1 Feature Contents CODE NOTE Shut It Down! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lockout/tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PP versus PVC Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fuel Oil and Piping Rules . . . . . . . . . . . . . . . . . . . . . . . 92 Pipe Reducers versus Bushings. . . . . . . . . . . . . . . . 113 PVC versus Polypropylene . . . . . . . . . . . . . . . . . . . . 116 Pressure Relief Valves and Discharge Tubes . . . . . . 156 Low-Water Cutoff Requirements . . . . . . . . . . . . . . . 158 Backflow Prevention. . . . . . . . . . . . . . . . . . . . . . . . . 161 Outdoor Airflow for Ventilation. . . . . . . . . . . . . . . . . 231 Mechanical Code Standards for Radiant Piping Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Proper Combustion and Ventilation Air Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Combustion Air Venting Installation. . . . . . . . . . . . . 302 Venting Requirements. . . . . . . . . . . . . . . . . . . . . . . . 304 Installation in Garages. . . . . . . . . . . . . . . . . . . . . . . . 318 Reducing Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . 328 Condensate Piping Compliance. . . . . . . . . . . . . . . . 329 Meeting Code Requirements . . . . . . . . . . . . . . . . . . 355 Investigate Local Building Codes . . . . . . . . . . . . . . . 405 Installation of Solar Thermal Storage Systems. . . . . 407 Following Electrical Codes . . . . . . . . . . . . . . . . . . . . 408 PROCEDURE Lifting Heavy Objects . . . . . . . . . . . . . . . . . . . . . . . . . 24 Steps for Lockout/tagout . . . . . . . . . . . . . . . . . . . . . . 30 Lighting the Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Diagnosing the Hot Surface Igniter. . . . . . . . . . . . . . . 76 Measuring the Signal Strength of the Flame Rod. . . . 79 Converting a One-Pipe System to a Two-Pipe System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Adjusting the Air Bands . . . . . . . . . . . . . . . . . . . . . . . 96 Recharging the Diaphragm-Type Expansion Tank with Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Hydronic System Piping Design . . . . . . . . . . . . . . . . 134 Installing a Differential Pressure Bypass Valve. . . . . 185 Calculating Pump Size . . . . . . . . . . . . . . . . . . . . . . . 203 Sizing a Finned-Tube Heater. . . . . . . . . . . . . . . . . . . 218 Soldering Copper Tubing. . . . . . . . . . . . . . . . . . . . . . 322 Using Press-Type Fittings. . . . . . . . . . . . . . . . . . . . . 324 Wiring a Cascade Boiler System. . . . . . . . . . . . . . . . 333 TIMEOUT FOR MATH Order of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Finding the Right Size Nozzle. . . . . . . . . . . . . . . . . . . 99 Calculating GPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Calculating Pressure Requirements. . . . . . . . . . . . . 133 Calculating Total Loop Length. . . . . . . . . . . . . . . . . . 259 Calculating Heat Loss. . . . . . . . . . . . . . . . . . . . . . . . 278 Confined or Unconfined? . . . . . . . . . . . . . . . . . . . . . 299 Recovery Rates: Example 1. . . . . . . . . . . . . . . . . . . . 377 Recovery Rates: Example 2. . . . . . . . . . . . . . . . . . . . 378 TROUBLESHOOTING Sensible Heat Formula. . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the Thermopile. . . . . . . . . . . . . . . . . . . . . . 72 Diagnosing a Defective Thermocouple. . . . . . . . . . . . 73 Do Not Be a Parts Changer. . . . . . . . . . . . . . . . . . . . . 97 Diagnosing a Defective Control Board. . . . . . . . . . . 168 Freeing a Struck TRV. . . . . . . . . . . . . . . . . . . . . . . . . 184 Repairing Radiant Tubing Leaks . . . . . . . . . . . . . . . . 249 Diagnosing Sizing Issues. . . . . . . . . . . . . . . . . . . . . . 357 Diagnosing Installation Issues. . . . . . . . . . . . . . . . . . 358 Line-Voltage Issues. . . . . . . . . . . . . . . . . . . . . . . . . . 358 Low-Voltage Issues. . . . . . . . . . . . . . . . . . . . . . . . . . 359 The Hopscotch Method of Troubleshooting. . . . . . . 360 Burner Circuits: Standing Pilots . . . . . . . . . . . . . . . . 360 Burner Circuits: Intermittent Ignition Systems. . . . . 361 Spark Ignition Systems. . . . . . . . . . . . . . . . . . . . . . . 361 Hot Surface Ignition Systems. . . . . . . . . . . . . . . . . . 362 Checking the Flame Rod Signal . . . . . . . . . . . . . . . . 362 Checking Venting Problems. . . . . . . . . . . . . . . . . . . 363 Replacing the Flue Liner. . . . . . . . . . . . . . . . . . . . . . 364 Checking Problems with Combustion Air. . . . . . . . . 365 Circulating Pump Issues. . . . . . . . . . . . . . . . . . . . . . 366 Problems with Air in the System . . . . . . . . . . . . . . . 367 Expansion Tank Problems. . . . . . . . . . . . . . . . . . . . . 371 Descaling a Heat Exchanger. . . . . . . . . . . . . . . . . . . 387