A O Smith SMILTE66D277V Light Service Commercial Electric Water Heaters Installation Guide

A O Smith SMILTE66D277V Light Service Commercial Electric Water Heaters

FOREWORD

The purpose of this manual is to explain how to change the voltage and wattage of a commercial electric water heater by changing the elements. This manual is not intended to explain the rebuilding of electric water heaters in the field. The number of heating elements must remain the same. Increasing or decreasing the number of heating elements from the original build is not approved by Underwriter Laboratories, Inc. The heater to be converted and the appropriate conversion for the heater must be found on the same page of this manual. Read the instructions contained on pages 4 through 7 before attempting any conversion.

WARNING
Electrical Shock Hazard

• Turn off power at the branch circuitbreaker serving the water heaterbefore performing any service.
• Label all wires prior to disconnectingwhen performing service. Wiring errorscan cause improper and dangerousoperation.
• Verify proper operation after servicing.
• Failure to follow these instructions canresult in personal injury or death

CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A QUALIFIED SERVICE TECHNICIAN OR QUALIFIED AGENCY.

CONVERSION MATERIALS

1. Screw Plug Element Remover : 1-1/2” deep well socket and ratchet.
2. Screwdrivers : Two required, one #2 Phillips and one slotted screwdriver.
3. Conversion kit : Includes conversion instructions, replacement electrical element(s), conversion kit label, caution label.

Models with Two Elements, 277 Volts, Single Phase, Simultaneous, Four-

Wire A-8 Circuit

INSTRUCTIONS

Using the table below, locate the row with the voltage and wattage (kW) the customer needs. Order the corresponding kit number. See pages 4 through 7 for detailed conversion instructions

Kits for Two-Element Models, 277 Volts Single Phase, Simultaneous, Four- Wire A-8 Circuit

REQUIRED ABILITY
CONVERSION OF ANY WATER HEATER LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO THAT OF A QUALIFIED SERVICE  TECHNICIAN OR QUALIFIED AGENCY

INTRODUCTION
Satisfying a customer order for an electric heater from inventory may require modification of the kW input or the voltage. Conversions may involve revision to one or both of these electrical characteristics. The number of elements cannot be changed.

HEATER PREPARATION
The heater should be placed in a well lit area. Removal of the shipping carton is not required. Locate front of carton (opposite side of heater identification label). Cut a three-sided flap into front of carton, cut should be on top, bottom and right side approximately 4” from carton edges. Leave the left side of the flap as a hinge. Cuts made 4” from the edge of carton will permit proper reclosure when conversion is completed. If changes are required to the Phase and/or the Simultaneous/Non-Simultaneous operation of the heater the top packaging locator will need to be removed for access to the heater’s electrical junction box. Remove the control panel screw on the water heater door(s). To expose elements, fold insulation up. DO NOT RIP INSULATION. Remove the plastic personnel protector(s). Take care not to damage protector

KW CONVERSION (ELEMENT REPLACEMENT)

1. A. Remove wires from one element at a time.
2. B. Remove element from heater using 1-1/2” deep well socket and ratchet. Return the elements to appropriate bin.
3. C. Open the appropriate conversion kit and remove the element(s). Check each element head to ensure correct voltage and wattage.
4. D. Install the new element with a 1-1/2” socket wrench. A new O-ring gasket should be installed on each element. Screw element into fitting until it seats. Tighten 1/2” to 3/4” turn with wrench.
5. E. Rewire the element. Screw terminals must be snug, however, caution must be exercised. Overtightening may break the terminal block, requiring replacement of the element.
6. F. Repeat steps A thru E for all other elements being replaced.

VOLTAGE CONVERSION
DO NOT CHANGE THE GROUND CONNECTIONS.

SIMULTANEOUS/NON-SIMULTANEOUS CONVERSION

1. A. Refer to Figure 1 Four-Wire Circuit for Dual-Element Heater for Simultaneous/Non-Simultaneous wiring configurations.
2. B. Locate the 4″x4″ junction box on top of the heater. Remove the cover.
3. C. The heater is factory wired for simultaneous operation. The heater may be converted to non-simultaneous operation by moving the red wire on terminal block L1 to terminal J.
4. D. Re-install the junction box cover

Notice
Recheck all terminals for tightness, proper wiring per schematic, and neatness of wiring. Heater should be no less than factory constructed quality and appearance.

WARNING!

• FIELD CONVERSIONS MUST NOT EXCEED 48 AMPS OF TOTAL CURRENT DRAW.
• DO NOT USE 6.1 KW FACTORY-INSTALLED ELEMENTS IN APPLICATIONS UNDER 277 VOLTS

FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN FIRE OR CAUSE DAMAGE TO THE WATER HEATER.

FINAL ASSEMBLY

1. A. CONTROL COVER(S).
   Replace plastic personnel protector(s). Unfold insulation. Cover all elements and thermostats as originally constructed. Replace door(s) and tighten the screws.

2. B. RATING PLATE MODIFICATION OF DUAL ELEMENTS ELECTRIC WATER HEATERS.
   Following is an example of the standard rating plate supplied on the front of dual element commercial electric water heaters.

Peel off the back of label and paste over the area as shown on the revised rating plate below.

CAUTION LABEL
Peel off back of caution label and place as near to rating plate as possible, taking care not to cover any existing labels.

CARTON IDENTIFICATION
Using a black permanent marker, cross out heater identification on carton as appropriate. In bold letters, write new electrical specifications on carton, matching those on the revised rating plate.

SHIPPING CARTON
Close and tape the cardboard flap on the front of carton and re-install the top locator if removed. Seal top of carton.

CAUTION
DO NOT ENERGIZE THE BRANCH CIRCUIT FOR ANY REASON BEFORE THE HEATER TANK IS FILLED WITH WATER. DOING SO WILL CAUSE THE HEATING ELEMENTS TO BURN OUT AND VOID WARRANTY

MISCELLANEOUS INFORMATION

FULL LOAD CURRENT IN AMPERES

kW Input| ****

208V

| ****

240V

---|---|---
4.5| 21.6| 18.8
5.5| N/A| 22.9

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