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How electric water heater works |
| How Electricity works with water
heater elements: The force of voltage pushes a flow of electrons (amperes) through the matrix (atomic structure) of the conductor (wire). The wire always offers resistance to the flow of electrons. Resistance is like friction, and causes heat on the wire. An undersized wire will cause more heat. Typically, heat on an electric wire means energy loss. Too much heat on the wire, and the circuit breaker trips.  To avoid tripped breaker and energy loss, the 240 volt water heater is connected to a 30 amp circuit breaker with #10 gauge sheathed cable. All residential wiring must be rated 600 volt as seen printed on the wire or embossed on the cable sheathing. Extension cords and other non-standard conductors are not permitted. When the water heater is ON, the voltage pushes the amperage (electrons) through a coil of resistance wire located inside the element. Resistance wire is tiny by comparison with #10 copper wire, yet engineered to get extremely hot without melting. When the resistance wire gets hot, it causes the water to get hot. Electric water heaters work with high efficiency because the #10 wires don't get hot, only the resistance wire and water get hot.  Buy elements: 208-240 volt: 2500 watt 3500 watt 4500 watt 5500 watt |
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Wiring Residential water is connected to 240 volt dedicated double breaker that serves no other load.  Use
30 amp breaker.Resources: Basic 240Volt water heater circuit How to wire thermostats Water heater is tripping circuit breaker Figure volts, amps, watts Wire and breaker size chart |
 How electric water heater worksTypical 240 volt household water heater has 2 heating elements .... the upper and lower elements. Elements are controlled by upper and lower thermostats. Each element is connected to a thermostat. Thermostats are
mechanical bi-metal switches that
read
temperature through side of tank wall and turn elements ON and
OFF. Typical water heater thermostats are not voltage
specific, and are rated for residential 120 to 240 and any commercial
voltages up to 480 volt, including 208, 277, 415, and 480 volt.
Residential water heater thermostats can be manually set to temperatures between 90ºF to 150ºF, or 110° to 160°F, depending on brand and calibration. High Limit trips at 170°F. All thermostat
settings are approximate ... all values +/- 5%.
Higher temperature settings use more electricity. Higher temps over 135°F risk scald and permanent injury. Average bath shower 104°F. Commercial water heater thermostats can have higher, more dangerous range of 120-180ºF. Maximum temperature allowed for water heaters of all types is 210°F before the TP valve releases water. Higher temps risk violent steam explosion if TP valve is capped off or removed. Do not install high
temperature commercial thermostats on residential water heater. It is
unnecessary and dangerous.
Typical bath-shower is 104°F. For safety and to avoid scalding, the recommended setting for all water heater thermostats (commercial and residential, gas or electric) that supply potable (drinkable) water into pipes where water can come in contact with people is 120°F. Higher
temperature commercial thermostats are used for dishwashing and other
high-temperature applications that are often governed by health codes,
or need for space heating etc ... but high temperatures are never
introduced into water pipes where water can come into contact with
people. A mixing valve is installed to temper or reduce temperature of
very hot water to 120°F before it enters supply lines.
ResourcesHow to adjust thermostats How to replace thermostat on electric water heater/ commercial and residential How to wire thermostats Advantages mixing valve How to increase amount of hot water  Electric water heaters are non-simultaneous Residential 240 volt 2-element electric water heaters are non-simultaneous, as can be seen on product label located on side of tank. This means both elements are never ON at same time (simultaneously) unless specific wiring inside heater is changed significantly. One element is ON, or the other element is ON, or both elements are OFF. How to wire water heater for simultaneous operation Upper thermostat is main controller. Starting with a cold tank, upper thermostat turns on upper element until top 2/3 of tank reaches temperature setting. After top of tank is heated, upper thermostat turns-off upper element and sends power to lower thermostat which turns on lower element. Lower element runs until tank reaches temperature setting. Lower element turns on-and-off during standby hours to keep tank temperature at thermostat set point. There is no air inside tank When hot tap is turned on at kitchen sink, hot water immediately exits top of tank. Hot water travels through hot-side pipe until it reaches faucet. At same moment hot leaves top of tank, new cold water immediately enters bottom of tank through plastic dip tube pipe. To save energy, never turn on hot tap when using only cold... because new cold water that enters tank must be heated to set point. Resources Read about dip tube 9-ways to save with water heater During 'standby' hours, between hot water use, lower element maintains tank temperature. Lower element keeps water hot by turning-on approximately 1-4 minutes each hour throughout day and night which equals 45Kwh - 216Kwh each month for standby operation depending on tank efficiency, maintenance, and seasonal incoming cold water temperature. Newer tanks with more insulation, or tanks located in naturally warm area turn on less frequently. Resources See math charts for heating water Kwh hour calculations Once hot water is used at faucet, cold water quickly fills bottom of tank. Lower element is a activated first, and when the upper part of tank is below set point, the lower element turns off and upper element turns on, and the heat cycle repeats. The temperature of incoming cold water affects how much energy is consumed. In winter, the incoming water is colder. Colder water means the elements must heat longer to reach the thermostat set point. Average groundwater temperature Tempering tank |
 Larger image Typical operation sequence of residential non-simultaneous water heater |
 The energy smart water heater operates same as residential non-simultaneous 2-element tank described above. The difference is energy smart uses electronic sensors, and proprietary electronic thermostat to measure temperature and activate elements. Apcom part #318125-000 Order from Sears or manufacturer Resources Whirlpool Energy smart electric Convert energy smart to regular water heater Types of water heaters |
 Commercial 3-phase electric water heaters Commercial 3-phase electric is different than single-phase residential electricity. 3-phase balanced water heaters (pictured) have similarities to residential heaters, but can vary, often having 6-9 elements. 3-phase non-balanced commercial water heaters are very similar to residential heaters, and have just two elements, and can be converted to residential use with a few alterations in wiring. Resources What is 3-phase 3-phase water heater Difference between single phase and 3-phase |
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Wiring Illustration shows basic wiring for 2-element non-simultaneous residential water heater. Wire colors vary. Resources: How to wire thermostats How to replace wire on water heater Water heater voltage: Electric water heaters work on any voltage 120, 208, 230, 240, 277 etc: Resources: How to connect water heater to generator Convert water heater to 120Volt 3-phase water heater Figure volts amps watts |
 Electrical
Safety: manufacturers
make a safe product-WET water heater is dangerous. Do not touch leaking water heater or water heater that is wet or was flooded without turning power off. - Gas and electric water heaters are both connected to water pipes and can act as ground conduit for electricity. Turn power OFF. Always turn power OFF when working on electric water heater  Test for
power without touching wire connectorsNEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resources: Water heater safety precautions How to test electric power is off |
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Elements Volts
and watts are printed on end of each element.Check label on side of tank for for voltage and wattage <> tank wattage is element wattage In 2-element tank, if lower element burns out, the amount of hot water is reduced. On 2-element tank, if upper element burns out, the lower element stops receiving electric power so neither element works and no hot water is available. Resources: Figure Volts Amps Watts for water heater How to identify and replace water heater elements How change element and remove sediment How to troubleshoot electric water heater Convert water heater to 120Volt for slower heating |
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Elements Elements
screw in or bolt in
depending on tank.Water heater elements are resistive, and similar to electric stove burners, except designed to be immersed in water. Elements instantly burn out if no water is inside tank. Elements burn out for different reasons and can be replaced. Resources: How to test elements. How to replace elements. Resources: How to troubleshoot electric water heater |
 Thermostats:Steel water heater tanks have anode rod that prevents tank from rusting. Periodic inspection and replacement of anode rod will extend life of water heater Save money by turning down thermostats For each 10ºF reduction, save 3-5% Resources: See how to turn down thermostat. How to increase amount of hot water Resources: How to adjust thermostats How to replace thermostat on electric water heater How to wire thermostats Troubleshoot water heater Basic water heater circuit Add another thermostat to gas or electric heater |
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 Tanks with two-elements are rated 240Volt Larger image |
 Thermostats
and elements must be covered with insulationCover, insulation and protector are necessary so thermostat can read correct temperature Reset button on upper thermostat of electric water heater is a safety feature and will trip when water inside tank reaches dangerous 170°F Remove upper cover and insulation to access reset button. Firmly push in reset button. If reset will not engage, then let tank cool before trying again. If problem persists, replace thermostat. Resource How to troubleshoot electric water heater |
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Install: Electric heater can be installed inside any unventilated space, for example a closet with door closed Electric water heaters do not burn hydrocarbon fuel and require no incoming oxygen supply or vent to outside. Water heater is steel tank, covered with insulation, and surrounded by metal shell 1) Steel tank holds pressure of hot water. 2) Tank can be rusted and leaking. 3) Insulation helps prevent heat loss. Install in naturally warm area helps efficiency. 4) Metal tank shell protects wires from damage. 5) Any short to metal tank will trip breaker. Ground wire must be connected to water heater. 6) Do not expose water heater to rain or water. Resources: Read about flooded water heater. Read about leaking water heater Anode rod How to install electric water heater |
 Anode rod: Steel water heater tanks have anode rod that prevents tank from rusting. Periodic inspection and replacement of anode rod will extend life of water heater Resources: Anode rods |
 Dip tube: Cold water enters tank through dip tube Resources: Read about dip tube Remove short water heater nipple New water heater making noise |
 For safety, manufacturers make a safe product Each tank has TP valve that releases water when temperature exceeds 170-180ºF. Temperatures above 180ºF can damage tank. Resources: How to test and replace TP valve TP valve code |
 Drain valve: Plastic drain valve and brass drain valves have 3/4" thread, and fit garden hose Resources: How to replace drain valve Water heater will not drain Leaking water heater |
  Tanks used for solar collectors must be rated for high temperature. Resources: Questions to ask before buying glycol solar system Convert AC water heater to DC water heater Convert AC water heater to DC water heater low voltage Batch solar water heater |
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| Advantages
of electric over gas: Electric heaters cost more to operate than gas heaters. But electric heaters can be maintained to last forever, are cheaper to buy and install, can be installed in small confined areas, can be connected to solar power, can have additional insulation, can be installed in dusty dirty environment like basement, workroom, shop, laundry, are not affected by exposure to household chemicals, do not puff out hydrocarbon byproduct at each home, are easy to fix and alter using generic off the shelf parts Resources: Which is best gas water heater Troubleshoot electric water heater. Solar PV water heater. How to wire thermostats. Compare timers. Is gas clean burning How to maintain water heater Anode rods Two water heaters |
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 Energy
guideThe yellow label shows estimated yearly cost for average family of 4. Yearly cost estimates can help when comparing water heaters, but actual cost varies widely. The label also shows 'first hour delivery' of heater. First hour delivery is amount of hot water a fully heated water heater can deliver in the first hour period. It doesn't mean the hot water will last an hour. Calculate first hour Water heater standards changed April 2015. New heaters are about 2% more efficient, except new standard is based on 125° testing temperature instead of older standard 135°. The lower temperature means less hot water in tank, which means lower first hour delivery. Every pound of hot water that leaves the tank is replaced by cold water that is heated and kept heated until next time hot is used. Increase amount of hot water Cost of running electric water heater at various rates 9-ways to save with water heater EF or energy factor is NOT efficiency. EF is a formula for calculating efficiency. There is a subtraction factor: EF = 0.960 – (0.0003 x V). V is volume, or tank gallonage. 40 gallon heater: .96 - (.0003 x 40) = .95 efficiency. As it turns out, the subtraction factor is so small that 30 gallon, 40 gallon and 50 gallon electric heaters each have .95 efficiency. See chart with new and old EF factors Water heating math 9-ways to save with water heater How to wire off-peak water heater. Electric heaters cost more to operate than gas heaters. However, electric heaters can be maintained to last indefinitely, are cheaper to buy and install, can be installed in small confined area, can be connected to solar power, wired several different ways, easily controlled with timer and home automation. How to control water heater with timer and home automation How to maintain water heater cleaning tank to maintain efficiency Manufactures have added more foam insulation to new water heaters. Most tanks come with heat-trap nipples or heat-trap inserts. Some heat traps can clog or cause whistling. Read about pressure issues and replacing manufacturer's heat-traps How to replace wire on water heater |
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Gas
water heater
Unlike electric water heaters, Gas water heaters need supply of air to support combustion |
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How gas water heater works: atmospheric and power vent  Larger image Resources: FVIR flammable vapor system Troubleshoot gas water heater How to adjust temperature on water heater How much does it cost to run gas water heater Which is best gas water heater |
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Gas
water heater parts Read about FVIR flammable vapor system Troubleshoot gas water heater How to adjust temperature 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 |
 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 |
Buy: |
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 nuts®, 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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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 |
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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 |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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