillips and one slotted screwdriver 3 Conversion kit Includes conversion instructions replacement electrical elements conversion kit label and caution label 4 Thread sealer When replacing screw in type elements be sure to use Dow Corning silicone sealant bathtub sealer on threads CONVERSION GUIDELINES Be sure to read and understand the conversion limitations and instructions prior to conversion 1 No addition or substraction of heating elements are allowed in the conversion process 2 Conversion kits are designed for specific voltage with Delta configuration no other configuration or voltage 15 al
5. GLE PHASE TO THREE PHASE 1 Disconnect blue wires from terminal L 1 2 Disconnect red wires from terminal L 2 3 Connect all blue wires to terminal L 2 with yellow wires dee 5565 5951 6665 EN 5 Incoming power will be connected to ol HEN terminals L 1 L 2 and L 3 at job site L3 ALL BLACK VELO ALL RED WIRES WIRES WIRES 4 Connect red wires to terminal L 3 A CAUTION Recheck all terminals for tightness proper wiring per schematic and neatness of wiring Heater should be no less than factory constructed quality and appearance CHECK ALL WATER AND ELECTRICAL CONNECTIONS FOR TIGHTNESS Vil FINAL ASSEMBLY COMMERCIAL STORAGE oie A CONTROL PANEL UL TANK WATER HEATER Replace foam door Cover all elements 2 ae eS and thermostats as originally constructed MODEL NUMBER SERIAL NUMBER ITEM ID PART NUMBER Replace T amp P valve package close door MEME relatch and tighten the two control panel screws Na or_ MATTE enge PHASE VOLTS AC ELEMENTS EACH OF BUILDINGS MEA B RATING PLATE MODIFICATION CAPACITY US GAL STANDBY LOSS MAX WORKING RATED MEASURED WATTS PRESSURE Following is a sample of the standard rating plate supplied on the front of the control panel door SAMPLE RATING PLATE The voltage element KW total KW data of the rating plate must be modified by covering them with the label provided in the conversion kit Be sure the new ratings on the label match
6. RODUCTION Satisfying a customer order for a commercial electric heater from inventory may require modification to the KW input the voltage or the phase Conversions may involve revision to 1 2 or all 3 of these electrical characteristics HEATER PREPARATION The heater should be placed in a well lit area Complete removal of the shipping crate is not required The front of the heater with the control box will be visible through the clear plastic Cut a 3 sided flap into the plastic cut should be on top bottom and right side approximately 4 from the wooden edge Release the two control panel screws and unlatch with knob on the water heater door To expose elements remove the foam door covering directly in back of the control panel door Remove the T amp P valve separate package KW CONVERSION ELEMENT REPLACEMENT A Remove wires from one element at a time It is not necessary to tag loose wires as the wiring schematic is inside the control panel door B Remove element from heater using part no 9000429015 or 1 1 2 deep well socket and ratchet Return the elements to appropriate storage bin C Open the appropriate conversion kit and remove the elements Check each element to ensure correct voltage and wattage D Install the new element starting it by hand Anew O ring gasket should be installed on each element Element threads should be lubricated with Dow Corning silicon sealant or equal Screw eleme
7. llow wires from terminal L 3 Connect all blue wires to terminal L 1 with black wires Connect all yellow wires to terminal L 2 with red wires Incoming power will be connected to terminals L 1 and L 2 at job site IMMERSION THERMOSTAT MODEL SINGLE PHASE TO THREE PHASE Disconnect blue wires from terminal L 1 Disconnect yellow wires from terminal L 2 Connect all blue wires and yellow wires to terminal L 3 Incoming power will be connected to terminals L 1 L 2 and L 3 at job site IMMERSION THERMOSTAT MODEL TRANSFORMER IMMERSION THERMOSTAT MODEL SINGLE PHASE TERMINAL BLOCK See fo of L2 ALL ALL O BLUE BLACK YELLOW RED WIRES WIRES WIRES IMMERSION THERMOSTAT MODEL THREE PHASE TERMINAL BLOCK SAI Ses SSS fo AU L3 ALL ALL ALL EE RED WIRES BLUE YELLOW WIRES C SURFACE THERMOSTAT MODEL SURFACE THERMOSTAT MODEL THREE PHASE TO SINGLE PHASE SINGLE PHASE TERMINAL BLOCK fl ef el SSS 565 656 666 1 Disconnect blue wires from terminal L 2 2 Connect all blue wires to terminal L 1 with black wires 3 Disconnect all red wires from terminal 1 3 4 Connect all red wires to terminal L 2 with yellow wires 5 Incoming power will be connected to terminals L 1 and L 2 at job site ALL ALL NO BLUE BLACK YELLOW RED WIRES WIRES WIRES SURFACE THERMOSTAT MODEL D SURFACE THERMOSTAT MODEL THREE PHASE TERMINAL BLOCK SIN
8. lowed 3 Refer to Branch Circuit Section in User s Manual for electrical specifications 4 Check all water and electrical connections for tightness after conversion TO USE THE TABLE 1 Find the element number of the heater that you wish to convert 2 Find the total kilowattage under Desired Input column then move across the Table on same line to voltage desired The kit number required for the conversion will be the one where the desired KW row intersects the voltage column 3 Order the appropriate kit number 4 Follow the conversion instructions detailed on pages 9 through 13 to complete conversion 5 Fill out the check list on Page 12 after completing the unit conversion CONVERSION KIT NUMBER TABLE Models Allowed For Conversion Total KW ElementKW 208v 277 av 6 2 9003335005 9003348005 9004115005 9003363005 o 3 9003336005 9003349005 9004116005 9005364006 NA 9003347005 9004120005 9003362005 N 5 6 NA 9003356005 9004129005 9003373005 No conversion kits available for 50 gallon capacity 9 element models equipped with surface mounted thermostat IA 6 NA 9003353005 9004125005 9003368005 IA Indicates the conversion kit with Incoloy Elements CONVERSION INSTRUCTIONS REQUIRED ABILITY CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED ELECTRICAL TRADESMAN INT
9. nt into fitting until it seats Tighten 1 2 to 3 4 turn with wrench E Rewire the element as directed on wiring schematic located inside control panel door Screw terminals must be snug however caution must be exercised Overtightening may break the terminal block requiring replacement of the element F Repeat steps A thru E for all other elements being replaced IV VOLTAGE CONVERSION A Surface thermostat models merely require installation of the appropriate elements to accomplish a change in voltage See KW conversion step Ill B Immersion thermostat models require installation of the appropriate elements AND may also require a transformer tap change Immersion thermostat models are equipped with a transformer having 5 connections common 208 240 277 and 408 and 2 secondary connections See the following diagrams Only one wire need be changed on the transformer to change voltage Remove the wire from the terminal marked 208 240 277 or 480 and attach it to the appropriate terminal marked 208 240 277 or 480 C Do not change the common connections or the secondary wire connections 4 IMMERSION THERMOSTAT MODEL TRANSFORMER CONNECTION TABLES Common 208 240 Common amp 240 Secondary Common 8 277 120V Common 480 1 2 3 4 5 OMMON 208V 240V 277 480V 7 SECONDARY 120V 6 V PHASE CONVERSION A IMMERSION THERMOSTAT MODEL THREE PHASE TO SINGLE PHASE Disconnect blue wires and ye
Download Pdf Manuals
Related Search