Bock Water heaters LCE6-1 User manual

CONVERSION KIT INSTRUCTION MANUAL
COMMERCIAL ELECTRIC WATER HEATER
Models: LCE6-1, LCE12-1, LCE20-1, LCE20-2, LCE30-2, LCE40-2, LCE50-2
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.

Table of Contents
1.0 General Information............................................................................................................1
2.0 Required Materials..............................................................................................................1
3.0 Approved Conversion Kits .................................................................................................2
3.1 Single Element Models...........................................................................................2
3.2 Dual Element Models 120/277V ............................................................................3
3.3 Dual Element Models 208/240/480V .....................................................................4
4.0 Conversion Instructions......................................................................................................5
4.1 Voltage or Wattage Conversion..............................................................................6
4.2 Phase Conversion....................................................................................................8
4.3 Operating Mode Conversion...................................................................................8
4.4 Replace Components ..............................................................................................9
4.5 Labeling ..................................................................................................................9
4.6 Close the Box........................................................................................................11
Appendix A –Approved Element Ratings ..............................................................................12
Appendix B –Wiring Diagrams ..............................................................................................13

- 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 wattage, voltage, phase, and element operating mode (from non-
simultaneous to simultaneous) on your Bock water heater. Wattage and voltage conversion is achieved
by changing the elements. Wiring jumpers are supplied to convert the phase or element operating mode.
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 Waters 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 and/or addition of wiring jumpers, 2) application of new labels and
identification of new ratings, and 3) resealing the box.
2.0 Required Materials
•Conversion Kit –matches specifications for heater required and is compatible with model to be
converted
•Socket (1-1/2” deep well) and ratchet
•Phillips (#2) screwdriver
•Filament packaging tape
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 Single Element Models
The conversion kits in this section only apply to models LCE6-1, LCE12-1, and LCE20-1. In the table
below, use the voltage and wattage for the required water heater to select the proper conversion kit
number.
***Original Heater***
Models 6-20, Single Element, 1-Phase, 120/208/240/277/480 Volt
***Required Heater***
Models 6-20, Single Element, 1-Phase, see below for Voltage and Wattage
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
120
1.5
1.5
26100
120
2.0
2.0
26102
120
2.5
2.5
26104
120
3.0
3.0
26106
208
1.5
1.5
26108
208
2.0
2.0
26110
208
2.5
2.5
26112
208
3.0
3.0
26114
208
4.0
4.0
26118
208
4.5
4.5
26120
208
5.0
5.0
26122
208
5.5
5.5
26124
208
6.0
6.0
26126
240
1.5
1.5
26128
240
2.0
2.0
26130
240
2.5
2.5
26132
240
3.0
3.0
26134
240
3.5
3.5
26136
240
4.0
4.0
26138
240
4.5
4.5
26140
240
5.0
5.0
26142
240
5.5
5.5
26144
240
6.0
6.0
26146
277
1.5
1.5
26148
277
2.0
2.0
26150
277
2.5
2.5
26152
277
3.0
3.0
26154
277
4.0
4.0
26156
277
4.5
4.5
26158
277
6.0
6.0
26160
480
2.5
2.5
26162
480
3.0
3.0
26164
480
4.0
4.0
26166
480
4.5
4.5
26168
480
5.5
5.5
26170
480
6.0
6.0
26172

- 3 -
3.2 Dual Element Models –120/277 V
The conversion kits in this section apply to models LCE20-2, LCE30-2, LCE40-2, and LCE50-2 that
were built for 120 V or 277 V supply voltage. In the table below, use the voltage and wattage for the
required water heater to select the proper conversion kit number.
***Original Heater***
Models 20-50, Dual Element, 1-Phase, 120/277 Volt, Non-Simultaneous
***Required Heater***
Models 20-50, Dual Element, 1-Phase or 3-Phase, Non-Simultaneous or Simultaneous
>>> See below for Voltage and Wattage <<<
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
Non-Simultaneous
Simultaneous
120
1.5
1.5
3.0
26174
120
2.0
2.0
4.0
26176
120
2.5
2.5
*
26178
120
3.0
3.0
*
26180
208
1.5
1.5
3.0
26182
208
2.0
2.0
4.0
26184
208
2.5
2.5
5.0
26186
208
3.0
3.0
6.0
26188
208
4.0
4.0
8.0
26192
208
4.5
4.5
9.0 #
26194
208
5.0
5.0
*
26196
208
5.5
5.5
*
26198
208
6.0
6.0
*
26200
240
1.5
1.5
3.0
26202
240
2.0
2.0
4.0
26204
240
2.5
2.5
5.0
26206
240
3.0
3.0
6.0
26208
240
3.5
3.5
7.0
26210
240
4.0
4.0
8.0
26212
240
4.5
4.5
9.0
26214
240
5.0
5.0
10.0 #
26216
240
5.5
5.5
11.0 #
26218
240
6.0
6.0
*
26220
277
1.5
1.5
3.0
26222
277
2.0
2.0
4.0
26224
277
2.5
2.5
5.0
26226
277
3.0
3.0
6.0
26228
277
4.0
4.0
8.0
26230
277
4.5
4.5
7.0
26232
277
6.0
6.0
*
26234
480
2.5
2.5
5.0
26236
480
3.0
3.0
6.0
26238
480
4.0
4.0
8.0
26240
480
4.5
4.5
9.0
26242
480
5.5
5.5
11.0
26244
480
6.0
6.0
12.0
26246
* NOT AVAILABLE
# THREE PHASE ONLY

- 4 -
3.3 Dual Element Models –208/240/480 V
The conversion kits in this section apply to models LCE20-2, LCE30-2, LCE40-2, and LCE50-2 that
were built for 208 V, 240 V, or 480 V supply voltage. In the table below, use the voltage and wattage for
the required water heater to select the proper conversion kit number.
***Original Heater***
Models 20-50, Dual Element, 3-Phase, 208/240/480 Volt, Non-Simultaneous
***Required Heater***
Models 20-50, Dual Element, 1-Phase or 3-Phase, Non-Simultaneous or Simultaneous
>>> See below for Voltage and Wattage <<<
Voltage
Element Input (kW)
Total Input (kW)
Kit Part Number
Non-Simultaneous
Simultaneous
120
1.5
1.5
3.0
26174
120
2.0
2.0
4.0
26176
120
2.5
2.5
*
26178
120
3.0
3.0
*
26180
208
1.5
1.5
3.0
26182
208
2.0
2.0
4.0
26184
208
2.5
2.5
5.0
26186
208
3.0
3.0
6.0
26188
208
4.0
4.0
8.0
26192
208
4.5
4.5
9.0 #
26194
208
5.0
5.0
*
26196
208
5.5
5.5
*
26198
208
6.0
6.0
*
26200
240
1.5
1.5
3.0
26202
240
2.0
2.0
4.0
26204
240
2.5
2.5
5.0
26206
240
3.0
3.0
6.0
26208
240
3.5
3.5
7.0
26210
240
4.0
4.0
8.0
26212
240
4.5
4.5
9.0
26214
240
5.0
5.0
10.0 #
26216
240
5.5
5.5
11.0 #
26218
240
6.0
6.0
*
26220
277
1.5
1.5
3.0
26222
277
2.0
2.0
4.0
26224
277
2.5
2.5
5.0
26226
277
3.0
3.0
6.0
26228
277
4.0
4.0
8.0
26230
277
4.5
4.5
7.0
26232
277
6.0
6.0
*
26234
480
2.5
2.5
5.0
26236
480
3.0
3.0
6.0
26238
480
4.0
4.0
8.0
26240
480
4.5
4.5
9.0
26242
480
5.5
5.5
11.0
26244
480
6.0
6.0
12.0
26246
* NOT AVAILABLE
# THREE PHASE ONLY

- 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. The kit contains the necessary parts to change the
voltage, wattage, phase, and element operating mode (simultaneous or non-simultaneous).
To access the water heater without disassembling the packaging, a 2-sided flap must be cut from the front
and right side of the cardboard box. Refer to Figure 1 for locating the cut. The opening on the right side
of the box shall only extend to the metal strap. Use the vertical edge along the front-left corner as a hinge
for the flap.
Figure 1: Cutting the Box

6
4.1 Voltage or Wattage Conversion (i.e.
Element Replacement)
4.1.1 Remove the screws (2x) from the top and
bottom of the access panel with a Phillips (#2)
screwdriver.
4.1.2 Pull the cover out of the foam barrier to
expose the thermostat and element. If
applicable, remove the insulation.
4.1.3 Remove the plastic protector from the
thermostat by lifting the protector forward and
up.
Set the foam barrier cover, insulation (if
applicable) and plastic protector 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 1-1/2” deep well socket wrench to
remove the original element from the tank.

7
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. Use the 1-1/2” socket wrench to tighten
another ½ to ¾ of a turn.
4.1.7 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. Overtightening may push the wire out
from under the screw - damaging the control,
breaking continuity, or both.
NOTE: Dual element models have an additional
element located behind the junction cabinet.
Loosen the set screw on the lower right side of
the cabinet and pull the door open to access the
element. Repeat steps 4.1.1 through 4.1.7 to
replace the element.

8
4.2 Phase Conversion
Dual element models are factory wired for
connection to a three-phase delta branch circuit.
The phase may be converted to single-phase by
adding a jumper to the terminal block.
4.2.1 Obtain a factory supplied jumper from the
conversion kit.
4.2.2 Insert the jumper into the L2 and L3
positions on the terminal block. Tighten the L2
and L3 screws to secure the jumper in place.
4.2.3 At the jobsite, the power supply will be
connected to L1 and L2.
4.3 Element Operating Mode Conversion
Dual element models are factory wired for non-
simultaneous element operation (i.e. only one
element may operate at a time). The operating
mode may be converted to simultaneous
operation (i.e. both elements can operate at the
same time) by adding a jumper to the terminal
block.
4.3.1 Obtain a factory supplied jumper from the
conversion kit. See image in Step 4.2.1.
4.3.2 Insert the jumper into the L1 and “OPEN”
positions on the terminal block. Tighten the L1
and “OPEN” position screws to secure the
jumper in place.
Refer to Appendix B for all wiring diagrams.
NOT ALL VOLTAGE, WATTAGE,
AND OPERATING MODE
CONFIGURATIONS CAN BE
CONVERTED FROM THREE-PHASE
TO SINGLE-PHASE. REFER TO
APPENDIX A FOR SPECIFIC
LIMITATIONS.
NOT ALL VOLTAGE, WATTAGE,
AND PHASE CONFIGURATIONS
CAN BE CONVERTED FROM NON-
SIMULTANEOUS TO
SIMULTANEOUS OPERATION.
REFER TO APPENDIX A FOR
SPECIFIC LIMITATIONS.

9
4.4 Replace Components
4.4.1 Make sure that the screw at every wiring
terminal is tight. DO NOT OVERTIGHTEN
THE SCREW. Overtightening may push the
wire out from under the screw - damaging the
control, breaking continuity, or both.
4.4.2 Install the plastic thermostat protector,
insulation (if applicable), foam barrier cover,
and access panel to their original locations.
4.5 Labeling
4.5.1 For single element models, 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 (on single
element models) will appear as shown below.
The red box shows the converted ratings.
4.5.3 For dual element models, peel-off the
ratings section on the conversion label and place
over the top section on the original ratings label.
4.5.2 Dual element models only - With a black
permanent marker, place an “x” over the phase
rating that DOES NOT match the rating of the
converted water heater.
PRIOR TO INSTALLING ALL
COMPONENTS TO THEIR
ORIGINAL LOCATIONS, CHECK
ALL WATER AND 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
4.5.3 Dual element models only - With a black
permanent marker, place an “x” over the “total
connected wattage” rating that DOES NOT
match the rating of the converted water heater.
4.5.4 The converted ratings label (on dual
element models) will appear as shown below.
The red box shows the converted ratings.
4.5.5 Dual element models only - If a jumper
was added, cover the original wiring diagram
(located on inside of junction cabinet door) with
a new diagram for the specific converted water
heater configuration. The table below specifies
the correct wiring diagram sticker based on
jumper location(s). The part number is located
at the lower right corner of the sticker.
Jumper Location(s)
Wiring Diagram
Sticker Part No.
L2-L3
23266
L1-OPEN
23267
L2-L3 & L1-OPEN
23268

11
4.5.6 With a black permanent marker, cross-out
the original heater ratings on the box and write
the converted ratings as applicable.
4.6 Close the Box
Close the flap on the box and seal the cut
with filament tape.

12
APPENDIX A

13
APPENDIX B