Audel HVAC Fundamentals, Volume 1

James E. Brumbaugh has spent twenty years in the residential and light commercial construction industry. He is an accomplished educator fluent in several languages, and has written more than fifteen books on HVAC, construction, and the building trades.

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