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How to convert energy smart water heater to ordinary water heater
Energy smart was originally designed to integrate with smart grid, but smart grid module never materialized due to 'privacy concerns' and shortage of usable data.
Smart grid products were overrun by the advent of wifi which offers usable data, but no privacy
Whirlpool energy smart
NEW energy smart
Why convert to regular water heater? 
1) So water heater will work with any voltage/ connect to 120 volt generator How to connect water heater to generator
2) So you can convert water heater to 120 volts   How to convert water heater to 120 volts      How to wire water heater thermostats
3) or ez same day repair using generic parts from hardware store How to replace water heater thermostat
4) Less vulnerability to surge/ electronics can blow out with surge    How to wire whole house surge protector
5) EZ diagnosis of problem/ buy parts locally .... How to troubleshoot electric water heater
6) No app, no sign-in, no privacy invasion, no pop-ups.... just a plain simple ez-to-fix water heater
7) So you can rewire for simultaneous or off-peak Read off peak water heater thermostats
8) So you can integrate two water heaters using same 30 amp breaker  Read two water heaters    New government water heater standards    55 gallon walk-in tub
9) So you can integrate with solar     Convert water heater to solar DC power
10) So you can add a timer without frying the electronics   Water heater timers
Energy Smart
OLDER style energy smart
OLDER style energy smart...
wiring is different than new energy smart ...
but... FINAL WIRING LOOKS THE SAME for both old and new style
Whirlpool energy smart Whirlpool energy smart with control on front
Regular thermostat can be installed in place of electronic thermostat
Simple re-wire and 2 thermostats is all that is needed
Do NOT use stranded wire to make conversion
Convert energy smart water heater
Larger image

Notice the upper thermostats on each diagram are mirror images
... the top two screws located above the reset button are the same L1 L3 on both electronic and regular thermostats
... while the screws located below the reset button are mirror images... with L4 with two wires moved to right side on regular thermostat... and T4 moved to right side... while T2 moved to left side
... wire color can vary.
Wiring diagrams for NEW energy smart with control on front
Issues:
Remove upper thermostat and upper thermistor located above upper element
Must buy upper thermostat and thermostat mounting bracket as shown below
The upper thermostat must be covered with insulation when finished

Remove lower thermistor located above lower element
Must buy upper thermostat and thermostat mounting bracket as shown below
The lower thermostat must be covered with insulation when finished

The grounding bracket may need to be removed to install bracket to hold mechanical thermostat
The mechanical thermostats must sit flat against the tank wall when finished (just like the thermistor must sit flat against tank wall to read correct water temperature)
All thermistors and thermostats read approximate temperature.

If you have foam insulation... then foam insulation is difficult to cut off precisely
All thermostats and elements must be covered with insulation when finished

Keep the elements that are provided with tank/ no need to change elements

DO NOT USE STRANDED WIRE/ use only solid copper wire under screw plates

Buy:
89T short/ dual-element thermostat at Amazon

Resources:
How to wire thermostats
How to replace thermostats
Add another thermostat to electric water heater
How to test elements
How replace elements
How to test if power is turned off

See larger
Electric water heater thermostats are interchangeable
Each works with your water heater


Temperature for household use
Set water heater thermostat temperature to 120-125
Manufacturer setting was 135 in 2012, and 125 after 2015 to meet new energy standards.
Hot tub = temperature 105
Typical shower-bath = 110F

Buy90-150 degree F for residential tank:
Water heater thermostats at Amazon
Rheem thermostats
More thermostats 
89T short/ dual-element thermostat
All therm-o-disc products

Resources:
Therm-o-disc 59T-66T sell sheet/ pdf
Therm-o-disc thermostats
Difference between Rheem thermostats
89T thermostat kit
89T thermostat
Thermostats
Therm-o-disc 89T short thermostat (shown) was standard with Bradford White heaters for several years before they switched to the full size 59T.
The smaller size fits into the energy smart more easily than larger thermostat... both 89T and 59T work same.

Buy 90-150 degree F for residential tank:
Water heater thermostats at Amazon
Rheem thermostats
More thermostats 
89T short/ dual-element thermostat
All therm-o-disc products

Resources:
Therm-o-disc 59T-66T sell sheet/ pdf
Therm-o-disc thermostats
Difference between Rheem thermostats
Upper and lower thermostats
thermostat temperature range
Thermostats
Buy residential upper and lower thermostats
Thermostats are interchangeable/ each works with your water heater
Typical residential thermostat ranges:
Therm-o-disc: Temperature range 90-150  reset trip @ 170
Aprom: Temperature range 110-160  reset trip @ 180
Temperage range approximate +/- 5
Rated 120, 208, 277, 480 volt AC
Calibration range between ON and OFF approximated at 10%

Buy 90-150 degree F for residential tank:
Camco thermostats at Amazon

Water heater thermostats at Amazon
Rheem thermostats
More thermostats 
89T short/ dual-element thermostat
All therm-o-disc products
Therm-o-disc thermostat protectors Thermostat protectors/ for therm-o-disc upper and lower thermostats 
Terminal protectors for therm-o-disc
Does not fit Apcom style
All thermostats are interchangeable

Buy
Upper element terminal protector
Lower element terminal protector
Water heater cover
Larger image
Thermostat and element must be covered
Cover, insulation and protector are necessary so thermostat can read correct temperature.
Thermostats exposed to room temperature will misread temperature and cause overheating.

Thermostat must sit flat against tank.
Rewire electric water heater Foam-insulated tank

Foam is used to fill cavity between inner steel tank and outer tank shell
The foam fits very tight against wire so wires cannot be replaced.

Start with 3/8" standard drill bit to drill through steel top.
Then use 36" drill bit to drill through foam
Drill through top of tank near wiring cavities
Keep drill bit near outer edge of tank shell

Buy
36" drill bits
Fish bit

Resource:
How to test water heater wires
PID Alternate method
Re-wire water heater for PID
Insert probe near lower thermostat.
Position against tank wall and cover w insulation

Wire thermostat and element as shown
240 volt line for water heater MUST be routed through ECO located on upper thermostat.
Why? Because ECO is safety device that will cut power to element in event of overheating.

PID is powered by 120 volt for example.
Hot and neutral are needed for PID.
Set temperature controller program.
When temperature probe senses cold water, then PID activates contactor
Contactor switches 30 amp water heater circuit, and lower element tuns on.
Lower element keeps tank hot.
This wiring design, both hot wires to element are cut off by contactor.
Do NOT connect 240 volt 30 amp water heater circuit to PID... must use contactor

Buy
PID Temperature controllers
Digital temperature controller
30 amp contactors

Solid State Relay Board for Arduino

Resources:
Contactors
Select breaker and wire size
Add another thermostat to water heater
Water heater with short nipple Replace short water heater nipple with brass or stainless steel nipple
Use 6 wraps of teflon tape on threads.
6 wraps is standard for all water heater connections, including TP valve and anode rod etc

Buy
3/4" x 6" brass nipple
3/4" x 6 stainless nipple (not recommended for softener)
Pipe threaders

Resources
How to maintain water heater
Flush tool
tank rinser
Tank rinser
Works with ball valve
Buy
Tank rinser at Amazon

Resources:
How to replace water heater drain valve
How to clean sediment out of water heater
How to replace thermostat
How to replace element
How to maintain water heater
Identify water heater valves
Advantages/ disadvantages/ Install mixing valve
Anode rod Prevent rusted water heater/ Inspect and replace anode rod
Applies to gas and electric heaters
Anode rod prevents steel tank from rusting
Remove and Inspect anode each 1-3 years

Resource:
How to replace anode rod
Tank pressure
Test pressure
Gas and electric
Pressure over 80 psi can damage water heater and damage plumbing pipes.
Faucets do not last as long, water heater can be damaged

Put BTG100 or similar gauge on water heater drain valve.
If pressure is high, then install pressure reducing valve.
Buy pressure gauges at Amazon
Water pressure gauges
Resource:
Test for low and high pressure on water heater
Pressure reducing valve and expansion tank
What if tank is not working? 
Read 'repaired water heater is not working'
 multimeter

Multimeter/ analog and digital

Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy
Multimeters at Amazon
Electric testers at Amazon
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire
Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrical repairs

Resource:
Basic house wiring

Non-contact voltage tester

Test for power without touching connectors
NEVER assume power is OFF
Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
wire connector assortment

Twist-on wire connector assortments

Do not reuse old connectors
Buy:
Connector assortment at Amazon
Connector assortment at Amazon
Resource
How to select and install twist-on wire connectors
Weatherproof wire connector

Weatherproof wire connector

Connector cavity is full of silicone
Built-in cover keeps silicone in place
Protect from water, dust etc
Buy from my affiliate links
Weatherproof size 14 to 6 Amazon
Weatherproof size 22 to 8 Amazon

Resource
How to select and install connectors
Wire connector wrench
Wrench to apply wire connectors
Tighten connector

Buy:
Wire connector blaster
Twist connector wrenches at Amazon

Resources:
How to twist wire
How to select and install twist-on wire connectors

Buy:
Blue for 16-14 wire
Yellow for 12-10 wire

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Push on wire connectors

Push-on wire connectors in place of twist-on connectors

Buy:
Push on wire connectors Amazon
Red 3P connector for 10-14 gauge wire
Lever connectors for stranded wire at Amazon
remove cable staple
Buy
End cutting nippers at Amazon

 
linesman pliers
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
End cutting nippers at Amazon

Use solid copper wire
Fire inside timer caused by stranded wire
Keep enclosure door closed at all times
Buy:
soldering guns
Resource

Timer caught fire

How to wire contactors/ relays
Busman HKP-HH fuse holder
How to wire inline fuseholder
AH3 off delay timer
How to wire delay timers
How to wire twin timers

Always keep enclosure (box) cover closed
Insdulation under screw plate
Larger image
Both wires MUST be same gauge
Max 2 wires under screw plate
Straighten each wire
Tighten screw very tight against copper wire



Larger image
Do not use stranded wire, it will come loose with heat expansion and overheat and cause burning.
Connect stranded and solid with wire connector and run jumper to screw plate.
30 amp breaker use 10 gauge /


Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp
Southwire electric tools
Yellow 12 gauge 20 amp


Yellow/ #12 gauge wire for 20 amp
with ground
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

NMB is house wiring
UF is underground
Rolls of stranded wire
White 14 gauge 15 amp


White/ #14 gauge wire for 15 amp
with ground
Buy:
14-2 gauge/ 15 amp
14-3/ 15 amp

NMB is house wiring
UF is underground
armored cable
Buy:
Armored cable
Southwire armored cable cutter
Southwire armored cable cutter
Buy:
Rolls of stranded wire

Stranded wire
stranded wire
Buy:
Rolls of stranded wire
50-60 amp breaker use 6 gauge /
6-2 wire
Buy:
6-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
40-50 amp breaker use 8 gauge /
6-2 wire
Buy:
8-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
    
Copper ground wire
Use same size as other wire in circuit

Buy:
12 gauge copper ground wire
Ground wire
Green ground wire
Ground pigtails
Ground rods/ ground clamps at Amazon

Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction
Match wire size and breaker amp rating
If your home was wired by professional electrician who pulled permits, then circuit breaker and wire size will match. If manufactured home or travel trailer has not been altered by homeowner then breaker and wire size will match.

If breaker is oversized for wire... fire danger
Breaker can let too much electricity travel through the wire. Wire can overheat and cause fire.
Call electrician if you suspect wiring is not correct,
Absolute electrocution danger when removing cover off main panel. More information below.
Main breaker terminals are still Hot when main breaker is turned off.

Buy
Wire wire at Amazon
Resource:
Select correct wire and breaker size
How to replace circuit breaker
Electricity leaves power plant What is 3-phase electric: power plant to end user
Basic house wiring
Gas and electric water heaters Buy
Electronic parts

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
Buy
Tools

DEWALT
Black and Decker
Stanley
SKIL
Makita
Porter-Cable
Bosch

Irwin Hand tools
Klein hand tools
Fluke electrical testing
Dremel hobby tools

Campbell Hausfeld air powered
Tekton automotive

Powerbuilt automotive
Saws and saw blades
box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
Subpanels
All control centers and parts
Enclosures
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
Din rail
Twin & one-shot
Woods
Intermatic
Tork
Low voltage power packs Recirculation systems
Enter Amazon from my links
Amazon

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