Gas Technician III

Learning Package

Module 9 – Introduction to Gas

Appliances
 Contents
Learning Outcomes: ....................................................................................................................... 3
Water Heaters:............................................................................................................................... 4
Forced Warm Air Furnaces: ......................................................................................................... 11
Venting & Venting Materials: ...................................................................................................... 20
Operating and Safety Controls..................................................................................................... 24
Pilot Terminology and Classification: ........................................................................................... 27
Heat Transfer: .............................................................................................................................. 30
Boiler Systems & Conversion Burners: ........................................................................................ 32

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  A gas technician must be able to work on many types
of gas-fired appliances. It can often be challenging as

Learning you must familiarize yourself with not only older installed

Outcomes: equipment but also new equipment, incorporating the

latest technological advancements, as manufacturers
strive to meet safety and efficiency requirements.

After completion of this module you will be able to:

Identify operating characteristics, features, and methods of heat transfer of

natural gas and propane appliances.

Explain the purpose of venting gas appliances.

Describe different types of gas venting material.

Describe types, purpose, and operation of draft diverters and draft hoods.

Describe the effect of vent restrictions on appliance draft.

Describe different types of burner classifications.

Identify pilot terminology and classification.

Identify and describe different ignition types and operating characteristics.

Describe different types of safety and operating controls.

Describe different methods of temperature sensing.

Describe the requirements associated with appliance conversions.

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  Conventional natural draft gas-fired residential
water heaters consist of a steel storage tank with a
Water cold water inlet and a hot water supply outlet. They
Heaters: have an atmospherically fired burner at the bottom
and are sometimes referred to as "under fired" water
heaters. They usually have a continuous pilot.

The flue passes vertically through the centre of the tank. A baffle is used in the flue
passage to improve heat transfer to the water. There are one or two inches of
insulation between the tank and the outer jacket.

Figure 9-1
Conventional Natural
Draft Water Heater

Water heaters are equipped with

a Temperature & Pressure Relief
Valve, known as a TPR or T&P
valve. The T&P valve is a safety
Figure 9-2 Breakdown of Natural Draft Water Heater Components
device activated by excess
temperature or pressure conditions within the tank. It will
release and spill water if the pressure or water temperature reach
unsafe levels.
Figure 9-3 T&P Valve

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 An anode is a metal rod usually made of magnesium or aluminum which helps prevent
corrosion of the tank. Electrolysis eats away the anode

Figure 9-4 Anode instead of the steel of the tank.

Once the anode is gone however, then the tank itself will start to corrode. The anode is
screwed into the top of the water heater and can be replaced if necessary.

Figure 9-5 Anode rod at new, partially depleted, and

completely depleted stage.

The dip tube directs incoming cold water down to the bottom of the tank, preventing
the mixing of incoming cold water with the out-going hot water.

Figure 9-6 Dip tube

Figure 9-7 Cold and hot water inlets. Double

lining on cold indicates presence of
dip tube

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 A combined thermostat and gas valve unit, known as a thermostatic control, controls
both the temperature of the water in the tank and the gas flow. Most
conventional natural draft water heaters utilize this type of control. It
senses when the water temperature drops below a certain point and
causes the burner to come on and heat the water. When the water
Figure 9-8 Thermostatic
Control
reaches the desired temperature it shuts off the burner. It utilizes the
“rod and tube” method of temperature sensing, where the expansion and contraction
of dissimilar metals in the sensor operate the gas valve in
response to water temperature changes.
Figure 9-9 Drain Valve
The drain valve allows the water heater to be drained for various
reasons including periodic removal of sediment or for replacement.

Power-Vented Gas Water Heaters

To make water heaters compatible with mid

and high efficiency furnaces, manufacturers
developed gas-fired water heaters with
induced draft fans. They force exhaust gases
either up the chimney or out a side wall
vent. Many of these units retain the draft
hood with its dilution air requirement and
have a hot surface ignition system operated
by an electronic gas control valve.

Figure 9-10 Power Vented Water Heaters

B
A C
Figure 9-11 Power venter (A) Burner assembly showing hot surface ignitor and flame rod positioning (B) Electronic gas
control valve (C)

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 High-efficiency condensing gas water heaters, like high efficiency furnaces, utilize an
additional heat exchanger made of corrosion-resistant materials for the condensing
part of the heat-exchange surface or a single specially
designed spiral heat exchanger. Flue gases are also
vented by many through a sidewall using high
temperature plastic vent.

There are numerous types of water heaters including high

capacity commercial and tankless types.

Tankless, or instantaneous water heaters are compact

heating units that provide hot water as it is needed. They
do not store hot water like Figure 9-12 High Efficiency Water Heater

traditional tank-type water

heaters.

Tankless water heaters work on demand using

flow/temperature sensors and computer circuitry that sense
the rate at which water flows through the unit.

Figure 9-13 Tankless Water Heater The circuitry then adjusts

the firing rate of the
burners (by staging and modulation) to match the amount
of hot water required
using the exact amount of
fuel needed at that
moment.

Figure 9-14 Commercial Water Heaters

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 Connecting copper water pipes to hot water heaters:

If you will be involved with the installation of water heaters, you will need to know
how to solder the copper water supply pipes. Soldering copper pipe, or "sweating" is
the heating of a joint by a torch, causing solder to melt and run into the joint, creating
a leak proof joint.

By using a propane torch to heat up the pipe and fitting being joined, solder can be
drawn into the heated joint through capillary action and spread evenly
between the pipe and fitting. Properly done, you will have a solid, leak-
free joint that will last for years. However, an improperly sweated joint
will eventually leak, requiring you to drain the system and start over.

Remember to use care when working with a torch. Keep the

Figure 9-15 Propane
Torch flame away from combustible materials. Also remember to let your work
cool before handling it. You may need to put some sheet metal behind the work area
to shield nearby combustible materials from the flame.

You cannot solder a joint with any water in the pipe. Before you start, remember to
shut off the main valve and drain the water from the supply line. If you have difficulty
soldering a joint due to moisture remaining in the pipe, you can try wadding up some
white bread and stuffing it about a foot back into the pipe end that you're soldering.
Once the pipe has been soldered and the water is turned back on, the bread will
disintegrate and be flushed out.

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 Soldering copper water pipes

Prepare the pipe surface. Clean the inside with a pipe reamer, twisting the reamer to
remove any burrs. Next, polish the inside of the fitting with a
wire brush to remove dirt and oxidation. Finally, polish each end
of the pipe that will join the fitting with an emery cloth. Use a
clean rag to remove any debris.
Figure 9-16 Sanding Cloth

Check the fit. Check that the pipe and fitting will join snugly, and then take them apart
again.

Apply flux to the outside edge of the pipe and the inside of the fitting. Flux prevents
the copper from oxidizing when heat is applied and helps solder flow easily into the
joint.

Connect the pipe to the fitting.

Prepare the solder by rolling out about 8 to 10 inches of solder.

Figure 9-17 Applying Flux
Bend the last few inches of the solder into a hook shape so it is easier
to maneuver.

Heat the pipe and the fitting. Wearing heavy gloves, light the torch with a spark
igniter, keeping the tip pointed away from you. Adjust the flame
so that the blue inner flame is about 1 to 2 inches long. Using the
inner flame, evenly heat the pipe and then the fitting.

Figure 9-18 Soldering Joint

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 Apply the solder. Try not to use the flame to melt the solder. The solder should melt
from the heat of the pipe and fitting.

Periodically touch the tip of the solder to the joint to see if the pipe and fitting are hot
enough to melt the solder.

When the copper reaches the right temperature, apply the solder against and around
the joint. The melting solder will be pulled into the joint, filling the gap completely, and
forming a waterproof seal.

Wipe away any excess solder. Once the solder has hardened enough to lose its sheen,
dampen a rag and use it to brush away any excess solder. Use caution, as the joint will
still be hot.

Test the joints after soldering by opening the main water valve and watching for leaks.

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  A forced warm air furnace is a complete unit, which
utilizes a metal heat exchanger to transfer heat, from
Forced the combustion of fuel gases within its interior, to air
Warm Air flowing over its exterior. The air is heated and
Furnaces:
supplied to rooms through the ducts of an air
distribution system by an air blower located in the
furnace. Note: Some older furnaces had no blower for air circulation

and these furnaces were known as a “gravity” warm air furnace.

Three common types of forced warm air furnaces include:

Natural Draft Furnace - conventional

Mid Efficiency Furnace - non-condensing

High Efficiency Furnace – condensing

B C

Figure 9-19 Various Furnaces (covers removed)

A A – Natural Draft
B – Mid Efficiency – Non Condensing
C – High Efficiency - Condensing

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 The Conventional or Natural Draft Furnace (Category I Appliance)

A conventional or natural draft furnace has no mechanical components that supply air
to the atmospheric burners for
combustion, or that assist in the
venting of flue gases. Vent
Warm heated air to rooms

In venting the products of

Draft
combustion, a natural draft is diverter

created as a result of the difference Heat Exchanger

in weight (or buoyancy) between the

Products of Gas
hot combustion gases and the cooler combustion valve

ambient air. The draft created

allows combustion gases to vent to Combustion
air inlet
the outdoors naturally, without Blower
Cool return air Blower
mechanical fan assistance. from rooms motor

A conventional or natural draft Figure 9-20 Conventional

furnace is designed to operate with Furnace

neutral pressure within the combustion chamber, called "zero

over-fire draft".

A zero over-fire draft is maintained by the use of a draft diverter

or draft hood.

Figure 9-21 Natural

Draft Created in Vent

Figure 9-22 Combustion Chamber

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 The draft diverter or draft hood introduces dilution air, from the room containing the
appliance, into the venting system.

The dilution air reduces the pull of the vent draft,

preventing the draft from affecting the neutral pressure
of the combustion chamber area. Additionally, the draft
diverter or draft hood prevents down draft conditions
(such as those created by outdoor wind conditions) from
affecting the neutral pressure of the combustion
chamber area.

The draft diverter or draft hood is often incorporated as Figure 9-23 Draft Diverter
incorporated as part of a
part of the appliance or as a separate draft hood in the conventional furnace

vent.

You should always check the draft at the draft diverter or draft hood of these
appliances (smoke test) to ensure there is proper draw and that there are no
obstructions or restrictions in the venting system.

Combustion gases can vent directly into the house if there is a blockage in the venting
system, or if there is a negative air pressure condition created by exhaust fans within
the room containing the appliance. This is known as spillage of combustion products.

Figure 9-24 Checking Draft

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 Many furnaces are equipped with a temperature activated "spill switch" in the draft
hood or draft diverter area. The spill switch is designed to shut the furnace down if flue
gas spillage occurs. Spill switches must be manually reset if activated.

Keep in mind that Section 4 of the B149.1-15 Gas Code was amended in regards to
“Mandatory Safety Checks for Residential (one or two family Dwelling) Natural Draft
Boilers Equipped with Draft Hoods 300,000 BTU’s or Less”.

As a licensed technician you must ensure that you are following the directions given in
this amendment should you encounter a natural draft boiler as indicated in the
amendment. This may require you to take CO readings in the flue gas upstream of the
draft control device (between the heat exchanger and the draft hood) with the boiler
operating at steady state under normal operating conditions and take appropriate
steps should you record unacceptable levels of CO.

In 1992, Federal standards required a minimum of 78% annual fuel utilization

efficiency (AFUE). AFUE represents the percentage of fuel that is converted into
heating energy over the course of the year. Because natural draft furnaces, which had
long been the industry standard years ago, had such a low seasonal efficiency (60-
65%), they no longer met this standard and the manufacturing of them stopped.
Subsequently, when replacement was necessary, conventional natural draft furnaces
were often replaced by “mid-efficiency" furnaces which at that time met the required
AFUE of 78%.

Currently, residential furnaces must have a minimum fuel efficiency level of 90% AFUE.
This is quite a rise from the previous 78% efficiency requirement. This applies to
furnaces manufactured after January 1, 2013 with an input of less than 225,000 Btu/h,
(65.92 kW) connected to a single-phase power supply.

Furnaces that have a minimum fuel efficiency level of 90% AFUE are considered to be
high efficiency condensing furnaces.

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 Although only high efficiency condensing models are currently being manufactured,
we must remember that there are countless homes presently equipped with either
natural draft or mid-efficiency furnaces and our knowledge of them continues to be
important.

Mid Efficiency / Fan Assisted Furnaces

Fan-assisted furnaces were developed

to increase efficiency. Like conventional
or natural draft furnaces, fan assisted
furnaces utilize atmospheric burners.
However, fan assisted furnaces use a
combustion fan and are not equipped
with a draft hood.

Figure 9-25 Fan-Assisted Furnaces

The combustion fan of fan-assisted
furnaces regulates air for combustion but it does not create any venting
pressure. Like the natural draft furnace, fan assisted furnaces rely on
buoyancy to vent the products of combustion.

Induced Draft Furnaces (Category III Appliance)

Induced draft furnaces not only regulate air for combustion, but also power
vent the products of combustion outdoors. They are non-condensing and
employ a special venting system recommended by the manufacturer such as
Type BH.

Special BH venting can include thermoplastic such as PVC (as mentioned in

Module 8) or high-grade stainless steel as illustrated in this Module (Types of
Venting Material).

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 Forced warm air furnaces generally fall into three main classifications.

Upflow Furnaces, (Lowboy & Highboy)

Downflow Furnaces

Horizontal Furnaces

Figure 9-27 Figure 9-28 Upflow Lowboy

Figure 9-26
Upflow Highboy
Downflow

Figure 9-29 Horizontal

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 High-Efficiency Condensing Gas Furnaces. (Category IV Appliance)

In a conventional gas furnace, a considerable amount of heat is lost up the chimney

from the combustion process, and from the room containing the appliance.

Condensing furnaces further increase energy efficiency by reducing the amount of heat
that escapes up the chimney, and from the room containing the appliance.

Condensing furnaces contain an additional heat exchanger made of a corrosion-

resistant material, typically stainless steel, which
extracts additional heat from the hot flue gases. This
allows condensing furnaces to be vented directly
outdoors through a sidewall using high temperature
plastic pipe such as PVC. However, combustion gases
are cooled to the point where the water vapour in the
flue gases condenses. Consequently, the condensate
must be piped to a floor drain or condensate pump.

Figure 9-30 High Efficiency

Condensing Furnace

Figure 9-31 High Efficiency Condensing Furnace Components

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 The burners associated with condensing furnaces are similar to conventional furnaces,
with draft supplied by an induced draft fan.
Generally, outside air for combustion is brought in
through plastic piping directly to a sealed
combustion chamber

Most high efficiency furnaces are currently

equipped with an electronically commutated blower
motor, or ECM motor.
Figure 9-32 High Efficiency Condensing Furnace Prior to the ECM motor, furnaces used a
Burners
single-speed, permanent split capacitor (PSC) blower
motor to convey hot air through the ductwork. When the PSC motor was operating it
produced 100% output only.
The ECM motor is a very efficient brushless DC motor that is operated by a controller
unit to run the blower at variable speeds. The ECM motor operates only at the speed
required to maintain the indoor temperature set point. This results in higher energy
savings and improved system performance.

Figure 9-33 ECM motor and control board

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 Pulse condensing gas furnaces are high efficiency furnaces that utilize a combustion
process that burns fuel in pulses rather than a continuous
burning flame.

Combustion takes place in a sealed environment. The

operation is as follows:

• First a charge of air and gas enters through

metering valves into the burner/heat exchanger.

• The charge is then ignited by a spark plug. Figure 9-34 Pulse Furnace

• Once combustion begins, the spark plug shuts off.

• The positive pressure from combustion closes the metering valves.

• This same pressure forces the hot gases out the tailpipe.

• The metering valves are forced open (due to the negative pressure
created) and a fresh charge of air and gas is then introduced.

This positive and negative phase repeats at a natural frequency about 30 times a
Figure 9-35
Pulse Furnace second.
Sequence of
Operation

Figure 9-36 Cut Out View of Pulse Furnace

Combustion Chamber

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  Proper venting of gas appliances is important to
Venting & ensure both safety and efficiency. The purpose of
Venting venting a gas appliance is to remove the products of
Materials: combustion safely outdoors. Gas appliances may be
vented outdoors either through a chimney flue, certified
vent, or factory built chimney

For a vent to operate properly, it must be the correct size and type for the
appliance. The requirements for vent sizing of natural draft and fan assisted Category 1
natural gas and propane appliances are indicated in Annex C of the B149.1-15 Natural
Gas and Propane Installation Code.

Air supply and venting go hand in hand and must be

looked at simultaneously. Keep in mind that the volume
of air vented from a room through the venting system,
needs to be replaced to ensure proper vent operation.

As seen in Module 6, appliance manufacturers generally

offer detailed information on proper venting of their gas
appliances. These instructions must be checked against
Code requirements as well as any applicable building
code requirements. When in doubt, consult the Figure 9-37 Single Wall Vent

authority having jurisdiction.

Every appliance must be vented to an effective chimney or vent unless an appliance is

approved for use without a vent.

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 Type B vents are generally used to vent gas appliances certified for use with draft hoods
or draft diverters. They are constructed of corrosion resistant material
and have a double wall construction, which encloses an insulating air
space.

Type L vent is constructed to withstand a higher flue gas

temperature than Type B vent. It is used to vent appliances that are
certified for use with Type L vent. Type L vent can also be used in place
of Type B vent.

When installing Category I gas fired heating appliances into a

masonry chimney, the chimney must be lined
and sized properly. Clause 8.12 - Chimneys, of
Figure 9-38 B Vent
the B149.1-15 Natural Gas and Propane
Installation Code specifies chimney and lining
requirements. Figure 9-39 Clay-lined
Chimney

Type BW vents are similar to Type B vent construction except

that they are oval in shape. They are designed specifically for
Figure 9-40 Metal Chimney
Liner installation in walls to vent recessed wall furnaces.

BW vent is currently not very common due to the

development of sidewall direct vent type appliances that utilize
high temperature plastic venting.

Figure 9-41 BW Vent

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 Type BH vents are used for negative or positive pressure venting of gas appliances.

Type BH vents are usually associated with a Special Venting System provided by the
appliance manufacturer.

You must ensure that you use the correct class of

Type BH venting, as there are numerous flue gas
temperatures ratings.

When using High Temperature Plastic Venting

(HTPV) Type BH Special Venting Systems associated with
Figure 9-42 BH Vent
high efficiency appliances, the
type of cleaning solvent, adhesive, and installation
instructions provided by the manufacture must be carefully
followed. Figure 9-43 636 Glue and
primer

Appliances that utilize HTPV must not be common-vented with other appliances or
vented to B-vent or masonry chimneys. All HTPV system installations must conform to
the requirements of the authority having jurisdiction.

Vents constructed using plastic piping shall be

certified to ULC S636 standard.

Figure 9-44 System 636 Venting

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 Examples of vented appliances
A
Hot water/ Steam boilers

Furnaces

Unit heaters

Duct furnaces

Incinerators

Water heaters

B C
Fireplaces
Figure 9-45 Various Vented Appliances:
A – Overhead infrared tube heater
All appliances that have a draft hood B – Wall hung boiler
C - Fireplace
supplied by the manufacturer

Unvented appliances must be approved for use without a vent. Some examples include:

Stoves/Ranges (overhead stoves vents should be on during stove operation)

Counter appliances

Gas Lights

Surface combustion infrared heaters

Figure 9-46
Green house carbon dioxide
A - Unvented Stove
generators (with limitations on B – Clothes Dryer

combustion rates and CO2 concentrations)

Specialized equipment of limited input

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 Operating and Safety Controls

When a thermostat calls for heat, it closes and energizes a gas control valve. When the set
point of the thermostat is reached, the thermostat opens to de-energize the gas valve.
Thermostats can be mechanical or digital.

Figure 9-47 Mechanical Thermostat Figure 9-48 Digital Thermostats

Figure 9-49 24v Thermostat Circuit

Blower Fan and Safety Shutoff Controls

A fan controller is a device used to turn the furnace blower fan

on and off in response to temperature changes within the
furnace's plenum. Fan controls can be activated by
temperature or electronically by a timer, often as part of the
furnace’s integrated electronic control board.
Figure 9-50 Blower fan
After the thermostat calls for heat, the gas valve is energized operation through
Integrated Furnace
initiating the burner process. The burner assembly starts Control Board

heating the air within the furnace plenum.

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 If a temperature activated fan switch is used, and the temperature of the air reaches the
cut-in temperature setting of the fan controller, the controller switch closes, starting the
blower fan. If activated by a timer, the
blower will start after a set amount of
time (30 seconds for example). The warm
air is then distributed throughout the

Figure 9-51 24v Fan Control Circuit ducts of the air distribution system.

When the thermostat is satisfied, it will open, shutting off the burner. The air within
the plenum will begin to cool. When the air temperature drops below the cut-off
temperature of the fan controller, the controller switch will open and the blower will
shut off. If a timer is used, the blower will shut off approximately 90 seconds later.
This timing can often be adjusted by the technician if necessary.

High limit controllers are used to prevent excessive and unsafe temperatures from
building up within the plenum. High limit controllers will shut the burner down if the
set point of the controller is reached.

L N

120/1/60

Blower
Motor

Blower
Figure 9-52 White Rogers Fan
High Limit Control Control
Switch

High
120/24v
Limit
Transformer
Switch

24V
Figure 9-53 Snap-
Acting Disk High Limit
Control
Thermostat

Gas
Valve
Figure 9-54 Furnace Schematic Diagram

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 Fan controllers are often combined with a high limit controller in one device.

The maximum setting for a high limit, according to Clause 7.8.6 of the B149.1-15
Natural Gas and Propane Installation Code for a conversion forced air furnace is 250.0
0
F (121.0 0C).

Figure 9-55 High Limit/Fan Combination Controls (Fan Center)

A limit controller contains a snap-acting switch operated by either a fluid-filled or

bimetallic sensing element.

Bimetal sensing elements are available in helical, flat-

blade, and spiral types. The bimetal sensing element is Figure 9-56 Bimetal Sensors

connected directly to the switch operator.

Fluid-filled sensing elements are connected to the controller

by a capillary tube that is filled with a temperature-sensitive
liquid.

Figure 9-57 Fluid-Filled

Temperature Sensor

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 Pilot
 A pilot burner is a device used in a gas-
Terminology
fired appliance to light the main gas
and
Classification: burner(s).

An aerated pilot is one in which air and gas are mixed before burning.

With a non-aerated pilot there is no premixing of the air and gas. Only surrounding
secondary air is used to complete the combustion process.

Although the non-aerated pilot produces a less stable flame than the aerated type,
non-aerated pilots are not as susceptible to clogging thus requiring less maintenance
than aerated types.

Figure 9-58 Aerated Pilot Figure 9-59 Non-

Aerated Pilot
Current ignition systems associated with residential and light commercial gas
appliances incorporate electronic flame sensing methods with Direct Spark,
Intermittent, or Hot Surface Ignition methods.

An automatic direct spark ignition (DSI) system ignites the main burner flame following
a call for heat.

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 An automatic intermittent pilot (IP) system ignites a
pilot flame, usually by a spark, upon a call for heat. The
pilot is then used to ignite the main burner.
Figure 9-60 Intermittent Pilot System

An automatic hot surface ignition (HSI) system ignites

the main flame with a hot surface igniter or glow bar
upon each call for heat.

Integrated furnace control boards provide power to

igniter (HSI or spark) and gas valve in Figure 9-61 Hot Surface Ignitor

addition controlling numerous other furnace functions, such as induced

draft and blower operation.

Figure 9-62
Integrated furnace
control board

Common types of pilots include: continuous, intermittent, Interrupted, and expanding.

Continuous pilot (standing or constant) - A pilot that burns without turndown

throughout the entire time the burner is in service,
whether the main burner is firing or not. Usually
associated with atmospheric type burners.

Figure 9-63 Continuous Pilot

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 Intermittent pilot - A pilot which is automatically lighted each time there is a call for
heat and burns during the entire period that the main burner is firing. It shuts off with
the main burner at the end of the heating demand.

Figure 9-64 Intermittent Pilot

Interrupted pilot - A pilot which is automatically lighted each time there is a call for
heat and in which the pilot is cut off automatically at the end of the flame establishing
period of the main burner.

Expanding Pilot - A pilot that burns at a low turndown throughout the entire time the
burner is in service, whether or not the main burner is firing, except that upon a call for
heat, the fuel flow to the pilot is automatically increased to produce a flame, which will
reliably ignite the main burner fuel.

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 Heat  Heat can be transferred by: conduction, convection, or
Transfer: radiation.

Conduction

Conduction is when heat moves through an object, or when heat moves from one
object to another when the two objects are in contact with one another. The rate of
heat transfer, or movement, depends on several factors including the temperature
differences, and the material of which the object or structure is comprised.

If a material is a good conductor of heat then the heat will move quickly. Metals have
properties which allow for movement of heat while being able to withstand
temperature extremes. If you were to hold a metal rod at one end while heating the
opposite end with a torch, it wouldn't take long before the end in your hand became
too hot to hold. The metal of boilers conduct heat from the fire side to the water side
of the boiler in the same manner.

Wood, on the other hand, is a poor conductor of heat. If you were to do the same
experiment with a wooden stick, the end in the torch's flame will start to burn while
the end you are holding would remain relatively cool.

Convection

Convection is the transfer of heat from a hot surface to air or

to water whenever cool air or water moves across a heated
surface.

Figure 9-66 Unit heater Heat

Exchanger Transferring Heat
by Convection
Figure 9-65 Furnace Heat
Exchanger Transferring Heat
by Convection

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 Heat can be transferred by forced air movement such as from a fan blower or by natural
air movement.

Natural air movement takes place as a result of the heated air becoming less dense and
lighter than the cooler air around it. The heated air begins to rise. As the hot air rises
the cooler air falls, establishing what is known as convection current.

Radiation

When an object is heated it begins to give off a form of energy called thermal radiation.
If you were to stand in front of a hot
radiator located on a wall, or under a
radiant heater, you would feel the heat
on your hands and face. That is radiant
Figure 9-68 Floor Mounted
energy. However, if someone were to Radiant Heater

Figure 9-67 Ceiling Mounted move in front of you, that person's body would block the radiant
Radiant Heater
energy from reaching you.

Thermal radiation can reach a frequency which our eyes recognize as light. You may
have seen these waves being emitted from a red-hot object or from coals in a fire.

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  Boilers are pressure vessels where water is heated to
Boiler produce either hot water or steam. The basic
Systems &
construction of residential low-pressure steam and hot-
Conversion
water space heating boilers consists of a fireside
Burners:
combustion chamber, a waterside chamber, and an
insulated steel covering.

The combustion process takes place in the lower combustion chamber while the upper
chamber contains steel tubes in which water is heated or converted to steam for
circulation through the pipes of the heating system.

Boilers are classified as either steam boilers or hot water boilers. Steam boilers are
classified as either low pressure (under 15 psig) or high pressure (over 15 psig).

A “hydronic heating system” is a term used to describe a system that uses a boiler to
heat water. The hot water is circulated through the house before returning to the
boiler to be reheated.

Gas-fired boilers for conventional hydronic heating

systems typically produce hot water at approximately
180°F (82°C) and are part of a closed system.

Figure 9-69 Hot Water Boiler

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 Components associated with hot water boilers for conventional space heating generally
include:

Water temperature/pressure gauge

Pressure relief valve

Low water cut-off

Operating and high limit controls (aquastats)

Components associated with steam boilers include:

Pressure gauge

Pressure relief valve

Low water cut-off

Operating and high limit

controls (pressuretrols)

Water column, gauge glass,

and tri-cocks

Figure 9-70 Steam Boiler

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 Fuel burners associated with boilers include fan assisted and forced draft:

Fan assisted burners utilize a blower on the inlet to the burner to provide 100% of the
combustion air. However, they do not provide enough air pressure to overcome any
restriction of the boiler or breeching.

Fan assisted burners must rely on the draft developed by a stack of sufficient height
and capacity to draw the flue gases through the boiler and boiler
breeching. The fans assisted conversion burner shown (Fig 9-68)
was often used to replaced oil burners on residential boilers.

Figure 9-71 Fan Assisted

Conversion Burner

A forced draft-firing or “power” burner utilizes a burner blower fan of sufficient size
and capacity to provide 100% of the air for combustion, plus enough air pressure
produced by the blower, to overcome the pressure drop through the boiler.

Figure 9-72 Commercial Boiler with Power Burner

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 Conversion of gas -fired appliances must be done in accordance with the manufacturer's
certified conversion instructions.

Conversion of appliances from natural gas to propane or from propane to natural gas is
only permitted if the appliance is certified to be convertible and is marked to this
effect.

When converted from one gas to the other, appliances that are not certified for
conversion shall be treated as new appliances requiring field approval. Only factory
conversion kits provided by the manufacturer are allowed.

When converting, the installer is responsible for ensuring:

Proper installation

Safe operation

Physical condition of appliance and heat exchanger

Obtaining permits if required

Source of fuel being replaced is left in safe and secure condition

Proper operation of venting

Combustion air is checked

Piping is checked and upgraded if required

Proper operation of operating and limit controls

**End of Module - Return to Course and Complete Associated Online Test(s)**

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