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How to convert energy smart water heater to ordinary water heater
There is no such thing as a smart grid module
Whirlpool energy smart
NEW eneegy smart
Why convert to regular water heater? 
So water heater will work with any voltage/ connect to 120 volt generator       How to connect water heater to generator
So you can convert water heater to 120 volts            How to convert water heater to 120 volts      How to wire water heater thermostats
For ez same day repair using generic parts from hardware store ..........    How to replace water heater thermostat
Less vulnerability to surge/ electronics can blow out with surge     How to wire whole house surge protector
EZ diagnosis of problem/ buy parts locally ....  How to troubleshoot electric water heater
No app, no sign-in, no privacy invasion, no pop-ups.... just a plain simple ez-to-fix water heater
So you can rewire for simultaneous or off-peak . Read off peak water heater thermostats
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
You can integrate with solar   Convert water heater to solar DC power
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
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
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 faom insulation... then foam insulation is difficult to cut off precisely
All thermostats and elements must be covered with insulation when finsihed

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

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

Resource:
How to test water heater wires


See larger
Thermostats are interchangeable/ each works with your water heater
Temperature range 90-150 Therm-o-disc/ reset trip @ 170
Temperature range 110-160 Aprom/ reset trip @ 180
Local YMCA hot tub = temperature 105/...  Typical shower-bath = 110F
Rated 120, 208, 277, 480 volt AC

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
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.
89T thermostat kit
89T thermostat
Thermostats are interchangeable/ each works with your water heater
Temperature range 90-150 Therm-o-disc/ reset trip @ 170
Temperature range 110-160 Aprom/ reset trip @ 180
Local YMCA hot tub = temperature 105/...  Typical shower-bath = 110F
Rated 120, 208, 277, 480 volt AC

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
Buy residential upper and lower thermostats
Thermostats are interchangeable/ each works with your water heater
Buy 90-150 degree F for residential tank:
Water heater thermostats at Amazon
Camco thermostats at Amazon
More thermostats
89T short/ dual-element thermostat at Amazon
Example Camco dual-element thermostat at Amazon
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
Rewire electric water heater Foam-insulated tank

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 bit
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 powrered 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
heat trap Heat traps can clog and make noise
Use illustration on left to open the heat trap washer by cutting off tabs
If missing, use washing machine hose washer
When homes have hard water, and repairs / installation are made to plumbing, then debris can clog the heat trap, causing low pressure and noise
heat trap insert
Buy
Hose washers at Amazon

Resources
Make your own heat traps
New water heater making noise

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 at Amazon
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 reducting 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
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 electrcial repairs

Resource:
Basic house wiring

Non-contact voltage tester
Test for power without touching connectorss
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 twist-on wire 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

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

Fire inside timer caused by stranded wire
Keep enclosure door closed at all times


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.



Orange/ #10 gauge for for 30 amp circuits including water heater
with ground
Buy
10-2 gauge/ 30 amp
10-3/ 30 amp

NMB is house wiring
UF is underground


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

Roll stranded wire

NMB is house wiring
UF is underground


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

Copper ground wire
Use same size as other wire in circuit

Buy
Spools of ground wire


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
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
Anode rods anode rods
Recirculation system

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

Gas and electric water heaters Buy
Industrial electric

Industrial supplies

Tools and home improvement

Home and garden

Hayward 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
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
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Woods
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Low voltage power packs Recirculation systems
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