I installed a new Intermatic 200w powerpack with 15 malibu lights using 131 watts. The lights turn on manually, but the timer doesn't work. How is this possible.

1) Copy following link for malibu power pack tips for longer transformer life:
http://waterheatertimer.org/Malibu-power-pack-stopped-working.html

2) Two plug choices on each outlet, Plug power pack into other outlet on receptacle.
Inspect for damage on outdoor outlet.
Replace outdoor outlet, and do not use quick connects. Connect wire directly to screws on side of device.
Replace GFCI outlet.

If you need further help, I’m available over the phone at https://www.6ya.com/expert/gene_9f0ef4df2f9897e7

300 watt power pack should have 300 watt load.
You have 165 watt load.
Copy following link for general tips to get Malibu power pack to last longer.
http://waterheatertimer.org/Malibu-power-pack-stopped-working.html

Problem might be the photo eye.
http://waterheatertimer.org/images/Malibu-8100-9045-01-large.jpg
Rotate manual dial to ON position and see if lights turn ON.
Keep in mind the digital power pack has photoeye that is light sensitive, and must be exposed to dark light to activate.
For timed functions. Rotate manual dial until it points at timer. Press clock set function button, and use up-down buttons to set current time. Press timer ON button, and then use up-down to set ON timer. Then press timer OFF button , and use arrow keys to set OFF time.

This product has 1 year limited warranty, contrast with old-type analog power pack with 5-year warranty.
Malibu does not even post a manual on their site, which might have troubleshoot section to illuminate why your system has problem,
http://malibu.brinkmann.net/customer_service/owners_manuals.aspx

If you need further help, I’m available over the phone at https://www.6ya.com/expert/gene_9f0ef4df2f9897e7

Timer is malfunctioning, or trippers are worn down and don't fully push the switch over.
See it timer operates on manual override.
Buy new trippers, and/or buy cheap plug-in timer, and then set power pack to override, and plug power pack into cheap timer.

Power Pack uses 107SB189 ON tripper, and 107SB192 OFF tripper

For information on Intermatic/Malibu power packs showing troubleshoot steps, replacement trippers, links to manuals, useful links, warranties and tips:
http://waterheatertimer.org/Malibu-power-pack-stopped-working.html

Add a comment with your experience so others with same-similar problem can benefit.

Also take advantage of fixya expert assistance live.
For a price, expert works with you while you work on timer or any do-it-yourself project.
Fixya is always less expensive than a service call.

You have malibu-type low-voltage transformer.

There are no repair parts for this type of timer, and nobody reports being able to fix timer once it goes bad.

1) "Harry" wrote to fixya with a work-around: He bought cheap plug-in timer, set malibu timer on override, and plugged malibu into wall timer.

2) Harry also said that his timer has 5 year warranty, and he was negotiating for replacement.
Contact Intermatic:
http://www.intermatic.com/customer%20service.aspx

3) Buy another timer:
http://www.amazon.com/Malibu-Intermatic-600watt-Professional-Transformer/dp/B000PGPO50

4) I found tips for next power pack that might save money:
The reason I add tips now, before power pack needs replacement is some fella wrote fixya.
He bought 500 Watt power pack to replace 300 Watt > thinking bigger was better.
Power pack burned out. Here's why:
a) Match wattage of bulbs with wattage of power pack
-15 each X 20 watt bulbs = 300 watts, so install 300Watt power pack
b) Installing a 500W power pack on 300W of bulbs will burn out bulbs and power pack.
c) Replace bulbs as soon as they burn out or other bulbs will burn out and power pack will burn out.
d) When working on bulbs, unplug power pack or it may burn out.
http://www.malibulights.com/guides_support/low_voltage_planning_guide/select_your_power_pack

Add a comment for more free help.
Also take advantage of fixya phone service.
For a price, expert speaks with you over phone while you work on timer or any do-it-yourself project.
Fixya is always less expensive than a service call.

If I understand correctly, you have a Malibu power pack and can manually turn lights on-off but timer is not working.

1) 'Harry' wrote fixya with a work-around for this problem. He bought cheap plug-in timer. Set power pack to override and then plugged power pack into cheap timer.

2) Harry also said he has 5 year warranty and was negotiating with malibulights.com for refund.
No word how that came out.

3) Other than Harry's solution, I have not found repairs and parts for power packs.
After hours of reading manuals, searching Malibu, Intermatic, ebay etc I found nothing.
There are folks who write fixya how they took apart their power pack, but nobody reported fixing a power pack once it goes bad.

4) Best I found are tips for next power pack that might save money:
The reason I add these tips now, before your power pack needs replacement is some fella wrote-in.
He bought 500 Watt power pack to replace 300 Watt > thinking bigger was better.
Power pack burned out. Here's why:
a) Match wattage of bulbs with wattage of power pack
-15 each X 20 watt bulbs = 300 watts, so install 300Watt power pack
b) Installing a 500W power pack on 300W of bulbs will burn out bulbs and power pack.
c) Replace bulbs as soon as they burn out or other bulbs will burn out and power pack will burn out.
d) When working on bulbs, unplug power pack or it may burn out.
http://www.malibulights.com/guides_support/low_voltage_planning_guide/select_your_power_pack

5) Add a comment for more free help.
Also take advantage of fixya phone service.
For a price, expert speaks with you over phone while you work on timer or any do-it-yourself project.
Fixya is always less expensive than a service call.

1) Amazon sells 600Watt power pack:
http://www.amazon.com/Malibu-8100-9600-01-Voltage-Power-Transformer/sim/B002ZRPM4A/2

2) I bought new 300Watt Malibu power pack at Home Depot about 2 months ago.
Near the lighting section.
My new power pack has electronic time clock, so no more 'slow clock.'
I think Home Depot had 600Watt.
Lowes carries different brand.

3) Manuals for power packs at Malibu lights.com
http://www.malibulights.com/customer_service/owners_manuals.aspx

4) Tips for buying and taking care of power pack:
-Match up wattage of bulbs with wattage of power pack
-15 each X 20 watt bulbs = 300 watts, so install 300Watt power pack
-Installing a 500W power pack on 300W of bulbs will burn out bulbs and power pack.
-Replace bulbs as soon as they burn out or other bulbs will burn out and power pack will burn out.
-When working on bulbs, unplug power pack or it may burn out.
http://www.malibulights.com/guides_support/low_voltage_planning_guide/select_your_power_pack

5) How to install power pack.
Before unplugging old power pack, check which bulbs are not working.
Replace bulbs using phillips screwdriver.
Unplug power pack.
Notice how wires are connected to power pack, write down terminal connections.
Some power packs have three terminals ... extra terminal is for additional photoelectric eye.
Use pliers or screwdriver to disconnect wires.
New power pack has has same terminals.
Plug in power pack.
Read instruction manual before connecting wires.
Save instruction manual because a few years that manual won't be around as products change.

Unfortunately when the power pack stops working there is no solution.
Your power pack has electricity so that is not the problem.
The bulbs turn on, so the bulbs are ok.
That means the power pack has malfunctioned, and needs to be replaced.

I did find some tips to help folks preserve their power packs:
1) Match wattage of bulbs with wattage of power pack
-15 each X 20 watt bulbs = 300 watts, so install 300Watt power pack
2) Installing a 500W power pack on 300W of bulbs will burn out bulbs and power pack.
3) Replace bulbs as soon as they burn out or other bulbs will burn out and power pack will burn out.
4) When working on bulbs, unplug power pack or it may burn out.
http://www.malibulights.com/guides_support/low_voltage_planning_guide/select_your_power_pack

Malibu home page
Malibu manuals

Try the manual override >>> un-plug power pack and try loosening manual override with WD-40

It sounds like the clock motor is unable to push the manual override
Don't continue to run power pack or the clock motor will burn up or break a plastic gear

If manual override will not work, or clock will not trip on lights, you need a new power pack
Power pack size chart and wire length

Be sure to buy same wattage power pack as you have
The 300 Watt unit is made for 15 - 20watt bulbs (15 x 20 = 300)
If you buy 600 Watt power pack and hook it up to 10 - 20 watt bulbs, it will burn out the bulbs
Manual also says to replace burned out bulbs ASAP or other bulbs will burn out.

You posted under Intermatic-malibu power packs.
Wattage of bulbs must match wattage of power pack or bulbs and power pack will burn out.

Your power pack might be damaged beyond repair.

For information on Intermatic/Malibu power packs showing troubleshoot steps, replacement trippers, useful links, warranties and tips:
http://waterheatertimer.org/Malibu-power-pack-stopped-working.html

You posted under Intermatic-malibu power packs.
There are no replacement clock motors.

Improvise by setting timer to override and plug power pack into cheap plug-in timer.

For information on Intermatic/Malibu power packs showing troubleshoot steps, replacement trippers, useful links, warranties and tips:
http://waterheatertimer.org/Malibu-power-pack-stopped-working.html