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How to replace wire on water heater |
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 |
 120 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. Buy 15 amp GFCI 20 amp GFCI |
Buy Basic electric book Home plumbing/ electrical codes  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 |
 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 |
 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 |
 Weatherproof
lever switch on outdoor lightsSafely 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 |
Buy: |
Push-on wire connectors in place of twist-on connectorsBuy: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 |
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 Never assume power is OFF Electrocution
warningDo NOT touch wet water heater or water heater that was flooded. Put down dry boards. Do not touch metal objects. Turn circuit breaker fully OFF. Test wire(s) at top of heater before removing covers. Or remove upper cover and use tester on all wires. Never touch water heater this is wet or was wet. Do not stand on wet surface/ put down dry boards. Buy: Non-contact
voltage tester AmazonMultimeters at Amazon Electric testers at Amazon Resources Test if electrity is OFF Leaking water heater Flooded water heater |
 Look for burned or melted wire Replace part Cut back wire Test continuity of wire/ or replace wire  Burned thermostat Replace part  |
✔ Burned wire/ Burned thermostat Action: Look for burned or melted wire connections. Replace part that burned wire is connected to. Test continuity of wire that has been burned. Replace wire that has no continuity. How to test continuity of wire: When burned wire is discovered/ or suspect Set multimeter to read ohms. Ohms is upside down horseshoe symbol Disconnect wires from each tank part. Test #1: Put tester leads on both ends of wire. If test reads ohms, then wire is good. Test #2: Test each end of wire to bare metal part of tank. If test reads ohms, then wire is shorted and must be replaced. Resource How to replace thermostats How to select and replace element  Test wire continuity with Multimeter Buy: Buy non-contact voltage tester at Amazon Multimeters at Amazon Electric testers Industrial and scientific |
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Use nose and eyes to find burned or melted wire Usually if there is a burned wire, then the screw terminals(s) where it is attached are also burned ... you might need to replace thermostat and/or element. The wire probably burned because it was loose under the screw terminal... so if you put new wire under a burned terminal, it might not tighten correctly... |
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Use #12
...
most modern electric water heaters use #12 wires inside tank from top
to lower part of tank. Do not put two different gauge wires on same
screw terminal. Use approved 600 volt (100° C) solid copper wire. Do NOT use stranded wire Never use lamp cord, or extension cord wire for permanent house wiring of any kind. Yellow/ #12 gauge wire for 20 amp with ground Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp |
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Wire color doesn't matter ... use black or white wire. Local box and hardware stores usually sell sheathed wiring n(cable) by the foot... buy a length of 12-2, or if they only sell rolls, buy 15-25 foot length Use only 600 volt electrically rated household wires. Never use extension cord for permanent inwall 120-240 volt wiring. Use utility knife to cut down the middle of cable ... over the copper ground wire ... careful not to cut into insulated wires ... and then cut short length of wire... Note: 12-3 wire has black, white, and red wire. |
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 Foam-insulated
tankPhotograph wires before disconnecting Foam is used to fill cavity between inner steel tank and outer tank shell The foam fits very tight against wire so wires cannot be replaced. if tank is under warranty, then submit claim for replacement. If warranty has expired, then drilling a hole is no problem. 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 bit Resource: How to test water heater wires Add another thermostat to gas or electric water heater |
| Making
alterations to water heater Voids product warranty but... Connect to solar Add another thermostat to gas and electric heater |
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Typical water heater
wiring: Thermostat and element must be covered with insulation Cover, insulation and protector are necessary so thermostat can read correct temperature. Thermostats exposed to room temperature will misread temperature and cause overheating. Thermostat must sit flat against tank. Water heater thermostats shold be set at 120°F according to safe practice, but can be set higher for more hot water.   Resource: How to adjust thermostat temperature How to wire water heater thermostats Increase amount of hot water Convert energy smart to regular water heater |
 Meter on water heaterThe 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 |
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 Add
indicator light to check operation of heater.Buy contactor and indicator/pilot light Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon 120 volt Pilot light at Amazon 120-240 pilot light indicator light 120v indicator light 120v Resources: How to wire water heater pilot light/ indicator light How non-simultaneous household water heaters work How to wire water heater thermostats Inline fuseholders See inside main breaker box Troubleshoot electric water heater |
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Thermostat protectors/
for therm-o-disc upper and lower thermostats Terminal protectors for therm-o-disc Does not fit Apcom style All thermostats are interchangeable Buy Upper element terminal protector Lower element terminal protector Resource: How to wire water heater thermostats |
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Replace wire on gas water heater Resources: How to replace burner on gas water heater How to replace thermocouple |
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Buy Industrial electric Industrial supplies Tools and home improvement Home and garden Hayward pool Pentair pool Southwire electric |
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Buy
Tools DEWALT Black and Decker Stanley SKIL Makita Porter-Cable Bosch Irwin Hand tools Klein hand tools Fluke electrical testing Dremel hobby tools Campbell Hausfeld air powered Tekton automotive Powerbuilt automotive Saws and saw blades |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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