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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 |
 120 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  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 |
 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 |
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 |
 Weatherproof
lever switch on outdoor lightsSafely 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 |
Buy: |
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 |
 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 |
  Larger image240 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. 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 |
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 Testing safety Tape 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 |
 Resource: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 |
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| 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. |
|
 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 |
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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 |
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 Solid copper wire only |
 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 |
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 |
  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 |
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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) |
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 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 |
 |
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 |
 Buy: Armored cable |
 Southwire armored cable cutter Buy: Rolls of stranded wire |
Stranded wire  Buy: Rolls of stranded wire |
50-60
amp breaker use 6 gauge /  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 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 |
 Buy: Multimeter Electrical testers |
 | Buy
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