American Water Heater HeavyDuty Commercial Electric Conversion Kit Instructions STCE ITCE User Manual

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FOR INSTALLATION BY QUALIFIED SERVICE PERSONNEL ONLY
CONVERSION KIT INSTRUCTIONS
Commercial Electric Water Heaters
 CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS 
INFORMATION RELATIVE TO YOUR SAFETY.  
PLEASE READ THOROUGHLY BEFORE 
ATTEMPTING ANY  CONVERSION.
125 Southeast ParkwayFranklin, TN 370681-800-433-2545
apcom-inc.com
PRINTED IN U.S.A. 1011      196679-003 
						

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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 con\
version 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 wat\
er.
REQUIRED ABILITY
CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED ELECTRICAL TRADESMAN.
CONVERSION MATERIALS
1. Screw Plug Element Remover: Part no. 9000429015 or 1-1/2” deep well s\
ocket 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.
TABLE OF CONTENTS
  KW Conversion (Element Replacement)  ............. 4
  Voltage Conversion  .............................................  4-5
  Phase Conversion  ...............................................  5-6
  Caution ................................................................  6
  Final Assembly ....................................................  6-7
  Check List ............................................................  7
  Miscellaneous Information  ................................... 7-8
    
Foreword  ...............................................................  2
Conversion Materials  .............................................  2
Conversion Guidelines  .......................................  3
Conversion Instructions
  Introduction ..........................................................  4
  Heater Preparation  ..............................................  4Page
Page 
						

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CONVERSION GUIDELINES
Be sure to read and understand the conversion limitations and instructio\
ns prior to conversion.1. No addition or substraction of heating elements are allowed in the conve\
rsion process;
2.  Conversion  kits  are  designed  for  specific  voltage  with  Delta  configuration,  no  other  configuration  or  voltage  is 
allowed;
3.  Refer to “Branch Circuit Section” in User’s Manual for electrical specifications;
4.  Check all water and electrical connections for tightness after conversio\
n.
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 des\
ired KW row intersects the voltage 
column.
3.  Order the appropriate kit number.
4.  Follow the conversion instructions detailed on pages 9 through 13 to com\
plete conversion.
5.  Fill out the check list on Page 12 after completing the unit conversion.\
CONVERSION KIT NUMBER TABLE
Models Allowed 
For Conversion Desired Input
Conversion Kit No. At Desired Voltage
Total KW Element KW 208V240V 277V 480V
models with  
3 Elements 6
29003335005 9003348005
90041150059003363005
9 3
90033360059003349005 9004116005**9003364005
12 4
900333700590033500059004117005 9003365005
13.54.590033330059003345005 9004118005**9003360005
15 5
90033340059003346005 9004119005**9003361005
18 6N/A9003347005 9004120005
9003362005
models with   
6 Elements 18
3
900334000590033540059004121005**9003369005
24 4
9003341005900335500590041220059003370005
27 4.5
900333800590033510059004123005**9003366005
30 5
900333900590033520059004124005**9003367005
36 6N/A9003353005 9004125005
9003368005
models with   
9 Elements* 36
4
90033440059003359005 90041260059003374005
40.54.5900334200590033560059004127005**9003371005
45 5
900334300590033570059004128005**9003372005
54 6N/A9003358005 9004129005
9003373005
   * No conversion kits available for 50 gallon capacity 9 element models e\
quipped with surface-mounted thermostat.
  ** Indicates the conversion kit with Incoloy Elements. 
						

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CONVERSION INSTRUCTIONS
REQUIRED ABILITY
CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED ELECTRICAL TRADESMAN
I.  INTRODUCTION
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.
II.  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 & P valve (separate package).
III. 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.  A new “O” ring gasket should be installed on each element.  Element\
 
threads should be lubricated with Dow Corning ®  silicon  sealant  (or  equal).  Screw  element  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 contr\
ol panel door.  Screw terminals must be 
snug, however, caution must be exercised.  Overtightening may break the terminal bloc\
k, 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 III.
  B.  Immersion thermostat models require installation of the appropriate elem\
ents 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 diagram\
s.
  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 ma\
rked 208, 240, 277 or 480.
    C.  Do not change the common connections or the secondary wire connections. 
						

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V.  PHASE CONVERSION
   A. IMMERSION THERMOSTAT MODEL
      THREE PHASE TO SINGLE PHASE
    1. Disconnect blue wires and yellow wires from terminal L-3.
    2. Connect all blue wires to terminal L-1 (with black wires).
    3. Connect all yellow wires to terminal L-2 (with red wires).
    4.  Incoming power will be connected to 
      terminals L-1 and L-2 at job site.
  
  
  
   B.  IMMERSION THERMOSTAT MODEL 
      SINGLE PHASE TO THREE PHASE
  1.  Disconnect blue wires from terminal L-1.
  2.  Disconnect yellow wires from terminal L-2.
  3.  Connect all blue wires and yellow wires to terminal L-3.
  4.  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
 IMMERSION THERMOSTAT MODEL
 THREE PHASE TERMINAL BLOCK
IMMERSION THERMOSTAT MODEL  TRANSFORMER  CONNECTION TABLES
 Volts  Line On  Load on
  208 Common & 208
  240 Common & 240  Secondary
  277 Common & 277    120V
  480 Common & 480480
277
240
208
CO M 
						

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 C. SURFACE THERMOSTAT MODEL 
    THREE PHASE TO SINGLE PHASE
  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  L-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.
 
 D. SURFACE THERMOSTAT MODEL 
    SINGLE 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).
  4. Connect red wires to terminal L-3.
  5. Incoming power will be connected to 
    terminals L-1, L-2 and L-3 at job site.
VI.    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
VII. FINAL ASSEMBLY
  A. CONTROL PANEL
  Replace foam door.  Cover all elements
  and thermostats as originally constructed.  
  Replace T & P valve package, close door, 
  relatch and tighten the two control panel screws.
  B. RATING PLATE MODIFICATION
  Following is a sample of the standard rating 
  plate supplied on the front of the control panel 
 door.
SURFACE THERMOSTAT MODEL 
SINGLE PHASE TERMINAL BLOCK
SURFACE THERMOSTAT MODEL
 THREE PHASE TERMINAL BLOCK
SAMPLE RATING PLATE 
						

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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 the conv\
ersion you have just completed.
        
 
Peel off the back of the label and paste over the existing rating plate as show\
n below. 
 
 C. Peel off back of caution label and attach label to upper right hand corner of c\
ontrol panel door.
  D. CRATE IDENTIFICATION
    Using  a  black  magic  marker,  cross  out  heater  identification  on  crate  as  appropriate.    In  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
	 	 All affected parts have been installed properly and have been checked for tigh\
tness.
	 	 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.
	 	 New rating plate overlay has been installed properly over the existing r\
ating plate.
VIII. 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, 36KW is normally supplied using six 6,000 wa\
tt elements.  It can however, be supplied   
using nine 4,000 watt elements.
SAMPLE RATING PLATE WITH CONVERSION LABEL 
						

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 B.  ELEMENT SIZE VERIFICATION
    All elements are marked with both wattage and voltage.  Verification can be made by measuring the ohms    
  resistance across the terminals of the elements.  Element must be discon\
nected from the circuit.  The following  
  table gives resistance in ohms for all elements used in commercial elect\
ric water heaters.
  Element ohms resistance  should be within ±5% of the above values.
  Examples: Elements with an ohm resistance of 14 ohms indicates that it i\
s either a 3,000 watt/208 volt element  
  and/or a 4,000 watt/240 volt element (dual rated type).
 CAUTION
NEVER OPERATE THE HEATER WITHOUT FILLING WITH WATER PER THE FILLING INSTRUCTIONS. FAILURE 
TO DO SO WILL DAMAGE INTERNAL PARTS.  
     OHMS RESISTANCE TABLE
       VOLTAGE
  WATTAGE  208  240   480
 2000  21.63 28.80 115.20
  3000  14.42 19.20 76.80
  4000  10.82 14.40 57.60
 4500  9.61 12.80  51.20
 5000  8.65 11.52  46.08
  6000   7.21  9.60 38.40
  Number  KW               Single (1) phase             Three (3) Phase
   KW  of   Each
  Input  Elements  Elements 208V 240V 480V 208V 240V 480V
   6    2.0 28.8 25.0 12.5 16.7 14.4   7.2
    9    3.0 43.3 37.5 18.8 25.0 21.7 10.8
  12    4.0 57.7 50.0 25.0 33.3 28.9 14.4
  13.5    4.5 64.9 56.3 28.1 37.5 32.5 16.2
  15    5.0 72.1 62.5 31.3 41.6  36.1 18..0
  18    6.0 - - - - 75.0 37.5 - - - - 43.3 21.7
  18    3.0 86.5 - - - -  - - - -    50.0 - - - -  - - - - 
  24    4.0 115.4 100.0  50.0 66.6 57.7 18.9
  27    4.5 129.8 112.5 56.3 74.9 65.0 32.5
  30    5.0 144.2 125.0  62.5 83.3 72.2 36.1
  36    6.0 - - - - 150.0  75.0 - - - - 86.6 43.3
  36    4.0 173.1  - - - - - - - -  99.9 - - - -  - - - -
 40.5    4.5 194.7 168.8  84.4 112.4  97.4 48.7
  45    5.0 216.3 187.5 93.8 124.9  108.3 54.1
  54    6.0 - - - - 225.0 112.5  - - - -  129.9  65.0
3
6
9
FULL LOAD CURRENT IN AMPERES 
						

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NOTES 
						

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NOTES