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Burned R1 Resistor

Use only 600 volt wire.
Lamp cord, extension cords are not rated 600 volt.
Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional.

30 amp breaker use 10 gauge /
120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.

Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps.
Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp
Southwire electric tools
Yellow 12 gauge 20 amp
120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire.
... cannot be connected to 30-40 amp breaker. 1

Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps.
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

NMB is house wiring
UF is underground
Rolls of stranded wire
HOOK UP Wires
White 14 gauge 15 amp
120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.

White/ #14 gauge wire,  with ground ... 15 amp capacity. Safe maximum 12 amps.
Buy:
14-2 gauge/ 15 amp
14-3/ 15 amp

NMB is house wiring
UF is underground
50-60 amp breaker use 6 gauge /
240 volt 50 outlet can be installed on 50 amp breaker only
6-2 wire
Buy:
6-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
40-50 amp breaker use 8 gauge /
240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only
6-2 wire
Buy:
8-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
     
Copper ground wire.
Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire.
Generally ... use same size as other wire in circuit
Buy:
12 gauge copper ground wire
Ground wire
Green ground wire
Ground pigtails
Ground rods/ ground clamps at Amazon
armored cable
Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock.

Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure.

All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes.
Movement, damage and deterioration are major cause of electrical failure.
Buy:
Non-metallic flexible conduit
Power whip
Armored cable
Southwire armored cable cutter
Pull boxes
Southwire armored cable cutter
Electrical tools must be insulated.
Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off.

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Electrician tools kits
KLEIN TOOLS
Tools kits
IRWIN tools
KNIPEX

Telephone cable knife
Low Voltage Mounting Bracket for Telephone
Push on wire connectors

Push-on wire connectors in place of twist-on connectors

Buy:
Push on wire connectors Amazon
Red 3P connector for 10-14 gauge wire
Lever connectors for stranded wire at Amazon
HOOK UP Wires

Protect wiring from damage
Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable.

-Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15
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End cutting nippers at Amazon


Electrically insulated tools
When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point.
Buy tools:
KLEIN TOOLS
Wire strippers at Amazon
Electric Wire Stripping Machine
Linesman pliers
Utility knife at Amazon
multimeter
Multimeters
Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire.
Buy:
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line

GFCI circuit breaker
A GFCI circuit breaker will protect all boxes on circuit.

Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment.

White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel.

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GFCI circuit breakers
Push down
single-pole breaker
1" wide Push down breaker
Plug-in breaker
Buy single-pole:
Choose from 15 to 60 amp
Eaton CL series
Siemens 15-60 amp

Single-pole tandem breaker
Tandem breakers
Push down
double-pole breaker
2" wide Push down breaker
Plug-in breakers
Buy double-pole:
Choose from 15 to 125 amp
Choose from 15 amp to 200 amp
Eaton CL series circuit breaker
Siemens circuit breaker
Double pole GFCI
GM40 timer
Larger image
Permanent ON-OFF override
GM40 Intermatic WQ timer
40 amp  120V-208V-240V-277V
Dip switches to select voltage
7-day with 15 minute intervals or 24 hour with 1.75 hour intervals
Buy
Buy GM40 24 hour at Amazon
Buy GM40 7-day at Amazon
Buy:
WHQ4     120-208-240-277Volt 24-hour at Amazon
Resources
How to wire GM 40 timer
GM40 instruction manual
Sell sheet with model numbers
How to set analog timers
Intermatic timers and manuals
GM40 timer
Permanent ON-OFF override
 GM40AV
40 amp 120V-208V-240V-277V
Automatically detects voltage
24 hour, 15 minute intervals
Power outage backup option
Buy:
GM40AV       120-208-240-277V at Amazon
GM40AVQ       w/ back-up battery at Amazon
Buy GM40 24 hour at Amazon
Buy GM40 7-day at Amazon
Manuals/ Resource:
GM40AV Manual
GM40AV sell sheet
Intermatic GM40AVE
Larger image
Permanent ON-OFF override
GM40AVE digital
40 amp 120V-208V-240V-277V
Automatically detects voltage
7-day programmable, 20 on 20 off set points
Power outage backup
Buy:
GM40AVE  120-208-240-277Volt at Amazon
GM40AVE at Intermatic

Manuals/Resources:
GM40AVE manual
GM40AVE sell sheet
FM1D 20 setpoint programming
FM2D 50 setpoint programming
Intermatic timers and manuals
woods wion contactor Woods Wifi
30 amp Woods 50054 WiFi contactor
Auto detect voltage/ 120, 208, 240, 277 volt
WiOn contactor connects to app on phone
How to wire wifi
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DEWENWILS brand wifi
Wifi power switch
WiOn contactor from Amazon
GE z-wave contactor

Resource:
How to wire WiOn for 120 volt and 240 volt
GE z-wave manual
Tork TU universal timer
Larger image
Permanent ON-OFF override
Tork TU series
40 amp 120V-208V-240V-277V
Automatically detects voltage
24 hour 15 minute intervals
Buy:
Tork TU series DPDT/ 120-277V universal timer at Amazon
Tork P1104-M 240Volt SPDT at Amazon
Tork P1104FM 240V SPDT with fireman switch at Amazon
Buy Tork DTU digital timer at Amazon

Manuals/ Resources:
Sell Sheet
TU wiring manual
TU instruction manual
Tork DTU water heater timer
Larger image
Permanent ON-OFF override
Tork DTU digital
40 amp  120V-208V-240V-277V
Automatically detects voltage
Replaces Intermatic GM40E
7-day programmable, 7 on 7 off set points, with random option.
Power outage back-up
Buy:
DTU40 At Amazon

Manuals/ resources
DTU40 instruction manual
water heater timer 24 hour mechanical timers
Long lasting
Skip-a-day option
Repairable with widely available parts
NO electronics to fail
Resources:
Intermatic 24 hour timers
Tork box timers

Compare all box timers
R1 and R2 resistors are a failure point on the timers shown above.
You can identify the problem by looking at the base of the resistors located on upper left corner on front of timer circuit board.
There will be a slight burned spot at the point where these resistors are soldered.
When this point is burned, there is no recovery.
Test the relays. Some timer functions might still operate.
For example, one fellow discovered that one-of-the-two relays still worked.
Note: 240 volt can be turned on-off with one relay.
The relays K1 and K2 from the GM40 may have different coil resistances, affecting the transfer efficiency on R1 and R2, causing them to overheat, due to relay supplier.
R1 resistor
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Unburned R1 R2 resistors

Note there is no high-heat or burn residue at end of each part
burned resistor

Burned R1 resistor on timer

R1 resistor burned, R2 resistor burned

Look at burned spot where the resistor is soldered.
This is a problem as timer ages.

Normally if R1 or R2 are burned... look carefully and other nearby parts have signs of burning also.
R1-R2 are usually first place you see overheat problem
but you can see that 4 resistors located on left side of dial and 3 resistors on right side have evidence of burned point at the solder joint.

No prevention steps. Check that timer is receiving correct voltage and Load does not exceed rating.
Solutions: Replace timer and Check if one of the relays function... sometimes a timer can be used with one relay.
In this case, it was an older-model defrost timer with several methods for wiring. We were able to get 1 relay to work, and the timer was used.

Frequently these timers with burned R1 are sold on ebay after they have been removed from service... simply because the timer looks good or repair seems simple.

Related solutions:
Use correct voltage to match timer
Do not exceed load rating on timer
Use correct wire and breaker

Resources:
Match breaker and wire size
Figure volts amps watts
Compare similar timers
Compare all box timers
GM series defrost timers
burned resistor on timer
Larger image
Keep wires straight
Use solid copper wire
If wiring terminal or end of wire are covered with green, use emery board to clean terminal and sandpaper to clean wire.
Insdulation under screw plate
Larger image
Both wires MUST be same gauge
Straighten each wire
If wire is corroded or overheated, clean the end with sandpaper and wipe with cloth.
If wire has been melted, cut back and reattach, or replace wire.
Tighten screw very tight against copper wire

Use wire connector  
Push on wire connectors
Use push-on wire connectors
3 wires/ or different gauge wires
Join wires with wire connector or push-on connector
Run jumper to screw terminal.
Buy:
Push on wire connectors at Amazon
Red 3P connector (shown) for 10-14 gauge wire
Connector assortment
Resource:
How to select and install wire connector
Fire safety/ Do not put stranded wire under screw plate
Do not install stranded wire under screw.
Problem1: picture shows 2 different gauge wires under screw plate
Problem2: Stranded wire will expand and contract and come loose under screw plate, even if it is the only wire under the screw plate
Attach stranded wire and solid wire with wire connector, and run solid copper jumper wire to screw terminal
Take photo of wires before starting.

Resources:
Timer caught fire
Load ratings for Intermatic timers/ pdf


Larger image
10-3-wire
10-3-wire  12 Ga
10 gauge or 12 gauge?
Compare your wire with short pieces of 10 and 12 gauge wire from local box store

10 gauge for 30 amp breaker.
10 gauge wire can have black-white and sometimes black-red

12 gauge for 20 amp breaker
12 gauge will have black and white wires
.
Resources:
Match color code and amp rating for wire
Basic house wiring
Add black tape when White wire carries voltage (applies to 208 and 240V circuits)
With 120 and 277 Volt circuits, White wire is Neutral, and Black is Hot
With 208 and 240 circuits, both wires are Hot, and both wires carry voltage
Black tape on White wire identifies wire is Hot and not Neutral
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Type 1 and type 2 surge protection surge protection
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box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
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