7.0 Manual - Updated 07.08.09

Applying Basic Electricity
7.0 Principles to Service Propane

Appliances
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LEARNING AIDS—These margin notes are provided to help you
identify sources, take precautions, or give guidance on your job.
Symbols
Warning: Important precaution that you should always remember when

performing the identified task.
Tools: This task requires special tools or procedures.
PPE: This is a task that requires personal protection equipment.
Paper Work or Forms: This task should be documented on your

company’s forms for compliance or legal reasons.
Safety Procedure: For your safety special precautions and safety

guidelines apply to this task or operation of equipment.
Electrical Hazard: This task involves an electrical hazard. Lockout and

Tagout procedures must be followed.
Explosive/Fire Hazard: This task involves a fire or explosion hazard. Use

appropriate precautions. Lockout and Tagout procedures may apply.
Technical
Technical Tips: This technique may be very useful as you do a task. Tip !
NFPA 54
The National Fire Protection Association: References to sections of the Or
LP-Gas Codes and Standards.
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References to Title 49, Code of Federal Regulations.
Department of Labor: (OSHA) administers federal employee safety and

health regulations.
Applying Basic Principles of Electricity
7.0
to Service Propane Appliances
Page
7.1.1 Identifying Basic Troubleshooting Principles 1

7.1.2 Identifying the Properties of Electrical Circuits 9
7.1.3 Applying a Systems Approach to Gas Appliance Troubleshooting 25
7.2.1 Identifying Basic Meter and Hazard Reducing Guidelines Used In 49
Measuring Electrical Quantities
7.2.2 Identifying Procedures for Measuring Voltage Between Two Given 69
Points In An Electrical Circuit
7.2.3 Identifying Procedures for Measuring Resistance Between Two 81
Given Points In An Electrical Circuit
7.2.4 Identifying Procedures for Measuring Current Between Two Given 93
Points in An Electrical Circuit
7.3.1 Identifying the Operating Characteristics of Common Sensing 103
Devices
7.3.2 Identifying the Components and Operating Characteristics of 129
Electronic Ignition Systems
7.3.3. Identifying the Components and Operating Characteristics of Wall 145
Thermostats (Heat Only)
7.3.4 Identifying the Components and Operating Characteristics of Limit 171
and Fan Controls
7.3.5 Identifying the Function and Characteristics of Draft Fans and 179
Controls
7.4.1 Identifying the Operating Characteristics of Circuit Control Devices, 187
Electromagnetic Devices and Transformers
7.4.2 Reading Electrical Control Circuit Diagrams 217
7.4.3 Identifying Systematic Troubleshooting Techniques and Guidelines 245
for Gas Operating Equipment
7.0 Performance-Based Skill Assessment Evaluation Packet 253
Identifying Basic
7.1.1
Troubleshooting Principles
Table of Contents
Table of Contents....................................................................................................... 1
Learning Activities...................................................................................................... 2
Identifying Basic Troubleshooting Principles.............................................................. 3
Identifying the Symptoms of the Problem ................................................................. 4
Identifying Steps in Diagnosing the Problem ............................................................. 5
Visually Examining the Electrical Circuit Components ............................................... 5
Identifying Principles of Testing ................................................................................. 5
Review ....................................................................................................................... 7
Performance Criteria Self-Check ............................................................................... 8

1
Learning Activities
Performance 1. Identifying Basic Troubleshooting Principles

Objectives
Check-Out
Your instructor will provide you with a list of incomplete
Activities statements concerning identifying basic troubleshooting
principles and a list of responses. Select the response that most
correctly completes each incomplete statement. (Knowledge
Assessment)
Your instructor or supervisor will require you to complete some
operations relating to identifying basic troubleshooting principles.
(Skills Assessment)
! Read Performance Objective 1:

Identifying Basic Troubleshooting " " Check your knowledge by
Principles completing the Review.
# To prepare for the Certification Exam complete the Performance Criteria Self-
Check found at the end of this module.
2
Identifying Basic
7.1.1
Troubleshooting Principles
Servicing gas appliances not only requires a knowledge of the operating principles
used in the equipment design, but the application of good troubleshooting routines
as well.
In this module you will learn to:
(1) Identify the symptoms of the problem

(2) Identify steps in diagnosing the problem
(3) Visually examine the electrical circuit components
(4) Identify principles of testing
In the early days of automobile technology, mechanics had a simple troubleshooting

guide, which was summed up in three fundamental areas—spark, timing and
mixture. When working on simple internal combustion engines, mechanics knew
that if an engine was not operating properly, the problem most often was a matter of
no spark to ignite the fuel, or that the spark was not happening at the proper time as
the cylinders were charged with a fuel/air mix, or the fuel/air mix itself was not within
the flammable range required for combustion.
There could be any number of mechanical problems or component failures that

might cause a problem with spark, timing or mix, but technicians knew that the
engine would not start, and the car could not go if spark, timing or mix was not right.
The best technicians on cars were technicians who applied systematic tests or
observation to determining if spark, timing and mix were right in order for the car to
run. Even now with all the complexity of modern automobiles—the best automotive
technicians are people who know
where to direct their attention and
what tests and observations will
lead them to a diagnosis of a
problem in the operation of the
engine or any other system on the
car.
Developing and consistently

applying troubleshooting skills is
the key to becoming a good
technician with any technology.
The need for good troubleshooting
skills is especially true for
technicians in the gas and heating, Figure 1. Gas Appliance Technician Using
ventilation and air conditioning Troubleshooting Skills
3
(HVAC) industries. The fundamental area that must be understood, observed and
tested by gas appliance technicians is the operation of electricity in the control and
operation of heating and air conditioning systems. A large number of all service calls
made by service technicians are diagnosed as electrical problems. While it is
certainly true that a technician must know and recognize that a gas appliance must
be understood as a system, it is also true that the technician is most productive
when he or she is working in a systematic way and can consistently apply electrical
trouble shooting methods.
Experience indicates that in most situations, when the exact problem in an electrical
circuit is not isolated it is because the service technician has not followed well
defined troubleshooting skills and properly applied knowledge of basic electricity.
The practice of basic troubleshooting skills is essential to efficiently isolate a

malfunctioning component in an electrical circuit. The skills listed below should be
considered a thought process rather than a step-by-step procedure to follow when
isolating problems in electrical circuits. Troubleshooting skills can be generalized in
the following categories:
(1) Identifying the Symptoms of the Problem.
When identifying the symptoms of the problem, attention should be directed

toward defining the function of the electrical circuit/system. This may be
accomplished by working with the user of the appliance to determine the
exact point of failure. This should isolate the problem to a relatively small
section of the circuit/system. A thorough check of this section of the
appliance and the corresponding manufacturer diagrams should lead to the
problem.
Probably the single most important rule in troubleshooting is to change only

one component in the circuit/system at a time. Usually it is the failure of one
component which stops the operations of an appliance. Sometimes more
harm than good results from excessively changing parts and random
adjustments.
An electrical component failure can result from a mechanical malfunction of

control components such as the improper opening and closing of switch
contacts. Limit switch trip arms are sometimes knocked out of adjustment or
broken off. Relays and contactors can become mechanically bound to
prevent operation. Component mounting bolts can become loose or break.
The possibilities of mechanical malfunction are unlimited, therefore, be sure
to check for mechanical failure which would affect the operation of the
electrical circuit/system being tested. For example, if an electrical circuit fails
because a limit switch does not close, the next step is to examine the limit
switch for a mechanical failure. Also, a burned out electric motor may be the
4
result of bad motor bearings. Repeated tripping of overload circuit breakers
may indicate a mechanical problem.
(2) Identifying steps in diagnosing the problem.
The diagnosis of the problem involves deciding which specific part of the
circuit/system may be involved in the problem(s). As was indicated when
identifying the symptoms, the problem(s) may be isolated to a relatively small
section of the circuit/system. At this point one of the most important tools
used for troubleshooting are diagrams of the electrical circuit/system.
Attempting to troubleshoot an electrical circuit/system without a drawing

(schematic diagram) of the circuit/system and a meter is usually a waste of
time. Even if the general control sequence is known, it is likely the order of
the devices in the circuit, wire numbers, and other information necessary to
be thorough in the troubleshooting procedure will be unknown.
Although some electricians are known not to use a drawing and a meter in
their troubleshooting, it is an indisputable fact they could be even better at
their job if the use of these tools was added to their knowledge and ability in
troubleshooting.
(3) Visually examining the electrical circuit components.
A visual check of the circuit components may reveal an obvious reason for
the problem, such as the appliance is not plugged into the electrical outlet, or
a broken electrical connection. A “visual” inspection should apply all of the
technician’s senses. A malfunctioning electrical component many times can
be located because of excessive localized heat causing the component to
malfunction.
While visually examining circuit components, the circuit diagrams should be

available for reference. If the problem cannot be identified by doing a visual
inspection of the circuit, the next step in troubleshooting is to perform a
testing procedure.
(4) Identifying principles of testing.
Unless systematic procedures are used when making the tests and recording
the results, testing the components of an electrical circuit/system can be very
confusing and unproductive. When testing the operating condition of an
electrical component or circuit, the technician should use diagrams of the
circuit(s) in order to understand the test results.
5
The application of these troubleshooting skills requires the service technician to be
knowledgeable in electrical control functions, components, circuits, and circuit
analysis using appliance manufacturer circuit diagrams and electrical test meters.
6
REVIEW:
Identifying Basic Troubleshooting Principles
Directions: Select from the list below the response that most correctly completes
each of the following statements. Write the letter of your choice in the
space provided.
A. 50
B. change only one component at a time
C. tank dimensions
D. 80
E. visual inspection of components and testing circuits
F. 10
1. Studies have found that service calls on heating, ventilation and air
conditioning (HVAC) equipment are diagnosed as electrical problems
approximately ____% of total service calls.
2. The single most important rule to follow when troubleshooting electrical

control circuits is _____.
Directions: Complete the following statement by filling in the blanks
3. Two appliance troubleshooting activities that require the use of

manufacturer’s circuit diagrams are:
7
7.1.1 Performance Criteria Self-Check:
Identifying Basic Troubleshooting Principles
Directions: Use the following performance criteria statements as a self-evaluation

in preparation for the final exam.
I can identify:
1. The approximate percentage of service calls that are diagnosed as

electrical problems.
2. The single-most important rule to follow when troubleshooting electrical

control circuits.
3. Two gas appliance troubleshooting activities that require the use of the
appliance manufacturer’s circuit diagrams.
8
Identifying the Properties of
7.1.2
Electrical Circuits
Table of Contents
Table of Contents....................................................................................................... 9
Learning Activities.................................................................................................... 10
Identifying the Properties of Electrical Circuits ......................................................... 11
Identifying the Physical Properties of Electrical Circuits........................................... 11

Source of Power ................................................................................................. 12
Control Switch..................................................................................................... 12
Load Device........................................................................................................ 12
Interconnecting Wires ......................................................................................... 12
Identifying Electrical Properties................................................................................ 14

Electrical Current ................................................................................................ 15
Source Voltage ................................................................................................... 15
Electrical Resistance .......................................................................................... 16
Electrical Power .................................................................................................. 16
Identifying Electrical Relationships........................................................................... 16

Ohm’s Law.......................................................................................................... 16
Watt’s Law .......................................................................................................... 19
Review ..................................................................................................................... 21
Performance Criteria Self-Check ............................................................................. 24

9
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

10
Identifying the Properties of
7.1.2
Electrical Circuits
Knowledge of electrical properties and characteristics of electrical circuits is a basic

requirement for troubleshooting appliances. Because the majority of appliance
service problems have electrical component or circuit solutions, the gas appliance
technician must learn the properties of electrical circuits to succeed in the
profession.
In this module you will learn to identify:
(1) Physical properties of electrical circuits

(2) Electrical properties
(3) Electrical relationships
The power circuit and control systems of propane-operated appliances consist of a

number of relatively simple circuits. There are many ways these circuits can be
interconnected to perform a variety of control functions. It is not necessary to know
all of the different ways control circuits can be wired. A good understanding of basic
control circuits and step-by-step testing of individual simple circuits will isolate faults
in the most complex control systems.
An electrical circuit may be considered as having two basic properties. These

properties may be classified as:
(a) Physical properties, and

(b) Electrical properties.
(1) Identifying the physical properties of electrical circuits.
A close examination of a simple electrical circuit will show the circuit consists
of four circuit elements as follows:
(1) Source of power,

(2) Control switch or switches,
(3) Load device,
(4) Interconnecting wires.
11
Figure 1. Circuit Element
Illustrated in Figure 1 are the four elements of a flashlight electrical

circuit drawn in pictorial form to show a picture of the circuit elements.
1) Source of power. Batteries are used as a source of power.
2) Control switch. A control switch is used to connect or disconnect the

power source from the load.
3) Load device. The load device in the flashlight circuit is the lamp bulb.
4) Interconnecting wires. In place of interconnecting wires the metal

flashlight case and spring are used to complete the circuit. Experience
shows that if any of these four elements is faulty, the flashlight will not
perform its function.
The elements of the flashlight electrical circuit illustrated in Figure 1 are

composed of circuit components (batteries, switch, and lamp). In propane
operated appliance control circuits symbols are used to represent the
components, therefore, using symbols for the components, the flashlight
circuit appears, as illustrated in Figures 2 and 3.
12
Figure 2. Figure 3.
Light De-energized Switch Closed - Path Closed
Switch Open - Path Open Light Energized
These diagrams are referred to as schematic diagrams.
As required by appliance standards, the schematic diagram is drawn in a

ladder diagram form, as illustrated in Figures 4 and 5. The circuit performs
exactly the same, and the lamp is energized when the switch is closed. In the
ladder-type schematic drawing, the source of electrical voltage will always be
the two vertical lines (or sides of the ladder) designated as L1 (line 1) and L2
(line 2).
Figure 4. Figure 5.
Switch Open - Path Open Switch Closed - Path Closed
Light De-energized Light Energized
A control circuit is typically used in appliances as a switch to turn the flow of
electricity on and off to load devices in other circuits. Compare the two-wire
low voltage control circuit in Figure 6 to the flashlight circuit in Figure 7. A low
voltage transformer (1) is used as a power source in place of batteries. A
normally open control switch (2) is used as a control. A relay coil (3) is the
load instead of a flashlight lamp. Also, a fuse (5) is added to the circuit to limit
the current flowing in the circuit. Four separate wires (4) are used to
13
interconnect the circuit elements. Both the flashlight circuit and this two-wire
control circuit operate in exactly the same manner.
Figure 6. Figure 7.
Control Circuit Connector Diagram of a Flashlight
(2) Identifying electrical properties.
There are basically three electrical quantities present in all operating electrical
circuit/systems. When performing a troubleshooting procedure, the
technician's job is to check for the presence of these quantities and determine
if they are in the correct relationships. The quantities are:
(1) Electrical current that flows in the circuit(s),

(2) Source voltage applied to the circuit/system,
(3) Electrical resistance to the current flowing in the circuit/system.
The drawing in Figure 8 illustrates the source voltage, electrical current, and
resistance in the flashlight electrical circuit illustrated in Figure 1, page 2.
Figure 8. Flashlight Electrical Circuit
(a) Electrical current. Electric current flowing in an electrical

circuit/system may be compared to the flow of propane through a
14
piping system. However, as illustrated in Figure 9, there is one primary
difference. In a propane piping system the propane flows from the
source, (storage container) to the load, (burner) where it is consumed.
In an electrical circuit/system the current flows from the voltage source,
(battery) through the load, (lamp) and back to the voltage source.
Figure 9. Comparing Propane Flow with Electrical Current Flow
The electrical current illustrated in Figure 9b, is composed of particles moving

in the electrical conductor. The charged particles are called electrons.
Therefore, electrical current may be referred to as electrons moving in the

conductor. Just as the rate of flow of propane moving through a piping
system is measured in cubic feet, the rate of flow of electrons moving through
an electrical conductor is measured in amperes. The mathematical symbol for
amperes is the letter "I" or "A." An ammeter is used to measure the amperes
of electricity flowing in a circuit.
(b) Source voltage. The source voltage in the flashlight circuit is

produced by two batteries. However, a voltage source is any device
which uses some kind of energy such as mechanical, chemical, heat,
etc. to produce electricity. Voltage producing devices commonly used
include:
Electrical generators (mechanical energy),

Batteries (chemical energy),
Thermocouples (heat).
15
Voltage is a term used as a measure of electromotive force.
Electromotive force is the amount of electrical pressure difference
between points in an electrical circuit. It is this pressure difference
which forces electrical current to flow in a circuit. The pressure in an
electrical circuit is measured in volts. Volts may be compared to
pounds or inches water column (W.C.) as measures of pressure in a
propane supply line.
The amount of voltage (electrical pressure) in an electrical circuit is

measured with a voltmeter. This may be compared to the amount of
propane pressure in a propane supply being measured with a gauge or
a manometer.
The mathematical symbol for volts is "E" or "V".
(c) Electrical resistance. Electrical resistance is the opposition to the

flow of electrical current (electron flow) in an electrical circuit. The
resistance in an electrical circuit/system is determined by the size of
the electrical conductor and resistive load devices in the circuit(s).
Electrical resistance may be compared to the opposition to the flow of
propane through a piping system caused by friction on the pipe walls,
pipe fittings, valves, regulators, etc. Electrical resistance is measured
in ohms. The mathematical symbol for electrical resistance is the letter
"R." The Greek symbol ! may be used for ohms.
(d) Electrical power. The unit of power most commonly used in the
electrical industry is the watt. Energy charges in the electrical industry
are based on watt hours. This compares to the BTU's per hour used in
the propane industry. One watt hour of power is equal to 3,413 BTU's
per hour. The mathematical symbol for electrical power is the letter
"W."
(3) Identifying electrical relationships. Electrical relationships basic to

electrical circuits may be expressed in Ohm's Law and Watt's Law.
(a) Ohm’s law. The mathematical formula used to describe the

relationships among the voltage, current, and resistance in an
electrical circuit is known as Ohm's law. A German physicist, Dr.
George Simon Ohm, introduced the law in 1827 in Berlin. His many
years of experimenting with electricity brought out the fact that the
amount of current which flowed in a circuit was directly proportional to
the applied voltage. In other words, when voltage increases, the
current increases; and when the voltage decreases the current
decreases.
16
If the voltage remains constant, the current will change as the resistance
changes, but in the opposite direction. The current will decrease as the
resistance increases and will increase as the resistance decreases. Ohm's
law states: The current which flows in a circuit (I) is directly proportional to the
applied voltage (E) and inversely proportional to the resistance.
There are three ways of stating this fundamental law:
(a) The pressure in volts is equal to the current in amperes multiplied by the
resistance in ohms: E = I x R (volts = amps times ohms).
(b) The current in amperes is equal to the pressure in volts divided by the
E
resistance in ohms: I=R (amps = volts divided by ohms).
(c) The resistance in ohms is equal to the pressure in volts divided by the current
E
in amperes: R= I (ohms = volts divided by amps).
A method which may be used to remember the relationships among E, I, and R is

to visualize the three quantities and a circle arranged, as illustrated in Figure 10.
volts = amps x ohms amps = volts / ohms ohms = volts / amps
Figure 10. Ohm's Law in a Mathematical Equation
By covering the quantity to be determined, the other two appear in the form
needed to solve the problem.
The equation E = I x R states the voltage (E) in an electrical circuit is equal to the
current (I) in amperes, multiplied by the resistance (R) in ohms. The examples
on the next page illustrate the use of Ohm's Law to determine voltage, current,
and resistance.
17
Example a. Consider the circuit illustrated in Figure 11. Assuming the
values for R=10 ohms and I=.3 amperes, the voltage (E) in the
circuit is determined by the equation:
Figure 11. Ohm's Law Applied to a Flashlight Electrical Circuit
Example b. Consider the circuit illustrated in Figure 12. Assuming the

values for E = 3 volts and the value for R = 10 ohms, the
electrical current (I) in the circuit is determined by the equation:
Example c. Consider the illustration in Figure 13. Assuming the value for
E = 3 volts and I = 0.3 amperes the resistance to the flow of
current in the circuit is determined by the equation:
18
(b) Watt’s law. Electrical power is the rate at which energy is expended
by (or supplied to) an electrical circuit. Electrical power is expressed in
watts. The number of watts of power expended or supplied to an
electrical circuit may be determined by a mathematical equation
referred to as Watt's Law. Watt's Law expresses electrical power by
an equation involving voltage (E) and electrical current (I). Watt's Law
is stated in a mathematical equation as P=IE. The meaning of the
letters in the equation are as follows:
P is electrical power in watts
I is current, in amperes
E is voltage, in volts
The equation P=I X E states the power expended (or supplied) to an electrical
circuit is equal to the voltage (E) in volts multiplied by the electrical current (I) in
amperes.
A method which may be used to remember the relationship among P, E, and I is

to visualize the three quantities in a circle arrangement, as illustrated in Figure
14.
watts = amps x volts volts = watts / amps amps = watts / volts
Figure 14. Watt's Law in a Mathematical Equation
The examples on the next page illustrate the use of Watt's Law to determine
electrical power, voltage, and current.
19
Example a. How much electrical power is an electrical motor expending
when it is operating on 120 volts and requiring 6 amperes of
electrical current?
Figure 15. Application of Watt's Law
Example b. What is the required voltage to light a 150 watt lamp, if the lamp
normally operates on 1.5 amperes?
Example c. How much current will a 150 watt lamp require operating on 120
volts?
20
REVIEW:
Identifying the Properties of Electrical Circuits
Directions: Each of the incomplete statements below is followed by a list of
responses. Select the response which most correctly completes each
statement. Mark the letter of your choice in the space provided.
1. The load device in this circuit is the _____.
( ) A. switch
( ) B. motor
2. A circuit that acts as a “switch”, turning the electricity on and off to load
devices in other circuits, may be called a _____.
( ) A. switch board
( ) B. control circuit
( ) C. power circuit
3. The motor in this circuit operates on _____ volts.
( ) A. 120
( ) B. 24
21
4. If the electric current required to operate the motor in this circuit is 15
amperes, the current flowing through the switch is _____ amperes.
( ) A. 0
( ) B. 120
( ) C. 15
5. The electrical pressure between two points in a circuit is measured in _____.
( ) A. volts
( ) B. amperes
( ) C. ohms
6. The purpose of a fuse in an electrical circuit is to _____.
( ) A. increase the current flow in the circuit

( ) B. increase the voltage in the circuit
( ) C. limit the current flow in the circuit
( ) D. limit the voltage in the circuit
7. The load device in the circuit illustrated below is the _____.
( ) A. switch
( ) B. battery
( ) C. lamp
8. The current flowing through an electrical circuit is measured in _____.
( ) A. volts
( ) B. resistance
( ) C. watts
( ) D. amperes
22
9. When the voltage is increased in an electrical circuit, the current in the circuit
_____.
( ) A. increases
( ) B. decreases
( ) C. stays the same
10. The mathematical symbol for voltage is E or _____.
( ) A. I
( ) B. V
( ) C. R
11. The electrical capacity of control transformers is rated in watts. If a 24

volt transformer is rated at 40 watts, the current capacity is _____.
( ) A. 16.6 amperes
( ) B. 1.66 amperes
( ) C. 64 amperes
( ) D. 16 amperes
23
Identifying the Properties of Electrical Circuits

I can identify:
1. The load component in a single control circuit.
2. The operation of a control circuit.
3. The purpose of a fuse in an electrical circuit.
4. The unit of measurement for specifying the rate of electrical current flow.
5. The mathematical symbol for voltage.
6. The effect voltage has on current flow in an electrical circuit.
24
Applying a Systems Approach to Gas
7.1.3
Appliance Troubleshooting
Table of Contents
Table of Contents..................................................................................................... 25
Learning Activities .................................................................................................... 26
Applying a Systems Approach to Gas Appliance Troubleshooting .......................... 27
Identifying Series Circuits......................................................................................... 27

Open Circuits ...................................................................................................... 28
Short Circuits ...................................................................................................... 29
Identifying Parallel Circuits....................................................................................... 29

Open Circuits ...................................................................................................... 30
Short Circuits ...................................................................................................... 31
Identifying the Significance of Voltage Drop at Points in a Circuit ............................ 32

Series Connected Loads..................................................................................... 33
Parallel Connected Loads ................................................................................... 34
Performing Basic Electrical Circuit Troubleshooting Skills ....................................... 34

Control Circuit Problems ..................................................................................... 34
Circuit Elements.................................................................................................. 35
Isolating the Fault in an Electrical Circuit ................................................................. 37

Troubleshooting Tip: Start Testing Procedures in the Middle of the Circuit......... 37
Troubleshooting Tip: Move Only One Test Lead at a Time................................. 40
Review ..................................................................................................................... 41
Performance Criteria Self-Check:............................................................................. 47

25
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

26
Applying a Systems Approach to Gas
7.1.3
Appliance Troubleshooting
Troubleshooting gas appliance problems is easier when technicians understand the

concept that the appliance operates as a system and its electrical circuits act to make
the system function. Understanding how circuits operate in the system requires a
basic knowledge of the types of electrical circuits used and how components work in
the different types of circuits.
In this module you will learn to:
(1) Identify series circuits

(2) Identify parallel circuits
(3) Identify the significance of voltage drop at points in a circuit
(4) Perform basic electrical circuit troubleshooting skills
(5) Isolate the fault in an electrical circuit
As discussed previously, the basic elements of an electrical circuit are the power
source, the load, a control switch, and the connecting wires. The power source
provides energy in the form of voltage. The voltage provided to the circuit causes
current to flow in the circuit. Resistance in the circuit, whether it is the resistance of
the load or of the connecting wires, opposes the current flow.
There are two ways components in an electrical circuit are arranged according to their
connection to each other. Components are connected in either series or parallel. An
electrical circuit may have a mixture of these two arrangements, with some
components connected in series, and others in parallel. In the following paragraphs
simple circuits and/or circuit conditions will be considered separately to simplify the
explanations.
(1) Identifying series circuits.
In CETP module 7.1.2, the circuits

considered had only one load device,
such as one lamp. In actual practice one
or more load devices may be connected
in a circuit. If load devices, switches, or
other components are connected in the
circuit in such a way the total current
passes through each component, they
are referred to as series-connected
components. The circuit diagram
illustrated in Figure 1 is a fuse, heater,
and switch connected in series. Figure 1. Series Circuit
27
A series circuit provides only one path for the current to flow. If the path is
broken, there is no current flow, and the circuit becomes an open circuit, or if
the resistance in the circuit suddenly becomes zero and the voltage remains the
same, the result will be a high current flow. The condition of no resistance and
high current flow is referred to as a short circuit. In the following paragraphs the
conditions of (a) open circuit, and (b) short circuit are explained.
5) Open circuits. Electrical circuits may be opened deliberately, such as by

switches, or they may be opened as a result of a defect or problem, such
as a broken wire or burned-out coil. Since too much current flowing in a
circuit can damage the power source and the load device, fuses are
used in the circuits to limit the amount of current. Therefore, if current
flow reaches the limit set by the fuse, the fuse opens the circuit and
stops the current flowing to the load device(s). Open circuits are
illustrated in Figure 2.
Figure 2. Open Electrical Circuits
28
6) Short circuits. A short circuit exists when current can flow from the
negative terminal of the power source through the connecting wires, and
back to the positive terminal of the power source without going through
the load device(s). A short circuit is illustrated in Figure 3.
The high current caused by the

short circuit can damage power
sources, burn the insulation on
connecting wires, and start fires
from the intense heat it produces in
conductors. Fuses and other circuit
breakers are the major means of
protecting against the dangers of
short circuits.
Figure 3. Short Circuit
Fundamental characteristics of series circuits include:
" A series circuit has only one path for the current to flow.
" If the current path in a series connected circuit is broken, the circuit is
open and no current flows.
" Series connected load devices allow the current to pass through each
load device.
(2) Identifying parallel circuits.
If load devices, switches, or other

components are connected in the
circuit in such a way they provide
different current paths, the
components are referred to as
parallel connected components, as
illustrated in Figure 4.
Electrical circuit components

connected in parallel only have a
portion of the current from the power
source flowing in each component.
Each load provides a separate path
for current flow. The separate paths Figure 4. Parallel Circuit
are called branches, and the current
flowing in each branch is called branch current. Since the current from the
power source is divided between or among the branches, the current in any
one branch is less than the current leaving the power source.
29
Since a parallel circuit provides more than one current path, even if one of the
current paths is open, current will flow in the remaining branch circuit(s),
provided a complete circuit remains. This does not mean the current in a
parallel circuit cannot be stopped by opening the circuit at one point. Therefore,
the performance of a parallel circuit which is open depends on the point in the
circuit where the open or break has occurred. If the resistance in a parallel
circuit branch suddenly drops to zero and the voltage remains the same, the
result will be a high current flow. The condition of no resistance and high
current flow in a parallel circuit branch is referred to as a short circuit.
In the following paragraphs the conditions (a) open circuit and (b) short circuit
are explained as they relate to parallel circuits.
(e) Open circuits. If the open or break in a parallel circuit is at a point where
total circuit current flows, the entire circuit is open and all current flow
stops, as illustrated in Figure 5.
Figure 5. Break (Open) at a Point of Total Current Flow
As illustrated in Figure 6, if the circuit is open at a point where only a branch

current flows, then only that branch is open and current continues to flow in the
remainder of the circuit. In order for a fuse to protect a parallel-connected circuit, it
must be connected at a point in the circuit where the circuit current flows, or each
branch must be fused.
30
L1 L2
FUSE
HEAT RELAY
Coil
Coil
FAN RELAY
Figure 6. Break (Open) at a Point Where Branch Current is Flowing
(f) Short circuits. When a parallel-connected circuit is shorted, the same

effects occur as when a series connected circuit is shorted. The effects
of a short are:
" A sudden and very large increase in circuit current

" Heating of connecting wires
" Possible burning of the insulation on the connecting wire
" The possible damage to the power source caused by excessive
current drain.
The branches of a parallel-connected circuit are connected directly

between the terminals (L1 & L2) of the power source. Therefore,
damaging short circuits are more likely to occur in parallel-connected
circuits than in series-connected circuits. If the load in a single branch of
a parallel-connected circuit is shorted, the circuit resistance drops to
zero. But if a series-connected load becomes shorted, the resistance of
the other loads connected in series will keep the circuit resistance from
dropping to zero.
31
(3) Identifying the significance of voltage drop a points in a circuit.
The voltage source, as illustrated in

Figure 7, is a battery which generates
an electrical force between the positive
and negative terminals. This is done
by chemically causing an excess of
negative electrons at the negative (-)
terminal and a corresponding lack of
electrons, or positive charges, at the
positive (+) terminal. This is referred to
as a difference of potential between the
Figure 7. Circuit Containing One terminals. When a wire or any
Load Device electrical conductor is connected
between the terminals, the difference
of potential causes electrons to flow from the negative terminal through the wire
and back to the positive terminal.
Every electron at the negative battery terminal has been given energy by the
battery. When the electron moves around the circuit it gives up the energy, so
when it arrives at the positive terminal it has lost all the energy the battery has
given it. The electron loses its energy by giving it to the circuit resistance,
usually in the form of light, heat, or a magnetic force.
Since the difference of potential across the battery terminals is given in volts,
the energy lost by the electrons in the circuit resistance is also expressed in
volts. Therefore, if a load is connected across the terminals of a 10-volt battery,
10 volts would be lost, or dropped, by the current flowing through the load. If
two or more loads are connected in series across the terminals of a voltage
source, some voltage would be dropped across each load, but the total voltage
dropped would be 10 volts.
As illustrated in Figure 8, if the

resistance of each light is the same, the
voltage drop across each light will be 5
volts. Therefore, the total voltage drop
in a circuit always equals the source
voltage.
In the following paragraphs voltage Figure 8. Circuit Containing

drops across (a) series, and (b) parallel Two Load Devices
connected loads will be considered.
32
(c) Series-connected loads. As illustrated in Figure 9, with series-
connected loads the voltage drop across all the loads is equal to the
source voltage, which is 24 volts. This is true whether there is one load
device or 50 load devices. If the source voltage remains constant, the
more load devices there are the less voltage drop across each load
device.
Figure 9. Series-Connected Load Devices
Since the voltage drop across any load device is the energy given to the load,
the voltage dropped depends on the current flowing through the load device
and the resistance of the load device. The greater the current flow or the higher
the resistance, the more voltage is dropped. And the smaller the current flow or
the lower the resistance, the less voltage is dropped.
If load devices connected in series have different resistances, as illustrated in

Figure 9 the voltage drop across each load device will vary, according to their
resistance.
The total resistance in the circuit illustrated in Figure 9 is calculated by adding

the resistances. In this circuit the total resistance is 12 ohms (2 + 4 + 6). The
source voltage is 24 volts (E). The current in the circuit is 2 amperes.
24
I = 12 . The voltage drop across the coil CR3 is 4 volts (E = 2 x 2). The voltage
drop across the coil CR2 is 8 volts (E = 2 x 4). The voltage drop across the coil
33
CR1 is 12 volts (E = 2 X 6). The total voltage drop (24 volts) is equal to the
source voltage 24 volts.
(d) Parallel-connected loads. As illustrated in Figure 10, in a circuit

composed of parallel-connected load devices, the source voltage is
dropped across each load. The reason for this is that all parallel load
devices are connected together across the power source.
Figure 10. Parallel-Connect Load Devices
(4) Performing basic electrical circuit troubleshooting skills.
The function of electrical control circuits is to provide the required voltage to the
coil (load) terminals. There may be any number of normally open or normally
closed control switches in the circuit on either side of the coil. However, when
the right combination of contacts are closed, this circuit is completed and full
voltage may be measured at the coil terminals.
Every electrical circuit has a definite number of possible faults. Each

component in the circuit and each interconnecting wire used to connect the
components is a potential source of trouble.
(a) Control circuit problems. Control circuit problems may be classified

into four basic types as follows:
" No Power. If there is no power, the circuit will not operate.
34
" Open Circuits. Any problem causing interference with the normal
flow of electrical current through the coil is considered to be an open
circuit fault. Such problems include a blown fuse, broken wire, loose
connection at terminals, and dirty contacts in push button switches,
limit switches, or relays.
" Short Circuits. Under certain conditions the flow of electrical current
may take a path different from that intended by the circuit design. A
short circuit may operate the coil at the wrong time or prevent the coil
from operating at the right time. In many cases the first indication of
a possible short circuit is a blown fuse in the control circuit.
" Defective Load. If the coils (load) will not operate with the required
voltage measured directly across the terminals, the load is defective.
An open circuit or a short circuit in the coil windings could be the
cause. When a coil is shorted, the fuse in the control circuit may blow
each time the control switch is operated.
(b) Circuit elements. To illustrate basic circuit faults consider the electrical
circuit of a flashlight. As illustrated in Figure 11, each of the four circuit
elements is capable of introducing a fault in the circuits as follows:
Figure 11. Flashlight Electrical Circuit
A Power Source. If the batteries are "dead," there will be no power.
B Control Switch. If the contacts in the control switch are corroded,

they will not complete the circuit when the switch is closed.
C Load. If the lamp bulb is "burned out," there will be no light.
D Interconnecting Wires. If there is corrosion in the battery case, the

circuit may be broken at a number of places in the circuit.
35
Figure 12. Simple Control Circuit
The circuit in Figure 12 illustrates that this circuit has eight possible "normal" faults.
These are called "normal" faults because they occur most frequently and relate to
open circuit problems. This circuit also has four "abnormal" faults caused by short
circuits. These will be covered later in this section.
Study the circuit in Figure 12 to understand why each fault results in an incomplete
circuit.
1 No power at control transformer,

2 Broken wire; power source to control fuse,
3 Control fuse "blown,"
4 Broken wire; control fuse to control switch,
5 Defective control switch (will not complete circuit),
6 Broken wire; control switch to relay coil,
7 Defective relay coil (open circuit),
8 Broken wire: relay coil to power source.
The term "broken wire" is used to describe any open circuit condition between
circuit components. Loose screws at element terminals may also cause an open
circuit. Check off each possible fault in the above list and also in Figure 13, on the
next page, to pinpoint the exact location and type of fault described. The table in
Figure 13 lists circuit components, their normal conditions, and fault conditions.
36
Circuit Normal Condition Fault Condition
Power source Voltage present No voltage

Control fuse Good (circuit completed) "Blown" (circuit broken)
Control switch Contacts "open" Will not complete circuit
Relay Coil Closes relay contact Coil "open" (will not operate)
when coil is energized
Wires Good (circuit completed) Open circuit (broken wire
or poor connections)
Figure 13. Normal Faults
(5) Isolating the fault in an electrical circuit. Assume the electrical control circuit
illustrated in Figure 14 does not operate when the switch is closed and a
voltmeter is used to isolate the problem.
Figure 14. Control Circuit With Switch Closed
(a) Troubleshooting tip: Start testing procedures in the middle of the

circuit. Since the circuit does not operate when the switch is closed,
open the switch and start troubleshooting by testing the voltage at the
terminals of the power source, then the control fuse, etc. With eight
possible faults, it may take eight tests to locate the problem.
37
One of the shortcuts used by experienced troubleshooters is to make the
first test at the middle of the circuit. Voltage is usually present on the
power source side of the switch and on the power source side of the coil,
as illustrated in Figure 15.
Figure 15. Control Circuit With Switch Open
The purpose of making the first test in the middle of the circuit is to
reduce the number of tests needed to isolate a fault. As an example, if
the meter indicates 24 volts when connected as indicated in the diagram,
it proves the voltage is present at these two points. Therefore, possible
faults 1, 2, 3, 4, and 8, as illustrated in Figure 12 (page 10), are
eliminated. In other words, in this particular circuit the first test provides
as much information as making five individual tests.
Each test can produce only one of two possible results. They will
indicate a "yes" voltage or "no" voltage. When this first test is made in
the middle of the circuit, the reading on the meter will indicate which
direction to go to find the fault. The first test is analyzed as follows:
24-Volts Measured with the Meter. This proves the circuit is

operational up to the two points being tested. Therefore, the fault must
lie somewhere between the switch and the relay coil (including the coil).
Zero-Voltage Measured with the Meter. This indicates there is a break

in the circuit somewhere between the switch and the voltage source on
one side of the circuit, or between the coil and the power supply on the
other side of the circuit.
If 24-volts are measured with the meter on this first test, move deeper
into the circuit with additional tests.
38
If the meter indicates 0-voltage on the first test, move back toward the
voltage source with additional tests.
The results of the tests are meaningless unless the technician knows
what to look for. For example, if 24 volts are measured with the meter on
the first test in this circuit, it means there is voltage at the test points.
Since a fault is usually a break in the circuit, the technician is looking for
a point in the circuit where the meter indicates 0-volts. This means if a
voltage is measured on the second test, the circuit is operational up to
the test point. Continue testing until the meter indicates 0-volts. The
fault must then be located between the last test point where the voltage
was present and the first point in the circuit where the meter indicated 0-
voltage.
If the meter indicates 0-voltage on the first test, it means there is a fault
or break in the circuit close to the voltage source. Therefore, additional
tests will be made in that direction. In this situation the technician will be
looking for completely different results. If the voltage is zero, the
technician will be looking for the test point where a voltage is present.
The break in the circuit must then be located between the last point with
no voltage and the first point with a voltage. Make the second test by
moving the test lead to test point #4, as illustrated in Figure 16.
Figure 16. Control Circuit - Second Test

Leave the other test lead connected to test point #6. With the switch
closed the circuit is complete, and the meter indicates a voltage. This
proves the switch is operating normally.
The next test point deeper into the circuit is test point #5 at the relay coil.
Move the test lead to test point #5, as illustrated in Figure 17, page 39.
With the switch closed the meter indicates zero voltage. The previous
test proved the presence of voltage at test point #4, but there is no
voltage at test point #5. The only circuit element between these two test
39
points is the wire connecting the switch to the relay coil. This indicates
there is a broken connection between test points #4 and #5.
Figure 17. Control Circuit Test Showing Broken Connection
(b) Troubleshooting Tip: Move only one test lead at a time. In the above
tests only one test lead was moved from one test to the next test. This is
very important when isolating a fault. In this particular series of tests,
voltage was present on the first test. Locating a point where zero voltage
was indicated isolated the fault.
If both leads had been moved and zero voltage was indicated, the exact
location of the fault would have been lost. By moving one lead at a time,
the fault must be located between the last test point with voltage and the
first point without voltage.
40
REVIEW:
Applying a Systems Approach to Gas Appliance
Troubleshooting
Directions: Select from the list below the response that most correctly completes
space provided.
A. source voltage E. voltage drop
B. short circuit F. series-connected components
C. series circuit G. parallel circuit
D. 80
1. If load devices, switches, or other components are connected in the

circuit in such a way the total current passes through each component,
they are referred to as ____.
2. If the conditions of no resistance and high current flow are present in an

electrical circuit a _____ exists.
3. Characteristics of a ____ include:

It has only one path for the current to flow.
If the current path is broken, the circuit is open and no current flows.
Load devices allow the current to pass through each load device.
4. Characteristics of a ____ include:

Load devices, switches, or other components are connected in the circuit
in such a way they provide different current paths.
5. The total voltage drop across all the loads in a series circuit is equal to
the ____.
6. The ____ across any load device is the energy given to the load;
therefore, the voltage dropped depends on the current flowing through
the load device and the resistance of the load device.
Directions: Fill in the blanks to complete this statement.
7. Two troubleshooting techniques to apply when isolating an electrical circuit fault

using a voltmeter are:
41
Directions: Refer to the circuits below. Note that each component in the circuits has
test points and that these test points are also listed in the Test Check
Table. Every possible voltage check for circuits is indicated. The symbol
" " indicates a voltage present and the symbol " " indicates no voltage
present. These symbols give simulated test information to effectively
diagnose and isolate the components in the circuits which are causing
the problem.
Problem #1
The customer's complaint is the motor does not run when all the switches are in
operative position.
Which component is defective?
Circuit #1
A-B B-A C-A D-A E-A F-A
A-C B-C C-B D-B E-B F-B
A-D B-D C-D D-C E-C F-C
A-E B-E C-E D-E E-D F-D
A-F B-F C-F D-F E-F F-E
A-G B-G C-G D-G E-G F-G
Test Table #1
42
Problem #2
The customer's complaint is the motor does not run when all the switches are in the
operative position.
Which component is defective?
Circuit #1
Test Table #2
43
Problem #3
The solenoid valve in circuit #2 does not operate when the switches are in the
operative position.
Which component is causing the problem?
Circuit #2
Circuit #2
Test Table #3
44
Problem #4
The motor in circuit #2 does not run when the switches are in the operative position.
Which component is causing the problem?
Circuit #2
Test Table #4
45
Problem #5
The solenoid valve in circuit #3 will not operate when the switches are in the operative
position. The problem is an open interlock switch. Fill in the Test Check Table
indicating the presence of a voltage between each test point.
Answer:
Circuit #3
Test Table #5
46
Performance Criteria Self-Check:
7.1.3 Applying a Systems Approach to Gas Appliance
Troubleshooting
Directions: Use the following performance criteria statements as a self-evaluation in

preparation for the final exam.
I can identify:
1. Characteristics of series-connected electrical circuit components.
2. The term that describes the condition of no resistance and high current flow.
3. Characteristics of a series-connected circuit.
4. Characteristics of a parallel-connected circuit.
5. The voltage drop across a connected load.
6. The voltage drop in a series circuit.
7. Two troubleshooting techniques to apply when isolating an electrical circuit

fault using a voltmeter.
47
48
Identifying Basic Meter and Hazard
7.2.1 Reducing Guidelines Used in Measuring
Electrical Quantities
Table of Contents
Identifying Basic Meter and Hazard Reducing Guidelines Used in Measuring

Electrical Quantities ................................................................................................. 51
Identifying the Operating Principle of the Basic Analog Meter Movement................ 52
Identifying How to Read a Typical Analog Multimeter Scale.................................... 52
Identifying the Operating Principle and Functions of a Voltmeter ............................ 53
Identifying the Operating Principle and Functions of an Ammeter ........................... 55
Identifying the Operating Principle and Functions of an Ohmmeter ......................... 56
Identifying the Operating Principle and Functions of Digital Multimeters (DMM) ..... 57
Identifying the Operating Principle and Functions of Clamp Meters ........................ 58
Identifying Principles of Meter Safety and Meter Categories ................................... 59

Electric Shock ..................................................................................................... 59
Meter Safety ....................................................................................................... 60
Over Voltage Installation Categories .................................................................. 61
Review ..................................................................................................................... 63
49
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

50
Identifying Basic Meter and Hazard
7.2.1 Reducing Guidelines Used in Measuring
Electrical Quantities
The multimeter is a primary tool for the appliance service technician. In this module
you will learn to:
(1) Identify the operating principle of the basic analog meter movement
(2) Identify how to read a typical analog multimeter scale
(3) Identify the operating principle and functions of a voltmeter
(4) Identify the operating principle and functions of an ammeter
(5) Identify the operating principle and functions of an ohmmeter
(6) Identify the operating principle and functions of digital multimeters (DMM)
(7) Identify the operating principle and functions of clamp meters
(8) Identify principles of meter safety and meter categories
There are many types and kinds of meters used by technicians doing electrical work.
The most widely used meters are the:
(1) Voltmeter - used to measure voltage

(2) Ammeter - used to measure electrical current
(3) Ohmmeter - used to measure electrical resistance
Sometimes these three meters are combined into one case and called a multimeter,
or V.O.M, (volt, ohm, milliampere) meter.
Multimeters, as illustrated in Figures 1a and 1b, are available as analog or digital

instruments. Each type of instrument has unique operating and measuring
capabilities. Proper care and use of any electric meter is essential for maintaining
accuracy and safety.
Figure 1a. Analog Multimeter Figure 1b. Digital Multimeter
51
Most V.O.M. meters indicate on calibrated scales the value of the measured
electrical quantity. The accuracy of measurement, especially with analog meters,
depends on the skill of the technician using the meter and the quality of the
instrument.
(1) Identify the operating principle of the basic analog meter movement
Basic Analog Meter Movement. The basic movement used in an analog
electrical measuring device consists of a fixed permanent magnet and a
moving coil.
As illustrated in Figure 2, the meter

movement depends on the interaction
between a fixed magnetic field created
by the permanent magnet and the
varying magnetic field around the coil.
The magnetic field around the moving
coil is caused by electrical current
flowing through the moving coil.
The coil of fine wire is suspended so it

can turn within a fixed magnetic field.
An electrical current flowing through
the coil in the proper direction will
create a magnetic field, which will
interact with the fixed magnetic field
and cause the moving coil to rotate.
Figure 2. Basic Analog Meter
Movement
The rotation of the coil which is connected to a pointer will cause the pointer
to move along a scale or dial as the coil rotates. The dial is calibrated in units
of measurement. The larger the current through the coil the greater the
rotation of the coil.
(2) Identifying how to read a typical analog multimeter scale.
Illustrated in Figure 3 is the face of a meter showing various scales. The top
scale, which is read from right to left, is the ohms scale. The ohms scale is
calibrated to read from 0-3000 ohms. Reading on the ohms scale can be
increased by adjusting the range switch on the meter. The scale marked DC
is used for measuring direct current and voltage values. Notice the scale is
calibrated to read values of 0-2.5, 0-5, and 0-10. The scale marked AC is
used for measuring alternating current (AC) voltage only. The AC scale is
also calibrated to read values of 0-2.5, 0-5, and 0-10. Like the ohms scale,
both the DC and AC reading can be increased by adjusting the range switch
on the meter.
52
Figure 3. Typical Analog Multimeter Face
(3) Identifying the operating principle and functions of a voltmeter.
There are several ways in which a voltmeter can be constructed but only the
basic meter movement as described above will be discussed here. Some
voltmeters are designed to measure only DC voltage; others measure only
AC voltage; and some can be used to measure either AC or DC voltage by
proper switch positioning.
If 110 volts were applied directly to the moving coil, the wire forming the coil
would be burned out immediately. Therefore, a very high resistance is placed
in series with the moving coil. With this arrangement only a very small current
flows through the coil of the meter. The amount of current flowing through the
coil would be on the order of thousandths of an ampere (1/1000) called
milliamperes.
In addition to protecting the voltmeter's moving coil, the high resistance in

series with the moving coil serves two other purposes. (This resistor is called
multiplier).
First, with practically no current flow through the moving coil, placing the
voltmeter in a circuit or across a single component in the circuit will not affect
the current flow in the circuit or the component. In effect current flow through
the circuit or component in the circuit is the same as though the voltmeter
were not connected.
Second, by switching to one of several multiplier resistors in a voltmeter, one

meter can be used to measure several ranges of voltage (for example,
0-2.5V, 0-10V, 0-50V, 0-250V, 0-1000V and 0-5000V volts) using an
appropriate scale on the meter dial. Illustrated in Figures 4 and 5 are
examples of the switch positions located on a Simpson 260 V.O.M. for
measuring both DC and AC voltage.
53
Range
Switch
{7.2.1.6}
Figure 4. Jacks and Switch Positions for Measuring DC Volts
Figure 5. Jacks and Switch Positions for Measuring AC Volts
Illustrated in Figure 6 is a scale calibrated to read the value of both DC and

AC volts. When DC voltage values are to be read, the selector switch on the
front of the meter is set on DC. If AC voltage values are to be read, the
selector switch is set on AC.
Figure 6. Meter Scale Calibrated to Measure AC or DC Volts
54
(4) Identifying the operating principle and functions of an ammeter.
Ammeters involve the same principles of operation as voltmeters. The name

ammeter is a shortened form of the proper name ampere-meter. Illustrated in
Figure 7, on page 9, is a DC scale. Like the voltmeter it has a pointer which
moves in front of a calibrated scale. In this figure the scale is calibrated from
0-10, 0-5, and 0-2.5 amperes. The movement of the pointer is proportional to
the amount of current flowing through the meter (moving coil).
Figure 7. Meter Scale

Current measurements require the ammeter be
placed in series with the part of the circuit being
measured as illustrated in Figure 8. So the
electrical properties of the circuit remain essentially
unchanged, the ammeter must have a very small
resistance. Only very, very small electrical currents
are measured by passing current through the
moving coil. The ammeter is actually a sensitive
voltmeter which measures the voltage drop across Figure 8.
a resistance placed in series with the circuit. Measuring Current
As with voltmeters, ammeters are designed to measure several ranges of
amperes. Illustrated in Figure 9 is an example of a meter designed to
measure amperes on the following scale: 0-500MA, 0-100MA, 0-10MA,
0-1MA, and 50M amps.
55
Figure 9. Milliampere Range
(5) Identifying the operating principle and functions of an ohmmeter.
The basic meter movement of a

voltmeter is also used for measuring the
resistance of a component. The
ohmmeter has a built-in set voltage
source (usually a small dry cell battery).
The ohmmeter should never be
connected to any outside voltage source.
Illustrated in Figure 10 is a simple
ohmmeter circuit. The circuit consists of
a basic meter movement, (Rm) a
variable resistance, (Rn) and a fixed
resistance (Rf). The resistance to be
measured is placed between the Figure 10.
terminals A and B. Simple Ohmmeter Circuit
Note the scale of an ohmmeter is the reverse of the voltmeter scale. The
voltmeter scale has the zero on the left as illustrated in Figure 7, page 5.
With the ohmmeter scale full deflection of the needle to the right end of the
scale is a reading of zero ohms, while the left end of the scale indicates an
infinite resistance, shown by the symbol:
Ohmmeters are designed to measure resistance on several ranges of

resistance values. The ohmmeter illustrated in Figure 11 is designed to read
on a scale of multipliers of 1,100, and 10,000 ohms.
56
Figure 11. Ohm Range
(6) Identifying the operating principle and functions of digital multimeters

(DMM).
Digital multimeters do not use the electromechanical movement method to

measure electrical quantities as described for analog meters. Instead, digital
meters use electronic components, semi-conductors and integrated circuit
technology. The values obtained are displayed as positive or negative
numbers (with decimal point if appropriate) on a display screen.
Figure 12. Voltage Measurement with

Digital Multimeter
Digital meters are available in many different designs and offer a variety of
features and accessories for measuring physical quantities such as heat, as
well as basic electrical quantities. Because of “auto-ranging” and “display
hold” features, DMMs are increasingly becoming more popular with
technicians, especially as appliances incorporate integrated circuit logic to
57
control appliance operation. An important feature to aid in determining
accuracy in readings is the use of analog bar graphs in the display on certain
functions. Figure 13 illustrates how a bar graph helps make a measurement
easier to interpret.
Figure 13. Bar Graph and Digital Display

The display in Figure 13 shows that the instrument is measuring in the 0 to 30
amps range. The wave symbol, ~, indicates that the current is AC. The bar
graph confirms that the actual reading is at least 7 on the 0 to 30 scale, with
the decimal in the digital display indicating that the actual reading is 7.25
amps AC. A bar graph shows changes in trends in a signal or electrical
quantity reading just like an analog needle, but is more durable and less
prone to damage.
To fully understand and use all the features and capabilities of a digital
multimeter, it is important to study the manufacturer’s instructions, and
consult any technical bulletins that may be available from the manufacturer.
(7) Identifying the operating principle and functions of clamp meters.
Technicians in the propane industry are frequently required to determine if

motors are starting and running properly. Determining starting and running
amp draw is the first step in making that determination. Using a clamp meter
makes the measuring of starting and running amps a fairly simple process.
Figure 14 shows an analog and a digital clamp meter.
Figure 14. Analog and Digital Clamp Multimeter
58
By comparing actual starting and running amps measured with the starting
and running amps design ratings stamped on motor data plates, a
technician can get a good start on diagnosing problems with motors. Often
the problem may be in the wiring supplying the current to the motor, and
excessively high amp readings are a strong indication of possible wiring
under sizing.
(8) Identify principles of meter safety and meter categories.
(a) Electric Shock.
While most people are aware of the danger from electric shock, few
realize how little current and how low a voltage is required for a fatal
shock. Current flows as low as 30 mA can be fatal (1 mA = 1/1000A).
Let's look at the effects of current flow through a "typical" 68 kilogram
(150 pound) male:
" At about 10 mA, muscular paralysis of the arms occurs, so that
he cannot release his grip.
" At about 75-250 mA, for exposure exceeding 5 seconds,
ventricular fibrillation occurs, causing disruption of the coordination
of the heart muscles—the heart can no longer function. Higher
currents cause fibrillation at less than 5 seconds. The results are
often fatal.
Now let's calculate the threshold for "hazardous" voltage. The
approximate body resistance under the skin from hand to hand across
the body is 1000!, under dry conditions. A voltage of only 30V across
1000! will cause a current flow of 30 mA. Under wet conditions, or if
there is a cut in the skin, resistance drops radically. The threshold of
hazardous voltage is cut in half to 15V.
For multimeter manufacturers and users, the object is to prevent
accidental contact with live circuits at all costs. Look for:
" Meters and test leads with double insulation.
" Meters with recessed input jacks and test leads with shrouded
input connectors.
" Test leads with finger guards and a non-slip surface.
" Meter and test leads made of high-quality, durable non-
conductive materials.
59
(b) Meter Safety.
Using meters safely requires you to be aware of the hazard of

electrical shock and how to reduce the risks through the application of
your knowledge and the proper precautions to apply when working
near electrical sources. Two factors regarding the selection and use of
electrical meters must be considered before using a meter.
" First—be sure that your test meters are rated to protect you in the
locations you will be working; and
" Second—be sure that the ratings of test leads and accessories
provide equal or greater protection.
Meter over voltage categories are based on performance standards

that must be met by a particular meter model and type made by a
specific manufacturer. They provide a basis for gauging the amount of
over voltage protection that the instrument generally provides the user.
As a general rule the instrument selected for use should provide the
highest protection for the user for the location and type of equipment
being tested. As shown in Figure 15, the closer the location to primary
(high voltage) sources, the higher the category the meter should have.
Your meter and test leads should have a category rating that you can
compare with the following chart:
Figure 15. Meter Categories by Location
As you can see by the chart on the next page, the measurements
typically done in the propane industry call for at least a Category III
instrument, even though the majority of the time, technicians will be
making measurements typical of Category II locations and equipment.
60
(c) Over Voltage Installation Categories.
Overvoltage
Brief Description Examples
Category
" Refers to the "origin of installation", i.e.,
where low-voltage connection is made to
utility power.
Three-phase at " Electricity meters, primary overcurrent
utility connection, protection equipment.
CAT IV
any outdoors " Outside and service entrance, service drop
conductors from pole to building, run between meter
and panel.
" Overhead line to detached building,
underground line to well pump.
" Equipment in fixed installations, such as
switchgear and polyphase motors.
Three-phase
" Bus and feeder in industrial plants.
distribution,
" Feeders and short branch circuits,
CAT III including single-
distribution panel devices.
phase commercial
lighting. " Lighting systems in larger buildings.
" Appliance outlets with short connections to
service entrance.
" Appliance, portable tools, and other
household and similar loads.
Single-phase " Outlets and long branch circuits.
CAT II receptacle " Outlets at more than 10 meters (30 feet
connected loads from CAT III source)
" Outlets at more than 20 meters (60 feet
from CAT IV source.
" Protected electronic equipment.
" Equipment connected to (source) circuits in
which measures are taken to limit transient
overvoltages to an appropriately low level.
CAT I Electronic
" Any high-voltage, low-energy source
derived from a high-winding resistance
transformer such as the high-voltage
section of a copier.
Meter ratings and capabilities vary by manufacturer.

Before working with a new meter, be sure to familiarize
yourself with all operating and safety procedures for that
meter. Read and follow the directions, warnings and
procedures given in the users manual.
61
Work Safely
Safety is everyone's responsibility but ultimately it's in your hands.
No tool by itself can guarantee your safety. It's the combination of the right
tools and safe work practices that gives you maximum protection. Here are a
few tips to help you in your work.
" Work on de-energized circuits whenever possible. Use proper lock-
out/tag-out procedures. If these procedures are not in place or not
enforced, assume that the circuit is live.
" On live circuits, use protective gear:
—Use insulated tools.
—Wear safety glasses or a face shield.
—Wear insulated gloves; remove watches or other jewelry.
—Stand on an insulated mat.
—Wear flame resistant clothes, not ordinary work clothes.
" When making measurements on live circuits:
—Hook on the ground clip first, then make contact with the hot lead.
Remove the hot lead first, the ground lead last.
—Hang or rest the meter if possible. Try to avoid holding it in your hands,
to minimize personal exposure to the effects of transients. (A transient
is a momentary high voltage spike which "rides" into circuits from an
exterior source such as a nearby lightning strike.)
—Use the three-point test method, especially when checking to see if a
circuit is dead. First, test a known live circuit. Second, test the target
circuit. Third, test the live circuit again. This verifies that your meter
worked properly before and after the measurement.
—Use the old electricians' trick of keeping one hand in your pocket. This
lessens the chance of a closed circuit across your chest and through
your heart.
SAFETY TIP
Protect yourself—Look for category and voltage ratings of
test leads and multimeters before attempting to measure
electrical values in any electrical circuit.
62
REVIEW:
Identifying Basic Meter and Hazard Reducing
Guidelines Used in Measuring Electrical Quantities
Directions: Select from the list below the response which most correctly completes
space provided.
A. equal to or greater J. 0 - 2.5 volts DC

B. 0 - 50 volts DC K. 0 - 100 MA
C. ammeter L. de-energized
D. live M. 30 mA
E. 15 volts N. 0 - 2.5 volts AC
F. greater O. V.O.M. or multimeter
G. ohmmeter P. ground
H. magnetic field Q. range switch
I. 0 - 2.5 amperes AC R. keep 1 hand in your pocket
1. The meter used to measure only electrical current is the _____.
2. The meter used to measure only electrical resistance is the _____.
3. A meter designed to measure voltage, resistance, and amperes is

referred to as a ______.
4. The rotation of the moving coil in an analog meter movement is

caused by a _____, produced by electrical current flowing through the
coil.
5. The meter illustrated below is set to read _____.
63
B. 0 - 50 volts DC K. 0 - 100 MA
D. live M. 30 mA
6. The selection of the electrical value to be measured using an analog

meter is made by adjusting the _____.
7. When the human body is grounded, contact with an electrical current

as low as _____ can be fatal.
8. Under wet conditions, or if there is a cut in the skin, the threshold of

hazardous voltage can be a low as _____.
9. The ratings of test leads and accessories to be used with a meter

should be ______ than the ratings required for the locations you will be
working in.
10a. Whenever possible, work on electrical circuits when they are ______.
10b. If lock-out/tag-out procedures are not in place or not enforced, assume

that the circuit is _____.
11a. When measuring electrical quantities, hook on the _______ clip first
then make contact with the hot lead. Remove the hot lead first, the
_______ lead last.
11b. To reduce the danger of electrical shock, ________.
12. The larger the current flowing through the coil, the _____ will be the
deflection of the meter pointer.
64
B. 0 - 50 volts DC K. 0 - 100 MA
D. live M. 30 mA
13. The analog meter illustrated below is set to read _____.
14. The analog meter illustrated below is set to read _____.
65
B. 0 - 50 volts DC K. 0 - 100 MA
D. live M. 30 mA
15. The meter illustrated below is set to read _____.
66
7.2.1 Identifying Basic Meter and Hazard Reducing Guidelines
Used in Measuring Electrical Quantities

I can identify:
1. The name of the meter designed for measuring electrical current.
2. The name of the meter designed to measure electrical resistance.
3. The name of the meter designed to measure volts, ohms, and

milliamperes.
4. The electrical effect which causes the rotation of the moving coil in an
analog meter movement.
5. The method used to select the appropriate voltage range when using an
analog multimeter.
6. The location of the range switch on an analog multimeter.
7. The minimum voltage that can be fatal.
8. The threshold of hazardous voltage under wet conditions or if there is a

cut in the skin.
9. Factors regarding the selection and use of electrical meters.
10. The safest time to work on circuits.
11. Safety procedures to use when making measurements on live circuits.
67
68
Identifying Procedures for Measuring
7.2.2 Voltage Between Two Given Points in
an Electrical Circuit
Table of Contents
Identifying Procedures for Measuring Voltage Between Two Given Points

in an Electrical Circuit .............................................................................................. 71
Establishing a Troubleshooting Routine................................................................... 71
Identifying Voltage or Electromotive Force .............................................................. 72
Connecting the Meter to Measure Electrical Current ............................................... 73
Reading Voltage Values .......................................................................................... 75
Review ..................................................................................................................... 78

69
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

70
7.2.2 Voltage Between Two Given Points in
A professional service technician uses established routines, knowledge and
experience to get the customer’s appliance problem identified and repaired in the
shortest time consistent with safety and quality work. In this module you will learn
to:
(1) Establish a troubleshooting routine

(2) Identify voltage or electromotive force
(3) Connect the meter to measure electrical current
(4) Read voltage values
(1) Establishing a troubleshooting routine.
Experienced appliance technicians typically apply a quick checklist of simple

problems that may cause the gas appliance to malfunction or not operate:
$ How does the customer describe the problem?

$ Is the gas supplied at the proper volume and pressure?
$ On water boilers, is the supply water valve open?
$ Is the appliance plugged in, or otherwise supplied with electrical power?
$ Are appliance access doors that hold in electrical interlock switches
properly installed and seated?
$ Are air filters in place and clean?
$ Are required appliance circuits and components properly electrically
grounded?
$ Is the electrical wiring to fan motors, as well as their start and run
capacitors, apparently in proper order? Are any associated pulleys
and belts in proper working order?
$ Is there low voltage power to the thermostat? Has the thermostat been
properly operated to establish a call for heat?
Listening to the customer leads the list, followed by a quick check of simple
problem conditions often reveals the cause of the service call. If these items
are apparently OK, more detailed troubleshooting is called for. The first step
is to locate the appliance manufacturer’s operating instructions and electrical
diagrams.
From the perspective of safety, it is better to not work near energized

electrical circuits. From a troubleshooting viewpoint, testing for proper supply
voltage is usually the first thing measured when troubleshooting an appliance
or a circuit.
71
It is true that a “continuity test”—a resistance measurement of a component
such as a solenoid coil—can be performed on a de-energized circuit.
However, a continuity test will probably not be your starting point unless you
have indications that a particular electrical component is faulty (which can
come in the form of a manufacturer’s service bulletin, or a very specific set of
symptoms from the customer). Continuity testing is addressed further in
CETP module 7.2.3.
As discussed in module 7.1.3, a quick method for isolating a wiring fault or

faulty component in a circuit is by testing for voltage in a systematic way in an
electrical circuit.
(2) Identifying voltage or electromotive force.
Electromotive force (EMF) is a term used to describe the electrical pressure

which causes electrical current to move through a conductor (circuit). The
unit of measurement for electromotive force is the volt. This is similar to
pounds per square inch; (psi) a measurement for gas pressure. For example,
the pressure in a propane line may be 25 psi, or the electromotive force in an
electrical circuit may be 1.5 volts. The symbols used for specifying volts are
the letters "E" or "V."
The most common devices used for generating a source voltage in electrical
power circuits are:
(1) Chemical (battery - the schematic symbol for the battery is:
(2) Mechanical (generator - the schematic symbol for the

generator is:
Figure 1 illustrates a basic electric circuit. The devices may be compared to a

pressurized gas container in a propane gas system.
72
Figure 1. Electrical Circuits
Any EMF introduced into a circuit by a voltage source is called a voltage rise.
For example, a 6 volt battery has a voltage rise of 6 volts.
When electrons flow through a load they give up their energy to the load.
Most often the energy is given off as heat. However, if the load is a light bulb,
both heat and light are given off. Notice that the energy provided to the circuit
by the voltage source is released to the circuit.
Since the energy introduced into the circuit is called voltage rise, the energy
removed from the circuit by the load is called a voltage drop. A voltage drop
is expressed in volts just as in the case with the voltage rise. In fact, the
voltage drop in a circuit is equal to the voltage rise. One difference between
voltage drop and voltage rise is that voltage drop occurs only when current
flows through the load. A battery has a voltage rise whether or not it is
connected to a circuit. However, a load produces a voltage drop only when
current flows through it.
(3) Connecting the meter to measure electrical current.
Voltage is always measured between two points. The schematic symbol for
the voltmeter is illustrated in Figure 2.
Figure 2. Symbol for Voltmeter
Notice that one of the leads is marked negative and the other is marked
positive. As with ammeters, polarity must be observed when measuring
voltage, especially when an analog meter is used.
73
When measuring voltage, the circuit
being tested is not broken or
disturbed in any way. As illustrated in
Figure 3, to measure the voltage
between two points, touch the two
leads of the voltmeter to the points
being tested, and observe polarity by
connecting the negative lead of the
meter to the more negative point
being tested. Also, the meter is
connected directly across the load. In
this case the volt meter is measuring
voltage drop. If the switch is opened,
current would stop flowing and the
voltage drop would be zero.
Figure 3. Measuring Voltage
Precautions to be taken when measuring voltages include the following

practices:
(1) Check to insure the voltage to be measured is not higher than the
meter can measure.
(2) Be certain the meter is set on the proper voltage range. If the value of
the voltage is unknown, set the range switch on the highest range.
(3) Be sure to hold the meter leads only by the insulated portions.
(4) When working on electronic equipment, it is a good practice to connect
one meter lead to ground, the common, or neutral, and leave it there.
This way only one hand is required to make voltage checks. This
reduces the chance of receiving an electrical shock, since there is no
complete path for current to flow through the body.
Figure 4a. One Lead Clipped to Ground, Figure 4b. Using One Hand to Probe
Common, or Neutral
74
(4) Reading voltage values.
Illustrated in Figure 5a is the front of a commonly used analog multimeter

showing the graduated scales, selector switch, and range switch. The meter,
as shown, is set up to measure DC voltages. Notice the selector switch is set
to measure DC circuits, and the range switch is set to measure 0-10 volts.
Figure 5b shows a digital multimeter configured to make the same

measurement.
Figure 5a. Analog Multimeter Set to Figure 5b. Digital Multimeter Set to
Measure DC Volts Measure DC Volts
The multimeters in Figure 5 are set to measure DC volts. On the analog
meter, with the selector switch set on DC and the range switch set on 10
volts, the pointer indicates a measurement of 2.6 volts. The digital meter
display indicates the same 2.6 volts.
When using an analog meter, the technician must remember that in some
cases it is necessary to apply the mathematical operation of increasing the
scale reading by the correct “power of 10s” to read the measurement. For
example: in Figure 5a the meter is set on the 10 V AC scale and readings are
made on the lowest line (0-10). If the meter were set on the 250 V AC scale,
the reading would be made on the top AC scale (0-2.5); however, the pointer
reading must be multiplied by 100.
75
The following examples illustrate how to read AC or DC volts on analog
meters with the range switch at various settings.
Example 1:
If the selector switch is set on DC, the range switch set on 50 volts, and the
pointer is positioned as shown, then the actual number of volts measured is 7
volts DC.
Example 2:
If the selector switch is set on DC, the range switch set on 250 volts, and the
pointer is positioned as shown, then the actual number of volts measured is
185 volts DC.
Example 3:
If the selector switch is set on AC, the range switch set on 50 volts, and the
pointer is positioned as shown, then the actual number of volts is 27 volts AC.
76
Example 4:
If the selector switch is set on AC, the range switch is set on 10 volts, and the
pointer is positioned as shown, then the actual number of volts measured is
3.7 volts AC.
Remember:
1. Voltage measurements are always made across a load or power
source.
2. Voltage measurements are always made parallel to the circuit.
3. Voltage measurements are made on “live” circuits—use protective
measures.
4. Do not attempt voltage measurements of the output of a spark or
hot surface ignition module. The voltages generated by these
devices are in excess of the measuring ranges of typical
multimeters and can damage your meter and may cause death or
injury.
77
REVIEW:
Identifying Procedures for Measuring Voltage
Between Two Given Points in an Electrical Circuit
space provided. A response may be used more than once.
A. voltage G. parallel
B. 9.3 H. 87.2
C. 150 I. V
D. volt J. in series
E. electromotive force (EMF) or voltage K. 1.5
F. listening to the customer’s description of the problem L. load
1. The initial steps in an appliance troubleshooting routine are _____,

followed by checking for simple conditions that may the cause of the
problem.
2. _____ is a term used to describe the electrical pressure which causes
electrical current to move through a conductor or circuit.
3a. Using the illustration below, if the selector switch is set on DC, the
range switch set on 250 volts, and the pointer is positioned as shown,
then the actual number of volts measured is _____ DC volts.
78
A. voltage G. parallel
B. 9.3 H. 87.2
C. 150 I. V
D. volt J. in series
E. electromotive force (EMF) or voltage K. 1.5
F. listening to the customer’s description of the problem L. load
3b. Using the illustration below, if the selector switch is set on AC, the
range switch set on 10 volts, and the pointer is positioned as shown,
then the actual number of volts measured is _____ AC volts.
4. When measuring electrical voltage the meter is connected _____ with

the circuit being tested.
5. A symbol used to denote voltage is the letter _____.
6. Electrical energy introduced into the circuit is referred to as _____ rise.

7. Electrical energy removed from an electrical circuit is referred to as
_____ drop.
9. When connecting a meter for a voltage measurement, the connection

is always across a ______ or power source.
10. The symbol used to represent the unit of measurement of

electromotive force is the _____.
79
7.2.2 Identifying Procedures for Measuring Voltage

I can:
1. Identify the initial steps in an appliance problem troubleshooting routine.
2. Identify the term used to describe the electrical pressure that causes
electrical current to move through a conductor (circuit).
3. Read AC or DC volts as indicated on the face of an analog meter.
4. How the meter is connected to a circuit for a voltage measurement.
80
7.2.3 Resistance Between Two Given
Points in an Electrical Circuit
Table of Contents
Identifying Procedures for Measuring Resistance Between Two Given Points

Applying Safety Precautions While Measuring Electrical Resistance ...................... 83
Identifying Electrical Resistance .............................................................................. 83
Identifying Variable Resistors and Their Functions .................................................. 84
Connecting the Meter to Measure Resistance Values ............................................. 84
Identifying the Operating Principle of an Ohmmeter Circuit ..................................... 85
Zero Ohms Adjusting: Analog Meters ...................................................................... 85
Zero Ohms Checking: Digital Meters ....................................................................... 86
Measuring Resistance Values ................................................................................. 87
Performing a Circuit Continuity Test ........................................................................ 88
Review ..................................................................................................................... 89

81
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

82
7.2.3 Resistance Between Two Given
Points in an Electrical Circuit
Continuity tests of coils and similar components can help identify a faulty appliance
part. Other tests for resistance are useful tools for troubleshooting individual
appliance components. In this module you will learn to:
(1) Apply safety precautions while measuring electrical resistance

(2) Identify electrical resistance
(3) Identify variable resistors and their functions
(4) Connect the meter to measure resistance values
(5) Identify the operating principle of an ohmmeter circuit
(6) Zero Ohms adjust: analog meters
(7) Zero Ohms check: digital meters
(8) Measure resistance values
(9) Perform a circuit continuity test
(1) Applying safety precautions while measuring electrical resistance.
Measuring resistance in circuit components calls for great care and is an

exacting operation. If fundamental rules are violated, damage can be done to
the customer’s equipment, your multimeter, and possibly to yourself.
Rule #1 Resistance measurements must always be done with the

circuit and equipment power supply off.
Rule #2 Because of Rule #1, lock-out and tag-out procedures should be

in place and enforced.
Rule #3 Never, NEVER attempt a resistance measurement on a printed

circuit board. The voltage supplied by your meter will, in most
cases, damage the circuit board (a very expensive part to
replace).
Rule #4 Without manufacturer’s instructions which detail the test

procedure for a particular component or circuit—along with the
acceptable range of resistance values for the component(s)—
you will probably have no need for a resistance measurement.
(2) Identifying electrical resistance.
If a short length of copper wire is connected between the terminals of a

battery, a large amount of electrical current will flow. In fact, the battery will
quickly become discharged, producing a potentially dangerous amount of
83
heat in the battery and connecting wire. If a short length of rubber is
connected between the terminals of a battery, no measurable current will
flow. It can be seen that the copper and the rubber have very different
characteristics when it comes to providing a path for current flow.
Copper offers little opposition to electrical current flow, while rubber practically
blocks electrical current flow. This opposition to current flow is referred to as
resistance (R).
Sometimes it is necessary to include a resistance in a circuit to limit electric

current flow. Devices used for this purpose are called resistors. Resistors
are poor conductors designed with high resistance to reduce current flow to
some desired level. Unlike switches, which are designed to provide an on-off
flow to the load, resistors control the level of current flow in the circuit.
There are two basic types of resistors according to their control function:
(1) Fixed resistor, and

(2) Variable resistor
The resistance value of a fixed resistor is designed to remain constant;

however, the resistance value will vary with changes in temperature. The
resistance value of most resistors will increase with increased temperature.
The schematic symbol for a fixed resistor is:
The unit of measurement for resistance is the ohm, with the symbol: !.
(3) Identifying variable resistors and their functions.
The resistance value of a variable may be varied from zero to some fixed
maximum value. The schematic symbol for a variable resistor is:
Variable resistors are useful in control circuits where a variance in output of

an electrical device is desired. Some variable resistors specifically designed
for this purpose are called potentiometers. A familiar application is a volume
control for audio speakers on older radios and televisions.
(4) Connecting the meter to measure resistance values.
Both analog and digital meters can be used to measure resistance value.
Unlike the other functions of the multimeter, the ohmmeter has a built in
voltage source. The ohmmeter should never be connected to any electrical
source.
84
(5) Identifying the operating principle of an ohmmeter circuit.
A basic ohmmeter circuit is illustrated in Figure 1. The operating principle of

the ohmmeter is to force a current to flow through an unknown resistance,
then measure the current. Remembering Ohms Law for a given voltage, the
current flow will be determined by the resistance in the circuit. That is the
amount of current flow measured by the meter is an indication of the value of
the unknown resistance. Therefore, the scale of the meter can be calibrated
to indicate ohms.
Figure 1. Basic Ohmmeter
The purpose of the battery is to force current through the unknown resistance.
In an analog meter, the meter movement is used to measure the current flow
through the completed circuit. The fixed resistor R1 limits the current through
the meter to a safe level. Variable resistor R2 is called the ZERO OHMS
adjustment, and is part of the V.O.M. The purpose for the ZERO OHMS
adjustment is to compensate for voltage changes because of battery aging.
(6) Zero Ohms adjusting: analog meters.
Each time the ohmmeter is used, check the zero indication on the meter
before measuring resistance. Check and adjust it each time the switch is
positioned to a different range. Figure 2, on the next page, illustrates the zero
check and adjustment of an analog clamp meter.
To set the ZERO OHMS controls on an analog meter, proceed as follows:
85
(1) Set the range switch at one of the resistance range positions, switch at
either - DC or + DC.
(2) Connect the black test lead in the COMMON - jack and the red test
lead in the + jack.
Figure 2a. Initial reading. Figure 2b. Zero adjustment reading.
(3) Clip the contact end of the test leads together to short out the
resistance circuit.
(4) Observe the meter indication. It should read zero on the right hand
end of the Ohms arc, which is at the top of the dial.
(5) If the pointer does not read zero, rotate the ZERO OHMS knob until it
does. If the pointer does not move far enough to read zero, one or
more batteries need to be replaced.
(6) When the pointer shows zero, unclip the shorted test leads. The
ohmmeter circuit is now ready to measure resistance.
(7) Zero Ohms check: Digital Meters.
Digital meters will typically not display a zero reading when the test leads are
shorted out. Check the manufacturer’s instructions to determine the specified
readings to expect. Figure 3 shows a digital meter with the leads shorted.
86
Figure 3. Digital meter “0” ohms display.
According to the manufacturer’s specifications for the meter shown in Figure

3, the display should show a reading # 0.2! with test leads touching
(shorted).
(8) Measuring Resistance Values.
Remember:
Always follow equipment and meter manufacturer's

instructions.
To measure resistance with an analog meter proceed as follows:
1. Turn off the power to the circuit.
2. Set the range switch in one of the resistance range positions.
Use R X 1 for resistance readings from 0 to 200 ohms.

Use R X 100 for resistance readings from 200 to 20,000 ohms.
Use R X 10,000 for resistance readings above 20,000 ohms.
3. Set the function switch at either - DC or + DC.
4. Connect the black test lead in the COMMON - jack and the red test
lead in the + jack.
5. Short the test leads together and adjust for zero ohms.
6. Separate the test leads; then connect them across the resistance to be
measured. If there is a "forward" and "backward" resistance such as in
rectifiers, switch back and forth between the two DC positions of the
function switch to reverse the polarity.
87
7. Read the indication on the OHMS arc at the top of the dial. Note this
arc reads from right to left for increasing values.
8. Multiply the readings by the multiplier factor at the switch position for
resistance value in ohms. "K" on the dial stands for "thousandths".
To measure resistance with an digital meter proceed as follows:
1. Turn off the power to the circuit.
2. Select resistance on the meter dial (!).
3. Plug the black test probe into the COM input jack. Plug the red test
probe into the ! input jack.
4. Connect the probe tips across the component or portion of the circuit
where you want to determine resistance.
5. View the reading, being sure to note the unit of measurement—ohms

(!), kilohms (k!), or megohms (M!).
NOTE: 1,000! = 1 k!
1,000,000! = 1 M!
(9) Performing a circuit or component continuity test.
A continuity test is a quick go/no-go resistance test that distinguishes

between an open and a closed circuit. As with all resistance measurements,
a continuity test must be made with the power disconnected. When you
suspect a particular component to be faulty and which should have low
resistance (such as a normally closed switch, or a motor winding or solenoid
coil)—a continuity test can be a very useful diagnostic method. Likewise if
you suspect a problem in connecting wiring or a connector, a continuity test
may be a great time saver.
88
REVIEW:
Identifying Procedures for Measuring Resistance
space provided. You may use an answer for more than one question.
A. R H. variable O. off
B. volt I. 23 P. never
C. ohm J. fixed Q. continuity
D. l K. 230 R. variable resistor
E. 52,000 L. centering
F. resistance M. 5,200
G. zero ohm N. 810
1. Resistance measurements must be done with the circuit and
equipment power supply _____.
2. You should _____ attempt a resistance measurement on a printed

circuit board.
3. This schematic symbol below represents _____.
4a. Using the illustration below, if the selector switch is set on DC, the
range switch set R:1, and the pointer is positioned as shown, then the
actual resistance value is _____ ohms.
89
G. zero ohm N. 810
4b. Using the illustration below, if the selector switch is set on DC, the
range switch set on R X 1,000, and pointer is positioned as shown,
then the actual resistance value is _____ ohms.
4c. Using the illustration below, if the selector switch is set on DC, the
range switch set on R X 100, and the pointer is positioned as shown,
then the actual resistance value is _____.
5. A continuity test must be performed with the power supply _____.
6. The unit of measurement for resistance is the _____.

7. There are two basic types of resistors according to their control
function; one is a variable resistor, the other is a _____ resistor.
8. If the voltage on a circuit remains constant, the current flow will be
determined by the _____ in the circuit.
90
G. zero ohm N. 810
9. The voltage change caused by an aging battery in an analog

ohmmeter circuit is compensated for by the _____ adjustment.
10. The letter symbol for resistance is _____.
11. A meter set to read ohms should ______ be connected to any
electrical source.
12. A _____ test is a quick go/no-go test to that distinguishes between and
open and a closed circuit.
13. The display on a digital meter will probably never read ______.
91
7.2.3 Identifying Procedures for Measuring Resistance
I can identify:
1. A fundamental rule for safely making resistance measurements
2. An appliance component where resistance measurements should never

be attempted.
3. The schematic symbol for a variable resistor.
4. The correct analog meter range switch setting for resistance readings.
5. The condition that must be verified before performing a continuity test on a

electrical circuit or component.
92
7.2.4 Current Between Two Given Points in an
Electrical Circuit
Table of Contents
Identifying Procedures for Measuring Current Between Two Given Points

Identifying Electrical Current and Its Unit of Measurement ...................................... 95
Classification of Electrical Current ........................................................................... 96
Connecting the Meter to Directly Measure Electrical Current .................................. 96
Applying Meter Input Protection ............................................................................... 97
Principles of Indirect Measurement of Current Values ............................................. 98
Using Current Measurement to Set a Thermostat Heat Anticipator ......................... 99
Review ................................................................................................................... 101
Performance Criteria Self-Check: .......................................................................... 102

93
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

94
7.2.4 Current Between Two Given Points in
Making current measurements is useful for checking proper operation of electrical
motors, heating elements, and setting the heat anticipator on some electro-
mechanical thermostats. In this module you will learn to:
(1) Identify electrical current and its unit of measurement

(2) Identify electrical current classifications
(3) Connect the meter to directly measure electrical current
(4) Apply meter input protection
(5) Use principles of indirect measurement of current values
(6) Use circuit current measurement to set a thermostat heat anticipator
(1) Identifying electrical current and its unit of measurement.
Electrical current flow is the flow of electrons from a negative to a positive

charge. Electric current flowing through an electrical circuit may be compared
to the flow of gas through a piping system. However, as illustrated in Figure
1, there is one primary difference. In a gas system the gas flows from the
source to the load (burner), and in an electrical system the current flows from
the voltage generator through the load and then back to the voltage
generator.
Figure 1. Comparing Gas Flow with DC Electrical Current Flow
The electric current, as illustrated in Figure 1, is composed of charged

particles moving in the electrical circuit. The charged particles are called
electrons. Therefore, electrical current may be referred to as electrons
moving in the circuit. Just as gas moving through a piping system is
measured in cubic feet, electrons moving in an electrical conductor are
measured in amperes. The mathematical symbol for amperes is the letter "I."
(The letter "I" stands for intensity of electron flow).
The unit of measurement for electrical current is the ampere. The ampere is
the rate at which electrons move past a given point.
95
The name ampere is often shortened to amps and is abbreviated "I" or "A."
Many times the ampere is too large a unit. In these cases metric prefixes are
used to specify smaller units. The milliampere (MA) is one thousandth (.001)
of an ampere. The microampere (m) is one millionth (.000001) of an ampere.
In other words, there are 1,000 milliamperes or 1,000,000 microamperes in
an ampere.
(2) Classification of electrical current.
Electrical current is commonly classified as either direct current DC or

alternating current AC. The measurement of current in this instruction sheet is
discussed primarily in terms of digital meters.
Current measurements are different from other measurements made with a
digital multimeter.
" Direct current measurements are taken by placing the meter directly
in series with the circuit being measured, thus allowing all circuit current
to flow through the meter circuitry. This method requires special
precautions and procedures.
" Indirect current measurement does not require the circuit to be

opened nor does it require the meter to be placed into the circuit.
Indirect current measurement does require the use of a current probe or
a clamp meter.
(3) Connecting the meter to directly measure electrical current.
To protect yourself and the ammeter the following steps should be followed:
Step 1: Turn off the power supply or

remove the power source from
the circuit to be tested. One
method of removing the power
source is to disconnect one leg of
the circuit from the power
source terminal.
Step 1: Disconnect the
Power Source
Step 2: Break the circuit (current path)
at the point where the current is
to be measured. Do this by
cutting, disconnecting or un-
soldering the connecting
wiring in the circuit. The reason
for breaking the current is the Step 2: Break the Circuit
ammeter is connected in series with
the leg of the circuit being tested.
96
Step 3: Select Amps AC (A~) or Amps DC (A ) as required.
Step 4: Plug the black test probe into the COM input jack. Plug the red test
probe into the highest expected range jack—this might be the 10
amp (10A) or 300 milliamp (300mA) input jack. (Clamp meters will
typically not have input jacks for direct current measurement.)
Step 5: Connect the ammeter into the

circuit. (WARNING: If an analog
meter is used—check to insure the
meter is properly connected by
observing the polarity. The
ammeter has two terminals; one is
labeled negative, (-) and the other
terminal is labeled positive (+). Step 5: Connect the
Current must flow through the Ammeter Into the Circuit
ammeter from the negative terminal
to the positive terminal. This can be
checked by tracing the wire from
the negative terminal back to the negative terminal on the battery or
other DC power source. If the ammeter is connected backwards,
the meter pointer will be deflected backwards and may be broken
or bent.)
Step 6: Connect the circuit or turn the circuit
power supply on, and read the
current value on the ammeter scale.
NOTE: On a digital meter, if the test
leads are reversed for a DC
measurement, a “-“ will show in the Step 6: Connect the Circuit
display. Wiring
(4) Applying meter input protection.
A common and costly mistake made with multimeters is to leave the test
leads plugged into the current input jacks and then to attempt a voltage
measurement. This causes a direct short across the source voltage through
a low-value resistor inside the meter called a current shunt. As a result, a
high current flows through the meter, and if the meter is not adequately
protected, can cause extreme damage to the meter and to the circuit, and
injury. Extremely high fault currents can occur if industrial high voltage
circuits are involved. Meters without fuse protection should not be used on
high-energy electrical circuits ($240V ac). Make it a consistent practice to
remove test probes from input jacks after completing measurements.
97
Always make sure the power is off before cutting or
unsoldering the circuit and inserting the meter for current
measurements. Even small amounts of current can be
dangerous.
Never attempt a voltage measurement with the test probes

in the current jacks. Meter damage or personal injury may
result!
(5) Principles of indirect measurement of current values.
In higher current applications (typically over 2A), where high accuracy is not
needed, a current probe or clamp meter is very useful. With a clamping
meter or current probe, it is not necessary to break the circuit. Instead a
current flowing through a single connecting wire is indirectly measured by the
magnetic field that is produced by an induction coil that comprises the clamp
or current probe. Figure 2 illustrates the use of a clamp meter to measure the
current in a branch circuit off a 20 amp circuit breaker. The clamp meter in
Figure 3 is used to measure the amperage of a hot surface igniter on a range
oven burner.
Figure 2. Measuring Current Draw on a Branch Circuit. (Display reads 0.7A)
Figure 3. Measuring Current Draw on one Lead of a Hot Surface Igniter
98
(6) Using current measurement to set a thermostat heat anticipator.
Technicians must measure the current amp draw of the heating circuit
components such as the gas valve, blower fan, and relays to properly set the
thermostat heat anticipator. The amp draw of these components is measured
in the R-W circuit using a clamp multimeter as shown in Figure 4. Accurate
amp draw readings can be obtained as a direct current measurement at the
thermostat sub-base terminals R and W.
As stated above, most clamp meters and current probes measure current in
values higher than those of an ammeter direct measurement. However, a
clamp meter can be configured to more accurately measure current flow by
wrapping a wire carrying the current around one jaw of the clamp, thus
increasing the strength of the magnetic field induced in the clamp coil. Figure
4 illustrates an easy method of obtaining actual amp draw. Take the amp
reading after blower motor has started.
Figure 4. Measuring Amp Draw for Heat Anticipator Setting
The actual value to use in setting the heat anticipator is obtained by dividing
the reading on the meter display by the number of wire turns around the
clamp jaw.
5.0 A on meter display

EXAMPLE: = 0.5 amps for thermostat anticipator setting
10 turns around jaws
99
Figure 5. Thermostat Anticipator Adjustment
100
REVIEW:
Identifying Procedures for Measuring Current
space provided.
A. parallel G. voltage M. rate
B. 1/1000 amps H. 10 amps N. input jacks
C. series I. heat anticipator O. ampere
D. number J. 1,000 amps P. blower fan
E. 1/1,000,000 amps K. disconnect
F. electrons L. polarity
1. A milliampere is equal to _____.
2. A microampere is equal to _____.
3. It is good practice to remove test probes from the_____ after com-

pleting measurements.
4. In order to properly set the _____, a current measurement must be

made of the circuit which includes the gas valve.
5. When reading current to match the gas valve circuit amp draw to the
thermostat, take the reading after the _____ has started.
6. The unit of measurement of electrical current is the _____.
7. When measuring electrical current the meter is connected in _____

with the circuit being tested.
8. Electric current may be referred to as _____ moving in the circuit.
9. The ampere is the _____ electrons move past a given point.
10. The first step in making a direct current measurement is to _____ the
power supply to the circuit.
11. Checking that the negative lead of an analog ammeter is connected to

the wire which leads to the negative terminal of the power source, and
the positive lead of the ammeter is connected to the wire which leads
to the positive terminal is referred to as observing _____.
12. Never attempt a _____ measurement with the test probes plugged into
the current input jacks.
101
7.2.4 Identifying Procedures for Measuring Current
I can identify:
1. The numerical equivalent of the milliampere (MA).
2. The numerical equivalent of the microampere.
3. The procedure for test probes when completing measurements
4. How to make a current measurement of the circuit, which includes the gas
valve.
5. How to take a current reading to match the gas valve and gas valve circuit
amp draw to the thermostat anticipator.
102
Identifying the Operating
7.3.1 Characteristics of Common Sensing
Devices
Table of Contents
Table of Contents................................................................................................... 103
Learning Activities.................................................................................................. 104
Identifying the Operating Characteristics of Common Sensing Devices ................ 105
Identifying Temperature Responsive Devices........................................................ 105

Bimetals ............................................................................................................ 105
Unevenly Heated Shapes ................................................................................. 108
Rod and Tube Sensors ..................................................................................... 108
Hydraulic and Pneumatic Bulbs ........................................................................ 109
Electrical Resistance Coils and Thermistors..................................................... 110
Fusible Links..................................................................................................... 111
Identifying Pressure Responsive Devices.............................................................. 111

Metallic Bellows and Diaphragm Sensors......................................................... 111
Coiled Metallic Tubing ...................................................................................... 112
Flow Sensor switches and sail switches ........................................................... 113
Identifying Liquid Level Sensors ............................................................................ 113

Electrical – Contact Type .................................................................................. 113
Float and Other Types ...................................................................................... 114
Identifying RPM Sensors: Centrifugal Switches for Motors.................................... 115
Identifying Temperature & Moisture Sensors for Dryers ........................................ 117
Identifying Flame Sensors for Safety Shutoff Devices ........................................... 117

Thermocouple................................................................................................... 118
Bimetal.............................................................................................................. 118
Hydraulic or Mercury Vaporization Type ........................................................... 119
Optical System.................................................................................................. 119
Flame Rectification ........................................................................................... 119
Review ................................................................................................................... 124
Performance Criteria Self-Check ........................................................................... 127

103
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

104
7.3.1 Characteristics of Common Sensing
Devices
A sensing device is an essential part of any control system. It senses temperature,
pressure, etc., and transmits a signal or motion to activate or deactivate a control
device. The control device then acts to control flow of gas, water, air, etc. In this
module you will learn to:
(1) Identify temperature responsive devices
(2) Identify pressure responsive devices
(3) Identify liquid level sensors
(4) Identify rpm sensors: centrifugal switches for motors
(5) Identify moisture sensors for dryers
(6) Identify flame sensors for safety shutoff devices
(1) Identifying temperature responsive devices.

In most gas appliances there is a need to control
temperature, such as the temperature of circulating
air in a furnace, or of stored water in a water heater, Possible Diagram Symbol
or the temperature inside a range oven. A number of
sensing devices, operating on fundamental principles
discussed in the preceding section, are used.
(a) Bimetals.
A bimetal, as illustrated in Figure
1, consists of two strips of different
metals fastened together along
their entire length.
The two metals used in the bimetal

strip are selected so that one will
expand more than the other when
the two are heated. In Figure 1a
metal H has a greater linear
coefficient of expansion than metal
L. When the bimetal strip is
heated as in Figure 1b, the strip of
metal H expands more than metal
L. Since the two strips are
fastened together, the only way it
can do this is for the two strips to
bend, as shown in Figure 1b. Figure 1. Bimetals Deflect When
Heated Because of the Different Rates
of Expansion of the Two Metals
105
The motion of the free end of the bimetal then can be used to activate a
control, such as a furnace limit control. When the heat source is removed
and the bimetal cools down to its original temperature, it returns to its original
shape.
The bimetal strip also can be formed in a

U-shape, as illustrated in Figure 2. When
the U-shaped bimetal is heated, the strip of
metal H having a greater coefficient of
expansion than metal L expands more than
the strip of metal L. This causes the leg of
the U-shaped bimetal to move to the right,
as illustrated in Figure 2b.
Upon cooling down the U-shaped bimetal

assumes its original shape, as illustrated in
Figure 2a. This type of bimetal sensor has
been used in room thermostats and furnace
limit controls.
A bimetal may also be made in the form of

a disc rather than strips, as illustrated in
Figure 3.
Figure 2. U-Shaped Bimetal

Deflects When Heated
Figure 3. Bimetal Disc Snaps When Temperature Changes

Two metals with different coefficients of expansion are selected, formed into
discs as shown, and fastened together. When relatively cool the disc is
bowed in one direction, as illustrated in Figure 3a. When heat is applied to
the disc, as illustrated in Figure 3b, metal H expands more than metal L.
Since the two discs are fastened rigidly together, the only way it can do this is
for the disc to warp into the shape shown in Figure 3b. The movement of the
center of the bimetal disc then can be used to activate a control, such as
106
some types of furnace limit controls, storage water heater energy cut off
devices, and clothes dryer limit controls.
When the disc is cooled it returns to its original shape. Because of their
shape these discs do not move from one position to another slowly. They
snap quickly when the force reaches a certain point.
In the illustrations shown in Figures 1, 2, and 3, pages 1 and 2, flames are

shown heating the bimetal strips and disc. These bimetals also can be
heated or cooled by other means, such as hot air or hot water, to move or
warp them in the manner described.
Another commonly used bimetal type sensor is a bimetal coil, two forms of
which are shown in Figure 4. In this type of sensor two strips of different
metals are fastened together, formed into a coil, and anchored at one end.
4a. Combination Limit & Fan Control 4b. Wall Thermostat

Figure 4. Operation of Bimetal Helix and Spiral Bimetal Coils
When the coil is heated one of the metal strips expands more than the other,
causing the coil to twist in the helical form shown in Figure 4a, or to expand in
the coil form shown in Figure 4b. The twisting type bimetal is often used to
activate a control such as a furnace limit/fan control, while the coil form is
frequently used in room thermostats.
107
(b) Unevenly heated shapes. The principle of thermal expansion of
metals also can be used in sensors made of only one material for
controls, in contrast to the bimetal which uses two different materials.
The single metal type of sensor consists of two legs of the same
material, such as steel, which are not heated to the same degree by
the heat source. Figure 5 illustrates such a device.
Figure 5. Single Metal Temperature Sensor Deflects

Because of Uneven Heating of Legs
In the single metal differential expansion sensor the “hot” leg and “cold”
leg are fastened together, and anchored firmly to an immovable
support. The hot leg is heated to a greater degree than the cold leg,
and expands more than the cold leg. As a result the free end of the
sensor element moves as shown in Figure 5. This movement is used
to activate a control. A common use of uneven heating of single metal
legs has been used in automatic gas pilots.
(c) Rod and tube sensors.
A rod and tube sensor is another device using the principle that some
metals expand more than others when heated, and contract more
when cooled. Figure 6 illustrates a rod and tube sensor.
108
Figure 6. Rod and Tube Temperature Sensor
In a rod and tube sensor the tube (or outer shell) is constructed of a
material such as copper which expands or contracts readily with
temperature change. This tube is anchored firmly at one end, and the
tube is inserted into a temperature-controlled fluid such as water.
Inside the tube is a rod (such as Invar) which changes its length either
a little or not at all with temperature changes. The rod is fastened
firmly to the inside of the closed end of the tube (the right in Figure 6)
and its other end is free to move.
When the fluid in which the rod and tube is immersed is cooled the
tube shortens, and the rod remains at its original length. The free end
of the rod then moves to the left as shown in Figure 6. This motion of
the rod is used to actuate a control. Perhaps the most common use of
rod and tube sensors is in storage water heater thermostats.
(d) Hydraulic and pneumatic bulbs.
Liquids and gases expand when they are heated and contract when
they are cooled. If these liquids or gases are contained in a closed
container or system, they cause a rise in pressure in that system as
they try to expand with temperature rise. Pressure within the system
falls again as the gases or liquids are cooled in the closed system.
These pressure variations with temperature change can be used to
actuate controls.
In both hydraulic (liquid) and pneumatic (gas) sensors, a bulb is

connected by a small-bore tube (capillary) to a device which actuates
the control, as illustrated in Figure 7.
109
Figure 7. Hydraulic or Pneumatic Bulb Sensors Rely on
Expansion of Confined Fluid to Actuate Controls
As heat is applied to the bulb by a flame, hot air, or hot water, the gas
or liquid in the bulb and actuator device expands and pressure
increases to actuate the control. Some sensors of this type are filled
with mercury which exists in the system as both a liquid and a vapor.
When the bulb is heated mercury is vaporized, and the pressure
actuates the control. Hydraulic and pneumatic temperature sensors
are often used in range oven thermostats, furnace limit controls, and
space heater temperature controls, to mention only a few applications
of this type of sensor.
(e) Electrical resistance coils and thermistors.
Resistance coil and thermistor sensors are used in electrical control

circuits to control current flow in the circuit to activate or deactivate
controls. This control of current, in turn, depends on the electrical
resistance of the coil or thermistor, which varies with temperature.
A resistor normally reduces current flow as it gets hotter.
A thermistor acts in the opposite way—it increases current flow

as its temperature increases.
110
(f) Fusible links.
Possible Diagram Symbol
Sometimes under adverse operating conditions, combustion products

may spill from the combustion chamber into another section of an
appliance. In some appliances a fusible link is connected by a wire in
the gas control circuit located just outside the combustion chamber. If
flames or hot gases roll out of the combustion chamber, the fusible link
melts and breaks the circuit, shutting off power to the gas control.
A cartridge-type fuse incorporated into an electrical circuit performs a

similar function. If a short circuit condition or overheating occurs, the
fuse will burnout and shut down the flow of electricity to protect other
circuit components.
(2) Identifying pressure responsive devices.
Other sensors used with some controls sense pressure changes caused by
heating or cooling. For example, such devices are used to control or limit
steam and/or water pressures in boilers and water heaters. These sensors
may take one of a number of forms.
(a) Metallic bellows and diaphragm sensors.
Metallic bellows or diaphragms sense pressure changes such as occur

in boilers. (Figure 8.)
Figure 8. Metallic Bellows and Diaphragm

Elements Convert Pressure into Linear Motion
111
When the pressure of the source – such as steam or water – to which
the bellows or diaphragm is attached increases, the bellows expand or
the diaphragm moves as shown.
As the pressure falls the bellows contract or the diaphragm moves

towards its original position. This motion is used to actuate a control.
Metallic bellows or diaphragms can be used where the source
pressure is relatively high, such as hundreds of pounds per square
inch.
For lower pressure applications flexible diaphragms can be used to

sense pressure changes, such as in gas pressure regulators, and air
or mechanical venting systems to prove pressure or vacuum. Again,
the motion of the diaphragm under pressure changes is used to
actuate the control.
(b) Coiled metallic tubing.
Coiled metallic tubing also can be used to sense pressure changes. This type of
device is known as a Bourdon tube. (Figure 9.)
Figure 9. Coiled Metallic Tube Sensor (Bourdon tube)
The Bourdon tube is elliptical in cross-sectional area and is bent into a

coil or circular arc. One end is closed and the other end connected to
a controlled pressure source.
When the source pressure builds, up pressure in the tube also rises
tending to straighten out the tube as shown by the dashed lines in
Figure 9. The motion of the tube is used to actuate a control.
112
(c) Flow sensor switches and sail switches.
Often it is necessary to sense the flow of air. For example, in an

appliance using a blower to supply combustion air, it is important that
flow of combustion air be assured before gas is allowed to flow to the
burner(s). A sail switch, as illustrated in Figure 10 is often used for this
purpose.
Figure 10. Sail Switch is Actuated by Air Movement
A sail switch consists of a sail (light plate) mounted on a pivot. With no

air flowing the sail is held in a position by a light spring or gravity, so
the switch contact points are either in the closed or open position,
making or breaking the electrical circuit containing the control. When
air flow strikes the sail it causes it to tip, closing the switch contact
points, completing the control circuit, and actuating the control.
(3) Identifying liquid level sensors.
Liquid level sensors are used to control the level of liquid in an appliance,
such as in a boiler.
(a) Electrical – contact type.
Liquid level sensors may be of the electrical contact type, as illustrated

in Figure 11.
113
Figure 11. Electrical Contact Type Liquid Level Sensor
This device takes advantage of the electrical conductivity of liquids.

Two probes are immersed in the liquid in the vessel, one above the
other, at the level at which the liquid is to be maintained. As long as
both probes are immersed in the liquid, as illustrated in Figure 12a the
electrical circuit is complete. If the liquid level in the vessel drops so
the upper probe is out of the liquid, as illustrated in Figure 12b the
electrical circuit is broken, activating or deactivating the control. Wiring
to the two probes must be electrically insulated from the vessel and
liquid. The circuit may be used to open and close an electrical water
valve to maintain the water level in the vessel at some predetermined
height, or may be used to shut off the gas supply to the appliance, if
the liquid level falls below a given level.
(b) Float and other types.
Float-type liquid level sensors may control the level of a liquid by

mechanical means as illustrated in Figure 12, or they may be electro-
mechanical devices, if they are linked to electrical contacts to switch
electrical current on and off.
114
Figure 12. Float-Type Device Controls Liquid Level
In Figure 12a the float is buoyed up by the liquid in the vessel to such a
position the valve to the liquid source is closed by linkage connected to
the float. If the liquid level falls in the vessel as in Figure 12b, the float
drops with the liquid level opening up the supply valve as shown.
Liquid then flows into the vessel until the liquid level again reaches its
original height (Figure 12a), lifting the float, closing the valve, and
shutting off the flow of makeup liquid into the vessel.
A similar arrangement with a float also can be used to open or close an

electrical switch, rather than the valve directly. This switch may be
used to open or close an electrically operated liquid supply valve.
Such a switch also can be used to shut off the gas supply to an
appliance (such as a boiler) when the liquid level drops to a given level
(low water cutoff).
(4) Identifying rpm sensors: centrifugal switches for motors.
If a weight on the end of a cord is whirled around, the weight pulls outward on
the cord. This outward pull is known as centrifugal force. Advantage can be
taken of this force in the design of centrifugal switches, used commonly to
sense rotation in motors. The principle of the centrifugal switch is shown in
Figure 13.
115
Figure 13. Centrifugal Switch Opens or Closes When Motor Rotor
is Turning. This illustration shows switch opening as motor runs.
A centrifugal switch consists essentially of a leaf spring fastened to the rotor,

as illustrated in Figure 13a, on which is mounted a weight and a switch
contact. A second fixed switch contact is mounted on the rotor. Electrical
leads from the two contacts are connected to slip rings on the drive shaft to
allow the switch to be part of an electrical circuit, even though the switch itself
is rotating on the rotor. With the rotor at rest or below the control speed of the
motor, the leaf spring holds the contact points together, completing the
electrical circuit. When the rotor starts to rotate, centrifugal force acts on the
weight.
If the speed of rotation exceeds the set speed, the centrifugal force action
causes the weight to pull on the leaf spring, separates the contacts, and
breaks or makes the electrical circuit, as illustrated in Figure 13b.
Usually centrifugal switches on motors are used for switching circuits external
to the motor circuit. For example, a switch may be placed in a gas control
116
circuit to assure a blower supplying combustion air to a power burner is
operating before gas is allowed to flow.
(5) Identifying moisture sensors for dryers.
Temperature/ Moisture Sensor Temperature Sensor

Diagram Symbol Diagram Symbol
A gas dryer is essentially a cabinet containing a rotating drum, in which

heated air is circulated to remove water from the clothes and dry them. For
various reasons the homemaker may want to remove virtually all or only part
of the moisture from the clothes. Several methods are available to achieve
this control over the degree of dryness. First, the homemaker can do this by
simply setting the length of the drying period, but this method is a risky one.
A more predictable method is automatic control of the dryer cycle by placing a

temperature sensor in the exhaust. As the clothes dry and less heat is
absorbed in evaporating water from the clothes, temperature of the exhaust
gases rise.
By turning the control to one of several settings the drying cycle can be ended
at an appropriate exhaust temperature to provide the desired degree of
dryness. A still more accurate method has been developed that uses an
enthalpy switch (senses temperature & relative humidity) and solid-state
electronics.
Electrical conductivity of fabrics varies with the amount of moisture contained

in the fabrics. In a dryness sensor system a pair of electrical contacts (large
metal plates) are located in the drum. These plates are positioned so they
are in contact with the tumbling clothes, which form part of the electrical
control circuit. With wet clothes the resistance is relatively low, and a small
electrical signal is conducted through the sensor. Solid-state electronic
components amplify this very small electrical signal to turn off the dryer timer
motor. As the clothes dry their resistance increases. The signal from the
sensor weakens to some point where the timer motor is no longer activated
and the drying process stops, leaving the clothes at the desired degree of
dryness as preset on a control.
(6) Identifying flame sensors for safety shutoff devices.
In gas appliances using automatic gas pilots it is necessary to assure that a

pilot flame is present which will ignite gas at the main burner(s). Several
types of sensors are used for this purpose. Some are of the types discussed
earlier and will be described only briefly.
117
(a) Thermocouple. The most common type of safety shutoff device
sensor is the thermocouple, as illustrated in Figure 14. As long as the
pilot flame acts to sufficiently heat the hot junction of the thermocouple,
the DC current produced will act to hold open a gas control valve,
allowing gas to flow to the appliance burner when gas is called for. If
the pilot flame is extinguished, the millivoltage output of the pilot drops
off towards zero, causing the safety shutoff device to shut off gas
supply to the appliance burner(s). Because the thermocouple is
heated by pilot flame, it must be made of materials resistant to
relatively high temperatures.
Figure 14. Thermocouple
(b) Bimetal. Some safety shutoff devices use bimetal sensors to assure
an ignition source is present. Safety shutoff devices of this type use a
single metal (stainless steel) sensor element, relying on uneven
heating of the two legs to open or close a switch.
With a pilot flame present of sufficient size to ignite the main burner(s),
the sensor causes closure of an electric switch in the circuit of an
electrical valve. If the pilot flame is extinguished, the sensor acts to
open this switch cutting off electrical current to the valve, which closes
to shut off the gas supply to the appliance.
(c) Hydraulic or mercury vaporization type. Other safety shutoff

devices use liquid or vapor expansion type sensors. The flame heats
the liquid in the sensor bulb. In some instances this liquid is mercury,
which vaporizes in the bulb. The resulting pressure buildup in the
sensor system acts on a metallic bellows or diaphragm, actuating a
118
switch or gas valve when the pilot flame is present. A mercury
powered diastat is illustrated in Figure 15.
Figure 15. Mercury Powered Diastat
(d) Optical system. It is also possible to detect the presence of flame by

optical sensors. Two such devices are the photocell and the photo
resistive sensor.
The photocell is an electron tube containing a light sensitive surface.

When light strikes this surface it generates a small amount of electrical
current. This current can then be amplified by electrical devices to
operate an electric relay, which in turn controls electric current flow to
an appliance control.
One type of photo resistive cell uses a grid of cadmium sulfide (CAD
cells), used in oil burner appliances only. The electrical resistance of
this material is very high when it is kept in the dark. However, when a
small amount of light strikes the active surface of the cell its resistance
drops off greatly. With this reduced resistance the material can pass
sufficient external current to operate a relay directly without the need
for electronic amplification, such as is needed with the photocell. The
relay then acts to provide control of electrical current to an appliance
control. Natural gas and propane flames do not provide enough light in
the visible light range to utilize CAD cells.
(e) Flame rectification. An electrical rectifier is a device, such as a

diode, which allows current to flow essentially in only one direction. In
other words, it converts an alternating (AC) current to a direct (DC)
current. It has been found that flames possess the capability of acting
as a rectifier. Flame rectification is used as the operating principle of
ignition and burner control systems on most high efficiency gas
furnaces and boilers. The discovery of the flame rectification principle
has made it possible to eliminate the standing pilot which was
responsible for up to 15% of the total gas consumed by residential
customer furnaces and boilers. Whether the ignition system is a spark
ignition system or a hot surface ignition system, flame rectification can
119
be used as the flame safety monitor to work with the safety control in
the pilot and main gas valve to prevent the accumulation of gas if the
ignition system fails. Figure 16 illustrates the design of a spark ignition
pilot burner that is designed to use flame rectification to signal to a gas
appliance control system that the flame is present.
Figure 16. Spark Ignition Flame Rectifier
A single rod is placed near the pilot burner so that when the pilot is lit
the rod is in the pilot flame. AC voltage is applied to the rod, and the
current passes through the flame on its path to a larger electrode
which is the sensor for the control circuit. The rectified DC current
flowing through the flame is then used to activate an electronic relay,
which in turn allows the gas valve to open as long as a pilot flame is
present. If the pilot flame is extinguished, the control circuit acts to
shut off gas flow.
Principles of Operation. There are two basic types of electronic

spark ignition systems in use today. One uses a spark to light the
main burner directly. This type is commonly referred to as a Direct
Spark Ignition (DSI) system. The second spark method used for
residential equipment is to light a pilot which then ignites the main
burner. The pilot flame must be proven before the main burner gas
valve is energized. This type is known as an Intermittent Ignition
Device (IID).
An IID modifies the standing pilot approach. An IID system

incorporates solid state electronic circuitry and a flame sensor to
120
replace the safety pilot valve and thermocouple normally associated
with standing pilot systems.
A third type of electronic ignition system uses a special type of

electrode which rapidly heats to approximately 2500°F when an
electric voltage is applied. This type of system is known as Hot
Surface Ignition and can be used with flame rectification to provide the
flame safety signal in much the same way that flame rectification works
with spark ignition.
Sensing Methods. With standing pilots,

heat is a necessary ingredient for proper
thermocouple operation. But this is not the
case with IIDs when flame conduction or
rectification is used. To better understand
the principles of flame conduction and
rectification, it is necessary to understand
the structure of gas flames, as illustrated in
Figure 17.
Figure 17.
Blue Flame
With the proper air-gas ratio to give a blue
Structure
pilot flame, three zones exist.
Zone 1:
An inner cone that will not burn because excess fuel is present.
Zone 2:
Around the inner, fuel rich cone is a blue envelope. In this area is a
mixture of vapor from the fuel rich inner cone and the secondary, or
surrounding, air. This is where combustion occurs.
Zone 3:
Outside the blue envelope is a third zone that contains an excessive
quantity of air.
Of concern is Zone 2, or the combustion area. This is where the

burning occurs and is the area that is of prime importance for good
flame sensor location.
A flame is a series of small, controlled explosions, which causes the

immediate atmosphere to become ionized. This ionization causes the
atmosphere to become conductive. This conductive characteristic is
used in flame conduction, as illustrated in Figure 18 on the next page.
121
With flame rectification, the flame and probes are used in a manner
similar to a switch that can change the circuit from AC to DC. There
are two features critical to flame rectification:
" The surface area of one probe that is exposed to the flame must be
greater than the area of the other probe; and
" The flame must be properly placed to provide the conductive path.
" Proper grounding from the power source is of the utmost
importance.
Figure 18. Flame Rectification
The flame in Figure 18 is used to conduct an AC signal. Both probes

are in contact with the flame. The probe with the largest surface area
attracts more free electrons and, as a result, becomes the negative
probe. Therefore, the direction for the conduction of current through
the flame is from the positive probe to the negative probe. Note also
that the AC voltage sine wave has not changed, but the negative
portion of the current sine wave has been chopped off. This positive
portion now represents a DC current. This is the phenomenon of flame
rectification.
Sending the Flame Signal to the Ignition Module. It is the

conversion to a DC milliamp signal to the ignition module that becomes
the signal that switches power to open the gas control valve and keeps
it open until the thermostat heat anticipator ends the “call for heat”.
Figure 19 on the next page illustrates how the rectified current is
established and sent to the flame sensing circuit.
122
Figure 19. Sending the Flame Safety Signal to the Sensing Circuit
123
REVIEW:
Identifying the Operating Characteristics of
Common Sensing Devices
Directions: Each of the following statements is followed by a list of responses.
Select the answer(s) which most correctly complete each statement.
Mark your choice(s) in the space provided.
1. Bimetal sensors respond to temperature changes due to:
( ) A. their tensile strength

( ) B. their moisture absorption tendencies
( ) C. differing expansion rates of metals exposed to heat (cold)
( ) D. all of the above
2. The sensing device most frequently used in limit switches is:
( ) A. bimetal strip
( ) B. bimetal disc
( ) C. bimetal coil
( ) D. twisting type bimetal
3. The sensing device utilized in water heater controls is typically a:
( ) A. rod and tube sensor

( ) B. bimetal sensor
( ) C. fusible link
( ) D. Bourdon tube sensor
4. Hydraulic and pneumatic temperature sensors are used in:
( ) A. range oven thermostats

( ) B. space heater controls
( ) C. refrigerant return lines
5. Which of the following statements about liquid level sensors are true?
( ) A. They are used in boilers.

( ) B. They are required in residential water heaters
( ) C. They all function to prevent “air lock.”
124
6. Some of the methods of removing virtually all or only part of the moisture from
the clothes are:
( ) A. setting the length of the drying period
( ) B. placing a temperature sensor in the exhaust
( ) C. using solid state electronics with a temperature/moisture
(enthalpy) switch
7. Some of the optical sensors are:

( ) A. a photocell
( ) B. an electrical rectifier
( ) C. a photo resistive sensor
8. Which of the following statements about an electrical rectifier are true?

( ) A. An electrical rectifier allows current to flow in essentially only
one direction.
( ) B. It converts DC current to AC current.
( ) C. An AC voltage is applied to the rod, which is the sensor for the
AC control circuit.
( ) D. All of the above.
9. Metallic bellows elements convert _____ into _____.

( ) A. linear motion, pressure
( ) B. pressure, linear motion
( ) C. temperature, linear motion
( ) D. none of the above
10. Which of the following statements about Bourdon tubes are true?
( ) A. A Bourdon tube is elliptical in cross-sectional area.
( ) B. A Bourdon tube is bent into a coil or circular arc.
( ) C. A Bourdon tube can be used where the source pressure is
relatively high.
( ) D. A Bourdon tube is connected to a wire in the gas control circuit
which is located near the combustion chamber
11. Which of the following statements about a sail switch are true?
( ) A. A sail switch is bent into a coil.
( ) B. A sail switch consists of a light plate mounted on a pivot.
( ) C. A sail switch is held in a position by a light spring or gravity.
125
12. Which of the following are liquid level sensors?
( ) A. fusible
( ) B. float type
( ) C. electrical contact type
( ) D. bimetal
13. Which of the following statements about electrical contact type liquid level
sensors are true?
( ) A. They take advantage of the electrical conductivity of liquids.
( ) B. They have a switch which opens or closes when motor rotor is
turning.
( ) C. Two probes are immersed in the liquid in the vessel with one
above the other at the level at which the liquid is to be
maintained.
14. Which of the following are some of the safety shut off device sensors?
( ) A. bimetal
( ) B. thermocouple
( ) C. fusible links
( ) D. vapor expansion sensors
( ) E. optical sensors
( ) F. electrical rectifier
( ) G. all of the above
126
7.3.1 Identifying the Operating Characteristics of
Common Sensing Devices
I can:
1. Identify and explain the operation of a bimetal.
2. Identify the most common type of furnace limit control sensing device.
3. Identify and explain the operation of a rod and tube sensor.
4. Identify the type of temperature sensor oven used in range thermostats.
5. Identify and explain the operation of a liquid level sensor.
6. Identify the sensor used on clothes dryers to regulate dryness of clothes.
7. Identify and explain the operation of an optical sensor.
8. Identify and explain the purpose of an electrical rectifier.
127
128
Identifying the Components and Operating
7.3.2 Characteristics of Electronic Ignition
Systems
Table of Contents
Identifying the Components and Operating Characteristics

of Electronic Ignition Systems ................................................................................ 131
Identifying the Purpose and Function of Electronic Ignition Systems..................... 131
Identifying Types of Electronic Ignition Systems .................................................... 131

Intermittent Spark Ignition Systems .................................................................. 132
Direct Spark Ignition Systems (DSI) ................................................................. 135
Hot Surface Ignition Systems (HSI) .................................................................. 137
Purging Air and and Gas/Air Mixtures Before Placing

Electronic Ignition System-Equipped Appliances Into Service ............................... 139
Review ................................................................................................................... 141

129
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

130
Identifying the Components and
7.3.2 Operating Characteristics of
Electronic Ignition Systems
Electronic ignition systems apply the flame rectification principle outlined in module
7.3.1. Service technicians must understand the operation of electronic ignition
systems to successfully service mid and high-efficiency furnaces and boilers. In this
module you will learn:
(1) The purpose and function of electronic ignition systems

(2) Types of electronic ignition systems
(3) How to purge air and gas/air mixtures before placing electronic system-
equipped appliances into service
(1) Identifying the purpose and function of electronic ignition systems.
The purpose of electronic ignition systems is to provide a verifiable ignition

source to establish the main burner flame and to monitor the flame throughout
the burner operating cycle. Development of electronic ignition systems has
been an important step in improving gas appliance efficiency by eliminating
the need for standing pilots which consume gas without contributing directly
to the productive heat transfer process. Electronic ignition systems must
provide a reliable ignition source and provide a safety check on the flame
while the gas is producing heat by combustion.
(2) Identifying Types of Electronic Ignition Systems.
Three types of electronic ignition systems will be discussed in this section:
(a) Intermittent Spark Ignition (ISI),

(b) Direct Spark Ignition (DSI), and
(c) Hot Surface Ignition (HSI).
In general, each of these systems is made up of the following components

that provide these functions:
1. an ignition module that responds to a signal from the gas appliance

thermostat provides voltage to
2. an ignition device which serves to start gas combustion;
3. a flame sensing device which produces a flame safety signal sent
back to the ignition module, and
4. a gas burner valve which is energized to open by a signal from the
ignition module.
131
5. A lockout device is also part of the system and serves to shut down
the appliance if the ignition of the gas cannot be confirmed within a
predetermined time.
From this general description of an electronic ignition system, it should be

noted that each component is designed to work only with the other
components the manufacturer designed to be a part of the system. This is an
important point that must always be remembered and followed.
" Always read and follow manufacturer’s instructions for

service and installation of system components.
" Never substitute a component or part that is not a
manufacturer’s designated replacement part for the
particular appliance being serviced.
" Electronic ignition modules are not field repairable.
" Use only factory supplied wiring components specified
for use with the particular electronic ignition system
being serviced.
(a) Intermittent Spark Ignition Systems. Intermittent spark ignition

systems use a pilot burner as the ignition device. The pilot burner is
not a standing pilot, and therefore is only ignited when the thermostat
calls for heat.
Identifying Components of
an Intermittent Spark
Ignition System. Figure 1
illustrates a wiring diagram for
an intermittent spark ignition
system. Please note that the
system includes components
that serve all the functions
required of an ignition control
system, and that the
components must be designed
to work together in order to
fulfill all the functions required Figure 1. Typical Ignition Wiring
of an ignition system. Diagram
Proper wiring must be provided to connect the thermostat, ignition

control module, pilot assembly, pilot and main burner combustion gas
valve, the lockout module, and the power supply (transformer).
132
Ignition Control Module.
High Voltage and Risk of Electrical Shock—DO NOT

TOUCH OUTPUT TERMINAL.
Disconnect power supply before servicing or replacing any

connection to an ignition control module.
EXPLOSION HAZARD—Turn off gas supply at appliance

shutoff valve before servicing.
Figure 2 pictures a spark

ignition control module. The
wiring terminal connections on
the module shown are located
at the lower edge of the
module. Ignition modules
respond to the call for heat
signal from the thermostat and
generate the ignition spark to
the pilot assembly and
thereafter send power to the
pilot valve. The ignition module
receives a flame proved signal
at the “sense” terminal when Figure 2. Ignition Control Module
the pilot flame is established.
The “flame proved” signal is produced by flame rectification. This
proof of flame signal causes the ignition module to send power to the
main burner gas valve.
On early Intermittent Spark Ignition units a separate lockout module

would be wired to the ignition control module to shut down the
appliance if the proof of proper ignition cannot be established. On
newer appliances and older appliances where the ignition system has
been repaired, the lockout module will not be a separate component.
All propane appliances that use electronic ignition systems should be
equipped with a lockout device, either as a separate component or
combined with the ignition control module.
133
Spark Ignition Pilot Assembly. Figure 3
illustrates a spark ignition pilot assembly.
The design of pilot assemblies will vary from
manufacturer to manufacturer, but each
design provides for a spark electrode, a pilot
orifice, burner and hood assembly, and a
target electrode for flame rectification. The
assembly shown in Figure 3 uses a flame
sensor rod as part of the flame rectification
circuit.
Many ignition control modules provide a “pre Figure 3. Ignition Pilot

purge time” before delivering the spark and Assembly
gas to the pilot ignition assembly. With these
systems there is a short delay between the thermostat call for heat
and the time of pilot spark and gas delivery to the pilot assembly.
Gas Valve. Gas valves used in ISI

systems are combination valves. One
valve is required for the pilot gas
supply—the second valve is required
for main burner supply. Each valve
must be wired to the proper terminal
on the ignition control module.
Manufacturers warn not to short

across the valve terminals. The
holding coils in all gas valves will not
tolerate high current flow, and are
easily burned out if shorted.
Figure 4. ISI Control Valve
Operating Sequence
Step 1. The ignition system reacts to the thermostat “call for heat” by
opening the pilot valve and by supplying a spark to the spark
electrode on the pilot assembly. (On pre-purge systems the
ignition module delays the opening of the pilot valve for the
programmed pre-purge time.) [If the pilot does not light, the
sequence moves directly to #6.]
Step 2. After the pilot is lit, an electronic circuit proves the presence of
the pilot flame using flame rectification.
Step 3. A slight delay is provided in the flame sensing circuit to
minimize problems due to pilot flame instabilities on ignition.
The flame-sensing signal to the ignition control module
134
activates the main burner circuit to the gas control valve,
allowing main gas to flow to the burner(s).
Step 4. Sparking continues for a few seconds into the main burner
cycle to insure dependable ignition.
Step 5. In case of flame outage or gas interruption, the flame sensing
circuit will shut off main gas flow and then attempt to relight
the pilot.
Step 6. If pilot ignition does not occur within a predetermined length of
time, the system will lockout and turn off power to the entire
system.
Resetting The System After A Lockout. To reactivate the system,

on most electronic ignition systems, turn the thermostat to its lowest
position for ten seconds and then return it to the desired thermostat
setting. Always read and follow manufacturer’s instructions.
(b) Direct Spark Ignition Systems (DSI). Direct Spark Ignition Systems
light the main burner without the use of a pilot burner. As illustrated in
Figure 5, a spark igniter electrode is placed near the main burner and
is the ignition device for the system.
Figure 5. Diagram of a Direct Spark Ignition System
135
Figure 6 illustrates a DSI ignition
control module. The control wiring
terminal connections on the module
shown are located at the lower
edge of the module, while the spark
igniter terminal is on the top surface
of the module. Ignition modules
respond to the call for heat signal
from the thermostat and generate
the ignition spark to the spark
igniter and thereafter send power to
the gas valve. When the flame is
established, a flame proved signal
produced by flame rectification is
required to maintain the main
burner gas flow, or on high-low Figure 6. Ignition Control Module
burner designs, to open
the second stage gas valve for high burner operation.
High Voltage and Risk of Electrical Shock—DO NOT

TOUCH OUTPUT TERMINAL. SPARK POTENTIAL IS
TYPICALLY 25,000 VOLTS MINIMUM.
Disconnect power supply before servicing or replacing

any connection to an ignition control module.
Spark Igniter and Flame Sensor. The spark igniter and flame sensor
are shown in the system diagram, illustrated in Figure 5, page 5.
These components provide the ignition device and flame sensor device
functions for the DSI system. Again flame rectification is the method
used to generate the flame proved signal that allows the sustained
opening of the main burner gas valve. Figure 5 also illustrates a
high/low burner configuration.
Gas Control Valves. Gas control valves in DSI systems do not have
the pilot burner valve used in ISI systems. DSI control valves may be
single main burner valves or combination valves that provide multiple
burner control or 2-stage burner control in the case of high/low
systems.
Operating Sequence.
Step 1. The ignition system reacts to the thermostat “call for heat” by
supplying a spark to the spark igniter mounted on the main
burner assembly.
136
Step 2. The main burner valve is opened to allow gas flow to the
burner.
Step 3. After a burner flame is established, the spark voltage is
reduced and the flame sensor generates a flame proved
signal by flame rectification. The flame-sensing signal to the
ignition control module sustains main burner circuit to the gas
control valve, allowing main gas to continue to flow to the
burner(s).
Step 4. If ignition does not occur within a predetermined length of
time, the system will lockout and turn off power to the entire
system.

(c) Hot Surface Ignition Systems (HSI).
Hot Surface Ignition differs

from the spark systems
primarily due to its ignition
device. Figure 7 illustrates a
silicon carbide igniter used in
HSI systems. Although these
igniters are designed to
perform in demanding outdoor Figure 7. Hot Surface Igniter
applications, until they are
installed, the component itself
is fragile and must not be
subject to rough handling.
The hot element will rapidly heat to temperatures in excess of 2500° F
when supplied its operating voltage. This high temperature provides a
dependable ignition source which is especially useful in outdoor and
roof top furnace applications where lockouts may be a problem for ISI
and DSI systems.
137
Ignition Module. Figure 8
shows two views of a HSI
ignition control module. Note
that the igniter wiring on the
module and the igniter are
connected with cannon plugs.
Figure 8a. HSI Ignition Control

Module
Figure 8b shows the control

diagnostics panel. The unit is
equipped with an LED
indicator lamp which signals
the system component that is
faulty by flashing a trouble
code in the event of a
component failure.
Figure 8b. Diagnostic LED Panel
Gas Control Valves HSI control valves must be matched to the

ignition system, as is the case of the other electronic ignition systems.
The control valve used with a particular appliance will be specified by
the manufacturer to provide the proper gas volume and the burner
design such as a single rate burner or a two stage high/low burner
system.
Operating Sequence
Step 1. The ignition system reacts to the thermostat “call for heat” on
prepurge systems with a time delay, and on non-prepurge
systems, by going directly into an igniter warm up period
(typically 30 to 40 seconds).
Step 2. The main burner valve is opened to allow gas flow to the
burner. Depending on the system, the igniter will remain
under full power for 2, 4, or 6 seconds during the initial main
burner opening cycle.
Step 3. After a burner flame is established, the igniter is de-energized
and becomes part of the flame sensor circuit. Other systems
utilize a separate flame sensor. With some systems, the
flame sensor generates a flame proved signal by flame
138
rectification. The flame-sensing signal to the ignition control
module sustains main burner circuit to the gas control valve,
allowing main gas to continue to flow to the burner(s). If a
flame is not sensed during the initial main burner open cycle
the main gas valve is closed.
Step 4. In a single try system the system will be in lockout after a one-
attempt failure. In multiple try systems, the above sequence
of ignition attempts will be repeated three times before lockout
occurs.

Note: Supply proper voltage polarity is of the utmost importance to any

electronic ignition module. If the polarity is not corrected, it may cause
lockout of the ignition module.
EXPLOSION HAZARD—Turn off gas supply at

appliance shut off valve before servicing.
(3) Purging air and gas/air mixtures before placing electronic ignition
system-equipped appliances into service.
Appliances equipped with electronic ignition systems are a tremendous value

to propane customers. They represent high efficiency and lower energy
costs.
They also provide an added safety margin in the event of an out-of-gas

situation, because they prevent the accumulation of gas at the appliance
when gas service is re-established.
A word of caution is in order here: Because the appliance may have to be

cycled through several lockout and ignition attempts (especially due to the low
volume of gas that flows through the pilot burner assembly on ISI systems)
technicians are sometimes tempted to vent air and gas/air mixtures near the
appliances to speed up the purging of air from the gas distribution lines. This
practice may result in injury or property damage.
139
NFPA 54 2006 8.3.3 Discharged of Purged Gases
The open end of piping systems being purged shall not discharge into
confined spaces or areas where there are sources of ignition unless
precautions are taken to perform this operation in a safe manner by
ventilation of the space, control of purging rate, and elimination of all
hazardous conditions.
Be sure you comply with these code requirements and your company’s safety
policies and procedures. If your company requires you to use a calibrated
combustible gas indicator, a self-igniting auxiliary burner, or prohibits purging
altogether—comply with safety codes and your company’s requirements.
140
REVIEW:
Characteristics of Electronic Ignition Systems
Select the answer(s) that most correctly completes each statement.
Mark your choice in the space provided.
1. Intermittent spark ignition systems use a _____ as an ignition device.
( ) a. silicon carbide igniter

( ) b. pilot burner
( ) c. spark igniter
( ) d. standing pilot
2. Electronic ignition systems _____ gas appliance efficiency.
( ) a. increase
( ) b. decrease
( ) c. do not affect
3. Electronic ignition modules are _____.
( ) a. not high voltage devices

( ) b. powered by gas valves
( ) c. not field repairable
( ) d. interchangeable
4. The purpose of electronic ignition systems is to provide _____ and to monitor the
flame throughout the burner operating cycle.
( ) a. a replacement for heat anticipators

( ) b. a back-up for the thermocouple
( ) c. an oxygen depletion sensor
( ) d. a verifiable ignition source
5. A(n) _____ serves to shut down the appliance if the ignition of gas cannot be
confirmed within a predetermined time.
( ) a. ignition device
( ) b. combination valve
( ) c. lockout device
( ) d. limit switch
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6. Wiring for electronic ignition systems is _____.
( ) a. explosion proof
( ) b. minimum 10 gauge
( ) c. installer supplied
( ) d. factory supplied
7. To reactivate most electronic ignition systems after a lockout _____.
( ) a. trip and reset the main power disconnect

( ) b. turn the thermostat to its lowest position for 10 seconds, then reset
( ) c. depress the pilot valve and vent for 10 seconds
( ) d. depress the igniter reset button
8. Direct spark ignition systems light the main burner _____.
( ) a. with a thermopile generated spark

( ) b. with a titanium carbide electrode
( ) c. without the use of a pilot burner
( ) d. with a flame sensor
9. Most electronic ignition systems verify ignition by _____.
( ) a. flame rectification
( ) b. time delay relay signal
( ) c. thermocouple generated voltage
( ) d. photo-galvanic regeneration
10. Gas valves in intermittent electronic systems are _____ combination valves.
( ) a. single outlet
( ) b. natural gas only
( ) c. 115 volt
( ) d. pilot burner/main burner
11. Hot surface igniters _____.
( ) a. are designed to heat slowly to avoid thermal shock

( ) b. require 10 seconds to cool after lockout
( ) c. rapidly heat to temperatures in excess of 2500%F
( ) d. are not suited to outdoor installations
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12. Manufacturers’ instructions warn technicians to _____ before servicing electronic
ignition control modules.
( ) a. discharge blower motor capacitors

( ) b. turn off the gas at the appliance shutoff valve
( ) c. purge gas lines
( ) d. take voltage measurements
13. During a pre-purge cycle the _____ is energized and the _____ is de-energized.
( ) a. ignition device/gas valve

( ) b. gas valve/thermostat
( ) c. lockout circuit/ignition device
( ) d. gas valve/lockout circuit
14. NFPA 54 _____.
( ) a. prohibits purging of gas/air mixtures inside buildings

( ) b. allows only qualified technicians to supervise the purging of gas/air
mixtures inside buildings
( ) c. states that air and gas/air mixtures shall not be discharged into
confined spaces or near ignition sources unless precautions are
taken to control hazards
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7.3.2 Identifying the Components and Operating
Characteristics of Electronic Ignition Systems

I can identify:
1. A system that provides a verifiable ignition source and monitors the flame
throughout the burner operating cycle.
2. The device that serves to shut down the appliance if the ignition of gas
cannot be confirmed within a predetermined time.
3. The ignition device for the intermittent spark ignition system.
4. The procedure to reactivate most electronic ignition systems after a

lockout.
5. A system that lights the main burner without the use of a pilot burner.
6. The type of igniters that rapidly heat to temperatures in excess of 2500% F.
7. The warning in manufacturer’s instructions that directs technicians to turn

off the gas before servicing electronic ignition control modules.
8. The code that states that air and gas/air mixtures shall not be discharged
into confined spaces or near ignition sources unless precautions are taken
to control hazards.
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7.3.3 Characteristics of Wall Thermostats
(Heat Only)
Table of Contents

of Wall Thermostats (Heat Only)............................................................................ 147
Identifying the Purpose of the Wall Thermostat ..................................................... 147
Identifying the Operating Characteristics of Electro-Mechanical Wall Thermostats147

Bimetal Sensing Devices .................................................................................. 148
Electrical Switching Action ................................................................................ 148
Temperature Adjustment .................................................................................. 150
Heat Anticipator ................................................................................................ 152
Thermostat Cover ............................................................................................. 154
Mounting Base.................................................................................................. 155
Selecting a Proper Thermostat Location................................................................ 155
Identifying Characteristics of Thermostat Circuits .................................................. 156
Identifying Variations in Electro-Mechanical Wall Thermostats.............................. 159
Identifying Possible Malfunctions of Electro-Mechanical Wall Thermostats........... 160
Installing a Millivolt Thermostat .............................................................................. 161
Identifying Elements of an Installation Checklist for Thermostats .......................... 162
Identifying Operating Characteristics of Electronic Thermostats............................ 162
Review ................................................................................................................... 166


145
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

.
146
7.3.3 Operating Characteristics of Wall
Thermostats (Heat Only)
For most heating systems, the call for heat signal to start gas appliance operations is
initiated by a wall thermostat. In this module you will learn to:
(1) Identify the purpose of the wall thermostat

(2) Identify the operating characteristics of electro-mechanical wall thermostats
(3) Select a proper thermostat location
(4) Identify characteristics of thermostat circuits
(5) Identify variations in electro-mechanical wall thermostats
(6) Identify possible malfunctions of electro-mechanical wall thermostats
(7) Install a millivolt thermostat
(8) Identify elements of an installation checklist for thermostats
(9) Identify operating characteristics of electronic thermostats
(1) Identifying the purpose of the wall thermostat.
The purpose of a wall thermostat is to monitor and automatically maintain a

desired set temperature within a specific area. The wall thermostat controls
the on/off action of the heat source. The wall thermostat controls the amount
of heat in a given space by allowing or preventing an electrical current to flow
through the contacts, initiating the call for heat that results in gas appliance
burner operation. The thermostat switch may be rated for millivolts, 24 VAC
or 120 VAC.
Two main types of wall thermostats are used with gas-fired equipment:
" Electro-mechanical thermostats
" Electronic thermostats (programmable or non-programmable)
(2) Identifying the operating characteristics of electro-mechanical wall

thermostats. The major components of the basic electro-mechanical wall
thermostat, as illustrated in Figure 1 are:
" Bimetal temperature sensing device
" Single pole/single throw (SP/ST) electrical switch
" Temperature adjusting knob or lever
" Heat anticipator
" Thermostat cover
" Mounting base
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Figure 1. Basic Components of a Mercury Contact Thermostat Control
These five basic components are basic to all wall thermostat controls.
(a) Bimetal Sensing Devices.
The temperature-sensing device in most residential wall thermostats is

bimetal. The bimetal configuration may vary from one design to
another; however, the function of the bimetal is the same. The bimetal
activates the single pole/single throw (SP/ST) switch in the wall
thermostat. Since the bimetal is a good conductor of electrical current,
it is sometimes used as part of the electrical circuit. (Figure 2.) The
bimetal in Figure 1 is used for activating a mercury capsule type SP/ST
switch.
(b) Electrical Switching Action.
The bimetal configuration in Figures 1 and 2 is a watch spring-shaped

design. When the thermostat in Figure 2 senses a demand for heat,
the bimetal warps in a clockwise direction forcing an attached magnet
to a position on top of a glass container. Within the glass container is
a pair of contacts. The upper contact is stationary. The lower contact
is movable and is mounted on a flexible hinge. The magnet, when
positioned on top of the glass container, creates a magnetic field
instantaneously snapping the lower movable contact against the upper
stationary contact.
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Figure 2. Magnetic Contact Wall Thermostat
The slow switching action of the contacts in some older thermostats

which used a U-shaped bimetal and one fixed contact and a moveable
contact on the bimetal (without a mercury bulb) often resulted in
contact failure. (Figure 3.) As the contact located on the bimetal
moves closer to the stationary contact arcing may occur. Arcing in this
situation is the electrical current jumping from one contact to the other
before the two contacts actually touch. The arcing action will cause
pitting or burning of the contacts. The pitting or burning of the contacts
reduces the conductance of electrical current causing a loss of the
switching action and eventual malfunction. Most of these thermostats
have already been replaced in the field.
Figure 3. Mechanical Thermostat with U-Shaped Bimetal
The snap or rapid switching action of the thermostats, illustrated in

Figures 1 and 2, eliminate arcing between the contacts. These
contacts are enclosed in a glass container. The glass container
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protects the surfaces of the contacts from corrosion and foreign
particles.
The glass capsule contains a drop of mercury and two electrodes

(contacts). The mercury is a fluid metal and a good conductor of
electrical current. The mercury and electrode perform a switching
action when the mercury comes into contact with the electrodes.
The mercury contained in the glass capsule not only is used as the
electrical conductor, but also because of the weight of the mercury,
provides a snap action style of switching. As the bimetal senses a
need for heat it warps clockwise. The tilting movement of the bimetal
and capsule cause the mercury to rapidly flow from one end of the
capsule to the other end where the electrode tips are located. The
mercury completes the circuit from one electrode to the other.
As the bimetal senses the preset temperature the bimetal warps

counterclockwise; as the bimetal warps the mercury is forced to roll to
the opposite end of the capsule from the electrode tips. This action
breaks the electrical circuit between the electrodes, therefore opening
the circuit to the source of heat.
(c) Temperature Adjustment. Wall thermostats are designed so they

may be manually adjusted to maintain various temperatures. The
range of many wall thermostats is from 40° F to 90° F. By adjusting a
selector knob or lever the wall thermostat is set to control a selected
temperature. Thermostats are supplied in several ranges for various
uses.
The wall thermostat, as illustrated in Figure 4, utilizes an adjustment

stem that engages with a knob on the cover. The thermostat also
utilizes a cam assembly which repositions the bimetal. As the knob
(stem) is positioned for a lower desired temperature setting, the cam
rotates in a clockwise manner. The cam, in turn, forces the watch
spring-shaped bimetal to rotate counterclockwise forcing the magnet to
lift away from the contacts in the glass container. With the absence of
the magnetic attraction the lower contact drops away from the upper
stationary contact, breaking the circuit.
As the knob (stem) is positioned for a higher desired temperature

setting the cam rotates counterclockwise, forcing the bimetal to rotate
in a clockwise manner. The magnet is then positioned on top of the
glass container attracting the lower contact, which touches the upper
fixed contact, and completes the circuit.
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Figure 4. Temperature Adjustment on a Wall Thermostat
The thermostat illustrated in Figure 5 utilizes a knob/stem

arrangement. A drive gear performs the function of the cam in the
previous thermostat description. As the knob (stem) is positioned for a
higher desired temperature setting, the attached drive gear rotates
clockwise. The drive gear mates with a gear attached to the bimetal
forcing it to rotate counterclockwise. This action forces the mercury
within the glass capsule to roll to the end where the electrode tips are
located, thus completing the circuit.
In selecting a higher temperature setting the drive gear forces the

bimetal and mercury switch to rotate clockwise, completing the circuit.
Figure 5. Temperature Adjustment on a Mercury Thermostat
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(d) Heat Anticipator. A component known as a heat anticipator is located
near the bimetal within the thermostat, as illustrated in Figure 5.
The heat anticipator is a small length of high resistance wire which is

connected "in series" with the thermostat circuit. The heat anticipator is
only operational when the contacts of the wall thermostat are closed.
The function of the heat anticipator is to generate a small amount of

heat near the area of the thermostat bimetal. The small additional heat
generated by the heat anticipator causes the thermostat (bimetal) to
open its contacts several degrees before the actual temperature of the
thermostat is reached. For example, if the thermostat is adjusted for
68° F, the heat anticipator will cause the thermostat contacts to open at
66° F. The thermostat, due to the heat generated by the heat
anticipator, anticipates the need to open its contacts before the set
point temperature is actually reached.
The thermostat breaks the circuit to the gas valve blocking gas from
flowing to the main burner. Although gas is blocked from flowing to the
main burner the heat exchanger walls are still hot. Heat is also
trapped within the plenum and ducts. For the time the blower
continues to run, the surplus heat is distributed throughout the
dwelling. Heat distributed throughout the dwelling, after the thermostat
has cycled off, will add the additional heat required to meet the
selected temperature setting of the thermostat (68° F).
If the heat anticipator were not in the thermostat circuit, the thermostat
would open its contacts at the exact pre-selected temperature (68° F).
However, the blower would continue to circulate the heat from the heat
exchanger, plenum and ducts throughout the dwelling. As a result, at
the time when the blower cycled off the temperature within the dwelling
would exceed the pre-selected temperature of the wall thermostat by
as much as 5° F. In this example the temperature of the dwelling
would overshoot the pre-selected temperature. Therefore, "overshoot"
is the amount of heat entering the dwelling after the selected
temperature of the wall thermostat has been reached.
The heat anticipator must be adjusted so it generates the proper

amount of heat for the particular system. The adjustment of the heat
anticipator must be calculated to the current draw of the components in
the thermostat circuit. Normally, all components of the system are
marked with the respective current draw. For example, if the gas valve
(solenoid) is rated at .2 amps and the time delay relay is rated at .3
amps, the total current draw in the thermostat circuit is .5 amps.
Because the gas valve and relay are "in parallel" with each other in the
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thermostat circuit, this current draw can be calculated by simply adding
the current draw of the components in the thermostat circuit or by the
use of an ammeter.
When an ammeter is used to determine the current draw the

thermostat contacts must be closed. The ammeter is attached "in
series" to one terminal of the thermostat and to the wire normally
attached to that terminal. NOTE: While determining the current draw
the heat anticipator must be positioned on the lowest setting and the
heated air blower fan must be running.
Figure 6. Heat Anticipator Adjustment (Bottom-Right)
In order to adjust the heat anticipator of the thermostat, as illustrated in

Figure 6, the anticipator adjustment should be positioned so as to
indicate a current draw of .5 amps.
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Figure 7. Heat Anticipator Adjustment (Top of Thermostat)
When observing the heat anticipator illustration in Figure 7, it will be

noted the anticipator is constructed of one short strand of high
resistance wire, opposed to the anticipator illustrated in Figure 6,
constructed of one length strand of resistant wire wound around a
small tab. Although the two styles of heat anticipators physically
appear different, they perform the same function.
When a wall thermostat is used to control the temperature of a

dwelling, it should be noted the temperature of the dwelling does not
remain precisely at the temperature the thermostat is set on (set point).
The primary objective of the wall thermostat is to provide as small a
change as possible from the set point temperature. Variance from set
point temperature is called operating differential. The heat anticipator
can correct a wide variance in temperature operating differential.
Systems which operate properly in well-insulated dwellings should
have an operating differential of about 1° F to 2° F.
(e) Thermostat Cover. The thermostat cover performs one common

function on all styles of wall thermostats: to cover and protect the
mechanical and electrical components from the elements. Dust, lint,
and insects drastically reduce the ability of the wall thermostat to
operate efficiently.
Many wall thermostats incorporate a temperature selection knob/lever

on the thermostat cover. The knob or lever simply mates with the
corresponding cam or gear drive when the cover is attached to the
thermostat body. Many thermostat covers also have a thermometer
(simple watchspring-shaped bimetal with indicator) which operates
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independently of any other thermostat component. The temperature
indicator scale shows the approximate room temperature at any
particular time.
NOTE: The temperature indicators (thermometer) of most wall

thermostats are normally only accurate to within plus or
minus 2° F to 3° F of the reading.
(f) Mounting Base. The mounting base of the wall thermostat is used to
mount the wall thermostat to the wall. The base should be positioned
on the wall according to the vertical and horizontal lines embossed on
the base. For example, in the case of mounting a mercury switch style
thermostat, the thermostat must be properly leveled using a common
level. The bimetal is calibrated to warp a certain amount at a certain
temperature, and if the thermostat is mounted improperly, it will not
maintain the correct temperature setting.
Wall thermostats not utilizing a mercury switch may be mounted with

less emphasis on exact vertical and horizontal lines. The bimetal
contact style wall thermostat will maintain the same temperature
regardless of the angle at which it is mounted.
Although the thermostat utilizes a single pole/single throw (SP/ST)

switch for temperature control, many styles of thermostats serve an
additional purpose. In many styles the wall thermostat serves to
independently actuate other control components of the system. For
example, some heating systems utilize a blower or fan assembly. The
wall thermostat may be of the style that activates the blower
independently from the rest of the system. In this case, the wall
thermostat is designed with a sub-base. The sub-base may be used
as a mounting base, but more important, it serves to facilitate the
wiring of the thermostat as well as any other component (blower),
which is controlled from the thermostat. The sub-base may utilize a
manual selector switch to actuate the other control components.
(3) Selecting a proper thermostat location.
Within any given space there is a variation in temperatures. Because of this

temperature variation the wall thermostat must be located in a position where
the temperature is near the average for a specific dwelling or room of the
dwelling. During the installation of the wall thermostat the proper location is
very critical. If the thermostat is not located in an average temperature zone,
the thermostat will sense and maintain improper temperatures. The wall
thermostat maintains temperature by evaluating the temperature of its
immediate surroundings.
155
For proper temperature control the wall thermostat should be located on an
inside wall of the dwelling, approximately five feet from the floor. It is
extremely important to avoid mounting the thermostat in an area where air
does not naturally circulate (dead air), or an area where air circulates too
readily (from blower duct). It is important to avoid mounting the thermostat on
walls that are usually hot or cold compared to the indoor air space. Also, the
position of lights, heat-generating appliances or electronic equipment, and
sunlight must be considered when installing a thermostat.
(4) Identifying characteristics of thermostat circuits.
The connection diagram of the basic wall thermostat circuit illustrated in

Figure 8 represents a 24 VAC gas heating circuit. The basic circuit includes a
24 VAC wall thermostat, a 24 VAC gas valve, and a 24 VAC transformer.
Figure 8. Basic 120/24 Volt AC Wall Thermostat Circuit
The 120 VAC supply enters the primary side of the transformer and is
reduced to a 24 VAC supply on the secondary.
Line one (L1) of the 24 VAC supply is attached to the wall thermostat. Line
two (L2) of the low voltage supply is attached to one terminal of the gas valve.
An additional line connects the wall thermostat with the other terminal of the
gas valve to complete the simple series circuit.
It will be noted the series circuit to the gas valve is broken because of the
open thermostat contact. As the bimetal of the wall thermostat detects a
need for additional heat, the bimetal warps and allows the two contacts to
touch. As the series circuit is completed to the gas valve, the gas valve is
156
allowed to open. Gas is allowed to flow to the main burner where it is ignited
by the pilot flame.
It can clearly be seen that the closing of the wall thermostat contacts
completes the series circuit to the gas valve, and the opening of the contacts
breaks the series circuit to the gas valve.
Illustrated in Figure 9 is a sub-base with one selector switch. The selector

switch on the lower portion of the thermostat controls a separate circuit to the
blower assembly and is labeled FAN AUTO and FAN ON. The "fan auto" or
automatic position provides a circuit for the blower to operate in conjunction
with the heating system. The "fan on" setting provides a circuit to turn the
blower on independently of the heating system. The reason for selecting the
FAN ON position may simply be the need to circulate fresh air throughout the
dwelling without the need for any heat. Essentially, the selector switch
provides a manual override which allows control of a component (blower)
independently of the heating system.
Figure 9. Wall Thermostat with Fan Selector Circuit
Line one (L1) of the 24 VAC supply is attached to the TR terminal (solenoid)
of the gas valve. The A terminal (solenoid) of the fan relay is also attached to
line one (L1). Line two (L2) of the 24 VAC supply is directly attached to the
TR terminal of the wall thermostat switch. The GV terminal of the thermostat
is directly attached to the TS terminal (solenoid) of the gas valve. With the
exception of the open thermostat contacts, a complete circuit from the power
supply to the load (gas valve solenoid) is made. The thermostat is located "in
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series" with the circuit. As the thermostat contacts touch, the gas valve
solenoid is energized and gas is allowed to flow to the main burner.
As the circuit is completed to the gas valve the fan relay circuit is also
completed. The gas valve and fan relay are located "in parallel" with each
other, but are located in the thermostat's series circuit. At the time the wall
thermostat contacts mate, the relay and gas valve are activated.
The reason for the addition of the fan relay to the system is to engage the 120
VAC or 240 VAC blower motor by a 24 VAC circuit. As the fan relay is
energized, and after a short time delay, the series circuit to the blower motor
is completed. Many systems utilize this method of energizing the blower
motor, although the utilization of a fan control is a more common method of
energizing the blower motor.
Sometimes the dwelling in which the thermostat is located is at a desired

temperature (thermostat contacts open), however, the air within the dwelling
becomes stuffy. To eliminate this problem the homeowner might simply
adjust the fan selector switch (in the wall thermostat) to the on position. This
allows the fan to operate independently of the heating system. As the
selector is adjusted from FAN AUTO to FAN ON, the fan relay is positioned in
an independent series circuit. As the fan relay (resistance wire) is energized,
after a short time delay, the blower activates and circulates fresh air
throughout the dwelling. The blower will continue to operate until the fan
selector is readjusted to the FAN AUTO position.
With the fan selector in the FAN AUTO position the thermostat is turned to a
desired temperature (68° F). As the temperature is selected the thermostat
contacts touch and complete the series circuit to the gas valve. The gas
valve is energized and gas is allowed to flow to the main burner, where the
pilot flame ignites the gas. After a short time delay the fan relay energizes the
blower motor. As the main burner flame heats the heat exchanger the blower
forces air over the exchanger walls and circulates the heated air throughout
the dwelling by means of ducts. NOTE: The reason the fan relay delays
before energizing the fan motor is to allow the burner flames to heat the
exchanger walls, so the blower circulates the warmed air rather than cold air
throughout the dwelling.
As the bimetal of the wall thermostat senses the increase in temperature the
bimetal warps and the contacts separate. The separation of the contacts
breaks the series circuit to the gas valve, thus blocking the flow of gas to the
main burner. At the same time, the circuit to the fan relay is broken and after
a time delay, breaks the circuit from the fan relay. The reason the fan relay
delays is so the blower can circulate air from the still hot heat exchanger
walls, utilizing all possible heat from the system. After the time delay the fan
relay cycles the blower off at the temperature (68° F). In order for this
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relatively exact temperature to be maintained, the wall thermostat must utilize
a heat anticipator.
(5) Identifying variations in electro-mechanical wall thermostats.
The varieties of heating equipment require a variety of different voltages. The

most common voltages used in residential heating equipment are millivolt and
24 VAC. These two popular styles of systems basically utilize the same style
wall thermostat switch. As a general rule each voltage supply utilizes a wall
thermostat specifically designed for that voltage. NOTE: A millivolt
thermostat does not have a heat anticipator and will not replace a 24 VAC
thermostat.
Some residential and many commercial systems utilize 120 VAC wall
thermostats. The major differences in the lower and higher voltage systems
are the contact design and the style heat anticipator. Low voltage wall
thermostats utilize light contacts rated for voltages near 24 VAC. The heat
anticipator of the low voltage wall thermostats is constructed of light
resistance wire and rated for 24 VAC. The high 120 VAC wall thermostat is
constructed with much heavier components. The bimetal sensing device in
the thermostat allows the 120 VAC contacts to quickly open or close. Due to
the higher amperage in the 120 VAC system, these contacts must utilize a
quick switching action. Arcing or burning will occur on the contacts, if a slow
gradual switching action is used. The 120 VAC wall thermostat, however,
performs the same function of opening and closing a series circuit to the heat
source, (control valve) as do the low voltage style thermostats.
The heat anticipator of the 120 VAC wall thermostat is constructed of a

carbon-disc rather than a high resistance wire. The main reason the
resistance wire is not used is that, due to the higher amperage of the system,
a 120 VAC resistance wire would generate too much heat. The carbon-disc
generates the required amount of heat for heat anticipation. Since these
styles of heat anticipators are nonadjustable, the 120 VAC wall thermostat
normally is supplied with several sizes of carbon-disc heat anticipators to
match the various system current ranges encountered in the field.
Millivolt wall thermostats do not utilize the standard style resistant heat
anticipator. Most millivolt wall thermostats utilize the bimetal as a heat
anticipator. The bimetal is wired "in series" with the millivolt circuit. The
bimetal is a good conductor and, therefore, the small amount of voltage which
is applied to the bimetal adds the same additional heat required for
anticipation. This style heat anticipator is nonadjustable. A millivolt
thermostat cannot be used in a 24 VAC or 120 volt system.
The other major variations in wall thermostats are the additional application
the thermostat may perform. For example, many wall thermostats are both
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heating and cooling models. A selector switch on the sub-base may be
adjusted from the cooling setting to the heating setting, depending on the
desired climate in the dwelling. The circuits of the heating/cooling models are
more complex, and the many variations prohibit inclusion in this section.
Due to the variations in brand names and variations of heating systems, the
different styles of sub-bases also cannot feasibly be illustrated and properly
explained.
(6) Identifying possible malfunctions of electro-mechanical wall

thermostats.
In the majority of wall thermostat oriented complaints the thermostat itself

normally is not faulty. The major leading causes for supposed
thermostat-malfunctions are: poor wire or terminal connections to the
thermostat, gas valve, relay, or transformer.
In order to properly test the electrical circuit of the wall thermostat, make the
following simple tests:
(1) The simplest method of testing the wall thermostat from the wall
thermostat location is to simply by-pass the thermostat contacts. If,
after turning the wall thermostat to the highest temperature setting and
the gas valve does not allow gas to flow to the main burner, remove
the wall thermostat. Disconnect the two wire leads of the thermostat
contact circuit and place them together while holding the wire
insulation (low or millivolt systems only). If, with the wire leads
temporarily held together, the gas valve allows gas to flow to the main
burner, the thermostat is most likely faulty. Replace when necessary.
(2) If, with the wire leads touching, the gas valve does not allow gas to
flow to the main burner, the thermostat is most likely good and the
malfunction is elsewhere.
(3) In order to test the thermostat switch for making or breaking the circuit,
first remove the thermostat from the mounting base and disconnect the
low voltage wires. Rotate the temperature selector knob to the highest
temperature setting. This procedure should close the thermostat
contacts. Attach the two leads of an ohmmeter to the two thermostat
terminals. The meter reading should register continuity (zero ohms),
which proves the contacts are touching and the internal thermostat
wiring is free of breaks. If the meter indicates the contacts are not
"mating," (meter register infinity) the contacts are either wedged open
or there is a break in the wall thermostat's internal wiring. Replace wall
thermostat where necessary.
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(4) With ohmmeter leads attached to the thermostat terminals, rotate the
thermostat selector knob to the lowest temperature setting. The
ohmmeter should register infinity, indicating the contacts are open. If
the ohmmeter indicates continuity, (zero ohms) the wires of the internal
thermostat circuit are shorted or the contacts are fused together.
Replace thermostat where necessary.
When checking out a malfunctioning system the service technician may

improperly jump-out (short) the terminals of the gas valve. (Only do this if one
thermostat wire is disconnected from the gas valve.) All manufacturers of gas
valves have a warning label located on the gas valve. The warning states
"Do not short (jump-out) gas valve terminals. This will result in damage of
wall thermostat and void warranty." Essentially, this statement warns against
jumping out the gas valve to determine if the wall thermostat is
malfunctioning. When incorrectly jumping out the gas valve the heat
anticipator of the wall thermostat is shorted, which causes it to burn out
destroying the wall thermostat.
Malfunctions in the selector switches must be checked in conjunction with the

sub-base schematic. Due to the varieties of sub-base styles specific testing
procedures cannot be itemized.
In many cases the metal of the thermostat must be recalibrated or readjusted,

as due to age, the bimetal will gradually fatigue. Due to the different styles of
thermostats and methods of calibration it is impossible to detail any general
recalibration procedures. Refer to specific manufacturer's recommended
recalibration procedures where applicable.
(7) Installing a millivolt thermostat.
Because of the very low voltage, the thermostat must not have any
measurable resistance at the contact point or the system will not operate.
Wire size is also critical when installing thermostats some distance away from
the gas valves they control. The length of the wire may require the use of
heavier gauge wire such as #16 or #18 gauge.
With a voltmeter measure the powerpile output, then progress through the
controls and finally check the voltage at the thermostat. Too much voltage
drop will cause a malfunction.
Wire sizing is important to a millivolt system and some users now send a
quantity of large cord with the heater to run the thermostat line.
161
(8) Identifying elements of an installation checklist for thermostats.
With the exception of item 5 which will not apply to electronic thermostats, the
following checklist should be used when installing thermostats.
& 1. Read and follow manufacturer’s installation instructions.
& 2. Be sure sub-base plate is level and secure.
& 3. Use wire gauge and type specified by manufacturer.
& 4. Avoid locations that subject the thermostats to other heating or

cooling devices or place the thermostat in air drafts that would
result in temperatures at the thermostat that are not typical of
the space that is being heated or cooled. Ask yourself: Would
this location give a false temperature reading to the thermostat?
Do not install thermostats where they may be affected by:
" drafts or dead spots behind doors, curtains in corners or

under cabinets.
" hot or cold air from ducts.
" radiant heat from sun, pipes or appliances.
" concealed pipes and chimneys.
" unheated (uncooled) spaces behind the thermostat such
as a outside wall.
& 5. Set the heat anticipator according to manufacturer’s directions,

and based on multimeter measurements made between the gas
control valve and the thermostat (on furnaces, this will usually
be made with the blower fan operating.)
& 6. Apply an approved sealant to the wall opening behind the sub-
base plate where the wires enter the wall to ensure that inner
wall space drafts do not adversely affect thermostat accuracy
and operation.
(9) Identifying operating characteristics of electronic thermostats.
Electronic thermostats offer enhanced comfort features and potential energy

savings to homeowners and commercial customers. In addition to the
temperature sensing and process controlling switching functions of electro-
mechanical thermostats, electronic thermostats provide the means for
162
“personalized” comfort programming, and for variable daily, weekly or
seasonal heating and cooling temperature control.
In most cases, electronic thermostats can be used to replace electro-

mechanical thermostats on existing heating/cooling systems, however, it may
be necessary on some replacement applications to install an isolating relay.
Read and follow manufacturer’s instructions.
Electronic thermostats are powered through the 24V heating or cooling

controls. Most models do not require a heat anticipator setting or adjustment,
however a current measurement will probably be required to ensure that the
current draw of the thermostat is within manufacture’s specifications. For
example, Honeywell, Inc. specifies that the current draw for its “Tradeline”
series be between 0.08 and 1.2 A.
Electronic thermostats are actually small but powerful computers. As with

most computers, electronic thermostats have a built in clock and daily, weekly
(and in some models) annual calendars. The system operator (home owner
or building maintenance technician) can program the thermostat to vary
temperature settings throughout the day, week, and with some thermostats,
seasons.
Figure 10 illustrates one type of electronic thermostat, and its electronic circuit
board.
Figure 10a. Electronic Thermostat Figure 10b. Circuit Board, Backup

Batteries and Programming Controls
After the computer is programmed, it calculates the exact time to turn on the
furnace or air conditioner or other components such as electronic filters,
humidifier, or outside air pre-exchanger. When calculating the time to switch
on these devices, it considers (1) indoor air temperature [and on some
models—outside air temperature], (2) the temperature of the wall, and (3)
when the operator wants the comfort temperature established.
The diagram in Figure 11, on the next page, illustrates how an electronic
thermostat programmed to provide an energy savings by lowering the
temperature in a building during the night or on weekends gradually raises
163
temperatures during a recovery period. The recovery period leads up to the
system operating in the comfort mode, a period where the temperature is set
higher or lower to provide people the temperature settings they typically
desire.
Unlike electro-mechanical thermostats which simply turn heating and air

conditioning systems on and off based on a current temperature sensing
element, electronic thermostats typically increase or decrease temperatures
gradually, turning the heating and cooling components on and off several
times to save energy by avoiding “overshooting” the comfort temperature
desired.
Figure 11. A Programmed Heating Control Cycle
Electronic thermostats do not require heat anticipator adjustment as is the

case with electro-mechanical thermostats. The function of the heat anticipator
is to electrically heat the bimetal heat sensor so that it will tend not to
overshoot the temperature selection. The computer programs of electronic
thermostats perform this function.
With some models of electronic thermostats, the computer also “learns” how
the building and heating/air conditioning components interact by memorizing
how long it takes to reach programmed temperatures under varying
conditions throughout the program cycles. Some newer boilers and furnaces
also incorporate indoor and outdoor temperature sensors to “fine tune” the
heating cycle program, and maximize appliance efficiency.
Just as the computer-controlled electronic emission systems in modern trucks

and automobiles record the system settings and operating conditions for a
series of previous operating cycles, some electronic thermostats used in
HVAC systems record temperature and response times in order to control the
HVAC operating cycles. In other words, they learn from experience. With
164
some models, it takes up to 8 days to build up the memory, and the
performance of the system will gradually become more efficient as the data is
collected. Usually, the operator can “override” this “smart” feature by turning
it off and selecting the desired temperature for the current or a specific future
time block.
Installation and wiring of electronic thermostats is similar to the procedures

used with electro-mechanical types. Figure 12 illustrates a typical wiring
circuit diagram. Most units are two-wire or three-wire circuits. Remember
that printed circuits boards should never be subjected to resistance or
continuity measurements using an ohmmeter or a multimeter set on the ohms
measurement scales. Always read and follow manufacturer instructions.
Figure 12. Electronic Thermostat Wiring Diagram for Furnace
Programming instructions for each make and model of

electronic thermostat will vary. Remember that customers
may have difficulty understanding the instructions and
Technical operating characteristics at first. To avoid a frustrated and
Tip ! unhappy customer, be sure that you understand how to
program and operate the thermostat, and then take the time
to explain the thermostat to the customer in a simple but
complete manner.
165
REVIEW:
Characteristics of Wall Thermostats (Heat Only)
Select the answer which most correctly completes each statement. Mark your
choice in the space provided.
1. The range of most wall thermostats is from _____ degrees F to _____

degrees F.
( ) A. 10 - 60
( ) B 20 - 70
( ) C. 30 - 80
( ) D. 40 - 90
2. The heat anticipator is a small length of high resistance wire which is

connected _____ with the thermostat circuit.
( ) A. "in parallel"
( ) B. "in series"
( ) C. "in series parallel"
3. When an ammeter is used to determine the current draw in the thermostat

circuit, the thermostat contacts must be _____.
( ) A. open
( ) B. closed
4. For proper temperature control, the wall thermostat should generally be

located on an inside wall of the dwelling, approximately _____ feet from the
floor.
( ) A. 4
( ) B. 5
( ) C. 6
( ) D. 7
5. Because of age the thermostat _____ may gradually fatigue.
( ) A. wires
( ) B. base plate
( ) C. mercury
( ) D. bimetal
166
6. Systems which operate properly, in well insulated dwellings, should have an
operating differential of about _____ degrees F to _____ degrees F.
( ) A. 0-1
( ) B. 1-2
( ) C. 2-3
( ) D. 3-4
7. The mounting base of a wall thermostat should be positioned on the wall

according to the _____ and ______ located on the base.
( ) A. left-right lines
( ) B. up-down dots
( ) C. vertical-horizontal lines
( ) D. vertical-horizontal dots
8. Will the horseshoe bimetal contact style wall thermostat maintain the same
temperature regardless of the angle at which it is mounted?
( ) A. yes
( ) B. no
9. The _____ setting on a thermostat provides a circuit to turn the blower on

independently of the heating system.
( ) A. "fan auto"
( ) B. "fan on"
( ) C. "fan go"
( ) D. "fan heat"
10. The temperature sensing device in most residential wall thermostats is _____.
( ) a. time delay
( ) b. fan relay
( ) c. millivolt
( ) d. bimetal
11. If the gas valve (solenoid) is rated at .2 amps and the time delay is rated at .3
amps, the total current draw in the thermostat circuit is _____ amps.
( ) a. .1
( ) b. .5
( ) c. .05
( ) d. .7
167
12. The component that monitors and automatically maintains a desired set
temperature within a specific area is the _____.
( ) a. wall thermostat
( ) b. anticipator
( ) c. terminal
( ) d. mercury switch
13. Electronic thermostats are actually _____.
( ) a. powered through the 60V heating or cooling controls

( ) b. simplistic circuit boards
( ) c. small, powerful computers
( ) d. magnet operated components
14. Heat anticipator adjustments are required in _____.
( ) a. electronic thermostats
( ) b. electro-mechanical thermostats
( ) c. mercury thermostat
( ) d. fan selector circuits
15. Thermostats that have mercury tube components must be _____.
( ) a. mounted level
( ) b. mounted out of direct sunlight
( ) c. mounted on interior walls
( ) d. all of the above
168
Characteristics of Wall Thermostats (Heat Only)
I can:
1. Identify the purpose of a wall thermostat.
2. Identify the range of most wall thermostats.
3. Identify and explain a heat anticipator.
4. Identify and explain how total current draw in a thermostat circuit is

calculated.
5. Identify the position of the thermostat contacts when an ammeter is used

to determine the current draw.
6. Identify the operating differential of a heat anticipator.
7. Identify the best location for a wall thermostat.
8. Identify the characteristics of an electronic thermostat.
9. Identify the type of thermostat that does not require heat anticipator
adjustments.
169
170
7.3.4 Operating Characteristics of Limit and
Fan Controls
Table of Contents

of Limit and Fan Controls...................................................................................... 173
Identifying the Purpose and Operating Characteristics of Limit and Fan Controls . 173
Purpose of a Limit Control ................................................................................ 173
Purpose of a Fan Control.................................................................................. 174
Review ................................................................................................................... 177

171
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

172
7.3.4 Operating Characteristics of Limit and
Fan Controls
A vital safety component of warm air furnaces and warm water boilers is the limit
control. In this module you will learn to identify:
The purpose and operating characteristics of limit and fan controls
(1) Identifying the purpose and operating characteristics of limit and fan
controls.
(a) Purpose of a Limit Control.

The purpose of a limit control is to monitor the heating system for
overheating conditions. The limit control turns off the heat source
before a dangerous condition arises. Most limit controls are
constructed of a normally closed (N/C) single pole/single throw
(SP/ST) heat sensitive electrical switch. Limit controls are used
primarily in warm air furnaces and warm water or steam boilers. In this
training module, discussion of limit controls is focused solely on warm
air furnace applications.
Physical Description. The design of limit controls vary greatly. Many

styles carry an adjustable temperature control. The more economical
limit controls have a fixed temperature setting. Temperature is sensed
by means of a bimetal device. An example is shown in Figure 1.
Figure 1. Disc Bimetal Limit Control
173
Circuit Operation. The limit control is a heat sensitive electrical
switch. It breaks the circuit to the heat source in the event of an
overheating condition. The limit control can be placed in several
different areas of the system's circuit.
Temperature Settings. Most limit controls are set to open their

contacts at 200° F, although the manufacturer determines the exact
setting. For example, consider a limit control operating with a
differential of 25° F. This means that at 200° F the bimetal forces the
contact open. The contact will not close until the temperature drops to
175° F.
(b) Purpose of a Fan Control.
The purpose of a fan control is to monitor the heating system and

activate the fan or blower after sufficient heat is available for
distribution. Most fan controls are constructed of a normally open
(N/O) single pole/single throw (SP/ST) heat sensitive electrical switch.
Physical Description of a Fan Control. The fan control completes

the circuit for the blower. The two most common styles of fan controls
in use are (1) heat sensitive fan controls and (2) time delay relay
controls.
Heat Sensitive Fan Controls. Heat sensitive fan controls sense

temperature by means of bimetals. Remember, fan controls are
normally open (n/o) contacts. As the bimetal detects heat the contacts
begin to close. A complete circuit is made when the contacts close
completely.
The fan control also provides a delay on the blower. When the walls of
the heat exchanger are still hot there is available warm air to circulate.
As the heat is conducted away from the heat exchanger the bimetal
detects the temperature drop and breaks the circuit by opening the
contacts. (Figure 2.)
174
Figure 2. Combination High Limit and Fan Control
(The Bimetal Sensor Extends Into the Heat Exchanger)
Fan Time Delay (Timer) Relay Controls. The time delay relay
basically provides the same function as does the fan control previously
described. The major advantage of the time delay relay is that a heat
sensitive fan control does not necessarily have to be used in the
circuit. Time delay relays are normally constructed of a flat bimetal
with an attached contact, a stationary contact, and a length of high
resistance wire.
The high resistance wire is either coiled near or coiled around the flat
bimetal. As the thermostat's circuit is made the resistance wire of the
relay begins to heat the area where the bimetal is mounted. As the
bimetal detects heat it warps and forces the contact mounted onto it to
touch the stationary contact. The series is completed and the blower
comes on.
The style of bimetal and the type of resistance wire determines the
delay time of the time delay relay. Time delay relays are commonly
available with time delays from 15 seconds to 300 seconds, though
120 seconds is a widely used time delay relay. A time delay relay will
175
commonly delay the opening of the contacts (sensor cool down period)
as long as it delayed the closing of the contacts.
176
REVIEW:
Characteristics of Limit and Fan Controls
1. The purpose of a limit control is to monitor the heating system for _____
conditions.
( ) A. limited
( ) B. stalled
( ) C. overheating
( ) D. dangerous
2. Most limit controls are constructed of a _____ single pole/single throw

(SP/ST) heat sensitive electronic switch.
( ) A. normally open (N/O)

( ) B. normally opposite (N/O)
( ) C. normally changing (N/C)
( ) D. normally closed (N/C)
3. Most fan controls are constructed of a _____ single pole/single throw (SP/ST)
heat sensitive switch.
( ) A. normally open (N/O)

( ) B. normally opposite (N/O)
( ) C. normally changing (N/C)
( ) D. normally closed (N/C)
4. A widely used time delay relay is _____.
( ) A. 15 seconds
( ) B. 120 seconds
( ) C. 200 seconds
( ) D. 300 seconds
177
Characteristics of Limit and Fan Controls
I can identify:
1. The purpose of a limit control.
2. The type of switch used in most limit controls.
3. The type of switch used in most fan controls.
4. A widely used time delay relay for activating and shutting down blower
fans.
178
Identifying the Function and
7.3.5 Characteristics of Draft Fans &
Controls
Table of Contents
Identifying the Function and Characteristics of Draft Fans & Controls ................... 181
Identifying The Function and Characteristics of Draft Fans in High Efficiency

Appliances ............................................................................................................. 181
Identifying The Function and Characteristics of the Pressure Switch in the

Draft Fan System ................................................................................................... 182
Review ................................................................................................................... 184

179
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

180
Identifying the Function and
7.3.5 Characteristics of Draft Fans &
Controls
High efficiency appliances remove so much heat from the fuel gases that draft fans
are needed to move the products of combustion through the appliance heat
exchangers and venting system to the outdoors. In this module you will learn to
identify:
(1) The function and characteristics of draft fans in high efficiency appliances
(2) The function and characteristics of the pressure switch in the draft fan system
(1) Identifying the function and characteristics of draft fans in high

efficiency appliances.
In the Basic Principles and Practices of Propane study course that you
completed to start your propane certification studies, you were introduced to
the phenomenon known as “latent heat of vaporization.” In the section that
discussed physical properties of gases, it was stated that as water is heated,
a thermometer will show the result of heat added to the water as a burner is
turned up until the water reaches its boiling point. If the thermometer reads
212°F (100°C) at atmospheric pressure at sea level, no matter how much
additional heat is added, the thermometer will not show a higher reading. The
only observable outcome of the added heat is an increase in the boiling
action. Scientists and engineers refer to this added heat as “hidden or latent
heat” of vaporization.
Combustion of propane or any fuel produces water vapor. This “boiled” water
is a hot flue gas, and in conventional gas appliances, provides the energy for
venting of the products of combustion. High efficiency furnaces and boilers
use a second heat exchanger to recover the latent heat of vaporization by
condensing the water vapor. As a result, the venting energy is reduced and
must be replaced by a draft fan.
Figure 1 on the next page illustrates the construction of a condensing furnace.

A draft fan is located just below the burner manifold. In the illustration the
draft fan is labeled “exhaust blower.” The purpose of the draft fan is to ensure
that the products of combustion will move through the primary heat
exchanger, and through the secondary heat exchanger, and ultimately to a
location completely outside of the building to be vented to the outside
atmosphere. The temperature of flue gases is reduced to such a degree that
the gases must be pushed out of the system by the draft fan. Because of the
low temperature of the flue gases, metal venting materials are not required.
Most condensing appliances are readily identified because their venting
181
systems and make up air intake piping are usually made up of PVC (or some
other type of approved plastic) piping sections and fittings.
Figure 1. Diagram of a Condensing Furnace.
(2) Identifying the function and characteristics of the pressure switch in the
draft fan system.
A pressure switch is connected to the draft fan by a sensing tube. (Figure 2.)
The purpose of the pressure switch is to confirm that the draft fan is
producing a draft pressure sufficient to move flue gases through the heat
exchangers to the outside atmosphere.
182
Figure 2. Pressure Switch Assembly
In most condensing furnaces, the draft fan pressure switch is wired in series
with a flame roll out switch, the blower fan limit switch and the ignition control
module. This arrangement ensures that the draft fan is providing the required
venting pressure or the entire system is shut down. Without the fan proving
action of the pressure switch, if the venting system malfunctioned, the
products of combustion, possibly including toxics such as carbon monoxide
could be introduced into the building, exposing people to the risk of injury or
death.
To test the operation of draft fan pressure switches, read and follow
manufacturers’ instructions. Usually the instructions will call for the insertion
of a tee fitting into the sensing tube, with the tee outlet tubing connected to a
water column manometer. The manufacturers’ instructions will give the
manometer pressure range to be expected for normal operation. NEVER
suck or blow on a pressure switch sensing tube—you may damage the
pressure switch.
A typical draft fan will supply air pressured to approximately

19 inches water column. Be sure that the manometer used
Technical to measure pressure is capable of measuring that pressure;
Tip ! typical u-tube water column manometers used for checking
low-pressure gas regulator output may give the technician an
unscheduled shower.
183
REVIEW:
Identifying the Function and Characteristic of Draft
Fans & Controls
1. The function of draft fans in condensing furnaces and boilers is to _____.
( ) a. increase flame temperature

( ) b. move products of combustion to the outside atmosphere
( ) c. dilute burner primary air
( ) d. circulate warm air through the air ducts
2. The purpose of the pressure switch is to confirm that the draft fan is
producing a draft pressure sufficient to _____.
( ) a. provide air intake

( ) b. reduce venting energy
( ) c. move flue gases through the heat exchangers to the outside
atmosphere
( ) d. initiate the exhaust blower
3. Pressure switches used to monitor draft fans should be tested by sucking or

blowing on the sensor tube.
( ) a. TRUE
( ) b. FALSE
4. Condensing furnaces _____ in their secondary heat exchangers.
( ) a. recover “latent heat” from water vapor in the flue gases

( ) b. boil off additional free water
( ) c. provide heat absorption for refrigerant used in air conditioning
cooling cycles
( ) d. recover carbon dioxide
5. Draft fan pressure switches are usually wired in _____ with a roll out switch, a
limit switch and a _____.
( ) a. series/gas ignition control module
( ) b. parallel/pilot valve
( ) c. series/thermostat
( ) d. parallel/fireman’s switch
184
7.3.5 Identifying the Function and Characteristics of
Draft Fans & Controls
I can identify:
1. The component in condensing furnaces and boilers that moves products

of combustion to the outside atmosphere.
2. The purpose of the pressure switch.
3. The possible outcome if you suck or blow on a pressure switch sensing

tube.
185
186
Characteristics of Circuit Control
7.4.1
Devices, Electromagnetic Devices &
Transformers
Table of Contents
Identifying the Operating Characteristics of Circuit Control Devices,

Electromagnetic Devices and Transformers .......................................................... 189
Identifying Gas Appliance Operating Systems ....................................................... 189
Identifying Circuits, Devices and Symbols ............................................................. 193

Circuits.............................................................................................................. 193
Devices ............................................................................................................. 194
Identifying Electromagnetic Controls...................................................................... 206
Identifying Electromagnetic Induction .................................................................... 207
Identifying Alternating Current ............................................................................... 208
Identifying Transformers ........................................................................................ 208
Review ................................................................................................................... 211

187
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

Check found at the end of this module
188
7.4.1 Characteristics of Circuit Control
Devices, Electromagnetic Devices
and Transformers
Understanding control circuits and how their components manage electrical current
flow is essential to serving gas appliances. In this module you will learn to identify:
(1) Gas appliance operating systems

(2) The operating characteristics of circuits, devices and symbols
(3) Electromagnetic controls
(4) Electromagnetic induction
(5) Alternating current
(6) Transformers
(1) Identifying Gas Appliance Operating Systems.
In order to successfully troubleshoot a gas appliance system, it is necessary

to apply a thorough understanding of the devices that control the operation of
the appliance, an understanding of the way electrical circuits are used to
operate the devices, and the ability to think of the appliance as a system
made up of smaller systems. Figure 1 is a graphic representation of the
operation of a fan-assisted electronic ignition gas appliance system.
189
Figure 1. Simple Sequence of Operation Flow Chart
190
The trouble shooting logic to use in gas-fired appliance manipulation follows a
sequence-of-operation method. Figure 1 is a graphic that shows the general
sequence-of-operation for a fan-assisted electronic ignition gas appliance.
The operating sequence differs by manufacturers but the basic operation is
as follows:
(1) The thermostat which responds to a drop in temperature sends a call for
heat signal (typically 24volts) to the gas appliance thermostat input
terminal (normally the “w” terminal);
(2) The draft inducer is energized through the gas appliance control system
(which may be a simple relay or an integrated circuit board);
(3) Once the draft inducer is operating and moving sufficient air across the
heat exchanger, the air proving switch will close and allow 24 volts to flow
through any closed safety switches to the input terminal of the ignition
module;
(4) After the ignition module receives a 24 volt signal, the sequence then
depends on the type of ignition system as follows:
a. Intermittent spark ignition: a high voltage spark is generated at the pilot

burner from the ignition module and simultaneously 24 volts is sent to
the pilot valve terminal of the gas control valve from the ignition
module. The gas/air mixture is lit by the high voltage spark. The flame
sensor then senses the pilot flame and sends a signal back to the
ignition module via ground. The ignition module recognizes the pilot is
burning and then sends 24 volts to the main valve terminal of the gas
control valve which opens and supplies main burner gas that is ignited
from the pilot. The pilot continues to operate while monitoring the
flame. If the pilot fails to light within a predetermined time (typically 30-
60 seconds), the ignition module will stop sparking, discontinue
sending 24 volts to the pilot valve and lockout until the power supply is
interrupted. Some systems will attempt the sequence 3 more times
before locking out.
b. Hot surface ignition: typically 120 volts is sent to the hot surface igniter
which heats up to a temperature of approximately 2500 degrees F.
After a predetermined time (typically 15-45 seconds) of the igniter
glowing, the ignition module will then send 24 volts to the gas control
valve which will open and allow main burner gas to flow to the main
burner that is ignited from the heat of the igniter. The flame sensor
senses the flame and sends a signal back to the ignition module via
ground and continues to monitor the flame. If the main burner fails to
light within the timing sequence built in to the ignition module (typically
4-8 seconds), the ignition module will lockout until the power supply is
interrupted. Some systems will attempt the sequence 3 more times
before locking out.
191
c. Direct spark ignition: this system works the same way as the hot
surface ignition system does except the ignition module sends a high
voltage spark to ignite the main burner gas;
(5) Once ignition is established on a forced warm air furnace, the heating blower
will turn on after a predetermined time and blow the heated air throughout the
air distribution system into the home. With a hydronic heating system, the
circulator(s) will distribute heated water through the distribution piping to the
baseboard or radiant heating system to heat the home.
(6) As the home is heated to the thermostat set point, the thermostat contacts
open, ending the call for heat and the cycle is complete.
The operating sequence begins and ends at the thermostat. The electrical
circuits manage the operating functions that are required to complete the call
for heat sequence and then shutdown the appliance when it is completed.
The appliance is an operating system made up of a number of smaller

systems which work together in a controlled way to produce the desired
results in a safe manner. This training module examines particular controls
and devices which must be understood in order for you to successfully read
circuit diagrams, troubleshooting flow charts and to apply proven
troubleshooting methods.
192
(2) Identifying the operating characteristics of circuits, devices and
symbols.
A wide variety of devices are used in control circuits for gas operated
equipment, as illustrated in Figure 2.
(a) Circuits. Consider each rung of

the ladder diagram as a complete
circuit for a "working" component
and its control. The working
component converts electricity to
some useful function. It could be
a motor, heater element, light,
solenoid, etc. The controlling unit
or switch turns the working
component on or off.
In this discussion, controls in a

circuit will be classified as
operating or safety controls.
An operating control turns a

working component on or off.
A safety control automatically

turns a working component or the
entire system off in case of a
malfunction or abnormal operating
condition. These controls are
usually referred to as fuses, circuit
breakers, overload protectors, Figure 2. Ladder Diagram
pressure switches, and limit
(Control Circuit—Bottom Section)
switches, which monitor current
flow, pressure, temperature, liquid
level, etc.
The three essential elements of each circuit are:
1. Component(s) that perform work (such as a blower fan or the

burner)
2. Component(s) which control (relays, switches, valves, and

electronic control modules)
3. Connecting wiring conveying electricity to the components in the

circuit.
193
Because the control circuit of gas-operated equipment is a collection of
circuits, understanding electrical circuits and the interrelation of several
components is an important tool for the appliance technician.
(b) Circuit Devices.
Safety Interlock Switch. Figure 3. illustrates a

safety interlock switch. This is also indicated in
the circuit illustrated in Figure 2, page 3. The
Figure 3. Interlock safety interlock switch is placed in the circuit to
Switch Symbol prevent the equipment from being operated in
an unsafe condition.
The interlock switch will open the circuit, if a door on the equipment is
open, or a panel designed to protect the operator is removed.
Temperature Actuated Switches. Temperature-actuated switches

are used in the circuit illustrated in Figure 2, page 3, as follows:
Fan control,
Limit control,
Rollout switch, and
Flue limit.
The symbols for temperature activated-switches are illustrated in

Figure 4.
{7.4.1.2}
(N/O) Normally (N/C) Normally

Open Contact Closed Contact
Figure 4. Symbols for Temperature Activated Switches
194
Figure 5. Combination Limit/Fan Control
The main function of the limit/fan control switch is to monitor the

heating system and activate the fan or blower, after sufficient heat is
available for distribution. Most fan controls are constructed of a
normally open (N/O) single pole/single throw (SP/ST) heat sensitive
electrical switch. The N/O contacts close at a set temperature and
complete the electrical circuit to the fan or blower.
Appliance manufacturers often integrate the fan switch and limit switch
into one unit using a common sensing element similar to the illustration
in Figure 5.
The function of the rollout switch is to monitor the combustion

chamber for flame rollout. The rollout switch interrupts the operation of
the heat source in the event flame rollout occurs. The rollout switch
operates in the same manner as the limit control switch.
The flue limit switch monitors the flue temperature. It interrupts the
operation of the heat source in the event the flue is not accepting the
products of combustion properly and the temperature exceeds the
preset temperature of the flue limit switch.
195
Pressure Switch. (Figure 6.)
There are various types of
switches activated by a change in
pressure. A diaphragm responds
pressure change and moves a
mechanical linkage to open or
close an electrical circuit.
The pressure switch used in the

control circuit illustrated in Figure
2, page 3, is located in the vent
system.
As the fan starts to turn, positive

(+) pressure starts to build in the Figure 6. Draft Fan Pressure
chamber of the power vent. The Switch
sensing tube conveys the increased pressure to the diaphragm
assembly.
The pressure moves the diaphragm, closing the normally open switch,
completing the 24-volt current path to the direct spark ignition (DSI),
intermittent ignition device (IID) or hot surface ignition module.
Relays are basically communication carriers. Relays are used in the

control circuit illustrated in figures as follows:
" fan relay
" system relay
Relays are electromechanical devices. (The relay is both an electrical

and mechanical device in one.) It has a plunger that moves through
the opening in a coil. Contacts are connected to the plunger. The
major parts of the relay are illustrated in Figure 7 on the next page.
196
Figure 7a Figure 7b
The contacts attached to the moving plunger move from a closed to an

open position, or from an open to a closed position. Contacts are
referred to as normally closed (N/C) or normally open (N/O) in relation
to the condition of the de-energized coil. When the coil is energized,
normally open (N/O) contacts close, and normally closed (N/C)
contacts open. Figure 7a shows the contacts in the normal or de-
energized condition of the coil.
When the coil of the relay is energized, the plunger moves up as

shown in Figure 7b. The movement is caused by a magnetic field.
Depending upon the situation,

the contacts of a relay may be
connected in one circuit and
the relay coil connected in
another circuit. For example, in
the diagram illustrated in Figure
8 the contacts on the fan relay
are connected in the line
voltage circuit (120V), and the
coil is connected in the low
voltage circuit (24V). The relay
device contains both of these
components. Notice the
symbol for the coil for
the fan relay is clearly marked.
Figure 8. Ladder Diagram
197
Solenoid. Solenoids, like the relay and contacts, are
electromechanical devices. When the coil of the solenoid is energized,
a magnetic field is produced around the coil. The force produced by
the magnetic field acts on the solenoid plunger. Because of this force
the plunger moves into the coil.
Solenoid operated valves are used

extensively in gas controls. For
example, Honeywell’s' Pilotstat®
power unit, as illustrated in Figure
9, uses electric current (DC) from
the thermocouple generator at the
pilot light to hold the safety shutoff
open to permit gas to flow to the
main burner. When the pilot is
burning and the magnet is
energized, the pole piece is held
against the magnet. The pole
piece is held manually against the
magnet when lighting the pilot
because the magnet is not strong Figure 9. Pilotstat® Power Unit
enough to pull the plunger in
against the resistance of the drop-out spring. After the pilot is lit and
burns for about one minute, the thermocouple heats up producing
electric current. The current from the thermocouple will produce the
magnetic force necessary to hold the safety shutoff valve open.
Ignition Systems. Whatever the ignition system, (standing pilot, or

electronic ignition) it must be capable of protecting against gas flowing
to the main burner when there is no source of ignition. For standing
pilots, the pilot safety circuit shuts off the gas supply to the main
burner, (and pilot in many cases) if the pilot goes out. For intermittent
ignition system pilots, the main burner valve will not open until the pilot
is established, and the main valve will close if the pilot goes out. For
hot surface and direct spark devices, the main burner valve will open if
there is no ignition but will shut down after prescribed "lock out" time.
198
Pilot safety systems are ONE THERMOCOUPLE PRODUCES
energized by a single 25 - 30 MILLIVOLTS
thermocouple or a thermopile.
10 THERMOCOUPLES PRODUCE
A single thermocouple produces 250 - 300 MILLIVOLTS
about 25-30 millivolts (DC).
Bundles of thermocouples 26 THERMOCOUPLES PRODUCE
connected in series, called 600 - 780 MILLIVOLTS
thermopiles, produce approx-
imately 250 or 750 millivolts Figure 10. Output Voltages
(DC). (Figure 10.)
The millivolts of electricity produced by the thermocouple or thermopile

is used to operate both gas safety valves and gas control valves.
In order to protect the thermopile

series circuit, the group of
thermocouples is typically
enclosed in a stainless steel
jacket. (Figure 11.)
Illustrated in Figure 12 is a
slightly different structure than
the wire lead thermopile. The
structure of the steel jacket and
the mounting nut are the same
as the wire lead thermopile.
Figure 11. Wire Lead Thermopile However, instead of utilizing two
wire leads for voltage transfer,
this thermopile uses a longer
copper capillary tube with one
inner wire lead. The inner wire
lead is the hot lead for voltage.
The capillary tube is used as the
circuit ground. This type of
capillary/attaching nut thermopile
is called a coaxial thermopile.
Figure 12. Coaxial Thermopile
199
Figure 13 illustrates an electromagnetic safety assembly. It
automatically cuts off the supply of gas to all burners in the event of a
pilot outage.
Figure 13. Electromagnet Safety Assembly
The pilot burner is the heart of the electromagnetic safety assembly. It

is used to ignite the main burner of the gas appliance, as well as
properly heat a control device or thermocouple. The pilot burner as
illustrated in Figure 13 is a standing or constant pilot used with the
electromagnetic safety assembly.
The thermocouple is the electrical power supply for the

electromagnetic safety assembly. When it is properly heated by the
pilot burner, the modern thermocouple will generate approximately 25
to 30 millivolts.
The millivoltage generated by the thermocouple is used to activate the

electromagnetic power unit. An electromagnet inside the power unit is
energized by the millivoltage. Once energized, the electromagnet
holds a valve (shutoff disc) off a valve seat, allowing gas to flow to the
pilot burner.
Transformer. Electrical controls used on gas-fired equipment typically

use a force of electric energy called alternating current (AC). Most
electrical loads on gas-fired equipment are energized at 120 volts
(AC), while some of the control circuits are energized at 24 volts (AC).
200
The transformer used in
gas-fired equipment con-
trols consist of at least two
separate coils, as illustrated
in Figure 14. The line
voltage is connected to one
coil, called the primary. The Figure 14. Control Transformer
control load is connected to
the other coil, called the secondary. Where the voltage is reduced
from the primary to the secondary, the transformer is referred to as
a step-down transformer. If the voltage is increased from the
primary to the secondary, the transformer is referred to as a step-up
transformer. The transformer in the control circuit illustrated in
Figure 2, page 3, is a step-down transformer.
Transformers, solenoids, and relays operate on the principle of

electromagnetism. The principle of electromagnetism is discussed in
more detail later in this training module.
Motors. Although there are

many types of electric motors,
the one most commonly used
in gas operated equipment is
referred to as a "capacitor
start" motor. The blower
motor is shown in Figure 15,
and the control circuit
illustrated in Figure 2, page 3,
is a multiple speed motor.
Figure 15. Blower Motor
The symbol (or in Figure 15) represents a

disconnect used in the motor circuit.
201
Gas Control Module.
Basically there are two
different types of electronic
ignition systems in use today.
One type uses a spark to
ignite the burner gas and the
other type uses a hot surface
to ignite the burner gas.
Illustrated in Figure 16 is a
typical gas control module. Figure 16. Gas Control Module
" Intermittent Pilot Ignition (IID) modules are designed for

residential gas operated equipment which operate on low voltage.
When powered by a 24 volt transformer and controlled by a suitable
temperature control, they:
- Check for a false flame signal (a flame simulating component or
system failure) before energizing the spark generator. If a false
flame signal exists, the module does not energize the spark
generator.
- Generate a high voltage potential for spark ignition of the pilot
burner.
- Open the pilot valve of the gas control.
- Discontinue ignition when the pilot flame is established. Some
modules are designed to provide timed trial for ignition, and lock
out on safety, if the pilot fails to ignite in the specified time.
- All propane modules require lockout in safety and discontinuing
sparking and control voltage.
- Open the main valve after proving the presence of the pilot flame.
- Shut down, if power is lost, and performs a new startup when
power is restored.
- Shut off the main gas valve on loss of pilot flame and starts a new
trial for ignition.
The flame monitoring circuit in the control module responds only to

this direct current to prove the presence of the pilot flame.
" Direct Spark Ignition.
Direct spark ignition (DSI) does away with the pilot altogether
and lights the main burner with an electric spark. Operation of
the burner depends on continuous detection of the main burner
flame by an electronic flame sensing system.
202
Direct spark ignition is used on some of the same applications as
Intermittent Pilot and in some applications where DSI is uniquely
suited as well.
Unlike intermittent pilot ignition, direct spark ignition is required to

light a significantly larger gas flow. Safety demands that ignition
and flame detection occur in a few seconds. (2)
" Hot Surface Ignition
Hot Surface Ignition (HSI) uses a special heating element to ignite

the main burner. The element rapidly heats to a temperature in
excess of 2500°F, instead of igniting the gas with an electrical
spark. HSI provides a highly reliable ignition source for outdoor
installations where wind is a problem for spark ignition. As is the
case with spark ignition systems, HSI systems usually use flame
rectification to prove the safe ignition of the burner.
Gas Controls (Dual Valve

Combination). Dual valve
combination gas controls are used
with all intermittent pilot ignition
systems. (Figure 17.) These
controls provide positive shutoff of
the main burner gas and have
independently operated (solenoid)
pilot valve operators.
Figure 17. Gas Control Valve
Figure 18, page 14, and Figure 19, page 15, are schematic diagrams illustrating
the theory of operation of the main valve controlling:
% the flow of gas to the burner,

% the on-off cycling function of the valve operator, and
% the servo pressure regulator method of maintaining the desired
outlet pressure to the burner manifold.
As illustrated in Figure 18 when the control is in the burner off

position, the diaphragm (5) and disc (3) in the main valve assembly
operate similar to a conventional diaphragm type valve. The valve
opens and closes in response to the admission or discharge of gas into
the pressure chamber (4) beneath the diaphragm. (The gas
performing this function is referred to as "working gas.")
203
Figure 18. Control in the Burner OFF Position
In the burner off condition, the working gas has been discharged such that there
is no lifting force being exerted by the diaphragm on the valve disc assembly.
The valve closing spring has firmly seated the valve disc, therefore blocking the
flow of gas to the burner.
The function of the valve operator is to control flow of working gas. It

incorporates an ON-OFF lever(1) which is electrically actuated by the
temperature control circuit.
Notice in Figure 18, in the OFF position the right-hand port is closed,
blocking the flow of gas into the working gas channel (2) from the
control inlet. Also, the evacuation gas channel (6) to the control outlet
is open. This has permitted the discharge of working gas from the
pressure chamber (4). Therefore, with the loss of working gas
pressure, the main valve has closed.
Figure 19, illustrates that when the control is in the burner ON position,
the ON-OFF lever (1) is in the position it assumes when the valve
operator is energized on a call for heat.
204
Figure 19. Control in the Burner ON Position
The left-hand outlet port is closed, and the right-hand supply port is
open permitting the flow of working gas into the main valve pressure
chamber (4). As previously described, the admission of working gas
into the pressure chamber causes an upward movement of the
diaphragm, therefore, lifting the valve disc to allow the flow of gas to
the burner.
When the right-hand supply port in the valve operator opens upon a
call for heat, a continuous flow of working gas goes into the servo
regulator pressure chamber (8) and through the evacuation gas
channel (6) into the control outlet. It is through the evacuation channel
that the servo regulator senses variations in outlet pressure. Any
variation in outlet pressure is instantly reflected back into the servo
regulator pressure chamber (8) and repositions the regulator
diaphragm (9). Movement of the regulator diaphragm in turn alters the
rate of flow of evacuation gas through the regulator valve (7) and
causes the following corrective action:
If the outlet pressure begins to rise, the servo regulator valve (7) opens
slightly to allow more working gas to discharge into the evacuation gas
channel (6). This decreases the pressure of the working gas in the
main valve pressure chamber (4) and repositions the main valve disc
(3) downward, closer to its seat. Therefore, the flow of main burner
205
gas through the control is decreased to correct for the rise in the outlet
pressure.
If the outlet pressure begins to fall, the servo regulator valve (7) closes
slightly to reduce the discharge of working gas into the evacuation gas
channel (6). This increases the pressure of the working gas in the
main valve pressure chamber (4) and repositions the main valve disc
(3) upward, further away from its seat. Therefore, the flow of main
burner gas through the control is increased to correct the fall in outlet
pressure.
(3) Identifying electromagnetic controls.
The action of solenoid-operated plungers is widely used in control work.

Such a plunger can be attached to a valve seat or disc. Energizing or de-
energizing the solenoid attracts or releases the plunger causing the attached
valve seat to open or close the valve. The valve illustrated in Figure 20,
operates on the electromagnetic principle. With the coil de-energized, the
valve stem and seat are held down by the force of gravity or a spring to shut
off flow through the valve. When the coil is energized, the magnetic field
around the coil lifts the valve stem and seat, opening the valve and allowing a
flow. Electromagnetic valves are usually called "solenoid valves." Solenoid
valves may be used for starting or shutting off the flow of gas.
Figure 20. Magnetic Operated Valve
The same electromagnetic principle is used to actuate remote controlled

switches. Figure 21 on the next page illustrates a switch which operates on
electromagnetic principles. Only a small amount of current is required to pass
through the coil to close or open the electrical contacts, which can switch
comparatively large load currents. A switch operated by means of a solenoid
is called a relay.
206
Figure 21. Magnetic Switch
(4) Identifying electromagnetic induction.
If a magnetic field is moved past a conductor, or if the conductor is moved

through a magnetic field, an electrical force (voltage) is induced in the
conductor. Figure 22 illustrates the permanent bar magnet is moved in and
out of the coil to induce an electrical current in the coil.
Figure 22. Magnetic Induction with a Stationary Coil

As the permanent magnet is moved into or out of the coil, the magnetic lines
around the magnet cut across the turns of the coil. When the turns of the coil
are cut by the magnetic lines of force, a voltage is generated across the ends
of the coil causing electrical current to flow.
One application of the induction effect is the transformer. Illustrated in Figure
23 is a primary winding (coil) connected to a 120 AC. A secondary winding
(coil) is placed close to the primary winding, but is not connected to it.
Opening and closing the switch results in a sudden movement of electrical
current in the primary winding. The sudden increase or decrease of current
through the primary winding causes a magnetic field to build up or collapse
around the primary winding. Since the magnetic lines of force cut across the
secondary winding, any sudden buildup or collapse generates a voltage
across the ends of the secondary winding.
207
Figure 23. Transformer Principle
(5) Identifying alternating current.
Alternating current flows in a conductor first in one direction and then in the
other direction. These reversals of direction occur periodically and rapidly.
Each change of direction is called an alternation and every two alternatives
are called a complete cycle. The number of cycles per second is called the
frequency of the alternating current. The standard frequency in the United
States is 60 cycles (Hertz) per second.
The rapid changes in direction of current flow and the quantity of current
flowing in conductor sets up a rapidly changing magnetic field around the
conductor and in coils.
(6) Identifying transformers.
Because of the changing magnetic

field caused by alternating current in
a conductor, a device called a
transformer is used to step-up or
step-down the voltage. As illustrated
in Figure 23, a conductor or coil will
"induce" a voltage in a nearby
conductor or coil while the magnetic
field of the primary coil was building
up from zero to a maximum and
again when the magnetic field was Figure 24. Basic “Step-Down” or
collapsing from a maximum to zero. “Step-Up” Transformer
In the same changing magnetic field
the voltage in the "primary" and "secondary" will be proportional to the
number of turns of wire in the primary and secondary coils.
Figure 24 illustrates the principle of a voltage transformer, which is a simple

method of increasing or decreasing the voltage of an AC circuit. A core of
208
iron is indicated in a form commonly used for better efficiency. In any
transformer the wire sizes, number of turns on the coil, and construction of
the iron core must vary with the power requirements of the circuit.
The voltage induced in the secondary

coil of a transformer depends upon the
number of turns of the primary coil and
the number of turns in the secondary
coil. This can be engineered by the
equation:
Ep (primary voltage)
Es (secondary voltage) =
Np(primary turns)
Ns(secondary turns) Figure 25. Transformer with a
1:1 Turn Ratio
The transformer illustrated in Figure 25 has 100 turns on the primary coil and
100 turns on the secondary coil. When 100 volts AC is applied across the
primary coil of the transformer, 100 volts will be read across the secondary
coil of the transformer.
Figure 26 illustrates that, if a

transformer has 100 turns in the
primary coil and 1000 turns in the
secondary coil, when 100 volts AC is
applied across the primary coil of the
transformer, 1000 volts will be read
across the secondary coil of the
transformer. A comparison of the
number of turns in the primary coil to
the number of turns in the secondary
coil is called the turn ratio. The turn
ratio illustrated in Figure 26 is 1:10. Figure 26. Step-Up Transformer
This is called a step-up transformer.
Lower voltage in the secondary winding

than in the primary winding can be
achieved by using fewer turns on the
secondary coil than on the primary coil.
As illustrated in Figure 27, 100 volts in
the primary is transformed to 50 volts in
the secondary winding by using 50
turns on the secondary winding and
100 turns on the primary winding. The Figure 27. Step-Down Transformer
turn ratio illustrated in Figure 27 is 2:1. This is a step-down transformer.
209
The transformer VA (volts X amps) is figured by multiplying the voltage output
of the transformer by the total circuit of the entire system. For example, a 24
volt transformer rated at 40VA, the current capacity is approximately 1.67
amperes. The VA of a transformer is the power output rating of the
transformer in watts. Therefore, the VA rating is an important consideration
when replacing a transformer. Transformers must meet two requirements:
1. The transformer must be capable of providing the power to pull in all

electromagnetic devices at once, under inrush or starting conditions.
The transformer should meet National Electronic Manufacturer's
Association (NEMA) performance standard ST2-1976.
The supply voltage to the ignition controls should be within the following
ranges:
120-VAC controls: 102 to 132 VAC

24-VAC controls: 0% load 26.5 ± .5 VAC
100% load 24.0 ± 1 VAC
2. The transformer must be capable of carrying the continuous current

draw of all components without overheating.
Because transformers have no physical connection between the primary and

secondary coils, the coils can be checked with an ohmmeter with the power
supply disconnected for open or shorted windings. If the output voltage of a
transformer is within 10% of its rating, the transformer is considered good.
210
REVIEW:
Identifying the Operating Characteristics of Circuit
Control Devices, Electromagnetic Devices and
Transformers
space provided. (Some letters may be used more than once.)
A. safety J. flue temperature limit switch

B. capacitor start K. 1
C. rollout switch L. solenoid
D. limit control M. operating
E. relay N. interlock
F. step down O. 3
G. open P. primary
H. 2 Q. secondary
I. switch R. closed
1. A control device which deliberately turns a working component in a

circuit on or off is classified as a (an) _____ control.
2. A control device which automatically turns a working component off in

case of an emergency is classified as a (an) _____ control.
3. A type of safety switch connected between the control circuit and

power source is referred to as a(an) _____ switch.
4. A safety device which monitors a heating system to prevent an

overheating condition is the _____.
5. A safety device which monitors a combustion chamber to prevent

flame rollout is called a _____.
6. Voltage is reduced from the primary to the secondary in a _____

transformer.
7. The type of motor most commonly used in gas operated equipment is

the _____ motor.
8. A safety device which monitors the temperature of flue gases is the

_____.
211
F. step down O. 3
G. open P. primary
H. 2 Q. secondary
I. switch R. closed
9. As illustrated in Figure 1, a switch operated by means of a solenoid is

called a _____.
Figure 1
10. Switch "S" controls the solenoid in the circuit illustrated in Figure 2.
The solenoid operates when the switch is _____.
Figure 2
11. Most solenoid valves are spring loaded, when electric current is not
passing through the coil the spring closes the valve. When electric
current flows through the coil an electromagnetic force will _____ the
valve.
212
F. step down O. 3
G. open P. primary
H. 2 Q. secondary
I. switch R. closed
12. In the circuit illustration in Figure 3, when the switch is closed the
solenoid valve will _____.
Figure 3
13. As illustrated in Figure 4, the number of switches that will have to be
closed for this solenoid to work is _____.
Figure 4
14. As illustrated in Figure 5, the solenoid will operate when the ON-OFF
15. switch is _____ and the limit switch is _____.
Figure 5
213
F. step down O. 3
G. open P. primary
H. 2 Q. secondary
I. switch R. closed
16. Thermostats and circuit breakers perform the same function in a circuit
as a _____.
17. As illustrated in Figure 6, the number of switches which must be closed

to operate the light is _____.
Figure 6
18a. A simple transformer has two windings. The windings are referred to
18b. as _____ and _____.
18c. The transformer winding connected to the power source is called the
_____ winding.
18d. The transformer winding connected to the load is called the _____
winding.
214
7.4.1 Identifying the Operating Characteristics of Circuit
Control Devices, Electromagnetic Devices and
Transformers

I can identify:
1. From an illustration the symbol that represents a safety interlock switch.
2. The device in a gas heating control circuit which monitors the heating
system and activates the fan blower, after sufficient heat is available for
distribution.
3. The device in a gas heating control circuit, which monitors the heating
system for an overheating condition.
4. The purpose of the solenoid, an electromechanical device.
5. From an illustration the symbol that represents a circuit disconnect.
6. How a flame monitor circuit in an intermittent pilot ignition system

responds in order to prove the presence of the pilot flame.
7. If solenoid valves are used extensively in gas controls.
8. The process known as magnetic induction.
9. The device used to step-up or step-down voltage in an alternating current.
215
216
Reading Electrical Control Circuit
7.4.2
Diagrams
Table of Contents
Reading Electrical Control Circuit Diagrams .......................................................... 219
Identifying Basic Circuit Diagrams ......................................................................... 219

Connecting or Component Diagram ................................................................. 219
Ladder Diagram ................................................................................................ 220
Identifying a Timer Bar Chart (Timer Cycle)........................................................... 222
Applying your Knowledge to Reading Circuit Diagrams......................................... 223

Circuit Diagram Worksheet-Standing Pilot Furnaces ........................................ 223
Circuit Diagram Worksheet-Condensing Furnace............................................. 228
Circuit Diagram Worksheet I-Heating/Cooling Packaged Unit .......................... 233
Circuit Diagram Worksheet II-Heating/Cooling Packaged Unit ......................... 236
Circuit Diagram Symbols.……………………………….…….………….……………. 239
Review ................................................................................................................... 242
NPGA Certified Employee Training Program

Performance-Based Skill Assessment Evaluation Packet
Applying Basic Principles of Electricity to Service Propane Appliances – 5/2005
217
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

218
Reading Electrical Control Circuit
7.4.2
Diagrams
In the course of repairing a gas appliance, technicians must routinely refer to

electrical circuit diagrams. In this module you will learn to:
(1) Identify basic circuit diagrams

(2) Identify a timer bar chart (timer cycle)
(3) Apply your knowledge to reading circuit diagrams
(1) Identifying basic circuit diagrams.
The controls used on gas-fired equipment are typically illustrated in two types
of diagrams: the connection diagram and the ladder diagram. The Heating,
Ventilation and Air Conditioning (HVAC) industry applies four basic rules
when drawing circuit diagrams. Learning and using these four rules can help
you more readily understand equipment circuit diagrams.
BASIC RULES FOR READING ELECTRICAL SYMBOLS IN CIRCUIT
DIAGRAMS—HVAC INDUSTRY STANDARDS
1. RELAYS and CONTACTORS are drawn in a de-energized condition.

2. SAFETY CONTROLS are drawn in their normal running position—closed.
(There are some exceptions to this rule.)
3. OPERATING CONTROLS are drawn normally open.
4. TIMER MOTORS are drawn in the “ready to start” position or at “ time zero”
on the bar cycle chart.
(a) Connecting or Component Diagram. Connection diagrams,

sometimes called component location diagrams, use symbols for
various parts of the control system. The parts of the control system
are located on a piece of paper in much the same relative position as
they are used in the equipment. As illustrated in Figure 1 on the next
page, the wires are connected from part to part in the same patterns as
used in the actual equipment.
219
Figure 1. Connection Diagram
Connection diagrams
" give component wiring instructions, and
" aid in identifying components.
(b) Ladder Diagram.
Ladder diagrams use symbols for

the component parts. Wires
connect the symbols to their
control units as simply as
possible.
Wiring is arranged as follows:
The leads from the power source

are drawn vertically on the paper
much as the "side rails" of a
ladder are located.
The neutral wire in a ladder

diagram is indicated by the
notation L2.
Figure 2. Ladder Diagram
220
The hot wire is indicated by the notation L1. Then each individual
circuit is placed crosswise as the "rungs" of a ladder would be. The
illustration in Figure 3 shows the electrical component parts, their
controls, and how the wires connect the controls to the power source.
Unlike the component diagram, the ladder diagram does not show the
actual location of components. Ladder diagrams are useful in
determining sequence of operation and how loads are activated in a
circuit.
Notice that in HVAC ladder diagrams, the step down transformer is the central
component and divider between high voltage load circuits and lower voltage
control circuits. Ladder diagrams graphically illustrate the requirements for safe
current flow:
1. Potential difference (voltage)

2. Proper path (no shorts between power legs, L1 and L2)
3. Switches to control loads
4. Loads that convert flow of electrons to useful work
Figure 4.
Simple Circuit Ladder
221
(2) Identifying a timer bar chart (timer cycle).
Time Bar Chart (Timer Cycle). Time bar charts are true sequence-of-
operation control diagrams. Also caller timer cycle charts, these diagrams are
commonly used to communicate sequence of operations for clothes washers,
dryers and dishwasher. Unlike circuit diagrams which provide wiring and
wiring connection information, time bar charts give technicians the means to
troubleshoot a series of equipment systems that are controlled through a
timed sequence. Figure 4 illustrates five lines from a time bar chart.
Figure 4. Time Bar Chart (Timer Cycle)
Each line on a timer bar chart corresponds to a device, switch or operation

that is controlled by a timer motor. Consider how this chart might be used to
represent the pre-purge and ignition cycle of a clothes dryer. Understanding
timer bar charts gives an analog model for understanding some of the control
operations handled by computerized process controllers that operate complex
HVAC systems.
222
(3) Applying your knowledge to reading circuit diagrams.
(a) Circuit Diagram Worksheet-Standing Pilot Furnace.
On the pages that follow, you will find connection and ladder diagrams for the
furnace illustrated in Figure 5. Your instructor will lead you through questions
on page 225 that will require you to refer to the diagrams found in Figure 6,
page 224.
Standing Pilot LP-Gas Furnace

KEY TO FURNACE DIAGRAM PARTS
1 Exchanger, Heat
4 Motor, Blower
5 Wheel, Blower
6 Capacitor, 7.5 MFD, 370V)
7 Relay, SPDT
8 Transformer
9 Switch, Interlock
10 Burner, Pilot
11 Thermocouple
12 Tube, Pilot
14 Orifice, Pilot Burner (L.P. Gas)
15 Valve, Gas (L.P. Gas)
16 Crosslighter
17 Shutter, Air (L.P. Gas)
18 Orifice, Main Burner (L.P. Gas)
#54
19 Burner
20 Control, Fan and Limit
Figure 5. Furnace Parts Diagram
223
Figure 6. Standing Pilot Furnace Connection and Ladder Diagrams
224
CIRCUIT DIAGRAM WORKSHEET—STANDING PILOT FURNACE
Instructions: Remove page 224 and place the circuit diagrams at the top of this page for
reference. Following the directions given below and by your instructor, fill in
the blanks that answer the questions given below.
1. Look at the Ladder Diagram on the right-hand side of page 224. Trace down the
Hot leg of the diagram.
A. What is the first component in the Hot leg
of the circuit?
B. According to diagram rule #2 on page 1, is
this device an operating control or a safety
control?
C. What voltage and current should be
expected across this device?
2. Use your pencil or finger to trace across the “rungs” of the 115 V section of the
ladder diagram.
A. What components are “loads?”
B. What control must close before the blower

will run?
C. What would cause the fan switch to close?
D. Is the fan switch an operating control or a
safety control?
3. Locate the Thermostat in the ladder diagram.
A. What voltage and current should be found
across the white wire and the red wire on
a call-for-heat?
B. What safety control is located between the
Thermostat and the Gas Valve?
C. What relay contacts must be closed for the
blower fan to operate?
D. What path across the Thermostat (which

terminals) is required for the blower to
operate to circulate warm air?
E. What path across the Thermostat (which
terminals) is required for the blower to
operate to circulate air without the furnace
burner operating (air circulating only)?
225
4. Look at the Gas Valve in the low voltage section of the ladder diagram.
A. What path across the Thermostat (which

terminals) is required to open the main
burner gas valve?
B. What component (critical to maintaining
the ignition source for the main burner,
and for safely shutting off the gas flow if
there is a pilot outage) is not shown on the
ladder diagram or the connection
diagram?
C. Is the Gas Valve an operating control or a
safety Control?
D. Suppose that the start capacitor on the

blower fan fails so that the blower does not
function. What device will shut off the
main burner if warm air cannot act on the
Thermostat? Draw its symbol.
5. Look at the Connection Diagram. Locate the HI VOLTAGE TERMINAL BOARD.
A. What wire color connects the HI speed

blower motor to the terminal connection to
?
B. What wire color connects the HI speed
blower motor terminal connection to ?
6. Locate the LO VOLT TERMINAL BOARD.
A. What wire color connects the TH terminal

of the Gas Valve to the Fan & Limit
Control & LO VOLT TERMINAL BOARD?
B. What wire colors are used to connect the
Fan Relay COIL to the terminal board?
C. What wire color connects the TR terminal

of the Gas Valve to LO VOLT TERMINAL
BOARD?
7. On a “call for heat” the main burner lights and after a short time shuts down. The
customer reports that this has happened repeatedly. The service technician
looks at the furnace and immediately notices that a brown wire is dangling
226
down and not connected to anything. After attaching the wire to the proper
terminal, the technician restores power to the system, resets the thermostat,
and the system seems to operate properly.
A. What device did the technician re-

connect?
B. What portion of the furnace should the
technician check to be sure it is not
damaged?
C. Why would the technician be concerned

about this portion of the furnace?
D. What would the technician look for?
E. What further testing could be done?
"THE TECHNICIAN PUZZLER"
8. This Worksheet has used a forced air furnace to illustrate the use of circuit
diagrams. As you answered the questions, you have used your
knowledge of system components and the diagrams to troubleshoot the
system. By tracing through the diagrams, you have been able to
diagnose possible system problems on a furnace. Now examine the
diagram again and solve this problem.
The blower fan on this model furnace runs

without a call for heat from the thermostat. The
only time it stops running is when the blower
access door is removed. What wiring
connection is probably wrong?
227
(b) Circuit Diagram Worksheet-Condensing Furnace.
On the pages that follow, you will find parts list, connection and ladder
diagrams for the furnace illustrated in Figure 7. Your instructor will
lead you through questions on pages 13 & 14 that will require you to
refer to the diagrams found in Figure 9, page 12.
Figure 7. Condensing Furnace Parts Diagram
228
SHORT LIST KEY TO CONDENSING
FURNACE DIAGRAM PARTS
KEY PART
DESCRIPTION
NO. NUMBER
2 Coil, Condenser 1000309
3 Wheel, Blower 600587
4 Motor ½ H.P. 4SP/ PSC Model #s 4002, 5002 613189
Motor ¾ H.P. SM 4SP/PSC Model #s 7502, 7504 613209
7 Capacitor, 7.5 MFD., 370V 706338
Capacitor, 10 MFD, 370V 91593
8 Transformer 613039
2 Switch, Interlock 611872
10 Relay, DPST 1000742
11 Relay, SPDT 92840
12 Module, Control 25V (Nat.) 612919
Module, Control 25V (L.P.) 612920
13 Switch, Limit Model #s 4002, 5002 1000823
Switch, Limit Model #s 7502, 7504 1000735
14 Blower, Exhaust 1001609
16 Control, Fan and Limit Model #s 4002, 5002 1000962
Control, Fan and Limit Model #s 7502, 7504 1000961
17 Switch, Limit 522559
18 Switch Pressure Model #s 4002, 5002 1000747
Switch Pressure Model #s 7502, 7504 1000748
19 Capacitor, 5 MFD, 370V 60974
21-28 Condensation Trap and Vent Assembly 1776
29 Burner, Pilot (Nat.) (with orifice) 612921
Burner, Pilot (L.P.) (with orifice) 612922
30 Orifice, Pilot (.018) (Nat.) 503211
Orifice, Pilot (.012) (L.P.) 612923
31 Wire, Spark 61481
32 Tube, Pilot 1001081
33 Orifice, Main Burner (Nat.) (No. 45) Model # 4002 609044
Orifice, Main Burner (Nat.) (No. 42) Model # 5002 609526
Orifice, Main Burner (L.P.) (No. 54) 609593
36 Valve, Gas Control (Nat.) 612926
Valve, Gas Control (L.P.) 612917
39 Baffle, Flue 613083
41 Exchanger, Heat Model #s 4002, 5002 1000418
Exchanger, Heat Model #s 7502, 7504 1000419
42 Tube, Sensor 611937
Figure 8. Condensing Furnace Parts List
229
Figure 9. Condensing Furnace Connection and Ladder Diagrams
230
CIRCUIT DIAGRAM WORKSHEET—CONDENSING FURNACE
Instructions: Use the circuit diagrams on page 230 for reference. Following the
directions given below and by your instructor, fill in the blanks that
answer the questions given below.
1. Look at the Ladder Diagram. Trace the low voltage wiring across the
terminals of the Thermostat and along the bottom of the circuit.
What device will be energized on a call for heat?
2. Look at the CONTROL BOX section of the Connection Diagram.
A. When is energized, what contacts open?
B. When is energized, what contacts close?
3. Look at the 115V section of the Ladder Diagram.
A. What device is energized if ?
B. What devices are energized if and

?
C. Applying what you know about Intermittent Spark
Ignition systems, what will be energized first when
the Ignition Module is energized?
4. On the Connection Diagram, locate the green wire between the Igniter Sensor
and the Ground Terminal in the Ignition Module. After the pilot flame is
established, what electrical current form should be found between the Igniter
Sensor and the Ground Terminal?
5. On the Low Voltage section of the Ladder
Diagram, trace across the system relay to the
Ignition Module. If the Exhaust Blower Fails, will
the Ignition Module begin the pilot burner ignition
sequence?
6. If your answer to #5 is “no”, why?
231
7. A service technician on a service call on a furnace of this type finds that when
0the Thermostat is reset and the call for heat is given, the exhaust fan is
activated, the Ignition Module establishes the pilot burner and almost
immediately after the main burner fires, the system shuts down. By (1) taking a
voltage reading between on the Low Volt Board and the terminal on the
System Relay immediately after the system shut down, and (2) a second
voltage reading between the Thermostat terminal and the secondary
transformer on the Flue Temp. Limit side, and (3) a third reading at the same
location a couple of minutes later, the technician determines that the venting is
obstructed. After clearing the vent obstruction, the system works properly.
The operation of what device led the technician to

the obstructed vent?
8. Name the safety devices that protect this furnace

in the event of a venting problem.
NOTES
232
(c) Circuit Diagram Worksheet I-Heating/Cooling Packaged Unit.
On this page and the pages that follow, you will find a parts list,
connection and ladder diagrams for an outdoor or roof mount
combination gas heat and electric cooling unit. Your instructor will lead
you through questions that will require you to refer to the diagrams
found in Figure 14.
Figure 10. Unit Heating Section Figure 11. Unit Side View
Figure 12. Heating Parts List Figure 13. Gas Valve & Burner
233
Figure 14. Heating/Cooling Packaged Unit Connection and Ladder Diagrams
(single-phase)
234
CIRCUIT DIAGRAM WORKSHEET I —HEATING/COOLING PACKAGED UNIT
Instructions: Use the circuit diagrams on page 234 for reference. Following the
directions given below and by your instructor, fill in the blanks that
answer the questions given below.
Look at the Ladder Diagram.
1. What is different about the power supply to this
unit compared to the diagrams for the previous
examples?
2. What is the first load you see at the top of the
ladder diagram between L1 and L2?
3. What are the next 2 loads across L1 and L2 as
you move down the diagram?
4. What system are the loads you listed in question 2
and 3 part of?
5. What set of contacts must be closed for the
compressor and fan motor to be energized?
Draw their symbols in the blanks provided.
6. What control must be energized for the contacts to
close that you named in 5? (Hint, look at the
connection diagram
7. What device is energized if ?
8. As you look at the high voltage section of the
ladder diagram, from down to the
transformer, what system are these components
in?
Look at the low voltage section of the ladder diagram.
9. Trace across the THERMOSTAT to the FAN
RELAY. Which of the THERMOSTAT terminals
must be switched closed for the FAN RELAY to be
energized?
10. Which of the THERMOSTAT terminals must be
switched closed for the CONTACTOR to be
energized?
switched closed for the HEAT RELAY to be
energized?
235
(d) Circuit Diagram Worksheet II-Heating/Cooling Packaged Unit.
Figure 15. Heating/Cooling Packaged Unit Connection and Ladder Diagrams

(3-phase)
236
CIRCUIT DIAGRAM WORKSHEET II —HEATING/COOLING PACKAGED UNIT
Instructions: Remove page 236 and place the circuit diagrams at the top of this
page for reference. Following the directions given below and by your
instructor, fill in the blanks that answer the questions given below.
Look at the Ladder Diagram on the right-hand side of page 236.
1. What is different about the power supply to this
unit compared to the diagrams for the previous
examples?
2. What system components connect between L1

and L2?

and L3?

and L3?
5. Is the low voltage section 3 phase?
6. What set of contacts must be closed for the

compressor and fan motor to be energized?
Draw their symbols in the blanks provided.
7. What device is energized if ?
8. Trace across the THERMOSTAT to the FAN

RELAY. Which of the THERMOSTAT terminals
must be switched closed for the FAN RELAY to be
energized?
237
switched closed for the CONTACTOR to be
energized?

switched closed for the HEAT RELAY to be
energized?
11. Is there any difference in the heating control

section between the single phase and the 3 phase
model of this HVAC unit?
NOTES:
238
239
240
241
REVIEW:
Reading Electrical Control Circuit Diagrams
space provided. (Answers may be used more than once.)
A. connection diagram G. closed

B. parts diagram/parts list H. ladder diagram
C. L1 I. L2
D. open J. switch
E. time bar chart K. voltmeter
F. primary L. secondary
1. In a ladder diagram, the neutral wire is represented as _____.
2. On HVAC circuit diagrams, operating controls are normally drawn

_____.
3. The “hot leg” of a ladder diagram may also be marked _____.
4. _____ are true sequence-of-operation control diagrams which allow

troubleshooting a series of systems and components that are
controlled through a timed sequence.
5. To determine what pilot burner and main burner orifice drill size is
required for L.P. or natural gas operation, read the appliance _____.
6. On HVAC circuit diagrams safety controls are drawn in their normal

running position—_____.
7. _____ give component wiring instructions and aid in identifying

components.
8. A _____ does not show the actual location of components; however, it

is useful in determining sequence of operation.
242
Reading Electrical Control Circuit Diagrams
I can identify:
1. The function of a connection diagram.
2. The notation used to indicate the neutral wire in a ladder diagram.
3. The function of a ladder diagram.
4. The operation of a circuit by reading circuit diagrams.
243
244
Identifying Systematic
Troubleshooting Techniques and
7.4.3
Guidelines for Gas Operated
Equipment
Table of Contents
Identifying Systematic Troubleshooting Techniques and Guidelines for Gas Operated

Equipment.............................................................................................................. 247
Identifying Fundamental Troubleshooting Techniques........................................... 247
Identifying System and Sub-System Troubleshooting Flowcharts ......................... 248
Setting and Applying Quality Control Measures..................................................... 250
Review ................................................................................................................... 251

Applying Basic Principles of Electricity to Service Propane Appliances – 5/2005
245
Learning Activities

Objectives
Check-Out
Assessment)
(Skills Assessment)

246
Identifying Systematic
Troubleshooting Techniques and
7.4.3
Guidelines for Gas Operated
Equipment
Throughout this training course the importance of applying systematic gas appliance
troubleshooting techniques and principles has been stated in a number of ways. This
final module in the course summarizes how those techniques are utilized. In this
module you will learn to:
(1) Identify fundamental troubleshooting techniques
(2) Identify system and sub-system troubleshooting flowcharts
(3) Set and apply quality control measures
(1) Identifying Fundamental troubleshooting techniques.
The operating sequence illustrated in Figure 1 could be used to describe the
operation of a number of gas appliances that use intermittent spark ignition.
This particular logic flow chart was created to describe the operation of a
hydronic heating system.
Figure 1. System Logic Flowchart
247
Logic flow charts are helpful tools for technicians, because they are reminders of
how the equipment is designed to operate, and the steps in the operation that
must be individually examined for proper operation. As you work on equipment
you will probably find yourself constructing your own visions of system logic
flowcharts either consciously or not. If your vision closely corresponds to the
way the manufacturer designed the equipment, your troubleshooting will be
simple, accurate and efficient.
(2) Identifying system and sub-system troubleshooting flowcharts.
Always use manufacturers’ technical manuals, operating instructions, circuit

diagrams and owner’s manuals. Often these manuals will contain
troubleshooting flow charts to help you with the complete system or sub-systems
that make up the appliance. Figure 2 is an example of a manufacturer’s ignition
system troubleshooting flow chart.
248
Figure 2. Ignition System Troubleshooting Flowchart
Using the flowchart is really easy. If you determine that the there is no spark
when the call for heat is given by the thermostat, the chart helps you follow a
logical series of tests or observations that yield a “yes” or “no” answer to a
249
troubleshooting question. Notice that on this chart, a “no” answer always leads
you to the next test or observation down the left side of the page. Similarly, a
“yes” answer leads you to the next test or observation down the right side of the
page.
Also, notice that on this particular chart that there are 5 places where the “yes”
answer leads to an operation that ends the flow. Four of these places have
logically led to a defective component that must be replaced or a condition that
must be corrected. The fifth simply says “System OK.” Although a number of
other components may have been defective and identified on the “no” side of the
diagram, by the time that you reach the end of the “yes” legs of the chart, the
ignition system will be operating properly. By following the flow chart,
unnecessary parts changing can be eliminated or minimized.
A number of manufacturers have complete appliance system troubleshooting

flowcharts included in their technical manuals. Basically the complete system
chart includes the sub-systems charts and ties them together in a
comprehensive troubleshooting guide.
(3) Setting and applying quality control measures.
Technical excellence calls for application of consistently high standards and

techniques. There are a number of checks that a good technician will make
while servicing any gas appliance. Items to check will include:
" Are the burner (and pilot, if so equipped) orifices the proper drill size for the
fuel and altitude?
" Is the gas valve listed on manufacturers’ recall lists?
" Is the gas control valve the proper valve for the fuel? If it is a valve that can
be converted, is it properly converted to the fuel?
" Is the gas supply pressure as specified for all operating conditions? (At
system lockup and at full flow with all gas appliances operating?)
" Is the venting correct for the appliance and in good condition?
" Are burners operating properly and producing a proper blue flame?
" Are safety controls operating properly?
" Is appliance piping, including sediment traps and manual shutoffs, installed
according to codes and your company’s basic safety procedures?
Providing quality gas appliance service to your customers is challenging and

important work. Give it your best. Always keeping the health, safety and
comfort of customers in mind and applying constantly improving technical skills
will result in personal and customer satisfaction.
250
REVIEW:
Identifying Systematic Troubleshooting Techniques
and Guidelines for Gas Operated Equipment
Directions: Complete the following statements by writing your responses on the lines
provided.
1. Logic flow charts are helpful tools for technicians, because:
a. ____________________________________________________________
b. ____________________________________________________________
2. Troubleshooting flow charts guide the technician through an appliance system or

subsystem by:
______________________________________________________________
251
7.4.3 Identifying Systematic Troubleshooting Techniques and
Guidelines for Gas Operated Equipment
Directions: Use the following performance criteria statements as a self-evaluation in

preparation for the final exam.
I can identify:
1. The function of logic flow charts.
252
Performance-Based Skill Assessment
7.0 Evaluation Packet
Task 7.1 Identifying Troubleshooting Skills in Gas Appliance Service.
Task 7.2 Measuring Electrical Quantities.
Task 7.3 Identifying the Operating Characteristics and Components of

Common Sensing Devices.
Task 7.4 Identifying the Operating Characteristics and Components of

Controls.
Employee’s Name (Please Print) Date of Skills Evaluation
Skills Evaluator Name (Please Print)
Table of Contents
I. General Instructions
II. Task Information
III. Employee Certification Checklist
IV. Performance Evaluation & Employer Record
NOTICE: THE SKILLS EVALUATOR MUST BE THE EMPLOYEE’S

SUPERVISOR OR SOME OTHER QUALIFIED PERSON WHO HAS COMPLETED
CETP “BASIC PRINCIPLES AND PRACTICES” OR IS FAMILIAR WITH THE
SUBJECT MATTER. CETP CERTIFICATION REQUIRES THAT THE EMPLOYEE
SEEKING CERTIFICATION CANNOT ACT AS HIS/HER OWN EVALUATOR.

Applying Basic Principles of Electricity to service Propane Appliances – 5/2005
253
I. General Instructions
Instructions for Use
This Performance-Based Skill Assessment Evaluation Packet is designed to:
" provide structured on-the-job training for the LP-gas employee under the
direction of an experienced and qualified skills evaluator, and
" standardize conditions under which the employee demonstrates his/her

performance of tasks that meet the requirements of the NPGA Certified
Employee Training Program.
Each task is divided into one or more operations on which the employee’s
performance is evaluated. Each operation is designated by the following symbol: &.
Also, under each operation is a performance guide that establishes the standard
used by the skills evaluator.
When an operation within a task is successfully performed by the employee

according to the criteria listed in the performance guide, a check (!) is placed in the
&.
After completing the checklist for those operations required in the employee’s job
duties, the skills evaluator and employee must sign their respective affidavits.
Section IV (pages 263 and page 264) is photocopied for the company’s personnel
training record files. The original of Section IV, pages 263 and 264, is then
forwarded to:
On-line Test Candidates: Paper test Candidates:

CASTLE Worldwide Industrial Training Services, Inc.
900 Perimeter Park Drive, Suite G 310 C.C. Lowry Drive
Morrisville, NC 27560 Murray, KY 42071
Instructions to the Employee
The Performance Based Skill Assessment Evaluation Packet is designed as a

training guide to assist you and your evaluator in performing the tasks listed on the
front cover. Practice the tasks as many times as needed to become confident and
proficient with the documents or equipment. Your skills evaluator will check and
observe your performance using the checklist included in each hands-on task
assignment.
The employee must adhere to all safety precautions. If a safety precaution is

violated, then the demonstration shall be stopped and the skills evaluator must

254
instruct the employee on the proper safety procedures that apply before allowing the
employee to continue.
The packet is designed to establish the basic conditions under which the employee
demonstrated his/her level of knowledge and proficiency.
Instructions to the Skills Evaluator

Review Section II, “Task Information."
Conduct the training as follows:
" Give a copy of the Performance Based Skill Assessment Evaluation Packet to
the employee.
" Review all of the instructions with the employee and answer any questions or
concerns about how it will be used.
" Demonstrate and/or talk the employee through each of the steps required to do
the task.
" Allow the employee time to ask questions and/or study the steps.
" Observe the employee performing the required steps; correct him/her as needed.
" Allow the employee to practice until he/she is confident.
" Evaluate the employee at his/her request.
" Complete Section III, “Employee Performance Checklist,” beginning on page
256.
" Complete both pages of Section IV, “Employer Record,” which must be signed
and dated by both the Skills Evaluator and employee on page 263.
" Remove Section IV (pages 256 and 257) from the packet and photocopy. Retain
photocopy for your files. For employee certification this form must be
received within 12 months of the Certifying Examination date. Mail original
to:

Morrisville, NC 27560 Murray, KY 42071
" This Evaluation Packet and the photocopy of Section IV (pages 263 and 264)
should be retained in the Company’s employee training files.

255
II. Task Information
Certification Standard: The employee's certification is based on satisfactory
completion of the operations listed under each task in the
Performance Based Skill Assessment Evaluation Packet.
Prerequisites: Successful completion of CETP Book 7.0 “Applying Basic
Principles of Electricity to Service Propane Appliances.”
References: Applicable LP-Gas Codes and company policies.
Evaluation: The skills evaluator must be the employee’s supervisor or some
other qualified person who has completed CETP “Applying
Basic Principles of Electricity to Service Propane Appliances” or
is familiar with the subject matter. CETP certification requires
that the employee seeking certification cannot act as his/her
own evaluator.
III. Employee Performance Checklist

Print or type all entries except signatures and initials.
Employee Name
Social Security No. Date
Skill Evaluator (Please Print)
I, , hereby attest the employee named on the
(Skill Evaluator’s Signature)
top line of this section has demonstrated the correct performance of the tasks listed
below and on following pages.
Skills Evaluator Notice: 7.0 skills evaluation requires the use of a gas appliance
equipped with an electronic ignition system.
Before starting the skills evaluation for the tasks on the following pages, the person
being evaluated must enter the following information:
Type of appliance used for task & Furnace & Boiler & Clothes Dryer
evaluations (check one or fill in the blank if & Other
“other”)
Manufacturer:
Model:
Serial Number:
The Skills Evaluator must certify the candidate’s correct entry of the appliance
information by signature.
Skill Evaluator Signature:

256
Task 7.1.1a
Visually examining circuit components and circuit diagrams to begin repair of
a gas appliance.
The employee is qualified to perform Task 7.1.1a at the following level:

Without At a customer location, training facility or company shop, the candidate for
Direct certification:
Supervision 1. Listened to a description of the problem as given by the customer or the
skills evaluator and wrote the symptoms provided on a service work order
' or other appropriate company service form.
2. Made a visual check of the appliance’s components, explaining to the skills
evaluator what was checked and why each component was checked (what
the service technician was looking for).
3. Examined the appliance circuit diagrams and pointed out to the skills
evaluator components that might be the cause of the appliance problem.
4. Explained to the skills evaluator how the circuit acts when electricity is
applied, and what testing steps would be applied to isolate the problem.
Task 7.1.2a
Using a circuit diagram to explain appliance circuit components.

Direct certification, using a circuit diagram for the appliance:
Supervision 1. Located and identified an electrical circuit.
2. Identified and explained the nature of each circuit component, including:
' " A fuse or fuse-type component on the appliance circuit diagram
" Connecting wiring, including color codes or other notations for the wiring
" Load devices
" Electrical source for the circuit
" The circuit switch or other controlling device
Task 7.1.3a
Using a circuit diagram to identify circuit types, and what voltage is present
when electricity is applied.

Direct certification, using a circuit diagram for the appliance:
Supervision 1. Identified a series-connected electrical circuit.
2. Identified a parallel-connected electrical circuit.
' 3. Identified and explained the source and expected voltage of electricity for
one of the circuit when it is energized.
4. Explained how the circuit components work in a normally operating
appliance.
5. Explained “voltage drop” and where it occurs in the circuit.

257
Task 7.2.1a
Demonstrating & explaining safety guidelines to apply when using an
electrical test meter.

Supervision 1. Correctly identified the type of electrical test meter, marking the box below
that describes the meter type.
' & Digital meter & Analog meter
& Multimeter & Voltmeter & Ampmeter & Ohmmeter
2. Identified the maximum voltage rating for the electrical test meter.
3. Identified the maximum voltage rating for the electrical test meter leads &
probes.
4. Examined the meter and leads to determine if they were safe for making
appliance circuit electrical measurements.
5. Verified proper operation of the meter by adjusting the scale or verifying
proper meter reading by “zeroing” the meter on the ohms setting.
6. Without attaching the meter leads to an electrical circuit, correctly set
the meter function switch (& scale switch if applicable), & plugged in the test
leads making the following electrical measurements:
( Circuit continuity
( Voltage
( Electrical current
( Component resistance
7. Demonstrated and explained meter safety precautions, including handling
the test meter, removal of electrically conductive jewelry, lead attachment to
circuits, and other safety practices.
Task 7.2.2a
Measuring voltage between two given points in an electrical circuit.
Supervision 1. Connected a multimeter into an electrical circuit, energized the circuit, and
correctly measured the voltage between specified points in the circuit.
' 2. Explained how the voltage measurement related to determining proper
operation of circuit components, and how voltage measurements are used
to diagnose appliance problems.

258
Task 7.2.3a
Measuring resistance between two given points in an electrical circuit.

Supervision 1. Demonstrated how to verify (& explained) the fundamental electrical circuit
condition that must present before and during electrical resistance
' measurement.
2. Connected a multimeter into a de-energized electrical circuit, and correctly
measured the resistance between the specified points in the circuit.
3. Explained how continuity checks and component resistance measurements
are used in diagnosing appliance problems.
4. Identified an appliance electrical system component that must never be
connected to an ohmmeter or multimeter set for resistance measurement.
7.2.4a
Measuring current between two given points in an electrical circuit.

Supervision 1. Connected a multimeter into an electrical circuit or connected a clamp type
meter, energized the circuit, and correctly measured the current between
' specific points in the circuit.
2. Identified a circuit load in appliances and bulk plant equipment frequently
checked before and after it is energized for rated current flow to verify
proper operating condition. (Evaluator hint: It has windings, an armature,
and is often connected to one or more capacitors or a magnetic starter.)
Task 7.3.1a
Identifying and explaining the operating characteristics of
common sensing devices.

Supervision 1. Identified on the appliance circuit diagram and on the appliance itself, each
of the following:
' " Bimetal device ) Limit control
If applicable to the appliance:
" Pressure sensor ) Optical sensor ) Liquid level switch
2. Explained the function of each of the devices listed & what the device
senses.

259
Task 7.3.2a
Identifying and explaining the operating characteristics of
electronic ignition systems.

Supervision 1. Identified on the appliance circuit diagram and on the appliance itself, each
of the following:
' " Igniter ) Ignition control module or circuit board
" Igniter lead ) Burner control valve
" The electrodes used for flame rectification sensing

As applicable to the appliance:
& Spark igniter & Hot surface igniter
2. Explained the function of each of the devices listed in the ignition and safety
control system.
Task 7.3.3a
Verifying proper location & operation of a wall-mounted thermostat.

Supervision 1. Located a wall-mounted thermostat and identified it as a(n)
& Bimetal contact type & Electronic type
' 2. Determined if the location was proper with regard to:
" Drafts from circulation to return air ) Dead air or blockage
" Exposure to heat or cold transfer sources

" Other factors that would detrimentally affect accurate control of the
connected appliance
3. If a bimetal contact type, used a multimeter to determine if the heat
anticipator setting was correct, and made adjustments if incorrect.
4. If an electronic type, explained how the thermostat regulates the heat
anticipator function.
Task 7.3.4a
Locating and identifying the type of limit control used to protect the appliance.

Supervision 1. Located the appliance limit control, and identified if it was a:
& Combination fan & limit control & Limit control only
' 2. Determined if the limit control was adjustable, and if adjustable, how the
adjustment is properly made.
Performance checklist continues on the next page.

260
3. Identified the appliance component protected by the limit control and
explained how it operates to protect the component and appliance.
4. Identified and explained conditions that typically result in limit control
operation.
Task 7.3.5a
Identifying and explaining the operation of a draft fan control.

Supervision 1. On the appliance and its circuit diagram, located the draft fan control, and
explained its operation.
' 2. Using a multimeter and manometer, demonstrated how to test the draft fan
control for proper operation.
Task 7.4.1a
Demonstrating and explaining the operation of coils, solenoids, relays, and
transformers.

Supervision 1. On the appliance and its circuit diagram, identified a step down transformer,
and explained its operation, including demonstration of the following items.
' Performance Guide:
a. Identified the primary and secondary windings of a step down
transformer.
b. Measured the secondary voltage across the windings of a step down
voltage transformer
c. Measured the primary voltage across the windings of a step down
transformer.
WITH POWER DISCONNECTED:
d. Measured and recorded the ohms resistance in the primary and
secondary windings of a step-down transformer.
2. Identified and explained the operation of a solenoid activated device.
3. Identified and explained the operation of a relay and relay switched device.

261
Task 7.4.2a
Reading and explaining electrical circuit diagrams.

Supervision 1. Identified and explained the uses of a ladder circuit diagram, including
pointing out the neutral wire and the hot wire on the diagram and wire color
' code if notated.
2. Identified and explained the uses of a component connection circuit
diagram, including pointing out the neutral wire and the hot wire on the
diagram and wire color code if notated.
3. Traced the flow of electricity through a component diagram and explained
the operation of controls and load devices as electricity is introduced into
each circuit.

262
IV. CETP Performance Evaluation / Employer
Record for "Appliance Service"
Employee Information: (print or type) Test Group Number (if known):
Social Security
Name Number
Employer
Address
City, State: Zip Code
Affidavit
I affirm that I am the person who has performed those items checked on this checklist. I
acknowledge that the performance checklists used are solely for the purpose of skills
assessment for the CETP certification requirements, and are not intended to replace or
modify company operating or safety procedures, and may not be appropriate for use in all
circumstances. I acknowledge that I am responsible for recognizing hazards and abnormal
conditions in my workplace and must exercise care and good judgment, always using
appropriate equipment, procedures and tools for the tasks I perform. Neither Industrial
Training Services, Inc. nor the National Propane Gas Association assumes any liability for
my actions, nor for my application of the skills assessment performance guides used in this
evaluation checklist.
Employee’s Signature ________________________________________________

Date ______________________________________________________________
Skills Evaluator Information: (print or type)
Name _____________________________________________________________
Organization/Employer________________________________________________
Telephone Number___________________________________________________
Affidavit
I affirm that I am the person who has administered this checklist, and that I have conducted
this employee skills assessment with integrity. I also affirm that the above named employee
is the person whose performance I evaluated, and that the above named person performed
the checked tasks at the indicated level without assistance from me or any other person.
Skill Evaluator’s Signature _____________________________________________

Date ______________________________________________________________

263
The employee is qualified to perform the listed operations at the following
level:
Without Note: This skills performance checklist is not valid and will not count toward
Direct certification unless a & in each task row is marked to indicate the employee’s
Supervision qualification status.
& Visually examining circuit components and circuit diagrams to begin
repair of a gas appliance. 7.1.1a
& Using a circuit diagram to explain appliance circuit components. 7.1.2a
& Using a circuit diagram to identify circuit types, and what voltage is
present when electricity is applied. 7.1.3a
& Demonstrating & explaining safety guidelines to apply when using an
electrical test meter. 7.2.1a
& Measuring voltage between two given points in an electrical circuit.
7.2.2a
& Measuring resistance between two given points in an electrical circuit.
7.2.3a
& Measuring current between two given points in an electrical circuit.
7.2.4a
& Identifying and explaining the operating characteristics of common
sensing devices. 7.3.1a
& Identifying the Components and Operating Characteristics of Electronic
Ignition Systems. 7.3.2a
& Verifying proper location & operation of a wall-mounted thermostat.
7.3.3a
& Locating and identifying the type of limit control used to protect the
appliance. 7.3.4a
& Identifying and explaining the operation of a draft fan control. 7.3.5a
& Demonstrating and explaining the operation of coils, solenoids, relays,
and transformers. 7.4.1a
& Reading and explaining electrical circuit diagrams. 7.4.2a
THIS PAGE MUST BE RETURNED AS SOON AS POSSIBLE, BUT NO LATER

THAN 12 MONTHS AFTER TAKING THE CERTIFICATION TEST TO:

Morrisville, NC 27560 Murray, KY 42071”

264

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Applying Basic Electricity

7.0 Principles to Service Propane

All rights reserved.

PERC program beneficiaries include propane retail marketers, producers,

By disseminating or publishing this document, PERC is not undertaking to render

i. With respect to the use of any information, apparatus, method, process, or

iii. That this document is suitable to any particular user’s circumstances.

Warning: Important precaution that you should always remember when

Tools: This task requires special tools or procedures.

PPE: This is a task that requires personal protection equipment.

Paper Work or Forms: This task should be documented on your

Safety Procedure: For your safety special precautions and safety

Electrical Hazard: This task involves an electrical hazard. Lockout and

Explosive/Fire Hazard: This task involves a fire or explosion hazard. Use

Department of Labor: (OSHA) administers federal employee safety and

7.1.1 Identifying Basic Troubleshooting Principles 1

Identifying Basic Troubleshooting Principles.............................................................. 3

Identifying the Symptoms of the Problem ................................................................. 4

Identifying Steps in Diagnosing the Problem ............................................................. 5

Visually Examining the Electrical Circuit Components ............................................... 5

Identifying Principles of Testing ................................................................................. 5

Performance Criteria Self-Check ............................................................................... 8

All rights reserved.

Performance 1. Identifying Basic Troubleshooting Principles

! Read Performance Objective 1:

In this module you will learn to:

(1) Identify the symptoms of the problem

In the early days of automobile technology, mechanics had a simple troubleshooting

There could be any number of mechanical problems or component failures that

Developing and consistently

The practice of basic troubleshooting skills is essential to efficiently isolate a

(1) Identifying the Symptoms of the Problem.

When identifying the symptoms of the problem, attention should be directed

Probably the single most important rule in troubleshooting is to change only

An electrical component failure can result from a mechanical malfunction of

(2) Identifying steps in diagnosing the problem.

Attempting to troubleshoot an electrical circuit/system without a drawing

(3) Visually examining the electrical circuit components.

While visually examining circuit components, the circuit diagrams should be

(4) Identifying principles of testing.

2. The single most important rule to follow when troubleshooting electrical

Directions: Complete the following statement by filling in the blanks

3. Two appliance troubleshooting activities that require the use of

Directions: Use the following performance criteria statements as a self-evaluation

1. The approximate percentage of service calls that are diagnosed as

2. The single-most important rule to follow when troubleshooting electrical

Identifying the Properties of Electrical Circuits ......................................................... 11

Identifying the Physical Properties of Electrical Circuits........................................... 11

Identifying Electrical Properties................................................................................ 14

Identifying Electrical Relationships........................................................................... 16

Performance Criteria Self-Check ............................................................................. 24

All rights reserved.

Performance 1. Identifying Basic Troubleshooting Principles

! Read Performance Objective 1:

Knowledge of electrical properties and characteristics of electrical circuits is a basic

In this module you will learn to identify:

(1) Physical properties of electrical circuits

The power circuit and control systems of propane-operated appliances consist of a

An electrical circuit may be considered as having two basic properties. These

(a) Physical properties, and

(1) Identifying the physical properties of electrical circuits.

(1) Source of power,