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How to wire water
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Buy residential upper and lower
thermostats Thermostats are interchangeable/ each works with your water heater 89T is discontinued/ replace with Apcom or Therm-o-disc Buy 90-150° F for residential tank: Rheem UV11698 Rheem SP11698 Camco 08163 Aprom / 110-160° Water heater thermostats at Amazon Camco thermostats at Amazon More thermostats |
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commercial upper and lower
thermostatsBuy commercial thermostat 120-180 degree F Rheem SP8293 / 170° Camco 08304 / 180° Rheem SP8295 / 170° Camco 08314 / 180° 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 Only use 180° F thermostat on commercial water heater that is rated for high temperature Marathon water heater is rated 170° F Thermostat for 3-phase non-balanced water heaters up to 480 Volt Resource How to change 3-phase water heater to single phase Read more about 3-phase water heater |
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brands of thermostats are interchangeable $48 for 2 low density 240 Volt 4500 watt elements/ + Upper and lower thermostat  Buy LOW density kit: Apcom plumbers pack Amazon 110°-160° Resource How to replace elements |
$35 for 2 high density 240 volt 4500 watt elements + Upper and lower thermostat  Buy HIGH density kit: Apcom plumbers pack Amazon 110°-160° Resource How to replace elements Low density elements might last longer in hard water |
$45 for 2
low density 240 Volt 4500 watt elements/+ Upper and
lower thermostat Buy LOW density kit: Therm-O-disc low density plumbers pack 90°-150° Resource How to replace elements New water heaters have high density elements. |
$45 for 2 high
density 240 Volt 4500 watt elements/ + Upper and lower
thermostat 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 |
| NON-simultaneous water heater thermostats | |
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Residential dual-element water
heater Both elements are never 'on' at same time unless tank is wired for other purpose (see owners manual). This is called 'non-simultaneous operation' since both elements are not 'on' at same time. Either upper element is 'on' or lower element is 'on,' or both are off. Buy thermostats from my affiliate links Water heater thermostats at Amazon Resources: How to replace thermostat How residential water heater works Troubleshoot electric water heater See inside main breaker box Water heater pilot light 3-phase water heaters Convert 3-phase water heater to single-phase  Adjust temperature using screwdriver. Typical residentail range 90-150°F Typical bath shower is 104°/ typical water heater thermstat setting 120°F All settings are approximate. Higher temperatures risk scald. Resources: How to adjust temperature/ gas and electric water heaters How to replace thermostats |
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Whirlpool
energy smart with electronic thermostat Many new water heaters are going to have electronic thermostats Purpose is for manufacturer to sell proprietary parts available only from them Higher prices. End DIY Cut out competitors who can sell generic parts Resources Whirlpool energy smart features and information Convert energy smart to regular water heater |
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Non-simultaneous thermostats
control 2 water heaters Simultaneous wiring will heat top of tank first. Redundant will turn ON as soon as cold water enters tank. How electric water heater works Purpose: Add additional tank so more hot water available at peak times, without adding additional wiring. Heater #1 must be satisfied before power is sent to heater #2. Heater #2 may not fully heat before heater #1 needs to turn ON again. This will happen IF water heater is poorly insulated or cold water is drawn from heater #1 or incoming water is very cold. Sequence is basically same as above. Water heaters with foam insulation may require long drill bit from home center or fry's to bring wire to top of tank. Be sure insulation and covers are put over thermostats so thermostat not exposed to cool temperatures and cause temperature misread. Buy 72" drill bit from Amazon Fish bits Resource/ more wiring options: Two water heaters/ with more wiring options |
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does this work? 240 volt water heaters have two hot wires arriving from circuit breaker. Each element is permanently connected to one hot wire, and will always test hot for 120Volt to ground. Thermostat opens and closes second hot wire to element. This action turns element ON-OFF Resource Basic water heater circuit Thermostat is either Hot on T2 or Hot on T4, but never Hot on both. (Some ECO thermostats are numbered 2 and 4). ... So the lower thermostat on water heater #1 will either send power to lower element on heater #1, or it will send power to heater #2. Water heater #2 will not turn ON unless water heater #1 is OFF When water heater #1 turns OFF, then heater #2 has 240V power available. |
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How
to make lower thermostat using upper thermostat If water heater has foam insulation, then replacing lower thermostat with ECO protected thermostat may not be easy. Take apart upper thermostat and make new lower thermostat that will work for the specific two-water heater diagrams shown above. When not to use: Do not remove ECO protection on upper part of tank. On simultaneous and single-tank off-peak water heaters, the ECO is require for lower thermostat operation. ECO protects you in case of overheating and is required for safe operation of water heaters. |
| Single element thermostat Same thermostat used for both 120V or 240V / For correct voltage of water heater, look at label on side of tank |
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 Single-element thermostat Dual-element thermostat 2 screws on right side 3 screws on right side See Larger You CAN use dual-element thermostat for single-element tank You CANNOT use single for dual tank |
Single element thermostat/ 120V
or 208V or 240V Same thermostat works for all voltages Screw numbers are 1 thru 4 Single-element is identical to dual-element thermostat, except all dual-element upper thermostats have 3 screws located on right side. You can use dual-element thermostat for single-element tank You cannot use single-element thermostat for dual-element tank, unless tank is being rewired for redundant and simultaneous operation. Wiring
illustrations for single element water heater:
 See Larger 240 Volt single See Larger 120 Volt single |
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Resources: How to add indicator light to thermostats How to replace thermostats How to test elements How to replace elements |
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Off
-peak water
heater thermostats |
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off-peak Purpose of off-peak ... save energy during peak electric prices. > Upper thermostat operates normally to keep top 2/3 tank hot. > Lower thermostat heats bottom 1/3 of tank when ordered by off-peak meter or timer Compare:  Off-peak
water heater thermostatsOrdinary water heater thermostats 1. Lower thermostat replaced with ECO-protected thermostat identical to upper thermostat. ECO safety red reset cuts off power when water in tank reaches dangerously high 150-180°F 2. Upper thermostat: Red wire is moved L4 to T4. Color of wires can be different. 3. Black wire from lower thermostat does not connect to upper thermostat T4 screw 4. Black wire from lower thermostat runs to top of water heater for connection to off-peak meter, or off-peak timer 5. 240 Volt potential exists between yellow wire and each black wire at top of water heater Resources: See Off-peak operation sequence See more OFF-peak options Off peak with two water heaters Off peak 120Volt |
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Tork DTU/ DPDT 40 amp/ 7-day
programmable timer used for OFF peak Wire water heater so lower part of tank is OFF during peak price times. Less hot water is available. Tank is cooling during peak price, and probably will not run unless hot is drawn from tap Buy: DTU40 at Amazon Resources: How to wire Tork DTU timer How to wire thermostats How electric water heaters work |
 Off-peak water heater timer |
EH40/ 30 amp/ 7-day programmable
Off peak water heater timer Lower thermostat receives power only when timer orders > Upper thermostat receives power full time Buy: EH40 at Amazon 30 amp timers Resource How to wire off-peak water heater to timer |
| Simultaneous water heater thermostats | |
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Simultaneous
water heater wiring/ both thermostats operate independently Used in large water heaters when elements cannot keep up with demand, or in high demand situations. Lower thermostat replaced with ECO protected thermostat. Each thermostat is wired separately. Additional wire from breaker box required Each thermostat wired to a separate circuit breaker, since each element draws 4500 to 5500 watts. Wattage appears on end of each element Figure wire and breaker size Turn up thermostat temperature to get more hot water Ways to increase amount of hot water California restaurant code requires 9000 watt (9K) simultaneous water heater certified by manufacturer. They do not allow rewire of residential tank since manufacturer will not certify. Restaurant must buy commercial simultaneous water heater costing $1500 to $3000 Read Restaurant water heater sizing 9000 watt water heater |
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Simultaneous DC water heater Read how to convert AC water heater to DC/ high voltage Convert AC water heater to DC/ low voltage |
 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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Simultaneous
water heater wiring/ both thermostats operate independently Upper and lower thermostats and elements work independently from each other. Increased first hour delivery of hot water Faster recovery time 4500Watt elements, then total wattage is 9000 watts. Use 50 amp breaker and #6 gauge wire or two 30 amp breakers and two 10 gauge wires 5500Watt elements, then total wattage is 11,000 watts Use 60 amp breaker and 6 gauge wire or two 30 amp breakers and two 10 gauge wires Oversizing breaker and wire runs cooler and is more efficient Off-peak Connect lower thermostat to timer and convert water heater into off-peak operation. Water heater companies are integrating their products with future smart-grid. Except they are installing electronic thermostats. Consider whole house surge protection Whirlpool's (American/ AO Smith water heater) new 'energy smart' The era of generic off-the-shelf parts is coming to an end quickly as companies try to boost sales by using proprietary parts that must be ordered from them. SO buy extra parts and water heaters now. |
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Change
water heater temperature
using Tork TU, Tork DTU, Intermatic GM40 40-amp/ 24-hour repeat
cycle timer with simultaneous wiring Not necessary to increase wire or breaker size for this diagram Use timer for two different temperatures on electric water heater. Applies to GM40 timer and Tork DTU timer and GE 15207 timer etc Either upper thermostat and element have power or lower thermostat and element have power. But not both at same time. Buy: Tork TU 40 amp 24 hour repeat cycle timer Tork DTU 7 day programmable timer Intermatic GM40 timer Install ECO-protected thermostat for lower thermostat. Both upper and lower parts of tank are ECO-protected from overheating Rewire tank so upper and lower parts are separate. Use GM40 timer to switch power between lower and upper parts of tank. Normal operation, the lower thermostat and element receive power and keep tank at temperature set point. Upper thermostat and element have no power. This is called 'redundant' water heater operation. This technique for heating tank more rapidly after cold water first enters tank. When timer activates, power to lower part of tank turns OFF. Power to upper part of tank begins. Upper thermostat is set for higher temperature. Since tank is at regular temperature, the higher setting means upper element will turn ON and begin heating tank to higher set point. Use this technique to heat water very hot for laundry cycle. Disadvantage: The lower part of tank will cool rapidly as new cold water enters tank, so this technique is good for making short-term batches of hot water. |
 Two 30 amp breakers required Larger image |
Z-wave contactor: 1) Off-peak water heater 2) simultaneous water heater 3) change water temperatures 4) water heater timer Set different scenes to utilize all 4 choices Resource: How to set and wire CA3750 Zwave contactor  Wires attach to either screw on element: Resources How to test elements How to replace elements  Resources How residential water heater works How to replace thermostats on electric water heater How to replace thermostats on gas water heater Troubleshoot electric water heater Troubleshoot gas water heater Buy thermostats Water heater thermostats at Amazon |
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AO Smith bulletin: Thermostat wiring diagrams Rheem thermostat and element wiring diagrams Bradford White thermostat and element wiring including 3-phase, single phase etc American water heater thermostats and troubleshoot State water heater thermostat and element wiring |
Marathon thermostat and element wiring Craftmaster thermostat wiring Whirlpool 2012 electric water heater thermostat wiring 3-phase electric water heater service manual |
| Redundant thermostats: Only lower element operate | |
 Step 1: Remove blue and yellow wires from upper thermostat Step2: Move black wire from terminal T4 to terminal T2 Tighten screws very tight against copper wire. Step3: ECO protected thermostat must remain at top of tank to protect against overheating event. |
Redundant
thermostat Upper element is disconnected. Lower element heats tank. Water heater responds immediately when cold water enters tank. Can possibly cause more stacking events Both thermostats control lower element. When upper part of tank cools, the lower element turns ON. Hot water rises. When lower part of tank cools, lower element turns ON. ECO-protected thermostat must be kept at upper part of tank to avoid overheating event that can damage or rupture tank, cause scalding, release of hot water through TP valve and distill chemicals out of the water.  Cold enters lower part of tank through plastic dip tube. |
| Homeowners should check with plumber before altering water heater wiring. See insurance data on water heater failure | |
| Redundant thermostats control 2 water heaters | |
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Additional
tank in series to double available hot water at peak times See wiring option below Read about two water heaters |
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Redundant
thermostats control 2 water heaters Purpose: Add additional tank so more hot water available at peak times, without adding additional wiring. Heater #1 must be satisfied before power is sent to heater #2. Heater #2 may not fully heat before heater #1 needs to turn ON again. This will happen IF water heater is poorly insulated or hot water is drawn from heater #1 or incoming water is very cold. Sequence: 1) Power from circuit breaker arrives at ECO-protected upper thermostat on heater #1 2) ECO protection might be required on upper part of tank to prevent overheating event since heat rises 3) Typical lower thermostat on heater #1 is replaced with ECO thermostat so power can be transferred to heater #2 when heater #1 thermostats are satisfied. 4) Once heater #1 is satisfied, power goes to heater #2. Either heater can be wired for redundant or typical non-simultaneous operation. The key is adding ECO-protected thermostat to lower part of heater #1, and adding wire from lower thermostat so power can be transferred to heater #2. Water heaters with foam insulation may require long drill bit from home center or fry's to bring wire to top of tank. Be sure insulation and covers are put over thermostats so thermostat not exposed to cool temperatures and cause temperature misread. Resource Read about two water heaters |
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How
to change wiring / foam-insulated tank Rewire foam insulated tank Drill through top of tank near wiring cavities Keep drill bit near outer edge of tank shell Buy 36" drill bits Fish bits Resource: How to re-wire electric water heater |
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If you cannot rewire water
heater because of foam insulation or other factors such as warranty: Re-plumb water heaters in series, and run additional 30 amp circuit to additional heater. Then put both water heater on a timer Both water heaters turn on-off at same time Resources  See
basic water heater circuitHow to wire WHQ timer and GM40 timer Water heater timer for two water heaters More box-type water heater timers |
| 3-phase
water heater thermostats |
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| Convert 3-phase balanced to
3-phase non-balanced for residential use has moved to another page Resource: 3-phase water heater |
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Timer for 3-phase water
heater 208, 240, 277, 480 etc See 3-phase timer wiring Or convert 3-phase non-balanced to single phase/ shown on 3-phase water heater Resource: 3-phase water heater |
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3-phase non-simultaneous Unbalanced Both elements are never ON at same time. Always use ECO-protected thermostat on upper and lower Elements will heat with any applied voltage Each element has volts and watts listed on side. Volts squared divided by watts = correct ohm rating to test if element is good. 3-phase water heater service manual Buy commercial grade 3-phase thermostat for 3-phase non-balanced water heater Camco 120F to 180F thermostat with reset button at Amazon (commercial grade only) Thermostats for residential water heater 90F to 150F at Amazon Identify unbalanced water heater: it looks just like ordinary tank-type heater and does not have metal large box with contactors attached to front of unit. 3-phase balanced water heater has large box attached to front of unit. Unbalanced means that 1 leg of the three phase carries greater load than other two legs. So this is just ordinary single-phase water heater except few wires moved so there is a 3-wire connection on top of unit. Difference is that 3-phase non balanced will usually have larger wires and breaker and elements. Unbalance water heater uses ordinary 2-pole element and thermostat, except thermostat can be rated for 40 amps at 240Volts, and 30 amps at 480 volts Ordinary hardware store thermostats are rated 30 amp at 240V. Buy 3-phase thermostat at Amazon 40 amp 240V thermostat at Amazon pdf file see page 7 Balanced load, means all three legs carry equal load. Balanced water heater uses element with connections for 6 wires. Illustrations for balanced: see lower on page |
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3-phase simultaneous Unbalanced. For example: L2 50 amps, L1 and L3 29 amps, depending on each element etc Compare with non-simultaneous shown above: Move Red wire from T4 on upper thermostat to L1 on upper thermostat Either element can turn ON, as temperature varies top and bottom of tank Always use ECO-protected thermostat on upper and lower Elements will heat with any applied voltage Each element has volts and watts listed on side. Volts squared divided by watts = correct ohm rating to test if element is good. Resources 3-phase simultaneous current load Heavy-duty commercial water heaters: Balanced 3-phase Commercial electric water heater troubleshoot Commercial electric water heater part diagnosis 3-phase electric water heater manual |
| 3-phase water heater
information has moved to another page Resource: 3-phase water heater |
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