Control And Switches; Blower Prover Switch; Blocked Outlet Prover Switch; Blocked Inlet Prover Switch - A.O. Smith SERIES 100 Installation & Operating Instructions Manual

CONTROLS AND SWITCHES
All BTH models are provided with four pressure switches. These switches
are essential to the safe and proper operation of the unit. All switches are
wired in series. The controller is set up to shut the unit down whenever
there is a failure of any of the switches. It is important to understand the
purpose of each switch.

BLOWER PROVER SWITCH

(SEE FIGURE 12)
The Blower Prover Switch is provided on the heater to verify that the fan is
operating. It is a positive pressure switch whose electrical contacts are
normally open. When the fan increases the pressure in the burner, the
pressure switch will allow the electrical contacts to close. The pressure
switch is connected to the burner tap by a piece of tygon tubing. This
tubing must be connected in order for the switch to change the electrical
contacts. The controller requires that the electrical contacts on this air flow
switch be open before it will allow the blower to come on.

BLOCKED OUTLET PROVER SWITCH

(SEE FIGURE 12)
The Blocked Outlet Prover Switch is set up to shut the unit off when a build-
up of positive pressure in the exhaust vent pipe occurs. This switch is a
positive pressure switch that requires an increase in pressure to change
the electrical contacts from normally closed to open. When this switch
prevents the unit from igniting, most likely the exhaust is blocked by some
means Check to see if the condensate is allowed to flow freely from the
exhaust elbow and for obstructions in the exhaust venting and exhaust
vent terminal. Also verify that there is no more than fifty equivalent feet
(15.2 m) of three inch PVC vent pipe on the exhaust.

BLOCKED INLET PROVER SWITCH

(SEE FIGURE 12)
The Blocked Inlet Prover Switch is set up to shut the unit off when a build-
up of negative pressure in the intake vent pipe occurs. This switch is a
negative pressure switch that requires an increase in negative pressure to
change the electrical contacts from normally closed to open. The switch is
connected to the pressure tap on the PVC flange connected to the inlet of
the blower. When this switch prevents the unit from igniting, most likely the
intake is blocked by some means. Check to see if there is no more than fifty
equivalent feet (15.2 m) of three inch PVC vent pipe on the intake. Also
verify that the intake and intake vent terminal is free of obstructions that
may prevent air from entering the unit.
FIGURE 12.

LOW GAS PRESSURE SWITCH

The Low Gas Switch (LGS) is a single-pole, normally open pressure switch
that will close its contacts when a rising pressure of 5.0 in. (1.25Kpa) W.C.
is encountered. The contacts will open when the pressure falls below the
fixed set point of 4.8"WC (1.18Kpa) for natural gas models and 8.5"WC
(2.08Kpa) for propane models. The LGS monitors the gas supply pressure
to the heater. If the gas supply falls below 4.8"WC (1.18Kpa), the main
burner is extinguished (if heater is running) or the heater will not start up.

ON/OFF SWITCH

The ON/OFF Switch is a single-pole, single-throw rocker switch. This
switch provides 120V from the line source to the heater.
THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING
ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE
TO GROUND CHECK INDICATES ZERO VOLTAGE.

HOT SURFACE IGNITER

The Hot Surface Igniter is a device that ignites the main burner by high
temperature (>1800°F or >982°C). When 120VAC is applied to the igniter,
sufficient heat is generated to ignite the main burner. Although improvements
have been made to strengthen the igniter, it is still fragile and care must be
taken when handling the igniter to prevent breakage.

GAS PIPING

Contact your local gas service company to ensure that adequate gas
service is available and to review applicable installation codes for your
area.
Size the main gas line in accordance with Table 3. The figures shown are
for straight lengths of pipe at 0.5" (125Pa) W.C. pressure drop, which is
considered normal for low pressure systems Note that fittings such as
elbows and tees will add to the pipe pressure drop.
DO NOT USE FLEXIBLE GAS PIPING.
TABLE 3. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET
OF GAS PER HOUR
(Based upon a Pressure Drop of 0.5") Water Column and 0.6
Specific Gravity Gas and max. gas pressure of 0.5 psig)
LENGTH NORMAL IRON PIPE SIZES (INCHES)
IN INPUT IN THOUSANDS BTU/HR
FEET 1/2" 3/4" 1"
10 175 360 680
20 120 250 485
30 97 200 375
40 82 170 320
50 73 151 285
60 66 138 260
70 61 125 240
80 57 118 220
90 53 110 205
100 50 103 195
125 44 93 175
150 40 84 160
175 37 77 145
200 35 72 135
LENGTH NORMAL IRON PIPE SIZES (INCHES)
IN
METERS 1/2" 3/4" 1"
3.0 51 105 199
6.1 35 73 142
9.1 28 59 110
12.2 24 50 94
15.2 21 44 83
18.3 19 40 76
21.3 18 37 70
24.4 17 35 64
27.4 16 32 60
30.5 15 30 57
38.1 13 27 51
45.7 12 25 47
53.3 11 23 42
61.0 10 21 40
13
(SEE FIGURE 12)
CAUTION
CAUTION
1 1/4" 1 1/2" 2" 2 1/2" 3"
1400 2100 3960 6300 11000 23000
950 1460 2750 4360 7700
770 1180 2200 3520 6250
660 990 1900 3000 5300
580 900 1680 2650 4750
530 810 1520 2400 4300
490 750 1400 2250 3900
460 690 1300 2050 3700
430 650 1220 1950 3450
400 620 1150 1850 3250
360 550 1020 1650 2950
325 500 950 1500 2650
300 460 850 1370 2450
280 430 800 1280 2280
INPUT IN KW
1 1/4" 1 1/2" 2" 2 1/2" 3"
410 615 1160 1845 3221
278 428 805 1277 2255
225 346 644 1031 1830
193 290 556 878 1552
170 264 492 776 1391
155 237 445 703 1259
143 220 410 659 1142
135 202 381 600 1083
126 190 357 571 1010
117 182 337 542 952
105 161 299 483 864
95 146 278 439 776
88 135 249 401 717
82 126 234 375 688
4"
15800
12800
10900
9700
8800
8100
7500
7200
6700
6000
5500
5000
4600
4"
6735
4626
3748
3192
2840
2577
2372
2196
2108
1962
1757
1610
1464
1347