Bradford White E32-120R Bedienungsanleitung

238-43984-00B 1/10

Conversion Kit Instructions

For Models: E32-50S, E32-80R, & E32-120R

(To be performed ONLY by qualified service providers)

Instructions for Conversion of Commercial Electric Models

NOTICE

The conversion procedure outlined in this manual is to be executed

ONLY by Qualified Service Personnel. Before attempting conversions

it is recommended that you read the detailed instructions described

herein.

The purpose of this instruction manual is to instruct about the changing of wattage, voltage, and electrical

phase for the commercial electric water heaters manufactured by Bradford White Corporation. Underwriters

Laboratories Inc. recognizes this procedure as herein presented and no deviation from these instructions

are allowed.

Special factory prepared “Conversion Kits” must be used for these conversions. There are separate

conversion kits that have individual instructions and MUST be followed. Page 4 of these instructions lists

the kits that have been prepared for the various wattages and voltages.

These instructions do not allow for a modification that adds or deletes the number of heating elements

originally supplied with the heater; therefore such a modification must NOT be attempted.

These conversion kits are only applicable to Models E32-50S / E32-80R / E32-120R.

The following information is provided to assist in the successful conversion of the water heater:

Page

Safety precautions .........................................................................3

Introduction ....................................................................................3

Required materials and tools .........................................................3

Water heater preparation prior to conversion.................................3

Conversion kits...............................................................................4

Conversion of water heater K-W....................................................5

Conversion of water heater operating voltage ...............................6

Conversion of water heater electrical power supply phase............7

Recheck and inspection of the conversion results.........................8

Concluding steps and reassembly after completion.......................9

Instructions for Conversion of Commercial Electric Models

Safety Precautions

NOTICE

The conversion procedure outlined in this manual is to be executed

ONLY by Qualified Service Personnel. Before attempting conversions

it is recommended that you read the detailed instructions described

herein.

Be sure to disconnect the water heater from the electrical supply before performing any servicing of the

electrical system or before attempting any of the conversion procedures. Never perform servicing of the

electrical system or any of the conversion procedures with wet hands or when you are in contact with water

that is on the floor or in the vicinity of the water heater.

Introduction

These conversions have been brought into being in order to expedite the water heater replacement activity.

Water heaters suitable for conversion have been wired at the factory to the maximum electrical duty for

which they have been designed. Therefore, internal electrical components are provided that satisfy the

maximum voltage and maximum electrical current conditions

Wattage, voltage, and phase requirements can be readily fitted to the heater. Conversions may involve

altering any one or all of these electrical characteristics.

Required Materials and Tools

•Screw-in element removal wrench --- or --- 1 ½” deep well socket wrench.

•Phillips head screwdriver

•Standard screwdriver

•Conversion Kit that includes: conversion instructions, electrical elements, product label overlay

(related to the newly created electrical parameters), and element gaskets. Refer to page 4 of these

instructions in order to determine the correct Conversion Kit numbers.

Water Heater Preparation

Locate the areas of the carton to be opened opposite the three electrical elements. A dotted line locates

the position on the carton that needs to be scored and cut. Make these three-sided cuts and fold the carton

flap outward to make an opening in the carton. The carton flap will be closed to seal the carton after

conversion is completed. Remove the three element cover screws and the element covers from the water

heater in order to provide access to the elements.

Locate the area of the carton to be opened opposite the electrical enclosure box. A dotted line locates the

position on the carton that needs to be scored and cut. Make this three-sided cut and fold the carton flap

outward to make an opening in the carton. The carton flap will be closed to seal the carton after conversion

is completed.

Instructions for Conversion of Commercial Electric Models

Conversion Kits for Models E32-50S-3/80R-3/120R-3

1. Refer to Table 1 below that contains water heater KW, Element Wattage, Voltage, and kit part

numbers.

2. Locate the KW of the required water heater.

3. Move across the table (to the right) until you reach the required voltage.

4. Select the required kit number.

5. Use that kit for this conversion.

6. Refer to the remaining pages for a detailed conversion procedure.

Table 1. Conversion Kit Table

Kit Part NumbersRequired

Total Water

Heater (KW)

Element

Wattage 208 volts 240 volts 480 volts

6 2000 265-43942-13 265-43942-07 265-43942-01

9 3000 265-43942-14 265-43942-08 265-43942-02

12 4000 265-43942-15 265-43942-09 265-43942-03

13.5 4500 265-43942-16 265-43942-10 265-43942-04

15 5000 265-43942-17 265-43942-11 265-43942-05

18 6000 265-43942-18* 265-43942-12 265-43942-06

*265-43942-18 will require control box replacement (included in kit).

These three element water heaters with surface mount thermostats have been factory wired with the

following common components; terminal block for max service wire size of 2 AWG, 3 elements each having

a surface mount thermostat with hi-limit control, two fuse blocks rated at 480 volts ac max, and 6 type G 30

amp fuses (rated at 480 volts max).

Instructions for Conversion of Commercial Electric Models

Wattage/Voltage Conversion --- Element Changes

1. Remove and replace one element at a time.

2. Disconnect the electrical wires from the element terminals.

3. Remove the electrical elements using the Screw-in element removal wrench --- or ---- a 1 ½” deep

well socket wrench.

4. Remove the replacement elements from the conversion kit. Check the element markings to ensure

correct wattage and voltage before installing.

5. Apply the new gasket (provided in the kit) to the element. Make sure the gasket is aligned correctly

and it is not rolled-over.

6. Thread the replacement element into the element fitting until it is seated. Tighten ½ to ¾ turns with

the element wrench.

7. Re-connect the wiring to the element terminals. The screw should be snuggly tightened but caution

should be exercised not to over tighten. Over tightening could fracture the element ceramic terminal

block, and would require replacement.

8. Repeat this procedure (steps 1 thru 7 above) for all other elements needing replacement.

Figure 1. Example of element removal/installation.

Element Cover

Element Gasket

Element

Instructions for Conversion of Commercial Electric Models

Voltage Conversion

1. Voltage conversion is accomplished by replacing the existing elements with elements that are rated

at the required voltage.

2. To accomplish this conversion refer to the above procedure for KW Conversion ---- Element

Changes.

3. Execute steps 1 thru 8 of that procedure.

Control Box Conversion

NOTICE

Control box conversion is ONLY required when converting water heater

to 18Kw 208v (Kit # 265-43942-18).

1. Open front panel of control box installed on water heater and disconnect the (6) load wires from fuse

blocks.

2. Remove (4) screws joining control box to water heater and remove control box.

CAUTION

Use caution to not damage any of the wire insulation when removing

control box.

3. Install new control box onto the water heater by feeding the wires through the back of the control box

and reinstall (4) mounting screws.

4. Reconnect wires to new fuse blocks. Be certain to match wire colors to Line side of fuse blocks.

Figure 2. Example of control box removal/installation.

Control Box

Wire Harness

(Load wires)

Instructions for Conversion of Commercial Electric Models

Electrical Phase Conversion

Electrical phase conversion will require a change from single-phase to three-phase or an opposite

conversion change from three-phase to single-phase. Each of these conversions will be explained

separately as follows:

Figure 3.

Example of finished Three Phase construction.

Figure 4.

Example of finished Single Phase construction.

Instructions to convert FROM Three-Phase TO Single-Phase:

(All connections are to be made on the LOAD side of the terminal block)

1. Disconnect blue wire and yellow wire from terminal L-3 of the terminal block.

2. Connect yellow wire to terminal L-1 of the terminal block. The black wires should remain connected

to L-1 of the terminal block as it was originally manufactured.

3. Connect blue wire to terminal L-2 of the terminal block. The red wires should remain connected to

L-2 of the terminal block as it was originally manufactured.

4. Field wiring for the water heater power supply will eventually be connected to the line terminals L-1

and L-2 of the terminal block when the product is installed.

Instructions to convert FROM Single-Phase TO Three-Phase:

(All connections are to be made on the LOAD side of the terminal block)

1. Disconnect yellow wire from terminal L-1 of the terminal block

2. Disconnect blue wire from terminal L-2 of the terminal block

3. Connect both blue and yellow wires to L-3 of the terminal block

4. Field wiring for the water heater power supply will eventually be connected to the line terminals L-1,

L-2, and L-3 of the terminal block when the product is installed.

Instructions for Conversion of Commercial Electric Models

Phase Conversion Only kits

Table 2. Phase Conversion Kits.

6KW 9KW 12KW

Volts Conversion

Kit Volts Conversion

Kit

208 265-45246-13 208 265-45246-14 208 265-45246-15

240 265-45246-07 240 265-45246-08 240 265-45246-09

480 265-45246-01 480 265-45246-02 480 265-45246-03

13.5KW 15KW 18KW

Volts Conversion

Kit Volts Conversion

Kit

208 265-45246-16 208 265-45246-17 208 265-45246-18

240 265-45246-10 240 265-45246-11 240 265-45246-12

480 265-45246-04 480 265-45246-05 480 265-45246-06

WARNING

Recheck and inspect to make certain all components involved in the

conversion are correct and secure.

Recheck all of the electrical wiring changes made against the wiring diagram requirements for accuracy.

Check to insure all of the electrical connections are tightly secured and the electrical wire routings are

orderly.

Special attention should be given to the electrical heating elements. The wattage and voltage rating of the

element is marked on the element itself. Confirm the marking agrees with the intended conversion.

Additionally, the element wattage can be verified by checking the electrical resistance (ohms of resistance)

with an Ohm Meter. This should be done initially before connecting the element to the circuit. The element

resistance should be plus or minus 5 percent of the following values:

Table 3. Ohms of Electrical Resistance.

Voltage Rating of the ElementElement

Wattage 208 volts 240 volts 480 volts

2000 21.6 28.8 115.2

3000 14.4 19.2 76.8

4000 10.8 14.4 57.6

4500 9.6 12.8 51.2

5000 8.7 11.5 46.1

6000 7.2 9.6 38.4

Instructions for Conversion of Commercial Electric Models

Concluding Steps

The water heater rating plate will need to be

modified because the conversion altered the

electrical characteristics of the water heater. Refer to

Figure 5which displays a typical commercial electric

rating plate that is to be altered. This rating plate is

placed on every Commercial Electric water heater

produced by Bradford White Corporation. Locate

this rating plate on the water heater you have just

converted.

Figure 5. Rating plate example.

Also locate the adhesive backed label (see Figure 6)

that is provided inside the kit. The label will be

marked with the new electrical data that is accurate

for the conversion just executed. The kit will contain

two labels for this voltage and KW, (1) for three

phase and (1) for single phase. Select the correct

label for the electrical phase in this conversion.

Figure 6. Rating plate overlay example.

Remove the adhesive peel strip and place this label

onto the rating plate in such a manner that the new

electrical data will appear in place of the data

originally marked. Refer to

Figure 7to the right that displays the rating plate

revision.

Figure 7. Rating plate with overlay installed.

Replace all insulation pieces and element covers that were removed. Replace the electrical enclosure door.

Heater identification information that was placed on the water heater carton must also be altered. This can

be done by making a bold face inscription on the carton with a large size black ink marker. Write the new

electrical data in place of the original data.

NOTES

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