DROMIX EWH-02 Electric Water Heater Tune-Up Kit Instruction Manual

1. Introduction and Overview

This manual provides detailed instructions for the installation, operation, and maintenance of the DROMIX EWH-02 Electric Water Heater Tune-Up Kit. This kit is designed to repair and extend the life of most common electric water heaters with dual elements, typically 30 gallons or larger with a minimum 14-inch tank diameter.

The kit includes:

• Two (2) 4500W 240V (3500W 208V) High Watt Density Copper Heating Elements
• One (1) Universal Upper Water Heater Thermostat
• One (1) Universal Lower Water Heater Thermostat
• Two (2) Terminal Protective Covers
• Two (2) Gaskets/O-rings for heating elements

This kit is compatible with many major brands, including BRADFORD WHITE, CRAFTMASTER, GENERAL ELECTRIC, GS WOOD, KENMORE, LOCHINVAR, A O SMITH, RELIANCE, RHEEM, RICHMOND, RUUD, STATE, MOR-FLO, and APCOM.

2. Safety Information

WARNING: ELECTRIC SHOCK AND SCALD HAZARD. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

• Always disconnect all power to the water heater at the main electrical panel (breaker) and the water heater's disconnect switch before attempting any service or installation.
• Ensure the water heater is completely drained if replacing heating elements.
• Never set the water heater thermostat above 120°F (49°C) to prevent scalding. Higher temperatures significantly increase the risk of severe burns. Consider installing point-of-use Thermostatic Mixing Valves.
• All electrical work should be performed by a qualified electrician or plumber in accordance with local codes and regulations. If you are unsure about any step, seek professional assistance.
• Use only UL Recognized electrical parts for your property's safety. The thermostats and heating elements in this kit meet these standards.

3. Specifications

Heating Elements:

• Wattage: 4500W at 240V (3500W at 208V)
• Material: High Watt Density Copper with Chromed Electroplate Coating for corrosion protection
• Thread Size: 1" (Diameter) x 11-1/2 NPSM Standard Thread
• Insert Length: 13-9/16" (fits tanks with a minimum 14" diameter)
• Installation Tool: Requires a 1-1/2" socket or wrench

Thermostats:

• Type: Universal Upper and Lower Element Thermostats (Thermo-O-Disc (TOD) Style)
• Voltage Range: 120V ~ 480V
• Temperature Adjustment Range: 90°F ~ 150°F (32°C ~ 66°C)
• High Limit: 170°F (77°C)
• Interchangeability: Exchangeable with Apcom Style thermostats

General:

• Minimum Compatible Tank Size: 30 Gallons
• Minimum Compatible Tank Diameter: 14 inches

4. Setup and Installation

Before beginning, review the Safety Information section (Section 2) and ensure all power to the water heater is disconnected.

4.1 Preparation

1. Turn off the circuit breaker supplying power to the water heater.
2. Turn off the dedicated power switch on the water heater itself, if present.
3. Shut off the cold water supply valve to the water heater.
4. Attach a hose to the drain valve at the bottom of the water heater and direct it to a suitable drain. Open the drain valve and open a hot water faucet in your home to allow air into the tank, facilitating drainage.
5. Allow the water heater to drain completely. This may take some time.

4.2 Replacing Heating Elements

1. Once the tank is empty, remove the access panels covering the heating elements.
2. Carefully disconnect the wiring from the old heating elements. Note the wiring configuration or take a picture for reference.
3. Using a 1-1/2" socket or wrench, unscrew the old heating elements. Apply steady pressure.
4. Remove the old elements and ensure that the old gaskets or O-rings are also removed from the tank opening.
5. Install the new gaskets onto the new DROMIX heating elements.
6. Insert the new elements into the tank openings and hand-tighten them. Then, use the wrench to tighten them securely, but do not overtighten to avoid damaging the tank threads.
7. Reconnect the wiring to the new heating elements, matching the original configuration.

4.3 Replacing Thermostats

1. Before removing, take clear pictures of the existing wiring connections for both the upper and lower thermostats. This is crucial for correct reinstallation.
2. Carefully disconnect the wires from the old thermostats.
3. Remove the old thermostats. They are typically clip-in type.
4. Install the new DROMIX upper and lower thermostats. Ensure they fit tightly against the tank surface. If necessary, gently bend the thermostat mounting clips to achieve a snug fit.
5. Reconnect the wiring to the new thermostats according to your reference pictures.

4.4 Installing Protective Covers

1. Once the thermostats are wired, install the provided terminal protective covers. These are push-to-clip type for easy installation and do not require additional tools.
2. Ensure the covers are securely in place to protect the electrical terminals.

4.5 Post-Installation

1. Close the water heater drain valve.
2. Open the cold water supply valve to the water heater.
3. Open a hot water faucet in your home to allow air to escape the tank as it fills. Close the faucet once water flows steadily.
4. Inspect all connections for leaks. Tighten any leaking connections as needed.
5. Once the tank is full and leak-free, restore power to the water heater at the main electrical panel and the water heater's disconnect switch.

5. Operating the Water Heater (Thermostat Adjustment)

The DROMIX thermostats allow for temperature adjustment between 90°F and 150°F (32°C and 66°C). The high limit is set at 170°F (77°C).

IMPORTANT NOTICE: For safety, it is recommended to set your water heater thermostats no higher than 120°F (49°C). Temperatures above 120°F significantly increase the risk of scalding, especially for children, the elderly, or individuals with disabilities. Even at 120°F, hot water can cause burns.

To adjust the temperature:

1. Ensure power is OFF before removing any access panels.
2. Carefully remove the protective covers and access panels to expose the thermostats.
3. Use a flathead screwdriver to adjust the temperature dial on both the upper and lower thermostats to your desired setting, not exceeding 120°F.
4. Replace the protective covers and access panels.
5. Restore power to the water heater.

6. Maintenance

Regular maintenance of your electric water heater, including timely replacement of heating elements and thermostats, can significantly improve its efficiency and prolong its lifespan.

• Annual Inspection: It is recommended to annually inspect heating elements for signs of corrosion or mineral buildup, and thermostats for proper function.
• Sediment Flush: Periodically flush the water heater tank to remove sediment buildup, which can reduce efficiency and damage elements. Refer to your water heater's manual for specific instructions.
• Anode Rod Check: Check and replace the anode rod as recommended by your water heater manufacturer to protect the tank from corrosion.

7. Troubleshooting

If your electric water heater is experiencing issues, the DROMIX EWH-02 Tune-Up Kit addresses common problems related to heating elements and thermostats.

Common Symptoms of Faulty Elements or Thermostats:

• Higher Electric Bill: Inefficient elements or thermostats can cause the water heater to work harder, increasing energy consumption.
• Slower Hot Water Recovery: Water takes longer to heat up.
• No Hot Water: A complete failure of one or both elements or thermostats.
• Lower Water Quality: Corroded elements can introduce rust or sediment into the hot water supply.
• Abnormal Thermostat Trip: The thermostat's high-limit reset button frequently trips, indicating an issue with overheating or a faulty thermostat.

If you experience these symptoms, replacing the heating elements and thermostats with the DROMIX EWH-02 kit is a common and effective solution.

8. Warranty and Support

The DROMIX EWH-02 Electric Water Heater Tune-Up Kit comes with a ONE YEAR WARRANTY.

If you encounter any issues, including but not limited to quality problems, please contact DROMIX customer support. We are committed to resolving any concerns and will assist with support, returns, or refunds as necessary.

For support, please refer to the contact information provided with your purchase or visit the DROMIX official website.