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Full Description
A reference you'll warm up to
From the background and basics of heating systems to the newest chip-based technology, this first volume of Audel's HVAC Library gives you comprehensive information you need on the job. Whether you're installing, servicing, repairing, or troubleshooting an old or new heating system, you'll find what you're looking for, from wood and coal furnace maintenance to new calculations and the latest environmental technologies and regulations.
* Review the basics of installation, wiring, and troubleshooting for different HVAC systems
* Choose the correct system for the space, climate, and needs
* Compare the economy and efficiency of various fuel types
* Install, maintain, and troubleshoot conversion units
* Find formula cross references, data tables with conversions, and listings of trade organizations and equipment manufacturers
Contents
Introduction xix
About the Author xxi
Chapter 1 Introduction 1
Heating and Ventilating Systems 2
Air Conditioning 4
Selecting a Suitable Heating, Ventilating, or Air Conditioning System 4
Career Opportunities 5
Professional Organizations 7
Chapter 2 Heating Fundamentals 9
British Thermal Unit 9
Relationship Between Heat and Work 9
Heat Transfer 11
Specific, Sensible, and Latent Heat 15
Heat-Conveying Mediums 16
Air 16
Steam 18
Water 22
Electricity 25
Chapter 3 Insulating and Ventilating Structures 27
Insulating Structures 27
Principles of Heat Transmission 28
Heat Transfer Values 29
Thermal Conductivity 29
Thermal Conductance 46
Thermal Resistance 47
Overall Coefficient of Heat Transmission 48
Condensation 48
Vapor Retarders 49
Air Barriers and Air/Vapor Retarders 51
Insulating Materials 52
Rigid Insulation Board 52
Reflective Insulation 54
Blanket or Batt Insulation 55
Loose-Fill Insulation 56
Blown-In Insulation 57
Foam Insulation 58
Building Construction and Location 58
Recommended Insulation Practices 59
Frame Walls 60
Masonry 60
Metal 63
Sandwich Construction 63
Basement Walls 63
Crawl Space Exterior Walls 63
Walls Between Separately Heated Dwelling Units 64
Wood or Metal Joist Frame Floors 64
Concrete Floors 66
Slab-on-Grade Floors 66
Floors of Sandwich Construction 66
Frame Ceilings and Roofs 67
Concrete Ceilings 68
Sandwich Ceilings 68
Windows and Doors 69
Insulating Attics, Attic Crawl Spaces, and Flat Roofs 69
Ventilating Structures 72
Chapter 4 Sizing Residential Heating and Air Conditioning Systems 73
Rule-of-Thumb Methods 74
Sizing Systems Using Coefficients of Heat Transmission 75
Outside Design Temperature 77
Inside Design Temperature 77
Design Temperature Difference 80
Determining Coefficients of Heat Transmission 80
Calculating Net Area 80
Heat Transmission Loss Formula 81
Computing Total Heat Loss 82
Loss in Doors and Windows 84
Loss in Basements 84
Loss in Slab Construction 86
Infiltration Heat Loss 87
Ventilation Heat Loss 92
The Average Value Method 93
Heat Loss Tabulation Forms 95
Estimating Fuel Requirements and Heating Costs 100
The Heat Loss Formula 100
The Corrected Heat Loss Formula 102
The Degree-Day Formula 102
The NEMA Formula 106
Manual J and Related Materials Used for Sizing Heating/Cooling Systems 106
Other Heating Costs 107
Determining Utility Rates 108
Chapter 5 Heating Fuels 111
Natural Gas 112
Manufactured Gas 113
Liquefied Petroleum Gas 113
Fuel Oils 114
Coal 117
Coke 119
Briquettes 119
Coal Oil 119
Wood as Fuel 120
Ash, Slag, and Clinker Formation 122
Soot 123
Comparing Heating Fuel Costs 123
Chapter 6 Warm-Air Heating Systems 125
Classifying Warm-Air Heating Systems 125
Gravity Warm-Air Heating Systems 128
Planning a Gravity Warm-Air
Heating System 129
Forced-Warm-Air Heating Systems 130
Planning a Forced-Warm-Air Heating System 131
Perimeter-Loop Warm-Air Heating Systems 132
Ceiling Panel Systems 134
Crawl Space Plenum Systems 134
Zoning a Forced-Warm-Air Heating System 136
Balancing a Warm-Air Heating System 136
Warm-Air Furnaces 137
Control Components 138
Ducts and Duct Sizing 139
Cooling with a Warm-Air Heating System 140
Air Cleaning 141
Humidifiers and Dehumidifiers 142
Advantages of a Warm-Air Heating System 144
Disadvantages of a Warm-Air Heating System 146
Troubleshooting a Warm-Air Heating System 146
Chapter 7 Hydronic Heating Systems 149
Classifying Hot-Water Heating Systems 149
One-Pipe System 150
Series-Loop System 152
Two-Pipe, Direct-Return System 153
Two-Pipe, Reverse-Return System 154
Combination Pipe Systems 155
Zoning a Two-Pipe System 155
Radiant Panel Heating 155
Other Applications 156
Gravity Hot-Water Heating Systems 157
Forced-Hot-Water Heating Systems 163
Hot-Water Boilers 164
Hydronic Furnaces 165
Combination Water Heaters 168
Control Components 169
Pipe and Pipe Sizing 170
Expansion Tanks 171
Circulating Pumps (Circulators) 173
Drainage 175
Heat-Emitting Units 175
Air Conditioning 176
Moisture Control 179
Electrically Heated Systems 179
Advantages of Hydronic Heating Systems 182
Disadvantages of Hydronic Heating Systems 182
Troubleshooting Hydronic Heating Systems 183
Chapter 8 Steam Heating Systems 185
Classifying Steam Heating Systems 185
Gravity Steam Heating Systems 186
One-Pipe, Reverse-Flow System 189
Upfeed One-Pipe System 190
Upfeed One-Pipe Relief System 192
Downfeed One-Pipe System 196
One-Pipe Circuit System 198
One-Pipe, Divided-Circuit Nonrelief System 200
One-Pipe Circuit System with Loop 200
Two-Pipe Steam Heating Systems 201
Two-Pipe, Divided-Circuit System 201
Vapor Steam Heating Systems 202
Open (Atmospheric) Vapor Systems 204
Closed Vapor Systems 209
Vacuum Steam Heating Systems 210
Natural Vacuum Systems 214
Mechanical Vacuum System 219
Combined Atmospheric Pressure and Vacuum Systems 221
Exhaust-Steam Heating 223
Proprietary Systems 228
High-Pressure Steam Heating Systems 242
Steam Boilers 244
Control Components 246
Hartford Return Connection 247
Pipes and Piping Details 248
Steam Traps 248
Pumps 249
Heat-Emitting Units 249
Air Supply and Venting 249
Unit Heaters 250
Air Conditioning 250
Troubleshooting Steam Heating Systems 251
Chapter 9 Electric Heating Systems 253
Central Hot-Water Systems 253
Central Forced-Warm-Air Heating Systems 256
Radiant Heating Systems 258
Baseboard Heating Systems 259
Electric Unit Ventilators 261
Electric Unit Heaters 262
Electric Space Heaters 263
Heat Pumps 263
Electric Heating and Cooling Controls 264
Insulation for Electrically Heated and Cooled Structures 265
Further Information 269
Advantages of Electric Heating and Cooling 269
Disadvantages of Electric Heating and Cooling 270
Troubleshooting Electric Heating Systems 270
Chapter 10 Furnace Fundamentals 273
Classifying Furnaces 273
Upflow Highboy Furnace 275
Upflow Lowboy Furnace 276
Downflow Furnace 276
Horizontal Furnace 278
Gravity Warm-Air Furnaces 279
Selecting a Furnace for a New House 279
Selecting a Furnace for an Older House 282
Furnace Components and Controls 282
Pipeless Floor and Wall Furnaces 285
Duct Furnaces 286
Geothermal Furnaces 286
Furnace Installation 288
Furnace Maintenance 288
Troubleshooting Furnaces 289
Chapter 11 Gas Furnaces 291
Types of Gas Furnaces 291
Standing-Pilot Gas Furnaces 294
Mid-Efficiency Gas Furnaces 295
High-Efficiency Gas Furnaces 297
Gas Furnace Components 299
Furnace Controls 300
Heat Exchanger 305
Gas Burners 308
Gas Pilot Assembly 311
Blower and Motor 313
Air Filter 313
Some Installation Recommendations 316
Locations and Clearances 317
Wiring 318
Duct Connections 320
Ventilation and Combustion Air 321
Venting 323
Flue Pipe 326
Chimney 330
Chimney Troubleshooting 331
Draft Hood 331
Pilot Burner Adjustment 337
Gas Input Adjustment 337
High-Altitude Adjustment 340
Changing Burner Orifices 340
Manifold Pressure Adjustment 342
Combustion Air Adjustment 343
Gas Supply Piping 346
Sizing Gas Piping 348
Installing Gas Piping 349
Typical Startup Instructions for a Standing-Pilot Gas Furnace 350
Typical Startup Instructions for an Electronic Ignition Furnace 352
Blowers and Motors 353
Air Delivery and Blower Adjustment 354
Direct-Drive Blower Adjustment 355
Belt-Drive Blower Adjustment 355
Air Filters 356
Air Conditioning 357
Installation Checklist 360
Gas Furnace Inspections, Service, and Maintenance Tips 361
Troubleshooting a Gas Furnace 363
Troubleshooting Charts 368
Chapter 12 Oil Furnaces 375
Conventional Oil Furnace 375
Mid-Efficiency and High-Efficiency Oil Furnaces 378
Mid-Efficiency (Noncondensing) Oil Furnace 379
High-Efficiency (Condensing) Oil Furnace 379
Basic Components of an Oil Furnace 382
Furnace Controls 382
Heat Exchanger 386
Oil Burner Assembly 388
Fuel Pump and Fuel Pump Motor 389
Blower and Motor 390
Combustion Air Blowers 392
Cleanout and Observation Ports 392
Vent Opening 392
Air Filter 392
Installing an Oil Furnace 393
Some Installation Recommendations 393
Location and Clearance 393
Wiring 394
Duct Connections 395
Ventilation and Combustion Air 395
Combustion Draft 397
Venting 397
Chimneys and Chimney Troubleshooting 399
Installation Checklist 400
Fuel Supply Tank and Fuel Line 401
Fuel Tank Location 402
Filler Pipe 404
Tank Vent Pipe 405
Oil Filter 405
Blowers and Motors 405
Waste Oil Furnaces 405
Air Conditioning 406
Starting the Burner 407
Oil Furnace Spillage 408
Oil Furnace Inspection, Service, and Maintenance Tips 408
Oil Furnace Adjustments 410
Troubleshooting Oil Furnaces 411
Troubleshooting Charts 414
Chapter 13 Coal Furnaces, Wood Furnaces, and Multi-Fuel Furnaces 419
Coal Furnaces 419
Sizing Requirements 419
Location and Clearance 420
Installation Recommendations 421
Duct Connections 421
Electrical Wiring 423
Ventilation and Combustion Air 424
Venting 430
Flue Pipe 430
Chimneys and Chimney Troubleshooting 430
Furnace Components 432
Automatic Controls 432
Furnace Grate 433
Coal Stoker 434
Hand-Firing Methods 434
Blower and Motor Assembly 435
Blower Adjustment 435
Air Filter 435
System Accessory Devices 435
Wood Furnaces 436
Wood Add-On Furnaces 437
Multi-Fuel Furnaces 438
Installation, Operating, and Maintenance Instructions for Coal,
Wood, and Multi-Fuel Furnaces 441
Assembly and Installation Recommendations 441
Maintenance Instructions 442
Multi-Fuel Furnace Operation 447
Troubleshooting Coal, Wood, and Multi-Fuel Furnaces 448
Chapter 14 Electric Furnaces 453
Electrical Power Supply 453
Planning Suggestions 454
Location and Clearance 455
Installation Recommendations 456
Duct Connections 456
Basic Components 457
Automatic Controls 458
Heating Elements 462
Timing Sequences 463
Safety Controls 464
Temperature Limit Controls 464
Secondary High-Limit Control 464
Furnace Fuses 464
Circuit Breakers 464
Transformer 468
Thermal Overload Protector 470
Electrical Wiring 470
Blowers and Motors 471
Air Delivery and Blower Adjustment 471
Air Filter 471
Air Conditioning 471
Maintenance and Operating Instructions 475
Furnace Air Filters, Electronic Air Cleaners, and Humidifers 475
Heating Elements and Heating Control Wiring 475
Blowers/Fans 476
Ducts 476
Thermostats 476
Furnaces without Air Conditioners 477
Troubleshooting an Electric Furnace 477
Chapter 15 Steam and Hot-Water Space Heating Boilers 481
Boiler Rating Method 485
Boiler Heating Surface 486
Boiler Efficiency 486
Types of Boilers 487
Gas-Fired Boilers 492
OilFired Boilers 493
Coal-Fired Boilers 493
Electric Boilers 497
High-Efficiency Boilers 502
Steam Boiler Valves, Controls, and Accessories 502
Steam Boiler Low-Water Cutoffs 505
Installing a Low-Water Cutoff 508
Fusible Plugs 515
Pressure Relief Valves 515
Pressure Controllers 517
Vacuum Relief Valve 519
Steam Boiler Aquastat 521
Blowdown Valve 521
Try Cocks 522
Steam Boiler Injectors 523
Water Gauges 524
Water Columns 526
Steam Gauges 526
Steam Gauge Pigtails 528
Hartford Return Connection 529
Hot-Water Boiler Valves, Controls, and Accessories 529
Hot-Water Boiler Low-Water Cutoffs 532
Hot-Water Boiler Pressure Relief Valves 534
High-Pressure Limit Switch 535
Hot-Water Boiler Aquastats 535
Pressure-Reducing Valves 538
Combination Valves 541
Balancing Valve 548
Backflow Preventer 548
Altitude Gauges 549
Circulator (Pump) 550
Air Separator 550
Purging Air from the System 553
Expansion Tanks 553
Air Supply and Venting 553
Induced-Draft Fans 558
Controlling Excessive Draft (Gas-FiredBoilers) 559
Tankless Water Heaters 560
Leaking Coils 561
Blowing Down a Boiler 561
Boiler Operation, Service, and Maintenance 562
Steam Boilers 563
Hot-Water (Hydronic) Boilers 564
Boiler Water 564
Cleaning Boilers 565
Troubleshooting Boilers 565
Boiler Repairs 568
Installing Boilers 568
Chapter 16 Boiler and Furnace Conversion 569
Preparation for Conversion 570
Basic Combustion Chamber Requirements 572
Combustion Chambers for Conversion Gas Burners 572
Combustion Chambers for Conversion Oil Burners 574
Construction Materials 576
Building a Combustion Chamber 578
Ventilation Requirements 580
Flue Pipe and Chimney 582
Baffling 584
Gas Piping and Piping Connections 584
Gas Input Setting 587
Installing a Conversion Gas Burner 589
Starting a Conversion Gas Burner (with Pilot Light) 590
Starting a Conversion Gas Burner (Pilotless) 593
Servicing a Conversion Gas Burner 594
Oil Tanks and Oil Piping 597
Installing a Conversion Oil Burner 598
Starting a Conversion Oil Burner 600
Servicing a Conversion Oil Burner 601
Troubleshooting Oil and Gas Conversion Burners 602
Appendix A Professional and Trade Associations 603
Appendix B Manufacturers 615
Appendix C HVAC/R Education, Training, Certification, and Licensing 627
Appendix D Data Tables 631
Appendix E Conversion Tables 669
Index 679
