How to remove water heater

Void the warranty
How to wire water heater pilot light/ indicator light
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Multimeter
Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire
Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrical repairs

Resource:
Basic house wiring

Non-contact voltage tester
Test for power without touching connectors
NEVER assume power is OFF

Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
GFCI receptacle120 volt 15 amp devices including GFCI, timers, switches, plugs, wifi controls etc can be installed on 15 or 20 amp breaker.

120 volt GFCI, outlet, receptacle that is rated 20 amp can be installed on 20 amp breaker only, but NOT on 15 amp breaker.  
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15 amp GFCI
20 amp GFCI
Buy
Basic electric book
Home plumbing/ electrical codes
Basic electric book
Or learn about basic household electricity... use and search my site/
Resource
Safe electric wiring
Basic house wiring

Use outlet tester to check for correct wiring on any 120 volt straight-blade outlet.
Buy:
Klein testers
Outlet tester
Circuit breaker finder
Electric usage monitor
armored cable
Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock.

Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure.

All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes.
Movement, damage and deterioration are major cause of electrical failure.
Buy:
Non-metallic flexible conduit
Power whip
Armored cable
Southwire armored cable cutter
Pull boxes
Southwire armored cable cutter
Electrical tools must be insulated.
Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off.

Buy:
Electrician tools kits
KLEIN TOOLS
Tools kits
IRWIN tools
KNIPEX
Connect wire to screw terminal
Use only 600 volt solid copper wire.
Do not use stranded wire or extension cord.
Do not use solder anywhere on residential 120-240 volt wiring.
Attach electric installation to structure. Tighten screws very tight against wire.

Buy:
NEC books
Dewalt plumbing/ electrical codes
Basic electric book
National electric code guide/ illustrated

Resources:
How to twist wire
How to select and install twist-on wire connectors
Lever switchWeatherproof lever switch on outdoor lights
Safely operate outdoor toggle switch
Replaces outdoor cover
Install over top of ordinary switch
Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc
Use weatherproof box for outdoor
Can be used indoor or outdoor

Buy:
Best choice: Cantex lever switch
Outdoor lever switches at Amazon
Lever switches

Resource
Cantex-toggle-switch-covers.pdf
Cantex-PVC-junction-boxes.pdf

Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire

Resource:
How to install terminal
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

Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable.

Code
-Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15
Buy
End cutting nippers at Amazon

 


When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point.
Buy tools:
Wire strippers at Amazon
Linesman pliers
Pro linesman plier
Needle nose pliers
End cutting nippers at Amazon

Weather resistant plastic box for outdoor extension cord connections, Christmas lights, outdoor power strip etc . Not for connecting wires with wire nutsŪ, or in-wall wiring, but can be used indoors to organize extension cords, power strips etc.
Weather resistant is not weatherproof or watertight. Use enclosures rated IP65 and IP67 for waterproof.
Extension cords cannot be used for permanent wiring.
Buy:
Large-medium-small electric cord box
Socketbox
Raintight enclosures
Water-tight cord lock
Resource: Enclosures and boxes
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 Pilot light at Amazon
Best 240 volt
120Volt pilot light at Amazon
Indicator lights at Amazon
NSI indicator lights
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
ANL fuseholder
Buy fuseholders at Amazon
240Volt Pilot light at Amazon
Best 240 volt
120Volt pilot light at Amazon
Indicator lights at Amazon
NSI indicator lights

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 thermostat, 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
ANL fuseholder
Buy fuseholders 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 120 volt coil
Mars contactors
Zettler miniature relay

Panel mount fuse holders at Amazon
ANL fuseholder
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
Omron relays/ 15 amp ... good up to 10 amp for double pole
Baomain relays/ up to 10 amp for double pole

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 120 volt coil
Mars contactors
Zettler SPDT miniature 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
Fish bits
Resource:
How to re-wire electric 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
Altelix enclosures
Fiberglasss enclosures
Tapered drill bit 1/4"-1-3/8 holes
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
Aprom / 110-160°
Buy/ commercial water heater thermostat 120-180° 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
Example Camco dual-element thermostat at Amazon


240Volt Pilot light at Amazon
Best 240 volt
120Volt pilot light at Amazon
Indicator lights at Amazon
NSI indicator lights

Panel mount fuse holders at Amazon
ANL fuseholder
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 additional fuseholders
Buy:
240Volt Pilot light at Amazon
Best 240 volt
120Volt pilot light at Amazon
Indicator lights at Amazon
NSI indicator lights

Panel mount fuse holders at Amazon
ANL fuseholder
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:
Metal enclosure
240Volt Pilot light at Amazon
Best 240 volt
120Volt pilot light at Amazon
Indicator lights at Amazon
NSI indicator lights
Panel mount fuse holders at Amazon
ANL fuseholder
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
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
Use only 600 volt wire.
Lamp cord, extension cords are not rated 600 volt.
Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional.

30 amp breaker use 10 gauge /
120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.

Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps.
Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp
Southwire electric tools
Yellow 12 gauge 20 amp
120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire.
... cannot be connected to 30-40 amp breaker.

Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps.
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

NMB is house wiring
UF is underground
Rolls of stranded wire
White 14 gauge 15 amp
120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.

White/ #14 gauge wire,  with ground ... 15 amp capacity. Safe maximum 12 amps.
Buy:
14-2 gauge/ 15 amp
14-3/ 15 amp

NMB is house wiring
UF is underground
50-60 amp breaker use 6 gauge /
240 volt 50 outlet can be installed on 50 amp breaker only
6-2 wire
Buy:
6-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
40-50 amp breaker use 8 gauge /
240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only
6-2 wire
Buy:
8-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
    
Copper ground wire.
Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire.
Generally ... use same size as other wire in circuit
Buy:
12 gauge copper ground wire
Ground wire
Green ground wire
Ground pigtails
Ground rods/ ground clamps at Amazon
armored cable
Armored cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure.

Non metallic flexible cables must carry ground wire, but does not have hazard of short circuit causing injury from shock.

All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes.
Movement, damage and deterioration are major cause of electrical failure.
Buy:
Armored cable
Southwire armored cable cutter
Non-metallic flexible conduit
Power whip
Pull boxes
Southwire armored cable cutter
Electrical tools must be insulated.
Always best to disconnect power, but issues of insulation failure, lack of proper grounding, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems pose a risk to anyone working on electric power.

Buy:
Electrician tools kits
Klein tools
Tools kits
stranded wire
12 ga Stranded wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring.
Buy:
Rolls of stranded wire

Protect wiring from damage
Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable.

-Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15
Buy
End cutting nippers at Amazon


Electrically insulated tools
When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances and heat on wire and creates possible weak point.
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
multimeter
Multimeters
Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire.
Buy:
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Gas water heater pilot light
Standing pilot light on gas water heater burns at all times. The flame heats end of thermocouple or thermopile 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 valve shuts OFF.
Troubleshoot resources for gas water heater pilot light
Troubleshoot and service manuals by type of gas control valve
How to light gas water heater
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SKIL
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Fluke electrical testing
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Tekton automotive

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Saws and saw blades
box timers Compare box timers

Control water heater w/ Z-wave
Intermatic control centers Control centers:
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Intermatic control centers Resource:
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programmable timer Resource:
Programmable timers
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