How to wire Tork DTU40
Tork-DTU40
How to wire Intermatic GM40
Intermatic GM series
Intermatic EH10 and WH21
Intermatic EH40 and WH40
  
Intermatic T-101 T103 T104
Pool timers and manuals
Intermatic T104P201

GE box timers
Sylvania timers
Intermatic ET series
Intermatic ET104C
Troubleshoot Intermatic
Compare timers
Compare all
Water heater Box timers
Search waterheatertimer.org / all results
Search using Find button  

 Tweet button  
How to troubleshoot Intermatic WH21 timer

Multimeter
Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy
Analog multimeter
Multimeters at Amazon
Klein multimeter
Electric testers at Amazon
Clampmeter for testing amp flow on line
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire
Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrical repairs

Resource:
Basic house wiring

Non-contact voltage tester
Test for power without touching connectors
NEVER assume power is OFF

Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
GFCI receptacle120 volt 15 amp devices including GFCI, timers, switches, plugs, wifi controls etc can be installed on 15 or 20 amp breaker.

120 volt GFCI, outlet, receptacle that is rated 20 amp can be installed on 20 amp breaker only, but NOT on 15 amp breaker.  
Buy
15 amp GFCI
20 amp GFCI
Buy
Basic electric book
Home plumbing/ electrical codes
Basic electric book
Or learn about basic household electricity... use and search my site/
Resource
Safe electric wiring
Basic house wiring

Use outlet tester to check for correct wiring on any 120 volt straight-blade outlet.
Buy:
Klein testers
Outlet tester
Circuit breaker finder
Electric usage monitor
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.

Buy:
Electrician tools kits
KLEIN TOOLS
Tools kits
IRWIN tools
KNIPEX
Connect wire to screw terminal
Use only 600 volt solid copper wire.
Do not use stranded wire or extension cord.
Do not use solder anywhere on residential 120-240 volt wiring.
Attach electric installation to structure. Tighten screws very tight against wire.

Buy:
NEC books
Dewalt plumbing/ electrical codes
Basic electric book
National electric code guide/ illustrated

Resources:
How to twist wire
How to select and install twist-on wire connectors
Lever switchWeatherproof lever switch on outdoor lights
Safely operate outdoor toggle switch
Replaces outdoor cover
Install over top of ordinary switch
Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc
Use weatherproof box for outdoor
Can be used indoor or outdoor

Buy:
Best choice: Cantex lever switch
Outdoor lever switches at Amazon
Lever switches

Resource
Cantex-toggle-switch-covers.pdf
Cantex-PVC-junction-boxes.pdf

Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire

Resource:
How to install terminal
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

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

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

 


When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point.
Buy tools:
Wire strippers at Amazon
Linesman pliers
Pro linesman plier
Needle nose pliers
End cutting nippers at Amazon

Weather resistant plastic box for outdoor extension cord connections, Christmas lights, outdoor power strip etc . Not for connecting wires with wire nutsŪ, or in-wall wiring, but can be used indoors to organize extension cords, power strips etc.
Weather resistant is not weatherproof or watertight. Use enclosures rated IP65 and IP67 for waterproof.
Extension cords cannot be used for permanent wiring.
Buy:
Large-medium-small electric cord box
Socketbox
Raintight enclosures
Water-tight cord lock
Resource: Enclosures and boxes
WH21 timerLarger image
240 Volt wiring diagram. Wires can be black-red, or more likely, black-white.
Check for loose wires and signs of burning-melting
Buy:
WH21 at Amazon
Resource:
WH21 manual
WH21 troubleshoot
Electrical ratings
1) WH21 is a 25 amp all purpose Single-pole 240 volt indoor mechanical timer.
Timer turns off one of the two hot wires. Timer is best for loads that are located indoor and adequately protected from water and earth contact.
WH21 can be used for any type load ... tungsten or incasdescent light bulb loads up to 1500 watt .. resistive loads like water heater up to 4500 watts ... or inductive LED lights, fan, motor, pump etc up to 2 HP.

2) WH21 will work with 240 volt 4500 watt water heater. Look at label located on side of tank for voltage and wattage. Typical 2-element water heater is 4500 watt.

3) WH21 will work with 240 volt 3800 watt (or less).

5) WH21 should NOT be used with 240 volt 5550 watt heater.
Why? 5500 watts divided by 240 volts = 22.91 amps.
WH21 is rated max 23 amps. This means timer is totally clocked out on amps. Amp flow increases heat. High heat causes deterioration which is major cause of electrical failure. Failures include melted contact points, loose and destroyed screw terminals that hold wires etc.

6) WH21 will NOT work for 120 volt heaters.
For 120 volt heaters and loads, you need different timer
Resource: Compare all box timers

7) Wire and breaker size.
Safe electric practice requires 30 amp breaker and 10 gauge wire for 240 volt 4500 to 5000 watt water heater.
30 amp breaker and 10 gauge wire are rated 30 amp with safe maximum of 80% of 30 amp .... 30 x .80 = 24 amps safe maximum for 30 amp breaker and 10 gauge wire.

8) If breaker is 20 amp, and wire is 12 gauge, then it will work fine with WH21 ... but not for 4500 watt heater. Solutions, change water heater elements to 3500 watt.
Why? 4500 watts divided by 240 volts = 20.83 watts, which is fine for WH21, but the 12 gauge wire and 20 amp breaker breaker are rated safe maximum 20 amp x .8 = 16 amps. So 20 amp breaker and wire are too small for 4500 watt, 18.75 amp water heater. (4500 watts divided by 240 volt = 18.75 amps)
The timer will work fine with 12 gauge wire and 20 amp breaker as long as voltage is 240 volt.
Resources:
WH21 manual
See Basic water heater circuit
Calculate volts amps watts
Should I change to 5500 watt elements?
If timer dial is rotating, and keeping good time, then clock motor is good. But trippers might be bad. Replace trippers.

Buy:
Buy new WH21 timer
Buy replacement trippers

If dial is NOT rotating, then clock motor might be bad.
Manually rotate dial to see if load turns on-off.
Use manual override button on timer to see if load turns on.
Buy:
Buy WH233-18 clock motor at Intermatic
Buy new WH21 timer
Buy replacement trippers

If dial is NOT rotating
Push circuit breaker fully off, then fully back on. Timer clock motor must be receiving 240 volt, and breaker can sometimes be tripped off on on one of the two Hot legs
Pull off the timer dial and then reset to make sure it is properly seated.
Timer dial must be pushed inward for dial to turn water heater on-and-off.
Test for 240 volt at timer
Testing safety
MultimeterTape tester leads to wood sticks.
Stand on dry boards
Do not touch metal
Wear dry clothes
Do not touch wet water heater
Do not touch wet timer box
Wear insulated gloves if risk is high
Do not hold metal object in mouth
Do not lean into anything made of metal
Buy:
Analog multimeter
Multimeters at Amazon
Buy non-contact voltage tester at Amazon
Electric testers at Amazon
Is water heater working?
Is water heater is receiving 240 volt across top two screws on upper thermostat?
Test for 240 volts across top two screws on upper thermostat.
Keep hands away from power. Tape tester to wood sticks.
Buy:
Analog multimeter
Multimeters at Amazon
Buy non-contact voltage tester at Amazon
Electric testers at Amazon
fiberglass ladder

If water heater is receiving 240 volts when timer is ON, and heater is not heating water, then water heater is suspect.
Resource: Troubleshoot electric water heater
WH21 timerResource:
WH21 manual

If you cannot get dial to rotate correctly, then check wiring.
Check that only copper wire and no insulation is inserted under pressure plate.
Check that screws are very tight against copper wire, and there is no evidence of melting or burning. Use nose to smell for burning, and ears to listen for crackling.
Do not use stranded wire. Do not mix 2 different gauge (size) wires under same pressure plate. Max 2 wires per terminal. Each wire should be on opposite side and not same side of screw. Use a screwdriver that is same size as slot in screw. Small screwdriver might not tighten screw well enough, causing loose wire, arcing, and eventual melt and failure that will destroy timer.

Manually rotate dial and see if water heater turns ON-OFF. Listen for bubbly-fizzing sound by putting ear against water heater. If tank is fully cold, then upper element should turn on. If tank is fully heated, then no element should turn on. If lower part of tank has cooled, then lower element should turn ON.
Resources   How electric water heater works           Troubleshoot electric water heater

Check for 240Volts across Line1 and Line2 on timer. Electrocution danger. Observe safety precautions shown on left.
Check that each Hot Line1 and Hot Line2 test 120Volts to green ground screw.
If you do not have 240Volts across Line1 and Line2, then circuit breaker might be tripped, or circuit breaker is loose on busbar. Action: Move wires to another same-amp circuit breaker.
Resource Test electricity to water heater

Terminal block has 3 screws: 1-2-3. Far right screw #3 is turned ON-OFF by timer. Other two screws #1-2 remain hot at all times. Test far right #3 screw to ground screw. When timer is ON, test should read 120Volts. Manually rotate timer dial. When timer is OFF, test should read NO volts. If test shows that timer is not turning ON-and-OFF, then timer is bad or trippers are worn and need replacement.

If dial is rotating correctly, but water heater never turns on-off, then trippers might be bad.
WH21 uses 156EB1945A trippers (set includes 2 silver and 2 brass trippers)
Intermatic trippers and parts     Order trippers from Intermatic
Buy:
Buy WH233-18 clock motor at Intermatic
Buy new WH21 timer
Buy replacement trippers

To stop timer from turning water heater ON-OFF, pull time dial outwards.
Timer must be reset for current time after power outage.
WH21 manual
David asks:
I have an Intermatic WH-21 timer.  One of the springs for the tripper mechanism broke.  I couldn’t find replacements for sale — do you know of a spring that could be bought elsewhere that would work?
Answer:
I do not have a resource for that part.
Over the years, I have not seen the spring listed anywhere on Intermatic or in one of their part sheets.
Go to the hardware and search through the Hillman drawers, or order directly from hillmangroup.com
The same mechanism is used for heavy duty E1010 and E1020 timers ... but they cost as much as wh21, unless you can find a used one somewhere. I do not know if the E1020 series has same spring.
Intermatic WH40 timer
Upgrade to WH40
Same as T104 except with convenient override lever
Larger image
If WH21 has stopped functioning
Upgrade to better timer.
Buy heavy-duty 40-amp WH40 or T104 timer as replacement.
Only 1 difference between WH40 and T104: WH40 has manual override that sticks out of enclosure.
Both WH40 and T104 are identical otherwise: Both are heavy-duty and have replaceable 156T1978A trippers and WG1573 clock motor.
Both WH40 and T104 run cooler with less amp loss from heat, than 25-amp WH21 timer

Buy:
WH40      208-240-277Volt 10000 watt 40 amp at Amazon
T104-20 (WH40)     208-240-277V (no external switch) at Amazon
156T1978 trippers at Amazon
Replacement trippers at Amazon
Clock motor WG1573 at Amazon
10-2 wire at Amazon
Resources
Wiring diagrams: How to wire WH40
How to wire T104
WH40 manual
WH40 sell sheet
How to operate and set timer
List of replacement parts
Photographs of timer and timer parts
Troubleshoot Intermatic timer
See all Intermatic water heater timers
See more water heater timers



GE 15070 in-wall timer to control water heater.
Installation requires contactor. Timer turns contactor ON-OFF.
See timer installation
See GE 15070 timer and similar timers
WH21 timer is 25 amp timer.
Volts x Amps = Watts
Watts divided by Volts = Amps
Most residential water heaters are non-simultaneous. This means both elements are not ON at same time.
How electric water heater works
How to wire thermostats

Calculate safe maximum for timers/ electrical circuits
Read label on side of water heater for element wattage. Element wattage is tank wattage.
For example: If water heater has 5500 watt elements: 5500 watts divided by 240Volts = 22.91 amps
4500 watt water heater divided by 240Volts = 18.75 amps.
Electricians use 80% rule for safe maximum. WH21 is rated for 25 amps x .8 = 20 amps.
Calculation shows that WH21 is ok for 4500 watt water heater, but beyond safe-maximum for 5500 watt water heater.
Exceeding safe maximum means WH21 will run hot and not last as long.

If electrical device is run at-or-near maximum amp rating, the device will not last as long because of heat.
Same as running a car at full throttle. Car will not last as long.
In contrast, 40-amp WH40 and T104 timers are better long term investment for water heater timer.
WH40 and T104 are rated for 40 amps, with safe maximum of 32 amps, so they withstand more amperage without heat loss, and will last longer.
How to wire WH40
How to wire T104
Intermatic T174 timer is identical to T104, except T174 has day-skipper feature

Calculate safe maximum for water heater circuit
If residential water heater is connected to 20 amp breaker and 12 gauge wire, then the same overheating problem occurs over time.
Circuit breaker will not last as long, and damage can occur to busbar.
See basic water heater circuit
20 amp breaker is subject to 80% safe-maximum rule.
20 amp circuit breaker x .8 = 16 amps. So safe maximum for 20 amp breaker is 16 amps.
As shown above, 4500 watt water heater draws 18.75 amps. And 5500 watt water heater draws 22.91 amps.
So 20 amp breaker with 12 gauge wire are rated too small for most water heaters. Over time the breaker can wear out sooner due to overheating.

Recommended that all water heaters be connected to 30 amp breaker and 10 gauge wire.
Safe maximum for 30 amp breaker x .8 = 24 amps.
30 amp breaker and 10 gauge wire run cooler, with less heat loss and more efficiency. Circuit breaker and main box last longer with less chance for heat damage.
Figure Volts Amps Watts for water heater

Solid copper wire only
Insdulation under screw plate
Larger image
Both wires MUST be same gauge
Straighten each wire
Tighten screw very tight against copper wire


Larger image

Connect stranded and solid with wire connector and run jumper to screw plate.
See example image

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
Red 3P connector (shown) for 10-14 gauge wire
Resource:
How to select and install wire connector
10-3-wire
10-3-wire  12 Ga
10 gauge or 12 gauge?
10 gauge is larger/ for 30 amp breaker. 12 gauge is smaller/ for 20 amp breaker
10 gauge wire can have black-white or black-red
12 gauge will have black and white wires

Buy short pieces 10 and 12 gauge wire at local box store
Compare with your wire.
Match color code and amp rating for wire
With 120 and 277 Volt circuits, white wire is always Neutral, and black is Hot
Hot wire is always switched on-off. Neutral wire remains connected without switching.
With 208 and 240 circuits, both wires are Hot, and both wires carry voltage.
Either Hot wire can be switched on-off. Or both Hot wires can be switched on-off.
Add black tape when white wire carries voltage (applies to 208 and 240V circuits)
CA3750
CA3750 has 5 knock-outs
1 on back, 1 on each side and 2 on bottom

Keep enclosure door closed
Fire safety
Always keep enclosure (box) cover closed
Romex connector Use Wire connectors, or conduit clamps to secure wire to enclosure
By code, all wire must be securely attached to enclosure to prevent wire pull-out.
Wires or conduit must be secured to structure, so there are no loose wires.
Wires inside the enclosure cannot lay over top of connection terminals.
Join all ground wires together and cover with wire connector.
Push ground wires down and away from connection terminals.
2T2500GA plastic outdoor enclosure has 5 knock outs for 1/2" and 3/4" Wire connectors 1 on back, 1 on each side and 2 on bottom
More Intermatic enclosures
30 amp breaker use 10 gauge /


Buy:
10-2 gauge/ 30 amp
10-3/ 30 amp
Southwire electric tools
Yellow 12 gauge 20 amp


Yellow/ #12 gauge wire for 20 amp
with ground
Buy:
12-2 gauge/ 20 amp
12-3/ 20 amp

NMB is house wiring
UF is underground
Rolls of stranded wire
White 14 gauge 15 amp


White/ #14 gauge wire for 15 amp
with ground
Buy:
14-2 gauge/ 15 amp
14-3/ 15 amp

NMB is house wiring
UF is underground
armored cable
Buy:
Armored cable
Southwire armored cable cutter
Southwire armored cable cutter
Buy:
Rolls of stranded wire

Stranded wire
stranded wire
Buy:
Rolls of stranded wire
50-60 amp breaker use 6 gauge /
6-2 wire
Buy:
6-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
40-50 amp breaker use 8 gauge /
6-2 wire
Buy:
8-2 wire
Southwire electric tools
NMB is house wiring
UF is underground
    
Copper ground wire
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

Buy
End cutting nippers at Amazon


Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
multimeter
Buy:
Multimeter
Electrical testers
Buy
Industrial electric

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
Buy
Tools
DEWALT
Black and Decker
Stanley
SKIL
Makita
Porter-Cable
Bosch

Irwin Hand tools
Klein hand tools
Fluke electrical testing
Dremel hobby tools

Campbell Hausfeld air powered
Tekton automotive

Powerbuilt automotive
Saws and saw blades
box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
Subpanels
All control centers and parts
Enclosures
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
Din rail
Twin & one-shot
Woods
Intermatic
Tork
Low voltage power packs Recirculation systems
Buy from my affiliate links every time/ thanks:
Amazon
As an Amazon Associate I earn from qualifying purchases
Enter Amazon from any link on my site, fill cart with any item ... purchases pay small commission

E-mail: geno03245w@gmail.com
My response might end up in spam folder, check email folders
Waterheatertimer on Twitter
Message thru facebook