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2014

Timer caught fire/ 

Fire inside timer/ Overheating

timer fire

Timer fire:

Cause: Stranded wire under COM2 terminal got hot, came loose and caused fire

Solution:
Replace timer
When installing timer, Use only solid copper wire
Solder end of stranded wire to make solid

Resource for timer manuals, wiring and purchase
GM40 series, GE 15000 series, Tork series
Intermatic defrost timers

Resources:
Match breaker and wire size

Fire inside timer caused by stranded wire
Keep enclosure door closed at all times
add solder to stranded wire

Fire caused by stranded wire

Do not use stranded wire under screw plate on timer, contactor, relay, outlet, switch or any electrical device

Stranded wire must be soldered or bonded to terminal / Heat from amperage can loosen wire and eventually cause arcing and fire

Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Buy:
soldering guns
Resource

Terminals
What is amperage
Basic house wiring
How to troubleshoot household electricity
Install arc fault breaker

Arc fault breaker will prevent fire inside timer caused by a loose wire or stranded wire

Arc fault breaker trips when there is short to ground (same as GFCI) but it also trips when a spark is detected on the line
Spark from loose wire will trip breaker... this will signal that wire is loose under the screw plate, or there is a ground fault on the line
Only one GFCI-protection device per circuit... so you cannot have GFCI and Arc fault on same circuit... nor can you have 2 GFCIs on same circuit.... they will cause tripping
It is OK to have more than one ordinary breaker or fuse per circuit

Buy
Arc fault breakers at Amazon

Resource:
How to wire arc fault
How to wire GFCI
burned resistor on timer

Burned resistor on timer

R1 resistor burned, R2 resistor burned

Replace timer
No prevention steps
Check that timer is receiving correct voltage and Load does not exceed rating.

This is common 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
This is true with older and newer models in the GM and Woods and Tork series digital timers, including defrost series

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


Resource:
Match breaker and wire size

Figure volts amps watts
More resources:
Compare all box timers
Compare same/similar types of timers
GM series defrost timers
R1 resistor

Unburned R1 R2 resistors

Note there are no high-heat or burn residue at end of each part
burned timer

Relay points

Points on timer relay can get burned
It is normal for carbon to build up on points, causing loss of electrical contact.
Turn power off, and use nail file to clean points

There are no replacement relays for these timers... but you can clean points with a nail file... and if relay is bad, frequently one of the two relays will still function, and load can be controlled by turning off 1 hot wire

Resources:
How to wire GM40 timer
Difference between relay and contactor
Contactors

prevent timer fire

Keep enclosure door closed

All electical connections must be made inside a box, and each box must have cover or dor to stop fire from spreading
High heat even will be confined inside the box, and provide fire safety

All electrical devices have amp rating and max amp overload rating

Resource:
Why you need ground wire
Fire inside Intermatic timer

Keep enclosure door closed

Outlet is warm   circuit breakers are warm Resource
How to troubleshoot household electricity


Causes: timer fire

Insdulation under screw plate
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.
Or add solder to stranded wire to make solid.
See example image

Fire safety

Use only solid copper wire, and no insulation under screw plate.

Max 2 wires under screw plate

Both wires same gauge

Do not use stranded wire, it will come loose with heat expansion and overheat and cause burning. Turn stranded wire into solid wire by soldering stranded wire.

Always keep enclosure (box) cover closed

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
Push-on connector is preferred for water heater thermostats or higher heat installations
Run jumper to screw terminal.
Buy:
Push on wire connectors at Amazon
Red 3P connector (shown) for 10-14 gauge wire
Lever nuts for stranded wire at Amazon
Resource:
How to select and install wire connector
10-3-wire
10-3-wire  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.
Resource
Match color code and amp rating for wire
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)
CA3750
5 knock-outs
1 on back, 1 on each side and 2 on bottom

Keep enclosure door closed
Romex connector

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
Resources:
More Intermatic enclosures
Wire clamps

Burned part on electric water heater

Replace part, cut back burned wire
Resource:
Electric water heater parts and replacement


Multimeter

Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy:
Multimeters at Amazon
Electric testers at Amazon 
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 electrcial repairs

Resource:
Basic house wiring

Non-contact voltage tester

Test for power without touching connectorss
NEVER assume power is OFF
Buy:

Non-contact voltage tester Amazon
Electric testers at Amazon
 
Resource:
How to test electric power is off

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Read about terminals
wire connector assortment

Twist-on wire connector assortments

Do not reuse old connectors 
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 twist-on wire connectors
Wire connector wrench

Wrench to apply wire connectors

Tighten connector 
Buy

Wire connector blaster
Twist connector wrenches at Amazon

Resources:
How to twist wire
How to select and install twist-on wire connectors
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
add solder to stranded wire

Turn stranded wire into solid wire

Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire

linesman pliers
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
End cutting nippers at Amazon

Fire inside timer caused by stranded wire
Keep enclosure door closed at all times

Fire caused by stranded wire

Do not use stranded wire under screw plate

Applies to timers, switches, outlets, pumps etc.
Small devices, with small loads, such as lamp socket, stranded wire is fine
Add solder to 1" length of tightly twisted stranded wire to make into solid wire
Heat wire. Touch solder to wire. Let cool. File away over-solder.
Buy:
soldering guns
Resource

Timer caught fire
Basic household wiring
Basic water heater circuit

Figure volts amps watts for electric water heater
Test elements
Replace elements
How to wire tankless electric
How to change water heater temperature using timer
Change water heater from 240Volt to 120Volt
Replace thermostats
How to wire thermostats
How to wire water heater for off peak operation

How to twist wire
How to wire Cooper 277 pilot light switch
How to wire combo switch-outlet
How to replace 3-speed fan switch
 

How to wire dimmer
How to wire 3-way dimmer
How to wire occupancy switch
How to wire motion detector
How to wire TM811 and TM8111 switches
How to wire wall timers
How to wire box timers
How to wire off-delay timer
Wire off-delay timer
How to wire pin timers

How to wire and troubleshoot photo eyes
Reverse photoeye so it turns on in day
24 Volt photoeye
24 volt programmable timer

How to wire switches
How to add switch
How to add 3-way switch


Timer for 3-way switch
Timer for 4-way switch

How to add outlet 
How to wire 3-way switches
How to wire 4-way switches


Troubleshoot Malibu outdoor lights
Terminals 
Select and install wire connectors
Select wire size

Electrical formulas
Electricians forum
 

Electrical pages


How to wire arc fault breaker
How to wire GFCI
How to wire GFCI combo

Basic water heater circuit
How to wire water heater for 120Volt
Install old work box

How to drop wire from attic
Wire connector

How to wire 240volt outlets
How to install 3-phase timer
How to wire 3-phase outlets
How to wire 3-phase surge protector
What is 3-phase

How to wire whole house surge protector
How to wire under-counter water heater
 

See inside main breaker box
Replace breaker
Install subpanel

Fuseholder
Contactors
How to solder wires
Whole house surge protector
3-phase surge protection
Circuit breakers

Difference between 120 volt and 240 Volt
Difference between 50Hz and 60Hz
How to install electric meter on water heater
How to wire water heater thermostat
How to wire water heater with switches and timers

6x6x4 Enclosures
Intermatic timer enclosures

Convert AC water heater to DC
How to wire DC solar water heater
DC relays for solar water heater
How to add another thermostat to water heater

How many Kwh to heat water
Chart for figuring heating time for electric heater

Gas and electric water heaters Support the economy:
Buy water heaters  from my associate links:

50 gallon Gas water heaters at Amazon
40 gallon gas water heaters at Amazon
50 gallon Electric water heaters at Amazon
40 gallon electric water heaters at Amazon
Hybrid / heat pump/ water heaters at Amazon

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
Gas and electric water heaters Industrial electric at Amazon

Industrial supplies at Amazon

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box timers Compare box timers

Compare ways to control Gas and Electric heaters
Intermatic control centers Control centers:
+ manuals and parts


All control centers and parts

Including Z-wave
programmable timer Compare programmable timers

Control water heater with programmable wall timer
Countdown timers Compare countdown timers

Control water heater with countdown timer

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