COMMERCIAL ELECTRIC WATER HEATERS
CONVERSION KIT INSTRUCTION MANUAL
Model 105, 108 &112
This conversion kit shall be installed by
qualified service personnel only. The conversion shall be carried out in accordance
with the requirements of the local authorities having jurisdiction; and local and
national electrical codes.
Disconnect from power supply before
attempting the conversion procedure.
Additional safety lockout procedures may
be required! Read all instructions before
proceeding with the conversion procedure.
®
C US
The purpose of this manual is to explain how to change the
voltage, wattage or phase of your commercial electric water
heater by changing the wiring configuration or the elements.
This manual is not intended to explain the rebuilding of commercial electric water heaters in the field.
The addition or removal of heating elements originally
supplied with the water heater is not permitted by CSA
International. This modification shall not be attempted.
IMPORTANT
READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE CONVERSION. PROPER CONVERSION
WILL PROVIDE SAFE AND EFFICIENT SERVICE, AND AVOID NEEDLESS EXPENSE NOT COVERED BY THE
WARRANTY. SHOULD YOU HAVE ANY QUESTIONS, PLEASE CONTACT YOUR LOCAL DEALER OR REFER
TO THE
THIS MANUAL FOR FUTURE REFERENCES.
GETTING SERVICE FOR YOUR WATER HEATER SECTION
OF THIS MANUAL.
SAVE
54000051
© 2012 Giant Factories Inc. Printed in Canada
IM043Bi-1112
Table of contents
Number
of
elements
Desired
Total Input,
(kW)
Desired Voltage
208 Volts 240 Volts 277 Volts
Conversion Kit Part Numbers
18 06999106 06999119 06999134 06999149
24 06999107 06999120 06999135 06999150
27 06999108 06999121 06999136
Conversion Kit................. 2
Conversion Guidelines ............ 2
Conversion Kit Selection .......... 3
Conversion Instructions ...........4
Water Heater Preparation ..........4
Wattage Conversion (kW) ..........4
Voltage Conversion .............5
Phase Conversion .............5
Final Assembly ...............6
Check List .................7
Miscellaneous Informations .......... 7
Getting service for your water heater .......7
Conversion Kit
This conversion kit shall contain the following items:
— One (1) conversion kit instruction manual;
— Two (2), three (3), four (4) six (6) or nine (9) replacement elements with gaskets
(Depending on the conversion kit model number);
— Four (4) 5/8” screws per element;
— One (1) conversion rating plate;
— Two (2) conversion labels (English & French).
Note: Always make sure kits are complete before starting the conversion process.
Conversion Guidelines
l
Water heater model number allowed for conversion must start with the following: 105, 108 or 112 and must have
been manufactured after January 1st, 2013 (see rating plate);
l
No addition or removal of heating elements is allowed in the conversion process;
l
Conversion kits for 208V, 240V, 277V and 480V are designed for specific voltages with “Delta” configuration. No
other voltage or configuration is allowed;
l
Conversion kits for 600V models are supplied with 347V elements because of the “Star” wiring configuration.
CAUTION: The 600V Models cannot be converted to any other voltages.
Conversion Tables
Refer to Table 1 for 208V,
240V, 277V and 480V Models
Refer to Table 2
for 600V Models
THE STRUCTURE
OF THE
MODEL NUMBER
105 = 40.5
108 = 61.4
NUMBER
112 = 99.1
OF ELEMENTS
1 0 5 6 B 3 2 7
TANK CAPACITY
Imp. gal
Imp. gal
Imp. gal
/ 48.6
/ 73.7
/ 119.0
US Gal.
US Gal.
US Gal.
VOLTAGE
A = 208 V
B = 240 V
C = 600 V
D = 480 V
E = 277 V
2
Conversion Kit Selection
CONVERSION FOR 208V, 240V, 277V AND 480V MODELS
1. Find the “Number of elements” in the water heater you wish to
convert
2. In Table 1, find the “Number of elements” in the water heater to be
converted (4th digit of model number on the rating plate, see page 2).
3. Then, move across the Table 1 on the same line to the “Desired
Voltage”. The appropriate Conversion Kit part number will be the
one where the “Desired total input” line intersects the “Desired
Voltage” column.
Table 1
105, 108
or 112
Models
EXAMPLE: For a 6 element water heater to be
converted to 27 kW / 480V, the appropriate
Convertion Kit part number is 06999151.
Table 2
Capacity & Type
105, 108 or 112 Models
Capacity & Type
Heavy
Duty
Medium Duty 4
Heavy Duty
Number
of
elements
3
6
9
Light Duty 2
Desired
Total Input,
(kW)
6 06999158
9 06999159
12 06999160
13.5 06999161
15 06999162
18 06999163
18 06999164
24 06999165
27 06999166
30 06999167
36 06999168
36 06999169
40.5 06999170
45 06999171
54 06999172
63 06999173
elements
Number
INPUT IN
KILOWATTS
ex: 27 = 27kW
4. Make sure that you have the proper conversion kit model
number to perform the desired conversion.
5. Follow the conversion instructions detailed in this manual.
6. Fill out the check list on page 5 once the conversion is completed.
No addition or removal of heating elements is allowed in the conversion process. Failure to do so could result in electrical shock
and/or property damage, personal injury, or death.
DESIRED VOLTAGE
Desired
of
Total Input,
208 Volts 240 Volts 277 Volts 480 Volts
(kW)
Conversion Kit Part Numbers
3 06999301 06999309 06999317 06999325
4.5 06999302 06999310 06999318 06999326
5 06999303 06999311 06999319 06999327
6
06999312 06999320 06999328
N/A
6 06999305 06999313 06999321 06999329
9 06999306 06999314 06999322 06999330
10 06999307 06999315 06999323 06999331
12
06999316 06999324 06999332
N/A
6 06999101 06999113 06999128 06999143
9 06999102 06999114 06999129 06999144
12 06999103 06999115 06999130 06999145
3
13.5 06999104 06999116 06999131 06999146
15 06999105 06999117 06999132 06999147
18 N/A 06999118 06999133 06999148
18 06999106 06999119 06999134 06999149
24 06999107 06999120 06999135 06999150
6
27 06999108 06999121 06999136 06999151
30 06999109 06999122 06999137 06999152
36 N/A 06999123 06999138 06999153
36 06999110 06999124 06999139 06999154
40.5 06999111 06999125 06999140 06999155
9
45 06999112 06999126 06999141 06999156
54 N/A 06999127 06999142 06999157
6
27
CONVERSION FOR 600V MODELS
Conversion
Conversion kits are available to modify total power (kW) of the water
Kit Part
heater in the field. Refer to Table 2 for the selection of the appropriate
Numbers
conversion kit.
1. Find the “Number of elements” in the water heater you wish to convert
2. Find the “Desired total input (kW)” in Table 2 that matches the num-
ber of elements.
3. The appropriate Conversion Kit part number will be on the last
column of this line.
VOLTAGE AND PHASE CONVERSION ARE NOT ALLOWED ON
600V MODELS
No addition or removal of heating elements is allowed in the conversion process. Failure to do so could result in electrical shock and/or
property damage, personal injury, or death.
3
NUMBER
OF PHASES
480 Volts
06999151
Number
of
elements
Desired
Total Input,
(kW)
Desired Voltage
208 Volts 240 Volts 277 Volts
Conversion Kit Part Numbers
18 06999106 06999119 06999134 06999149
24 06999107 06999120 06999135 06999150
27 06999108 06999121 06999136
Conversion Kit Selection
CONVERSION FOR 208V, 240V, 277V AND 480V MODELS
1. Find the “Number of elements” in the water heater you wish to
convert
2. In Table 1, find the “Number of elements” in the water heater to be
converted (4th digit of model number on the rating plate, see page 2).
3. Then, move across the Table 1 on the same line to the “Desired
Voltage”. The appropriate Conversion Kit part number will be the
one where the “Desired total input” line intersects the “Desired
Voltage” column.
Table 1
Number
Model & Type
of
elements
Light Duty 2
Medium Duty 4
105, 108
or 112
3
Models
Heavy Duty
6
9
*IMPORTANT : Any 6 element model cannot be converted to 30kW/208V - 1 phase nor 36kW/ 240V-1 phase
EXAMPLE: For a 6 element water heater to be
converted to 27 kW / 480V, the appropriate
Convertion Kit part number is 06999151.
Desired
Total Input,
(kW)
3 06999301 06999309 06999317 06999325
4.5 06999302 06999310 06999318 06999326
5 06999303 06999311 06999319 06999327
6
6 06999305 06999313 06999321 06999329
9 06999306 06999314 06999322 06999330
10 06999307 06999315 06999323 06999331
12
6 06999101 06999113 06999128 06999143
9 06999102 06999114 06999129 06999144
12 06999103 06999115 06999130 06999145
13.5 06999104 06999116 06999131 06999146
15 06999105 06999117 06999132 06999147
18 N/A 06999118 06999133 06999148
18 06999106 06999119 06999134 06999149
24 06999107 06999120 06999135 06999150
27 06999108 06999121 06999136 06999151
30 06999109* 06999122 06999137 06999152
36 N/A 06999123* 06999138 06999153
36 06999110 06999124 06999139 06999154
40.5 06999111 06999125 06999140 06999155
45 06999112 06999126 06999141 06999156
54 N/A 06999127 06999142 06999157
4. Make sure that you have the proper conversion kit model
number to perform the desired conversion.
5. Follow the conversion instructions detailed in this manual.
6. Fill out the check list on page 5 once the conversion is completed.
No addition or removal of heating elements is allowed in the conversion process. Failure to do so could result in electrical shock
and/or property damage, personal injury, or death.
DESIRED VOLTAGE
208 Volts 240 Volts 277 Volts 480 Volts
N/A
N/A
Conversion Kit Part Numbers
06999312 06999320 06999328
06999316 06999324 06999332
480 Volts
Table 2
Model & Type
105, 108 or 112 Models
Model 112 only
*IMPORTANT : Model 105 and 108 cannot be converted to 63kW
Number
of
elements
3
Heavy
Duty
6
9
Desired
Total Input,
(kW)
6 06999158
9 06999159
12 06999160
13.5 06999161
15 06999162
18 06999163
18 06999164
24 06999165
27 06999166
30 06999167
36 06999168
36 06999169
40.5 06999170
45 06999171
54 06999172
63* 06999173
6
Conversion
Kit Part
Numbers
27
06999151
CONVERSION FOR 600V MODELS
Conversion kits are available to modify total power (kW) of the water
heater in the field. Refer to Table 2 for the selection of the appropriate
conversion kit.
1. Find the “Number of elements” in the water heater you wish to convert
2. Find the “Desired total input (kW)” in Table 2 that matches the num-
ber of elements.
3. The appropriate Conversion Kit part number will be on the last
column of this line.
VOLTAGE AND PHASE CONVERSION ARE NOT ALLOWED ON
600V MODELS
No addition or removal of heating elements is allowed in the conversion process. Failure to do so could result in electrical shock and/or
property damage, personal injury, or death.
3
Conversion Instructions
The conversion of a commercial electric water heater may require modification to the total input (kW), the voltage or
the phase. The conversion may involve modification to one, two or all three of these electrical characteristics.
Disconnect from power supply before attempting the conversion procedure. Additional safety lockout procedures
may be required!
Read all instructions before proceeding with the conversion procedure. Failure to do so may result in property
dammage, personal injury or death.
Water Heater Preparation
Before you start the conversion, make sure that you have the proper conversion kit model number in order to perform
the desired conversion.
If the water heater needs to be shipped after the conversion is completed, make sure not to damage the cardboard
box when performing the conversion. A dash line has been punched into the front of the cardboard box to give access
to the control panel and element panel of the water heater. Gently remove the dashed portion of the box to gain
access to the water heater. If there is no dash line punched into the cardboard box, the box will have to be removed
completely by removing staples and then sliding it upward over the water heater.
Open the element access panel and electrical junction box (if required) by releasing the two turn lock screws using
a flat screw driver.
Remove the fiberglass insulation from the element panel to expose the elements.
Conversion process shall be performed before initial installation. Otherwise, special care shall be taken to
disconnect power and to completely drain the tank before attempting next steps.
Wattage Conversion (kW)
1- Open the conversion kit box and check each element to ensure that they have the correct voltage and wattage
marking on the flange for your conversion.
2- Measure the ohm resistance across the terminals of each element. Elements must be disconnected from the
circuit. Refer to Table 3 for ohms values for all elements used in commercial electric water heater. Ohms resistance should be within ± 5% of the values in Table 3.
3- Remove both wires from the element installed on the tank, one element at a time.
4- Remove the four bolts securing the element to the tank using a 5/8” socket.
5- Remove the element and gasket.
6- Clean the tank flange surfaces of any dirt or debris.
7- Install the new element and gasket provided in the kit. Use four new 5/8” screws provided and tighten them in a
diagonal pattern. Do not over tighten the screws or damage will occur.
8- If a thermostat was installed on that element, make sure to re-install such thermostat bracket over the element.
Insert the thermostat behind the bracket. Check that the thermostat is in contact with the tank. If necessary, bend
the clips to provide more pressure.
9- Reconnect the wires to the element terminals. Consult the wiring diagram located inside the control panel door
for proper connections.
10- Repeat steps 3 thru 9 for all elements on the tank.
4
Voltage Conversion
480V 277V 240V 208V 0V
PRIMAIRE
X1 X2
0V 120V
A voltage conversion will require that all elements be replaced.
Surface Mount Thermostat:
1. Install the appropriate element control. See previous section “Wattage Conversion (kW)”.
2. Change the voltage tap on the control transformer. Each heavy duty model is equipped with a control transformer
having 5 connections: common (0V), 208V, 240V, 277V and 480V as well as secondary connections: 0V and 120V.
See the following figures. Only one wire needs to be changed on the control transformer in order to change
voltage. Remove the wire from the terminal marked 208V, 240V, 277V as well as 480V and attach it to the appropriate terminal marked 208, 240, 277 or 480 for the conversion.
480V 277V 240V 208V 0V
PRIMARY
480V 277V 240V 208V 0V
X1 X2
0V 120V
0V 120V
CAUTION: 600V WATER HEATERS CANNOT BE CONVERTED TO ANY OTHER VOLTAGES.
Phase Conversion
Phase conversion applies only to 208, 240
or 480 Volts Water heater models.
Surface mount thermostat – Three phase to single phase
1. Disconnect all blue wires and yellow wires from terminal L3
on the power distribution block.
2. Reconnect all blue wires to terminal L1.
3. Reconnect all yellow wires to terminal L2.
4. Connect incoming power to terminal block L1 and L2.
Surface mount thermostat – Single phase to three phase
1. Disconnect all blue wires from terminal L1
on the power distribution block.
2. Disconnect all yellow wires from terminal L2.
3. Reconnect all blue and yellow wires to terminal L3.
4. Connect incoming power to terminal block L1, L2 and L3.
Three Phase
L1 L2 L3
Power distribution block
BLACK RED BLUE &
YELLOW
Single Phase
L1 L2
Power distribution block
CAUTION
600V Models cannot be converted to Single Phase.
277V Models cannot be converted to Three Phases.
Note : Actual part may differ slightly from illustration depending on model.
BLACK & RED &
BLUE YELLOW
5
Verification
5.25” X 3.75” sur papier adhésif blanc mat
Check that all electrical connections are tightly secured and that wire routings are neat and orderly. Make sure that
you have done the proper wiring as specified in these instructions and on the wiring diagram.
NEVER OPERATE the water heater before it is completely filled with water.
Final assembly
Replace the fiberglass insulation in the element panel to cover all elements and thermostat as originally constructed.
Close the element access panel and electrical junction box (if required) by tightening the turn-lock screw(s) using a
flat screw driver.
1- Check that the conversion rating plate information matches the conversion you have just completed. Install the
conversion rating plate over the right bottom part of the original rating plate of the water heater. Make sure that
the conversion rating plate covers the electrical specifications of the original rating plate as illustrated below.
1
Conversion rating plate
2- Install the conversion label as close as possible to the rating plate. Make sure to fill out the
required information on the label: Date of conversion and who converted the water heater.
If the water heater needs to be shipped once the
conversion is completed, make sure to cross out
the water heater electrical specifications on the
shipping label located on the top corner of the
cardboard box. Use a black marker to write the
new electrical specifications on the cardboard
box, matching those on the conversion rating
plate. Close and tape the dashed portion of the
cardboard box that was opened to gain access to
the water heater. If the cardboard box was
removed, insert the cardboard box over the water
heater and staple it on the wooden pallet.
Manufacturing date
XXXX-XX-XX
2
17.30 17.30 17.30 52.00
18,000W 18,000W 18,000W 54,000W
600 VAC - 3 - 60Hz
THIS UNIT WAS FIELD CONVERTED
CETTE UNITÉ A ÉTÉ CONVERTIE EN CHANTIER
Kit # 06999172
CONVERSION LABEL
Refer to the “CONVERSION INSTRUCTIONS” provided with
the conversion kit for important information
on the conversion of this water heater.
This water heater was converted
with kit No.:_________________________on ________________
by:___________________________________________________
_____________________________________________________
Affix this conversion label as close as possible to the existing rating plate.
(name and address of organization making this conversion,
who accepts the responsibility for the accuracy of this conversion)
(day/month/year)
.
55000157
6
Check List
Replacement elements and gaskets have been installed properly and have been checked for tightness. ......... L
Replacement elements have been wired as per instructions and wiring diagram label on the unit.. .............. L
All connections have been checked for tightness.. .................................................... L
Replacement elements have been leak checked.. .................................................... L
Fiberglass insulation has been re-installed over the heating elements and thermostats.. ...................... L
Appropriate voltage and phase change have been performed as per instructions and wiring diagram label on the unit.. L
Conversion rating plate and conversion label have been installed as instructed. ............................ L
Water heater has been filled with water.. ........................................................... L
Full load current values of TABLE 4 are compatible to supply line voltage.. ................................ L
Miscellaneous Information
All elements are marked with both wattage and voltage. Verification can be made by measuring the ohms resistance
across the element terminals. Element must be disconnected from the circuit. The following table gives resistance in
ohms for all elements used in commercial electric water heaters. Element ohms resistance should be within ±5% of
the values below.
Ohms Resistance Table 3
Voltage
Wattage 208 240 277 480 347
2,000 21.63 28.80 38.36 115.20 72.00
3,000 14.42 19.20 25.58 76.80 40.14
4,000 10.82 14.40 19.18 57.60 30.10
4,500 9.61 12.80 17.5 51.20 26.76
5,000 8.65 11.52 15.35 46.80 24.08
6,000 9.60 12.79 38.40 20.07
7,000 17.20
NOTE: Based on Ohms law. Results can vary depending on temperature.
Part Number
Wattage and
Voltage
Certification
Mark
Manufactured
date (week-year)
Table 4
Total Full Load Current in Amperes
Total Input,
kW
6 3 2 28.8 16.7 25.0 14.4 21.7 12.5 7.2 5.8
9 3 3 43.3 25.0 37.5 21.7 32.5 18.8 10.8 8.7
12 3 4 57.7 33.3 50.0 28.9 43.5 25.0 14.4 11.5
13.5 3 4.5 64.9 37.5 56.3 32.5 48.7 28.1 16.2 13.0
15 3 5 72.1 41.6 62.5 36.1 54.2 31.3 18.0 14.4
18 3 6 86.5 50.0 75.0 43.3 65.0 37.5 21.7 17.3
18 6 3 86.5 50.0 75.0 43.3 65.0 37.5 21.7 17.3
24 6 4 115.4 66.6 100.0 57.7 86.6 50.0 28.9 23.1
27 6 4.5 129.8 74.9 112.5 65.0 97.5 56.3 32.5 26.0
30 6 5 144.2 83.3 125.0 72.2 108.3 62.5 36.1 28.9
36 6 6 173.1 99.9 150.0 86.6 130.0 75.0 43.3 34.6
36 9 4 173.1 99.9 150.0 86.6 130.0 75.0 43.3 34.6
40.5 9 4.5 194.7 112.4 168.8 97.4 146.2 84.4 48.7 39.0
45 9 5 216.3 124.9 187.5 108.3 162.5 93.8 54.1 43.3
54 9 6 259.6 149.9 255.0 129.9 194.9 112.5 65.0 52.0
63 9 7 302.9 174.9 262.5 151.6 227.4 131.3 75.8 60.0
Number
of
Element
Element
Input
208 Volts 240 Volts 277 Volts 480 Volts 600 Volts
1ph 3ph 1ph 3ph 1ph 1ph 3ph 3ph 347V
Voltage
Always make sure that full load current is compatible with electrical supply lines before turning the power to ON.
Getting service for your Water Heater
Refer to the “GETTING SERVICE FOR YOUR WATER HEATER” section in the Owner’s Manual supplied with your
Water Heater.
7
40 Lesage Avenue, Montréal-Est (Québec) H1B 5H3 CANADA
Telephone: (514) 645-8893 Toll free: 1 (800) 363-9354
General fax: (514) 640-0969 Customer - Service fax: (514) 645-8413
www.giantinc.com
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