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Wiring detailsReturn to Page 1: Overview and buy materials for timer project Return to page 2: Assembly and wiring for timer project Resource: safe electric wiring |
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Use
hammer and screwdriver to remove knock outs Hit with sharp strike of hammer, and then twist out blank using pliers Use linesman pliers to bend and then remove extra metal for larger hole Fill unused holes with snap-in plug from electric dept. Use tapered drill bit to make hole anywhere Buy tapered drill/ step drill bit for any size hole Step drill bits at Amazon Neiko tapered drill bit 1/4"-1-3/8 holes |
 Contactor shown is safe for 1 residential water heater. Use 1 contactor per each water heater |
Bolt contactor
into 6x6x4 enclosure using #8-32 bolts Buy: Indoor 6x6x4 metal pull box with cover and knock-outs Indoor 6x6x4 pull box with knockouts on 4 sides/ Wiegman Outdoor 6x6x4 box with bottom knockouts Indoor 6x6x4 metal pull box with cover and knock-outs/ Raco Indoor/ hinged door 10x10 x 6 / Bud Industries Indoor / hinged door/ 6x8x4 box / Bud Industries Bud industries boxes at Amazon Arlington boxes at Amazon Resource 6x6x4 boxes Contactors |
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Install
old work box/ inside hollow wall Drop one end of 14-2 wire into old-work box I prefer 14 gauge wire for this project because it is easier to connect to fuseholder if fuseholder requires solder connection. Also 14 gauge is easier to bend, and to easier to attach to small wires on timer  Resource See How to install old-work box |
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Connect solid wire to stranded
wire 1) Strip stranded wire longer 2) Wrap stranded around solid wire 3) Twist wire connector over both wires 4) Twist wire connector very tight 5) Pull stranded wire and make sure it will not come loose Do NOT solder end of stranded wire to make solid ... amperage will melt solder. Connect stranded wire to short jumper of solid copper wire and cover with twist on connector |
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Wire
connector must cover all exposed wire Solid copper wires do not need to be twisted to make good connection. Stranded-to-stranded and solid-to-stranded need to be twisted. Do not use aluminum wire. Twist connector very tight so it will not fall off. Use only wire connectors with metal coil inside so it will bite into copper wire. Do not re-use old wire connectors. Always use new wire connectors. |
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Install
busman fuseholder Drill 1/2" hole Install Busman fuse holder with 15A fuse Push fuseholder cap inward and twist to open fuseholder Cartridge fuse installs either end first Fit fuse into fuseholder cap snugly, and then insert into fuseholder Push in and rotate cap to make connection Buy Buy fuseholders ANL fuseholder Best electric practice: Solder wires before installing fuse Hot wire from contactor will connect to top fuseholder connection. Wire going to timer will connect to side of fuseholder Electrically separate these connections by bending away from each other and/or adding tape as insulator |
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Why fuse is required To avoid fire hazard. To protect 15 amp timer and 14 gauge wire from too many Amps, and overheating. This water heater timer project draws 120 Volts off 'one leg' of the 240 Volt 30Amp water heater circuit. It is against code to connect 15 amp wires and timers to 30 amp circuit without fuse protection. 15 Amp fuse will protect wire between contactor and fuseholder, protect wire going to and from timer, and protect timer. |
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Buy
fuseholder that accepts terminals Solder can melt with the flow of amperage Solder can only be used for structural wiring such as intercom, phone, doorbell etc Buy: Terminal kit at Amazon with crimp tool Electrical terminals at Amazon Blue 14-16 gauge female terminals 20 pcs at Amazon Yellow 12-10 gauge female terminal 16 pcs 360 pc assortment at Amazon |
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Use
terminals for solid wire or stranded wire Yellow female for #10-12 wire Blue female for #14-16 wire Crimp terminal onto wire/ also suggest soldering Resource Read more about terminals |
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Terminal
connections required for contactor See additional image: Resource Read more about contactors Each water heater must have a separate contactor See illustration for controlling 2 water heaters to same timer |
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Wires
connected to contactor There is notched groove on either side of screw Wire must fit into groove Straighten copper end of wire No insulation can be under screw Tighten screws VERY tight |
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Do
NOT use stranded wire or install solid wire and stranded wire under
same screw
Do NOT install #10 and #14 wire under same screw With the contactor on this project:, install only #10 wire under screw on contactor Install #14 wire to contactor using female terminal: illustrations show above Stranded wire can be connected to solid wire using wire connector, and then put stranded under screw plate. Stranded wire can gradually loosen under screw plates as wire is heated and cooled by current (amperage = heat). Eventally the lose wire starts to arc and then |
 Illustration shows #14 ground wire from timer connected to metal box using green ground screw |
Metal
box requires grounding/ plastic box does not require grounded box 2 ground screws/ drill hole in box and thread with 10-32 tap |
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Ground
wires that are connected with wire connector must be down and away from
all
other wires Straighten ends of wire Keep ends of wire aligned Apply wire connector very tightly |
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Push
ground wires down and away from all other wires If any wire comes loose from wire connector, the connection must be re-done using new wire connector ResourceHow to select right wire connector |
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All
wires entering box MUST be held firmly in place with clamp Resource Read about wire clamps: |
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Here
is where we are so far All open wires are stapled to solid structure. Wire inside wall cannot be stapled to structure, but is secured inside wall by old work box Work inside 6x6x4 enclosure >Note: Wire connector used in each hole where wire enters enclosure >Mount contactor at angle using 8-32 bolts with lock nut >Attach 10-2 wire from breaker to one side of contactor >Attach 10-2 wire going to water heater to other side of contactor >Put 2 green ground screws in bottom of 6x6x4 metal box (when using 6x6x4 plastic enclosure: connect all grounds with wire connector) >Connect all ground screws |
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How
to install 240Volt indicator light Drill 1/2" hole in enclosure Indicator will light up when power is turned ON going to water heater Does not tell you if water heater is actually working. As long as wires remain inside enclosure, fuse protection on pilot light wires is not required. If you are installing the pilot light in remote location, and run wires outside of box, then wires must be fuse-protected or must be 10 gauge wires. Buy: 240Volt Pilot light at Amazon 120Volt pilot light at Amazon Indicator lights at Amazon Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon |
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240
Volt pilot light/ Pilot light turns ON when water heater is sending
power to element Element and thermostat wiring must be identical to wiring shown If upper element is burned out, then tank will have no hot water. If lower element is burned out, then tank will have less hot water. If ECO reset button, located on upper thermostat, is tripped, then power is not available to elements. Required in-line fuseholder and 120Volt 15 amp ceramic fuse located on black wire, and another fuseholder on red wire, going to pilot light. This is to protect pilot light and wire-to-pilot-light from 30 amp overheat danger Insulation must be put back over thermostats, and metal cover re-installed on front of water heater for heater to operate correctly and safely. if thermostats exposed to room-temperature air, they will not read temperature correctly. Buy contactor and indicator/pilot light Panel mount fuse holders at Amazon ANL fuseholder Buy fuseholders at Amazon 240Volt Pilot light at Amazon Indicator lights at Amazon Resources: How to wire water heater pilot light for 120V or 240V How non-simultaneous household water heaters work How to wire water heater thermostats Inline fuseholders See inside main breaker box Troubleshoot electric water heater |
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Install
cover over 6x6x4 enclosure
All boxes and switches and panels must have cover. All boxes and switches and panels must have cover Cover ensures containment of spark and possible fire hazard Resource Troubleshoot household electricity |
 Each
water heater must have a separate contactor see
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Project is done |
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Use
timer and save
Resource Family chart for setting water heater timer Bath and shower Hot water usage |
 Contactors/ relays |
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