OPERATION AND MAINTENANCE: HEATING SYSTEMSRecord of Changes - 3_410_050002FOREWORD - 3_410_050003CONTENTS - 3_410_050004CHAPTER 1. INTRODUCTION - 3_410_050005REFERENCES - 3_410_050006APPENDIX A. MIL-HDBK 1114/2 OPERATION AND MAINTENANCE: HEATING SYSTEMSMAINTENANCE AND OPERATION OF HEATING SYSTEMSFOREWORD - 3_410_050010CONTENTS - 3_410_050011CONTENTS-continued - 3_410_050012CONTENTS-continued - 3_410_050013CONTENTS-continued - 3_410_050014FIGURES - 3_410_050015FIGURES-continued - 3_410_050016FIGURES-continued - 3_410_050017TABLES - 3_410_050018Section 1. INTRODUCTION - 3_410_050020Maintenance Program - 3_410_050021Tool RequirementSafety - 3_410_050023Safety-continuedSection 1. SELF-STUDY QUESTIONSSection 2. RESIDENTIAL AND COMMERCIAL GAS FIRED FURNACESFigure 1. LP Storage TankFigure 2. Pressure/Temperature Relationship for Propane and ButaneGas Burning EquipmentFigure 3. Cross Section of a Typical Atmospheric Gas BurnerFigure 4. Fixed Orifice for Delivery of Fuel GasTable 1. Orifice Capacity Table (1000 Btu/hr)Light-OffPilot BurnerFigure 6. Electrical Voltage Generation Using Two DiodesFigure 8. Pilot Light Flame PositionsCombination Gas ValveFigure 10. Combination Gas ValveBimetal Type PilotHeat Exchanger - 3_410_050040Figure 13. Low Gas Pressure CutoutFurnace FanFigure 15. Furnace ArrangementsFigure 17. Fan Safety Cutoff SwitchesFigure 18. Time Delay Fan SwitchFigure 19. Internals of Time Delay Fan SwitchFigure 20. Combination Fan Limit SwitchMillivoltage SystemsPilot RelayFigure 22. Pilot Generator and Thermocouple ConstructionFigure 23. Pilot Operated Diaphragm ValveAutomatic Flue DamperElectronic Ignition SystemsRetrofitting to Electronic IgnitionCondensing FurnacesTable 2. Pilot Burner Service Analyis ChartTable 3. Troubleshooting Furnace OperationsTable 3. Troubleshooting Furnace Operations-continued - 3_410_050058Table 3. Troubleshooting Furnace Operations-continued - 3_410_050059Table 3. Troubleshooting Furnace Operations-continued - 3_410_050060Section 2. SELF-STUDY QUESTIONSSection 3. RESIDENTIAL AND COMMERCIAL OIL-FIRED FURNACESOil CombustionOil Combustion -continuedTable 4. Amount by Weight and Volume of Conmbustion Products When One Pound of Fuel Oil is BurnedTable 5. Amount by Weight and Volume of Combustion Products When One Pound of Fuel Oil is BurnedRole of Excess Air in CombustionFigure 27. Representation of the Effect of Excess Air on Combustion Gas TemperatureFigure 28. The Effect of Excess Air on Carbon DioxideExcessAir-Smoke RelationshipCombustion ChamberFloor SizeFigure 30. Combustion Chamber DesignTable 6. Combustion Chamber Sizing DataTable 6. Combustion Chamber Sizing Data-continueSoft RefractoryFigure 31. Recommeded Minimum Inside Dimensions of Refractory Type Combustion ChambersHeat Exchanger - 3_410_050078Draft - 3_410_050079Figure 32. Approximate Relationship for Percent Excess Air With Flame Temperature and Volume of Combustion GasesDraft-continuedDraft RegulatorsFigure 33. Draft RegulatorFlue and Chimney ExhaustTable 8. Recommended Size and Height for ChimneysTable 9. Common Chimney Troubles and Their CorrectionsFigure 34. Diagram of Common Chimney TroublesFigure 35. Oil Burner for Residential UseFlame-Retention BurnersFigure 38. Flame Retention Oil BurnerFigure 39. Conventional and Retention Head FlamesFunction of Flame Retention BurnersAdverse Effects of Flame Retention BurnersBurner MotorPrimary ControlsFigure 41. Stack-Mounted Primary ControlFigure 42. One Piece Primary ControlStack DetectorFlue Gas Measurement and Flue Loss EfficiencyAssumptions - 3_410_050100Oxygen MeasurementsFigure 46. Theoretical Combustion Relationship Between Carbon Dioxide and Oxygen for No. 2 Heating OilFigure 47. Bacharach instrument Company's Fire Finder Efficiency ChartTable 10. Efficiency Table for No. 2 Oil (Oxygen vs. Temperature)Table 10. Efficiency Table for No. 2 Oil (Oxygen vs. Temperature)-continuedTable 11. Efficiency Table for No. 2 Oil (Carbon Dioxide vs. Temperature)Table 11. Efficiency Table for No. 2 Oil (Carbon Dioxide vs. Temperature)-continuedFigure 48. Graph of Heating Plant EfficiencyMeasurement of Carbon Dioxide or OxygenAmount of Carbon Dioxide in a Gas StreamTesting with FyriteOther Carbon Dioxide or Oxygen Measurement TechniquesMeasurement of Flue Gas TemperatureSmoke MeasurementFigure 51. Bacharach Smoke Spot TesterDraft - 3_410_050116Figure 52. Oil Burner Smoke ScaleFigure 53. Draft Measurement DevicesTroubleshootingBurner Does Not Operate CorrectlyBurner Does Not Operate Correctly-continuedSection 3. SELF-STUDY QUESTIONSSection 4. THERMOSTATSFigure 55. Three-Wire Thermostat With a SubbaseThermostats-continuedFigure 56. Manual Changeover, Heating and Cooling Thermostat With SubbaseFigure 57. Internal Wiring of a Four-Wire Heating/Cooling ThermostatFigure 58. System Wiring for a Four-Wire Thermostat With Heating and Cooling AnticipatorsFigure 59. Four-Wire Thermostat SubbaseTable 12. Thermostat Service AnalysisGas Furnace Electrical CircuitsFigure 61. Temperature Limit Switch in 120-Volt CircuitFigure 62. Horizontal or Downflow Furnace With Timed Start Fan ControlFigure 63. Furnace With Bimetal Pilot Safety SwitchFigure 64. Honeywell S-86 Electronic Ignition CircuitFigure 65. Intermittent Pilot System (IPS)Figure 65. Intermittent Pilot System (IPS)-continuedFigure 66. Direct Spark Ignition System Troubleshooting ProcedureFigure 67. Carrier, BDP, Payne Pick-Hold Type IgnitionFigure 68. Automatic Pilot Reignition System Used on Roof-Top FurnacesFigure 69. Automatic Electronic Reignition SystemOil Furnace Electrical CircuitsFigure 70. Honeywell R8118 Oil Burner ControlFigure 71. Honeywell R8119 Oil Primary ControlSection 4. SELF-STUDY QUESTIONSSection 5. ELECTRIC HEATHeating ElementFigure 73. Electric Heating ElementOperating SequenceBlower ControlFigure 76. Electric Heat Single ElementElectric Furnace Electrical Circuits-continuedFigure 77. Electric Heat - Two Elements Operated From a Two-Stage Room ThermostatFigure 78. Electric Heat - Three Elements Sequenced From One Room ThermostatFigure 79. Electric Heat - Two Elements Sequenced From One Room Thermostat and an Outdoor ThermostatSection 5. SELF-STUDY QUESTIONSSection 6. STEAM AND HOT WATER SYSTEMSTwo-Pipe Water SystemControl of Water CoilsFigure 83. Two-Pipe Reverse Return Hot Water SystemFigure 84. Two-Pipe Reverse Return System used to Provide Heating or Cooling Figure 85. Unit HeaterFigure 86. Face and Bypass DampersSteam PipingCondensate Systems - 3_410_050165Condensate PipingFigure 90. End-of-Main Drip Leg Prevents Accumulation of Condensate in the Stream HeaderFigure 92. Lifting Condensate to an Overhead Return HeaderFigure 93. Modulated Steam Coil With Vacuum Breaker and 12 - to 24 - Inch Minimum Liquid LegFigure 94. Steam Distributing (Non-Freeze) Type CoilCondensate PumpsFigure 96. Piping Detail to Allow for Pipe ExpansionSection 6. SELF-STUDY QUESTIONSSection 7. STEAM TRAPSMechanical TrapsThermostatic TrapsFigure 98. Float TrapFigure 100. Bimetallic TrapLiquid Filled Bellows or Diaphragm TrapFigure 102. Float and Thermostatic (F&T) TrapFigure 103. Operation of a Float and Thermostatic TrapThermodynamic TrapsFigure 105. Orifice TrapsPiston Impulse TrapDisk TrapSelecting the Type of TrapTable 13. Steam Trap Selection GuideTable 13. Steam Trap Selection Guide-continued - 3_410_050188Table 13. Steam Trap Selection Guide-continued - 3_410_050189Table 14. Steam Trap Operating CharacteristicsTable 14. Steam Trap Operating Characteristics-continuedTrap LimitationsSizing TrapsTable 15. Estimating Condensate LoadsInstallation GuidelinesFigure 108. Typical Steam Trap InstallationsInstallation Guidelines-continued - 3_410_050197Installation Guidelines-continued - 3_410_050198Implementing StandardsTable 18. Examples of Steam Loss for Various Orifice Sizes at 100 psigReplacing Old or Faulty TrapsContinous Inspection and MaintenanceEstablishing an Inspection and Maintenance ProgramSystem StandardsFigure 109. Example Baseline Survey FormTable 19. Inspection and Maintenance Program TrainingInspection SchedulesUpgrade of the SystemInspection Methods - 3_410_050209Figure 110. Illustration of Difference Between Flash Steam and Live SteamSound DetectionTable 20. Normal Pipe Temperature at Various Operating PressuresFigure 111. Steam Trap Inspection EquipmentInspection for MisapplicationTrap FailuresInspection Reports and RecordsTable 21. Troubleshooting Steam TrapsTable 21. Troubleshooting Steam Traps-continuedFigure 112. Example of Inspection LogTrap Repair and ReplacementTable - 3_410_050221Figure 113. Steam Trap Shop Test StandSection 7. SELF-STUDY QUESTIONSSection 8. HEAT PUMPSHeat Pump ComponentsFigure 116. Refrigerant Piping for a Heat PumpFour-Way Reversing ValveFigure 118. Four-Way Reversing DriveEffect of Outside TemperatureFigure 8. SELF-STUDY QUESTIONSSection 9. HEATING SYSTEMS MAINTENANCE PROCEDURESGas Burners - 3_410_050232Controls-continuedSection 9. SELF-STUDY QUESTIONSAPPENDIX A. PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEAPPENDIX A. PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE-continued - 3_410_050236APPENDIX A. PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE-continued - 3_410_050237HOT WATER BOILERS (350, 000 Btu/h or less)HOT WATER BOILERS (350, 000 Btu/h or less)-continued - 3_410_050239HOT WATER BOILERS (350, 000 Btu/h or less)-continued - 3_410_050240STEAM BOILERS (350, 000 Btu/h or less)STEAM BOILERS (350, 000 Btu/h or less)-continued - 3_410_050242STEAM BOILERS (350, 000 Btu/h or less)-continued - 3_410_050243STEAM BOILERS (350, 000 Btu/h or less)-continued - 3_410_050244HEAT PUMPS CompressorsHEAT PUMPS CoilsACCESSORIES Oil Traps and SeparatorsACCESSORIES ThermostatsACCESSORIES Other AccessoriesAPPENDIX B. ANSWERS TO SELF-STUDY QUESTIONSAPPENDIX B. ANSWERS TO SELF-STUDY QUESTIONS-continued - 3_410_050251APPENDIX B. ANSWERS TO SELF-STUDY QUESTIONS-continued - 3_410_050252APPENDIX B. ANSWERS TO SELF-STUDY QUESTIONS-continued - 3_410_050253APPENDIX B. ANSWERS TO SELF-STUDY QUESTIONS-continued - 3_410_050254REFERENCES - 3_410_050255GLOSSARY - 3_410_050256GLOSSARY-continued - 3_410_050257GLOSSARY-continued - 3_410_050258GLOSSARY-continued - 3_410_050259GLOSSARY-continued - 3_410_050260GLOSSARY-continued - 3_410_050261GLOSSARY-continued - 3_410_050262GLOSSARY-continued - 3_410_050263GLOSSARY-continued - 3_410_050264GLOSSARY-continued - 3_410_050265GLOSSARY-continued - 3_410_050266GLOSSARY-continued - 3_410_050267GLOSSARY-continued - 3_410_050268GLOSSARY-continued - 3_410_050269GLOSSARY-continued - 3_410_050270GLOSSARY-continued - 3_410_050271GLOSSARY-continued - 3_410_050272GLOSSARY-continued - 3_410_050273GLOSSARY-continued - 3_410_050274GLOSSARY-continued - 3_410_050275GLOSSARY-continued - 3_410_050276GLOSSARY-continued - 3_410_050277GLOSSARY-continued - 3_410_050278GLOSSARY-continued - 3_410_050279GLOSSARY-continued - 3_410_050280GLOSSARY-continued - 3_410_050281STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL - 3_410_0502823_410_05