How to remove water heater

Void the warranty
Waterheatertimer.org
is a self-help site
Replace water heater element

How to wire GFCI
9 ways to save with water heater
How to install point of use water heater Point of use water heater
Compare 16 electric and 3 gas water heater timers How to wire water heater thermostats
Emergency steps: how to turn off water heater
How to install recirculation system Point of use water heater
How to wire tankless electric Figure Volts Amps Watts for water heater Low water pressure How to set timers

How to wire 3-phase timer
Troubleshoot electric water heater Troubleshoot gas water heater How to wire subpanel
Type 1 and type 2 surge protection surge protection
Search waterheatertimer.org / all results
Search using Find button  

 Tweet button  
How to wire water heater pilot light/ indicator light
indicator light on water heater This design is from Rheem, and available on other brands.
It assumes you are using 12 gauge wire to each LED, and that the LEDs are not located remotely.
If LEDs are located remotely, then use inline fuse.

Four 240 volt indicator lights.
LED Common shares a wire with each of the other LEDs
Each LED must connect to Common on 1 leg, and the other leg goes to terminal on thermostat.

Common LED is ON whenever the unit has power.
ECO  LED is off when reset button tripped.
Lower LED is off when lower thermostat is off.
Upper LED is off when upper element is off.

Buy:
240Volt red Pilot light at Amazon
Indicator lights at Amazon
water heater pilot light
Larger image
240 Volt pilot light/ Pilot light turns ON when water heater is sending power to element
Wire pilot light directly to each element (fuse required)
Do not connect stranded wire under same screw with solid wire
If upper element is burned out, then tank will have no hot water.

Fuse will protect entire length of green wire

Buy contactor and indicator/pilot light
Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon
240Volt red Pilot light at Amazon
Indicator lights at Amazon

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

Larger image
240 Volt pilot light/ Pilot light turns ON when water heater is sending power to element

Element and thermostat wiring must be identical to wiring shown
Or wire pilot light directly to each element (fuse required)

If upper element is burned out, then tank will have no hot water.
If lower element is burned out, then tank will have less hot water.
If ECO reset button, located on upper thermatat, is tripped, then power is not available to elements.
Required in-line fuseholder and 120Volt 15 amp ceramic fuse located on black wire, and another fuseholder on red wire, going to pilot light.
This is to protect pilot light and wire-to-pilot-light from 30 amp overheat danger
Insulation must be put back over thermostats, and metal cover re-installed on front of water heater for heater to operate correctly and safely.
if thermostats exposed to room-temperature air, they will not read temperature correctly.

Buy contactor and indicator/pilot light
Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon
240Volt red Pilot light at Amazon
Indicator lights at Amazon

Resources:
How non-simultaneous household water heaters work
How to wire water heater thermostats
Inline fuseholders
See inside main breaker box
Troubleshoot electric water heater
water heater indicator light
Larger image
120 Volt pilot light
Contactor or relay with 240 Volt coil is needed
240 Volt from element activates contactor
Contactor turns on light bulb or any 120 volt load
Contactor can also turn on 12-24 volt circuit

Buy from my affiliate links:
Contactor with 240 volt coil
Contactor with 240 volt coil
Zettler SPDT minature 240 volt relay
Dayton 240 volt relay

Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon

Resource:
Read more about contactors
How to wire zettler
Terminals
Since there is a 15 amp fuse on the line, you can use lightweight relays. Do not use 10 amp relay (shown in illustration on left) on 30 amp line without inline fuse as illustrated in drawing above
Buy:
240 volt general purpose relay and surface-mount socket
Surface mount socket for Omron
Dayton SPDT 240 volt relay
Buy:
12 volt DC solar panel
water heater indicator light
Larger image
120 Volt pilot light
Contactor or relay with 240 Volt coil is needed
240 Volt from element activates contactor
Contactor turns on light bulb or any 120 volt load
Contactor can also turn on 12-24 volt circuit

Buy from my affiliate links:
Contactor 40 amp with 240 volt coil
Contactor 40 amp with 240 volt coil
Zettler SPDT minature 240 volt 30 amp relay

don't use lightweight relays on 30 amp line unless you add inline fuseholder as illustrated in drawing above
Dayton 240 volt relay


Resource:
Read more about contactors
How to wire zettler
Terminals
Select contactor

Wires between element and contactor can be any color
Wires can connect to either side of contactor and either screw on element
240 volt water heater :Use contactor with 240 volt coil
Buy:
240Volt coil At Amazon

120 volt water heater Use contactor with 120 volt coil
Buy:
120Volt coil At Amazon

Resources:
120 volt under counter water heaters and installation
Toggle water heater between 120V to 240V using timer
Convert AC water heater to DC photovoltaic
Change water heater temperatures using timer
Change water temperatures/ toggle between voltages/ off peak/ using zwave
Contactors and relays
  Treminals Use solder when applying terminal to solid wire
Crimp terminals onto stranded wire
Solid wire requires solder

Do not put stranded wire under screw plate
Flat terminals are ok under screw plate

Buy:
Terminal kit

Resources:
Terminals

Voids product warranty
How to change wiring on electric water heater / foam-insulated tank
Rewire foam insulated  tank
Foam insulation makes it impossible to change wiring.
Foam is pressurized and used to fill cavity between inner steel tank and outer tank shell
The foam fits very tight against wire so wires cannot be replaced.

Start with 3/8" standard drill bit to drill through steel top.
Then use 36" drill bit to drill through foam
Drill through top of tank near wiring cavities
Keep drill bit near outer edge of tank shell

Buy
36" drill bits
Resource:
How to re-wire elecrtric water heater
How to convert AC water heater to DC
Solar connections Junction boxes can be located at top of water heater or side of water heater
Buy:
6x6x4 box
Bud industries 11x7x5 box without knockouts
Boxes from Bud Industries
Boxes from Attabox
Arlington boxes at Amazon
Intermatic Grasslin boxes
Wiegmann boxes
Cantex boxes
Carlon boxes
Raco boxes
Hoffman boxes
Pull boxes

Resource:
Compare enclosures
Control enclosure          water heater control box


Insdulation under screw plate
Larger image

   
Fire safety/ 
Only solid copper wire under screw plate
Use only solid copper wire
Do not put insulation under screw terminal
Take photo of wires before starting

Maximum 2 solid copper wires under screw plate
Max 2 wires under screw plate
Each wire must be same gauge
Attach multiple wires with wire connector, and run jumper to screw terminal
Resource:
Wire and breaker size charts
Do not put stranded wire under screw plate
Do not install stranded wire under screw
Attach stranded wire and solid wire with wire connector, and run solid copper jumper wire to screw terminal
Do not install stranded and solid copper wires under same screw plate
Take apart thermostats How to make SPDT lower thermostat using upper thermostat
If water heater has foam insulation, then replacing lower thermostat with ECO protected thermostat may not be easy.
Take apart upper thermostat and make new lower thermostat that will work for the specific two-water heater diagrams shown above.

When not to use:
Do not remove ECO protection on upper part of tank.
On simultaneous and single-tank off-peak water heaters, the ECO is require for lower thermostat operation.
ECO protects you in case of overheating and is required for safe operation of water heaters.
Buy/ for residential 90-150 degree F:
Water heater thermostats at Amazon
Shorter style 89T33 thermostat kit at Amazon
Example Camco dual-element thermostat at Amazon
Buy/ commercial water heater thermostat 120-180 degree F
3 phase non-balanced water heater thermostat
Camco 120F to 180F thermostat (commercial grade only)
Camco 180F lower thermostat (commercial grade only)
Residential water heater is not rated for more than 150F
lower thermostat activates alert SPDT Lower thermostat activates alert/ pilot light or bell when element is NOT heating
Bell or pilot light activates when thermostat reaches set point.
Buy:
Water heater thermostats at Amazon
Shorter style 89T33 thermostat kit at Amazon
Example Camco dual-element thermostat at Amazon

Wireless transmitter at Amazon
120Volt wireless receiver

240Volt Pilot light at Amazon
120Volt pilot light at Amazon
Indicator lights at Amazon

Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon
12 volt dc indicator light Indicator for PV SOLAR only
Do not put stranded wire under screw terminals./ fire hazard
Do not put 2 different gauge wires under same screw terminal/ fire hazard
Use terminals or join wires with wire connector or solder stranded wire to make solid
Resource:
How to wire solar water heater for DC
Read about Terminals

Larger image
How to install 120Volt indicator light
Drill 1/2" hole
Choose location at enclosure

Indicator will light up when power is turned ON at timer going to contactor
Does not tell you if water heater is actually working.
Resource:
How to install water heater timer
___________________________________

120V indicator should have additional fuseholder
240V should have 2 additonal fuseholders
Buy:
240Volt Pilot light at Amazon
120Volt pilot light at Amazon
Indicator lights at Amazon

Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon
indicator light to water heater
Larger image
How to install 240Volt indicator light
Drill 1/2" hole
Choose location at enclosure

Indicator will light up when power is turned ON at timer going to contactor
Does not tell you if water heater is actually working.
Resource:
How to install water heater timer
___________________________________

240V wired in this way does not require fuse protection on pilot light

Buy:
240Volt Pilot light at Amazon
120Volt pilot light at Amazon
Indicator lights at Amazon

Panel mount fuse holders at Amazon
Buy fuseholder at Amazon
Buy fuseholders at Amazon

How to meter 240Volt water heater Use Hour meter
Requires two 240Volt hour meters. One meter for each element.
Install meter on each element as shown in illustration.
240Volt potential exists across element terminals. When thermostat closes the circuit, then 240Volt element is turned ON. The hour meter will turn ON at same time.

Buy:
UWZ48E-240U 240 volt AC hour meter at Amazon
Intermatic ac hour meters at Amazon

Intermatic 120 volt hour meter
120 volt hour meters at Amazon

Resource:
How to install electric meter on water heater

How to read hour-meter results:
Wattage of element must be determined
Use multimeter to check voltage of water heater
Look at label on side of tank for different wattages at different voltages
Lower voltage means lower wattage than shows on element.
Confirm element wattage printed on end of each element

For example 4500 watt element and 240 volts
Hour meter reads 6 hours
4500 watts x 6 hours = 27,000 watt hours
27,0000 divided by 1000 = 27 kilowatthours
Install Hour meters
Illustration is for illustration purpose only.
Wiring should NOT be open as shown in illustration.
All wiring should be enclosed inside covered electrical box.

Actual installation might require drilling holes in water heater covers and installing electrical box directly to front of water heater.

Factory insulation and covers must be put over both elements and thermostats so water heater thermostat will read correct temperature

Altering water heater will void warranty

Buy:
UWZ48E-240V AC hour meter at Amazon
Intermatic bezel to support UWZ hour meter
Intermatic ac hour meters at Amazon

Resource:
How to install meter on electric water heater
Water heater cover Cover thermostats with insulation
Factory protector, insulation and covers must be put over both elements and thermostats so water heater thermostat will read correct temperature.

Thermostat exposed to cooler room temperatures and will misread tank temperature, leading to scalding and overheating dangers.

Resources:
Water heater safety precautions
Troubleshoot electric water heater


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
Resource
Timer caught fire

Resource:
How to install terminals
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
Treminals
Terminals
Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Read about terminals

Orange 10 gauge 30 amp


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 20 amp


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 15 amp


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
Ground rods at Amazon

Gas water heater pilot light
Standing pilot light on gas water heater burns at all times. The flame heats end of thermocouple or thermopiile which creates small current. The current travels to gas control valve and tells the control to keep the gas turned ON. If pilot light goes out, then gas control valvue shuts OFF.
Troubleshoot resources for gas water heater pilot light
Troubleshoot and sevice manuals by type of gas control valve
How to light gas water heater
Gas and electric water heaters Industrial electric at Amazon

Industrial supplies at Amazon

Industrial and scientific Amazon
Tools
Shop Amazon - DEWALT
Shop Amazon - Black and Decker
Shop Amazon - Stanley Tools
Shop Amazon - SKIL Tools
Shop Amazon - Porter-Cable Tools
Shop Amazon - Bosch Tools
Shop Amazon saws and saw blades
box timers Compare box timers

Control water heater w/ Z-wave
Intermatic control centers Control centers:
+ manuals and parts


All control centers and parts

Including Z-wave
programmable timer Compare programmable timers

Control water heater with programmable wall timer
Countdown timers Compare countdown timers

Control water heater with countdown timer

Enter Amazon from my links
Amazon

E-mail: geno03245w@gmail.com
My response might end up in spam folder, check email folders
Privacy policy
Search
Author page/ My Books