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Burned R1 Resistor
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| 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  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  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 |
 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 |
 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 Telephone cable knife Low Voltage Mounting Bracket for Telephone |
Push-on wire connectors in place of twist-on connectorsBuy: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 Buy 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 |
 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. Buy GFCI circuit breakers |
Push down 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 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
 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 |
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 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 |
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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 |
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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 Buy 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 |
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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 |
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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 |
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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. |
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Unburned R1 R2 resistorsNote there is no high-heat or burn residue at end of each part |
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Burned R1 resistor on timerR1 resistor burned, R2 resistor burnedLook 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 |
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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. |
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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 |
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 |
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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 |
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  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 |
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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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Buy Electronic parts Industrial supplies Tools and home improvement Home and garden Hayward pool Pentair pool Southwire electric |
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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 |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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