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How to repair EH40 timer
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.

Buy:
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
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
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.

Buy
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
EH40Larger image
EH40 240Volt timer

30 Amp programmable/ DPST
Nema1 indoor enclosure
Minimum 1 minute set times
Up to 6 on-off per week
AA battery for backup and power-outage carryover
1 year limited warranty
Override button located on face of timer.
Temperature range -40ºF to 104ºF/ back-up battery will fail when exposed to freezing temperatures
7-3/4" high x 3" deep x 5" wide
Use 10 gauge wire, 30 amp breaker rated for 4500+ watt element

Inductive: 30 Amp, 240 VAC
Resistive: 30 Amp, 240 VAC
Tungsten: 5 Amp, 240 VAC
1 ½ HP, 240 VAC
Reset timer using reset button before programming

 If you are using EH40 for a Load (light, fan, motor, appliance etc) that consumes more than 30 amps, then timer can overheat and fail.
For exampe, EH40 is wrong timer for 2 Hp irrigation pump. You need a 40 amp timer. Resource: How to wire T104 timer
 If EH40 is exposed to high heat or freezing temps, then these enviromental conditions can cause timer to fail.
 If EH40 is installed for outdoor use, or a damp location, it can fail.
To help reduce problem, install EH40 inside Nema3R weather resistant enclosure. Buy: Nema3R enclosure
EH40 timer Basic troubleshoot steps
-Flip circuit breaker fully off and then fully on to make sure timer has power
-Test for 240 volts across terminals 1 and 2
-Check AA battery located below the buttons, replace with new, clean terminals
-Reset timer and reprogram
Buy:
Intermatic EH40 timer
30 amp timers
Electrical testers
Resources:
240V EH40 manual
Figure volts amps watts of water heater
How to wire EH40 water heater timer
Compare all box timers

EH40 is battery operated timer

Battery compartment located beneath buttons
Size AA battery lasts 2-3 years
Clean battery terminals, If terminals are corroded, the timer may be not functional. Clean with white vinegar using q-tip to remove corrosion.
Install new battery, reset timer using reset button, reprogram and see if function is restored.
Buy:
Batteries
Check load rating:
EH40 is rated for 240 volt AC alternating current at 60Hz
(Hz is number of rotations per second of power plant generator: US and Americas 60Hz. Europe, Asia, Africa etc 50 Hz)

30A resistive at 240V AC.
30A inductive (motor, LED) 2.0 hp at 240V AC.
5.0A at 240V AC Tungsten (incandescent light bulb)

EH40 is rated for 4500-5500 watt 240 volt water heater
Is the Load working?
Load is the water heater, motor, light bult etc.
Check if load is functioning: by-pass relay terminals and hardwire directly to terminals 1-2
Don't assume override is functioning

Do not expose timer to freezing temperatures: battery will fail

EH40 timer wiring
Is one relay working?
EH40 has 2 relays, terminals 3-4 and terminals 5-6...
240 volt circuit has 2 hot wires... and EH40 has 1 relay for each hot wire
But 240V load can also be switched on-off using 1 relay
If one relay stops working, you can use the other relay and control circuit
Test EH40 to see if one relay is still good:
First, test terminals 1-2 to makes to sure you have 240V
Next, Turn timer ON using the override button
Test across terminals 2 and 4 for 240 volt
Test across terminals 1 and 6 for 240 volt

EH40 wiring By-pass one relay and timer still controls 240 volt
If one test reveals 240V and other test reveals 0 volts, then 1 relay is good and other relay is bad.
By-pass the bad relay by moving wire from terminal 4 to terminal 3 -or move wire from terminal 6 to terminal 5

Resources:
T100 series timers and manuals
How to wire T100 series
How to set box timers
Troubleshoot box timers
Trippers and parts
Model numbers, and manuals
How-to-troubleshoot-Intermatic-timer.html
Match wire size and breaker and load
Timer caught fire

Are there any loose or burned wires?

Loose wire will spark and cause carbon deposits, melt end of wire, melt insulation or screw plate or start fire.
Prevent major issue by keeping enclosure door closed all all times.... this will reduce damage, starve fire from oxygen and extinguish flames.

Cut back melted part of wire, clean up screw plate if possible, reattach wire, use only solid copper wire, never stranded wire, reset timer, change battery and check timer functionality.

10 gauge wire and 30 amp breaker is rated for 4500+ watt water heater
Timer is rated 30 amp
EH40 does not have a connection terminal for Neutral.
Neutral is not needed for 240 volt circuits.

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
Use correct wire and breaker
Use only 600 volt solid copper wire
Match amp load with wire size and breaker
All 3 ... amps ... wire size ... and breaker ... must be matched

Breakers are rated by amps.
Each breaker is rated for 80% safe maximum
So 30 amp breaker has safe max 30 x .80 = 24 amps

Each load (light, motor, appliance etc) has a watt and volt rating.
Figure amps for load:
If load is 4500 watt water heater, that is connected to 240 volt ...
then divide 4500 watts by 240 volts = 18.75 amps
18.75 amps exceeds safe max for 20 amp breaker (16 amps)
Use 30 amp breaker

Each breaker has a corresponding wire size
20 amp breaker: use 12 gauge wire
30 amp breaker: use 10 gauge wire

Resources:
Wire and breaker sizes
Figure volts amps watts for water heater
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
Basic electric safety can include:
Adding black tape when White wire carries voltage (applies to 208 and 240V circuits)
Why? Black tape on White wire identifies wire is Hot and not Neutral
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
Never use aluminum wire
Aluminum can only be used if device, timer, outlet, etc is rated CO/AL
CO for copper ... AL for aluminum.
Intermatic timers are NOT rated for AL aluminum wire
Did a surge event cause failure?
Nearby lightning strike can destroy electronics throughout facility
Make sure all loads and circuit are properly grounded
Press reset button, reprogram
Install type 1-2 surge protection inside main breaker box
Install type 3 surge close to water heater
Buy 240 volt/ 7-day:
Intermatic EH40 timer at Amazon
30 amp timers
Intermatic surge protection

Resource:
Compare box timers
How to wire EH40 timer
EH40 in exterior enclosureEH40 can be installed inside a PLASTIC OR METAL OUTDOOR ENCLOSURE
Be mindful that EH40 is battery operated.
Batteries grow weak much faster in cold temperatures (for example car battery ... which is rated for cold)
The AA battery is not rated for continual exposure to very cold temperatures.
However, unlike the standard Nema1 indoor inclosure that comes with EH40, a Nema 3R outdoor enclosure can protect against dust and dirt accumulation, in addition to outdoor rain.
Buy:
Nema 3R metal enclosure 2T2485GA
Nema 3R plastic enclosure 2T2485GA
Resources:
Boxes and enclosures
Code for installing electric boxes

Other choices can include the 30 amp  ET1700 series
Buy:
ET1705C/            Steel indoor box/ 30 amp/ 7-day/ SPST programmable/ at Amazon
ET1705CPD82/   Plastic outdoor box w/ see-thru door/ 30 amp
ET1705CR/          Steel outdoor box/ 30 amp
Resource:
ET series timers and manuals

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
wire connector assortment

Twist-on wire connector assortments

Do not reuse old connectors
Twist wire connector very tight. Pull wires to ensure they will not come loose. Cover all bare copper.
Buy:
Connector assortment at Amazon
Connector assortment at Amazon
Resource
How to select and install twist-on wire connectors
Weatherproof wire connector

Weatherproof wire connector

Connector cavity is full of silicone
Built-in cover keeps silicone in place
Protect from water, dust etc
Buy from my affiliate links
Weatherproof size 14 to 6 Amazon
Weatherproof size 22 to 8 Amazon

Resource
How to select and install connectors
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
remove cable staple
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

 
linesman pliers

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 nuts®, 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

How to wire contactors/ relays
Busman HKP-HH fuse holder
How to wire inline fuseholder
AH3 off delay timer
How to wire delay timers
How to wire twin timers
Support the economy:
Buy water heaters from my associate links:

50 gallon Gas water heaters at Amazon
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Resources:
How to install gas water heater
How to install electric water heater
Troubleshoot gas water heater
Troubleshoot electric water heater
Point of use water heaters
Resources:
Troubleshoot Gas valves with manuals
Icon gas valve

How to replace water heater element Waste King disposal
How to wire tankless electric


Install point of use water heater
Titan tankless

Contactors/ relays
Install and troubleshoot garbage disposal Waste King disposal
Programmable timers

Woods timers
surge protection
Anode rods anode rods
Recirculation system

Tankless recirculation
Point of use water heater
Type 1 and type 2 surge protection surge protection
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Electronics

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
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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
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