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Burned R1 Resistor
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 MultimeterTest for breaks in wire/ Test for voltageMost 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 electrical repairs Resource: Basic house wiring |
 Non-contact voltage testerTest for power without touching connectorsNEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resource: How to test electric power is off |
Twist-on wire connector assortmentsDo not reuse old connectorsBuy: Connector assortment at Amazon Connector assortment at Amazon Resource How to select and install twist-on wire connectors |
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 |
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 |
 Buy: Blue for 16-14 wire Yellow for 12-10 wire Resource: How to install terminals |
 TerminalsBuy:Terminal kit Blue for 16-14 wire Yellow for 12-10 wire |
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 |
 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 Utility knife at Amazon End cutting nippers at Amazon |
 Use solid copper wire Fire inside timer caused by stranded wire Keep enclosure door closed at all times Buy: soldering guns Resource Timer caught fire |
 Buy 24 hour: GE 15135 24-hour/ 40 amp/ outdoor metal box 56922 plastic box at Amazon Resources: 15207 Manual Quick-start guide to wiring More GE timers and manuals |
 Buy 24 hour or 7-day: GE 15136/ 7 day/ 7 programs /40 amp/ outdoor metal box Resources: GE 15132 manual How to wire GE 15136 More GE timers and manuals |
 Buy 24 hour: Woods 59402 timer Resources: 59401 and 59402 manual 59402 sell sheet More Woods timers |
 Larger image Permanent ON-OFF override Buy 24 hour/ or 7-day DTU40 At Amazon Resources: DTU40 instruction manual Sell sheet with model numbers |
 GM40 series 7-day and 24 hour Resources: GM 40 series timers with same wiring Compare all box timers |
 Resources: Intermatic 24 hour timers Tork box timers Compare all box timers |
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and R2 resistors are a failure point on the timers shown above. You can identify the problem by looking at the base of the resistors located on upper left corner on front of timer circuit board. There will be a slight burned spot at the point where these resistors are soldered. When this point is burned, there is no recovery. Test the relays. Some timer functions might still operate. For example, one fellow discovered that one-of-the-two relays still worked. Note: 240 volt can be turned on-off with one relay. The relays K1 and K2 from the GM40 may have different coil resistances, affecting the transfer efficiency on R1 and R2, causing them to overheat, due to relay supplier. |
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Unburned R1 R2 resistorsNote there is no high-heat or burn residue at end of each part |
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Burned R1 resistor on timerR1 resistor burned, R2 resistor burnedLook at burned spot where the resistor is soldered.This is a 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 but you can see that 4 resistors located on left side of dial and 3 resistors on right side have evidence of burned point at the solder joint. No prevention steps. Check that timer is receiving correct voltage and Load does not exceed rating. Solutions: Replace timer and Check if one of the relays function... sometimes a timer can be used with one relay. In this case, it was an older-model defrost timer with several methods for wiring. We were able to get 1 relay to work, and the timer was used. 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 Resources: Match breaker and wire size Figure volts amps watts Compare similar timers Compare all box timers GM series defrost timers |
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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 |
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 at Amazon Red 3P connector (shown) for 10-14 gauge wire Connector assortment Resource: How to select and install wire connector |
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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 . 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 |
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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 |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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