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How to replace wire on water heater

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
GFCI receptacle120 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
Basic electric book
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
armored cable
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
Southwire armored cable cutter
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
Lever switchWeatherproof lever switch on outdoor lights
Safely 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

Treminals

Terminals

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

Resource:
How to install terminal
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

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
Never assume power is OFF
Electrocution warning
Do NOT touch wet water heater or water heater that was flooded.
Put down dry boards. Do not touch metal objects.
Turn circuit breaker fully OFF.
Test wire(s) at top of heater before removing covers.
Or remove upper cover and use tester on all wires.
Never touch water heater this is wet or was wet.
Do not stand on wet surface/ put down dry boards.

Buy:
Non-contact voltage tester Amazon
Multimeters at Amazon
Electric testers at Amazon

Resources
Test if electrity is OFF
Leaking water heater
Flooded water heater
Melted wire
Look for burned or melted wire
Replace part
Cut back wire
Test continuity of wire/ or replace wire

Burned thermostat
Burned thermostat
Replace part

Burned wire/ Burned thermostat
Action: Look for burned or melted wire connections. Replace part that burned wire is connected to. Test continuity of wire that has been burned. Replace wire that has no continuity.

How to test continuity of wire: When burned wire is discovered/ or suspect
Set multimeter to read ohms.
Ohms is upside down horseshoe symbol
Disconnect wires from each tank part.
Test #1: Put tester leads on both ends of wire.
If test reads ohms, then wire is good.

Test #2: Test each end of wire to bare metal part of tank.
If test reads ohms, then wire is shorted and must be replaced.

Resource
How to replace thermostats
How to select and replace element


Test wire continuity with Multimeter
Buy:
Buy non-contact voltage tester at Amazon
Multimeters at Amazon
Electric testers
Industrial and scientific

Use nose and eyes to find burned or melted wire

Usually if there is a burned wire, then the screw terminals(s) where it is attached are also burned ... you might need to replace thermostat and/or element.
The wire probably burned because it was loose under the screw terminal... so if you put new wire under a burned terminal, it might not tighten correctly...

Use #12 ... most modern electric water heaters use #12 wires inside tank from top to lower part of tank. Do not put two different gauge wires on same screw terminal.

Use approved 600 volt (100° C) solid copper wire.
Do NOT use stranded wire
Never use lamp cord, or extension cord wire for permanent house wiring of any kind.
Yellow/ #12 gauge wire for 20 amp
with ground
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp
Wire color doesn't matter ... use black or white wire.

Local box and hardware stores usually sell sheathed wiring n(cable) by the foot... buy a length of 12-2, or if they only sell rolls, buy 15-25 foot length
Use only 600 volt electrically rated household wires. Never use extension cord for permanent inwall 120-240 volt wiring.

Use utility knife to cut down the middle of cable ... over the copper ground wire ... careful not to cut into insulated wires ... and then cut short length of wire...
Note: 12-3 wire has black, white, and red wire.
Rewire electric water heater Foam-insulated tank
Photograph wires before disconnecting
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.
if tank is under warranty, then submit claim for replacement.
If warranty has expired, then drilling a hole is no problem.

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
Add another thermostat to gas or electric water heater
Making alterations to water heater
Voids product warranty but...
Connect to solar
Add another thermostat to gas and electric heater
           Solar connections
electric thermostat on gas water heaterelectric thermostat on gas water heater
Typical water heater wiring:

Thermostat and element must be covered with insulation
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.
Water heater thermostats shold be set at 120°F according to safe practice, but can be set higher for more hot water.

Water heater cover

Resource:
How to adjust thermostat temperature
How to wire water heater thermostats
Increase amount of hot water
Convert energy smart to regular water heater
Meter on water heater
The 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
Add indicator light to check operation of heater.

Buy contactor and indicator/pilot light
Panel mount fuse holders at Amazon
ANL fuseholder
Buy fuseholders at Amazon

120 volt Pilot light at Amazon
120-240 pilot light
indicator light 120v
indicator light 120v

Resources:
How to wire water heater pilot light/ indicator light
How non-simultaneous household water heaters work
How to wire water heater thermostats
Inline fuseholders
See inside main breaker box
Troubleshoot electric water heater
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

Resource:
How to wire water heater thermostats
Replace wire on gas water heater

Resources:
How to replace burner on gas water heater
How to replace thermocouple
Support the economy:
Buy water heaters from my associate links:

50 gallon Gas water heaters at Amazon
40 gallon gas water heaters at Amazon
50 gallon Electric water heaters at Amazon
40 gallon electric water heaters at Amazon
Hybrid / heat pump/ water heaters at Amazon

Resources:
How to install gas water heater
How to install electric water heater
Troubleshoot gas water heater
Troubleshoot electric water heater
Point of use water heaters
Resources:
Troubleshoot Gas valves with manuals
Icon gas valve

How to replace water heater element Waste King disposal
How to wire tankless electric


Install point of use water heater
Titan tankless

Contactors/ relays
Install and troubleshoot garbage disposal Waste King disposal
Programmable timers

Woods timers
surge protection
Anode rods anode rods
Recirculation system

Tankless recirculation
Point of use water heater
Type 1 and type 2 surge protection surge protection
Buy
Industrial electric

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
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