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How to select and replace thermostat on electric water heaterResource: How to replace thermostat on GAS water heater |
| Calibration: all mechanical thermostats are calibrated approximately. Actual shut off temperature can vary by +10°F or -10°F The temperature in lower part of tank can drop by 15-25° before turn on, but upper part of tank will still be hot. Tank should deliver 70% of tank volume before usable (104°) water runs out. For more precise control of temperature use PID: Resource: add another thermostat to water heater   |
Buy residential upper and lower
thermostats Thermostats are interchangeable/ each works with your water heater Temperature range 90-150° Therm-o-disc/ reset trip @ 170° Temperature range 110-160° Apcom/ reset trip @ 180° Local YMCA hot tub = temperature 105°/... Typical shower-bath = 110°F Rated for 120, 208, 277, 480 volt AC single phase and 3-phase. No DC rating, but work with 48 volt DC. 89T is discontinued/ replace with Apcom or Therm-o-disc Buy: 90-160 degree F for residential tank: Water heater thermostats at Amazon Rheem thermostats More thermostats Rheem UV11698 Rheem SP11698 Camco 08163 Aprom / 110-160° Resources: Therm-o-disc 59T-66T sell sheet/ pdf Therm-o-disc thermostats Difference between Rheem thermostats |
 Residential tank thermostat is rated 90-160° F Residential tank is NOT rated for pressure and temperature of 170-180° water. Only use 180 F thermostat on commercial water heater that is rated for high temperature Marathon water heater is rated 170 degrees F |
170-180°F Commercial
upper and lower thermostats Commercial thermostats are used for 3-phase balanced and other commercial heaters rated for high temperature. Residential water heater TP valve will release water at 170° Buy:/ 3 phase water heater thermostat 120-180° F Upper thermostat Camco 120°F to 180°F Lower thermostat Camco 120° to 180°F lower Resources: Read more about 3-phase water heater |
 Break apart therm-o-disc dual element thermostat and you get: 66T DPST manual reset bi-metal switch/ high limit 170F + 59T SPDT regulating thermostat with 60 degree adjustable range |
DIY help for 2 water
heaters: Make lower
thermostat from upper Read about two water heaters Best to replace both thermostats. There is no guaranteed way to test thermostats. If thermostat is sticking, then test includes rotating temperature knob which can temporarily unstick thermostat. So bad thermostat appears to work correctly. Resources: Add another thermostat to gas or electric water heater |
| Thermostat failures: Sticking in
open or closed position, calibration loss, melted parts, fire etc. Thermostat temperature calibration is approximate in all thermostats. Typically, bi-metal thermostats have triggering range from 5 to 15° for SPST (single element tank) and 17-27° (double-element tank) for SPDT. Tank temperature can drop considerably before thermostats begins to heat water, and manufacturer says 'it's normal'. Wide range can be annoying if you run low of hot water: Install new thermostat for better results. Close range can cause TP to release water after several short draws of water from tank... because top of tank is already hot but added cold water activates thermostat and lower element makes more hot water that causes top of tank overheat. Resources: Ways to get more hot water |
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| Difference between single-element
/ dual-element thermostat Thermostat for dual-element tank has 3 screws on right side. Thermostat for single-element tank has 2 screws on right side. Dual element thermostat will work in place of single-element, but single-element thermostat will not work for dual. All dual-element and single-element thermostats works on 120V / 208-240V/ 277V / 480V etc All thermostats are generic and can be used in place of each other... except you cannot use single for dual Upper thermostats have ECO reset button that trips when temperature reaches 150°-170° Buy from my links: Single element thermostat/ therm-o-disc Single-element thermostat/ 89T style at Amazon Single element thermostat/ Apcom style You can use dual element thermostat/ not necessary to buy single element Water heater thermostats at Amazon Resources: Therm-o-disc 59T-66T sell sheet/ pdf Therm-o-disc thermostats Therm-o-disc T36 |
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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 Protectors are important when inspecting water heater and pushing reset button without risk of electrocution Never stand on wet surface or outdoor soil... always put down dry boards to stand on Do not touch or lean into anything made of metal when working on water heater that has power. Never touch wet water heater or water heater that was flooded... make certain power is OFF Buy: Upper element terminal protector Lower element terminal protector |
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89T thermostat kit Buy from my affiliate links Shorter style 89T single-element thermostat at Amazon 89T13 dual-element thermostat at Amazon 89T13 dual element kit with jumper wire Shorter style 89T single-element thermostat at Amazon 89T short/ dual-element thermostat at Amazon |
$45 for
2 low density 240 Volt 4500 watt elements/+ Upper and lower thermostat/
Temperature range 90-150° Therm-o-disc/ reset trip @ 170° Buy LOW density kit: Therm-O-disc low density plumbers pack Resource How to replace elements |
$45
for 2 high density 240 Volt 4500 watt elements/ + Upper and lower
thermostat/ Temperature range 90-150° Therm-o-disc/ reset trip @ 170° Buy HIGH density kit: Therm-O-disc high density plumbers pack Therm-O-disc high density Therm-o-disc high density / copper element Resource How to replace elements |
| All
brands of thermostats are interchangeable $48 for 2 low density 240 Volt 4500 watt elements/ + Upper and lower thermostat/ Temperature range 110-160° Apcom/ reset trip @ 180°  Buy LOW density kit: Apcom plumbers pack Amazon Resources: How to replace elements |
$35 for 2
high
density 240 volt 4500 watt elements + Upper and lower thermostat/
Temperature range 110-160° Apcom/ reset trip @ 180° Buy HIGH density kit: Apcom plumbers pack Amazon Resource How to replace elements New water heaters have high density elements. Low density elements might last longer |
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Resources for gas: Identify and troubleshoot gas water heater thermostat How to replace gas water heater thermostats |
| Replacement steps start here | |
 Power if OFF Do not empty water out of heater |
Turn power OFF Turn off 20 or 30 Amp circuit breaker to 240V water heater See basic water heater wiring diagram Or 20 Amp circuit breaker to 120V water heater Check label on side of water heater for appliance voltage Figure volts amps watts Wattage is stamped on end of element see example |
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 Never
assume power is OFF/ Use non-contact voltage testerUse non-contact voltage tester on timer, on wire, on outlet 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. Never stand on bare ground, 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 at Amazon Buy non-contact voltage tester at Amazon Electric testers at Amazon Shop Amazon - Industrial and scientific Shop Amazon - Industrial Electric Products |
 How to find age of water heater |
How to use ordinary
tester/ 120, 208, or 240V: Stand on dry boards Never touch wet water heater unless power is OFF Tape tester leads to wood sticks 1. Test black wire to ground wire 2. Test black wire to white wire 3. Test white wire to ground wire If indicator lights up, then electricity is present. |
 Newer tanks have foam insulation that may need to be cut back. Insulation must be re-installed. |
Do not empty water out of heater Not necessary to wait for water to cool. Can be done with hot water inside tank. Power must be OFF. Use screwdriver to remove covers and insulation from tank Some 240Volt tanks have single access door and single thermostat Buy new parts that match old Buy parts at hardware store Thermostats and elements are generally interchangeable between brands of electric water heater Exception is Whirlpool energy-smart shown lower on page. Thermostats usually covered with plastic protector shield. New protector shield packaged with some new thermostats Purpose of protector is to protect homeowner from electrocution when pushing reset button or adjusting temperature when power is ON. Older heaters may not have plastic shield. Buy: Upper element terminal protector Lower element terminal protector |
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Take photo of wires ...
before starting Take photo of wires or draw picture showing location of each wire |
 Larger image See large image of overall wiring diagram Wire colors can vary Take photo of wiring before starting.  See upper thermostats showing numbers |
Steps to replace thermostat Instructions are same for both upper and lower thermostats Power is OFF, and tested that power is off using steps above Use digital camera and take photo of wires or draw picture showing location of each wire Remove wires from thermostat Thermostat is held in place by metal spring that snaps over ears on thermostat Pull back metal spring on both sides (make a tool using piece of coat hanger wire) Slide out old thermostat Put new thermostat in place, wiggle thermostat around to make sure it is held flat and tight against tank by metal spring Thermostat reads temperature through surface of metal tank Use screwdriver to adjust temperature See images showing how to adjust temperature to 120° (or higher if hot water runs short) Re-connect wires <> tighten screws very firm against copper wire Important .... Push-in red reset button firmly to make sure it is engaged After thermostat is replaced, put factory insulation back over thermostat Insulation must cover thermostat to avoid higher water temperatures than desired set point Tank must be full of water or elements will instantly burn out Turn power ON Put ear against water heater to hear bubbly fizzing sound that says water heater is 'on' If tank is fully heated, water heater will not turn on. If tank is partially heated, then lower element will turn on. If tank is cold, then upper element will turn on. How it works Put access doors back on tank Access doors and insulation are required for thermostat to read correct temperature If water heater is still not working, see troubleshooting |
 Burned thermostat What caused it? Electricity found path from terminals on thermostat to bare metal tank. But fire did not spread because tank factory-installed covers and insulation were on side of tank Always connect ground wire to water heater Always keep insulation and cover installed on tank. |
Inspection finds Burned
thermostat or melted wire Turn power OFF Replace part Test wires  Test wires with Multimeter Buy: Multimeters at Amazon Resource How to test water heater wires |
| Fire safety | Fire safety All wires must be same gauge (same diameter). Or connect different gauge wires using push-on wire connectors Only copper wire used. Solid wire only. Never use stranded wire. Only copper under screw plate, no insulation under screw plate. Maximum 2 wires under screw plate. Wires must be fully inserted under screw plate. And screw plate very tight against wires. Wires cannot run over top of thermostat or elements, and must be pushed aside. Wires can run over top of other wires, but not at point where wires are making connection to either element or thermostat. |
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Use push-on wire connectors when
wires are too short Buy: Push on wire connectors at Amazon Red 3P connector (shown) for 10-14 gauge wire Yellow 4P for 12-18 gauge wire  |
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Thermostat must sit flat against
tank Wiggle thermostat to make sure it sits flat against tank Thermostat sits flat against tank wall so temperature reading is accurate and water heater is protected from overheating Access doors and insulation must be put back over thermostat to avoid higher water temperatures than desired set point, which leads to overheating, which will trip ECO reset. |
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Double-check thermostat wiring Compare wiring with illustration Resources: How to wire thermostats How water heater thermostats work Red reset button: ECO energy cut off turns off power to water heater when temperature reaches 150°-170° |
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Adjust temperature on thermostat
using screwdriver. Recommended temperature is 120 degrees F for efficiency and to avoid scalding water. If home is running short of hot water, turn temperature up. Thermostat settings are approximate. Calibration is different for each thermostat. Use cooking thermometer to measure water temperature when exact temperature is needed. Problems from high temperature setting include higher bill, faster sediment build-up. Minerals can distill out of water when water is above 140 degrees. Water expands with higher heat. TP valve releases water. Pressure should not exceed 80 psi. Resources: How to adjust water heater temperature 9 ways to save with water heater Test and replace TP valve. Install expansion tank. Inspect for leaks once per year. Test for high water pressure over 80psi that can damage tank and pipes Formulas and terminology |
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Insulation and cover must be over
thermostat. Exposing thermostat to cool room temperature will cause tank to overheat. Thermostat cannot read correct temperature unless covered correctly. Buy: Upper element terminal protector Lower element terminal protector Resource Troubleshoot electric water heater |
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Inspection
finds leak/ rust around element Resources: Replace element and gasket Inspect anode rod Leaking water heater resources How to install electric water heater |
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Circuit
breakers/ push fully OFF / and then fully ON Water heater is tripping breaker How to replace circuit breaker How to wire gfci Can AC breaker be used for DC breaker How to reset circuit breaker Not enough space for circuit breakers Circuit breakers How to install subpanel Why you need ground wire Match breaker and wire size How to wire subpanel See inside breaker box How to wire safety switch How to wire whole house surge protector Figure volts amps and watts Figure correct wire and breaker |
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Add
another thermostat to water heater For example turn off power to recirculation pump that pumps water from solar panel or secondary tank...or control electric water heater from the gas water heater... or turn off solenoid valve that turns off gas line... or connect to indicator light to notify when tank reaches set point... or connect to solenoid water valve that turns on hot water. Thermostat is mechanical and will work with 12-12 Volt AC-DC, 120-208-240, 277 volt AC electricity. Resource Add another thermostat to gas or electric water heater |
 Bi-metal thermostat with magnet for all kinds of DIY projects |
Bi-metal
thermostats/ fireplace, furnace, cooling fan etc Magnetic .... no bracket needed. ON at 120F / OFF at 90 F... use relay if you want OFF at 120F and ON at 90F Rated 15 amps @ 120 Volt. Works with any voltage 12-24-28-120-208-240-277 Mechanical switch requires no voltage to operate switch Buy 90-120 degree F thermostat: Magnetic thermostat kit at Amazon Thermostat switches at Amazon Adjustable thermostat 90-120 Oven thermostat Resources: Bi-metal thermostat switch limits T36 therm-o-disc |
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 See basic 120V and 240V water heater circuits |
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 Do it yourself water heater |
 How to twist wire |
 How to wire off-peak water heater |
 How to install and troubleshoot gas water heater |
 Troubleshoot leaking water heater |
 Contactors |
 Hot water circulation system |
 Anode rods |
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Recirculation systems |
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