Chapter 1 HVAC Formulas & Conversions . . . . .

1-1
Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Air Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Fan Laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Pulley Laws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Refrigeration Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 HVAC Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2 Ductwork & Ventilation . . . 2-1

Converting Round Duct Areas to Square Feet . . . . . . . . . 2-3 Duct Cross Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Duct Longitudinal Seams. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Properties of Steel and Plate Iron . . . . . . . . . . . . . . . . . . . 2-7 Fibrous Glass Duct Stretch-Out Areas . . . . . . . . . . . . . . 2-10 Weights of Nonferrous Sheet Duct Material . . . . . . . . . . 2-12 Weights of Sheet Metal Duct Material. . . . . . . . . . . . . . . 2-14 Weights of Steel Sheet Duct Material . . . . . . . . . . . . . . . 2-17 Weights of Nonferrous Sheet Duct Material . . . . . . . . . . 2-20 Weights of Galvanized Steel Bands . . . . . . . . . . . . . . . . 2-21 Volume of Air Required . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Fresh Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Air-Duct Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Air Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Conversion Data for Pressures . . . . . . . . . . . . . . . . . . . . 2-29 Recommended Gages for Duct Systems . . . . . . . . . . . . 2-30 Weights of Metal Angles, Equal Legs, Lb. per Lin. Ft. . . 2-40 Weights of Floor Plates, Skid Resistant, Raised Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Weights of Round Hanger Rod, Threaded Ends . . . . . . 2-41 Weights of Aluminum, Steel and Copper Ductwork for Straight Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
vii

Chapter 3 Design & Installation . . . . . 3-1

Chimney Connector and Vent Connector Clearance from Combustible Materials. . . . . . . . . . . . . . . . . . . . . . 3-3 Standard Clearance for Heat-Producing Appliances in Residential Installations . . . . . . . . . . . . . . . . . . . . . . . 3-4 Standard Clearance for Heat-Producing Appliances in Commercial and Industrial Installations. . . . . . . . . . . . . 3-5 Clearance (in Inches) with Specified Forms of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Performance of Storage Water Heaters . . . . . . . . . . . . . . 3-7 Heat Value per Cord (Million BTU) of Wood with 12% Moisture Content. . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Heat Value per Cord (Million BTU) of Green Woods. . . . . 3-8 Typical Firewoods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Weather Zones and the Size of Tank Required . . . . . . . 3-10 BTU Content of Fuel Oil. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Properties of LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Usage Estimates For Gas Water Heating; per Month in USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Usage Estimates For Electric Water Heating; per Month in USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Winter Design Temperatures for Major U.S. Cities. . . . . 3-13 Ground Temperatures (U.S.) Below the Frost Line . . . . . 3-16 Heat Gain Factors (Walls, Floor and Ceiling) . . . . . . . . . 3-18 Average Air Changes per 24 Hr. for Storage Rooms Due to Door Openings and Infiltration (Above 32F) . . 3-20 Heat Removed In Cooling Air to Storage Room Conditions (BTU per cu. ft.) . . . . . . . . 3-21 Infiltration Rate Through Various Types of Windows . . . 3-22 Infiltration Through Various Types of Wall Construction. 3-23 Recommended Limit Control Settings . . . . . . . . . . . . . . 3-23 Common Terminal Identifications . . . . . . . . . . . . . . . . . . 3-23
viii

Relay Position and Effect on Gas Burner . . . . . . . . . . . . 3-24 Twin-Type Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Millivolt Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Suggested Duct Velocities for Low Velocity Systems . . 3-27 Design Pressures for Refrigerant Testing . . . . . . . . . . . . 3-28 Attic Vent Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Ventilation Requirements for Refrigeration Machinery in Hot Areas . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Specific Heat of Various SubstancesLiquids . . . . . . 3-32 Specific Heat of Various SubstancesGases. . . . . . . . 3-33 Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Room-Cooling Requirements in BTU . . . . . . . . . . . . . . . 3-35 Neuron Chip Simplified Block Diagram. . . . . . . . . . . . . . 3-36 Neuron Chip Block Diagram . . . . . . . . . . . . . . . . . . . . . . 3-38 Neuron Chip Pin Assignment . . . . . . . . . . . . . . . . . . . . . 3-40 Neuron Chip Block Diagram . . . . . . . . . . . . . . . . . . . . . . 3-41 Neuron IC Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Neuron IC Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Lonworks Node Block Diagram . . . . . . . . . . . . . . . . . . . 3-44

Chapter 4 Plan Symbols . . . . . . . . . . . 4-1

Pipe Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Standard Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Equipment Designations . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Control Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Steam Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Firesafety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Piping Specialities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Air Moving Devices and Components . . . . . . . . . . . . . . 4-38 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
ix

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Auxilliary Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Energy Recovery Equipment . . . . . . . . . . . . . . . . . . . . . . 4-56 Power Recources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57 Miscellaneous Plan Symbols. . . . . . . . . . . . . . . . . . . . . . 4-57

Chapter 5 Electrical & Motors . . . . . . 5-1

Calculating Root-Mean-Square. . . . . . . . . . . . . . . . . . . . . 5-3 Power Formulas1, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Typical Power Wiring Color Code . . . . . . . . . . . . . . . . . . . 5-4 Conduit Size vs. Wire Size. . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Tightening Torque in Pound-Feet-Screw Fit . . . . . . . . . . . 5-5 Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Enclosure Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Designing Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Tips on Selecting Motors. . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Facts to Consider. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Types of Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Setting Branch Circuit Protective Devices . . . . . . . . . . . 5-13 1 Motors and Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 3 230 V Motors and Circuits240 V System . . . . . . . 5-17 3 460 V Motors and Circuits480 V System . . . . . . . 5-20 Motor Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Coupling Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Typical Motor Power Factors. . . . . . . . . . . . . . . . . . . . . . 5-29 V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Common Service Factors . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Motor Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Motor Frame Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Chapter 6 Conversions Factors & Units Of Measure . . . . . . . . . . . . . . . . . 6-1

Commonly Used Conversion Factors . . . . . . . . . . . . . . . . 6-3 Electrical Prefixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Common Prefixes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Common Electrical Quantities . . . . . . . . . . . . . . . . . . . . . 6-10 Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Electrical Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Commonly Used Geometrical Relationships . . . . . . . . . 6-14

Chapter 7 Materials & Tools . . . . . . . . 7-1

Cable Clamps for Wire Rope. . . . . . . . . . . . . . . . . . . . . . . 7-3 Pulleys and Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Standard V Belt Lengths. . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Wire and Sheet Metal Gauges. . . . . . . . . . . . . . . . . . . . . 7-16 Wire Wrope SlingsStraight Leg . . . . . . . . . . . . . . . . . . 7-19 Manila Rope SlingsStraight Leg . . . . . . . . . . . . . . . . . 7-20 Manila Rope SlingsBasket . . . . . . . . . . . . . . . . . . . . . 7-21 Safe Load for Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Sheet Metal Screw Characteristics . . . . . . . . . . . . . . . . . 7-24 Whitworth Bolt & Torque Characteristics . . . . . . . . . . . . 7-25 Metric Bolt & Torque Characteristics. . . . . . . . . . . . . . . . 7-26 Bolt & Torque Characteristics . . . . . . . . . . . . . . . . . . . . . 7-27 Metal-Working Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Chapter 8 Trouble Shooting . . . . . . . . 8-1

Common Problem Spots . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Trouble Shooting Gas-Fired Furnaces . . . . . . . . . . . . . . . 8-7 Trouble Shooting Oil-Fired Furnaces. . . . . . . . . . . . . . . . 8-11 Trouble Shooting Coal-Fired Furnaces . . . . . . . . . . . . . . 8-16 Trouble Shooting Electric Furnaces. . . . . . . . . . . . . . . . . 8-19
xi

Trouble Shooting Reversing Valve . . . . . . . . . . . . . . . . . . 8-21 Trouble Shooting Boilers . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Trouble Shooting Air Conditioning. . . . . . . . . . . . . . . . . . 8-27 Trouble Shooting Damper Motor. . . . . . . . . . . . . . . . . . . 8-36 Trouble Shooting Gas Burners . . . . . . . . . . . . . . . . . . . . 8-37 Trouble Shooting Oil Burners. . . . . . . . . . . . . . . . . . . . . . 8-39 Trouble Shooting Oil Burner Primary Control . . . . . . . . . 8-43 Trouble Shooting Thermocouples . . . . . . . . . . . . . . . . . . 8-45 Trouble Shooting Fuel Pumps and Fuel Units . . . . . . . . 8-46 Trouble Shooting Steam Systems . . . . . . . . . . . . . . . . . . 8-48 Trouble Shooting Self-Contained Air-Conditioner . . . . . 8-53

Chapter 9 Glossary. . . . . . . . . . . . . . . . 9-1 Chapter 10 Industry Associations . . 10-1 Chapter 11 Toll Free Numbers For HVAC Manufacturers . . . . . . . . . . . . . 11-1

xii

INFILTRATION THROUGH VARIOUS TYPES OF WALL CONSTRUCTION

TYPES OF WALL Brick Wall 8 in. Plain Plastered Plain 13 in. Plastered Frame Wall, Lath and Plaster WIND VELOCITY, MILES PER HOUR 5 2 0.02 1 0.01 0.03 10 4 0.04 4 0.01 0.07 15 8 0.07 7 0.03 0.13 20 12 0.11 12 0.04 0.18 25 19 0.16 16 0.07 0.23 30 23 0.24 21 0.10 0.26

RECOMMENDED LIMIT CONTROL SETTINGS

Hot-water system (gravity) . . . . . . . . . . . . . . . . . . . . . . . . . . 180F Hot-water system (forced) . . . . . . . . . . . . . . . . . . . . . . . . . . 160F Warm air (forced) . . . . . . . . . . . . . . . . . . . . . . . . . . 200F Warm air (gravity) . . . . . . . . . . . . . . . . . . . . . . . . . . 300F Steam system . . . . . . . . . . . . . . . . . . . . . . . . . off 3 lb.- on 1 lb. Vapor system . . . . . . . . . . . . . . . . . . . . . . . . . off 4 oz.- on 2 oz.

COMMON TERMINAL IDENTIFICATIONS

LETTER R W Y G O B X P Z WIRE COLOR Red White Yellow Green Orange Brown TERMINAL FUNCTION Power supply; transformer Heating control; heating relay or valve coil Cooling control; cooling contactor coil Fan relay coil Cooling damper Heating damper Malfunction light Heat pump contactor coil Low-voltage fan switch

3-23

4-47

TROUBLE SHOOTING REVERSING VALVE

PROBLEM Valve Will Not Shift From Heat to Cool
Defective coil Pilot valve operating correctly Dirt in one bleeder hole Replace coil Deenergize solenoid, raise head pressure, and reenergize solenoid to break dirt loose. If unsuccessful, remove valve and wash out. Check on air before installing. If no movement, replace valve, add strainer to discharge tube and mount valve horizontally. Repair leak and recharge system Repair electrical circuit Raise head pressure, and operate solenoid to free. If still no shift, replace valve. Recheck system Raise head pressure and operate solenoid to free partially clogged port Stop unit. After pressures equalize, restart with solenoid energized. If valve shifts, reattempt with compressor running. If still no shift, replace valve.

ACTION

Low refrigeration charge No voltage to coil Clogged pilot tubes

Pressure differential too high Both ports of pilot open. Back seat port did not close. Piston cup leak

8-21