Service
INSTALLATION
INSTALLING GAS FURNACES
SELECTING GAS FURNACE SITES
01 Locating furnaces in attics
02 Locating furnaces in crawlspaces
03 Locating furnaces in closets
04 Locating furnaces in basements
05 Locating furnaces in utility rooms
06 Locating furnaces in garages
07 Locating packaged furnaces on rooftops
08 Locating packaged furnaces for outdoor ground level installations
MOUNTING FURNACES
01 How to suspend horizontal furnaces in attics
02 How to suspend horizontal furnaces in crawlspaces
03 How to mount horizontal furnaces on attic floors
04 How to mount upflow / downflow furnaces in closets
05 How to mount upflow / downflow furnaces in basements
06 How to mount upflow / downflow furnaces in utility rooms
07 How to mount upflow / downflow furnaces in garages
08 How to mount packaged furnaces on rooftops
09 How to mount packaged furnaces for outdoor ground level installations
01 Installation of gas piping
02 Installation of field wiring
03 Convert from gas to LP
INSTALLATION OF METAL VENTING SYSTEMS
01 Determination of routing
02 Cutting of metal vent systems to proper length
03 Assembly of metal vent systems
04 Securing of metal vent systems
05 Installation of vent termination
INSTALLATION OF PVC / ABS VENTING SYSTEMS
01 Determination of routing
02 Cutting PVC & ABS pipe to proper length
03 Dry-fitting the assembly
04 Sealing PVC pipe
05 Sealing ABS pipe
06 Securing of pipe
07 Installation of vent termination
INSTALLATION OF CONDENSATE DRAINS FOR CONDENSING F
01 Determination of routing
02 Cutting PVC pipe to proper length
03 Dry-fitting the assembly
04 Sealing PVC pipe
05 Securing of pipe
06 Installation of condensate drain pan - attic installations
07 Installation of condensate drain pumps
DUCT INSTALLATION
DUCT FABRICATION EQUIPMENT
01 Ductboard tools - 90 V-groove, end cutoff, female shiplap, hole cutter, stapler, etc.
02 Flex tools - tensioning strap tools, knives, etc.
03 Metal tools - metal snips, sheers, benders, breaks, hand formers, calipers, rulers, stapler,
etc. - Recommended AC Installer
FIELD CONSTRUCTION / INSTALLATION
01 Ductboard installation technique
02 Techniques for joining dissimilar duct
03 Duct of alternate materials - wood, aluminum, etc.
INSTALLING METAL DUCT
01 Assembly methods for rectangular duct
02 Installation technique - rectangular metal
03 Assembly methods for round duct
04 Installation technique - round metal
05 Hanging ductwork
06 Sealing metal duct
07 Insulation - internal and external, vapor barriers
08 Assembling for low noise and low pressure drop
INSTALLING FLEXIBLE DUCT
01 Assembly methods - appropriate length
02 Flexible duct joints
03 Hanging flexible duct
04 Installation technique - flex duct
05 Sealing flexible duct
INSTALLING DUCTBOARD
01 Assembly methods for ductboard - supports
02 Installation technique - ductboard
03 Hanging methods for ductboard
04 Sealing ductboard
INSTALLING GRILLES, REGISTERS, DIFFUSERS, & DAMPER
01 Mounting to ductowrk
02 Securing methods
CHASES USED AS DUCTS
01 Floor joists as air ducts
02 Vertical chases
RECONNECTING DUCT WHEN REPLACING EQUIPMENT
01 Reconnecting metal duct
02 Reconnecting flexible duct
03 Reconnecting ductboard duct
INSTALLATION OF PLENUMS AND DUCTS
01 Sizing plenums for physical fit
02 Types and styles of plenums selected for oil furnace
03 Insualtion of plenums
INSTALLING ACCESSORIES
INSTALLING THERMOSTATS
01 Locating and mounting
02 Wiring electromechanical thermostats
03 Wiring electronic thermostats
04 Programming of electronic thermostats
INSTALLING HUMIDIFIERS
01 Installing humidifiers
02 Wiring humidifiers
03 Controlling humidifiers
INSTALLING ELECTRONIC AIR CLEANERS
01 Installing electronic air cleaners
02 Wiring electronic air cleaners
03 Controlling electronic air cleaners
INSTALLING ECONOMIZERS
01 Installing economizers
02 Wiring economizers
03 Controlling economizers
START-UP AND CHECKOUT
PRE-START PROCEDURES
01 Gas supply and proper shutoff
02 Electrical
03 Adequate combustion air provisions
04 Venting system
05 Ductwork system
06 Condensate system
START-UP PROCEDURES AND CHECKS
01 Voltage checks
02 Check thermostat and set heat anticipator
03 Motor checks
04 Airflow checks
05 Check call for heat sequences
06 Manifold gas pressure check
07 Flame quality check
08 Firing rate
LEAK DETECTION TOOLS
01 Soap solution
02 Electronic leak detectors
03 Ultrasonic leak detector
04 Pressurization for leak detection
05 Meter calibration and maintenance
AIRFLOW MEASUREMENTS
AIRFLOW VELOCITY MEASUREMENTS
01 Pitot tube and manometer in measuring static pressure
02 Discharge velocity equipment
03 Velometer - electronic and mechanical
04 Anemometer
05 Velocity measurement procedures
06 Gauge calibration
07 Introduction to airflow in Residential HVAC
08 Velocity
AIRFLOW PRESSURE MEASUREMENTS
01 Overview of static pressure measurements
02 Inclined manometer
03 Diaphragm type differential pressure gauge
04 U-tube manometer
05 Electronic manometer / pressure measurement
06 Gauge / meter calibration
07 Absolute vs. Gauge Pressure
08 Static pressure
09 Air pressure measurement terminology
10 Velocity pressure
11 Total pressure
AIR VOLUME MEASUREMENTS
01 Airflow hood
02 Formulae for determining CFM of air
03 Formulae for weight of air
04 Locations for air volume measurements
05 Airflow volume - CFM / SCFM (Static CFM)
SERVICE
PREVENTIVE MAINTENANCE
MECHANICAL PM CHECKS
01 Filters
02 Lubrication
03 Packaged unit cabinet care
04 Fan blades / blower scroll
05 Gas connections
06 Flue / vent stack inspection
07 Combustion air supply
08 Duct
09 Heat exchanger
10 Burner assembly
11 Airflow
ELECTRICAL PM CHECKS
01 General wiring
02 Induced draft motor
03 Supply air motor
04 Operation sequence
COMBUSTION PM CHECKS
01 Sequence of operation checks
02 Air intake / exhaust
03 Flame color
04 Flame size
05 Ignition
06 Temperature rise
DIAGNOSTICS
TROUBLESHOOTING SEQUENCE OF OPERATION
01 Check for proper sequence of operation
02 Interpreting system at sequence interruption
ANALYZING REPORTED SYMPTOMS
01 Insufficient / no heat
02 Short cycle
03 Humidity problems
04 Drafty
05 Noise problems
06 System runs continuously
07 High utility bills
08 Wide swings in room temperatures
09 Air quality
SYSTEM AIR SIDE DIAGNOSTICS
01 Temperature checks
02 Check system static pressure
03 Check system velocity
ELECTRICAL CIRCUIT CHECKS
01 Supply voltage
02 Indoor blowers
03 Wall thermostat
04 Transformers
05 Electronic controllers - input / output
06 Flame rectification
07 Pilot ignition
08 Thermocouple / power pile generator
09 Gas valve
ELECTRICAL COMPONENT CHECKS
01 Thermostat
02 Transformers
03 Fuses and breakers
04 Relays and contactors
05 Capacitors
06 Pressure controls
07 Limit controls
08 Centrifugal switch
09 Door interlock switch
REPAIR
01 Electrical wiring
02 Electrical components
03 Fuel supply
04 Flue stack / venting system
05 Condensate / drain system
REPLACEMENTS
01 Transformers
02 Relays and contactors
03 Indoor blowers
04 Capacitors
05 Heat exchanger
06 Gas valve
07 Safety circuit switches
08 Draft motor
09 Pilot / ignitor assembly
10 Flame sensing rod
VENT SYSTEM CHECKS
01 Natural / gravity draft
02 Forced draft
DIAGNOSING GAS COMBUSTION PROBLEMS
01 Flame "roll-out"
02 Flame "lift-off"
03 Discolored flame
04 Intermittent flame
05 Partial burner flame
06 Delayed ignition
07 Carbon build up
08 Flashback
09 Trip on high limit
10 Carbon Monoxide
OVERVIEW OF ELECTRICAL TROUBLESHOOTING
LOW VOLTAGE CIRCUITS
01 Voltage tests
02 Control string analysis
03 Understanding the logic of low voltage troubleshooting
04 Troubleshooting equipment with electronic devices.
05 Troubleshooting with schematics
06 Troubleshooting without schematics
07 Current tests
08 Equipment continuity tests
09 Ground tests
LINE VOLTAGE CIRCUITS
01 Voltage tests
02 Current tests
03 Component tests
04 Circuit tracing line voltages
05 Troubleshooting with schematics
06 Troubleshooting without schematics
07 Equipment continuity tests
08 Ground tests
GAS PRESSURE MEASUREMENTS & DETECTION
PRESSURE MEASUREMENTS
01 Manometer
02 Dial gauge
LEAK DETECTION
01 Leak detection solution
02 Electronic leak detectors
FLUE GAS ANALYSIS & LEAK DETECTION
FLUE GAS ANALYSIS
01 O2 measurements
02 Carbon Dioxide measurements
LEAK DETECTION
01 Carbon Monoxide detector - electrical
02 Carbon Monoxide detector - manual-monoxor
AIR BALANCING
GATHERING DESIGN INFORMATION
01 Interpreting plans
02 Interpreting specifications
03 Interpreting equipment information
04 Interpreting control data
05 Modifying plans
PREPARATION OF SYSTEM FOR AIR TESTS
01 Locating registers, grilles, equipment, controls, and dampers in building walkthrough
02 Setting dampers for tests
03 Setting thermostat for tests
04 Checking for proper fan operation and rotation
05 Checking for proper static pressure and temperature
PROCEDURES FOR CONDUCTING AIR TESTS
01 Measurements of each supply outlet - total readings
02 Measurements of each return inlet - total readings
MAKING ADJUSTMENTS
01 Adjust airflow to achieve required total airflow
02 Re-measure total supply and return grille airflow
03 Adjust dampers to obtain design airflow
04 Re-measure total airflow to verify that it is within +/- 10%
FINAL TEST
01 Comparing manufacturer's equipment information with test results
02 Record sheave, pulley, and belt sizes data
03 Test and record full load motor amperes
04 Test and record voltage
05 Test and record motor and fan RPM
06 Test and record supply and return static pressures
07 Test and record supply and return air temperatures - heat and cool
COMPLETION OF APPROPRIATE FORMS
01 HVAC system report
02 System diagrams
03 Duct traverse or data pulley forms
04 Instrument list - including calibration dates
BASIC HVAC SYSTEM ANALYSIS
NOISE PROBLEMS
01 Interpreting supply / return air volume
02 Interpreting supply / return air velocity
03 Noise problems
04 Blower cavitation
05 Oil canning
06 Motor / belt noise
07 Vibration
HIGH UTILITY BILLS
01 Interpreting supply / return air temperature
02 Interpreting supply / return air volume
03 Evaluating duct leakage
04 Evaluating duct insulation
05 Envelope infiltration
06 Thermostat air sensing
WIDE TEMPERATURE SWINGS
01 Interpreting supply / return air temperature
02 Interpreting supply / return air volume
03 Evaluating duct leakage
04 Evaluating duct insulation
05 Envelope infiltration
06 Thermostat air sensing
SINGLE AREA IS HOT OR COLD
01 Interpreting supply / return air temperature
02 Interpreting supply / return air volume
03 Evaluating duct leakage
04 Evaluating duct insulation
05 Envelope infiltration
06 Thermostat air sensing
INDOOR AIR QUALITY
01 Number of air changes per hour
02 Odor control
03 Contaminants
ANALYZING REPORTED SYMPTOMS IN HEATING
POOR HEATING
01 Interpreting supply / return air temperature
02 Interpreting supply / return air volume
03 Interpreting supply / return air velocity
04 Evaluating duct leakage
05 Using temperature drop across evaporator coil
HUMIDITY PROBLEMS
01 Interpreting wet bulb and dry bulb temperatures
02 Interpreting supply / return air volume
03 Determining the need for additional humidity
04 Evaluating duct leakage
DRAFTY
01 Interpreting supply / return air temperature
02 Interpreting supply / return air volume
03 Interpreting supply / return air velocity
SYSTEM COMPONENTS
INTRODUCTION TO BASIC SYSTEMS & COMPONENTS
HEAT TRANSFER
01 Fundamentals of heat transfer
02 Psychrometrics
FURNACE CONFIGURATIONS & APPLICATIONS
GAS FURNACES WITH SPLIT SYSTEM AIR CONDITIONER
01 Introduction to gas furnace with split system AC
02 Electrical layouts
03 Specifications
04 Attic layouts
05 Crawlspace layouts
06 Closet layouts
07 Basement layouts
08 Ventilation options
09 Regional considerations
MULTI-POSITION FURNACE
01 Four-way
02 Three-way
03 Two-way
PACKAGED GAS FURNACE SYSTEMS
01 Introduction to package gas furnace systems
02 Electrical layouts
03 Specifications
04 Single story applications
05 Multi-story applications
06 Applied with crawlspace duct designs
07 Ventilation options
08 Economizer options
09 Regional considerations
COMBUSTION PROCESS FOR GAS FURNACES
COMBUSTION - NATURAL GAS
01 Describe methane's role in combustion
02 Describe carbon dioxide as a product of combustion
03 Describe oxygen's role in combustion
04 Describe carbon monoxide as a product of combustion
05 Describe ethane's role in combustion
COMBUSTION - MANUFACTURED GAS
01 Describe liquefied petroleum's role in combustion
02 Describe butane's role in combustion
03 Describe propane's role in combustion
FUNDAMENTALS OF GAS COMBUSTION SYSTEMS
01 Category I - Negative pressure vent - non-condensing
02 Category II - Negative pressure vent - condensing
03 Category III - Positive pressure vent - non-condensing
04 Category IV - Positive pressure vent - condensing
NATURAL DRAFT GAS FURNACE - COMPONENTS
HEAT EXCHANGERS
01 Clamshell construction
02 Materials
BURNERS
01 Describe ribbon burners
COMBUSTION AIR REQUIREMENTS
DIRECT VENT (OUTDOOR AIR) SPECIFICATIONS
01 Attic applications
02 Crawlspace applications
03 Closet applications
04 Basement applications
05 Rooftop applications
NON-DIRECT VENT (INDOOR AIR) SPECIFICATIONS
01 Attic applications
02 Crawlspace applications
03 Closet applications
04 Basement applications
AIR DISTRIBUTION
DUCT SYSTEMS
01 Duct system design
02 Duct configurations
03 Return configurations
04 Return grille locations
05 Supply locations
SUPPLY BLOWERS
01 Introduction to supply blowers
02 Supply blowers - types and selection
03 Blower operation
04 Fan laws
WIRING LAYOUTS
POWER WIRING
01 Power wiring for package unit furnace
02 Power wiring for split system furnace
LOW VOLTAGE
01 Overview of low voltage wiring
NATURAL DRAFT GAS FURNACE - OPERATION
GAS FURNACE - OPERATION
01 Overview of operation for standing pilot furnace
02 Overview of operation for intermittent pilot furnace
03 Overview of operation for direct ignition furnace
STANDING PILOT IGNITION
01 Basics of operation
02 Flame switch type
03 Thermocouple type
INTERMITTENT PILOT IGNITION
01 Spark ignited pilots
02 Hot surface ignited pilots
DIRECT IGNITION
01 Spark ignited
02 Hot surface ignition (HSI)
VENT SYSTEMS
01 Fundamentals of gravity flow draft systems
02 Horizontal vent systems
SEQUENCE OF OPERATION
01 Typical operation for standing pilot furnace
02 Typical operation for intermittent pilot furnace
03 Typical operation for direct ignition furnace
CONTROL FUNCTIONS
01 Fan control
02 Heat exchanger limit control
03 Roll-out switch
04 Flame proving - flame switch and thermocouple
05 Gas valve
06 Door interlocks
INDUCED DRAFT NON-CONDENSING - COMPONENTS
HEAT EXCHANGERS
01 Clamshell construction
02 Materials
03 Tubular
BURNERS
01 Describe ribbon burners
02 Describe in-shot burners
INDUCED DRAFT BLOWERS
01 Introduction
02 Role in system operation
INDUCED DRAFT NON-CONDENSING - OPERATION
GAS FURNACE - OPERATION
01 Overview of operation for standing pilot furnace
02 Overview of operation for intermittent pilot furnace
03 Overview of operation for direct ignition furnace
STANDING PILOT IGNITION
01 Basics of operation
02 Flame switch type
03 Thermocouple type
INTERMITTENT PILOT IGNITION
01 Spark ignited pilots
02 Hot surface ignited pilots
DIRECT IGNITION
01 Spark ignited
02 Hot surface ignition (HSI)
VENT SYSTEMS
01 Vertical vent systems
02 Horizontal vent systems
SEQUENCE OF OPERATION
01 Typical operation for standing pilot furnace
02 Typical operation for intermittent pilot furnace
03 Typical operation for direct ignition furnace
CONTROL FUNCTIONS
01 Fan control
02 Heat exchanger limit control
03 Roll-out switch
04 Flame proving - flame sensor and thermocouple
05 Pressure proving switch
06 Gas valve
07 Door interlocks
08 Ignition control
INDUCED DRAFT CONDENSING - COMPONENTS
HEAT EXCHANGERS
01 Clamshell construction
02 Materials
03 Tubular
04 Secondary heat exchanger
BURNERS
01 Describe in-shot burners
INDUCED DRAFT BLOWERS
01 Introduction
02 Role in system operation
INDUCED DRAFT CONDENSING - OPERATION
GAS FURNACE - OPERATION
01 Overview of operation for intermittent pilot furnace
02 Overview of operation for direct ignition furnace
INTERMITTENT PILOT IGNITION
01 Spark ignited pilots
02 Hot surface ignited pilots
DIRECT IGNITION
01 Spark ignited
02 Hot surface ignition (HSI)
VENT SYSTEMS
01 Vertical vent systems
02 Horizontal vent systems
SEQUENCE OF OPERATION
01 Typical operation for intermittent pilot furnace
02 Typical operation for direct ignition furnace
CONTROL FUNCTIONS
01 Fan control
02 Heat exchanger limit control
03 Roll-out switch
04 Flame proving - flame sensor and thermocouple
05 Pressure proving switch
06 Gas valve
07 Door interlocks
08 Ignition control
09 Condensate proving switch
NON-SENSING CONTROLS
RELAYS AND CONTACTORS
01 Introduction to relays and contactors
02 Basics of relay and contactor operation - inrush and holding
03 Selecting relays and contactors
04 Application considerations for relays and contactors
GAS VALVES - SINGLE STAGE
01 Basics of construction
02 Basics of operation
03 Slow opening valves
04 Snap opening valves
05 Step opening valves
GAS VALVES - TWO STAGE
01 Basics of construction
02 Basics of operation
IGNITION CONTROL SYSTEMS
OVERVIEW OF IGNITION CONTROLS
01 Elements of gas furnace ignition systems
02 Introduction to ignition controls for natural draft / standing pilot furnaces / manually lit
03 Introduction to ignition controls for induced draft / intermittent pilot spark ignition systems
04 Introduction to ignition controls for induced draft / intermittent pilot hot surface ignition systems
05 Introduction to ignition controls for induced draft / direct ignition / spark ignition systems
06 Introduction to ignition controls for induced draft / direct ignition / hot surface ignition systems
STANDING PILOT
01 Components and functions
02 Ignition sequence
03 Safety
INTERMITTENT PILOT
01 Components and functions
02 Ignition sequence
03 Safety
DIRECT IGNITION
01 Components and functions
02 Ignition sequence
03 Safety
ELECTRONIC CONTROLS
OVERVIEW OF ELECTRONIC CONTROLLERS
01 Input / output operations
02 Logic
ELECTRONIC THERMOSTATS
01 Fundamentals of electronic thermostats
02 Selecting electronic thermostats
03 Overview of electronic thermostat operation
04 Fossil fuel kits
ELECTRONIC TIMERS
01 Introduction to blower delay timers
ELECTROMECHANICAL SENSING CONTROLS
ELECTROMECHANICAL WALL THERMOSTATS
01 Basic thermostat types and operation
02 Selecting wall thermostats and sub-bases
03 Thermostat terminals and wiring
04 Using electromechanical thermostats
05 Selecting location
ELECTROMECHANICAL TEMPERATURE CONTROLS
01 Introduction to bimetal controls
02 Disc type temperature limit controls
03 Fuses and fuse links
04 Fossil fuel kits
05 Motor overloads
PRESSURE CONTROLS
01 Operation of pressure controls
02 Using pressure controls
03 Combustion air proving (pressure) switch
APPLIED KNOWLEDGE: REGS, CODES, & DESIGN
EPA REGULATIONS
EPA INDOOR AIR QUALITY
01 Fresh air supplies
NATIONAL ELECTRICAL CODE
NEC REQUIREMENTS
01 Overview of NEC code
02 Circuit breaker and fuse requirements
03 General wiring practices
04 Class I wire sizing
05 Class II wire sizing
06 Conduit sizing
07 Definitions
08 Safety listings - UL / ARL / ETL
STATE AND LOCAL REGULATIONS AND CODES
STATE AND LOCAL REGULATIONS
01 State requirements for technicians
02 Use of Carbon Monoxide detectors
03 Smoke detector requirements
CODES
01 Plumbing
02 Municipalities
03 Gas furnace for Lt. Commercial
04 Gas furnace for Residential
NATIONAL FIRE PROTECTION ASSOCIATION
REQUIRED COMPONENTS
01 Return air sensors
02 Fire dampers
FIRE PREVENTION
01 Overview of fire prevention
VENTING REQUIREMENTS
01 Specifications for venting
02 Types of venting systems to be used
DESIGN CONSIDERATIONS - TOTAL COMFORT
TEMPERATURE
01 Designing for capacity
02 Using ASHRAE standards
HUMIDITY
01 Role of humidity in total comfort
02 Using ASHRAE standards
INDOOR AIR QUALITY
01 Ventilation - total comfort
02 Air cleaning for total comfort
03 ASHRAE standards for air quality
SOUND LEVEL
01 Equipment location considerations
02 Isolation, mounting pad, duct, and structure
DESIGN CONSIDERATIONS - GAS FURNACE EQUIPMENT
GAS FURNACES WITH SPLIT SYSTEM AIR CONDITIONER
01 System designs - closets, basements, etc.
02 Equipment location
03 Electrical layouts
04 Ventilation - fresh air
05 Regional design considerations
06 Combustion flue gases
07 Ventilation - equipment
08 Condensate drains / pans
09 Mounting of equipment
10 Combustion air
11 Fuel gas atmospheric burner - forced air system
PACKAGED SYSTEMS
01 System designs
02 Equipment location
03 Electrical layouts
04 Ventilation - fresh air
05 Mounting of equipment
06 Combustion air
COMBUSTION GAS VENTING
01 Sizing flue pipe - AGA tables
02 Flue pipe layout - AGA tables
03 Adapting vent draft control - damper
04 Roof fittings - cap, collar, flashing, etc.
05 Pipe types - PVC and B-metal
DESIGN CONSIDERATIONS - EXTERNAL COMPONENTS
DIFFUSERS, REGISTERS, AND GRILLES
01 Selecting diffusers, grilles, and registers for capacity
02 Selecting diffusers, grilles, and registers for reduced sound
03 Selecting diffusers, grilles, and registers for throws, spread, and pressure drop
04 Locations
ACCESSORIES
01 Humidifier sizing
02 Retrofit automatic ignition kits
03 Electronic air cleaners (EAC's)
MECHANICAL CODE
COMBUSTION AIR
01 Sizing air intakes in confined spaces
02 Sources of combustion air
FURNACE ACCESS
01 Access to furnace
02 Access to service panel
GAS PIPING
01 Sizing for capacity
02 Length limitations
03 Attachment to appliance
INDUSTRY STANDARDS
EQUIPMENT STANDARDS
01 Introduction to industry standards
02 ARI / IAS standards for ratings
SYSTEM STANDARDS
01 Introduction to industry standards
02 ASHRAE standards
BIDS AND PROPOSALS
SYSTEM SIZING
01 Survey of requirements
02 Selecting equipment
03 Sizing components
04 Adding accessories
05 Basic calculation of heating loads
ESTIMATING INSTALLATION
01 Installation price
02 Understanding proposal forms
03 Understanding bid forms - bid to specs and flat rate pricing
04 Legal implications of a bid
EFFECT OF ELECTRICAL SUPPLY ON BID
01 Effects of electrical power on bid
02 Electrical analysis - power