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Photos
of WH40 timer/ same as T100 series timers More Intermatic timers and manuals |
 Mechanism only Mechanism with fireman switch |
To replace mechanism Turn power OFF Take photo of wires Remove plastic insulator covering wires Disconnect wires from timers Push thumb spring located top left side inside box Thumb spring will release mechanism Tip mechanism out and lift upward to remove Buy: T101M 120V SPST T102M 208-277volt SPST T103M 120V SPST T104M 208-277V DPST T104M201 same as T104 except with fireman switch T106M 208-277V with NO NC terminals |
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Release timer from box using thumb spring |
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 Never
assume power is OFFUse non-contact voltage tester on timer, on wire, on outlet to see if power is present. Press button on tester, if single beep then no power is present. If continuous beep then power is present. Never stand on bare ground, always stand on dry boards, do not hold or touch anything metal when working on timer or water heater that has power, tape tester leads to wood sticks, never touch wet water heater, or flooded water heater, or timer that had a short or fire without turning power OFF. Buy: Multimeters Buy non-contact voltage tester Electric testers Shop Amazon - Industrial and scientific Shop Amazon - Electronic Products Resources: How to test is water heater electricity is OFF |
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How
to set and operate When insulator is installed, it is safe to touch inside of timer. Always keep door closed to avoid fire hazard from sparking.   Resources: How to set and operate T100 series timers |
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WH40
timer /has override on front of timer Override lever clicks back-and-forth as trippers turn water heater on-off. If you move manual override lever, then regular timing schedule resumes at next tripper when the tripper moves override lever. Buy: WH40 timer |
 Wire color can vary |
Resources: More wiring diagrams How to wire water heater thermostats Troubleshoot electric water heater Off-peak ideas See inside main breaker box Difference between 120V and 240V Convert water heater to 120Volts Change WH40 into 120Volt timer Change clock motor from WG1573 to WG1570 Buy: WG1570 120 volt clock motor |
 Larger image 240V clock wires from back of timer connect to terminals 1&3 156T1978A tripper WG1573 clock motor |
Basic
wiring diagram: Intermatic WH40, T104, T104-20, T174 208-240 Volt timer Resources: WH40 manual How to wire WH40 Same wiring at T104 series, T174 series, and Pool timers: T104R3, T104P201, T104R201 etc. Intermatic pool timers How to set and operate T100 series timers Trippers and parts |
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WH40
wires identical to T104 timer Resources: How to wire T104 same as WH40 |
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208-240VLarger image 208-240 volt 3-phase |
WH40
controls 3-phase Resources: WH40 controls 3-phase How to wire 3-phase timer What is 3-phase electricity |
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Choose
wire and breaker size Resources: Color code and amp ratings for wire Figure volts amps watts for water heater |
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Pointer
is stationary and points at 6:00 position Store extra trippers on dial by putting 2 off trippers next to each other Minimum on-off 1 hour because of tripper thickness 156T1978A tripper WG1573 clock motor Resources: How to set and operate WH40 timer |
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Operation: Off tripper pushes lever. On tripper pushes same lever other direction Lever is also connected to override lever. Override lever snaps back-and-forth each time tripper moves lever. Trippers are softer metal than lever. Trippers are designed to wear out so timer lasts decades with replaceable trippers and clock motors. 15 minute delay Trippers rotate around on the dial. After the tripper moves the lever, then the tripper is still blocking the manual override lever from moving to another position until after the tripper rotates out of the way. This takes 15 minutes. |
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Tripper lever can become worn. Remove yellow dial. Inspect the point where tripper hits the tripper lever. Ideal conditions the tripper wears out before the tripper lever. But if grease is allowed to dry out then the lever can wear down before the tripper. Symptoms of this problem would be timer not functioning after new trippers are installed. If the trip or lever is worn down as shown in photograph then a new timer needs to be purchased. The trip lever is not sold separately except with new mechanism. Resource T100 series timers |
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Trippers
for Intermatic T100 series 156T1978A tripper 2 sets ON and OFF trippers Trippers are softer metal and are designed to wear out without damaging timer. Buy: 156T1978A set 2 Resources: Intermatic trippers |
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Maintain
WH40 Noisy operation, and prolong life of timer Clean with compressed air Apply white grease on tripper lever & gears Turn off power, and spray flammable WD40 on gears to lubricate Buy: White grease WD40 |
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Yellow
dial can be removedRemove yellow dial by removing 6-32 x 1/2" screw using size T-15 star screwdriver bit. Remove spring, and add bit of white grease to spring where it rotates against pointer. Move override lever to ON position. Yellow dial lifts off of center shaft. Add bit of white grease to outside of center post.. Motor gear rotates small gear, and small gear rotates big gear attached to yellow dial. Yellow dial rotates around center post. Clean timer: Turn off power, pull timer out of box, Clean out timer with compressed air, and spray WD40, add a bit of white grease to lever where trippers make contact | |||||
Back
of WH40When the override lever clicks, the lever directly moves a slide bar located on back of timer that mechanically opens-closes electrical contacts. Closed switch mean light bulb is ON. Open switch means light bulb is OFF. T100 series design ensures that brass contact points cannot stick or arc-fuse together Another image |
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Plastic
gears will strip out before damaging metal gears of timer mechanism So timer lasts many years, and clock motor can be replaced |
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WG1573
clock motor
can be replacedResources: How to replace Intermatic clock motor How to troubleshoot Intermatic timer Intermatic replacement parts Maintain WH40 White grease on override & gears Clean with compressed air Turn off power, and spray flammable WD40 on parts to lubricate |
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 Look for clock number  Consumes 3 watts power |
WG1573
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 Buy replacement clock motor for WH40: 240Volt WG1573 Resource: How to replace Intermatic clock motor Adapt WH40 to different voltages: Buy clock motors: Change Intermatic timers by changing clock motor Change WH40 into 120Volt, 24Volt, 480Volt, etc by changing clock motor 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 Buy 50 Hz for T100 series/ for europe, asia etc America use 60 Hz power. Rest of world uses 50 Hz. 50 and 60 hertz devices are not compatible. WG1571 motor for 50 Hz 120Volt at Intermatic WG1574 motor for 50Hz 208-277V Amazon |
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Older
WH40 still ticking Less space for wiring Some older models use same parts. New T104M mechanism still snaps into enclosure Resources: Intermatic replacement parts |
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Tork
IAP adapter Any timer can fit into Intermatic enclosure Just buy another Intermatic timer, and snap new timer into old enclosure. Buy IAP adapter Tork timer Resources: Intermatic enclosures Tork timers and manuals |
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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 |
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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 |
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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 |
