FAULT FINDING GUIDE

Immersion Heater Not Working: Fault Finding Guide

Step-by-step fault finding for immersion heaters that are not heating, tripping the RCD, or overheating. Covers thermostat failure, element burn-out, sacrificial anode checks, wiring faults, safe isolation, and repair costs for 2026.

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11 min readUpdated 2026-05-18Andrew Moore, Founder of Elec-Mate

Written and reviewed by Andrew Moore, founder of Elec-Mate, against BS 7671:2018+A4:2026, IET Guidance Note 3 and the IET On-Site Guide.

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Key Takeaways

  • 1Always isolate the immersion heater circuit at the consumer unit and prove dead with a voltage indicator before carrying out any work — immersion heaters operate at 230V and draw 3kW or more.
  • 2Thermostat failure is the most common cause of an immersion heater not working. The thermostat can be replaced without draining the cylinder, making it a quick and relatively low-cost repair.
  • 3A failed heating element requires draining the hot water cylinder before replacement. Element replacement typically costs £80 to £150 in parts and labour combined.
  • 4The sacrificial anode (where fitted) should be inspected every two to three years. A depleted anode causes accelerated corrosion of the cylinder and element.
  • 5An immersion heater that repeatedly trips the RCD or MCB suggests a fault to earth in the element — this requires immediate replacement and should not be reset and left.
01 · Fault Finding Guide

How Immersion Heaters Work

An immersion heater is a self-contained electric heating element fitted directly into a hot water storage cylinder. It operates at 230V and typically draws 3kW, heating the water around it through direct conduction. Most cylinders have one or two heater bosses — the upper heater heats a small volume quickly for washing up, whilst the lower heater heats the full cylinder capacity.

  • Heating element — a resistance wire enclosed in a copper or titanium sheath, immersed directly in the water. Elements are rated 3kW for domestic use. The element is threaded into the cylinder boss and sealed with a washer.
  • Thermostat — a bimetal strip or electronic sensor that cuts power when the water reaches the set temperature (typically 60°C). The thermostat is clipped to the element sheath inside the heater head and can be replaced without draining the cylinder.
  • Thermal cut-out (TCO) — a secondary safety device that disconnects the heater if the water overheats above approximately 85°C to 90°C. Unlike the thermostat, the TCO requires manual resetting with a screwdriver. A TCO that keeps tripping indicates a faulty thermostat allowing the water to overheat.
  • Sacrificial anode — a magnesium or aluminium rod fitted in the cylinder to protect the copper or steel tank from corrosion by sacrificing itself. Not all cylinders have an anode, but where fitted it should be checked every two to three years.

The immersion heater circuit is a dedicated radial circuit from the consumer unit, wired in 2.5mm² twin and earth cable, protected by a 16A MCB and typically an RCD. The heater is switched via a 20A double-pole switch with a neon indicator, mounted on the airing cupboard wall.

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02 · Fault Finding Guide

Safe Isolation Before Any Work

Safe isolation is mandatory before any work

An immersion heater operates at 230V and draws up to 3kW. Contact with live terminals can cause cardiac arrest, severe burns, or death. Never rely on the double-pole switch alone — isolate at the consumer unit.

The safe isolation procedure for an immersion heater circuit follows the same steps as any electrical isolation:

  1. 1Switch off at the double-pole switch — turn the DP switch to off and verify the neon indicator has extinguished.
  2. 2Switch off at the consumer unit — locate the immersion heater MCB (usually labelled "Immersion" or "Hot Water") and switch it off. Lock the board if possible.
  3. 3Prove dead with a voltage indicator — use a GS38-compliant voltage indicator to test between all live conductors at the heater terminals before touching anything. Test the tester on a known live source before and after.
  4. 4Post a warning notice — place a warning notice on the consumer unit stating "Do not switch on — work in progress" to prevent accidental re-energisation.

These steps apply whether you are a qualified electrician carrying out a repair or a competent person inspecting the heater head. Members of the public should not remove the heater head cover without completing safe isolation first.

03 · Fault Finding Guide

Thermostat Failure — Most Common Fault

Thermostat failure is the most frequently encountered immersion heater fault. The symptoms depend on the mode of failure:

  • Thermostat fails open (no heat) — the thermostat cuts out and does not reset. The element receives no power. The symptom is cold water despite the heater being switched on for several hours. Check the thermal cut-out button on the heater head — if it has popped out, press it back in. If the TCO trips again quickly, the thermostat is failing to cut off at the correct temperature, allowing overheating.
  • Thermostat fails closed (overheating) — the thermostat does not cut out when the water reaches temperature. The water overheats and the TCO trips. The symptom is intermittent hot water — the TCO must be manually reset each time. This is a fire and scalding risk and should be rectified immediately.
  • Incorrect temperature setting — the thermostat dial may have been inadvertently turned down. Check the temperature setting on the thermostat — it should be at 60°C. Temperatures below 50°C allow Legionella bacteria to survive.

Thermostat replacement does not require draining the cylinder. After safe isolation, the heater head cover is removed, the thermostat is unclipped from the element sheath, and the replacement is clipped in. The job typically takes 30 to 60 minutes for an electrician. Thermostat parts cost £10 to £25; labour is £40 to £80, making total repair cost approximately £50 to £105.

04 · Fault Finding Guide

Element Burn-Out

A burned-out heating element is the second most common immersion heater fault. Elements fail due to age, limescale build-up in hard water areas, or electrical breakdown of the insulation. The element typically fails by developing a fault to earth, which trips the RCD.

  • Testing the element — after safe isolation, disconnect the element wires at the heater head. Using a multifunction tester set to insulation resistance test (500V DC), measure between each element terminal and earth. A healthy element reads above 1MΩ. A reading below 0.5MΩ indicates failing insulation. Zero ohms or a reading of a few ohms indicates a direct earth fault — the element must be replaced.
  • Element continuity — measure resistance between the two element terminals. A 3kW, 230V element has a resistance of approximately 17.6 ohms (R = V²/P = 230²/3000). An open-circuit reading (infinite resistance) confirms the element wire has burned through.
  • Element replacement procedure — the cylinder must be fully drained before the element can be removed. This involves isolating the cold water supply, connecting a hose to the drain cock, and draining into a suitable gully. The element is then unscrewed (using an element spanner) from the cylinder boss, and the new element fitted with a new sealing washer. The cylinder is then refilled and checked for leaks before reconnecting the electrical supply.

In hard water areas (most of England south and east of a line from Exeter to the Humber), consider fitting a titanium or incoloy element rather than copper. Titanium elements resist limescale significantly better and typically last twice as long as copper elements in hard water.

05 · Fault Finding Guide

Checking the Sacrificial Anode

Many unvented hot water cylinders and some vented cylinders include a sacrificial anode — a rod of magnesium or aluminium that corrodes preferentially to protect the cylinder walls and the heating element. Anodes are particularly important in hard water areas where electrochemical corrosion is accelerated.

  • When to inspect — inspect the anode every two to three years, or whenever the cylinder is drained for element replacement. In areas with highly aggressive water (low pH, high chloride content), inspect annually.
  • Signs of depletion — a depleted anode is less than 50% of its original diameter, or is severely pitted. A completely depleted anode provides no protection. The cylinder then begins to corrode directly, leading to pitting of the element sheath and eventually cylinder failure.
  • Replacement cost — anode replacement requires draining the cylinder. The anode itself costs £15 to £40. Combined with element replacement, anode replacement at the same time adds minimal extra cost since the cylinder is already drained.

Not all cylinders have an accessible sacrificial anode. If yours does not, consider a powered anode system (impressed current cathodic protection) if you are replacing the cylinder, particularly in coastal or industrial areas with aggressive water chemistry.

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06 · Fault Finding Guide

Wiring Faults

Wiring faults on immersion heater circuits are less common than element or thermostat failures but should be investigated if element and thermostat tests are satisfactory.

  • Loose terminal connections — the heater head terminals can work loose over time due to thermal cycling. A loose neutral connection causes the element to run intermittently. A loose earth connection means the circuit has no earth fault protection. After safe isolation, check all terminals at the heater head for tightness.
  • Overheated cable — if the element has been running with a loose connection or the heater has been overloaded, the cable insulation at the heater head may have degraded. Inspect the cable sheathing for discolouration, cracking, or brittleness. Degraded cable must be replaced.
  • Faulty double-pole switch — the DP switch can fail internally, particularly older rocker-style switches. Test voltage at the switch output terminals (with the switch in the on position) after safe isolation of the consumer unit is confirmed. Replace the switch if it fails to pass voltage when switched on.
  • Tripped RCD or MCB — always check the consumer unit first. An immersion heater circuit protected by a 16A MCB should not trip under normal operation. A tripping MCB suggests an overload or short circuit. A tripping RCD confirms an earth leakage fault — almost always a failed element.
07 · Fault Finding Guide

Repair vs Replace — Costs for 2026

Deciding whether to repair or replace an immersion heater depends on the age of the cylinder, the nature of the fault, and the local labour rates. Here are typical UK costs for 2026:

  • Thermostat replacement — £50 to £105 all-in. Parts £10 to £25, labour £40 to £80. No cylinder draining required. Most cost-effective first repair.
  • Element replacement (copper) — £80 to £150 all-in. Element £15 to £40, labour £60 to £110. Cylinder draining adds 30 to 60 minutes. If the anode is due, replace it at the same time for an additional £15 to £40 in parts.
  • Element replacement (titanium or incoloy) — £120 to £200 all-in. Titanium elements cost £40 to £80 but last significantly longer in hard water areas. The premium pays back within one replacement cycle.
  • Full cylinder replacement — £400 to £800 fitted for a vented copper cylinder. Unvented cylinders cost £800 to £1,500 installed due to the additional complexity and Part G Building Regulations notification requirements. If the cylinder is over 15 years old, full replacement is often the better long-term investment.
  • Wiring repairs — replacing a faulty DP switch costs £40 to £80. Replacing a metre of cable at the heater head costs £50 to £100. A full circuit rewire (if the cable is degraded throughout) costs £150 to £300.

As a general rule: if the cylinder is under 10 years old, repair is usually the right choice. If the cylinder is over 15 years old or has had multiple repairs, full replacement offers better value and significantly reduces the risk of a catastrophic cylinder failure.

08 · Fault Finding Guide

For Electricians: Immersion Heater Work

Immersion heater repair and replacement is routine domestic work for electricians. It falls under Part P of the Building Regulations in England and Wales as notifiable electrical work in a bathroom or kitchen (the airing cupboard is treated as a kitchen for Part P purposes if adjacent to a kitchen). Registration with a competent person scheme such as NICEIC or NAPIT means you can self-certify the work without local authority notification.

Issue a Minor Works Certificate

Thermostat and element replacements require a Minor Electrical Installation Works Certificate under BS 7671. Use the Elec-Mate app to complete and issue the certificate on site, send a PDF to the customer, and keep a signed copy in your records.

Quote Quickly, Win the Job

When diagnosing a fault, use the Elec-Mate quoting app to produce a professional quote on site while the customer is present. Customers who receive a quote immediately are far more likely to approve the work the same day.

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Frequently Asked Questions — Immersion Heater Faults

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