4. WARM-AIR HEATING SYSTEMS
Learning Objective: Identify the different types of warm-air systems, gas-fired and oil-fired furnaces, components, controls, and the procedures for installation, operation, and maintenance.
Heating equipment for complete air-conditioning systems is classified according to the type of fuel burned, the Btu capacity of the furnace, and the method of circulating the warm air. Warm-air systems are generally identified as either a gravity-type or a forced-air type system.
Gravity furnaces are often installed at floor level. These are really oversized, jacketed space heaters. The most common difficulty experienced with this type of furnace is a return-air opening of insufficient size at the floor. Make the return-air opening on two or three sides of the furnace wherever possible. Provide heat insulation above the furnace top to avoid a possible fire hazard.
Gravity warm-air heating systems operate because of the difference in specific gravity (weight) of warm air and cold air. Warm air is lighter than cold air and rises when cold air is available to replace it.
The majority of the furnaces produced today are of the forced warm-air type. This type of furnace includes the elements of a gravity warm-air system plus a fan to ensure adequate air distribution. It may include filters and a humidifier to add moisture to the air. The inclusion of a positive pressure fan makes possible the use of smaller ducts and the extension of the system to heat larger areas without the need for sloping ducts. It is possible to heat rooms located on floors below the furnace if necessary. Forced-air furnaces are manufactured in a variety of designs. A typical oil-fired furnace is shown in figures 4-15 and 4-16. A typical gas-fired furnace is shown in figure 4-17.
Figure 4-15.—Cutaway view of a typical oil-designed furnace.
Figure 4-16.—Cutaway view of a horizontal stowaway oil furnace.
Figure 4-17.—Gas-fired vertical warm-air furnace.
In a forced-air system, the fan or blower is turned on and off by a blower control which is actuated by the air temperature in the bonnet or plenum. The plenum is that part of the furnace where it joins the main trunk duct (fig. 4-18). The blower control starts the fan or blower when the temperature of the heated air rises to a set value and turns the fan or blower off when the temperature drops to a predetermined point. Thus the blower only circulates air of the proper temperature.
Figure 4-18.—Electrical circuit showing how blower control operates blower motor when temperature in plenum rises.
A knowledge of air distribution principles is important when dealing with central warm-air heating systems. Satisfactory heating from warm-air systems is absolutely dependent upon proper distribution of warm air from the heat source to all portions of the space served. Warm air must be distributed in quantities that are required to offset the rate of heat released to each room. With radiator systems, distribution is primarily a problem of getting enough hot water or steam to each radiator to be sure the radiator heats to its rated capacity. It is not possible to deliver more heat through steam or hot water than the radiator is designed to transmit. With warm-air systems, however, the rate of air delivery and the temperature of the air delivered to the room determine the amount of heat reaching each room. Temperature balance, therefore, is primarily a problem of controlling air distribution.
Factors, such as velocity, volume, temperature, and airflow direction, play an important part in temperature balance. In addition and for human comfort, space-temperature variations and noise levels must also be considered. Convection currents result from the natural tendency of warm air to rise and cold air to fall. Examples are the temperature variations near doors and windows, and when dense, cool air is drawn away quicker than warm air. Objectionable noise will result at supply diffusers if room velocities exceed 25 to 35 feet per minute (fpm). Air stratification and cold floors may also result when supply diffusers are not properly located within the space.
Patterns of air distribution vary with the positions of supply diffusers. A diffuser that discharges through the floor in an upward direction or downward through the ceiling provides a vertical distribution of air. On the other hand, a diffuser that discharges through a wall provides a horizontal distribution of air. The spread for either the horizontal or the vertical pattern depends on the setting of the diffuser vanes. A low horizontal discharge provides the most effective distribution Air distribution that results from different diffuser locations is shown in figure 4-19.
Figure 4-19.—Air diffuser distribution.
As previously mentioned, warm-air heating systems are generally identified as either the GRAVITY TYPE or the FORCED-AIR TYPE. The type of duct distribution used further identifies these installations. There are two types of duct layouts: (1) the INDIVIDUAL DUCT, where each duct is connected directly to the furnace plenum, and (2) the TRUNK AND BRANCH DUCT, where the trunk duct connects to the furnace plenum and then branches off to the outlets. These two types are shown in figures 4-20 and 4-21.
Gravity-type furnaces are rated in leader area capacity, the LEADERS being the warm-air pipes. With respect to return ducts, the register-free area and the return-air duct should not be less than 1 1/4 times the area of the leader serving a given area. Gravity-type installations, as shown in figure 4-21, use the individual duct layout.
Figure 4-20.—Trunk and branch duct distribution systems.
Figure 4-21.—A typical gravity warm-air heating system (individual duct).
Forced warm-air systems usually have a register temperature range of 150°F to 180°F. Ducts can be in the form of a trunk with branches or with individual leaders from a plenum chamber. Furnaces used with forced-air installations must be equipped with automatic firing devices. Velocities usually are in the range of 750 to 900 fpm in trunks and approximately 600 fpm in branches. Outlet velocities at registers may be as high as 350 fpm.
In this section, construction features, basic components, gas burners, and controls of gas-fired furnaces are discussed.
The various gas-fired furnaces available today have similar basic components; however, there, are variations in design with respect only to dimensions and airflow. Unit features pertinent to dimensions and airflow are important when selecting a furnace for a particular space or application. A vertical counter-flow unit, for example, is normally used where supply ducts are located beneath the floor, because it has the return in the top and the outlet in the bottom. The most commonly used unit is the UPFLOW HIGHBOY which, as a rule, draws air from the side or bottom and discharges it from the top. It can be installed in small spaces. In the HORIZONTAL UNIT, the air flows in one side and out the other. This unit is suitable for installation in crawl spaces, attics, and basements. In another type, sometimes called a LOWBOY, both the return and the outlet are at the top. It is a shorter and wider version of the up-flow unit. The different airflows are shown in figure 4-22.
Figure 4-22.—Furnace airflow designs.
Another type of furnace is the DUCT FURNACE. It is designed for mounting in a duct system where air circulation is provided by an external fan. It is generally used with an air- conditioning system to supply heat during the heating season by using the same ductwork. This type can be installed as a single unit or in batteries for larger requirements. A typical gas-fired duct furnace is shown in figure 4-23.
Figure 4-23.—Typical gas-fired duct furnace.
Gas-fired furnaces have three main parts—the return-air compartment that houses the blower and filter components, the warm-air compartment that includes the heat exchanger radiators and combustion enclosure, and the combustion air and fuel compartment. This arrangement is shown in figure 4-24.
Figure 4-24.—Internal view of a furnace.
The components and assemblies of a gas-fired furnace can be broken down into six units. Each unit is discussed briefly below. Refer to figures 4-23 and 4-24 as we go along to identify the location of individual parts.
The furnace casing, sometimes called the cabinet, along with the framework, contains and supports the components of the unit. It also provides an insulating chamber for directing return air through the heat exchanger into the warm-air outlet.
The blower is a centrifugal fan that provides the circulation required to move warm air across the heated space. It also pulls the return air from the space back to the furnace.
The burners are usually the Bunsen type regardless of their size or shape. Figures 4-25 and 4-26 show Bunsen burners. The burner nourishes the flame, as it provides the correct mixture of primary air and fuel gas to the combustion area.
The gas manifold assembly includes the gas valves, pressure regulator, and those components that automatically control the flow of gas to the pilot and main burner. It is directly connected to the burner.
Figure 4-25.—Typical Bunsen burners.
Figure 4-26.—Bunsen type of burner.
Gas Burners and Controls
To use natural gas, a nearly ideal fuel, requires comparatively simple equipment and unskilled labor. This clean gas is almost free of noncombustible and is therefore clean. However, it is relatively dangerous compared to coal or oil because it mixes easily with air and burns readily. Extreme care must be exercised to prevent or stop any leakage of gas into an unlighted furnace or into the boiler room. All gas burners should be approved by the American Gas Association and installed according to the standards of the National Board of Fire Underwriters.
The gas burners used in gas-fired furnaces usually have a non-luminous flame and are the Bunsen type, as shown in figures 4-25 and 4-26. Part of the air needed for combustion is primary air that is drawn into the burner mixing tube or "venturi," where it mixes with the gas that burns at the burner ports. The secondary air is supplied around the base of each separate burner flame by natural draft or is induced by a draft fan.
The gas burner controls include the following units—manual gas valve, gas pressure regulator, solenoid gas valve, diaphragm valve, pilot light, thermocouple, thermocouple control relay limit control, heat exchanger, draft diverter, and humidifier (fig. 4-27). A manual gas cock or valve must be installed ahead of all the controls.
Figure 4-27.—An automatic gas burner control system.
MANUAL GAS VALVE.—The manual gas valve is installed on the heating unit next to the gas pressure regulator. It is used to shut off the gas to the heating unit in case some of the controls must be repaired or replaced.
GAS PRESSURE REGULATOR.—The gas pressure regulators used in domestic gas-heating systems are usually of the diaphragm type, as shown in figure 4-28. A gas pressure regulator maintains the desired pressure in the burner as long as the gas main pressure is above the desired pressure. When the gas pressure to the burner is low, the pressure-regulating spring pushes the diaphragm down, in turn, pushing the pilot valve down. When the pilot valve opens, supply pressure is applied to the top of the operating piston. As the operating piston moves down, the main valve opens, admitting supply pressure to the burner. As burner pressure rises, the diaphragm is pushed up against the pressure-regulating spring, closing the pilot valve. This removes the supply pressure from the top of the operating piston and the piston return spring pushes the piston up, closing the main valve. The regulator is thus closed every time the burner pressure gets above the desired amount. Turning the adjusting screw at the top can vary the setting of the regulator.
Figure 4-28.—A gas pressure regulator.
SOLENOID GAS VALVE.—The principles of construction and operation applied in all solenoid gas valves are similar. However, the design of each individual unit differs somewhat from the others. The two most common types of solenoid gas valves are the standard solenoid valve and the recycling solenoid valve discussed in the following paragraphs.
The standard solenoid gas valve shown in figure 4-29 is of the electric type. It is suitable for use with gas furnaces, steam and hot-water boilers, conversion burners, and industrial furnaces. This valve operates when a thermostat, limit control, or other device closes a circuit to energize the coil. The energized coil operates a plunger, causing the valve to open. When there is a current failure, the valve automatically closes because of the force of gravity on the plunger and valve stem. The gas pressure in the line holds the valve disk upon its seat. To open this valve during current failure, use the manual-opening device at the bottom of the valve. When the electric power is resumed, you should place the manual-opening device in its former position.
Figure 4-29.—A standard gas solenoid valve.
The recycling solenoid gas valve shown in figure 4-30 can be used with the same heating equipment as the standard solenoid gas valve. The design of this valve differs from that of the standard solenoid gas valve, because it is equipped with an automatic recycling device that allows the valve to switch to manual operation during power failure. However, upon the resumption of power, the thermostat automatically resumes control of this valve.
Figure 4-30.—A recycling solenoid valve.
DIAPHRAGM VALVE.—The diaphragm gas valve shown in figure 4-31 can be used interchangeably with a solenoid gas valve. Its main feature is the absence of valve noise when it is opening or closing. In this type of diaphragm valve, the relay energizes and opens the three-way valve, so the gas pressure on the top of the diaphragm is released to the atmosphere. Reducing the pressure on the top of the diaphragm in this manner causes the gas supply pressure to flex the diaphragm upward, opening the main gas valve. When the relay is de-energized, the vent to the atmosphere is sealed and pressure from the gas supply is allowed to be applied to the top of the diaphragm, forcing it down and sealing the main valve.
Figure 4-31.—A diaphragm gas valve.
PILOT LIGHT.—The gas pilot light in a gas-heating unit is a small flame that burns continuously and lights the main burner during normal operation of the heating unit. It is located near the main burner, as shown in figure 4-27.
The gas flow to the pilot light is, in some cases, supplied by a small, manually operated gas shutoff valve on the main gas line above the main gas valve. In other cases, the gas can be supplied from the pilot tapping on a solenoid gas valve, as shown in figure 4-29. In more expensive heating units, the gas for the pilot light is often supplied by a thermocouple-controlled relay.
THERMOCOUPLE. —A thermocouple is probably the simplest unit in the electrical field that is used to produce an electric current by means of heat. It is constructed of two U-shaped conductors of unlike metals in the form of a circuit, as shown in figure 4-32. If these conductors were composed of copper and nickel, respectively, and are joined as shown in the figure, two junctions between the metals exist. If a flame heated one of these junctions, a weak electric current would be produced in the circuit of these conductors. A series of junctions can be arranged to form a thermopile to increase the amount of current produced, as shown in figure 4-33.
Figure 4-32.—The principle of a thermocouple.
Figure 4-33.—A thermopile.
In the heating field, thermocouples and thermopiles are used to produce the electrical current used to operate such units as gas valves, relays, and other safety devices.
The thermocouple is located next to the pilot light of the main gas burner, as shown in figure 4-27. It generates the electric current (usually 50,000 microvolts) which holds open a main gas valve, a relay, or any other safety devices, permitting gas to flow to the main burner. Soon after the pilot light is extinguished, current ceases to flow to these safety devices, thus causing them to shut off the gas to the heating unit. These safety devices will not operate again until the pilot light is lighted and current is again generated by the thermocouple.
THERMOCOUPLE CONTROL RELAY.—The thermocouple-operated relay shown in figure 4-34 is a safety device used on gas-fired heating equipment. The thermocouple, when placed in the gas pilot flame, generates electricity. The electric current energizes an electromagnet that holds a switch or valve in the OPEN position as long as the pilot flame is burning. When the pilot flame goes out because of high drafts or fuel failure, the electromagnet is de-energized, thus closing and preventing the opening of the switch or valve. The closing of the valve or switch prevents the burner from filling the combustion chamber with unburned gases.
Figure 4-34.—A typical thermocouple and valve relay assembly.
To re-light the pilot light, push up the reset button at the bottom of the relay and allow the gas to flow to the pilot light. Since some heating units are not equipped with relays, the pilot light is not automatically shut off in case of gas supply failure.
The relay shown in figure 4-35 is an electrical switch type of relay. It is entirely electrical and can be used as a controlling unit for either the magnetic or diaphragm gas valves. This unit is actuated by the electric current generated by the thermocouple. It controls the operation of the gas valve in the magnetic and diaphragm valves. A relay of this type must also be reset manually for normal operation.
Figure 4-35.—An electric switch type of relay.
LIMIT CONTROL.—The limit control in a gas burner system is a safety device. It shuts off the gas supply when the temperature inside the heating unit becomes excessive. The limit control device can be adjusted to the desired setting. It exercises direct control on the gas or diaphragm valve.
HEAT EXCHANGER.—This unit or assembly may be either a single or sectional contoured steel shell. It extends vertically from the burner enclosure to the flue exit. Functionally, it transmits heat from the hot gases of combustion to the circulating warm air that passes the outer surfaces.
Draft Diverter.—The diverter is simply a sheet metal chamber that encircles the flue. It has an opening at the bottom to allow air to be drawn in by the flue draft. Its purpose is to reduce the downdrafts and updrafts that are objectionable to pilot and burner operation.
Humidifiers. —Humidifiers used with forced warm-air heating systems are usually of the pan type shown in figure 4-36. Unless the water is relatively free of solids, these humidifiers require frequent attention, since the float may stick in the OPEN position or the valve may clog. Overflowing of the pan may result in a cracked heating section, and a stopped-up inlet valve will make the humidifier inoperative.
Figure 4-36.—Cutaway view of a typical humidifier.
The drum type of evaporative humidifier uses an evaporation pad in the shape of a wheel. The slow-turning wheel is submerged in the water in the lower pan where the sponge-like plastic foam material becomes saturated with water. The wheel lifts this portion of the pad and exposes it to the warm, dry air flowing through it. The air then absorbs more moisture because of lower relative humidity at a higher temperature.
Oil-fired furnaces are similar to gas-fired units in physical arrangement. Internally, oil-fired units have three areas—the burner compartment, the combustion and radiating chamber, and the blower compartment. Figure 4-37 shows a cutaway view of a typical oil-fired furnace.
Figure 4-37.—Cutaway view of a typical oil-fired furnace.
Like gas-fired units, oil-fired units are also available with various airflow designs. The model shown in figure 4-15 is designed with both the return-air inlet and the warm-air outlet in the top. More compact models (fig. 4-37) are available with the return-air inlet at the side or bottom below the radiating and combustion area. The warm-air outlet is at the top.
A floor furnace is shown in figure 4-38. This type of oil-fired unit is smaller, lighter in construction, and is designed to be hung from the floor of the space served. Only a minimum of clearance is required below the floor.
Figure 4-38.—Oil-fired floor furnace.
Oil burners may be separated into various classes, such as domestic and industrial. Since domestic oil burners are used almost universally in warm-air furnaces, they are the only ones covered in detail in this lesson.
Domestic Oil Burners
Domestic oil burners atomize the oil and are usually electrically power driven and are used in small central heating plants. They deliver a predetermined quantity of oil and air to the combustion chamber, ignite it, and automatically maintain the desired temperature.
Domestic oil burners are classified according to various methods, none of which is entirely satisfactory because of the overlapping among a great number of models. Classification may be by type of ignition, draft, operation, method of oil preparation, or features of design and construction.
DESIGN AND CONSTRUCTION.—One of the most common types of domestic oil burners is the pressure-atomizing gun type of burner. Gun type burners atomize the oil by fuel-oil pressure. The fuel-oil system of a pressure-atomizing burner consists of a strainer, pump, pressure-regulating valve, shutoff valve, and atomizing nozzle (fig. 4-39). The nozzle and electrode assembly includes the oil pipe, nozzle holder, nozzle, strainer, electrode insulators, electrodes, supporting clamp for all parts, and static disk. The oil pipe is a steel rod with a fine hole drilled through it. This hole reduces oil storage in the nozzle to a minimum that prevents squirting at the nozzle when the burner shuts off.
Figure 4-39.—High-pressure gun type of oil burner.
The air system consists of a power-driven blower with means to throttle the air inlet, an air tube that surrounds the nozzle and electrode assembly, and vanes or other means to provide turbulence for proper mixing of the air and oil. The blower and oil pump are generally connected by a flexible coupling to the burner motor. Atomizing nozzles can be furnished to suit both the angle of spray and the oil rate of a particular installation. Flame shape can also be varied by changing the design of the air exit at the end of the air tubes. Oil pressures are usually about 100 psi, but pressures considerably greater are sometimes used.
Electric ignition is almost exclusively used. Electrodes are located near the nozzle but must not be in the path of the fuel oil spray. The step-up transformer provides the high voltage (usually 10,000 volts) necessary to make an intense spark jump across the electrode tips.
FUEL UNIT.—There are many types of fuel units available for oil burners; however, the T-type, two-stage fuel unit is the most commonly used. Figure 4-40 shows this type of unit. It is an oil pump with two strainers mounted on the body of the oil burner and operated by the blower motor shaft.
Figure 4-40.—A typical T-type, two-stage fuel pump.
The T-type, two-stage fuel unit can be used on a single-line or on a two-line system. When Number 1 on the strainer cover is next to the letter marked on the body of the pump, it is correctly arranged for a single-line system. It is set up for a two-line system when the cover is turned so Number 2 is adjacent to the same letter.
A two-line system is necessary when the bottom of the fuel tank is below the level of the pump. The suction line from the tank is connected to the pump port marked "Inlet." The return line is connected to the pump bypass port and is directed back into the tank. With the one-line system, the return line is not used.
Ignition Electrodes.—The heat of a spark jumping between two ignition electrodes ignites the fuel (fig. 4-39). The voltage necessary to cause the spark to jump is much more than the line voltage available. Therefore, an electric transformer is used to step up the line voltage to approximately 10,000 volts.
The wall flame burner has an oil distributor and fan blades mounted on a vertical shaft directly connected to the motor. The oil distributor projects the oil to a flame ring made of either refractory material or metal. Figure 4-41 shows this type of burner. The hot flame ring vaporizes the oil, and the oil vapors mix with air and burn with a quiet blue flame that sweeps the walls of the furnace. Ignition may be electric, gas-electric, or gas. High-grade fuel oil is necessary for satisfactory performance.
Figure 4-41.—Vertical-rotary burner of the vaporizing or wall flame type.
Horizontal Rotary Type.—The horizontal rotary type was originally designed for industrial use; however, sizes are available for domestic use. It has a wider range of fuel-burning capacity than the high-pressure gun type and can accommodate heavier grades of fuel. Figure 4-42 shows this type of burner.
Figure 4-42.—A horizontal-rotary oil burner.
The major parts of the burner are the housing, fan, motor, fuel tube, and rotating atomizing cup. The atomizing cup and fan are driven at the same speed by a directly connected electric motor. Oil is fed through the fuel tube to the inner surface of the atomizing cup. The oil spreads over the surface of the cup, which turns at 3,450 revolutions per minute (rpm). It then flows to the edge of the cup where it is thrown off. The whirling motion and the resulting centrifugal force separates the oil into fine particles, as it leaves the cup. Primary air supplied by the fan is thrown in around the outer edge of the rotating cup and given a whirling motion in the direction opposite that of the oil. The streams of air and oil collide and thoroughly mix, as they enter the combustion chamber.
OIL BURNER CONTROLS.—The purpose of oil-burner controls is to provide automatic, safe, and convenient operation of the oil burner. The system is designed to maintain the desired room temperature, to start the burner as required, and to ignite the fuel to initiate combustion. However, in case trouble arises during operation, the burner must be stopped and further operation prevented until the trouble has been corrected.
Oil-burner controls are essentially the same as stoker or gas controls. The only difference is that the oil burner has, in addition, two ignition electrodes and a primary or safety control. A diagram of a typical forced warm-air control system is shown in figure 4-43.
Figure 4-43.—Typical forced warm-air control system.
Primary Control.—The burner primary control is electrically connected between the thermostat and the burner, as shown in figure 4-43, and it performs several functions. The primary control closes the motor and ignition circuits when the thermostat calls for more heat. It breaks the motor circuit and stops the burner when the motor first starts if the fuel fails to ignite or if the flame goes out. The control prevents starting of the burner in case of electrical failure until all safety devices are in the normal starting position.
An interior view of a primary control is shown in figure 4-44. This control device is also equipped with a high-temperature limit control. This control shuts down the heating plant whenever the temperature of the furnace becomes excessive. For example, if the thermostat is exposed to a blast of cold air for a long period of time, the heating plant could run long enough to become overheated to the point of severe damage or external fire if it was not for this high-temperature limit control.
Figure 4-44.—Interior view of a primary control.
Limit Control.—The limit control is a device that responds to changes in air temperature (in a warm-air heating system), to changes in water temperature (in a hot-water heating system), and to changes in steam pressure (in a steam-heating system). The limit control has two distinct functions. The first function is to control the operation of the fire so the temperature and pressure of the heating plant never exceeds safe operating limits. This function is distinctly for safety control.
The second function of the limit control is to limit the temperature and pressure of the heating system for better temperature regulation in the building. This function is particularly useful in controlling coal-fired heating systems where the coal bed continues to give off heat when the stoker motor stops. By lowering the setting of the limit control, however, it is possible to prevent an excessively hot fire that would continue to throw off excessive amounts of heat after the thermostat has been satisfied.
Temperature-Responsive Devices.—Many automatic control units, such as the thermostat, limit control, fan control, and many others, must respond to temperature changes. Actually, these are the instruments that use a temperature change to cause the electrical contacts inside each unit to open and close. The opening and closing is an indicating signal that is transmitted to the primary control for specific action, such as starting or stopping the operation of the heating plant.
Bimetallic Strip.—Some automatic control units are equipped with a switch that contains a straight bimetallic strip to open and close electrical contacts. This actuating device is made by welding together two pieces of dissimilar metals, such as brass and Invar, as shown in figure 4-45, view A. Below a certain predetermined temperature, this strip does not deflect or bend. However, when the strip is heated, it bends in the direction of the metal that expands the least, as shown in figure 4-45, view B.
Figure 4-45.—Bimetallic strips:
A. Typical strip; B. Expansion of the strip; C. With electrical switch.
Actually, this electrical switch is constructed, as shown in figure 4-45, view C, by welding two electrical connections and contacts to the strip. A switch of this type can then be used to control electrical circuits, because the bimetallic strip responds to temperature changes. This is a basic example of how this principle of bimetallic strip operation is used in many temperature-responsive automatic units. Other control switches contain bimetallic strips that are spiral, U-shaped, Q-shaped, or even in the shape of a helix, as shown in figure 4-46.
Figure 4-46.—Various types of bimetallic strips.
Vapor-Tension Device.—The vapor-tension principle is also used to actuate some types of automatic control units. This is a common type of temperature-measuring device in which the effects of temperature changes are transmitted into motion by a highly volatile liquid. The most used vapor-tension device is the simple compressible bellows, as shown in figure 4-47, view A.
Figure 4-47.—Tension devices:
A. Vapor-tension device; B. Pressure-tension device closing electrical contacts.
The bellows is made of brass. It is partially-filled with alcohol, ether, or other volatile liquid not corrosive to brass. When the temperature around the bellows increases, the heat gasifies the liquid inside and causes the bellows to extend. The extension closes a set of electrical contacts, as shown in figure 4-47, view B. When the bellows cools again, it contracts. The contraction opens the electrical contacts.
Remote-Bulb Device.—Liquid-filled devices are not always limited to the simple bellows. There are some remote-bulb devices that not only have a bellows but also have a capillary tube and a liquid-filled bulb, as shown in figure 4-48.
Figure 4-48.—Schematic of a remote-bulb device.
When the liquid in the bulb is heated, part of it gasifies and forces its way through the capillary tube into the bellows. This increased pressure inside the bellows causes it to extend and open a set of electrical contacts (or open or close a valve). When the bulb cools, the gas liquefies and decreases pressure inside the bell ows. This decreased pressure allows the bellows to contract and close the electrical contacts.
Pressure-responsive devices are actuating mechanisms installed in units, such as steam-pressure controls, steam-pressure gauges, and pressure regulators.
Bellows.—One type of pressure-responsive actuating device uses bellows in a way similar to that of the remote-bulb type. In this application, the bellows extends and contracts in response to changes in steam pressure. The action caused by movement of the bellows opens or closes a set of electrical contacts.
Bourdon Tube.—Another type of pressure-responsive actuating device is found inside of the pressure gauge shown in figure 4-49. In this actuating device, the pressure is applied inside a hollow, partially flattened, bent tube, called a Bourdon spring tube. The pressure inside this tube tends to straighten it, and in so doing, it moves the lever mechanism that turns the pointer. The pressure gauge measures the pressure in pounds per square inch (psi).
Figure 4-49.—A typical Bourdon spring tube.
Humidity-responsive devices open or close solenoid or motorized valves, which control the flow of water or steam to humidifying equipment. The sensitive element, which actuates the motion in this device, consists of a group of human hairs. These hairs lengthen when the humidity is high and shorten when the humidity is low.
Accumulation of dust and grease on these hairs, while not damaging, may decrease the sensitivity of the controller. Consequently, the element should be cleaned periodically with a camel's-hair brush and clean ether. A complete wetting with distilled water should follow this cleaning.
Electrical Switches.—Electrical switches in heating control equipment operate electrical circuits in response to signals from automatic control units. In other words, the actions initiated by devices responsive to temperature, pressure, and humidity changes open or close switch contacts. These, in turn, control the operation of the heating plant through electrical circuits. Switches may be either the snap-action type or the mercury type.
Snap-action switches vary in their designs.-Some are constructed so they have an over-center spring arrangement that is designed so the movement of the actuating lever engages the spring and causes the switch to move with snap-action. The snap-action type of switch is shown in figure 4-50, view A.
Another snap-action switch shown in figure 4-50, view A, has a small magnet that causes the electrical contacts to remain firmly closed. It also provides the switch with the snap-action effect. The contacts of this switch must open or close quickly to avoid excessive arcing across the points. Arcing burns the contacting surfaces, which eventually causes switch failure.
A mercury switch has the electrical contacts and a small amount of mercury in a hermetically sealed short glass tube, as shown in figure 4-50, view B. Tilting the switch causes the mercury inside the tube to cover or uncover the contacts. When the contacts are covered, the electrical circuit is completed.
Figure 4-50.—Electrical switches:
A. Snap-action switch;B. Mercury switch.
Every electrical switch is designed so it has a specific rated capacity in amperes and volts; for example, a capacity of 8 amperes at 110 volts. An electrical switch should never be overloaded because overloading causes overheating, which eventually results in switch failure that can create a fire hazard.
The standard controls furnished for automatic fuel-burning equipment come in sets designed for warm-air, hot-water, and steam-heating systems. A standard set usually consists of a thermostat, limit control, primary control, and electric motor. Auxiliary controls are those designed for a specific function in a warm-air, hot-water, or steam-heating system. They are in addition to the standard controls.
Thermostat.—The thermostat is the nerve center of the heating-control system. It is the sensitive unit that responds to changes in room temperature. It indicates whether more or less heat is required from the heating plant. It transmits the indicating signal to a primary control for action. This indicating signal is initiated by closing or opening electrical contacts in the thermostat.
Thermostats often differ in construction according to the type of primary control with which they are to be used. Probably the most used thermostats are the spiral-bimetallic type and the mercury-bulb type.
An electric clock thermostat has the additional features of an electric clock and an automatic mechanism that can be adjusted to change the thermostat setting at a desired time. For instance, it can be adjusted to reset the thermostat automatically from 80°F to 60°F at 11:00 p.m. (when 80oF heat is not needed). Then it will reset the thermostat to 80oF at 6:00 a.m. (when more then 60°F heat is needed).
The location for the thermostat should be representative of that part of the building in which heat is needed to maintain a comfortable temperature. The best location is on an inside wall, just a few feet from an outside wall and about 4 1/2 feet above the floor. The thermostat wiring must conform to local electrical ordinances.
To check the calibration of a thermostat, hang-an accurate test thermometer within 2 inches of the device. Allow 15 to 30 minutes for the thermostat and thermometer to adjust themselves to room temperature. The thermostat contacts should close when the control knob or dial is set at the temperature indicated by the test thermometer. You should not try to recalibrate the thermostat if the closing point varies 1°F or less. When calibration is necessary, follow the manufacturer's instructions.
Since there are many types and makes of oil- and gas-fired warm-air furnaces on the market, detailed assembly instructions to suit all makes and types cannot be given in this manual. However, some general instructions, which apply to both oil-fired and gas-fired furnaces, except as noted, are given below.
Carefully follow assembling instructions included with each furnace or blower shipment. Each piece or casting is manufactured to fit in its proper place. Parts are seldom interchangeable.
Install furnaces in a level position. If the floor is uneven, use a steel wedge, a cast-iron wedge, or the leveling bolts provided on some equipment. Use a spirit level to make sure the unit is level.
Gas-fired and oil-fired forced-air units, which have the blower below the heating element or combustion chamber, should be set on masonry at least 3 inches thick and extending at least 12 inches beyond the casing wall. Install all other units on a cold masonry floor. Provide enough clearance to permit easy access for repairs. Make the clearance at least 18 inches from wood or other combustible material unless you install an asbestos board at least 1 inch from the combustible material. Units may be installed near masonry walls; however, leave ample room to permit proper servicing.
Furnace cement is furnished with each cast-iron furnace. Seal all furnace joints with a liberal amount of furnace cement between sections to ensure the furnace is gastight. Asbestos rope is furnished with a number of furnaces; follow the manufacturer's instructions covering its use. See that projections from the furnace, such as the smoke pipe or clean-out doors, extend through the outside of the casing.
In assembling a furnace, be sure to tighten all bolts. Draw each bolt until it is almost tight. Then, after all bolts have been installed, draw each one gradually until all are uniformly and properly tight. Avoid drawing bolts too tight, as this can crack or break a casting or buckle a steel plate.
After assembling the furnace, check all doors for free operation and tight fit.
Install the downdraft diverters furnished with the equipment on all gas-burning furnaces. Diverters are developed for individual furnaces.
Use a vent or smoke pipe that is at least as large as the smoke-pipe outlet of the furnace.
Figure 4-51.—Typical smoke pipe (flue) installation.
Securely fasten the vent or smoke pipe at each joint with a minimum of three sheet metal screws. Install horizontal pipe with a pitch upward of at least l-inch per linear foot (fig. 4-51).
Ventilate the furnace room adequately to supply air for combustion. Provide an opening having 1 square inch of free-air area for each 1,000 Btu per hour of furnace input rating with a minimum of 200 square inches. Locate the opening at or near the floor line whenever possible. In addition, provide two louvered openings, each having a free-air area of at least 200 square inches in it, at or near the ceiling as near opposite ends of the furnace room as possible.
Tank installation is largely governed by local conditions. Listed here are the principles of tank installation that give greatest freedom from service problems. Adhere as closely to these recommendations as local conditions permit.
When possible, install single-pipe gravity oil feed on inside tanks or elevated outside tanks (fig. 4-52). This type of installation is used for single-stage pumps. Use a 1/4-inch globe valve at the tank instead of a larger size. Larger valves sometimes cause tank hum.
Figure 4-52.—Diagram of piping for inside or outside elevated tank installations.
For all installations, use a continuous piece of 1/2-inch copper tubing from the oil tank or valve to the burner and a similar piece for the return when required. The principle is to minimize the number of joints and thus minimize the possibility of air or oil leaks.
For inside installations where it is necessary to run the piping overhead between the tank and burner, when the burner is either above or below the tank level, the two-pipe system is recommended. This requires the use of a two-stage pump.
A dual-stage pump may be changed from a single-stage to a two-stage pump to accommodate a single-pipe or two-pipe system. The stages on a Webster fuel pump can be changed by removing the four screws on the pressure side of the pump and lining the Number 1 up with the letter on the pump body for a one-pipe system. The Number 2 lined up with the letter is for a two-pipe system. Most Sunstrand fuel pumps are shipped from the factory set up for a one-pipe system. To change to a two-pipe system, remove the 3/8-inch pipe plug from the bottom of the pump housing. There you will find an Allen head plug. Remove this plug for a two-pipe system.
Figure 4-53.—Diagram of piping for buried outside tank.
Install the outside tanks (fig. 4-53) according to the instruction below.
Normally, when you are installing an underground fuel tank, the suction and return lines are made of black iron from the tank to the inside of the building, and there the burner is connected by copper tubing with a coil in it (not shown in the illustration) to eliminate vibration.
The return line is usually installed in the opposite end of the tank. Carry it to within 5 inches of the bottom. This creates an oil seal in the two lines, and any agitation caused by return oil is safely away from the suction line.
A 1 1/2-inch fill line and a 1 1/2-inch vent line are recommended. Carry the vent well aboveground and put a weatherproof cap on it. Pitch the vent line down toward the tank.
Use special pipe dope on all iron pipe fittings that carry oil. Treat the underground outside tank and piping with a standard preparation or commercial corrosion-resistant paint.
MAINTENANCE OF FUEL OIL SYSTEMS
Among the major duties of the HVAC technician are troubleshooting and servicing oil burners. To keep the burner in good operating condition, you must be able to recognize the symptoms of various types of trouble and must know how to make various service and maintenance adjustments to the burner.
Before getting into a discussion on trouble-shooting and servicing of oil burners, let's point out some information on fuel oil firing,
Fuel Oil Firing
Because fuel oils do not burn in the liquid state, several physical conditions must be attained to affect complete and efficient combustion.
- Either the liquid must be thoroughly vaporized or gasiifed by heating within the burner, or the bunrer must atomize it so vaporization can occur in the combustion space.
- The mist must be thoroughly mixed with sufficient combustion air.
- Required excess air must be maintained at a minimum to reduce stack thermal loss.
- Flame propagation temperature must be maintained.
Vaporization within the burner is generally confined to small domestic services, such as water heating, space heating, and cooking, and to some industrial processes. Burners for this purpose are usually of the pot type with natural or forced draft, gravity float-type feed control, and hand or electric ignition. Kerosene, diesel oils, and commercial oils of grades Nos. 1 and 2 are suitable fuels because they vaporize at relatively low temperatures.
If oil is to be vaporized in the combustion space in the instant of time available, it must be broken up into many small particles to expose as much surface as possible to the heat. This atomization is done in three basic ways:
- By using steam or air under pressure to break the oil into droplets
- By forcing oil under pressure through a suitable nozzle
- By tearing an oil film into tiny drops by centrifugal force
Primary combustion air is usually admitted to the furnace through a casing surrounding the oil burner. The casing is spiral-vaned to impart a swirling motion to the air, opposite to the motion of the oil. Three types of burners used for atomization are the steam- or air-atomizing burner, the mechanical-atomizing burner, and the rotary-cup burner.
Burners should be piped with a circulating fuel line, including cutout, bypass, pressure-relief valves, and strainer ahead of the burner. Burners should be accessible and removable for cleaning, and the orifice nozzle plates should be exchan geable to compensate for a wide range in load demand.
Steam-Atomizing and Air-Atomizing Burners
The burners consist of a properly formed jet-mixing nozzle to which oil and steam or air is piped. The conveying medium mixes with fine particles of fuel passing through the nozzle, and the mixture is projected into the furnace. Nozzles may be of the external or internal mixing type, designed to project a flame that is flat or circular and long or short. A burner should be selected to give the form of flame that is most suitable for furnace conformation. Nozzles should be positioned so there is no flame impingement on the furnace walls and so combustion is completed before the i-lame contacts the boiler surfaces.
Steam-atomizing burners are simpler and less expensive than the air-atomizing type and are usually used for locomotive and small power plants. They handle commercial grade fuel oils Nos. 4, 5, and 6 and require a steam pressure varying from 75 to 150 psi. The oil pressure needs to be enough to carry oil to the burner tip, usually from 10 to 15 psi. Burners using air as the atomizing medium are designed for three air pressure ranges: low pressure to 2 psi, medium pressure to 25 psi, and high pressure to 100 psi.
Figure 4-54 shows a steam-atomizing burner of the external mixing type. In view (A), the oil reaches the tip through a central passage and whirls against a sprayer plate to break up at right angles, view (B), to the stream of steam. The atomizing stream surrounds the oil chamber and receives a whirling motion from vanes in its path. When air is used as the atomizing medium in this burner, it should be at 10 psi for light oils and 20 psi for heavy oils. In view (C), combustion air enters through a register; vanes or shutters are adjustable to give control of excess air.
Figure 4-54.—Steam-atomizing burner.
The burner is universally used except in domestic or low-pressure service. Good atomization results when oil under high pressure (to 300 psi) passes through a small orifice and emerges as a conical mist. The orifice atomizing the fuel is often aided by a slotted disk that whirls the oil before it enters the nozzle.
Figure 4-55 shows a mechanical-atomizing burner. View (A) is a cross section of the burner; view (B) shows the central movable control rod that varies, through a regulating pin, the area of tangential slots in the sprayer plate and the volume of oil passing through the orifice; view (C) shows a design with a wide-capacity range, obtained by supplying oil to the burner tip at a constant rate in excess of demand. The amount of oil burned varies with the load; the excess is returned.
Figure 4-55.—Mechanical-atomizing burner.
Horizontal Rotary-Cup Burner
The burner (fig. 4-56) atomizes fuel oil by tearing it into tiny drops. A conical or cylindrical cup rotates at high speed (about 3,450 rpm), if motor driven. Oil moving along this cup reaches the periphery where centrifugal force flings it into an airstream. It is suitable for small low-pressure boilers.
Figure 4-56.—Rotary-cup oil burner.
Before attempting to start or to service oi I burners, see that you have the proper maintenance equipment available. One item of equipment needed is a pressure gauge set. This should consist of a 150 psi pressure gauge, fittings to connect it, and a petcock for removing the air from the oil line when starting the burner. You will need a full set of Allen setscrew wrenches for bypass plugs and for adjusting the nozzle holder and electrodes. Make sure you have a socket wrench of proper size for removing or replacing the nozzle, an open-end wrench as required for the nozzle holders, and a small thermostat wrench. This wrench comes packed with the thermostat and is used for adjusting the differential. A small screwdriver is required for adjusting pressure at the regulator and installing and servicing the thermostat. Another important item is pipe dope, and if available, use the oil-line type only. If in doubt, order a can of special oil-pipe dope for use on all pipe threads requiring dope. A nozzle assortment should also be kept on hand. It is cheaper to make a change, time considered, than to clean the nozzle on the job. When a few nozzles have accumulated, clean them in the shop.
When installing a nozzle, use a socket wrench for turning the nozzle. Be sure the nozzle seat is clean. Screw it on until it reaches the bottom, then back it off and retighten it several times to make sure of a tight oil seal. Do not overtighten the nozzle or the brass threads will become deformed, making it difficult to remove the nozzle.
Clean the nozzles in the shop on a clean bench. A nozzle is a delicate device. Handle it with care. Use kerosene or safety solvent to cut the grease and gum; use compressed air, if available, to blow the dirt out. Use goggles for eye protection when blowing dirt out with compressed air. Never use a metal needle to clean the opening; it will ruin the nozzle. Sharpen the end of a match or use a nonmetallic bristle brush to clean the opening.
When you are checking the nozzle, adjustments may have to be made in the distance of the nozzle from the tube end, the distance of the ignition points ahead of and above the nozzle, and the distance or gap between the ignition points. Figure 4-57 shows these nozzles adjustments. The nozzle tip is set 5/8 inch apart, 1/8 inch ahead of the nozzle, and 1/2 inch above the nozzle center line. These settings are given only for this particular illustration. Actual adjustments should always be made according to the specific settings in the manufacturer's instruction manual. Always tighten electrodes securely to ensure permanent adjustment.
Figure 4-57.—Setting of ignition points and nozzle.
When reinstalling either the pump or the motor, check the coupling to ensure there is no end pressure on the pump shaft as evidenced by lack of end play. If there is end pressure, the coupling should be loosened, moved closer to the pump, and re-tightened.
When oil burners are operated, operating problems will occur. These problems can cause interruption of service, inefficiency, and damage to the equipment in the system. To ensure proper operation and efficiency, you will need to be able to identify and correct these difficulties.
After the burner has been visually adjusted and allowed to run about 30 minutes, reduce the stack draft until there is just enough over-fire draft in firebox to keep the pressure from increasing under unfavorable draft conditions. The draft regulator helps maintain a constant draft in the furnace regardless of outside weather conditions. Adjust the draft by properly setting the adjuster. Too little draft is likely to cause firebox pressure, odors in the building, and possible smoke or smothering of the flame. Too much draft accentuates the effect of a possible leak in the furnace, lowers the percentage of CO2 in the flue gas, and, in turn, reduces the overall efficiency of the unit. After the burner flame and draft are properly adjusted, a flue-gas analysis should show a CO2 content of approximately 10 percent. If it does not, recheck the burner air adjustment and inspect for air leaks. For best results, the flame should be just large enough to heat the building properly in cold weather.
Air supplied to the burner will then be the minimum for clean combustion. If the furnace is large enough and the burner has been set for correct oil flow and minimum amount of air, stack temperature should not exceed 600°F. Higher stack temperatures indicate that the fire is too large or the furnace too small, or that there is too much excess air.
It is almost impossible to set and adjust a burner without instruments or test equipment. Proper instruments, in good working order, must be available in the heating shop for use by personnel who service this equipment.
The draft gauge, usually of the pointer-indicating type, is used to determine suction in the smoke pipe or combustion chamber. Suction is measured in inches of water. Carefully follow the instructions for operating the instrument.
The stack thermometer is used to indicate the temperature of gases in the smoke pipe. Insert the thermometer halfway between the center and outside of the smoke pipe and not more than 12 inches from the furnace between the smoke pipe connection and the draft regulator or barometric damper. Be careful to prevent the thermometer from being influenced by cold air taken in by the draft regulator.
The flue-gas analyzer is used to determine the percentage of CO2 produced by combustion. The CO2 reading shows how much excess air is being used. Along with the stack temperature, it denotes the efficiency of the furnace. If, despite a good flame setting, CO2 readings are low, examine the furnace for air leaks.
Maintenance requirements include cleaning the strainer, servicing the valve seat and needle valve, and adjusting the pressure regulator. Strainers must be cleaned frequently to prevent the screen from clogging and causing a shutdown. A good test for valve operation consists of removing the nozzle line at the pump connection, starting and stopping the pump, and observing whether the valve cuts off sharp and lean. When necessary, the valve is easily serviced by removing the valve chamber cover, holding spring, washer, adjusting spring, cap, and bellows assembly. Then, by taking off the nut that is marked "Nozzle," the valve, valve guide, and plug assembly can be removed.
Adjustment of the pressure regulator can be done by replacing the vent plug with a pressure gauge, removing the cover screw, and using an Allen wrench to turn the adjusting screw clockwise to increase the pressure or counterclockwise to decrease the pressure.
Burner failure or improper unit operation can be caused by various problems. Often the problem can be pinpointed by observing the type of failure and giving it some thought before attacking the problem. At other times, the cause can only be determined by a process of elimination. Table M in appendix II lists specific oil pump troubleshooting procedures, while table K, also in appendix II, lists general oil burner troubleshooting procedures. Check the simplest and more obvious items before progressing to the other checks.
Questions for Lesson 4
- With warm-air systems, the amount of heat reaching each room is determined by what two factors?
- What are the four airflow designs of gas-fired furnaces?
- What safety device on gas-fired heating equipment reacts to the operation of the pilot flame?
- What device shuts off the gas supply when the temperature inside the heating unit becomes excessive?
- What are the three internal areas of an oil-fired furnace?
- What device is the nerve center of the heating control system?
- What are the two most commonly used types of thermostats?
- A steam-atomizing burner requires a steam pressure of what range for atomizing?
- Electrode adjustments should always be set on burners according to what publication?
- What instrument is used to determine the percent of CO2 produced by combustion?