How to select and replace water heater element

Use element wrench/ heat with torch
\Resource:
Remove rusted/stuck element

How to select & replace water heater element

With information about buying elements -and- How to clean sediment out of tank

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2023

Dry fire/ warranty

If tank is not full of water... and no water is covering element when power is turned on => the upper element will burn out immediately => called dry fire.
On ordinary residential 2-element tank., the Upper element dry-fires. Lower elements do not dry-fire ....
When tank is filled with water, then upper element turns on first... and lower element does not receive power until top of tank is heated.
If upper element dry-fires, then upper part of tank is not heated, so power never gets to lower part of tank. Lower element does not dry-fire.
Warranties do not cover dry-fire.
Be sure tank is full of water. When filling tank, open tub spout on hot side. When water flows from tub spout, then tank is full.
Resource:
Read about dry fire/ pdf page 2

Basics for selecting element
Look at watts and volts printed on end of each element.
Volts: Match volts shown on element with volts shown on label on side of water heater. Do not install 120V element on 240V water heater or the 120 volt element will burn out.
Watts: Label on side of tank shows volts, and shows watts for upper element & lower element & total connected watts (connected wattage is max consumption of appliance)
When selecting element, buy same wattage or less wattage... keep volts the same.

It might be ok to install higher watt: replace 4500 with 5500 if breaker is 30 amp and wire is 10 gauge. Read analysis
It is ok to install lower watt: replace 4500 with 3500 as long as voltage is same. Lower watt means less heat, so element can last longer. Lower wattage will not void product warranty.
Some tanks have 4500 watt on upper element, and 3500 watt on lower element... might save money

240 volt 4500 watt element heats about 21-40 gallons per hour.
240 volt 3500 watt heats about 16-30 gallons per hour. Assuming full 240V is present. Electrical standard for 240 volt residential service is 250v max, 220v minimum. 250v will not burn out 240v element.

Standard 240v 4500 watt water heater is also rated 3800 watt at 208 volt, as printed on element and tank label. 208v is a standard single-phase voltage in the Americas, derived from 3-phase commercial services in some apartments and buildings. What is 208 volt

Residential water heaters are NON-simultaneous as shown on product label. This means upper element is ON -or lower element is ON -or both elements are OFF - but both upper and lower are never ON at same time -unless wiring is changed to meet other objectives

Resources:
Figure volts amps watts for water heater
How electric water heaters work
How to wire thermostats
Increase amount of hot water

Buy smaller wattage or same wattage element?
Larger wattage voids product warranty, plus possible fire hazard. Read analysis
Smaller wattage will NOT void product warranty.
Smaller might be better: will cause electrical breaker to run cooler, and element and breaker last longer, but Smaller wattage will heat water less quickly so reheating tank takes longer.

Resources:
240Volt / 4500 watt element heats 21 gallons per hour; 3500 heats 16 gallons per hour See chart
Clean old elements using white vinegar
Elements are sold at local hardware or home center, or on-line. Buy extra to keep on hand.
See ways to increase amount of hot water

Screw-in elements

Elements burn out frequently?
Then buy low watt density ,... or buy lower wattage
Thse are two different things.

1) Change 4500 watt higth density element to 4500 watt low density.

Density = Watts per square inch of element: So a low density or foldback element spreads the wattage over a larger surface, so each square inch of element is cooler than high density element that packs the same heating into fewer square inches.

All new water heaters come with high density elements. You can replace with either high or low density as long as watts and volts are same.
No loss of efficiency or faster heating by choosing low or high density.
Low density element resists burnout and tend to last longer.

Low density foldback elements including Camco 5-year warranty elements (shown below) are for problem water with high mineral content,

2) Change 4500 watt element to 3500 watt.
Lower wattage can also last longer because the element does not burn as hot.

If circuit breaker is 20 amp, then 3500 watt elements are correct choice to prevent overheated wire and breaker

Buy:
Low density element
Low density element
See Low, medium and high density image

Camco elements Use 1-1/2" socket A0-Smith-elements-2022.pdf
5 year warranty Ultra Low Watt Density/ ripple Hard water element Resists high mineral count Minimum 13-15" diameter tank Buy: 240 volt: 4500 watt 4500 watt 13" diameter 5500 watt Camco ripple elements Reliance 5500 watt ripple Voltage of element must match incoming voltage from circuit breaker.. 30 amp breaker and 10 gauge wire are good for elements up to 5000 watts. If tank label shows 4500 watt, then installing higher wattage 5000 watt element might void product warranty. Why? One reason, the factory installed wires inside tank are 12 gauge, that are too small for 5000 watt.	$13 - $26 5 year warranty Ultra Low Watt Density/ foldback Hard water element Resists high mineral count Check minimum tank diameter Fits any tank above minimum dia Buy: 120 volt 1500 watt 120 volt 8" minimum Buy: 240 volt: 2500 watt 3500 watt 4500 watt 5500 watt Camco/ no extended warranty Low Watt Density/ foldback Check minimum tank diameter Fits any tank above minimum dia Buy: 240 volt: 2500 watt 3500 watt 4500 watt 4500 watt 12 pack 5500 watt	Camco/ no extended warranty/ High Watt Density Standard on all new water heater Can use foldback as replacement Match volts and watts Check minimum tank diameter 120 Volt point-of-use water heater Buy: 120 volt: 1000 watt 120 volt 8" tank diameter 1400 watt 120 volt 1650 watt 120 volt 7.5" minimum 1750 watt 120 volt 9" minimum 2000 watt 120 volt 9" minimum Buy: 240 volt 1500 watt 2000 watt 12 pack 2500 watt 3000 watt 3500 watt 3800 watt 4000 watt 4500 watt
Camco Universal flange/ & Flat flange Including small tank, point-of-use water heater elements
Camco/ 5 year warranty Low density foldback Hard water element Resists high mineral count Buy: 240 Volt 4500 watt 240 volt Camco/ no extended warranty Foldback Minimum Tank diameter varies Buy: 240 Volt universal flange 4500 watt 240 volt 9" diameter Buy: 240 Volt flat flange 4500 watt 240 volt 13" tank Hatco booster heater elements Buy: Hatco elements Hatco 480 volt elements	Camco/ no extended warranty High density Minimum Tank diameter varies Buy: 120 Volt 6-9" diameter tank 1500 watt 120 volt 9" tank 2000 watt 120 volt 9" tank Buy: 240 Volt 1500 watt 240 volt 8" tank 2500 watt 240 volt 10" tank 3000 watt 240 volt 12" tank 3000 watt flat flange 14" tank 4500 watt 240 volt 13' tank 4500 watt 240 volt 15" tank Larger image/ uses 3/8" screws Convert flange to screw-type Convert round, flat and universal For any standard water heater Buy: Camco adapter kit Reliance adapter kit Resource: How to install adapter kit /pdf page 2	Use 1-1/2" socket to remove elements Buy: Camco element socket Tekton water heater socket Deep impact socket $20 Breaker bar $7 Ordinary Residential element wrench Today's hex-head elements have rounded corners, and thinner profile. Making it difficult to hold wrench on element while turning. Socket is easier to use than ordinary element wrench. Use weight of water: Loosen element while tank is full of water. Then drain tank before unscrewing element.
Rheem elements Use 1-1/2" socket Resistored element is unique to Rheem which claims longer life because resistor is added. No science supports the claim of longer life, but resistorized might resist dry-fire.
Resistored Rheem/ no extended warranty Low Watt Density/ foldback Buy: 240 volt/ resistored: 4500 watt resistorized 6000 watt resistorized Resistored elements Buy: 208 volt: 2000 watt 208 volt 208 volt elements Buy: 480 volt (can be used single-phase or 3-phase element non-balanced): 4500 watt 480 volt 5500 watt 480 volt 6000 watt 480 volt 480 volt elements Buy: 277 volt: 6000 watt 277 volt copper 6000 watt 277 volt stainless 277 volt elements	Rheem/ no extended warranty Low Watt Density/ foldback Minimum 14" diameter tank Buy: 240 volt/ copper non- resistorized: 4500 watt copper 240 volt Buy: 240 volt/ stainless steel non- resistorized: 4500 non-resistorized Amazon 5500 non-resistorized Amazon Rheem elements	Rheem/ no extended warranty NON-resistorized copper I know of no advantage of copper vrs stainless steel or other materials High Watt Density Buy: 120 volt copper: 2000 watt 120 volt Buy:: 240 volt copper: 1500 watt 240 volt 2000 watt 240 volt 3000 watt 240 volt 3000 watt 240 volt 5500 watt 240 volt

Plumbers pack
All brands of thermostats are interchangeable $48 for 2 low density 240 Volt 4500 watt elements/ + Upper and lower thermostat Buy LOW density kit: Apcom plumbers pack Amazon 110°-160° Resource How to replace elements	$35 for 2 high density 240 volt 4500 watt elements + Upper and lower thermostat Buy HIGH density kit: Apcom plumbers pack Amazon 110°-160° Resource How to replace elements Low density elements might last longer in hard water	$45 for 2 high density 240 Volt 4500 watt elements/ + Upper and lower thermostat Buy HIGH density kit: Therm-O-disc high density plumbers pack Therm-O-disc high density Therm-o-disc high density / copper element 90°-150° Resource How to replace elements

	Elements are 1" straight thread/ 11.5 threads per inch/ Convert element port to 1" pipe thread Adapt element NPSH straight thread to NPT pipe thread NPSM thread Buy: 1x1
	Stainless 1" nut/ .5 threads per inch/ Convert element port to 1" pipe thread Adapt element NPSH straight thread to NPT pipe thread NPSM thread Buy: 1" NPT nut
	Identify Element wattage and voltage Watt rating of tank appears on label on side of tank Match same watt rating of new and old elements. Smaller wattage is ok. Larger wattage is not ok. Product warranty, and electrical safety code, support same-wattage or smaller-wattage element. Do not use larger wattage element than shows on water heater label. 12 gauge wire and 20 amp breaker, use max 3800 watt element 10 gauge wire and 30 amp breaker, use max 6000 watt element What size wire do you have? Buy short pieces 10 and 12 gauge wire and compare with your wire Resources: Choose wire and breaker Figure volts amps watts for water heater Water heater is tripping breaker

Before replacing element: Follow steps 1-7
	Step 1) Press reset button and see if heater works Press reset button. Put ear against tank and listen for bubbly fizzing sound If reset button will not reset and lock in place, then replace thermostat If reset keeps tripping, then thermostat is main suspect, check for loose wire, element might be the cause. There is no reliable thermostat test, so replace thermostat is easiest solution. Resources: How to replace thermostat Buy water heater thermostats
	Step 2) Reset circuit breaker Push breaker fully OFF and then fully ON If breaker will not reset, then elements might be the problem, move wires to another same-size breaker like dryer circuit If water heater works fine on different same-size breaker, then replace breaker: read how to replace circuit breaker If breaker resets but keeps tripping, then elements might be the problem: read water heater is tripping breaker Resources: Water heater is tripping circuit breaker How to replace circuit breaker
	Step 3) Test if water heater is getting Voltage Low voltage can cause less hot water Test across top two screws on upper thermostat Tape tester leads to wood sticks... keep hands away from live power If voltage does not show on tester, then power coming to water heater is suspect Step 4) No Hot water / Less Hot water can be bad element/ or bad thermostats Test elements as shown below. If elements check out, then replace thermostats If upper element is bad, there will be no hot water Step 5) Very hot water can be shorted element/ or bad thermostats Test each element screw to metal tank as shown below If elements are OK, then replace thermostats Resources: How to replace thermostats Troubleshoot resources
	Step 6) Test element Less hot water and no hot water indicate possible element failure, or thermostat failure, or low voltage etc. Test elements. Requires multimeter/ power is off/ do not drain tank/ remove wires from element/ takes 10 minutes Look at volts watts printed on end of element/ Put battery in multimeter/ Set multimeter to read ohms/ Ω symbol No wires on element. Test for ohms across both screws on element/ volts squared divided by watts = ohms Test for ohms between each screw and the steel tank/ should read zero Resources: Step by step: How to test elements Buy multimeter
Larger image	Step 7) General troubleshoot If there is some hot water, then upper element is good. Test lower element. Action: How to test water heater element If both elements are good. Action: Push reset button, reset circuit breaker before replacing both thermostats Overheating, or very hot water: Action: test both elements before replacing both thermostats. Read more Reset button keeps tripping: Action: test both elements before replacing thermostats. Read more NO hot water: Action: Press reset button. Fully reset circuit breaker, test both elements. Read more New water heater, or repaired water heater not working: Read action If voltage is reduced, then watt-consumption of element is also reduced. This can cause hot water shortage: Read more More resources: How to remove stuck element How to test water heater element

Replacement and clean out start here
Larger image	Get tools ready: Flashlight, long water hose, washing machine hose, voltage tester, duct tape, cordless screwdriver, flat tip screwdriver, phillips screwdriver, channel locks (big pliers) Replacement element, element wrench Short hoses for vacuuming out sediment Shop vac and extension cord... remove bag and filter from shop vac so it will work with wet sediment from water heater
	Step 1: Turn power OFF
	Never assume power is OFF/ Test for power Always check for power before starting. Use non-contact voltage tester on wire, on outlet, on timer, on element, on thermostat etc to see if power is present. Press button on tester, if single beep then no power is present. If continuous beep then power is present. Use at top of heater... use it at each element Safety: Never stand on bare soil or wet surface, always stand on dry boards, do not hold or touch anything metal when working on timer or water heater that has power, tape tester leads to wood sticks, never touch wet water heater, or flooded water heater, or timer that had a short or fire without turning power OFF. Buy: Multimeters Simple multimeter/ Test continuity or voltage Buy non-contact voltage tester < Electric testers Resource: How to test if water heater electricity is off
See larger
	Step 2: Remove hose cap using channel locks Hose cap prevents drips Have one ready, in event valve leaks when finished Righty tighty/ lefty loosey Rotate hose cap counter clockwise to loosen Buy: Hose caps on Amazon
	Step 2a: See if tank will drain Do NOT turn off water <> full pressure is needed Connect garden hose to water heater. Put hand on the white valve ... as if it was a door knob... then ... Rotate tank drain counter-clockwise to open. See if water comes out end of hose. Wait... Do Not drain tank yet Weight of water inside tank will hold tank in place when loosening element.
	Clogged drain? Connect washing machine hose to water heater drain-valve <> Connect garden hose between outdoor spigot and washing machine hose <> turn on outdoor spigot for a few seconds so water pressure flushes tank open Resources: What to do if water heater will not drain How to replace drain valve My house: images of garden hose and washing machine hose
	Step 3: Turn off cold water Turn off water going into water heater. Do this by shutting off water valve just above water heater -or- close main shut-off valve to house This will stop all hot water going to each faucet
	Step 4: Open tub valve ON HOT SIDE only This will release hot water pressure This will let air into line so water heater will drain Leave tub valve open so at end of job you know when tank is full of water before electricity is turned back on.
	Step 5: Remove outside cover, inside insulation, and plastic element cover Cover and insulation must be put back when finished. Otherwise thermostat will not read correct temperature.
	Step 5a: Remove thermostat shields Upper and lower parts of tank use different cover Start by unlatching cover at top Some covers also latch on each side, while other slide off Purpose of cover is to prevent electric hazard when adjusting temperature while power is ON Make sure power is OFF when performing this step... use non-contact voltage tester Buy: Camco 08113 Upper thermostat shield 08103 Lower thermostat shield 08130 kit with both thermostats and shields Resource: How to replace thermostats Camco parts .pdf
See Larger	Step 6: Check for Burned wire melted parts Use nose to check for burned smell. Use eyes to look for burned and melted parts Damaged wire can be caused by sediment filling bottom of the tank and then overheating element. Resource: How to test water heater wires
	Cut back damaged wire Any damaged wire must be repaired Use wire nut to extend wire if necessary Usual wire size for inside of tanks is #12 solid copper wire/ never replace with stranded wire Test wires How to test water heater wires
	Step 7: Choose Element wrench or socket Lightweight 1-1/2" element wrench available hardware store, home center, plumbing supply Best is 1-1/2" socket I use socket because it grabs the element easier Buy: Water heater element socket 1-1/2" Heating element wrenches Camco heavy duty element socket Marathon elements are 1-7/8"
	Optional purchase: Electric impact wrench for elements Use for removal of element only. Do not tighten element with impact wrench Buy: Impact wrenches Special 1-1/2" socket for elements
	Step 8: Do not drain tank yet SLIGHTLY Loosen element while tank is full of water Loosen element SLIGHTLY while tank is FULL Weight of water will hold tank while you twist wrench Turn element wrench counter-clockwise Must push on wrench to keep it in position on element, or wrench will slip off Do not remove element -or- water will flood out hole Next step, drain tank. Also good time to check anode rod How to replace anode rod
	How to remove stuck element/ open the link Torch, WD40, drill bolt holes and remove with wrench, use impact wrench Make sure water heater is full of water / for weight / when loosening element Resource: Remove rusted/stuck element
	Step 9: Drain tank Open drain valve located at bottom of tank
	Step 10: Remove element and old O ring --- after tank is drained Take out old element Element will have rubber ring that seals the tank. Remove O ring and element. Before going further, Check inside tank for loose pipe coming from top <> broken dip tube causes reduced hot water and wasted electricity Resources: Dip tubes Anode rod
	Step 11: Assemble shop vac and hoses Remove bag from shop vac so it will operate as wet vac I use the hoses that are shown on left. The element opening is 1" in diameter Garden hose bends into tank 3/4" PVC is nice fit with garden hose 1" clear tube fits 3/4" PVC 30" piece of 1/2" CPVC reaches back of tank Check there are no holes in the hose so you get good suction Resource: My house: image of my shop vac Buy: Wet dry vacs
	Step 12: Vacuum out tank Tape hoses together with duct tape. Clear package tape also works. Masking tape does not work. Turn vacuum ON. Insert hose or pipe. Move hose or pipe around. Remove and clean end of hose or pipe as needed. Clear tube is handy Length of 1" clear tube lets you see if sediment is flowing past. Sediment is a slurry of water and calcium carbonate that clogs the pipe easily <> so it's handy when you can see when the stuff is flowing past. Short piece of garden hose bends into tank. Use 1/2" cpvc to break up debris Protect carpet from rusty water Buy: Duct tape Shop vacs
	It doesn't have to be perfect It will not be perfect... that's ok Buy Tank rinser Resource How to clean tank and household pipes with bleach How to maintain water heater
	Step 14: Check new element & O ring Put new O ring in place Use new O ring> Do not re-use old O ring Test new element if you want: Resource: How to test element for continuity See Larger
	Step 15: Clean opening and install element Wipe off around opening. Do NOT use teflon tape or any sealant > not necessary unless tank is damaged
	Step 16: Tighten element Don't over tighten, a firm snug is enough
	Step 17: Attach wires to either screw Tighten screws very tight against copper wire Only solid copper wire, No insulation under the screw head Note: the burned wire was cut back and replaced with good copper wire and with solid insulation
	Step 18: Insulation Put insulation back over element and thermostat Re-use foam insulation, or pack with fiberglass insulation
	Step 19: Close drain & put covers on Close drain <> put cover and insulation on <> turn on water Do NOT turn power ON until tank is full of water Insulation must be reinstalled over thermostat Do not turn on circuit breaker until tank is full of water Drain valve drips??? Use garden hose cap if drain valve drips Buy brass garden hose cap Resources: How to replace drain valve
	If drain will not stop dripping: add brass hose cap Pick up plastic hose cap at local big-box-store, and replace later with brass hose cap Buy: Brass hose caps
Wait to turn on breaker	Wait Do NOT turn power On ..... until tank is full: Wait for tank to fill Water heater elements must be immersed in water or they will burn out instantly Burn out is called dry fire, and is not covered by element warranty. Replace burned out element with new element.
	Step 20: Wait for tank to fill Open bathtub spout ON HOT SIDE only After water heater fills with water, water will start to come out bathtub valve 40 gallon tank might fill in 15-20 minutes or less
	Tub is running on HOT side. Tank is full. ✔ Bathtub hot water side is running with no air gaps <> turn off tub <> momentarily open TP valve on water heater to bleed last of water <> turn on circuit breaker
	Step 21: Turn power On\ Push breaker FULLY off, the FULLY back on. Turn on breaker <> put ear against water heater <> bubbly fizzing sound says it's working <> wait 10 minutes to see if water is getting hot. Put EAR against side of tank and listen for bubbly fizzing sound 4500 watt tank heats 21 gallons per hour 240 volt, 40 gallon tank, with 4500 watt elements will take 2 hours to heat completely
	Step 22: Clean out shop vac/ Let vac dry before putting lid on Hang up hose so it will dry/ shake out hose a few days later Shop vac must be cleaned out Put debris in a bucket so it will dry Calcium carbonate is not harmful to environment
	Job is finished
	Step 23: What if tank is not working? Read 'repaired water heater is not working'

Meter on water heater
The Kwh meter is din rail mounted inside enclosure.
Records billable power usage in Kwh. Multiply by rate you pay per Kwh to get monthly/ yearly cost of running electric water heater.

Buy
Bomain power meter
Ketotek power meter
240 volt pass through Kwh meter
2T2502GA beige plastic enclosure
2T2500GA grey plastic enclosure
din rails

Resource:
Enclosures
Figure volts amp watts for water heater

3-phase water heaters

Balanced wye, 3-phase water heaters are not covered here.
See wiring for 3-phase balanced
Resource
3-phase water heaters

Technical information

Water heater efficiency:
Electric water heaters operate at 92% efficiency
Gas water heaters operate at 61% efficiency
Tankless gas heaters operate at 80% efficiency

'Efficiency' is not same as 'energy saving' .
All costs are energy: Consider total cost of water heater: Cost of heater, installation, repairs, whether repairs are do-it-yourself, if parts are generic and available locally, life expectancy of unit, monthly energy bill over life of unit, and disposal-replacement cost
Other factor will weigh eventually including direct carbon emissions released at each home from gas appliances vs electric.

If there was a breakthrough water heater that suddenly lowered people's bills, and reduced overall energy consumption, people would be waving their monthly bill in the air and everybody would know. There is no such thing.
Research pdf: water-softener/water-heater efficiency comparison
Read do-it-yourself: 9 ways to save with a water heater

Effect of hard-water with water-softener
Efficiency of gas and electric water heaters is unchanged over time when hard water is softened, however softened water depletes anode rod and will increase risk of rusted tank unless anode rod inspected and replaced every 2 years. Once anode rod is 50-75% depleted, water heater tank begins to rust. This condition leads to leaking water heater which cannot be repaired. Rusted water heaters can rupture and cause massive damage as water runs until problem is discovered.
Read more & See Anode rod options

Effect of hard-water with NO water-softener:
> if hard water is untreated, then Efficiency of tank-type gas heater drops 6-8% after two years > cleaning tank of sediment build-up will not restore full efficiency with gas heaters > however, regular flushing to prevent sediment can maintain efficiency
> Tankless gas heater will fail when pressure sensor clogs with sediment within 2-3 years depending on hardness of water > regular de-liming will not restore efficiency of tankless > softener and filter are required
> Efficiency of electric heater stays at 92% until sediment reaches bottom element > cleaning tank and replacing lower element restores full efficiency > regular flushing to prevent sediment build-up also maintains efficiency
Research pdf: water-softener/water-heater efficiency comparison

Water-softener reduces life of anode rod in gas and electric water heaters
Water heater manual says: "Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. The use of water softener may decrease life of water heater tank."

Anode rod options

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How to select & replace water heater element

With information about buying elements -and- How to clean sediment out of tank

Dry fire/ warranty

Use 1-1/2" socket to remove elements

Before replacing element: Follow steps 1-7