Electricians - Is my Timer System damaged?

Question

I have a DG120 Tork timer system. Here is a schematic of the wiring for it: http://tork.com/pdf48w.htm

I believe i have hooked it up correctly but when i turn on this sytem to set the schedule i notice that it is already providing output to the load (which is an outlet jack area, 2 of them, where i connect my pond pumps to). Its very strange because although the timer system says it is "OFF" i am still getting power to the load. The wiring is in a way that the "NO" has a wire connected to it (see the diagram) but there is no wire to "NC".

And here is where it gets stranger. When i move the wire from "NO" to "NC" i notice i only get output power to one outlet jack area and not to both areas. And it still didn't matter if the timer system was showing "OFF". It still was providing power to the one outlet jack.

My guess is the internal switch is damaged and stuck part way between "NO" and "NC" but mostly at "NO" which would explain why it gives full power to both jacks.

Answer 1

Glad to see that you are so persistent. Now that the story is a little more clear, my thought is that the pond pumps might be drawing too much for the timer contacts to handle. It probably welded the contacts together. The timer has a load rating and this needs to be compared to the amp draw of each motor. If one motor is falls within range but two does not then you can only run one pump per timer or you will need a larger contact relay. The timer could operate the larger relay and that relay will operate the pumps. email if me you like

Answer 2

To answer your final assumption first: there can be no 'stuck between' on a relay. It's either on or off. NO means when the relay is not engaged there should be not completed circuit and NC means just the opposite, almost 95% of the time a relay will be wired NO. Basically, one wants something to happen when the relay is engaged.

Sounds to me without looking at it, that the relay is broken and stuck in NC position. A relay is nothing more than an electromatic solenoid that is (in your case is used to control 120v). Problems like this invariably need a hands on experienced troubleshooter. Since the unit is most likely outside it's subject to moisture and the solenoid can rust. If you can get to the relay try tapping it with something..I don't know how big it is or how sturdily built....You just might get it to unfreeze. I suspect it was never designed to be wired in NC position, hence the strange results.

It is feasable that the electronic control could be fried...very likely in fact..in which case (if yours looks clean) go buy another put the old in a box and return it as broken. Why should you suffer because the manufacturer makes a shoddy product. Consider it a citizen's warranty arrest case.
It's like the spell checker her at Yahoo Answers..I'd like to put in a box and return ii- It works (maybe) 50% of the time.

Sounds like you should get a new unit if you can't figure out what is causing the problem and fix it. Today as you know everything is made in China and nothing is made to be repaired.

Thanks Sam Walton.....

Good Luck....
PS Try not to be standing in a puddle with the circuit on while trying to repair....and I assume you have a good ground fault on that pond...Nothing worse than elecrtrocuted Koi!

Answer 3

hope this will help,
some where there is a way to remove the whole unit pull it out and inspect that the contacts flip back and forth mechincally
Now reisntall
check and makle sure yo uhave the proper voltage from pwer
first let's check the power to the plugs
check that each plugs work corectly
i think you have them on indivual lines from the timer
make sure they work
take and make sure the clock or timer works
there should be a jumper from the line side to the timer hot
and a white wire will go to the white.

does your timer have a dial you can touch it and lighty hold it to see if it is moving.
now hook up one line to your pumps to the load and then the other the whites or neutrals go together.

If this don;t help
break it down into segments
i always use this KISS
keep it simple stupid

hope this helped and be carefull