APCom CSB120, CSB120I, CSB120S, STCE31-50, STCE31-80 Instructions Manual

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Page 1

FOR INSTALLATION BY QUALIFIED SERVICE PERSONNEL ONLY

CONVERSION KIT INSTRUCTIONS

For Models CSB52** “I or S”, CSB82** “I or S” & CSB120** “I or S”

And Models (A)STCE31-50/80/119, (A)ITCE31-50/80/119

Commercial Electric Water Heaters

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PL E AS E R EA D TH O RO U GH LY BEF O RE ATTEMPTING ANY CONVERSION.

PRINTED IN U.S.A. 1208 196679-002

125 Southeast Parkway

Franklin, TN 37068

1-800-433-2545

apcom-inc.com

Page 2

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.

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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

Models Allowed

For Conversion

CSB or

(I, S)TCE

models with

3 Elements

CSB or

(I, S)TCE

models with

6 Elements

CSB or

(I, S)TCE models with 9 Elements*

Desired Input Conversion Kit No. At Desired Voltage

Total KW Element KW 208V 240V 277V 480V

6 2 9003335005 9003348005

9 3

12 4

13.5

15 5

18 6 N/A 9003347005 9004120005

18 3

24 4

27 4.5

30 5

36 6 N/A 9003353005 9004125005

36 4

40.5

45 5

54 6 N/A 9003358005 9004129005

4.5

9003336

9003337

9003333

9003334

9003340

9003341

9003338

9003339

9003344

9003342

9003343

005 9003349005 9004116005**

005 9003350005

005 9003345005 9004118005**

005 9003346005 9004119005**

005 9003354005

005 9003355005

005

005 9003352005

005 9003359005 9004126005

005 9003356005

005 9003357005

9003351

9004115

9004117

9004121

9004122

005 9004123005**

9004124

9004127

9004128

005

005 9003365005

005

9003363

9003364

9003360

9003361

9003362

9003369

9003370

9003366

9003367

9003368

9003374

9003371

9003372

9003373

005

* No conversion kits available for 50 gallon capacity 9 element models equipped 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 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 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 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.

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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

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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.

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

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The voltage, element KW, total KW data of the rating plate must be modied by covering them with the label provided in

the conversion kit. Be sure the new ratings on the label match the conversion you have just completed.

Peel off the back of the label and paste over the existing rating plate as shown below.

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 identication on crate as appropriate. In bold letters, write

new electrical specications in crate, matching those on the revised rating plate.

E. SHIPPING CRATE

Close and tape the plastic ap on front of crate.

CHECK LIST

 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.

 New rating plate overlay has been installed properly over the existing rating 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 watt elements. It can however, be supplied

using nine 4,000 watt elements.

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B. ELEMENT SIZE VERIFICATION

All elements are marked with both wattage and voltage. Verication can 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 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

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 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 - - - - - - - -