A.O. Smith DRE 52, DRE 80, DRE 120, DVE 52, DVE 80 Technical Documents

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FOR INSTALLATION BY QUALIFIED SERVICE PERSONNEL ONLY

CONVERSION KIT INSTRUCTIONS

Models DRE & DVE 52, 80, & 120

Commercial Electric Water Heaters

Series 100

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PL E ASE R EAD TH O ROU GHLY BEFO RE ATTEMPTING ANY CONVERSION.

PRINTED 0210 196678-003

500 Tennessee Waltz Parkway

Ashland City, TN 37015

1-800-433-2545

www.hotwater.com

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 eld.

Addition of heating elements or subtraction of heating elements in the eld 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 TRADESMAN.

TABLE OF CONTENTS

Foreword ............................................................... 2

Conversion Materials ............................................. 2

Conversion Guidelines ....................................... 3 Conversion Instructions

Introduction .......................................................... 4

Heater Preparation .............................................. 4

Page

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

CONVERSION MATERIALS

1. Screw Plug Element Remover: Part no. 9000429015 or 1-1/2” deep well socket and ratchet.

Page

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 specic voltage with Delta conguration, no other conguration or voltage is

allowed;

3. Refer to “Branch Circuit Section” in User’s Manual for electrical specications;

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

Desired Input Conversion Kit No. At Desired Voltage

Models Allowed

Total kW

For Conversion

6 2 9005587105 9005600105 9005615105 9005621105 9 3 9005588105 9005601105 9005616105** 9005622105

DVE/DRE

52, 80, 120

12 4 9005589105 9005602105 9005617105 9005623105

13.5 4.5 9005585105 9005597105 9005612105** 9005618105

15 5 9005586105 9005598105 9005613105** 9005619105 18 6 N/A 9005599105 9005614105 9005620105 18 3 9005592105 9005606105 9005627105** 9005632105 24 3 9005593105 9005607105 9005628105 9005633105 27 4.5 9005590105 9005603105 9005624105** 9005629105 30 5 9005591105 9005604105 9005625105** 9005630105 36 6 N/A 9005605105 9005626105 9005631105 36 4 9005596105 9005611105 9005637105 9005641105

40.5 4.5 9005594105 9005608105 9005634105** 9005638105

DVE 52, 80, 120

45 5 9005595105 9005609105 9005635105** 9005639105 54 6 N/A 9005610105 9005636105 9005640105

with

3 Elements

DVE/DRE

52, 80, 120

with

6 Elements

DRE 80, 120

with

9 Elements

Element kW

208V 240V 277V 480V

* No conversion kits available for 50 gallon capacity 9 element models equipped with surface-mounted thermostat. ** 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

I. INTRODUCTION

Satisfying a customer order for a commercial electric heater from inventory may require modication 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 ap into the plastic, cut should be on

top, bottom and right side approximately 4” from the wooden edge.

Release the two control panel screws on the water heater door.

To expose elements, remove the foam door inside the control panel.

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 tting 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 III.

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.

480

277

240

208

COM

IMMERSION THERMOSTAT MODEL TRANSFORMER

CONNECTION TABLES

Volts Line On Load on 208 Common & 208 240 Common & 240 Secondary 277 Common & 277 120V 480 Common & 480

V. PHASE CONVERSION

A. IMMERSION THERMOSTAT MODEL THREE PHASE TO SINGLE PHASE

1. Disconnect blue wires and yellow wires from terminal L-3.

IMMERSION THERMOSTAT MODEL TRANSFORMER

IMMERSION THERMOSTAT MODEL

SINGLE PHASE TERMINAL BLOCK

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

THREE PHASE TERMINAL BLOCK

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.

SURFACE THERMOSTAT MODEL

SINGLE PHASE TERMINAL BLOCK

D. SURFACE THERMOSTAT MODEL SINGLE PHASE TO THREE PHASE

SURFACE THERMOSTAT MODEL

THREE PHASE TERMINAL BLOCK

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.

SAMPLE RATING PLATE

+ 14 hidden pages