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How
to troubleshoot electric water heater |
| Tests and steps that will fix most problems | |
| 4)
EZ do it yourself repairs Power is OFF |
Reset circuit breaker. Turn power
OFF when doing steps listed in this section Inspect for leaks Use nose and eyes to inspect tank parts for loose wires and burning Push reset button located on upper thermostat Replace both thermostats Test both elements Replace elements Adjust thermostat temperature Check faucets for crossover. Read below for troubleshoot by symptom. |
| 5) Word-search this page | Computer: Use Ctrl+F feature on laptop or desktop
browser Go to Edit and select Find, or click Ctrl+F Phone etc: Little box with arrow at corner of screen ... drop down menu has search |
| Maintain water heater Save $5 to $10 per month by doubling life of water heater |
✔
Maintain
water heater/ pays $5-10 per month Resources: Flush each 6 months Inspect for leaks each 6 months Check and replace anode rod each 1-3 years Troubleshoot resources for gas Safety precautions Read and save product manual 9 ways to save with water heater |
| Troubleshoot starts here | |
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✔ Push circuit breaker
fully OFF, and then fully ON Identify correct 2-pole breaker Circuit breaker can look ok, but still be tripped on one leg (one side). Push circuit breaker all the way OFF, and then all the way back ON. ... turn on hot 10-15 minutes later and see if heater is working. Resources: How to replace circuit breaker Water heater is blowing breaker Choose correct wire and breaker size Water heater not getting 240 volts |
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Reset button on
electric water heater located on upper thermostat Power is off Open upper cover on side of tank and pull up insulation. Avoid touching any screw terminals unless power is off. Firmly push in thermal reset button. If reset is not tripped out, then reset is not problem. If reset will not stay pushed in, then replace thermostat Use nose and eyes to inspect thermostat for signs of high heat and burning. Replace burned thermostat or element. Inspect for water seep, water leak, and signs of rusted parts. Tank may be leaking, or element is leaking. Leaking water heater Must Re-install insulation and cover for thermostat to function correctly Why does reset button trip? Bad thermostat usually, replace thermostat, then if problem continues then test or replace both elements. How-to replace thermostats ECO basics How-to test elements |
 Therm-o-disc |
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Test for power across top two screws on upper thermostat Power is ON .... tape tester leads to wood sticks This test will tell if heater is getting 240 volts This is the only reliable test. Other electrical tests are not accurate, such as testing for voltage on elements. Test for minimum 220 volts, max 250 volt. This is the upper and lower range allowed for residential 240 volt service. |
 Breaker is tripping Water heater not receiving 240Volts |
✔ Water
heater not receiving 240Volts: Action: Reset breaker: Push breaker fully OFF and then fully back ON. Power is ON 1) Loose breaker can trip breaker. Action: Wiggle breaker and listen for crackling sound and smell of burning. Move wires to another identical-sized breaker and see if problem continues. Replace circuit breaker. Power is off 2) Loose wires on breaker can cause tripping. Action: Turn off main breaker, Tighten both wires on circuit breaker. 3) Short caused by wiring inside tank can trip breaker. Action: If breaker will not reset, move breaker wires to identical-sized breaker and see if problem continues. If different breaker trips also, then short is located at tank or along wire going to tank. Inspect wire to tank for damage caused by nail, staple or rat gnaws. 4) Short inside tank: Inspect for burned wires and melting. Test for continuity between each wire and bare metal part of water heater. Set multimeter to read ohms. Any positive test to bare metal hull of water heater indicates shorted wire that will trip breaker. 5) Wet water heater can trip breaker. Action: leave breaker OFF and inspect for leaks. 6) Undersized breaker and wire can trip. Action: make sure breaker is 30 amp and wire is 10 Gauge 7) Flooded water heater must be replaced: Resource: Water heater is tripping breaker How to replace circuit breaker |
 Larger image AO Smith parts sheet/ pdf Bradford White generic parts Rheem parts/ pdf |
✔ Basic parts:
Part
replacement and wiring diagrams 1: Elements and wiring Test water heater elements How to replace element and clean tank How to remove stuck, rusted element Wiring diagrams for elements/ residential single-phase, commercial 3-phase Wiring diagrams Figure volts amps watts for water heater 2: Thermostats and wiring How to replace thermostats Test thermostats Wire water heater thermostats Change temperature Test wires 3: Anode rod and dip tube and TP valve Anode rod/ replacement, odor etc Dip tube How to test and replace TP valve Review all types water heater valves |
   Test electricity to water heater |
✔ New water heater not working/
or repaired water heater not working Power is ON -Circuit breaker tripped or tripped on one leg. Action: Move breaker switch fully off, and then fully on -Water heater not receiving 240V, yet appears to have voltage: Test across top two screws on upper thermostat for 240V. -Water heater is tripping breaker. Read steps -Use nose to see if circuit breaker smells burned. Use hand to see if breaker is warm. - Check wires are connected tight on breaker. See images -Move wires to another same-size breaker Read testing steps Power is off -Was tank full of water before power was turned ON? If not, then replace upper element. -Press reset button firmly on all new upper thermostats, and new tanks. See image -Check that wires are tight, and not burned on thermostats, or elements. -Insulation was not put over thermostats, so thermostat exposed to cool air and not reading tank temperature. Action: install insulation completely over thermostat and element. How eclectic heater works -Thermostats were replaced, but wires might not be right. Action: See non-simultaneous wiring -New thermostat is bad. -Thermostats were replaced. Check if wire insulation is under screw plate. -Only copper wire should be under screw plate. -Thermostat loose and not sitting flat against tank. Wiggle each thermostat. -Look for rusted clip that might not hold thermostat tight against metal tank. -Elements were not tested or replaced. Actions: Test element How to replace element and clean tank -Elements were replaced, and wires are tight under screws, but thermostats were not replaced. Action: Replace thermostats -Wire connections at top of tank are loose. Actions: Check wire nuts at top of water heater. Twist wire together. Make sure ground wire attached to green screw. -Inspect wires inside tank carefully. Look for wire insulation under screw plate, loose wires on each element and thermostat. -Use nose and eyes to find burned parts. -Bad wire. Wire melted or partially melted. Shorted wire between parts Test wires -Tank not heated yet. 240V 4500 watt Electric water heater heats 21-28 gallons per hour, 3500 watt heats 17+ gallons. Example chart Read more -Leak is causing hot water to run out of tank. Actions: Turn off taps. Put ear against pipe and listen for running water. -Open TP valve and see if tank has hot water at top of tank. How to adjust temperature -Open drain valve and see if lower part of tank is heated, if tank has hot water, plumbing is suspect and not water heater. -Cold and hot water lines are reversed. Action: Look at markings on top of tank to identify cold and hot inlets. Run hot water for a moment and see which pipe feels warm: that will be hot pipe. -Household pipes are clogged with sediment. Factory-installed heat traps at top of tank are clogged. -Action Read Low hot water pressure -Action: Read new water heater making noise -Single handle faucet cartridge bad, check valve bad not letting water flow correctly. Action: Read about crossover Install dual handled faucets Check valve -Water heater was dropped. Action |
 Tank must be full of water Test elements |
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Tank must be full of water -or- upper element
burns out Power is off -Fill water heater tank before turning circuit breaker ON. -Turn water ON. Open bathtub spout. Wait for full stream of water. Turn bathtub off. Lift TP lever on water heater for moment to bleed last of air from tank. Tank is full of water. Turn circuit breaker ON. -Warranty does not cover 'dry fire' -Dry fire affects upper element only ... does not affect lower element in ordinary 2-element residential non-simultaneous water heater. Buy: Water Heater Elements Resources: How to replace element How to test element |
 Gradually/ suddenly less hot water can be caused by sediment in bottom of tank |
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Gradually less hot water: Power is off Upper element is good if you have some hot water, but thermostats and lower element might be bad Quick answer: Adjust temperature up on thermostats. Check circuit breaker is good, open tank covers inspect for burned wire, replace both thermostats. Adjust thermostat temperature How to replace thermostats Causes: Power is ON 1) Check for under-voltage. Action: Test across top two screws on upper thermostat for 240 volt. Undervoltage can cause hot water shortage. Power is off 2) Sediment inside tank. Action: How to clean sediment out of tank and replace element 3) Hot water slow to arrive: Read about crossover 4) Thermostat going bad. Action:. Replace both thermostats 5)Temperature needs to be set higher. Action: Adjust temperature 6) Loose wire on lower thermostat or lower element. Action: Look for burned wires and overheated parts. Replace part that wire is connected to. How to replace thermostat How to replace element 7) Broken dip tube letting cold water enter upper tank. Actions: Remove cold water nipple and pull out dip tube for inspection. Look for bits of plastic in aerator. Read broken dip tube 8) Other possible causes: Shorting wire, shorting breaker, bad lower element. Test electricity TP valve running, leaking faucet, broken pipe. How to replace TP valve 9) Bad single-handled faucet cartridge or check valve Test for crossover 10) Family consumption is higher than before Ways to increase amount of hot water |
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Suddenly LESS hot water: Tank
has some hot water a) If tank has some hot water, then following suspects are eliminated: Red reset button is good, upper element is good, Circuit breaker is not tripped on one leg. Quick answer: Power is off:-Test/replace lower element: How to test element How to replace element Replace both thermostats How to replace thermostats Causes include: 1) Check for under-voltage. Action: Test across top two screws on upper thermostat for 208-240Volts How to test water heater circuit Water heater will work with any voltage, but will heat slower with undervoltage. Read more Calculate recovery 2) Temperature needs to be set higher, especially on lower thermostat. Action: Adjust temperature 3) Bad upper or lower thermostat. Actions: Replace both thermostats 4) Leaking tank has caused rusted parts. Inspect elements. Check for leaking. Leaking water heater 5) Water leak running hot out of tank. Turn off all taps and put ear against hot pipe 6) Bad lower element and sediment build-up. Action: How to test element. How to replace element and clean out sediment. 7) Loose wires. Action: Look for signs of burning and high heat. Cut back wire & Test wire for continuity as shown in next step. Replace part connected to burned wire. 8) Defective wire between upper and lower parts of tank. Action. Replace both wires from top of tank. How to wire thermostats 9) Rare: Broken dip tube letting cold water enter upper tank. Actions: Remove cold water nipple and pull out dip tube for inspection. Look for bits of plastic in aerator. Read broken dip tube 10) TP valve is running hot water out of tank, leaking faucet, broken pipe. Action: Turn off all water. Listen for sound of running water. How to test and replace TP valve 11) Bad single-handled faucet cartridge or check valve Test for crossover 12) Family consumption is higher than before Ways to increase amount of hot water |
 ✔ Suddenly NO hot waterQuick answer: Power is ON -Test for 240 volt across top two screws on upper thermostat Power is off: -Click circuit breaker on-off. Push red reset button firmly. -Check for burned and melted parts at breaker box, top of heater, and at thermostats and elements. Replace both thermostats How to replace thermostats Causes: 1) Water leak can short-out water heater parts. Always stand on dry boards when working with electric heater. Actions: Check for evidence of leaks and rust around elements that can short parts: Action: Replace shorted parts. Check for leak top of tank, bottom of tank. Actions: Replace rusted water heater: Read leaking water heater 2) Red reset button tripped. Action: Push ECO reset button firmly. If ECO 'high limit' doesn't reset, replace upper thermostat. How to replace thermostats 3) Bad upper thermostat: Action: Replace both thermostats. How to replace thermostats 4) Loose/burned wiring: Action: Check all connections for signs of burning. Cut back or replace wire. Replace element or thermostat that burned wire is connected to. How to replace thermostats How to replace element 5) Burned/ melted wire at upper part of tank. Action: Open top cover and use nose and eyes to inspect. Read more 6) Bad upper element. Actions: How to test elements. How to replace elements. 7) Under-voltage. Action: Test across top two screws on upper thermostat for 220-240Volts. How to test water heater circuit 8) Circuit breaker tripped, or tripped on one leg: Actions: Flip breaker all the way one direction and then back again. Listen for crackling sound and smell of burning. Move wires to another same-size breaker How to test water heater circuit. How to replace circuit breaker 9) TP valve is running hot water out of tank, leaking faucet, broken pipe. Action: Turn off all water. Put ear on pipe. Listen for sound of running water. How to test and replace TP valve 10) Faulty check valve on recirculation system, or plumbing pipes. Bad single-handle faucet cartridge. Read about Crossover 11) Clog in water line. Read about Low hot water pressure 12) Melted wire nut or burned part Read list of actions |
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 Very hot water |
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Very hot water Power is off Quick answers: Stacking; / Bad thermostat: How to replace thermostats / Cracked element: Test elements Causes: 1) Bad thermostat causing runaway heating. Action: Replace thermostats How to replace thermostats 2) Many short draws of hot water can cause tank to overheat. Action: Read about Stacking 3) Missing insulation. Action: Check that factory insulation is installed over thermostats, and has not been removed 4) Look that thermostat is sitting flat against tank. Action: wiggle thermostat back and forth. 5) Bad upper or lower element can continue heating even if thermostat is OFF. Action: Test elements for short through center of element. How to test elements 6) Thermostat set too high. Thermostats are calibrated for approximate temperature, and can change over time. Action: Check temperature setting on thermostat TP valve leaking How to check & replace TP valve |
 30 seconds Hot water is slow or cold |
✔ Hot water is cool or never
arrives: Power is off Quick answer: Open TP valve briefly and see if water is hot inside tank, check for crossover, inspect for leaks. Causes: 1) Water leak is running hot water out of tank: Action: turn off all water and listen for sound of running water. 3) Leaking TP valve: How to check & replace TP valve 4) Crossover: Read about crossover 5) Bad check valve causing cold to enter hot pipe. Action: replace check valve 6) Broken dip tube letting cold water enter upper tank. Actions: Remove cold water nipple and pull out dip tube for inspection. Look for bits of plastic in aerator. Read broken dip tube 7) Faulty recirculation system;: Clean recirculation system check valve with white vinegar Recirculation system |
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Low pressure Low water pressure & clogged pipes: Resource: Low water pressure Test hot water volume /pdf |
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✔ Rusty water Quick answer: Tank is rusted and needs to be replaced. Anode rod prevents rust. Replace anode rod. Well water has high iron content, flush tank periodically Rusty water can indicate rusted water heater. Replace anode rod and rusting will stop. How to check and replace water heater anode rod If tank hull is rusted and ready to rupture, it is time to shop for a new heater before rupture causes massive damage. How to inspect water heater for leak |
| Rumbling/ popping/ whistling sounds |
✔ Sounds from water heater: Rumbling, popping, whistling sounds from inside water heater are generally not a problem, and are caused by air pockets trapped in sediment, or element covered by deposits. Sediment reduces efficiency. Read 1) Cause: Sediment inside tank. Action: How to clean sediment out of tank and replace element 2) Heat pump electric water heater has fan and compressor and will make sound when operating Read 3) Clean elements with white vinegar, a natural organic product that is very effective. Use white vinegar to clean faucets, shower heads, tub surrounds, hard water, and pet odors on tile. 4) Recirculation system motor causes sound: Action: turn off recirc pump and listen for sound Recirculation system 5) Read long list of possible causes for water heater makes sound 6 New water heater makes noise |
 Larger image Pipes bang when water turned OFF Water hammer |
✔ Pipes bang -Pipes can bang and make noise if sediment has restricted water lines, or if pipes do not have air chamber. -Water is moving through pipes and around elbows, and if lines are clogged, it will cause sounds. This can be caused by slow build-up of sediment or happen suddenly following plumbing repairs. Action: call plumber or replace problem pipes. -If pipes shake and make noise when faucet is turned off, the air chamber might be cause. Called air hammer. Water does not compress. Turn tap off, and sudden stop of moving water causes pipes to shake, and bang into boards and drywall inside wall, causing sound. This can loosen pipe joints, and damage water heater -Action: Turn water taps off slowly instead of rapidly. Best solution: add air chambers at each faucet (or buy water hammer arrestor), check pressure/ lower water pressure to less than 80 psi, add pressure reducing valve on cold water line before water heater. -Household Air chamber is located behind walls on both Hot and Cold water lines at each faucet, and washing machine, etc. Buy: Water hammer arrestors at Amazon |
 Remove Heat trap inserts and nipples  |
✔ Water heater noise (sometimes
with low water pressure) -Whistle, hum, vibration can be caused by factory-installed heat traps. -Clogged heat trap nipples at top of tank cause sounds and low pressure. This can be caused by slow build-up of sediment or happen suddenly following plumbing repairs, such as installing new water heater or nearby street repairs etc. -Remove heat traps. Install di-electric nipples without heat-trap constrictor. Up to 6 wraps teflon tape. -Water heater companies install heat-traps to increase energy efficiency. -Factory-installed heat traps can clog and cause noise and low pressure problems. Read about low hot water pressure -Make your own heat traps and save $9 per year. Illustration 1 Illustration 2 If heat trap nipple is connected to dip tube. Make curved dip tube by heating and bending dip tube Buy: Dielectric nipples at Amazon ✔ Nipple stuck, will not come out -Insert 5/8" or 3/4" carriage bolt so nipple will not collapse -Use pipe wrench and heavy hammer to rotate nipple, use galvanized pipe to make cheater bar -Wedge steel pry bar across both nipples to help hold water heater Buy: Dielectric nipples at Amazon Resources: Read more: How to remove short water heater nipple Low hot water pressure |
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✔ Air bubbles come out of faucet Air sputters out of faucet  1) If Water well is suspect... inspect air volume control Buy: Air volume control at Amazon Resource; Water heater valves 2) If City water is suspect or recirculation pump is suspect .... Add air vent Buy: Air vent/ Float vent |
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Outgassing/ Hydrogen gas in water line/ explosion danger -Anode rod reacts with harmless bacteria. -Usually on a water well if water heater sits unused for several weeks. -Turn on hot and do not strike match or turn on switch ... open windows and doors etc -New water heater can have reactive anode rod. -New water softener can cause anode to be reactive Resources: Outgassing: Hydrogen Gas in water line Replace anode rod |
| Bad
Smell Rotten eggs  |
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Bad smell, rotten egg smell: Quick answer: Harmless bacteria reacts with anode rod to produce rotten egg smell. Replace anode rod -Add hydrogen peroxide regularly -Replace anode rod -Install power anode rod -Removing anode rod permanently prevents odor but tank rusts out quickly Other causes: Dirt got into line when repairs were made and bacteria entered tank; Garden hose left in standing water so water got sucked into household water heater where bacteria has multiplied. New water heater was installed in place of old water heater that had depleted anode rod. Resources: Water heater sulfur smell Water chemistry and water heater/ pdf Replace anode rod Flush water heater to remove smell Buy powered anode rod for permanent solution Flush water heater with bleach |
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✔ Sludge/ odor Open drain valve and water is white, gray, brown, black, etc. Chemicals can distill out of water if temperature is set over 140 degrees F How to adjust water heater temperature Chemicals can settle in bottom of heater. DO NOT STIR up sludge so it enters pipes. Action: Turn off electric power. Turn off incoming water. Open bathtub spout. Open drain at bottom of heater and let water drain. When tank is empty, open incoming water and begin flushing heater. Keep flushing until water is clean. Open access to tank by removing TP valve or Cold water inlet. Pour in 2 pints hydrogen peroxide, and fill tank with water. Do not use clorox or it will be difficult to flush out when finished. Use hydrogen peroxide. Repeat treatment as needed. Hydrogen peroxide is simple hydrogen and oxygen and non-harmful when used as debriding agent or mouthwash. Clorox is harmful. Resource: How to replace drain valve Water heater will not drain For odors, also read about anode rod |
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✔ Not enough hot water Ways to increase amount of hot water No Hot after 1 bath, then review 'suddenly less hot water' directly above And review 'sound of running water' directly below. Put ear against pipe and listen for running water. No Hot after several baths, then water heater may be too small. Set temperature higher. Clean out sediment. Size chart. Clean out sediment. Turn up thermostats Oversized garden tub or whirlpool bath requires 80 gallon first hour delivery. 80 gallon electric or 50 gallon gas can just meet demand of oversized bathtub Electric water heater must be at least 60 gallon, and set thermostat higher Resources: How to select correct size water heater See first hour chart |
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✔ Sound of running water/ High
electric bill Water leak can run hot water out of tank. Steps below might not be conclusive if pipes are plastic, and you cannot hear water moving past in pipe. 1) Turn off all faucets inside house, and outdoor spigots 2) Put ear against hot-side pipe 3) Listen for sound of running water 4) Look for signs of water around tank Leaking water heater 4) Fix drips and leaks Crossover 5) Clean sediment out of tank How to clean sediment 6) Look at TP overflow tube to see if TP is leaking water Resources: Test and replace TP valve How to Maintain water heater How to Increase amount of hot water |
| ✔ Electric bill skyrocketed Resource Water-heater-causing-high-electric-bill  Causes 1) New smart meter was installed on house. Old meter might have been inaccurate Action: Break meter glass with hammer and they will replace with another new meter purchased from China. The new Smart meters are tested accurate. Low chance of getting two meters in a row that are bad, so breaking meter gives second opinion. Wear goggles. 2) Water heater could be the cause. Is water very hot? Test elements. Replace thermostats. 3) Turn off all breakers except water heater. See if meter is still showing usage. Turn off breaker to water heater and see if meter slows or stops. In some cases, if water heater element is shorted to ground, the meter will continue running. Test elements 4) Water leak is running hot water out of tank, causing elements to run continuously. Action: Fix leaks. Turn off all taps. Put ear against pipe and listen for water running. Check TP overflow tube. 5) Water heater bleeding electricity to ground. Actions: Open covers and inspect tank parts for burned wire. Test wires between tank parts. Test and replace elements: How to test elements Test for leaks to ground. Turn power OFF and completely disconnect ground wire from tank. Turn power ON and look at meter, but do NOT touch tank with ground wire disconnected. 6) Malfunctioning heat-pump water heater. Call service tech. This page doesn't cover heat-pump troubleshoot. 7) Water heater circuit connected to another usage in addition to water heater. Action: Check 240V circuit breaker has only 2 individual wires. Follow cable to see if junction box is found. Turn off breaker and check if other usage points are out. Check if neighbor's house has outage when you turn off your breaker. 8) If home has recirculation system, the thermostat on recirc system might be bad. Water heater recirculation system Resources: How to install electric meter on water heater |
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Leaking
water heater Quick answer: Read: water heater is leaking Do not touch water heater that is wet. Turn power OFF before touching. <> Rusted tank needs replacement before rupture > Read: water heater is leaking ✔ Off peak ideas Resources: Off peak water heater options Change water heater from 240 to 120 Connect water heater to generator |
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TP valve Do NOT cap off TP valve TP drizzles water when pressure is too high... add expansion tank. TP releases water when temperature exceeds 210°F 210° is extremely dangerous, turn off breaker and let tank cool several hours before using faucets or repairing tank. Replace thermostats. Replace elements. Resources: Water heater is leaking How to test and replace TP valve TP Valve code Identify water heater valves |
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Flooded
water heater should be replaced
 Do not touch
wet water heater
Do don't touch water
heater standing on wet surface1) Water heater cannot dry out unless covers and insulation are left off tank. If covers and insulation are missing, then thermostats cannot read correct temperature. 2) Wet insulation is shock and electrical danger 3) Wet water heater is shock hazard. All parts must be replaced, wires checked and insulation totally dry. Read about flooded water heaters Flooded water heater American flooded water heater Water heater flooded and now breaker is tripping |
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Drain valve 1) Use brass garden hose cap on drain valve to stop dripping 2) How to replace drain valve 3) Water-heater-will-not-drain |
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Water heater will not drain Use household water pressure and washing-machine hose to flush open water heater Read more |
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Element stuck Drill and tap holes, insert 1/4" bolts, use pipe wrench Drain tank before drilling. How to remove element Ratchet is better than element wrench Use element wrench or 1-1/2" ratchet. Marathon tanks require 1-7/8" Leave tank 3/4 full of water to loosen element. Weight of water will stabilize tank while you push and twist element wrench. Then drain tank before removing element. |
 Look for burned or melted wire Replace part Cut back wire Test continuity of wire/ or replace wire  Burned thermostat Replace part |
✔ Burned wire/ Burned thermostat Power is off 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. Bad wire: Tanks with foam insulation may need to be replaced How to replace thermostats  Test wire continuity with Multimeter Buy: Buy non-contact voltage tester at Amazon Multimeters at Amazon Electric testers at Amazon |
 Change water heater from 240Volts to 120Volts, uses less wattage per minute of operation |
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Installed
new element, and now ECO is tripping: Power is off Quick answer: Replace thermostats and test elements Inspect for burned parts and and loose wires: Replace burned part. ECO trips when wire gauge is too small for element wattage, causing heat that trips ECO. This happens if replacement element has greater wattage than shows on label on side of tank. Compare rating label on side of tank with wattage rating printed on end of each element. Resources: Change water heater from 240 to 120 Connect water heater to generator Off peak water heater options ✔ Installed new element, and now Circuit breaker is tripping: Any element over 3800 watts must have 10 gauge wire and 30 amp breaker Move wires to different breaker and see if problem continues Resources: Replace circuit breaker Troubleshoot Household electric |
 Apcom style thermostat 100-150° high-low/ reset trip @ 170° Upper thermostat: ECO reset button  Therm-o-disc 89T 90-150° high-low/ reset trip @ 170° 240Volts arrive at upper thermostat |
✔ ECO reset tripped Information Red reset button or 'high limit control' or Energy Cut Off or ECO will cut off electric power to entire water heater. ECO shuts off both hot wires in the 240V circuit. Diagram on left: 240V arrives at L1 and L3 screws of upper thermostat <> when ECO is tripped, L1 and L3 screws are hot but electricity stops there. Push reset button firmly. If ECO resets and water heater turns ON and works, then watch over next few days if ECO reset trips again. ✔Causes: ECO tripped Check if wire is 10 gauge and breaker is 30 amp. 1. ECO will trip when either upper or lower thermostat sticks in ‘on’ position causing continuous heating. Once water reaches 150-180° F, the ECO trips and turns off electricity to water heater. 2. Loose wire or electrical connection inside thermostat -or- between parts can trip ECO. Loose wires generate heat, causing high resistance. ECO senses heat from bad connection and trips. Loose wires cause burning and melting and should be visible on inspection, and/or cause burned smell. Not every loose wire will cause ECO to trip, only those that cause upper thermostat to overheat. Action: Replace part connected to burned wire. Test thermostats How to replace thermostats How to replace element Use multimeter to test wire for continuity 3. Bad element shorted to ground near center of element will trip ECO. When element is shorted to ground near center of element, the short does not draw enough current to trip circuit breaker. By design, a thermostat only turns off 1 hot wire, but a 240V water heater has 2 hot wires. If short does NOT trip breaker, then 120-volts flows to ground through half of element, continuing to heat water until ECO trips. Actions: How to test elements. How to replace elements. 4. ECO can trip if factory-installed insulation and cover have been removed. Result: Thermostat exposed to cooler temperatures and misreads temp inside tank. Elements overheat tank. Action: re-install insulation 5: ECO can trip if water heater has stacking event where repeated short draws of hot water can overheat tank. Action: read about stacking 6. ECO can trip if water heater is wet from flood, leak or tank failure. Look for signs of rust and dampness. The spring holding thermostat flat against the tank will rust so thermostat is not held tight against tank wall, and then tank overheats. Thermostat must sit flat against tank. 7. Factory insulation that ordinarily covers thermostat is missing. Other link: Test electricity to water heater |
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ECO reset keeps tripping Power is off Quick answer: Replace both thermostats, test elements. Check for loose wires. How to replace thermostats How to test elements Causes: 1) Make sure thermostats are covered with insulation, protector, and cover. See image Without insulation, Thermostat exposed to room temperature will misread temperature and cause overheating. 2) Make sure thermostat sits flat against tank wall. Wiggle thermostat. Check that bracket is not rusted and loose. 3) Bad upper or lower thermostat. Action: Replace both upper and lower thermostats. How to replace thermostats 3a) Upper thermostat wired wrong during replacement See residential thermostat wiring Wire colors vary 4) Bad element causes run-away heating. Action: Test elements. How to test elements 5) Many short draws of hot water can cause tank to overheat. Action: Read about Stacking 6) Make sure watt rating printed on end of element matches watt rating showing on label located on side of tank. 7) Use nose and eyes to inspect for burned parts and melted wire. How to test wires 8) Loose, partially-melted wire will cause overheated wire. Overheated wire will cause ECO to trip. Inspect wires. Make sure wires are firmly under screw plate. Check that no wire insulation is under screw plate. 9) Label on side of tank will show 240Volt Non-simultaneous for residential dual-element water heater. Make sure water heater is wired correctly. Check water heater wiring 10) If water heater was flooded, then all parts must be dry. Flooded water heater 11) Undersized wire from breaker can cause overheated wire, but should trip breaker instead of tank ECO. For 240Volt: If breaker is 20 amp, wire must be 12 gauge, and maximum 3800 watt elements. If breaker is 30 amp, then wire must be 10 gauge, and 4500 or 5500 watts elements. Match breaker and wire size |
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✔ Elements burn out frequently: Power is off Causes include: a) Sediment in bottom of tank How to replace element and clean out sediment. b) Very hard water. Install softener. Read about softener and anode depletion c) Install low watt density element. and/or Change element. Install element with less than 3800 watt See image Read pdf d) Aggressive high pH water. Test water. e) Loose wire on element. Open covers and inspect all wires for loose connections and signs of burning. Buy: Low density elements Resource: Read about elements Water heater formulas and terminology pdf |
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Element shorted to ground across steel tankTURN POWER OFF What happens: Elements work on either 120Volt and 240Volt - 240Volt water heaters have 2 Hot wires. Each hot wire is called a leg. Each leg is 120Volts with 240Volt potential when both legs are connected together. Difference between 120Volts and 240V - Thermostats turn off one leg in the 240Volt circuit. The other leg puts live power at element at all times. - Each element will test for live120Volts between the element and steel tank at all times. - When thermostat turns ON, that event connects the second leg to the first leg, and element turns ON. - In some cases, the element can crack or short. In most cases, the short will trip circuit breaker. - If the crack or short is far enough along in the element, the resistance will not cause breaker to trip. The short travels across steel tank hull to the ground wire at top of tank. - The ground wire will complete 120Volt circuit. Element continues heating, and will not turn off. This causes runaway heating, and TP valve will release water or ECO reset will trip, or water will be hotter than usual. Action: How to test elements -Note: Choose wiring diagram illustration on right to avoid runaway heating caused by cracked lower element. See wiring illustration Wiring diagram illustrated on right will NOT prevent cracked element. It will only mask problem of cracked element on lower element, and prevent cracked lower element from causing run away heating. The element will still be cracked. Wiring diagram illustrated on right does not change upper element from causing runaway heating due to cracked element. |
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 ✔ Electric shockTURN POWER OFF Call electrician immediately. This must be solved professionally. There are too many possible causes to list. There is a dangerous short, and the short is not being properly grounded. Possible causes at water heater: Flooded water heater. Replace flooded water heater: Flooded water heater Cracked element shorted to ground as described above. Action: How to test elements Shorted wire between elements or thermostats. Action Test wires. Ground wire is not connected to tank. Action: connect ground wire to ground screw at top of tank. Hot and Cold water pipes are not bonded. Action: add #6 copper jumper wire between hot and cold pipes. Ground wire has come loose from ground rod. Action: Turn power off and reconnect ground wire. Do not ground main panel to water pipe. This can be caused by any electric line coming into contact with a pipe anywhere inside or outside your home. Inside a wall for example. Electrician will need to test the suspect faucet to ground to determine the voltage... and then click off each circuit breaker one at a time to locate which electric circuit is shorting to water pipe. For example basement room addition, or water well. Contact insurance company for their policy, especially if problem started after damage occurred to home, such as nearby lightning strike, or flood, You must still call electrician |
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  Therm-o-disc Residential 90-150° high-low/ reset trip @ 170° Commercial 110° to 170°/ 120° to 180°/ reset trip 190° |
✔✔✔✔Thermostat calibration There are different types of water heater thermostats: Apcom, therm-o-disc, upper and lower etc, -All mechanical thermostats work the same, and are interchangeable.. -Calibration is the temperature range including the range of high-low temperatures, for example you can set thermostat to 120° or 125° etc. Once you set the temperature, that is the highest the temperature can go with tolerance of +/- 5°. -Temperature at bottom of tank can drop 9° before thermostat turns on again. -A thermostat that is out of calibration is one that no longer working within the temperature ranges. -Don't assume every shortage of hot water is caused by water heater. Plumbing problems such as crossover, water leak, and water leak of Hot water line connected to toilet can cause shortage. Replacing thermostats is easy way to start diagnosing problems. Some models of commercial thermostats can reach can 170-180°, but this temperatre exceeds safe residential temperature (150° max), and exceeds safety limit for residential tank, and will cause reset button to trip at 170°F. Commercial water heaters that use very high temperatures, like a booster heater, are manufactured to meet the temperature and pressure of very hot water. Resources: How to replace thermostat How to wire thermostats Compare types of thermostats Booster water heaters |
 Either wiring diagram for non-simultaneous Larger image Wire colors vary |
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Thermostats and tank wiring Resources: How to test thermostats How to replace thermostats How thermostats work Off peak thermostats and timers How to wire thermostats Simultaneous, non-simultaneous, redundant, single-element, off-peak, two water heaters Household water heater = Non-simultaneous thermostat operation How to control water temperature with timer  |
 What is 3-phase |
✔ Unbalanced 3-phase simultaneous, non-simultaneous will troubleshoot nearly same as shown on this page Lower thermostat will be ECO protected. Wiring at top of tank will vary by brand. Resources: See 3-phase non-balance wiring Bradford White 9000 watt light commercial water heater Heavy-duty commercial 3-phase balanced electric water heater is different. 3-phase balanced troubleshoot: Resources: Commercial electric water heater troubleshoot Commercial electric water heater part diagnosis How to wire 3-phase timer |
| Understand water
heater safety
features:
Residential electric water heaters have 3 critical safety features: <> 1. Circuit breaker that cuts power at service panel <> 2. TP valve see image that releases water if pressure builds inside tank <> or if water temperature reaches 210°F 3. ECO red reset button, or high limit, that turns off electricity when overheating is detected ... includes water temperature reaching 170°F, or loose wire on thermostat. 4. Ground wire that conducts electrical short back to ground rod. Never touch water heater that is wet or was wet, unless power is confirmed OFF. 5 TP valve and ECO prevent water heater explosion. In physics, hot water expands and puts pressure on container holding water. Metal tank will rupture violently if water gets too hot. ECO is first line of defense. The next safety device before water heater explodion is a properly functioning through ¾” pipe. Test and replace TP valve |
| Power is ON means risk of electrocution which can be sudden, or can take a moment or two, and will include anyone who grabs a hold of you. Have your spouse knock you loose from wires using a 2x4, and then treat possible stopped heart and 3rd degree burns. If you are not familiar with electricity, and/or spouse does not want to hit you with a board, then use EZ repair above, or call plumber, or electrician. If you want to understand how to test water heaters, then keep reading information below. | |
Power
is ON means risk of electrocution Action #1: test for 240Volt at upper element  Action #2: Test for 240Volt at top of tank  |
✔ Quick answer: Push reset button on upper thermostat. Open drain valve and see if water is hot at bottom of tank. Open TP valve and see if water is hot at top of tank. See if you got water pressure or clog: Low hot water pressure Check tank label for voltage of appliance. If circuit breaker is burned or broken, water heater receives 120V, so heater appears to have electricity but is not working. Use multimeter to test water heater for 240V at L1-L3 screws on upper thermostat -and- test breaker Turn breaker fully off and then back on, wiggle breaker and listen for crackling sound of shorting breaker; move wires to another same amp 240 breaker]. Replace circuit breaker. Turn off all faucets and put ear against pipe listen for water leak. Bad faucet cartridge or crossover problem: Read about Crossover Other causes: red reset button tripped, upper thermostat bad, upper element burned out, loose or shorted wire: read steps below. ✔ Test for 240Volts Power is ON Water heater appears to have power, but doesn't make hot water because circuit requires 240Volts.
Power is ON during test. Stand on dry boards. Do not touch or lean into
anything made of metal.Action #1: Test for 240Volts across top two screws on upper thermostat. Action #2: Test each screw to bare metal part of heater. Each screw should test for power. Action #3: If action #1 does not show 240Volts, then test wires at top of water heater: Black to Red must test for 240V. Black to ground tests 120V and Red to ground tests 120V. See basic water heater circuit If 240Volts is not present. Check circuit breaker and wire between breaker and water heater If water heater has 2 elements, then water heater is 240Volts. If circuit breaker is tripped on one leg and delivering 120Volts, then water heater appears to have electricity but doesn't work. Buy Buy non-contact voltage tester at Amazon |
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Melted
wireCauses: -Loose connection: Wire nuts not secure. Wires not twisted together. Expansion and contraction from heating caused sparking and melt. -Action: Install wire nut correctly. Twist wire very tight. How to twist wire and select correct wire nut -Non-copper wire joined with copper wire. Action: change all wiring to copper. Avoid aluminum wire. -Thermostat shorted, causing both elements to be ON at same time. And wires were overloaded. Action: Open covers, use eyes and nose to inspect for burned melted parts. Replace thermostats and test elements  -Wire
too small for water heater. Look at watt rating on label on side of
tank. Compare with watt rating printed on end of each element. For
elements less than 3801watts at 240Volt, 12 gauge wire is fine. Use 20
amp breaker. For elements 3800 watts to 6000 watts at 240Volt, use 10
gauge wire and 30 amp breaker. Figure volts amps watts of water heaterNearby lightning strike can cause unusual and isolated events. Can melt 1 wire or 1 connection. Can cause widespread damage throughout house. Action: Call electrician How to test wire Install whole house surge protection Read more below ✔ Melted wires discovered ✔ Breaker tripped, and now ECO is tripping: ✔ Water heater had leak, or flooded and now ECO is tripping: Water heater flooded and now breaker is tripping  ✔ Water heater Quick answer: Replace thermostats and test elements and clean sediment out of tank Quick answer2: Check that wire size matches watt rating on label on side of tank, and matches watt rating printed on each element. Greater than 3800 watt element at 240V requires 10 gauge wire and 30 amp breaker. Figure volts amps watts of water heater Water leak shorted parts. Action. Check for leak Move wires to different circuit breaker to see if breaker is causing problem. How to replace circuit breaker Use nose and eyes to Inspect for burned thermostat or element and and loose wires: Replace burned part. Melted wire can carry correct voltage but will not carry necessary amperage. This can cause water heater not to operate correctly, and/or trip ECO, and or melt wires, and cause breaker to trip. Wire can no longer carry element amperage, causing heat that trips ECO. If melt is far enough down tank, it will not trip ECO and tank will test out electrically but still not work. This happens when water heater leak caused short. Or if circuit breaker tripped. Or if water heater had a fire. Or if symptoms match above, then Replace wires. New water heaters with foam insulation might require replacement. Melted wire will pass continuity test How to test wire |
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 Larger image How electric water heater works Off peak water heater options |
✔ Information about water heater design Water heater is steel tank, covered with insulation, and surrounded by metal shell. Metal shell protects wiring. 1) Steel tank holds pressure of hot water. 2) Steel tank can be rusted and leaking. Resources: Leaking water heater. Read about anode rod 3) Insulation helps prevent heat loss. 4) Metal shell protects wires from damage. 5) Any short to metal tank will trip breaker. Ground wire must be connected to water heater. ✔ 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. |
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Under-counter water heater How to install under counter water heater |
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Water heater timer Resources: Box timers Use timer to Change temperature of electric water heater Off-peak water heater ideas |
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Water heater wifi and zwave Zwave contactor Control water heater with wifi phone DIY control using ordinary zwave or wifi wall switch |
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Connect Water heater to any
voltage generator Resources: Connect water heater to any voltage generator Convert water heater to 120Volt Off-peak water heater ideas |
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How old is water heater? Find manufacturer and serial number on side of tank How to find age of water heater Water heater manufacturers Leaking water heater How to maintain water heater ✔ Tank must be in upright position to work correctly. Laying tank on side will cause water heater not to work efficiently. Elements will still heat water, but tank design is for hot water to travel to top of tank where hot outlet is located. How it works |
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✔Dropped
water heater/ water heater fell over Electric water heater will be repairable. External metal shell can dent without causing problem as long as element-thermostat covers are not pushed against electrical parts, and water connections are good. (Drop gas water heater will probably break TRD/FVIR requiring water heater replacement Read) 1) Electric elements might break. Action: Test elements 2) Thermostats might becomes loose and not touch tank wall. Action: Check if each thermostat sits flat against tank. Push in red reset button. 3) Wires might be loose. Action: Open covers and inspect for loose wires. 4) Anode rod or dip tube might break. Action: Stand tank upright. Remove lower element and see if dip tube or anode rod are touching bottom of tank. Replace anode rod Replace dip tube. 5) Internal steel tank will not be harmed, except enamel 'glass' liner might crack or chip. Action: Inspect and change anode rod each 2-3 years to prevent rusting. 6) Drain valve might breaker off: Action: How to replace drain valve 7) Earthquake straps good idea for safety. Read about earthquake straps Earthquake straps at Amazon |
| Earthquake | Earthquake
straps good idea for safety. Read about earthquake straps |
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Attic/
basement Resources: How to remove water heater from attic How to lift heavy water heater into attic |
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Away weekends
-or- gone 6 months > Should water heater be drained? Yes. If water heater is old and could fail. Or if a failed tank will flood belongings or home. Install drip pan under heater. No. The anode rod cannot protect tank from rusting unless water heater is full. Anode rods > Should water be turned OFF? Yes. Close water shut-off valve and open hot tap for a moment to relieve pressure. This action will protect home from possible flood if tank develops leak. Leaking water heater > Should power to water heater be turned OFF? Yes, > if tank will not freeze. No, > if tank can freeze > then turn thermostat down to lowest setting Or drain heater. Another option is to install timer, and turn water heater ON for 1 hour every day. When returning home, simply remove off trippers from dial and set override to ON 24-hour repeat cycle timer > Any problems when returning? Possible odor problems inside tank after several weeks: turn off taps for several minutes .. or drain a bit of water out of tank, and pour in 2 pints hydrogen peroxide. See information More info Rare hydrogen build-up in tank after several weeks. Open faucet located at highest point in home, let hot run for minutes. If hydrogen is present, air will come out faucet. Do not turn on light switch that could cause spark until area is vented. Read about hydrogen Read more |
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