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MAINTENANCE
Open the electrical junction
5
box or remove the lower
access panel on the water
heater, fold back the insulation, and
remove the plastic element/
thermostat cover.
Figure 34 - Electrical Junction Box
With the tank drained and
6
power off, remove the power
wires from the element you
intend to replace.
Remove the bad element
7
using an element wrench.
Make sure the new element is
8
the correct replacement by
referring to the water heater's
data plate for voltage and wattage
information.
Clean the threads in the tank
9
opening with a rag. Insert the
new element equipped with a
rubber gasket. NOTE: Use a drop of
hand dishwashing liquid to lubricate
the gasket to help avoid damaging the
gasket as it is being tightened. Tighten
with an element wrench.
NOTICE: Do not turn power back on
until the tank is completely full of water.
For complete instructions on filling the
tank, follow Step 8 in the Installation
section.
Refill the tank by opening the
10
cold water supply valve. Make
sure a hot water faucet is
26 • Commercial Electric Water Heater Use and Care Guide
open and the drain valve is closed.
Allow the hot water to run full for at
least three minutes to make sure the
tank has all the air removed and is
completely full of water. Failure to
perform this step can cause the upper
heating element to burn out. Once you
are certain the tank is completely full
of water, close the hot water faucet.
Figure 35 - Drain Valve
Check the newly installed
11
element for leaks. If a leak is
present, tighten the element
until the leak stops. If you cannot stop
the leak, drain the tank and remove
the element. Inspect the gasket for
damage. If the gasket is damaged,
replace the gasket and re-install the
element.
Once the element is
12
successfully installed and
there are no leaks, replace the
power wires, thermostat cover,
insulation, and access panel. Make
sure all wire connections are tight.
Close the electrical junction box.
Restore power to the water
13
heater. It may take two hours
for the tank to heat up.
Replacing the Thermostat
WARNING! Working on an
energized circuit can result in severe
injury or death from electrical shock.
Turn power off. Check wires with a
non-contact circuit tester to make
sure power is off. When you are
finished, be sure all covers are secured
to reduce the risk of fire and electric
shock.
To replace the thermostat, you'll need
the following tools and supplies:
• A non-contact circuit tester. Always
turn power OFF and check with a non-
contact circuit tester before working on
the water heater.
L1
L3
RESET
L2
L4
T1
T2
T4
89T
THERM O DISC
181°F
120°F
83°C
140°F
60°C
Figure 36 - Upper and Lower Thermostats
• A replacement thermostat (available
at local plumbing supplier).
• A business card to check the gap
between the thermostat and the
tank
• Tape and a permanent marker to
mark the wires
• A flat blade and a Phillips screwdriver
Steps for Replacing the
Thermostat:
Turn the power OFF at the
1
circuit breaker or remove
fuses.
NOTICE: It is not necessary to drain the
tank to replace a thermostat.
Open the electrical junction
2
box on the water heater and
fold back the insulation. Using
a non-contact circuit tester, check the
power wires to make certain the power
is OFF.
Figure 37 - Non-Contact Circuit Tester
49°C
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