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Should I change from 4500 watt water heater to 5500 watt?

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Ultra low watt density
5 year warranty
Ultra Low Watt Density/ ripple
Hard water element
Resists high mineral count
Minimum 15" diameter tank
Buy 240 volt:
4500 watt at Amazon
4500 watt at Amazon 13" diameter
5500 watt at Amazon
Camco elements at Amazon

Lifetime warranty
4500 watt +limited lifetime element

Reliance / no extended warranty
Low density/ ripple
Min 13" tank
Buy 240 Volt
Reliance 5500 watt ripple at Amazon
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Ultra low watt density
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 240 volt:
2500 watt at Amazon 
3500 watt at Amazon
4500 watt at Amazon
5500 watt at Amazon

Warranties do not cover dry fire (electricity ON before tank is full of water).
Resource:
Read about dry fire/ pdf page 2
Low watt density
Camco/ no extended warranty
Low Watt Density/ foldback

Check minimum tank diameter
Fits any tank above minimum dia
Buy 240 volt:
2500 watt at Amazon
3500 watt at Amazon
4500 watt at Amazon
4500 watt 12 pack
5500 watt at Amazon

6000 watt at Amazon/ 17" minimum tank  (6000 watts requires 8 gauge wire)

Elements on this webpage are rated for AC voltages.
AC elements with work with DC
Low watt density
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
1500 watt 120 volt 8' tank diameter
1650 watt 120 volt 7.5" minimum
1750 watt 120 volt 9" minimum
2000 watt 120 volt 9" minimum
120 Volt elements at Amazon
Buy 240 volt
1500 watt at Amazon
2000 watt 12 pack
2500 watt at Amazon
3000 watt at Amazon
3500 watt at Amazon
3800 watt at Amazon
4000 watt at Amazon
4500 watt at Amazon
4500 watt 12 pack
There are two angles to the problem.
1) You can buy water heaters with 5500 watt elements via the manufacturer. This will give you 4-7 gallons more hot water per tank vs 4500 watt heater, and might cost premium, but will be made with correct wiring and have full warranty support.
Resource: Example spec sheet   Reliance spec sheet
There are no problems with this as long as heater is connected to 30 amp breaker using 10 gauge solid copper wire.
30 amp breaker supports 80% x 7200 watts = 5760 watts.

2) You can convert ordinary residential water heater from 4500 watt elements to 5500 watt by replacing elements and get '4-7 more gallons hot water' per tank.
-This will void product warranty, and possibly cause hazard because standard wiring inside ordinary 4500 watt tank is frequently undersized 12 gauge and not the larger 10 gauge. Max for 12 ga wires is 4800 watt, but safe max for 12 ga wire is 80% x 4800 = 3840 watt, meaning that 12 gauge is barely suitable for 4500 watt elements, but definitly not suitable for 5500 watt elements.

Note: Reducing element wattage from 4500 to 3500 will not void product warranty, and will heat slightly less hot water, plus lower wattage elements tend to last longer and not burn out as frequently because they run cooler. Install low watt density elements will also lower risk of burn out.
Can I replace 4500 watt elements with 5500 watt?
Sure, go ahead. Resource: How to replace water heater element
You can definitely replace 4500 watt with 5500 watt and get 4-7 gallons more hot water from a tank. Plus turn up thermostat setting from 120° to 130° to achieve more than 4-7 gallons, but you should absolutelty pay attention to cautions about wire size that are shown above.

For detailed analysis, and cautions, keep reading.

Should you do it? Maybe.
Instead of replacing elements, try turning up thermostat to 130-140° and see if that works. This easy step will save a bit of time and money vs changing elements.
You can also install mixing valve along with higher thermostat setting and pinch out a bit more hot. Buy: Mixing valve
Neither action will void water heater warranty.
Resource:
How to replace water heater thermostat
How to adjust temperature
How to increase amount of hot water
Advantages-disadvantages mixing valve
Why switch to 5500 watt?
5500 watt elements will heat water faster than 4500 watt. This means faster 'recovery' and higher 'first hour delivery.' These are industry terms that mean specific things.
First hour delivery is the amount of usable hot water from a single continuous draw... recovery is how many gallons the tank can reheat per hour.
In other words, 5500 watt elements give you about 7 gallons more hot water from the tank than 4500 watt. Results vary widely depending on tank condition, thermostat setting, incoming water temps etc.
Formula: first hour delivery = (tank capacity) x .70 + (recovery) ... assumes tank is in tip top shape ... electric service is delivering full voltage, etc Resource: How to clean sediment out of heater
Let's assume 40 gallon electric water heater with incoming water temperature of 60° and thermostat set to 120°. Buy: Cooking thermometer   Temperature gauge
Calculate first hour based on recovery numbers from manufacturer:, which are rooted in basic physics of heating water ... but may not match your heater exactly.
4500 watt elements = 31 gallon per hour recovery = 59 gallons first hour delivery.
5500 watt elements = 34 gallon per hour recovery = 66 gallons first hour. Or 7 gallons more, or another shower.
Typical bath uses 15-22 gallons hot. Typical shower uses 4-9 gallons hot.
Resources:
Calculate first hour delivery
Recovery chart

Higher wattage elements can be a useful strategy for getting more hot water out of a tank, without increasing tank size, especially in wintertime when incoming cold water is coldest. Remember if incoming water is colder, then first hour delivery can drop to 51 and 56 gallons for 4500 and 5000 watt elements. ResourceWay to increase amount of hot water
thermostat temperature rangeGetting more hot from a tank can be accomplished by raising the thermostat setting from 120°F to to 130-140°, and installing mixing valve.
When thermostat is higher, then the tank holds more heat energy and lasts longer because you mix the hot with more cold at the tap to keep water at the 104-110°F temperature that is typical for shower, bath, hand washing. Resource: How to install under counter water heater
Less hot is consumed from tank with each bath-shower, and so less cold water enters tank per shower, water inside tank cools more slowly ...,. and overall amount of hot water produced by a fully heated tank is higher.
You can further increase tank capacity by using a tempering valve: Buy: Mixing valve Resource: Advantages-disadvantages mixing valve

If faster recovery is needed, or you need tank to reheat more quickly so more showers can be taken sooner, then higher thermostat might not solve problem because recovery has dropped below 31 gallons, and is now 27 gallons for 4500 watt element. Why? Because water heater must heat water longer to achieve higher 130°F temperature. All numbers are approximate and vary by condition of heater, incoming water temperature, thermostat calibration etc.
Thermostat calibration is +-5-8%.
Combining higher temperature setting plus 5500 watt element will give 33 gallon recovery. Resource: Recovery chart As a result, the first hour delivery (amount of hot from tank) is more than 7 gallons since the element is faster heating and the thermostat setting is higher.

Risk from higher thermostat setting
1) There is a known and documented risk of scalding if water heater temperature is set over 120°F, especially with disabled people, older people and children who might NOT feel or respond to sensation, or have delayed response.
Resource Scald chart
2) Higher temperatures cause water to expand, putting steel tank under more pressure.
Resource
: TP valve code and hazards
3) Closed system and high pressure: As long as tank is not rusted and ready to burst. there is no outright risk to the tank itself if temperature is raised, but if pipes are subjected to higher pressure because of specific plumbing problems, then the plumbing could be issue. Resource: Closed system
A bursted water heater or broken pipe can spew hot water all over a person, and flood home for hours when folks are at work.
Resource
:  Prevent rusting and replace anode
Wait. There can be problems when you install 5500 watt elements.
Product warranty is voided. Of course you can put your 4500 watt elements back into tank before making claim
(1) 5500 elements heat faster and put more strain on tank, causing warranty to cover issues that were not intended.
There is probably no measurable effect on longevity of tank itself by turning up thermostat or adding 5500 watt elements if tank is not old, rusted and ready to burst, since the TP valve and thermostat ECO (reset button or energy cut off) will protect tank from overheating and high pressure.
Resources
: TP valve code  Prevent rusting and replace anode

BUT the electrical wiring could be issue, even with well-maintained tank, and would definitely affect warranty.

(2) Electrical problem ... according to electrical code, a residential 240 volt water heater is required to have 10 gauge wire with 30 amp breaker ... which is fine for 4500 or 5500 watt ... because the safe max calculation: 30 amp x 80% = 24 amps. 24 amps x 240 volt = 5760 watts.
So 30 amp breaker and 10 gauge wire will safely support the 5500 elements.
But 12 ga wire and 20 amp breaker (sometimes found with older homes that are still within code that applied when home was built) will not work for 5500 watt. Do not upsize the breaker to 30 amp, unless wire is also changed to larger 10 gauge to match safe wiring codes.
Resource: Color code for wire and breaker

This is the point where the electrical problem arrives:
Water heater manufacturers often install smaller 12 gauge wires inside water heater that connect to thermostats and elements. To check your tank, buy short piece of 10 gauge solid copper wire from local hardware and compare size of copper with wire inside tank.

Calculation: 12 gauge wire has safe max 20 amp x 80% or 16 amps ... 16 amps x 240 volts = maximum 3840 watts ... so 12 gauge internal wiring is barely enough to support 4500 watt element. Meaning the 12 gauge wires inside tank are already running hot and inefficient. The problem is mitigated by the short length of the wires.
Since the load (water heater) is not 'continuously operating' then electric code allows manufacturers to do this since 12 gauge wire can carry the full 20 amps or 4800 watts before overheating. It's not best because heat means energy loss, and more potential for burned wire, or damaged element and thermostat ... but 12 gauge wire works safely for the 4500 watt heater, but is highly questionable for 5500 watt.
If you install 5500 watt elements in a tank that has 12 gauge wire for internal wiring, then that means the 12 gauge wires that are rated 3840-4800 watts are now carrying 5500 watts ... which will cause more inefficiency, and increase chance of short circuit and melted wire, especially at elements and thermostats.
The wire can be damaged, and element or thermostat melts. Elements and thermostats are replaceable, but a melted wire can also short out against tank and destroy the wire, making the heater impossible to repair. It will generally not cause a fire hazard for home, but it can increase risk and repair costs.
Resource: Test water heater wires
I caution strongly against installing 5500 watt element in a tank that has 12 gauge internal wiring, or installing 5500 watt element in a water heater that is connected to 20 amp breaker.

Energy loss with higher wattage
If your heater has 4500 watt elements then that's running the breaker and wire at cooler temperature than 5500 watt.
Heat is the enemy of all things electrical ... inching up wear and tear on breakers, busbar, power company transformer etc .,.. heat costs money, and all costs are energy
....Therefore, from conservation perspective the 4500 watt is better than 5500 watt.

Labeling and water heater alterations
Local codes vary widely and are usually more strict for commercial applications.
Typically, a residential water heater comes wired for non-simultaneous operation. This means either the top element is ON, or bottom element is ON, or both elements are OFF ... but at no time are both elements ON at same time. Resource: How electric water heaters work
The product label located on side of tank will show non-simultaneous.
Water heaters can be special ordered to meet other wiring objectives, such as simultaneous or off peak etc. The label and warranty would match the water heater.
If a heater is rewired for off-peak or simultaneous etc, then technically the owner of heater should apply to manufacturer for a new label. This is rarely done, and we know the manufacturer would never send a label. You might as well photoshop your own label and paste it on if desired.
The best route is to say nothing, since notifying the manufacturer would immediately void product warranty .. assuming someone at company was paying attention, which is also unlikely.
Resources: How to wire water heater thermostats    3-phase water heaters     9000 watt water heater
The same applies if you change element wattage. The label shows 4500 watt or 3500 watt etc, but if you change to 5500 watt, then the label should be changed to reflect the alteration. Of course contacting manufacturer or getting a new label would be sketchy unless manufacturer agreed ahead of time and work is performed by licensed technician ... but for commercial application, if a heater is altered, and doesn't have matching label, then some inspector might get overly enthusiastic and create a problem ... explaining why the issue needs to be mentioned.

Resources:

Calculate first hour delivery
Calculate recovery
Calculate peak hour demand
Ways to increase amount of hot water

Heat on electrical wires is caused when the force of voltage pushes a current of electrons (amperage) through the matrix (atomic structure) of a conductor (wire).
The wire offers resistance to the current of electrons ... resistance is like friction that produces heat on the wire.
Higher wattage, means more amperage is flowing along the wire, means more heat. Heat means inefficiency, and risk of shortened life for all things electrical.

Resource:
Safe-electric-wiring.html

Single-phase elements

Resources:
Replace element
Test element
Install electric water heater

Troubleshoot electric water heater
Remove old element
Marathon elements
Figure volts amps watts
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. 1

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
HOOK UP Wires
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.

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multimeter
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Clampmeter for testing amp flow on line

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
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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 resistance and heat on wire and creates possible weak point.
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Electric Wire Stripping Machine
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