I have a two element WH and after a few tests I figured out what was wrong and how to fix it. My setup is non-simultaneous, which means only one WH element is activated at a time. The non-simultaneous connection reduces maximum ampere loads, which reduces PIK energy costs and is good for the environment. When the VT is cold, the upper element is turned on first, and then the lower element in the non-simultaneous block. To test this theory I connected an electrical clock (non-digital) to the bottom cell's black wire and grounded the clock to WH. Disconnect the bottom red wire. By connecting a clock with hands I didn't have to sit by the water heater and wait for the relay to switch. When the top thermostat reached the correct temperature, it turned off the top element and the clock began to work. When I visited the WH later that morning it was 30 minutes on the clock so I knew the thermostat had kicked in. I took off the watch, connected the bottom element, everything is fine.
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