Piping & Tubing Systems Tests

Module 10: Advanced Piping & Tubing Systems

• Pressure drop refers to the difference in working pressure between the gas meter outlet and the appliance regulator inlet.
• High-pressure testing must occur before appliances are installed
• Refer to clause 6.22.2b for details
• Code mandates the use of three specific tests: high pressure, leak test using meter/manometer, and leak test with liquid solution

Types of tests

• High-pressure testing requires disconnecting the piping at the gas meter and before the appliance valve train
• Minimum permissible test time and pressure can be found in table 6.3
• Leak test utilizes the lowest volume test dial on the meter or a manometer to test when the meter and appliance are connected
• Leak test operates under normal operating pressure for 10 minutes
• Leak tests employing liquid solutions (bubble tests) are conducted at normal operating pressure, checking all fittings for leaks
• Another leak detection method involves using a manometer for systems up to 14" wc

System Safety and Valves

• Purging gas systems should use hoses equipped with "dead man's" handles
• Systems exceeding 400,000 BTU/hr can be purged to an open burner
• Manual valves present in gas systems are 1/4 turn valves
• Manual shut-off valves contain a break point (weak point) and must be installed so the weak point is oriented to the appliances side
• Manual shut-off valves can be installed either indoors or outdoors
• A valve marked with '#3.16' on its handle or body is approved for outdoor use

Piping Codes and Standards

• (6.1.1) Piping or tubing systems should consist of steel, copper, or plastic
• (6.1.2) Reusing piping, tubing, and fittings requires cleaning, inspection, testing, and ensuring equal performance to new materials
• (6.2.1) Piping has to comply with ASTM A53/ASTM A106 standards
• (6.2.2) Fittings used with steel pipe must be made of either iron or steel
• (6.2.3.1) Gas piping operating at pressures up to 125 Psig needs to be at least schedule 10 NPS ½ - 2”
• (6.2.4) Copper tubing should be Type G, Type K, or Type L for gas systems
• (6.2.8) Underground copper tubing must be Type L or Type G
• (6.2.10) Hoses and fittings should have a minimum working pressure of 350 Psig
• (6.2.17) Only plastic is approved for underground outdoor gas service
• (6.3.9) Concealed piping must be NPS ½” or greater
• (6.7.2(a)) Stairwells, apart from those in dwelling units, cannot have pipes or tubing installed
• (6.7.2(b)) Piping or tubing can be installed in a dumbwaiter
• (6.8.3) Table 6.2 provides the table for the spacing of supports
• (6.9.1) Steel piping joints must be threaded, flanged, press-connected, or welded
• (6.9.2) Piping of NPS 2-½” and over requires welded pipe joints
• (6.9.6) Jointing sealant usage is contingent on certification to CAN/ULC-S642
• (6.9.7) Gasket material cannot be natural rubber

Module 11: Basic Electricity

• Volts (E) denotes pressure
• Amperage (I) Flow indicates flow
• Ohm (R) indicates resistance
• Watt (P) is a measure of power
• 1 Watt is equivalent to 3.41 Btu/hr
• Equations: E=IxR, I=E/R, R=E/I
• 1 kilowatt equals 1000 watts
• To optimize meter accuracy when values are unknown, select the highest value, then readjust the meter to center the scale
• Ammeters are to be read in series with the electrical power switched on
• Voltmeters are to be read in parallel with the electrical power switched on
• Ohmmeters are read across a disconnected device or circuit with the electrical power switched off

Components of an Electrical Circuit

• Source: e.g. a transformer, which functions as both a source and a load
• Path: A conductive pathway for current flow
• Controllers: elements that regulate a circuit's operation and are classified diversely
• Loads: devices or components that consume power in the circuit
• Manual controllers: main disconnect switches
• Automatic controllers: temperature, pressure, and flow controls
• Operating controls: normally left in the open position
• Safety controls: normally found in the closed position
• Short circuit: Caused by bypassing the load in a circuit
• Result: Triggers overcurrent and the tripping of circuit breakers or fuses
• Relays: switch contacts are designated similarly to the coil that operates it on schematic diagrams
• Contactors: function similar to relays but handle higher currents, like those of a motor
• Transformers: exclusively applicable to AC, not DC
• Transformers: Rated based on the volt-amperes (VA) that the secondary winding handles

Fundamental Motor Principles

• Motors: rely on electromagnetism for operation
• Stator: electrical current creates a magnetic field at each pole via coiled wires
• Rotor: rotational component due to shifts in magnetism
• Horsepower: More horsepower implies greater amperage
• Electrical wire insulation: provides protection and ensures safe circuit operation
• NMD: suitable exclusively for dry environments
• NMW: usable in damp settings
• Unsheathed conductors intended for outdoor applications must be run in liquid-tight conduit
• BX cable/armoured cable

Electrical Conductors

• TEK (watertight BX cable)
• Electrical Conductors (referenced from C.E.C 2006)
• 14 AWG: Rated for 15 amps
• 12 AWG: Rated for 20 amps
• 10 AWG: Rated for 30 amps
• Over-fusing a circuit: May lead to overheating and fire
• Conductors: Can be either solid or stranded
• Resistance: Increases with conductor length
• Resistance: Decreases with larger conductor diameter as its resistance decreases
• Increased resistance: Causes an increase in voltage drop along the conductor

Combination Panels and Systems

• Supply voltage: In residential systems, it is 240/1/60
• Minimum panel size: At 100 amps
• Important: Ground is not neutral
• Components of electrical distribution system: electrical meter, main switch disconnect, fuses or circuit breaker, distribution panel, wire conductors
• Service conductor composition: Service conductors in residential distribution includes two hot wires, one neutral wire, and one ground wire

Safety and Wiring

• GFCI: Used in wet locations
• Detects minor amperage leakages to ground (5mA)
• Single phase wiring: supply voltage is 240V
• Small appliances: Use 120V (with a neutral wire)
• Three phase power: Used in commercial and industrial applications at (208-230v) or (575v)
• Composition: Involves three live wires and a ground
• Characteristics: Higher starting torque and lower amperage than single phase
• Pictorial Diagrams: Illustrate physical locations of wires/components
• Connection Diagram: Shows the connectivity/wiring of components, similar to pictorial diagrams, used for wiring or tracing
• Ladder or Schematic Diagrams: Illustrate circuit operation and component functions
• Contacts: Have same designation as their control coils
• Main disconnect: Shown open
• Condition: Switches are shown normally, used for troubleshooting Electrical Symbols
• Electrical service supplied to a building is measured in Amperes (Amps)
• A bonding conductor connects the non current carrying parts of electrical equipment, raceways, and enclosures to the ground.
• The unit of electromotive force is volts
• 4 components of an electrical circuit: Source, Path, Controllers, Loads
• Unsheathed conductors run outdoors must be in liquid-tight conduit
• Bypassing a load will cause the system to short circuit

Module 12: Controls–Mechanical & Electronic: Call for Heat

• Gas valve energizes by bringing on the heat.
• Fan control closes upon reaching set temp (140°F).
• Blower motor begins.
• A call for heat has been satisfied but the thermostat opens.
• The gas valve de-energizes.
• Fan control opens once the temperature cools to the set point (90°F).
• Last, the blower motor shuts off.
• System in standby.

Thermostats

• Function normally open (falls when the temp is low, opens when reaching its set temperature)
• Heating of the bimetallic sensor is known for sensing the movement of the mercury bulb to close and opens the control switch
• They control valve and ignition and are set in series with a gas.
• 750mv (low voltage has to be isolated), 24v, 120/240
• Must be located:
• On the inside wall.
• 5 feet of the floor.
• and away from the heat source.

Heat anticipator

• A heating thermostat uses a small resistance heater that fools the thermostat into opening sooner than it normally should, to help moderate the temperature.
• High limit can only be 250°F by code.
• Normally closed Klixon: is built with a snap disc that opens the electrical circuit quickly when an unsafe condition takes place.
• Fan limit control: Action of heated bi-metal spiral causes a switch to open and can be wired by 24v or 120v circuit
• some high limits are manual resets

Fan Control types

• normally open (closes when heat is present)
• Klixon: built with snap action disc switch.
• fan limit control: action of a heated bi-metal spiral causes switch to close (140 or 150°F).
• Door switch.
• When closed, activates when the fan blows hot air with the need of a heat exchanger, if not, it'll just blow cool air until the heat exchanger catches up.
• can be wired in 24v (usually energizes a 24v fan relay coil)
• or 120v circuit (energizes the furnace fan directly) Normally, close.
• Is a switch on the access panel; when the panel is open, it releases the switch, which deactivates a system.

Flame Rollout

• Is normally closed.
• Switches are triggered by flame flashes backward.
• Indirectly senses failure of the induced draft fan motor or spillage condition in the venting system.
• The sensing element, either capillary or a Klixon disk, has the switch and it snaps open and later, the main gas valve.
• A manual reset must be in place.

Induced Draft Pressure Switch

• Type: Automatic safety control (normally open).
• It senses negative pressure to detect whether an induced fan motor can close.
• The pressure sensing element closes when the induced fan motor is triggered.
• This locks the ignition control sequence.
• if the draft pressure switch opens during the firing process, the main gas valve must de-energize.

Controls Operation

• The controls operation of the main gas valve is if an unsafe venting issue occurs.

Air Flow Sensing Switch

• Type: Automatic safety control (normally open). _ Senses: Airflow developed by an air-moving device. _ Action: The action of the switch occurs when the air closes through a duct.

Depends of the control and Application

• Depending upon the application: An air flow sensing switch must be wired in a series to a: electronic cleaner, humidifier, a electric heater.
• Without airflow, these devices shut down, therefore, the air-sensing switches closes when the furnace cuts.
• Fan Centers are built with devices that centralize air conditioning equipment, and contains:
• A fan center contains: The relay is energized during a call for cooling or 120 - 24 volt transformer and a single pole/double throw relay.
• This causes the closing of the normally open switch and sets the furnace fan to start when centers are built. Is through the normally closed switch of the fan center.

Control is Maintained

• the control is maintained through to the end by the fan limit control and temperature regulator.
• Control of the transformer in the center replaces the transformer in the furnace. Operation and Types of controls Aquastat (Hot Water Boilers): Automatic operating control (normally open), water temperature can be detected, action is maintained when the valve, well or unit closes if the water reaches bellow the safe temperature reading. Valves are designed for gas only, water or pump. Types: Low Water Cut Off: automatic safety control (normally closed), senses the water level to make sure it follows code. It detects water levels; if at any time the level starts to drop, the float switch will open the electrical wire that links the main gas to the unit. Gas Valves, Main gas. Note: When there is a change, a pipe fitter or plumber has to take responsible for the control.
• Safety controls are always closed. Water flow switch: This can be automatic saftey control (normally open), senses if water has developed by the system’s pump, and triggers when there has been paddle operation if the water moves, resulting in the flow of this switch which acts as a safety to the unit as a whole. Pressure control switch: (steam boilers): This has to be automatic, it can work by steam flow, and the pressure in the boiler between can be high/low depending on its pressure reading so its designed properly. With the low pressure switch and high the burner should also start or drop too much steam resulting in more gas emission. Control, it needs to maintain steam pressure as a boiler.

Flame Contol System

• Main valve is: Opens the switch when steam pressure is detected!
• Types of pilots Pilot: A pilot that burns non stomps that are activated over certain timeframes.
• Safety feature need to meet code of 15psi is the highest safety check. Types of pilots:

1. Continuous
2. intermittent
3. interruptedpilots Couplers: This can be caused/defined by an electrical equipment’s ability to contain an electrical system during heat exposure. Operation is best when an area around its circuits is generating higher voltage. To operate: A valve set to a pilot flame needs to show a millivoltage during all operations. It’s best when it generates 25 to 30 millivolts during operation by using common combustion.

Flame Ionization, Rectification, and Rods

• Flame Ionization: The flame must heat energy causing air atom to exist but if energy can transfer electrons as atoms allow the fame rod to activate.

• Flame rectification: Can cause short circuit if there is corrosion on it, better to have ground that is longer than the spark electrode for better performance.. Rods for flame transfer: Rods usually need to project from a smaller metal which can extend to a small metal, the goal is to ensure the rod creates a ground for the circuit and an electrical signal.

• Pilot is mounted with rules such as:

• be located if it can be found easily. Mounted well

• Not too close to the exchanger in order to keep flame strong with air to light it. Good installation with proper testing is key to ensure the flame works with proper voltage usage. And they are also 3 types of pilots you use too:

• Continous pilot: a pilot always lights the entire time.

• Interrrmittent: Lights stay but only work based if there is a burn cycle. Interruption is an element during shut down.

Heat Transfer and Voltage

• When voltage transfers energy its called a thermopile: System needs to protect voltage between 10 during its wire/safety transfer, with features that keep energy within an optimal level if issues ever occur. This is a voltage test. Can contain circuit codes where millivolts are set to its range. There must be a drop test set for min: 2-4v before testing it is used. Or 2-3 to make sure pilot and other sources drop during flame. Must pass pilot test for the pilotstat/time. Must be on for max 90 seconds for residential reasons. During test, use 700 to 800 during code. During close circuit for term open is 6, then with this on anticipation is has to have about 120 before the 50m wire loss for these components/features that have low. Check for easily observable pilot first, then apply burner with air for a proper installation.. It’s best to find clean yellow flame first, if not replace all burners to match correct position with the coupler. Clean the equipment safely, be mindful if you have to use air in any cases to ensure its clean.

Flame Type Classifications

• YELLOW FLAME: Check air opening and install new equipment. WAVING light is cause of issues with air, air flow must be reset and a draft has to exist. SMALL BLUE FLAME can be fixed if there is a change it will increase flow. NOISY LIFTING: Requires air flow to calm gas flow and ensure the setting is adjusted to each job position.

Module 16- Ignition and Operation

All systems follow certain features to sustain safe operation levels.. 18: They must have flame protection measure to ensure to monitor if any irregularity occurs

They often relay gas for burner operation plus, for operation reasons they must sustain 0.7 or higher range for flame to be present, with about 18-150 max . With operation of high levels, lockout during issues such as a spark . Main is safety , it sustains line to reduce major failures. Hot surfaces have burners that are lit but, the best source is what uses silicon carbids for proper performance..

Types operation:

• It needs to have enough vent, be hot for its heat surface if it exists, plus have the best feature for a safety during operation or even when you must test the process: 1): make sure the unit has start checks

2. Check is lighting to start sequence.

• Then continue the pilot light before its gas ignites.
• and follow proper start checks too, including to watch the burner is all.

Ignition Valves and Parts

Parts are used: It contains devices that turn it from gas the device that is used for safety that may be used for burn process. ( this method is not the usual method but it can be) with the amount or its millivolt in system must be able to allow operations with proper install levels or air is not to be released to the machine, with proper intake and exhaust levels to keep everything going that there must be certain voltage before operations due to certain levels..

Operation of Controls

These two have specific factors the device has to follow for the air flow/temp.

The goal is to not contain low amounts for high volume, For the flow they must use about 2-2 at its high point.

• The goal is too cool, these need to remove energy in order for what its needed
• Heat pump requires more than coolant in the air to sustain more and be ready for different situations.

Module 24 Air Control System

• These are looped in an environment to release a large high pressure, some may include:
• Extra notes
• Ducts are residential If air pressure gets small system may lose effectiveness Supply. A line of air that provides the heat needed to ensure air levels

Extended Plenum and Duct Systems

• Is known as the body air and helps the body heat.
• It’s a line that is smaller yet has the large pressure, in homes.
• Its great to have many air and to ensure heat stays in each environment. Lineds are used for sound, air and energy balance.. This can affect temperature and moisture to stay moisture. They consist of materials in hvac, if not the noise of the system is affected