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Troubleshoot Intermatic T10604R
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How
to wire Intermatic T10604R Troubleshoot Intermatic T10604R Tech support options |
 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 |
 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: 1000 volt Tool kit Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
 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 |
 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: Cantex lever switch Leviton lever switch Outdoor lever switches at Amazon Resource Cantex-toggle-switch-covers.pdf Cantex-PVC-junction-boxes.pdf |
Weatherproof wire connectorConnector cavity is full of siliconeBuilt-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 |
 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 |
 Weatherproof
outlet coverSafely use extension cord with weather resistant cover Buy: Outlet covers |
 Weatherproof
boxFor adding outdoor wiring Drill through back of indoor box, and through wall to install new outdoor outlet. Buy Hubbell Bell PVC box Hubbell Bell aluminum box |
 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" and 2" 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 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 |
 T10604 240
Volt control center for 2 speed pumpUses 208-240 volt T104 and T106 timers located side-by-side inside control center. Max 40 amp (safe max 32 amp). Rated for up to 5 Hp. 12" (30.5 cm) high x 12" (30.5 cm) wide with latch x 4-1/4" (10.8 cm) deep Heavy duty, very reliable, widely available replacement parts, long lasting powder-coated Nema 3R weather-resistant enclosure. Up to twelve on-off settings per day, minimum 1 hour duration. How to operate and set T104 timers/ pdf Resource: See charts for motors: amp, distance, wire size This control panel has no circuit breaker spaces. Has 2 knockouts for 120 volt switch, outlet etc. Read information how to install and wire for 120 volt outlet/ switch  BuyT104 mechanism T106 mechanism T10604R with T106 and T104 Pentair pool Hayward pool Resources: T10604 manual Parts sheet Control centers and parts Digital control centers and parts Freeze control centers and parts |
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Step 1: Wire the control panel busbar 120 volt + 208-240 volt with breakers Use 10-3 with ground Breaker base with 8 spaces Breakers fit on either side of busbar Use single breaker for 120V, double breaker for 240 volt Resource More control panel wiring |
 Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction Damp- wet locations: For direct burial underfoot, in contact with damp soil ... or for other damp locations ... use UF-B wire ... or use plastic conduit. UF-B wire can be difficult to strip back for wiring.  |
Match
wire size and breaker amp rating If your home was wired by professional electrician who pulled permits, then circuit breaker and wire size will match. If manufactured home or travel trailer has not been altered by homeowner then breaker and wire size will match. Safe maximum of amp draw on a breaker is 80% rated value of breaker. Look at label on each load (TV, refrigerator, box fan etc). Add up total watt load on circuit. Divide the watts by the voltage on line = amps. Main breaker terminals are still Hot when main breaker is turned off. Absolute electrocution danger when removing cover off main panel. More information below. Use 600 volt solid copper wire only Do not use stranded wire inside main breaker box or any permanent box. Stranded wire can be used for connectors and plugs, but comes loose under screw terminals of breaker, switch, outlet, or timer etc when heat on wire causes expansion and contraction of wire. Do not use extension cord for permanent household wiring Extension cords are used for connectors and plugs only. Read about extension cord code Buy: Southwire at Amazon Resource: How to replace circuit breaker Ampacities source for TW and UF insulated wires: NEC table 310-16 |
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Install GFCI
circuit breaker
inside main breaker panel? Outdoor circuits are always safer with GFCI protection, and GFCI installation might be required to meet local codes. Caution, only 1 GFCI per circuit. So if your are going to install 120 volt plugs inside the panel (as shown lower on page) then these will be automatically protected by the 240 volt GFCI breaker. Illustration shows 2-pole 240Volt GFCI. The ordinary 240Volt breaker does not have white wire The GFCI 240Volt breaker has white wire that connects to neutral busbar. Buy: 240 volt GFCI breaker GFCI circuit breakers |
 Step 2:Wire the timers T10604R wiring for 2 speed pump For controlling 240 volt 2-speed pool pump (or any pump or motor up to 40 amp 5 Hp) with minimum cost and long-term reliability. Replacement parts are available and can be installed DIY using ordinary tools. T10604 consists of T104 on right side and T106 timer on left side. Both timers have a clock motor that rotates yellow dial once per day. Dial can hold up to 12 sets of trippers, for 12 off-offs per day. T10604 comes with 4 sets of trippers for 2 OFF and 2 ON each day for each timer. How it works: T104 timer controls overall on-off function for pump. T106 timer controls when pump is high or low speed. Incoming 240 volt connects to Terminals 1 and 2 on T104 timer. When T104 is OFF, then the pump is OFF. When T104 is ON, terminals 2 and 4 are activated with power. Terminal 4 sends power to COM wire on pool pump. Terminal 2 sends power to T106 timer. The T106 timer is always ON. It is either in the NO or NC position depending on clock settings. So when power arrives from T104, the T106 timer automatically sends power to either the High or Low speed wire on pump. Once the pump has power on the COM wire and either the Low or High speed wire, then the circuit is complete and pump turns ON. This means the circuit to pump is completed when the High speed wire and COM wires both have power .... or when the Low speed and COM wires have power. |
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Wiring for 2 speed pump
(same as illustration above) Uses T104 (right) and T106 (left) timers located side-by-side inside control center. Each 240 volt timer has a separate 3 watt WG1573 clock motor that rotates yellow dial 1 revolution per 24 hour period. Clock motors are reliable but can be replaced if they slow or stop operating. Both clock motors are connected to terminals 1 and 3 on T104 so they receive continuous power. Buy T104 mechanism T106 mechanism T10604R with T106 and T104 /208-240V for 2-speed pumps Pentair pool Hayward pool More wiring diagrams on following links: How to wire T104 How to wire T106 How to wire Hayward 2 speed pool pump How to wire freeze control How to wire T10404R and T10101R How to wire control centers |
| Larger image Add a freeze thermostat to T10604  When temperature drops below set point (35°F), the freeze thermostat turns on 240 volt contactor coil .... completing circuit that bypasses on-off function of T104 timer ... This sends power to pump on COM wire and sends power to T106 .... which turns on pump in either high or low speed depending on T106 timer setting. If T104 is turned on at same time freeze circuit is on, it will not matter since pump is turned on anyway. Electricity will simply choose path of least resistance to supply power to pump. Contactor and freeze thermostat can be installed directly inside the T10604 enclosure. Take care that electrical connections do not touch sides of metal enclosure. Use plastic box cover between contactor and metal enclosure as needed. If necessary, install contactor inside separate enclosure Buy: Freeze thermostat Contactor 40 amp 240 Volt coil Packard contactor Mars 2-pole and 3-pole contactors Terminal kit Blue terminals for 16-14 wire Separate enclosure    Other
freeze options: BuyPA102 mechanical thermostat and SPDT relay PF1102M 240 volt freeze thermostat Freeze control Inline freeze switch/ 15 amp max Resources: How to wire PF1202T and PF1222TB Intermatic freeze controls and manuals Resource How to make a freeze outlet |
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Install
wiring devices inside
the enclosure First remove rectangular knock-out(s) in dead front. Remove front panel Remove hex head screws from enclosure and install 21T156A stand-offs in place of screws. 6-32 Attach deco-style wiring device to standoffs. Replace front panel Buy: 21T156A stand-offs pack 4 each 21T166A stand-off 3" long / pack 2 Resource: How to wire control center GFCI Must bring 3 wire cable with 2 Hots, ground, Neutral from breaker box so the 120 volt outlets have Neutral wire. If circuit breaker is 30 amp or above, then install a line fuse to match amp rating of outlets. Buy: ANL fuseholder e2 fuseholder with platinum plating ANL fuses  |
| Wiring Tips | |
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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 |
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 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: Red 3P connector (shown) for 10-14 gauge wire Lever connectors for stranded wire |
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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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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 Buy: Southwire romex cable 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 |
| Troubleshoot
T10604R -Flip circuit breaker fully off and then back on. -Check that both clock motors are connected to terminals 1 and 2 on the T104 timer. -Observe if both clock dials are rotating 1 revolution per day. If dials are not rotating, then clock motor is bad, unit is not getting voltage, or is getting incorrect voltage. -Convert timer to either 120 Volt or 240 volt by changing clock motor Buy: 240 volt clock motor for T10404R 120 volt clock motor for T10101R -Check if each clock dial has ON and OFF trippers fastened to yellow dial. -Move both override levers to ON position and pump should turn ON. If pump worked previously and doesn't work with both overrides in ON position, then check for 240 volt across terminals 1 and 2 on T104. -If pump turns ON when overrides are in ON position, but pump does not turn ON when timers operate normally, then replace trippers. -Observe if the trippers push the override lever back and forth between ON position and OFF position. If the dial rotates tripper past the override lever, and override lever does not change position, then most likely problem is worn trippers need to be replaced.  Buy:
trippers156T1978A set 2 156T1978A trippers PA115 - 25 sets -If the trippers are sliding past the override lever, and new trippers do not solve problem, then replace timer module. Buy: T104M DPST 240 volt mechanism T106M SPDT 240 volt timer Buy 120 volt: T101M SPST 120 volt mechanism only T105M SPDT 240 volt timer - Undersized wire and breaker can cause malfunctions. - Check that motor load is working correctly. Look at rating plate on motor for voltage and amperage requirements. - Convert control center timers to either 120 Volt or 240 volt by changing clock motor Buy: 240 volt clock motor for T104 or T106 120 volt clock motor for T104 or T106 -If the above steps check OK, then check terminal connections and wires. Max 2 wires under a terminals. Do not use stranded wire. Clean corroded wires with sandpaper, or use white vinegar to help dissolve build-up on terminals. Tighten screws very tight against copper wire. Use only copper wire. |
| Repair Parts/ clock motors | |
 Look for clock number  Consumes 3 watts power |
Clock motor can
be replaced Star screws 3 watt consumption = 26,280 watts per year = 26.28 Kwh per year @ .12 = $3.15 operating cost 60 Hz for US market/ 60 Hz for Europe Asia Resource: How to replace Intermatic clock motor Adapt any timer above to different voltages: Applies to T104, T174, WH40, pool timers etc WG1573 for 60 Hz 208-277V WG1573 208-240Volt WG1570 for 60 Hz 120V WG1570 120Volt WG1576 for 60 Hz 480V WG1576 480Volt CW190-10 for 24 volt 60 Hz 24V at Intermatic America use 60 Hz power. Rest of world uses 50 Hz. 50 and 60 hertz devices are not always compatible. WG1571 motor for 50 Hz 120Volt at Intermatic WG1574 motor for 50Hz 208-277V Amazon |
Buy trippers 156T1978A set 2 156T1978A trippers PA115 - 25 sets Intermatic mail-in order form Timer dial can hold 12 sets 1 on- 1 off for each 24 hour period |
 Fireman switch turns off pool heater 10 minutes before pool pump turns off. Pool heater must have fireman connection. Do not connect power wires inside timer to fireman switch... the heater connects to fireman switch Can be installed on any T100 series timer. Resources Fireman's switch pdf How to wire fireman's switch Buy: 156T4042A Fireman switch Amazon |
 156T6738A insulators Add Insulator to override switch for electric safety  Buy: 124T1948 single pole for T101, T102, T105 124T1952 double-pole for T103, T104, T106 |
| Add a transformer to get 120 volt | |
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Convert 240 volt to 120 volt
using step down
power transformers Reliable ... efficient ... no moving parts ... years of service ..... requires enclosure 5.1 x 5.6 x 3.6 inches ; 3 pounds Connect 240 volt incoming voltage to Primary side, connect 120 volt output wires to secondary side. Inputs and outputs are AC. Buy: Siemens industrial transformers Choose enclosure that is large enough Bud industries hinged box 6x8x4 Metal outdoor Enclosure/ with 1/2-3/4" knockouts Polycarbonate enclosures drill for knockouts Thomas and Betts 6x6x4 plastic with cover at Amazon Bud industries 11x7x5 box no knockouts Tapered drill bit 1/4"-1-3/8 holes  Example Nema 3R indoor outdoor enclosures   |
  Example
wiring diagram for transformerIf the input voltage is 220-230-240 volt, then connect one wire to terminals H1 and H3, connect other wire to H2 and H4. If input voltage is 440-460-480 volt (480 for Americas), then connect one wire to H1 and other wire to H4, then jumper a wire between H2 and H3. Larger image of transformer Buy: Siemens MT0050 industrial transformer Note: 60 Hz Hot to Hot 240 volt is for power grid in Americas, 50 Hz Hot to Neutral 230 for Europe, and 50 Hz Hot to Neutral 220 for Australia etc. |
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 Neutral wire on output? When ordering: "If the dual voltage is separated by an “X” (120 x 240), the transformer can be connected only for 120 volts or 240 volts, and no neutral is available. But, if dual voltage is separated by a “slash” (120/240), an additional Neutral connection is possible since the mid-point becomes available for 240/120 3-wire operation." Resource pdf pg 4 Read more about transformers |
Encapsulated step down
Transformers/ Typical
household use would be to step 240 volt down to 120 volt. Convert 240Volt to 120Volt without needing neutral wire from breaker box Convert 480Volt to 240Volt  Type
3R indoor/outdoor enclosure480 volt to 240 volt Wiring not illustrated Two wires from 480Volt input connect to H1 and H4 on the Primary side, and then H2 and H3 are twisted together and covered with wire nut. Secondary output 240V, 1 wire connects to X1 and X3 and other wire to X2 and X4 240 volt to 120 volt Wiring shows Fig-55 Two wires from 240Volt input connect to H2 and H3 on Primary side, and then H1 and H4 are twisted together and covered with wire nut. Shown with Red arrow on Fig-Acme-1  Secondary
output 120V, 1 wire connects to X1 and X3
and other wire to X2 and X4.
Shown Green arrow on Fig-Acme-1Secondary output with 120/240V, 1 wire to X1 or X2 or X4. Then X2 and X3 are twisted together and covered with wire nut. Shown with Blue arrow on Fig-Acme-1 Buy: 500 watt 240-120 volt step down 1000 watt 240-120 volt step down 1000 watt step down 2000 watt 240 volt to 120 volt step down Encapsulated transformers Acme step down - 120/240 primary/ 120 240 secondary Resources: Acme ransformer wiring Dry transformer installation Match wire and breaker size How to wire a subpanel Read about household single-phase electricity Read about 3-phase How to wire 3-phase timers |
 Larger image Build your own 2 speed controller Any Hp motor or pump 40 amp relay & contactor = 5 Hp @ 240 volt Buy from my affiliate links: Buy 40 amp contactor with 120 volt coil 40 Amp DPDT relay at Amazon Siemens power relays Schneider W199 relay NTE open frame relays Packard DPDT fan relay Magnecraft 50-1289-1 relay box and cover Fiberglasss enclosures Resources: How to assemble parts Compare programmable timers Wire size and amp charts for motors Information on contactors Enclosures and boxes |
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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 |
