Bock Water heaters CE050 User manual

Bock Water Heaters, Inc. Conversion Kit Instructions Electritherm CE50-119 Series
Revision: 2 Date: 07/26/2019
CONVERSION KIT INSTRUCTION MANUAL
COMMERCIAL ELECTRIC WATER HEATER
Models: CE050, CE080, CE119
This conversion kit shall be installed by a qualified service agency
in accordance with the manufacturer’s instructions and all
applicable codes and requirements of the authority having
jurisdiction. The information in these instructions must be
followed to minimize the risk of fire or explosion or to prevent
property damage, personal injury or death. The qualified service
agency is responsible for the proper installation of this kit. The
installation is not proper and complete until the operation of the
converted appliance is checked as specified in the manufacturer’s
instructions supplied with this kit.

Bock Water Heaters, Inc. Conversion Kit Instructions Electritherm CE50-119 Series
Revision: 2 Date: 07/26/2019
Table of Contents
1.0 General Information............................................................................................................1
2.0 Required Materials..............................................................................................................1
3.0 Approved Conversion Kits .................................................................................................2
3.1 Three Element Models............................................................................................2
3.2 Six Element Models................................................................................................3
3.3 Nine Element Models .............................................................................................4
4.0 Conversion Instructions......................................................................................................5
4.1 Voltage and/or Wattage Conversion.......................................................................6
4.2 Fuse Conversion (if applicable)..............................................................................7
4.3 Transformer Conversion (if applicable)..................................................................8
4.4 Replace Components ..............................................................................................9
4.5 Labeling ..................................................................................................................9
4.6 Close the Crate......................................................................................................10
Appendix A –Full Load Current and Overcurrent Protection ................................................11
Appendix B –Wiring Diagrams..............................................................................................12

- 1 -
1.0 General Information
Installation of this conversion kit must be performed by a qualified service agency. A qualified service
agency is any individual, firm, corporation or company which either in person or through a representative
is engaged in and is responsible for the connection, utilization, repair or servicing of electric equipment or
accessories; who is experienced in such work, familiar with all precautions required, and has complied
with all the requirements of the authority having jurisdiction.
This kit is for the conversion of voltage and/or wattage on your Bock water heater. Before beginning,
verify that the water heater model to be converted is compatible with the conversion kit. If the kit number
is not compatible with the model to be converted, contact your local sales representative or Bock Water
Heaters to obtain the correct kit.
Proper conversion of the Bock water heater must include the following, 1) replacement of original
elements with conversion elements, 2) replacement of original transformer fuses (if applicable), 3)
replacement of original transformer (if applicable), 4) application of conversion ratings label, and 5)
closing the crate.
2.0 Required Materials
•Conversion Kit –matches specifications for heater required and is compatible with model to be
converted
•1-1/2” deep well socket and ratchet
•7/16” nut driver or socket wrench
•Phillips (#2) screwdriver
•5/16” nut driver or flat head screwdriver
The total number of heating elements in the water heater must be the same before
and after the conversion. Any other configuration could result in unsafe conditions
at the water heater.
Failure to maintain the total number of elements is not approved by Bock Water
Heaters, Inc. or Underwriters Laboratories, Inc.

- 2 -
3.0 Approved Conversion Kits
3.1 Three Element Models
The conversion kits in this section only apply to models CE050, CE080, and CE119 that were
manufactured with three heating elements. In the table below, use the voltage and wattage for the
required water heater to select the proper conversion kit number.
***Original Heater***
Models CE050/CE080/CE119, Three Element, 208/240/277/480 Volt
***Required Heater***
Models CE050/CE080/CE119, Three Element, see below for Voltage and Wattage
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
208
4.5
13.5
2631A
208
5.0
15.0
2632A
208
6.0
18.0
2633A
240
4.5
13.5
2631B
240
5.0
15.0
2632B
240
6.0
18.0
2633B
277
4.5
13.5
2631C
277
5.0
15.0
2632C
277
6.0
18.0
2633C
480
4.5
13.5
2631D
480
5.0
15.0
2632D
480
6.0
18.0
2633D
All voltage and input configurations shown above are compatible with a three phase or single phase
supply.
If converting to or from 277 V, the transformer will need to be converted for compatibility with the new
voltage. Contact Bock Water Heaters to purchase the correct transformer. Please reference the table below
for part numbers.
Description
Part Number
277 V Transformer
20502
208/240/480 V Transformer
20500

- 3 -
3.2 Six Element Models
The conversion kits in this section only apply to models CE050, CE080, and CE119 that were
manufactured with six heating elements. In the table below, use the voltage and wattage for the required
water heater to select the proper conversion kit number.
***Original Heater***
Models CE050/CE080/CE119, Six Element, 208/240/277/480 Volt
***Required Heater***
Models CE050/CE080/CE119, Six Element, see below for Voltage and Wattage
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
208
4.0
24.0
2634A
208
4.5
27.0
2635A
208
5.0
30.0
2636A
240
4.0
24.0
2634B
240
4.5
27.0
2635B
240
5.0
30.0
2636B
277
4.0
24.0
2634C
277
4.5
27.0
2635C
277
5.0
30.0
2636C
480
4.0
24.0
2634D
480
4.5
27.0
2635D
480
5.0
30.0
2636D
All voltage and input configurations shown above are compatible with a three phase or single phase
supply.
If converting to or from 277 V, the transformer will need to be converted for compatibility with the new
voltage. Contact Bock Water Heaters to purchase the correct transformer. Please reference the table below
for part numbers.
Description
Part Number
277 V Transformer
20502
208/240/480 V Transformer
20500

- 4 -
3.3 Nine Element Models
The conversion kits in this section only apply to models CE050, CE080, and CE119 that were
manufactured with nine heating elements. In the table below, use the voltage and wattage for the required
water heater to select the proper conversion kit number.
***Original Heater***
Models CE050/CE080/CE119, Nine Element, 208/240/277/480 Volt
***Required Heater***
Models CE050/CE080/CE119, Nine Element, see below for Voltage and Wattage
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
208
4.0
36.0
2637A
208
5.0
45.0
2638A
208
6.0
54.0
2639A
240
4.0
36.0
2637B
240
5.0
45.0
2638B
240
6.0
54.0
2639B
277
4.0
36.0
2637C
277
5.0
45.0
2638C
277
6.0
54.0
2639C
480
4.0
36.0
2637D
480
5.0
45.0
2638D
480
6.0
54.0
2639D
The voltage and input configurations shown above are compatible with a three phase or single phase
supply except for 208V/54kW. 208V/54kW shall only be operated with a three phase supply.
If converting to or from 277 V, the transformer will need to be converted for compatibility with the new
voltage. Contact Bock Water Heaters to purchase the correct transformer. Please reference the table below
for part numbers.
Description
Part Number
277 V Transformer
20502
208/240/480 V Transformer
20500

- 5 -
4.0 Conversion Instructions
Prior to starting the conversion, confirm that the conversion kit number matches the number shown in this
manual for the original heater and the required heater. If converting to or from 277 V, a new transformer
needs to be purchased separately from the conversion kit.
Figure 1 shows how to access the water heater without disassembling the entire crate. Use a box cutter to
cut along the dotted access line to create a door. Cutting inside of the lines or cutting with a blade longer
than 0.75” may cause damage to the product.
Figure 1: Opening the Crate

- 6 -
4.1 Voltage and/or Wattage Conversion
(i.e. Element Replacement)
4.1.1 Remove the bolts (4x) from the top and
bottom corners of the access panel with a ⁷/₁₆”
nut driver or socket wrench.
4.1.2 Remove the insulation to expose the
elements.
4.1.3 Remove the insulation from the plastic
flanges.
Set the insulation to the side in a safe area. All
parts must be returned to their original position.
4.1.4 Use a Phillips (#2) screwdriver to loosen
the two screws on the element and remove the
wires.
4.1.5 Use a 1½” deep well socket wrench to
remove the original element and O-ring from the
tank.
4.1.6 Obtain the required element and new O-
ring gasket. Turn the element into the threaded
tank fitting by hand until the gasket contacts the
fitting.

7
4.1.7 Use the 1½” socket torque wrench and
tighten the element to approximately 50 ft/lbs.
4.1.8 Insert the bare wire ends under each screw
terminal. If necessary, use a pair of rounded
pliers to redirect the wires to the screw
terminals. DO NOT DAMAGE THE WIRE
INSULATION.
Tighten the screws with the Phillips screwdriver
until snug. DO NOT OVERTIGHTEN THE
SCREW.
NOTE: Repeat steps 4.1.4 through 4.1.8 to
replace the remaining elements.
4.2 Fuse Conversion (if applicable)
Note: This step is required only if the
conversion changes the operating voltage.
4.2.1 Use a 5/16” nut driver or flat head
screwdriver to loosen the screw on the right side
of the electrical enclosure door. Pull the door
open.
4.2.2 Find the fuse block that is located to the
right of the transformer (with the three small
fuses). Remove the two fuses that are connected
to the primary side of the transformer (the
middle and right fuses).
4.2.3 Insert the two fuses that were supplied
with the conversion kit into the two empty fuse
holders.

8
4.3 Transformer Conversion (if applicable)
Note: This step is required if converting
voltages to/from any voltage other than 277V.
Skip to step 4.3.3 if converting to/from 277V
4.3.1 Disconnect the black wire from the
primary side of the transformer.
4.3.2 Reconnect the black wire to the correct
terminal on the primary side as shown in the
table below.
Note: The following steps are required only if
converting to 277 V from 208/240/480 V OR
to 208/240/480 V from 277 V.
4.3.3 Disconnect the four wires from the
transformer. Note which wires are removed from
the primary and secondary sides. Keep the wires
separate and label them if necessary.
4.3.4 Remove the transformer from the panel by
removing the four sheet metal screws.
Primary
Voltage
Primary Side
Secondary Side
H1
H2
H3
H4
X1
X2
208 V
RD
BK
-
-
RD
WH
240 V
RD
-
BK
-
RD
WH
480 V
RD
-
-
BK
RD
WH

9
4.3.5 Install the new transformer in the same
location with the four sheet metal screws.
4.3.6 Reconnect the wiring to the transformer.
There shall be a red and a black wire connected
to the primary side. A red and a white wire shall
be connected to the secondary side. Refer to the
table below and the wiring diagrams in
Appendix B for more details.
Note: H2 location on 277V transformer is
different than on the 208/240/480V
transformer, see image.
For the 277 V transformer:
(See Image Above)
Primary
Voltage
Primary Side
Secondary Side
H1
H2
X1
X2
277 V
RD
BK
RD
WH
For the 208/240/480 V transformer:
(See transformer image in Step 4.3.2)
Primary
Voltage
Primary Side
Secondary Side
H1
H2
H3
H4
X1
X2
208 V
RD
BK
-
-
RD
WH
240 V
RD
-
BK
-
RD
WH
480 V
RD
-
-
BK
RD
WH
4.4 Replace Components
4.4.1 Make sure that the screw at every wiring
terminal is tight. DO NOT OVERTIGHTEN
THE SCREW.
4.4.2 Double check all wiring to the elements.
Refer to Appendix B for all wiring diagrams.
PRIOR TO INSTALLING ALL
COMPONENTS TO THEIR
ORIGINAL LOCATIONS, CHECK
ALL ELECTRICAL CONNECTIONS
FOR TIGHTNESS. LOOSE
CONNECTIONS ARE A FIRE
HAZARD.
RECHECK ALL TERMINALS FOR
TIGHTNESS, PROPER WIRING PER
SCHEMATIC, AND NEATNESS OF
WIRING.
HEATER SHALL BE NO LESS THAN
FACTORY CONSTRUCTED
QUALITY AND APPEARANCE.

10
4.4.3 Return the small pieces of insulation to the
plastic flanges.
4.4.4 Place the large sheet of insulation in front
of the elements and secure the access panel to its
original position with the four bolts.
4.4.5 If applicable, close the electrical enclosure
door and tighten the screw to lock the door.
4.5 Labeling
4.5.1 Peel off the ratings section on the
conversion label and place over the top section
on the original ratings label.
4.5.2 The converted ratings label will appear as
shown below. The red box shows the converted
ratings.
4.6 Close the Crate
Close the cardboard door and securely tape
the box closed with packaging tape.

11
APPENDIX A
Full Load Current and Overcurrent Protection

12
APPENDIX B

13

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