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How electric water heater works Troubleshoot electric water heater Troubleshoot-gas-water-heater Troubleshoot Bosch tankless Do-it-yourself
2015

Wire Connectors

       Push in romex connector
Drill 3/4" hole for 1/2" Wire connector
Drill 1" hole for 3/4" Wire connector
Wire connectors fit knock-outs in electric boxes. Buy at hardware store.

Purpose of Wire connector: clamp down on wire to stop movement and protect wire from sharp edges of knock-out hole.

Boxes with built-in clamps do not need Wire connectors connector.
Buy:
Wire connectors / clamps at Amazon

Join wires inside octagon box

Clamp wires firmly so they cannot be puuled out of box, even if somebody trips over wires.

Often, octogon boxes and wall boxes have built in clamps

Use cable staples to attach wires firmly to solid structure
Octagon box

Metal octagon box

Metal boxes have groved channels at corner for clamping ground wires to metal box
Octagon box

All boxes must be covered.


Electric connections must be inside covered box.
Push wires down.
Make sure wire nuts are not loose
Install box cover
Electric box knock out

Use hammer and screwdriver to remove knock outs

Hit with sharp strike of hammer, and then twist out blank using pliers
Use linesman pliers to remove extra metal for larger hole
Fill unused holes with snap-in plug from electric dept
Use tapered drill bit to make hole anywhere
Plastic enclosure

Drill holes in plastic enclosure:

Drill 3/4" hole for 1/2" Wire connector
Drill 1" hole for 3/4" Wire connector
Buy:
6x6x4 plastic box:
no pre-drilled holes... must drill holes for Wire connectors connections, 1/2" hole for fuseholder, 3/16" holes for bolts to hold contactor, plastic box does not need ground screw connected to box
Cantex 6x6x4 PVC plastic enclosure with cover at Amazon
Thomas and Betts 6x6x4 plastic with cover at Amazon
Bud industries 11x7x5 box without knockouts

More boxes: Resource
6x6x4 enclosures
Grasslin and Intermatic boxes
tapered drill bit

Optional: Tapered drill bit for plastic or metal box

Buy tapered drill/ step drill bit for any size hole
Step drill bits at Amazon
Neiko tapered drill bit 1/4"-1-3/8 holes

Buy electric wiring Book
Black and Decker Complete guide to wiring
More resources;
See inside main breaker box
Orange 10 gauge 30 amp


Orange/ #10 gauge for for 30 amp circuits including water heater with ground
Buy Southwire Romex®:
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

500 feet 12 gauge 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


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
How to test wire
Element tests for 120 volts
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 wire nuts
NEVER assume power is OFF
Buy:

Non-contact voltage tester Amazon
Electric testers at Amazon

Resource:
How to test electric power is off

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Read about terminals
wire nut assortment

Wire nut assortments

Do not reuse old wire nuts
Buy

Wire nut assortment at Amazon
Wire nut assortment at Amazon

Resource
How to select and install wire nuts
Weatherproof wire nut

Weatherproof wire nut

Wire nut 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 wire nuts
Wire nut wrench

Wire nut wrench

Tighten wire nut
Buy

Nut blaster
Wire nut wrenches at Amazon

Resources:
How to twist wire
How to select right wire nut
Push on wire connectors

Push-on wire connectors in place of wire nuts

Buy:
Push on wire connectors Amazon
Red 3P connector for 10-14 gauge wire
Lever nuts for stranded wire at Amazon
add solder to stranded wire

Turn stranded wire into solid wire

Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire

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

Fire caused by stranded wire

Do not use stranded wire under screw plate

Applies to timers, switches, outlets, pumps etc.
Small devices, with small loads, such as lamp socket, stranded wire is fine
Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire
More links:
Troubleshoot Household electricity
Stress test main breaker and main breaker panel
Basic household wiring
Basic water heater circuit

Figure volts amps watts for electric water heater
Test elements
Replace elements
How to wire tankless electric
How to change water heater temperature using timer
Change water heater from 240Volt to 120Volt
Replace thermostats
How to wire thermostats
How to wire water heater for off peak operation

How to twist wire
How to wire Cooper 277 pilot light switch
How to wire combo switch-outlet
How to replace 3-speed fan switch


How to wire dimmer
How to wire 3-way dimmer
How to wire occupancy switch
How to wire motion detector
How to wire TM811 and TM8111 switches
How to wire wall timers
How to wire box timers
How to wire off-delay timer
Wire off-delay timer
How to wire pin timers

How to wire and troubleshoot photo eyes
Reverse photoeye so it turns on in day
24 Volt photoeye
24 volt programmable timer

How to wire switches
How to add switch
How to add 3-way switch


Timer for 3-way switch
Timer for 4-way switch

How to add outlet
How to wire 3-way switches
How to wire 4-way switches


Troubleshoot Malibu outdoor lights
Terminals
Select and install wire nuts
Select wire size

Electrical formulas
Electricians forum

Electrical pages


How to wire arc fault breaker
How to wire GFCI
How to wire GFCI combo

Basic water heater circuit
How to wire water heater for 120Volt
Install old work box

How to drop wire from attic
Wire cable connector

How to wire 240volt outlets
How to install 3-phase timer
How to wire 3-phase outlets
How to wire 3-phase surge protector
What is 3-phase

How to wire whole house surge protector
How to wire under-counter water heater


See inside main breaker box
Replace breaker
Install subpanel

Fuseholder
Contactors
How to solder wires
Whole house surge protector
3-phase surge protection
Circuit breakers

Difference between 120 volt and 240 Volt
Difference between 50Hz and 60Hz
How to install electric meter on water heater
How to wire water heater thermostat
How to wire water heater with switches and timers

6x6x4 Enclosures
Intermatic timer enclosures

Convert AC water heater to DC
How to wire DC solar water heater
DC relays for solar water heater
How to add another thermostat to water heater

How many Kwh to heat water
Chart for figuring heating time for electric heater

Electricity leaves power plant What is 3-phase electric: power plant to end user
color code household wire
Wire sizes

Terminals

Wire nuts
Do it yourself
Do it yourself water heater

Electricity from pole to breaker box

Compare all water heater timers
color code household wire
Wire sizes

How to wire off-peak water heater

Gas and electric water heaters Support the economy:
Buy water heaters  from my associate links:

50 gallon Gas water heaters at Amazon
40 gallon gas water heaters at Amazon
50 gallon Electric water heaters at Amazon
40 gallon electric water heaters at Amazon
Hybrid / heat pump/ water heaters at Amazon

Resources:
How to install gas water heater
How to install electric water heater
Troubleshoot gas water heater
Troubleshoot electric water heater
Point of use water heaters
Gas and electric water heaters Industrial electric at Amazon

Industrial supplies at Amazon

Industrial and scientific Amazon
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
Intermatic control centers Control centers:
+ manuals and parts


All control centers and parts

Including Z-wave
box timers Compare box timers

Control with 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
Compare power packs

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