| Concepts of
Operation. Millivolt style gas heaters control the flow of gas with the main gas
valve, item 3 above. This valve is powered with a very low voltage supply
source, called the pilot generator. The original name for this device is
called a 'thermopile', and is simply an encased, twisted pair of wires
made from dissimilar metals, such as copper and zinc. When this type of
twisted wiring is heated, it generates a small voltage.
The gas heater uses this
voltage to operate 2 separate electro-magnetically operated valves inside of
it. These precision devices are designed to open and allow the flow of
gas, with as little as 250 millivolts applied to them, however, the valves are
most effective with approximately 450 millivolts of power.
Most pilot generators will
generate as much as .850 volts (850 millivolts), when new. Over time,
this voltage level will deteriorate, and the valve's operation may become
erratic, and sometimes just stop working altogether. At that point, if
the voltage output of the pilot generator is less than .250 volts underload
from the gas valve, then it's time to replace the generator.
The Pilot
Valve
The first valve is called the
pilot valve. When you initially ignite a pilot light flame, you must hold
down the rotating valve select switch for a short while to get the pilot to
stay lit. What is happening, is that while you are holding down the red
knob, you are bypassing the electrically activated pilot valve, and allowing
the thermopile/pilot generator to heat up sufficiently, to generate enough
voltage to keep the pilot valve open. Once this happens, the valve is
opened, and then you can release the control knob.
This provides a critical safe
operation feature, in that if the pilot light ever goes off, the pilot
generator cools off, and subsequently, without enough voltage to keep it open,
the pilot valve will turn itself off, preventing flooding of gas in the heater
or the room where it is located.
Main Gas
Valve
The main gas valve, simply
supplies gas to the burner manifold. Also operated by the pilot
generator, the voltage/current flow from the generator goes through a number of
devices in a daisy chain fashion. If any of these devices break the
circuit, the main gas valve will shut down, stopping the heater from
operating. These devices almost always incorporate a thermostat, on/off
switch, high temperature limit switches located in the water manifolds,
pressure switch, and a flame switch which is usually located near the front
opening of the burner tray compartment.
What's a Fireman
Switch?
Sometimes, there is also a
connection block usually colored red, called the 'fireman' switch
connection. What this is normally used for, is for a connection to a
remote thermostat, and to a micro-switch contained inside the pool/spa
timer.
In the latter, let's say that
you've got a pool or spa pump set to turn on at 4:00, and turn off at
8:00. The position of the microswitch on the timer, shuts down the heater
operation approximately 15 minutes prior to pump shut down, to give the heater
time to cool down with the water continuing to run through it. On some
heaters, without this switch, it is possible to cause problems with the heat
exchanger, and/or heater manifolds due to excess heat build up after the pump
has shut down.
The millivolt heater is quite
an efficient system, and has been proven for many many years, and as such, is
still being produced by many manufacturers.
Service
Precautions
Never under any circumstances,
disassemble a gas valve and attempt to repair it. These are extremely
precision devices, and the slightest error in reassembly, including scratching
the milled surfaces or warping the control rods, could result in a disaster
that could burn your house down... or worse. Always replace the gas valve
as a complete assembly.
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