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How to test water heater wires
Do not touch electric water heater that is wet. Turn Power OFF.
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
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
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

Telephone cable knife
Low Voltage Mounting Bracket for Telephone
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
HOOK UP Wires

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 resistance and heat on wire and creates possible weak point.
Buy tools:
KLEIN TOOLS
Wire strippers at Amazon
Electric Wire Stripping Machine
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

GFCI circuit breaker
A GFCI circuit breaker will protect all boxes on circuit.

Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment.

White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel.

Buy
GFCI circuit breakers
Push down
single-pole breaker
1" wide Push down breaker
Plug-in breaker
Buy single-pole:
Choose from 15 to 60 amp
Eaton CL series
Siemens 15-60 amp

Single-pole tandem breaker
Tandem breakers
Push down
double-pole breaker
2" wide Push down breaker
Plug-in breakers
Buy double-pole:
Choose from 15 to 125 amp
Choose from 15 amp to 200 amp
Eaton CL series circuit breaker
Siemens circuit breaker
Double pole GFCI
Avoid electrocution/

Tape multimeter leads to wood
Stand on dry boards
Do not touch metal
Wear dry clothes
Do not touch wet water heater

Buy:
Non-contact voltage tester at Amazon
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Outlet tester
Circuit breaker finder
Electric usage monitor
Test electricity Power is ON

Test for 240Volt across top two screws on upper thermostat.

Turn Power OFF to conduct rest of tests

If tank is not receiving 240Volts, test electricity to water heater
Water heater cover
Larger image
Turn power OFF

Open covers on water heater

Remove insulation and plastic protectors
Foam insulation might need to be cut back

Buy:
Non-contact voltage tester
Power is OFF
Tighten all screws very tight against copper wire
Look for signs of high heat and burning.
Look for melted insulation on wires. Look for burned or blackened wires.
Use nose and smell for burning.
Melted wire
Look for burned or melted wire
Replace part
Cut back wire
Test continuity of wire/ or replace wire
Inspection of water heater finds burned wire:
Power is OFF
Action:
Replace part that burned wire is connected to.
Test continuity of wire that has been burned.
Replace wire that has no continuity.

Resources
How to test element.
How to replace element
How to test thermostat. (it is easier to replace both thermostats)
How to replace thermostat
How to wire thermostats


Multimeters at Amazon
Analog and digital multimeter
How to test continuity of wire:
When burned wire is discovered/ or bad wire is suspect
Power is OFF
Set multimeter to read ohms.
Disconnect wires from each tank part. For example disconnect wire from thermostat and disconnect other end of wire from element.
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.
Tanks with foam insulation may need to be replaced.

Test wire between water heater and breaker box
Turn off breaker.
Remove wires from top of heater.
Re-test wires on tank.
Test wire from breaker with breaker off. A wire from breaker can have continuity but still be shorted to ground or be partially melted.
Test for continuity between each wire and each wire to ground. There should be no current flowing between any of the wires.
Read
Buy:
Multimeters
Electrical testers
Push on wire connectors If wire is too short / use push-on wire connector
Do not use wire connectors inside water heater
Do not put stranded wire under screw plate... fire hazard from wires getting loose
Maximum 2 wires under screw plate
Buy:
Push on wire connectors Amazon
3 Port for 10-14 wire/ 50 pcs
6 port for 12-18 / 50 pcs
Lever nuts for stranded wire at Amazon
Check if wire insulation is under screw plate.
Loose wires cause high heat and fire
Only copper wire should be under screw plate.
Check that wires are tight.

Melted wire will pass continuity test.

If ECO keeps tripping, and thermostat is good, and water is not overheated, then replace wires inside tank.
Breaker tripped, and now ECO is tripping:
Water heater had leak, and now ECO is tripping:
Quick answer: Replace thermostats and test elements
Inspect for burned parts and and loose wires: Replace burned part.

ECO trips when wire is partially melted due to short or electrical overheat.
Wire can no longer carry element wattage, causing heat that trips ECO.

This happens if water heater leak caused short. Or if circuit breaker tripped. Or if water heater had a fire. Replace wires.
Resource:
Water heater is tripping breaker
wire water heater thermostat
This voids product warranty
How to change wiring / foam-insulated tank
Rewire foam insulated  tank
 If wire is bad/ replace wire
If tank has foam insulation, then replace tank if warranty is current.

If tank is beyond warranty, and has foam insulation, then drill hole and drop new wire down into heater, or drill holes and install conduit on outside of tank.

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
Drill horizontally as needed to run wire into wiring cavities

Buy:
36" drill bit
Fish bit

Resource:
How to test water heater wires
Water heater element Undersized wire can cause melted parts.
If you installed new element, and now ECO is tripping:
Quick answer: Replace thermostats and test elements
Inspect for burned parts and and loose wires: Replace burned part.

ECO can trip when wire gauge is too small for element wattage, causing heat that trips ECO.
This happens if replacement element has greater wattage than shows on label on side of tank.
Compare rating label on side of tank with wattage rating printed on end of each element.
Select correct wire and breaker size
Transfer switch
Use twist lock plug for extension cord that plugs into compressor
Install 20 or 30 amp as needed.
X Y terminals go to either Hot,
W is always Neutral
G is ground
These are standard markings for 240 volt plugs and outlets.
Connect X to one hot busbar inside the transfer switch, connect Y to other hot busbar, ground and Neutral to respective terminals
Buy:
Leviton 2711/ 125-250 volt/ 20-30 amp/ 3 pole
Resources
How to wire subpanel
How to wire transfer switch
How to wire twist lock plugs
All brands of thermostats are interchangeable
New water heaters have high density elements. Low density elements can last longer
Low density elements for problem water and frequent burnout


Buy LOW density kit:
Apcom plumbers pack Amazon
110°-160°
Resource
How to replace elements
How to replace thermostats
How to wire thermostats

High density, same heating power as low density

Apcom thermostats
Buy HIGH density kit:
Apcom plumbers pack Amazon
110°-160°
Resource
How to replace elements
Low density elements for problem water and frequent burnout

Therm-o-disc thermostats
Buy LOW density kit:
Therm-O-disc low density plumbers pack
90°-150°
Resource
How to replace elements
Low density elements for problem water

Therm-o-disc thermostats
Buy HIGH density kit:
Therm-O-disc high density plumbers pack
Therm-O-disc high density
Therm-o-disc high density / copper element
90°-150°
Resource
How to replace elements

Electricity from pole to breaker box

See basic 120V and 240V water heater circuits

Compare all water heater timers
Do it yourself
Do it yourself water heater

How to twist wire

How to wire off-peak water heater
Cutler Hammer C25BUB230A
Contactors
Recirculation system
Hot water circulation system
Low water pressure
Low water pressure


Stacking
Troubleshoot gas water heater

Troubleshoot Electric heater

How to install tank-type gas water heater
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
Resources:
Troubleshoot Gas valves with manuals
Icon gas valve

How to replace water heater element Waste King disposal
How to wire tankless electric

How to install tankless recirculation


Install point of use water heater
Titan tankless

Contactors/ relays
Install and troubleshoot garbage disposal Waste King disposal
Programmable timers

Woods timers
surge protection
Anode rods anode rods
Recirculation system

Tankless recirculation
Point of use water heater
Type 1 and type 2 surge protection surge protection
Buy
Electronic parts

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
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
box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
Subpanels
All control centers and parts
Enclosures
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
Din rail
Twin & one-shot
Woods
Intermatic
Tork
Low voltage power packs Recirculation systems
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