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Multimeter Test for breaks in wire/ Test for voltage Most appliance require 80% rated voltage to function correctly Buy Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line 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 |
 120 volt 15 amp devices
including GFCI, timers, switches, plugs, wifi controls etc can be
installed on 15 or 20
amp
breaker.120 volt GFCI, outlet, receptacle that is rated 20 amp can be installed on 20 amp breaker only, but NOT on 15 amp breaker. Buy 15 amp GFCI 20 amp GFCI |
Buy Basic electric book Home plumbing/ electrical codes  Or learn about basic household electricity... use and search my site/ Resource Safe electric wiring Basic house wiring |
 Use outlet tester to check for correct wiring on any 120 volt straight-blade outlet. Buy: Klein testers Outlet tester Circuit breaker finder Electric usage monitor |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX |
Connect wire to screw terminal Use only 600 volt solid copper wire. Do not use stranded wire or extension cord. Do not use solder anywhere on residential 120-240 volt wiring. Attach electric installation to structure. Tighten screws very tight against wire.  Buy: NEC books Dewalt plumbing/ electrical codes Basic electric book National electric code guide/ illustrated Resources: How to twist wire How to select and install twist-on wire connectors |
 Weatherproof
lever switch on outdoor lightsSafely operate outdoor toggle switch Replaces outdoor cover Install over top of ordinary switch Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc Use weatherproof box for outdoor Can be used indoor or outdoor Buy: Best choice: Cantex lever switch Outdoor lever switches at Amazon Lever switches Resource Cantex-toggle-switch-covers.pdf Cantex-PVC-junction-boxes.pdf |
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Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon |
 Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. Code -Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
   When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point. Buy tools: Wire strippers at Amazon Linesman pliers Pro linesman plier Needle nose pliers End cutting nippers at Amazon |
 Weather resistant plastic box for outdoor extension cord connections, Christmas lights, outdoor power strip etc . Not for connecting wires with wire nutsŪ, or in-wall wiring, but can be used indoors to organize extension cords, power strips etc. Weather resistant is not weatherproof or watertight. Use enclosures rated IP65 and IP67 for waterproof. Extension cords cannot be used for permanent wiring. Buy: Large-medium-small electric cord box Socketbox Raintight enclosures Water-tight cord lock Resource: Enclosures and boxes |
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This design is from Rheem,
and available on other
brands. It assumes you are using 12 gauge wire to each LED, and that the LEDs are not located remotely. If LEDs are located remotely, then use inline fuse. Four 240 volt indicator lights. LED Common shares a wire with each of the other LEDs Each LED must connect to Common on 1 leg, and the other leg goes to terminal on thermostat. Common LED is ON whenever the unit has power. ECO LED is off when reset button tripped. Lower LED is off when lower thermostat is off. Upper LED is off when upper element is off. Buy: 240Volt Pilot light at Amazon Best 240 volt 120Volt pilot light at Amazon Indicator lights at Amazon NSI indicator lights |
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240
Volt pilot light/ Pilot light turns ON when water heater is sending
power to element Wire pilot light directly to each element (fuse required) Do not connect stranded wire under same screw with solid wire If upper element is burned out, then tank will have no hot water. Fuse will protect entire length of green wire Buy contactor and indicator/pilot light Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon 240Volt Pilot light at Amazon Best 240 volt 120Volt pilot light at Amazon Indicator lights at Amazon NSI indicator lights Resources: How non-simultaneous household water heaters work How to wire water heater thermostats Inline fuseholders See inside main breaker box Troubleshoot electric water heater |
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240
Volt pilot light/ Pilot light turns ON when water heater is sending
power to element Element and thermostat wiring must be identical to wiring shown Or wire pilot light directly to each element (fuse required) If upper element is burned out, then tank will have no hot water. If lower element is burned out, then tank will have less hot water. If ECO reset button, located on upper thermostat, is tripped, then power is not available to elements. Required in-line fuseholder and 120Volt 15 amp ceramic fuse located on black wire, and another fuseholder on red wire, going to pilot light. This is to protect pilot light and wire-to-pilot-light from 30 amp overheat danger Insulation must be put back over thermostats, and metal cover re-installed on front of water heater for heater to operate correctly and safely. if thermostats exposed to room-temperature air, they will not read temperature correctly. Buy contactor and indicator/pilot light Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon Resources: How non-simultaneous household water heaters work How to wire water heater thermostats Inline fuseholders See inside main breaker box Troubleshoot electric water heater |
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120
Volt pilot light Contactor or relay with 240 Volt coil is needed 240 Volt from element activates contactor Contactor turns on light bulb or any 120 volt load Contactor can also turn on 12-24 volt circuit Buy from my affiliate links: Contactor with 240 volt coil Contactor with 120 volt coil Mars contactors Zettler miniature relay Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon Resource: Read more about contactors How to wire zettler Terminals |
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Since there is a 15 amp
fuse on the line, you can use lightweight relays. Do not use 10 amp
relay (shown in illustration on left) on 30 amp line without inline
fuse as illustrated in drawing above. Buy: 240 volt general purpose relay and surface-mount socket Omron relays/ 15 amp ... good up to 10 amp for double pole Baomain relays/ up to 10 amp for double pole Buy: 12 volt DC solar panel |
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120
Volt pilot light Contactor or relay with 240 Volt coil is needed 240 Volt from element activates contactor Contactor turns on light bulb or any 120 volt load Contactor can also turn on 12-24 volt circuit Buy from my affiliate links: Contactor 40 amp with 240 volt coil Contactor 40 amp with 120 volt coil Mars contactors Zettler SPDT miniature 240 volt 30 amp relay don't use lightweight relays on 30 amp line unless you add inline fuseholder as illustrated in drawing above Dayton 240 volt relay Resource: Read more about contactors How to wire zettler Terminals |
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Select
contactor Wires between element and contactor can be any color Wires can connect to either side of contactor and either screw on element 240 volt water heater :Use contactor with 240 volt coil Buy: 240Volt coil At Amazon 120 volt water heater Use contactor with 120 volt coil Buy: 120Volt coil At Amazon Resources: 120 volt under counter water heaters and installation Toggle water heater between 120V to 240V using timer Convert AC water heater to DC photovoltaic Change water heater temperatures using timer Change water temperatures/ toggle between voltages/ off peak/ using zwave Contactors and relays |
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Use
solder when applying terminal to solid wire Crimp terminals onto stranded wire Solid wire requires solder Do not put stranded wire under screw plate Flat terminals are ok under screw plate Buy: Terminal kit Resources: Terminals |
 Voids product warranty |
How
to change wiring on electric water heater / foam-insulated tank Rewire foam insulated tank Foam insulation makes it impossible to change wiring. Foam is pressurized and 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 bits Resource: How to re-wire electric water heater How to convert AC water heater to DC |
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Junction
boxes can be located at top of water heater or side of water heater Buy: 6x6x4 box Altelix enclosures Fiberglasss enclosures Tapered drill bit 1/4"-1-3/8 holes Boxes from Bud Industries Boxes from Attabox Arlington boxes at Amazon Intermatic Grasslin boxes Wiegmann boxes Cantex boxes Carlon boxes Raco boxes Hoffman boxes Pull boxes Resource: Compare enclosures |
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Fire
safety/
Only solid copper wire under screw plate Use only solid copper wire Do not put insulation under screw terminal Take photo of wires before starting Maximum 2 solid copper wires under screw plate Max 2 wires under screw plate Each wire must be same gauge Attach multiple wires with wire connector, and run jumper to screw terminal Resource: Wire and breaker size charts Do not put stranded wire under screw plate Do not install stranded wire under screw Attach stranded wire and solid wire with wire connector, and run solid copper jumper wire to screw terminal Do not install stranded and solid copper wires under same screw plate |
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How
to make SPDT lower thermostat using upper thermostat If water heater has foam insulation, then replacing lower thermostat with ECO protected thermostat may not be easy. Take apart upper thermostat and make new lower thermostat that will work for the specific two-water heater diagrams shown above. When not to use: Do not remove ECO protection on upper part of tank. On simultaneous and single-tank off-peak water heaters, the ECO is require for lower thermostat operation. ECO protects you in case of overheating and is required for safe operation of water heaters. Buy/ for residential 90-150 degree F: Water heater thermostats at Amazon Aprom / 110-160° Buy/ commercial water heater thermostat 120-180° F 3 phase non-balanced water heater thermostat Camco 120F to 180F thermostat (commercial grade only) Camco 180F lower thermostat (commercial grade only) Residential water heater is not rated for more than 150F |
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SPDT
Lower thermostat activates alert/ pilot light or bell when element is
NOT heating Bell or pilot light activates when thermostat reaches set point. Buy: Water heater thermostats at Amazon Example Camco dual-element thermostat at Amazon 240Volt Pilot light at Amazon Best 240 volt 120Volt pilot light at Amazon Indicator lights at Amazon NSI indicator lights Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon |
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Indicator
for PV SOLAR only Do not put stranded wire under screw terminals./ fire hazard Do not put 2 different gauge wires under same screw terminal/ fire hazard Use terminals or join wires with wire connector or solder stranded wire to make solid Resource: How to wire solar water heater for DC Read about Terminals |
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How
to install 120Volt indicator light Drill 1/2" hole Choose location at enclosure Indicator will light up when power is turned ON at timer going to contactor Does not tell you if water heater is actually working. Resource: How to install water heater timer ___________________________________ 120V indicator should have additional fuseholder 240V should have 2 additional fuseholders Buy: 240Volt Pilot light at Amazon Best 240 volt 120Volt pilot light at Amazon Indicator lights at Amazon NSI indicator lights Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon |
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How
to install 240Volt indicator light Drill 1/2" hole Choose location at enclosure Indicator will light up when power is turned ON at timer going to contactor Does not tell you if water heater is actually working. Resource: How to install water heater timer ___________________________________ 240V wired in this way does not require fuse protection on pilot light Buy: Metal enclosure 240Volt Pilot light at Amazon Best 240 volt 120Volt pilot light at Amazon Indicator lights at Amazon NSI indicator lights Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon |
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Use
Hour meter Requires two 240Volt hour meters. One meter for each element. Install meter on each element as shown in illustration. 240Volt potential exists across element terminals. When thermostat closes the circuit, then 240Volt element is turned ON. The hour meter will turn ON at same time. Buy: UWZ48E-240U 240 volt AC hour meter at Amazon Intermatic ac hour meters at Amazon Intermatic 120 volt hour meter 120 volt hour meters at Amazon Resource: How to install electric meter on water heater How to read hour-meter results: Wattage of element must be determined Use multimeter to check voltage of water heater Look at label on side of tank for different wattages at different voltages Lower voltage means lower wattage than shows on element. Confirm element wattage printed on end of each element For example 4500 watt element and 240 volts Hour meter reads 6 hours 4500 watts x 6 hours = 27,000 watt hours 27,0000 divided by 1000 = 27 kilowatthours |
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Install
Hour meters Illustration is for illustration purpose only. Wiring should NOT be open as shown in illustration. All wiring should be enclosed inside covered electrical box. Actual installation might require drilling holes in water heater covers and installing electrical box directly to front of water heater.  Factory
insulation and covers must be put over both elements and
thermostats so water heater thermostat will read correct temperature Altering
water heater will void warrantyBuy: UWZ48E-240V AC hour meter at Amazon Intermatic bezel to support UWZ hour meter Intermatic ac hour meters at Amazon Resource: How to install meter on electric water heater |
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Cover
thermostats with insulation Factory protector, insulation and covers must be put over both elements and thermostats so water heater thermostat will read correct temperature. Thermostat exposed to cooler room temperatures and will misread tank temperature, leading to scalding and overheating dangers. Resources: Water heater safety precautions Troubleshoot electric water heater |
 Meter on water heaterThe Kwh meter is din rail mounted inside enclosure. Records billable power usage in Kwh. Multiply by rate you pay per Kwh to get monthly/ yearly cost of running electric water heater. Buy Bomain power meter Ketotek power meter 240 volt pass through Kwh meter 2T2502GA beige plastic enclosure 2T2500GA grey plastic enclosure din rails Resource: Enclosures Figure volts amp watts for water heater |
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| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker.  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. 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 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... 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 |
 Armored cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. Non metallic flexible cables must carry ground wire, but does not have hazard of short circuit causing injury from shock. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Armored cable Southwire armored cable cutter Non-metallic flexible conduit Power whip Pull boxes |
Electrical tools must be insulated. Always best to disconnect power, but issues of insulation failure, lack of proper grounding, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems pose a risk to anyone working on electric power. Buy: Electrician tools kits Klein tools Tools kits |
 12 ga Stranded wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring. Buy: Rolls of stranded wire |
Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances and heat on wire and creates possible weak point. Buy tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
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Buy
from my affiliate links every time/ thanks: Amazon Enter Amazon from any link on my site, fill cart with any item ... purchases pay small commission E-mail: geno03245w@gmail.com My response might end up in spam folder, check email folders Waterheatertimer on Twitter Message thru facebook |
