Module 23

Forced Air Add-on

Devices
Most add-on devices are optional, but filters are not. A forced-air
furnace must never be operated without a filter installed. Without
air filtration, dust and lint will build up on the 臼mace’s internal
parts, resulting in loss of efficiency, equipment damage and possi-
ble fire.
Add-on devices such as filters, air cleaners, humidifiers and cooling
coils improve the air quality in a building heated by a forced-air
furnace.
Filters and air cleaners of various kinds remove particulate matter
企om the air. Humidifiers increase the relative humidi帘， increasing
comfort for building occupants. Cooling coils allow the forced-air
furnace to function as a central air conditioner.

At the end of this m。dule you will be able t。：

• select, install and maintain appropriate air 币lters and air

cleaners

• select, install and maintain appropriate humidifiers

• inspect and clean an add-on cooling coil

·t-l
·-
Gas Technician 2 Training - Module 23
C Canadian standards Association
 Ken Bales, Manager, Gas Information Products, CSA, wis~es to acknowledge the following individuals
who contributed as members of a Review Panel during th~ development of the original edition of the
Gas Technician 2 Training Materials. In addition, British C~lumbia Institute of Technology (BCIT) is
acknowledged for its work in the technical development and editing of the original edition.

c。ntribut。rs and members of the Review Panel

John Co忧.er Canadore College

Bill Davies Union Gas Limited
Eric G_rigg Canadore College
Warren Hayes Superior Propane Inc.
Darrel Hilman Southern Alberta Institute of Technology
Ken Kell Centra Gas Manitoba
W. John Lampey Alberta Advanced Education & Career Develoi:jment
Lorne Lowry Algonquin College
Jim Noseworthy Durham College
Gary Prentice Environmental Energy Consultants
Nick Reggi Humber College
Rick Rogozinski Union Gas
Ron Royal Fanshawe College
John Semeniuk Northern Alberta Institute of Technology
Allen Sidock Cambrian College
John Simmons Loyalist College
David Stainrod D.J. Stainrod & Associates Ltd.
Terry Waters Enbridge Consumers Gas

IV Gas Technician 2 Training - Module 23

。 Canadian Standards Association
岛1odule 23
Table of Contents

Unit 1 Air filters and cleaners

Types and applicati。ns ..........................….......... 3

Media filters. …··········································…........ 5

Electrostatic filters .........…................................. 13
Electronic air cleaners .................….........……… .15
Assignment 1 ...........…................……................. 29

Unit 2 Humidifiers
Functi。n and control .............................…......... 33
lnstallati。n .........…............................................. 39

Operation and service ....................................... 43

Assignment 2 ..............…................................... 49

Unit 3 Cooling coils

Checking and cleaning c。。ling coils ................. 53
Assignment 3 ...........…...............….................... 59

Gas Technician 2 Training - Module 23 v

«:> Canadian Standards As四ciation
Unit 1 Air filters and cleaners

Purpose A forced-air furnace cannot be operated without air filtration. The gas
technician must be familiar with the various types of filters available,
be able to install them correctly and instruct customers in their
maintenance to ensure safe, efficient operation of the gas furnace.
It is important 岛r 由e gas technician to understand the advantages and
disadvantages of media and electrostatic filters and electronic air
cleaners, so they can help customers choose the air filtration system
best suited to their needs.

Learning 1. Describe three types of air cleaning equipment (media filters,

electrostatic filters and electronic·air cleaners) that can be used
objectives with forced-air furnaces.

2. Describe the function, installation and maintenance of media

filters.

3. Describe the function, installation and maintenance of electrostatic

filters.

4. Describe the function, installation and maintenance of electrostatic

filters.

Gas Technician 2 Training - Module 23 1

©Canadian S恼ndards Association
 Topics
1. Types and applications! .......................................................”.. 3
Choosing the correct system .J. ....…······· ......................…….......…................4

2. Media filters .................. ~ .................…........…............................ 5

Function ...........…........…........ )..................….........…........…................…….....5
Installation and location ......... !. ................…················…...............................6
· Instructions to the customer ... )............…·····················….................................8
Maintenance and service ....... !. ................….......………······················…......... 12

3. Electrostatic filters ....... …........”··”··”··”..................”··”··….. 13

1

Function ......................…........ )..…········凋….........…........................…….......… .13

Installation and location ......... !. ...........................................…………………... 14
Instructions to the customer ... ). ....................….........................….................. 14
Maintenance and service ..….. !. ............…..................…….......….........…........ 14

4. Electronic air cleaners.I.........….............................................. 15

Function ................................. )...国......................…..........................…........... 15
Installation and location ........ .! .....….........….................….............................. 17
Instructions to the customer.. J. ...…………………..................................……··川21
Maintenance and service ....... !...................................….................................25

Assignment 1...................................…..............................…........ 29
1

2 Gas Techniαan2T1『·aining - Module 23

© Canadian Standards Assoc阳tion
 TOPIC 1

Types αnd αrpplicαtions

All forced-air furnaces require air filtration to operate safely and

efficiently. Some 且rrnaces are intended to be used with specific types of
filters, but in many cases the appropriate filter or air cleaner must be
chosen and added on to the forced-air furnace.

Ensuring proper air cleaning requires effort by both the technician and the
custom阻 All air cleaning devices, whether filters or air cleaners, require
ongoing maintenance and cleaning. Some of this maintenance must be
done by the customer.

The gas technician must understand:

• operation of the filter or air cleaner
• benefits and disadvantages of the-filter or air cleaner
• installation procedures
• requirements for customer cleaning and maintenance
• service procedures.

The customer must understand:

• importance of regular cleaning for efficiency, safety and air quality
• cleaning schedule required for their unit
• cleaning procedures and basic maintenance.

There are three basic possibilities for air filtration, all of which will be
discussed in detail in this Unit.
• Media filters
Media filters, sometimes called mechanical filters, are the simplest
form of air filtration. They are made from such media as fibreglass, and
positioned in the air stream. Air is forced through the filter and particles
removed. The filter media can be reusable or disposable. Media filters
of high, low and medium efficiency are available.
• Electrostatic air filters
Electrostatic air filters are media filters made from a material 由at
generates a static charge in response to air flow. The static charge
attracts particles to the medium.

Gas Technician 2 Training …- Module23 3

© Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

• Electronic air cleaners

Electronic air cleaners (EA<[::) also use an electrostatic charge to remove
and collect particulate cont minants from the circulated air system. The
EAC uses an external powtjr source to generate the charge that attracts
particles, and charged plate~ ， rather than a media filter, to collect them.

Choosing the
correctsyste『Y、 Severa 阳s should be cor ered when choosin
system:
• degree of air cleanliness required
• amount and type of dust in ~he air to be filtered
• operating resistance to airflpw (pressure drop)
space available for filtratio* equipment
initial costs of the system
ongoing costs of maintainiqg or replacing filters
• operating costs, predicted llfe of the system and efficiency of the
system.

Each type of air filtration apprqach has advantages and disadvantages

which are addressed h 也e appropriate topic.

4 Gas Technician 2 Training - Module 23

© Canadian Standards Association
 TOPIC 2

Mediafilteγs

Media filters are the simplest form of air filtration. Two types of media
filters are most commonly used in residential installations: slab filters and
hammock filters. Extended panel filters and moving curtain filters, while
more efficient, are usually used only in industrial or commercial
applications.

Function
Media filters physically remove particles from the air stream.
• Rαmmockfilters
Hammock filters are located on a frame or hammock that surrounds the
fan in the forced-air furnace (see Figure 1-1). If a forced-air furnace is
intended to be used with a hammock filter, the filter holder will be
factory installed.

Figure 1-1 Hammock filter

• Slab filters
Slab filters consist of layers of filter material, usually fibreglass, held in
place by a cardboard frame (Figure 1-2). The fibers are treated with oil
or a similar adhesive. Filters for residential use are usually about one
inch thick. Most slab filters are designed for one-time use and must be
discarded when they are di均＇·

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AIR FILTERS AND CLEANERS UNIT 1

Advantages and dis回dvantages of media filters

• Advantages
initial cost and upkeep *e low
efficient for the removal of lint.
• Disadvantages
low efficiency on norm 1 atmospheric dust
airflow decreases as pat.1ticles collect in filter.

Ins饭 llation
and location Slab filters should be positionelf according to 也e forced-air furnace
manufacturer ’s instructions. In ~ome cases the filter ma~ be installed in the
plenum. When a 由.b-type filtet is installed in a left or r
on an up臼ow furnace the 岛ct卜supplied filter may have to be trimmed to
fit. However, the effective filtet area should be no less than that
recommended by the furnace ntanufacturer.

Sometimes a filter rack must b~ installed to hold the filter in position. The
filter rack is usually located be een the furnace casing and the return-air
plenum.

6 Gas Technician 2 Training - Modu悔 23

。 Canadian S罩ndards Association
UNIT 1 AIR FILTERS AND CLEANERS

Ins阳 lling the filter rack

Appropriately-sized filter racks will usually be shipped with the furnace
that uses them. They are most commonly installed on furnaces with a side
au return.
1. The side of the furnace cabinet will likely have embossed angles
indicating the location of 也e racks (Figure 1-3a).
2. Cut the return opening, using the angles as guides.
3. Mount the filter rack over the opening (Figure 1-3b).
4. Proceed with the duct work.

、，

(b)
Embossed
angles

Figure 1-3 Installing a filter rack

Impact on air flow

All media filters, whe也er mechanical or electrostatic, add resistance to air
flow. The thickness of the filter should con岛rm to original 也ickness
specifications for the 岛reed air furnace. Adding extra filters to the filter
chamber in an a忧empt to improve indoor air quality can seriously 泊pede
furnace operation. This should be explained to 由e customer.

As filters fill with particles，也e air volume flowing through them decrease.
Restrictions in air flow cause problems in both heating and cooling units.
Abnormally high circulating air temperatures can occur in heating cycles,
causing the furnace to switch off on 也e high limit control. Freeze-ups can
occur in cooling cycles.

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© Canadian Standards Association
 AIR FILTERS AND CLEANERS UNIT 1

Instructions
to the Regular cleani吨。fair cleaner~ and filters is crucial for optimum cleaner
customer efficiency.

Di向r filters:
• are th ost com町lOI
performance
• creat mp删ure char 叫at are 由tr:
furnace
• decrease operational presstjres in systems with add-on air conditioni吨，
causing floodback which d~mages the compressor
• cost mone弘 since exce回Vf accumulation can block the 削ow,
岛rcing the unit to work harder and use more energy.

Filter cleaning must be done o];i a regular, and frequent, basis-more

frequently than service calls a ·~required. It is the responsibility of the gas
technician to point out the filte~ ＇s location to the user and to establish a
filter change or cleaning schedµIe. The gas technician must be sure the
customer understands the insta~lation procedure for new filters, and knows
what size and type of filter is 呻quired.

Caution!

A A forced-air卢rnace must nev~r be operated without a filter installed. Dust

and lint will build up on the卢阳aces internal parts, resulting in loss of effi-
ciency, equ伊ment damage and, possible fire.

Replacing and clea~ing filters

Filters should be inspected ev~ry month in 由e heating season, and cleaned
or replaced as required. They .Pust be cleaned or replaced at least twice a
ye矶 and any tin削hey become clogged.

. Replacement furnace filters arf available 丘。m the dealer. The replacement
filter must be the same size an~ type as was originally supplied with the
furnace.
在 JW
地警；

8 Gas T假如nician 2 Training - Module 23

© Canadian Standards Assoc阳tion
UNIT 1 AIR FILTERS AND CLEANERS

Downflow furnaces

Downflow furnaces contain two or four disposable slab air filters. They are
located in a filter cabinet on top of the furnace (Figure 1-4). Typical filter
replacement instructions follow.
1. Remove the two screws holding the filter box door in place and remove
the filter box door assembly.
2. Pull the filters out of the box, flexing them as necessary to get them
past the flue pipe.
3. Insert the replacement filters. Make sure they are properly positioned in
retaining clips on the back panel.
4. Re-install the filter box door assembly and secure it with the two
screws.

Remove filters
from right side

Figure 1-4 Typical filter position on a downflow furnace·

Upflow furnaces

Upflow furnaces may contain a cleanable, re-usable hammock filter within

the furnace blower compartment in either a bottom or side (left or right)
return air inlet. Figure 1-5 illustrates these two options.
1. Power to the unit must be disconnected before the blower door is
removed.
2. Remove the blower access door.

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©Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

3. Loosen the filter retaining "lfvire at the front of the unit.

4. When replacing the cleane4 filter, make sure the filter retaining wire is
secured in place at b时h th front and back of the unit.
5. Replace the blower access ~oor and restore 出e power.

Filter
retainer

Blower access
door

Figure 1-5 Possible ~lter positions on an upflow furnace

Filter frames

Filters may be located outside 出e furnace in a filter frame (Figure 1-6).

ηie filters in a filter frame may be either disposable or re-usable slab
filters. They should slide out eljlsily for replacement (if disposable) or
cleaning (if re-usable).

Figure 1-6 Access to filters in a side filter frame

Specific media filters

Consult the manu臼ctur町、 in~tructions for the specific w让t before
showing the customer how to replace or clean the filter. The instructions
here are provided as a general !guideline_

10 Gas Te<如nician 2 Training - Module 23

© Canadian Standa『[Link]<副ation
UNIT 1 AIR FILTERS AND CLEANERS

Hammock filters

Hammock filters usually contain disposable filter material that must be

replaced, as described below.
1. Before you remove the filter unit, place a floor covering material on the
floor.
2. Slide the entire filter out of the unit.
3. Loosen the screws 也at hold the media to the rack and remove it.
4. Wrap the old media in newspaper and discard it.
5. Unroll new media and cut it to the correct size.
6. Attach the media to the rack. One side of the media is usually coated
with oil, to enhance particle collection. This coated side should be
opposite the blower. (In an up-flow unit, the coated side will face
down.)
7. Slide the filter back into the blower compartment.

Re-usable slab filters

Re-usable slab filters are made from polyure出ane and coated with an oil-
based filter spray.
1. Remove the filter from 由e unit.
2. Remove the media from the filter 企ame

3. Wash or vacuum the media. Use hot water and detergent for washing.
4. Squeeze water from the media and return it to 由e frame.
5. Coat the side of the media opposite the blower with a filter spray to
enhance particle collection. The filter spray must be applied before the
filter is repositioned in the furnace. Do not re-oil the filter in place. If
re-oiling is done while the filter is in position, oil will be sprayed on 由e
blower assembly and heat exchange surfaces.
6. Reposition the filter in the unit.

Gas Technician 2 Training - Module 23 11

© Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

Disposable slab

Disposable slab filters are usua~ly made from fibreglass and cardboard.
1. Remove the filter from the nit.
2. Wr叩 in newspaper and disfard.
3. Place new filter in unit. TM new filter must be the same size. If there
are arrows on the filter 仕a~e，也ey must be placed to match the system
air flow.

Caution!

A Disposable filters must be di，叫rded, not re-used. Re·创edfilters will not

remove particles 笔庐ctively.

Maintenance
and service Other 也an cleaning re-usable :[Link], and replacing disposable ones, little
maintenance can be done on m~dia filter systems. When the furnace is
being inspected, the technician should include an inspection of the filters.
Re-usable filters need to be re' laced if they are damaged.

Disposable filters should not b~ vacuumed. Vacuuming will remove

mineral oils alo鸣 with the dirt~ and the filter will no longer work.

12 Gas Technician 2 Training - Module. 23

。 Canadian Standards Association
 TOPIC 3

Electγvstαtic filteγs

Electrostatic filters may replace standard media filters if more filtration is

necessary.

Function
Electrostatic air filters use a combination of static electricity and filtering
media to remove particles 仕om the air. The filter media is usually made of
layers of nylon or woven polyethylene fibre encased in a frame (see Figure
1-7). In appearance it is similar to a disposable slab filter. As the air stream
travels through the filter, static electricity is generated. The static charge
affects the particles, which are then more likely to cling to the filter
medium. Most electrostatic air filters are washable and reusable.

Figure 1-7 Electrostatic filter

Adv an阳ges and disadvantages

• Advantages
no electricity required
more efficient than media filters without electrostatic cha电e.

• Disadvantages
- less efficient than electronic air cleaners.

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© Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

Installation
and location Because electrostatic filters are a form of slab filter, they are installed in the
same position and way as slab filters: either inside the plenum or in a filter
仕ame. Consult the manufactur’er ’ s specifications for installation
mstructlons.

Instructions
to the The electrostatic air filter must be regularly cleaned to ensure proper
customer furnace function. The typical electrostatic filter is reusable. It can be
cleaned in the following ways:
vacuum mg
If the filter is lightly soiled, vacuuming will be sufficient to remove the
particles. The upstream side of the filter should be vacuumed first, and
the downstream side second. Some electrostatic filters can be
vacuumed in place. Consult the manufacturer's instructions for
specifics.
• flushing with clean water
From time to time, the filter should be flushed thoroughly with clean
wate卫 This can be done with a hose or shower nozzle. It is not
necessary to dry the filter before returning it to position, but excess
water should be shaken 仕om it to prevent it dripping into the ductwork.
washing with detergent
If the filter is greasy, it should be washed with detergent. This can be
done in a bathtub, but care must be taken not to scratch the tub with the
filter frame. The filter should be rinsed with clear water before it is
returned.

Maintenance
and service The electrostatic air filter should be inspected by the technician when the
furnace is inspected. Damaged filters must be replaced.

14 Gas Techniαan 2 Training - Module 23

© Canadian Standards Association
 TOPIC 4

Electγonic aiγ cleαneγs

An electronic air cleaner (EAC) may be free-standing, or may be designed

to be installed into central heating and cooling systems. The basic
operation is the same. In this Unit, EACs designed to be installed into the
heating and cooling system are discussed.

Function
Electronic air cleaners have four sections: pre-filter; charging section;
collecting section and power pack or voltage section.
• Pre：βlter
The pre-filter screens large particles before they enter the electrostatic
field. It may be fine wire mesh, expanded aluminum or foam. The large
particles removed by the pre-filter might cause excessive arcing (and
excess ozone production) if they were allowed to enter the high-voltage
section of the air cleaner cell.

Note:
The pre：斤lter serves the same purpose as the slab or hammock卢lter in the
furnace blower compartment, so when an electronic air cleaner is installed
any existing slab or hammock卢lter must be removed.
• Chat宫ing section
The charging section (cell) consists of a band of small-diameter wire
filaments, or ionizer wires. They are supplied with high DC voltage
(between 6 and 25 kV DC) from the power pack. The wires are
suspended equidistant between grounded plates. The high voltage on
the wires creates an electrostatic field, also called an ionizing field. The
positive ions create flow across the airstream. As airborne particles
pass through the field，出ey become positively or negatively charged
(Figure 1-8).
• Collecting section
The collector cell contains a series of parallel plates. Alternate plates
are charged with a positive direct current voltage of 4 to 10 kV DC.
Plates that are not charged are at ground potential. The charged
particles passing into this section are attracted to the plates by the
electric field on the charges they carry. These capture and hold
contaminate particles of the opposite charge. Retention may be
augmented by oils or adhesives on the plates.

Gas Technician 2 Training - Module 23 15

© Canadian Standards Association
AIR FILTERS AND CLEANERS UN'T 1

• Power pack or voltage section

The power pack consists of a step-up transformer and a rectifier circuit
(also called a voltage doubler) The step-up transformer increases
incoming 120 V AC cuηent to 3000-3500 Vat the collector cells. The
rectifier circuit conve归 this to 7500-8500 V DC at the charging cells.

System switch
The air cleaner is controlled by a manual system switch.

Air proving switch

The air proving switch is used to make sure that the electronic air cleaner is
functioning only when the furnace blower is in operation.

』＿ Alternate plates
Airflow •，川、厅’ ~ grounded

P仙伽ns ～～咽’／：号： 1 -' ~Intermediate plates

-t£ili ..--
1 -
+ charged to high
positive potential
必rflow +_____...-ri
J）；川’~ ~：： 三巳τ＝甲「~
+

圣王阳创ical paths of
Wires at high~ 勺＇：＇、＼，／叮＝＝＝＝二一一一一
positive p创ent副．川忖 ν／
//

Positively charged
particle

Figure 1-8 Cross section of ionizing electronic air cleaner

Advantages and disadvantages

• Advantages
- System resistance remains unchanged as particles are collected
- Fine particulate matter such as cigarette smoke and pollen is removed
- Collection of particles does not impair system operation
- Highly efficient.
• Disadvantages
- Odours of vapours such as tobacco smoke are not removed. (To
reduce these odours an activated carbon filter may be added
downstream of the EAC to filter out odours.)
” high initial cost

- produces ozone
- customer-performed maintenance and cleaning more complicated
than for media filters.

16 Gas Technician 2 Training - Module 23

© Canadian Standards Association
UNIT 1 AIR FILTERS AND CLEANERS

Installation
and location Electronic air cleaners are typically installed in the return air plenum. They
may be installed in the return air duct close to the blower compartment, or
between the plenum and the blower.

Air cleaners can be installed in the outdoor-air intake ducts of buildings

and residences or in the recirculation and bypass air ducts. Air cleaners are
always placed ahead of heating or cooling coils and other air-conditioning
equipment in the system. This protects the other equipment from dust and
increases its efficiency.

Sheet me阳l modifications

If the duct is a different size than the air cleaner cabinet, gradual transitions
are recommended. Gradual transitions reduce air turbulence and increase
efficiency. The expansion should be no more than 20 degrees, or about 4
inches per running ft (100 mm per 300 linear mm) on each side of a
transition fitting (Figure 1-9). If there are turns in the duct adjacent to 由e
田tit, turning vanes should be installed to assure even air distribution across
the face of the electronic cells. 刀tis will help to keep the blower and
evaporator coil clean and ens田e 也e unit functions efficiently.

20 degree expansion per side per fitting

(4 inches per running ft)
(100 mm per 300 linear mm)

Return
air duct
Electronic
air cleaner cabinet

Figure 1-9 Transition fitting for electronic air cleaner installati。n

·Gas Technician 2 Training - Module 23 17

C Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

Installation of electronic air cleaners

Electronic air cleaners must be installed according to manufacturer's
instructions. The example provided here is only intended as a general
guideline for the major steps.

Electronic air cleaners:

• must filter the entire return air stream
must not exceed acceptable restrictions to air flow
must be installed with clearances 也at match manufacturer ’s
specifications and allow for service access. If necessary a duct
offset can be used to provide space for an electronic air cleaner
(See Figure 1-10).
• should be installed upstream 仕om the humidifier, if at all possible.
Moisture from the humidifier will cause mineral and salt buildup in the
EAC. If the EAC must be installed downstream from the humidifier,
the distance between the two units should be as great as possible. This
will enhance the performance and minimize problems with both units.
部－

hMm
E』

RM 怠MWH

SCPD
nHi 川川
mW

。仔set
7 ’ LE、

At least
7inches
&!___ (175 mm)
Turning vanes help
distribute airflow evenly

Figure 1-10 Duct offset to allow space for an electronic air cleaner

18 Gas Technician 2 Training - Module 23

© Canadian Standards As部C陆目on
UNIT 1 AIR FILTERS AND CLEANERS

Step 1: Preparation

As much dust as possible should be removed from the heating system

before the electronic air cleaner is installed.
1. Clean the blower compartment. Remove and discard the furnace filter.
2. Power vacuum the ductwork to remove accumulated dust in an existing
home, or construction dust in a new home. Clean the furnace fan blades
as required. Since the electronic air cleaner removes particles only 仕om
circulating air, it cannot remove dust that has settled in the blower
compartment or distribution ducts.

Step 2: Attach cabinet to furnace

1. Remove and set aside the access door, electronic cell(s) and prefilters.

Note:
Electronic cells and ionizing wires are veηy delicate and must be
handled with caution. The power door must be replaced accurately and
securely.
2. Align the cabinet with the re阳m air opening.
3. Create an opening in the furnace to match air cleaner cabinet opening.
4. Install a transition when furnace and air cleaner openings are di任erent
sizes.
5. Be sure the unit is firmly supported and level. Place blocks under the
cabinet if necessary.
6. Attach the cabinet securely to the furnace. Either attach the cabinet
directly or use a starting collar fitted in the furnace opening. Either drill
holes and fasten with sheet metal screws or rivets, or use slip joints.

Step 3: Install turning vanes if necessary

Turning vanes should be installed if the electronic air cleaner must be

located close to a tum in the ductwork. The vanes will ensure even airflow
over the face of the unit (Figure 1-11 ).

Gas 丁echnician 2 Training - Module 23 19

。 Canadian Standards Association
AIR FILTERS AND CLEANERS UNIT 1

C二3 C二二3

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γTiv
一－ua
一 nn
咱
m臼
li11 ce

h晴
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产←』d

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UFU

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Figure 1-11 Turning vanes distribute ai 『flow evenly

Step 4: Fasten cabinet to duct work

Install a transition when the opening on the air cleaner and the opening on
the duct are different sizes.

Step 5: \'1币ring

Electronic air cleaners function only when the blower is operating and air
is in motion. When properly installed, the EAC is electrically or
mechanically interlocked with the furnace or cooling system blower
circuit, and can only operate when the 臼mace blower is energized. The
interlock is accomplished by installing a sail switch in the return air duct.
When the blower is energized, the air movement causes a fin on the sail
switch to move, closing a set of electrical contacts to the EAC and
energizing it.

Ozone production
A properly functioning EAC will produce a small amount of ozone. This
ozone odour may be noticeable. The gas technician should explain this
odour to the building occupants. A strong ozone odour can indicate
continuous arcing and brush discharge in the electronic air cleaner and
indicates that service is needed.

20 Gas Technician 2 Training - Module 23

。 Canadian Standards Association
UNIT 1 AIR FILTERS AND CLEANERS

An activated carbon filter can reduce the odour of ozone. The activated
carbon filter must be installed downstream from the air cleaner. Since some
activated charcoal filters are combustible, it is important that pa此ides 仕'Om
the air filter not be able to fall into the EAC.

Note:
H电~h ozone odours can occur if there is too little air卢ow through the filter.

Instructions to
the customer Electronic air cleaners require cleaning eve可 one to six months. In a home
with several people and pets, where residents smoke tobacco and have
hobbies such as woodworking, frequent cle缸由ig will be necessary. In a
smaller household with no smokers, pets or individuals with dusty hobbies
less 企equent cleaning will be needed.

Since cleaning must be done 仕equently, and other service more rarely, the
customer must know how to clean the electronic air cleaner. Some
customers may also be happy to replace broken ionizing wires themselves.
All other servicing should be done by a trained technician.

The technician must:

show the customer the location of the power switch (and test switch, if
the EAC includes one)
ensure that the customer knows how to remove and clean filters and
cells, according to 也e manufacturer ’s instructions for the unit.

A wash reminder schedule is included with most electronic air cleaners and
should be posted in a convenient place for customer reference. Some air
cleaners have an indicator light 由at comes on to indicate 也at the cells 缸e
dirty and air cleaning efficiency is diminished. Ideally the cells should be
washed frequently enough that 也is light never comes on.

Caution!

A Power to the Electronic Air Cleaner must be turned off bφre cells are
cleaned. Turning the power offdischarges the electronic cells. Sometimes it
takes a卢w minutes for the charge on the cells to dissipate. Pressing the
test button after the unit is turned off will dis，吻。但 the charge to ground.

Gas Technician 2 Training - Modu拖到 21

。 Canad阳n Standa『＇dS Associatiort
AIR FILTERS AND CLEANERS UNIT 1

Cleaning the cells

This whole procedure can be done by the customer. The technician should
be sure that the customer understands the steps involved.
1. Slide cells out of cabinet. Be careful: cells may have sharp edges.
2. Wash the cells either by soaking, at a coin-operated do-it yourself car
wash, or in an automatic dishwasher. (See details below). Care must be
taken not to damage the ionizing wires, no ma忧er which method is
used. Detergent is usually used for cleaning. Follow manufacturer ’s
specific instructions for cleaning materials.
3. After washing, inspect the cells for dirt or residue. Repeat the washing
process if necessary.
4. Before reassembling the EAC, clean the prefilter. The pre-filter screen
may be washed with detergent or vacuumed, whichever is more
convenient. Do not wash the prefilter in the dishwasher or a car wash.
Since the prefilter contains lint that can become caught in cells, do not
soak it at the same time as the cells.
5. Before reassembling the EAC, inspect the ionizing wires and replace
any that are broken. (See details below.)
6. Reassemble the EAC.
7. If the EAC has a drying unit, engage it.
8. Tum power on at main disconnect.

Note:
Some electronic air cleaners will not operate until they are completely dry.
Others will opera战 but wet cells and pr听lters may cause arcing. 扩the
unit is equ伊'[Jed with a Check LED, the light m句Y come on when cells and
pr，ψlters a陀 wet. Leave the electronic air cleaner turned offfor two or
three hours until the cells and pr1φlter are completely 向y to avoid these
problems.

Dishwasher method

Before washing the cells in the dishwasher, check the dishwasher manual.
Somemanu臼cturers of dishwashers do not recommend using them to wash
electronic cells.
Place cells on the bottom rack with the air flow aηows pointing up.
Be sure they are placed in such a way as to allow good water
circulation.
• Use regular dishwashing detergent.

22 Gas Technician 2 Training - Module 23

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UNIT 1 AIR Fil TERS ANO CLEANERS

• Run them through a complete wash cycle.

• Do not allow the dishwasher to run through the dry cycle. The dry cycle
will bake on any contaminants that remain on the cells and impair air
cleaner efficiency.
Allow the cells to cool completely in the dishwasher, or wear protective
gloves, to avoid burns when removing the cells.
• Hot water may accumulate in the tubs supporting the collector plates.
Tip the cells to drain these tubes.
Wipe the ionizer wires and contact board on the end of the cell gently
using a small damp cloth.
If dirt or residue remains in the dishwasher, run the dishwasher again,
empty, to clean it.

Soaking method

• Cells should not be soaked in a bathtub, since their sharp edges can
scratch the tub finish.
Fill a container large enough to immerse one or both cells with very hot
wat优

• Dissolve o/4 cup of regular automatic dishwashing detergent per cell. If

the detergent does not dissolve readily, or forms a scum on the water,
use softened water or try another brand.
• After the detergent is completely dissolved, lower the cell(s) into the
container and soak each cell for 15-20 minutes.
Lift the cells up and down a few times, then remove them.
• Rinse the cells with a fine spray and soak again in hot clean water for 5-
15 minutes.
• Stand the cells upright to drain.

Carwash method

Cells can be washed at a coin-operated do-it-yourself car wash with a hand

sprayer.
• Hold the nozzle at least two feet away from the unit to avoid breaking
ionizer wires or bending the collector plates 丘。m the high pressure
stream of water.
• Follow the wash and rinse cycle recommended for cars. Do not wax the
cells.
• Rinse until the water draining from the cell( s) no longer feels slippery
to ensure that all detergent has been removed.

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AIR FILTERS AND CLEANERS UNIT 1

Checking and replacing ionization wires

The fine tungsten wires in the charging section of the electronic cell are
brittle and can easily break or become damaged. The customer should be
shown how to inspect the cell 仕om the upstream side, to be sure no wires
are broken or out of position. Broken wires can cause visible arcing or
sparking. They must be replaced (Figure 1-12). Replacement wires are
supplied cut to length with eyelets on both ends for installation.

Some customers may prefer to have the technician replace ionizing wires
rather than doing it themselves.

Replace broken wires

1. Remove the broken wire, being careful not to damage the spring
connector. Be sure all parts of the wire are removed.
2. Hook the eyelet of the new ionization wire over the spring connector on
one end of the cell.
3. Hold the opposite eyelet with needlenose pliers and stretch the wire the
Ieng由 of the cell.

4. Depress the opposite spring connector and hook the eyelet over it.

24 Gas Technician 2 Training - Module 23

© Canadian Standards Association
UNIT 1 AIR FilTERS AND CLEANERS

Spring
connectors

Courtesy ofHoneywell Limited

Figure 1-12 Replacing ionization wires

Maintenance
and service Cleaning of cells and replacement of ionizing wires can be done by the
customer, but other maintenance and service must be done by a trained
technician.

Basic. maintenance
Before the beginning of the heating and cooling seasons, the solid state
components and ionizing wires of the electronic air cleaner should be
inspected. The exact procedure for checking the unit will vary depending
on the manufacturer, so manufacturer ’s instructions must be consulted. A
typical procedlire follows.

Check components

Checking the compone础 at beginning of the heating and cooling 回a sons

is basic preventive maintenance for the electronic air cleaner. Checking the
components requires a volt meter or multimeter.
1. Be sure 也e power 企om the main disconnect to the EAC is in the “ on”
pos1tlon.

Gas Technician 2 T1刚刚ng 『 Module23 25

© Canadian Standards Assα掬tion
AIR FILTERS AND CLEANERS UNIT1

2. To check the operation of the sail switch (or electrical blower interlock)
energize the 如mace blower. If the EAC does not operate句 the sail
switch may be faulty.
3. Check to see that the voltage indicator light is on. If the light is not on,
but the unit operates, the light is faulty.
4. Push the Test Button on the front of the EAC access door. Pushing the
button shorts the hot side of the collector section to ground and should
produce one or more loud snapping sounds in the section. This
indicates that the EAC is working properly. The test button will
discharge the cells.
5. Remove the access door.
6. With the voltmeter or multimeter set to AC, check voltage to the power
pack. (Should read 120 V AC). If the power pack is not working, the
solid state power supply within the power supply box can be replaced.
7. With the voltmeter or multimeter set to DC, check voltage to the
collecting section plates (3000-3500 V DC).
8. With the voltmeter or multimeter set to DC, check voltage to charging
ionization wires (should read 7500-8500 v dc).

Caution!

A Electronic air cleaners operate at high vohαge to chm宫e particles. Follow

manufacturers instructions carφlly when servicing them to avoid hazard.

Troubleshooting

Visible arcing or sparks and higher-than-expected ozone odour should be

investigated by the technician.

If there is visible arcing or sparking, check the cell for short circuits using
an ohmeter. Make sure power to the EAC is off and cells are discharged.
Check the resistance between the frame of the cell and the ionizer, and the
frame of the cell and the collector contacts. In each case the resistance
should be infinite.

If a cell is sparking continuously in one place, the plates need to be

repositioned. Consult the manufacturer ’s instructions for correct
positioning of plates.

26 Gas Technician 2 Training - Module 23

。 Canadian Standards Association
UNIT 1 AIR FILTERS AND CLEANERS

If the customer complains of an ozone odour:

• make sure the air cleaner shuts off when the furnace blower is not
active
make sure there is adequate air flow through the unit.

Gas Technician 2 Training - Module 23 27

© Canadian Standards Association
呐峭，，.
 UNIT 1 AIR FILTERS AND CLEANERS

Assignment .1
When you have completed the following questions, ask your instructor for the
Answer Key.

I. Why are air cleaners installed ahead of heating or cooling coils and air conditioners?

2. What are two ways in which a mechanical filter could restrict air flow?

3. Name three types of air cleaners 由at can be used with a forced-air furnace.

4. Which type of air cleaner is usually the least expensive?

5. Which type of air cleaner is usually the most expensive?

6. Name two advantages of an electronic air cleaner.

」

7. Do electronic air cleaners remove smoke odours 企om the conditioned air?

8. How can smoke odours be reduced?

9. Whatmust 由e gas technician do before installing any air cleaner?

10. If there are aηows on a filter 企ame, which way must they face?

11. Why should re” usable filters be re-oiled before 由.ey 缸e replaced in 也e furnace?

12. What must be done before opening the blower door on a forced-air furnace?

13. How frequently should furnace filters be inspected 扭曲e heating season?

Gas Technician 2 Training - Modu陆 23 29

© Canadian Standa叫s Association
AIR FILTERS AND CLEANERS UNIT 1

14. How frequently should filters be replaced?

15. 认Thy can disposable filters not be re-used?

16. Name three problems that can result 丘。m operating a forced-air furnace without a filter?

17. What is the most common cause of inadequate heating or cooling performance?

18. 轨电at damage can a dirty filter do in a system that includes ad也on air conditioning?.

19. How can clean filters save the customer money?

20. What are the four components of an electronic air cleaner?

21. What can happen if ionizer wires are broken?

22. What can happen if the electronic air filter is turned on when cells are wet?

23. If cells are washed in a dishwasher, why should the drying cycle not be run?

24. How frequently should an electronic air cleaner in a residential installation be cleaned?

25. Name three factors that may be present in a home that would suggest cleaning must be more
frequent.

26. Describe the basic function of an electronic air cleaner.

27. If the power pack is not working, what should be done?

28. List three methods for cleaning the cells of an electronic air cleaner.

30 Gas Technician 2 1口raining - Module 23

。 Canadian Standards Association
Unit2 Humidifiers

Purpose Since the comfort of building occupants depends on both air tempera-
ture and relative humidity, the gas technician should understand
humidification.
There are many types of humidifiers. They must be installed carefully
so they do not damage the heating and cooling equipment.

Learning 1. Describe the function of different types of humidifiers and their

control.
。同ectives
2. Describe installation procedures for humidifiers.

3. Describe operation requirements and service procedures for

various 句rpes of humidifiers.

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© Canadian Standards As始ciation
 Topics
1. Function and control .................….....................…................. 33
Control of the humidifier. …………………..........…....,………·“…·…...... 33
Pan humidifiers ……········……...………·…………………….........….......... 34
Wetted element hum1d1fiers ..…·······································…..........…........... 36
Atom1z1ng humidifiers ................…...............…………............……................ 37
Steam humidifiers ....……………口，．．……… E …………...... 38

2. Installation ....”··”.................................................................... 39
Sizing ............……....... ··················…...…………………·…·四........ 39
Location ....................................................…..............…........39
Other installation requirements ..............‘…...............................................41

3. Operati。n and service .........…............................................... 43

Common operation requirements ...... .... ..................……··………...... 43
Service guidelines for specific types ........……........…---………….............. .44
Instructions to the customer ...….................……………….............…........…… .45
Troubleshooting .............…········· •••••••..• ··•·•••••· ..•.•....•.•.••••••..••..••.. 46

Assignment 2 ................................................................…............ 49

32 Gas Technician 2 Training - Module 23

。 Canadian Standards Association
 TOPIC I

Function and control

Humidifiers add water vapoilr to the air in a building, increasing the
relative humidity. Relative humidity is a measurement of the percentage
amount of water vapour contained in the air, compared to the amount that
can be contained (100%) when the air is saturated.

Warm air can hold more water than cold air, so relative humidity changes
with the temperature. In warm desert climates (such as Arizona) relative
humidity is always low. In cold climates, such as are found in much of
Canada, the relative humidity inside is low in the winter when the
temperature is low outside.

The comfort level of a room is a function of both temperat田e and relative

humidity. When a room is too 由y
也e room may feel colder than its actual temperature
• there may be high levels of static electricity
building occupants may be more susceptible to colds and other air-
home viruses, since excessive dryness reduces the effectiveness of the
nasal membranes.

A humidifier adds moisture to the air, increasing the relative humidity and
the comfort level. In most cases a relative humidity of 40% will be most
comfortable for building occupants.

Humidifiers may be either stand-alone devices or an integrated part of the

building ’s heating and cooling system.η1ey can be installed either h 也e
furnace plenum or duct, or attached to the plenum or duct so as to introduce
water vapour into the air 由earn.

Control of the
humidifier Most humidifiers 缸e controlled by humidistats.

Humidistats
The humidistat is an electric switch which controls the operation of the
humidifier in response to changes h 也e building’s relative humidity. 咀1e
humidistat includes two settings: one for relative humidity, and one for the
outside air temperature (usually in degrees Fahrenheit). Building occupants

Gas Technician 2 Training - Module 23 33

© Canadian Standards A部ociation
HUMIDIFIERS UNIT2

set the humidistat by selecting the desired relative humidity and adjusting
由e temperature gauge to the approximate outside temperature.

Humidistats can be mechanically or electronically controlled.

• Mechanically-controlled
The mechanically-controlled humidistat contains a strip of moisture-
sensitive plastic film that elongates as humidi可 rises. When humidity
reaches the preset level, the strip 位iggers a switch that turns the
humidifier off. When humidity falls the strip shrinks and starts the
humidifier.
• Electronically controlled
Electronically controlled humidistats contain electrical sensors that
va可 in resistance as the relative humidity changes. These humidistats
can detect very small changes m_relative humidity. They are used in
settings where precise control is needed, such as laboratories.

The position of the humidistat is 挝iportant. If the humidistat is not in the

right place，也e relative humidity will not be measured correctly and the
building may be less comfortable. The humidistat is normally mounted in
the area where air is being controlled. A location near the thermostat is
convenient for building occupants.

Pan·
humidifiers Pan humidifiers are the simplest form. They consist of an open pan of
wat矶山ually installed in the plenum，由at evaporates directly into the air.
Pan humidifiers do not require a humidistat.

Basic pans
A shallow pan is installed in the 如mace plenum. A flow control device
connected to the household water supply maintains a constant water level.
ηie humidification rate is low, approximately 0.0036 gals./hr/sq ft of pan
. surface area.

Pan with wicking plates

Pans with wicking plates are similar to the basic pan type, but have vertical
water-absorbent plates to increase the surface area {Figure 2-1 ）.ηie
humidification rate is slightly higher than 由at of a basic pan humidifier,
but is still low.

34 Gas Technician 2 Training - Module 23

© canadian Standards Association
UNIT2 HυMIDI FIERS

Figure 2-1 Pan humidifier with wicking plates

Electrically heated pan

The electrically-heated pan humidifier 扭曲e same as the basic pan, but the
water in the pan is heated by a hot water coil, steam coil or electric element
in the pan (Figure 2-2). Its humidification rate is higher than basic or
wicking plate pan types. With a I 000 Watt element, it may evaporate 0.36
to 0.48 gals/hr/sq i王．

Water vapor

Overflow
drain

000000000
阳t exchanger / '"lcT"'- To drain plug
electric, steam, for pan blowdown
or hot water

Figure 2-2 Heated pan humidifier

Gas Technician 2 Training - Module 23 35

©Canadian Standards Association
HUMIDIFIERS υNIT2

Wetted
element All wetted-element humidifiers operate on the same principle. An open-
humidifiers textured medium, the evaporatmg surface, is wetted and the water it
contains evaporates into the air. The medium may be a fixed pad that is
wetted by a spray or fed by gravity, or it may be dipped into a water
reservoir on an electrically-powered paddle, drum or rotating belt. Wetted-
element humidifiers are controlled by humidistats.

Drum humidifiers
Duct-mounted drum humidifiers contain a 24 V AC motor and a wheel or
drum covered with foam. When the humidistat calls for humidity the drum
rotates 也rough a water reservot汇 This saturates the foam. Warm air 仕om
the supply plenum passes through the humidifier, and picks up moisture
from the media. The moistened air enters the return air plenum and is
distributed throughout the home by the furnace blower.ηie reservoir
contains a float and water valve to automatically control water level and
prevent overflows. A drum humidifier is shown in Figure 2-3.

Figure 2-3 Drum humidifier for in-duct inst副 lati。n

Evaporator-pad humidifier
Similar to the drum humidifier, the evaporator-pad humidifier is
duct-mounted and is connected between the warm-air supply plenum and
the return air supply. Air flows 企om the warm-air supply plemum through
a moisture-laden evaporator pad, picking up moisture and returning moist
air to 由e return air supply of the furnace. In the model illustrated in
Figure 2~4, the pad is “we忧ed＇” by water controlled through a solenoid
valve and distributed over 也e pad by a distributor trough at the top of the
humidifier. Water not evaporated drains from the bottom of the humidifier.

36 Gas Technician 2 Training - Modu始 23

© Canadian Standards Association
UNIT2 HUMIDIFIERS

Evaporator-pad

Solenoid valve ＿斗
assembly

Figure 2-4 Evaporator-pad humidifier

Spray humidifiers
Spray humidifiers use a sprayed stream of water, rather than a reservoir, to
wet the medium. When the humidistat calls for humidity, a solenoid is
energized and opens a water valve. The open valve allows water to flow
from a cold water pipe through the 24 V AC solenoid valve and water line
to a nozzle, where it is sprayed on the humidifier medium. From this point
the operation is the same as a drum humidifier.
dM
叫－m

AKH
品，‘川 M

mwm
唱Ad ’’
山A

S
Atomizing humidifiers introduce small droplets of water directly into
either the duct air stream or the conditioned space. There are several ways
in which the water can be atomized: centrifugal force and spray nozzle are
the most common. Ultrasonic vibrations can also be used.

Centrifugal atomizing humidifiers

Centrifugal atomizing humidifiers contain a spinning disk or cone that
breaks the water into a mist, or a rotating disc which slings water into the
air from a reservoir. This 句rpe is shown in Figure 2-4.

Gas Technician 2 Training 由 Module23 37

© Canadian Standards Association
HUMIDIFIERS UNIT2

Water 一＋

Figure 2-5 Centrifugal atomizing humidifier

Spray” nozzle atomizing humidifiers

Spray-nozzle atomizing humidifiers have a fine spray nozzle that creates
fine droplets and sends them into the duct airstream. The nozzle may use
water pressure alone, or a mixture of air and water.

Atomizing humidifiers are often portable or console-type units, but they

can also be installed so that the water will be directed into a ducted central
system. If they are connected to the ducts, they should only be used when
由e 且imace is operating. If the fan is not running the moisture they
introduce can accumulate and cause corrosion, mildew and other moisture
problems.

Note:
Atomizing humidifiers should not be used with hard waleχ The minerals
contained in hard water leave the evaporating water vapour as dust that
will be distributed through the building.

Steam
humidifiers Since steam is water vapour at high temperature, introducing steam into the
airstream is an efficient way to add water vapour to the air. There are
several kinds of steam humidifiers, many used only in industrial or
commercial installations. Generally steam humidifiers are of two types:
those that are self-contained (containing a heating element) and those that
it飞ject steam 仕om a boiler into the space or into the duct system. Steam
humidifiers connected to duct systems must be placed where the air can
absorb the vapo町， to ensure that condensation does not occ田面 the ducts.

Self-contained
Self-contained steam humidifiers convert tap water to steam by electrical
ener~~· They can be 岳出－standing and unconnected to the duct system, or
can i乓ject steam into the duct system.

38 Gas Technician 2 Training - Module 23

©Canadian S姐ndards Association
 TOPIC 2

·Installαti on

Because there are so many types of humidifiers, detailed descriptions of

humidifier installation are not provided. Follow the manu臼cturer ’s
instructions for the specific model and type of humidifier to be installed.
Size and correct location must be considered for any installation.

Sizing
Before a humidifier is installed the correct size must be determined.
Several factors help to determine the size required:
size of the area to be humidified (in cu ft)
• the construction or “tightness”。f the building
• Code requirements for air changes per hour
lowest outdoor tempera~ure in the area
level of relative humidity desired.

Manufacturers' specifications should be consulted to ensure the unit

chosen is appropriate for the space to be humidified.

Location
The manufactur町’s specifications will describe where specific humidifiers
should be positioned. Humidifiers can be installed in four different
locations:
• In a bypass duct
Pan, wetted-element or steam humidifiers can be used in a bypass duct.
The bypass duct is a loop that forms a bypass 齿。m the main system
(Figure 2-5). Humidifiers installed in this location are passive：由at is,
they do not contain a 臼n or other method of moving air. Air circulates
through the units because of differences in pressure between the warm
and cool side of the furnace.
The bypass humidifier may be mounted on either the supply plenum or
duct or the cold air return plenum or duct. The bypass duct must
connect the return and supply-side plenum or ducts, wherever the
humidifier is actually mounted.

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©Canadian S恼ndards Association
HUMIDIFIERS UNIT2

• Jn the supply or return-air plenum

Pan, wetted element or atomizing humidifiers can be installed in a
plenum.
• Under the supply duct
Pan, steam or wetted-element humidifiers can be mounted to an
opening on the underside of a supply duct. It is best to choose the
supply duct 由at serves the largest area in the building. This makes
distribution of humid air more efficient.
• In the supply duct
Pan, wetted element or atomizing humidifiers can be used. Atomizing
humidifiers must be wired to operate only when the furnace fan is
operatmg.

Humidifiers must not exhaust onto air conditioning coils, air filters,
electronic air cleaners, blowers, or turns in a duct. They must not be located
in the furnace casing or above a heat exchanger. They should be positioned
so if water spills, it will not spill onto electrical components.

The humidifier location must allow access for service and maintenance.

If a humidifier is used with an electronic air cleaner, it must be located

downstream from the electronic air cleaner to avoid damage to 出e EAC.

..
Humidifier

Cold air
return
Warm
air

Heat ; Blower
source

Figure 2-6 Bypass wetted element humidifier

40 Gas Technician 2 Training - Module 23

©Canad阁n Standards As臼ciation
UNIT2 HUMIDIFIERS

Other
installation Water supply, electrical connections, sheet metal modifications and drains
requirements must be considered as part of the installation process.

Water supply
Hard water (water that contains a high mineral content) can cause various
problems in humidifiers. Nozzles, tubes, and evaporative elements may
collect precipitated solids and become clogged. Mineral solids 也at enter
the air stream can leave a layer of white dust on furniture and floors
throughout the home.

There are various ways to avoid this problem.

• The water supply to the humidifier can be softened. This process
usually adds sodium to the wat也 Since the sodium itself precipitates
out in humidifier reservoirs over an extended period, provision must be
made for the reservoir to be flushed out on an ongoing or periodic
basis.
• Chemicals that prevent scaling (the precipitation of minerals) can be
added to 出e humidifier pan. Consult the manufactur町、 literature
before adding any chemicals to the humidifier.

"Furnace-humidifier electrical connection

Atomizing humidifiers installed in a duct or plenum must operate only
when the furnace blower is operating. Atomizing humidifiers introduce
droplets of water into the ducts. If the air is not moving the drops will fall
on the duct surface, causing moisture accumulation. This moisture can
encourage the growth of mildew, compromising indoor air quality. It can
also cause corrosion.

To ensure the atomizing humidifier works only when the blower is

operating, an electrical interlock is required. The interlock is accomplished
by installing a sail switch in the return air duct. When the blower is
energized, the air movement causes a fin on the sail switch to move,
closing a set of electrical contacts to the atomizing humidifier and
energ1zmg 1t.

Evaporative humidifiers (pan type or wetted element) may operate

independently of the furnace so no interlock is required.

Power bypass humidifiers contain a transformer which must be used.ηie

humidifier must not be connected to the transformer on 也e furnace, if there
is one, since this could overload the furnace transformer.ηie humidifier

Gas Technician 2 Training - Module 23 41

©Canadian Standards Assoc国tion
HUMIDIFIERS UNIT2

transformer should not be wired in to the thermostat circuit. If it is, the

thermostat would receive a different cuηent draw depending on whether or
not the humidistat was calling for moisture.

If a humidifier transformer is installed on a furnace with a direct drive

motor, the wiring and control system must prevent the humidifier
transformer 企om over-voltage created by 由e motor ’s idle windings.

Sheet me恼i modifications

When a humidifier is installed in or under a duct, in a plenum or in a bypass
duct, modifications must be made to the sheet metal. Follow the
manufacturer ’s instructions for the specific humidifier concerning the size
of the openings required, and proper sealing of openings.

Drain
Many types of humidifiers require a drain to be installed. Check
manufactur1町、 instructions and the local plumbing code to determine
specific requirements.

－‘飞

42 Gas Technician 2 Training - Module 23

。 Canadian Standards A部ociation
 TOPIC 3

Operation and service

The operation of the humidifier should be checked when the forced-air
furnace is inspected prior to the start of the heating season.

It is especially important to be sure the humidifier is clean prior to the

beginning of the heating season. When water remains in a humidifier for an
extended period (for example, over the summer) it may become a breeding
environment for fungi, bacteria, algae and viruses. If the reservoir is not
cleaned before the furnace blower is turned on, these contaminants can be
distributed throughout the house. This will lower indoor air quality and add
to indoor air pollution.

Common
operation Factors such as water level, mechanfoal operation and humidistat function
requirements should be checked. The guidelines for operation given here are general.
Check the manufacturer ’s specifications for specific operation
requtrements.
• Wi.αter level correct
If the water level in the reservoir is too high, water can overflow into
ducts, ultimately causing corrosion and/or development of mildew. The
water level must be set to 也e manufacturer ’s specifications.
Floαt valve assembly operating
η1e float valve assembly must be working and adjusted properly to
maintain the correct water level.
• Humidistat working
To check the operation of the humidistat, it is necessa可 to have an
independent measure of the relative humidity in the building. A sling
psychrometer can provide 也is confirmation. The operation of the sling
psychrometer is explained in 由e troubleshooting section of this unit.
• Clean overflowldrα'in line αnd reservoir pan.
η1e hose may need to be removed for cleaning. Check to be sure the
drain is not blocked.
The reservoir pan should be cleaned at 也e beginning and end of 由e
heating season, and more 丘equently if the pan seems slimy. The
technician must be sure the customer understands how to clean their
humidifier according to manu也ctur町、 instructions.

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HUMIDIFIERS UNIT 2

Service
guidelines for Always check the mam出cturer ’s manual for guidelines specific to the
specific types humidifier being serviced.
• Ui每tted element humidi斤ers
If the wetted element is mounted on a drum or paddle, the drum or
paddle must be turning for the humidifier to operate correctly.
The media in wetted-element humidifiers or wick type pan humidifiers
should be cleaned or replaced at the beginning of every season. The
humidifier pad must be kept clean to permit proper absorption and
evaporation of water. If the media is a cleanable type, it can be washed
with detergent. Mineral (scale) deposits can be scraped loose lightly
with a putty knife if necessary.
The humidifier pad should be replaced if 让 will no longer conform to
the drum properly after cleaning.
• Atomizing humid伊ers
The nozzle must be spraying freely, or the drum turning.
• Steam humidi斤ers
Steam generation must be Qccurring, and the nozzle must not be
blocked.

Wettec问lement spray humidifiers

ηie no2:zles
on spray humidifiers must be inspected to ensure they have not
become blocked by dirt or mineral deposits.
1. Turn humidistat off.
2. Clean or replace media. Install the media diagonally into the cabinet
for the pu甲oses of this 阳ne-up, so the nozzle can be seen from 由e
front opening.
3. Tum on the water supply.
4. Open the damper to the humidifier.
5. Tum on the furnace blower.
6. Set the humidistat so it calls for humidity. The solenoid water valve
should open.
7. Check the nozzle spray. If the spray is uneven or irregular, replace the
nozzle.
8. Replace the filter medium in the normal position.

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UNIT2 HUMIDIFIERS

Drum-type humidifiers

Drum-type humidifiers include a clutch assembly that must be inspected

and cleaned.
1. Clean mineral deposits from the clutch assembly. Detergent can be
used. Scale (mineral deposits) can be scraped with a pu忧y knife.
2. Clean the drain pan.
3. Clean the ori丑ce between the water source and the float valve
4. Tum on the furnace blower and set the humidistat so it calls for
humidity. The motor should rotate.
5. Adjust water level screw.

Instructions
to the The customer must perform seasonal maintenance on the humidifier and
a司just it as necessary.
customer
• Fall
If the humidifier contains a media pad, it should be cleaned prior to the
beginning of the heating season. If there is a reservoir, it should be
cleaned with vinegar and water.
If the humidifier is a bypass 。rpe, the bypass duct damper must be
opened.
The float level should be checked and adjusted as necessary and the
humidistat set to the desired relative humidity, approximately 40%.
Winter
The customer should check the windows of the building for
condensation, a sign of excess humidity, and adjust the humidifier as
necessary. The customer should check the level of water in the
humidifier periodically.
• Summer
The humidifier reservoir should be drained. If there is a bypass duct
damper, it should be closed.

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HUMIDIFIERS UNIT2

Tr，。u bles h。。ting

When a customer reports a lack of humidity:

check the relative humidity in the conditioned space using a sling
psychrometer
• troubleshoot the humidifier, especially the humidistat, water supply and
electrical system.

Note that in extreme weather conditions few humidifiers will be able to

provide the desired humidity level.

Testing relative humidity

The sling psychrometer (Figure 2-6) measures air temperature using two
thermometers, a wet bulb and a d叩 bulb, mounted on a base. 咀1e apparatus
has a handle that allows it to rotate rapidly in the air. As the psychrometer
moves, air flows over the thermometers. Moisture is evaporated 企om 也e
wet bulb. When the temperature stabilizes on the two thermometers,
readings are taken. Readings are. compared "to tables provided with the
device to find the relative humidity based on the two temperatures.

Dry bulb
thermometer

Courtesy ofAmerican Publishers, Inc.

Figure 2-7 Sling psychrometer

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UNIT 2 HUMIDIFIERS

Troubleshooting the humidifier

• Humidistat
When the relative humidity has been tested, set the humidistat for a
higher level and see if it activates. If the humidistat is functioning and
the relative humidity in the conditioned space is not what it is calling
for, the humidistat may be incorrectly calibrated. It may be possible to
recalibrate the humidistat, or it may need to be replaced.
Water supply
Make sure the supply line has not become plugged and that the float
valve is adjusted properly, so an optimum level of water is maintained
in the reservoir. If the float is damaged, it can be replaced.
If the humidifier overflows, and the level/float setting is correct, the
seat on the entire float assembly may need to be replaced
If the humidifier is based on a wetted element, make sure the medium is
not clogged, dirty or saturated with mineral deposits. Clean or replace
it if necessary. Damaged elements must also be replaced to prevent
water in liquid form from entering the ducts.
In an atomizing humidifier, make sure the drum is turning properly, and
the spray nozzle is not blocked.
• Electrical connections
If the humidifier is not functioning at all, the problem may be electrical.
Check circuit breakers, the humidistat and low-voltage controls ifthere
are any. If the humidifier has a motor, as some atomizing and wetted
element types do, check it to see if it-is burned out.
Mineral deposits may cause a humidifier to switch itself off. If a
component is locked or bound because of a mineral buildup, in some
humidifiers a thermal fault overload protector may open, shutting the
unit off. In this case the component should be cleaned or ~eplaced.

Other potential problems

There are some other potential problems which should be repaired,

although they will not prevent the humidifier from functioning.
• Dust
If excessive dust is caused by a humidifier, the dust will be white, since
it is caused by mineral buildup.ηie media should be cleaned or
replaced.

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HUMIDIFIERS UNIT2

• Moisture in the ducts

Moisture may be found in the ducts if an atomizing humidifier is
installed, and the humidifier is operating when the furnace blower is
not. The atomizing humidifier must operate only when the furnace
blower is on and the furnace is operating. Check to be sure it is not
operating when the “ fan only" mode is selected since heat is required to
evaporate the water droplets created by the atomizing humidifier.
. Wαrter overflow
The float valve may need to be cleaned, replaced or adjusted if water
has overflowed. The drainage/overflow line should be checked in case
it has become blocked.

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 UNIT2 HUMIDIFIERS

、、－－
Assignment 2
When you have completed the following questions, ask your instructor for the
Answer Key.

I. Why should atomizing humidifiers operate only when the furnace blower is operating?

2. What three problems may be caused by relative humidity that is too low?

3. What is the approximately ideal level of relative humidi守 for optimum comfort in a residence?

4. What is the major di他rence between atomizing humidifiers and other types of humidifiers?

、、』－

5. If excessive dust in a building is coming from the humidifier, how can it be identified?.

6. Name two common problems that can result from water overflow 企om a humidifier.

7. What device con位ols the operation of a humidifier?

8. If a humidifier is used in a system with an electronic air cleaner, where should the humidifier
be mounted?

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HUMIDIFIERS UNIT2

9. How frequently should the water-holding reservoirs in humidifiers be cleaned?

10. Why is it important to clean the holding reservoir thoroughly?

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 Unit3 Cooling coils

Purpose η1e installation and major servicing of cooling coils in con unction
with gas-fired forced-air 缸maces is done by air conditioning techni-
cians, not gas technicians. However, the gas technician will be
required to inspect and clean the cooling coil as part of regular furnace
se凹icmg.

Learning 1. Describe how to check cooling coils for proper function, and clean
cooling coils.
objectives

、、白，

、、町，

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C Canadian Standards Association
 Topics
1. Checking and cleaning cooling coils .......…......................… 53
Measuring temperature change ..… ……………...…·……………... ········ .. 54
2

Measuring pressure drop across coil ....………··…...........…........................ 55

lmportan四 of coil cleanliness. ………胃口......… ………··········· ············…… 56
Cleaning the cooling coil. ……......……....…...........町.........……················ ,... 57

Assignment 3 .............…··….........................….............................. 59

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 TOPIC 1

Checking and cleaning

cooling coils
Adding a cooling coil to a forced air furnace adapts it for use as a central
air conditioner. Although the installation and servicing of the air
conditioning unit is done by air conditioning technicians, the cooling coil
must be cleaned as part of regular furnace maintenance. A dirty coil, like
a dirty furnace filter, restricts air flow. Figure 3-1 shows a 句rpical cooling
coil.

Courtesy ofBryant Heating and Cooling Systems

Figure 3-1 A typi饵l cooling coil

This 可pe of air conditioning system consists of a cooling coil and a

condenser. The coil (sometimes called m “ A ” coil because of its shape)
may be mounted in the supply plenum, or in a cabinet between the supply
plenum and the duct. The condenser is usually located outside the building.
• Two lines circulate refrigerant between the “ A ” coil and the condenser
coil.
The compressor moves the re企igerant around the loop.
• As the furnace forces air through the “ A ” coil, the coil absorbs heat
企om the air, causing the liquid re丘igerant to change to 由e vapo町 state.
\ }

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COOLING COILS UNIT3

• The refrigerant vapour moves to the condenser coil, where heat is

removed to the outdoors, causing the vapourous refrigerant to return to
a liquid state.
• The liquid refrigerant returns to the cooling coil.

Cooling coil units are available for upflow, downflow and horizontal
furnaces. The coil is housed in a cabinet. Figure 3-2 shows possible
locations of the cooling coil cabinet. The liquid used as a coolant varies
depending on the specific unit.

争 Return

。own flow
巳二＝二二＝1 furnace

Upflow

’
furnace

Su I
Figure 3-2 Possible locations of the cooling coil cabinet

MeasL』 ring
temperature The same method is used to measure either the temperature drop across a
change cooling coil or temperature rise across the heat exchanger.
1. Punch or drill a hole in the supply and re阳m air plenums. Where
possible the holes should be about three feet from the furnace.
2. Place a thermometer into 也e air flow through each of the holes.
3. Operate the equipment for about five minutes, with the fan running to
establish the normal air temperature rise or drop. This term means the
di他rence between supply air temperature and return air temperature.

4. To calculate temperat旧e drop across the coil, subtract the temperature

at the supply side 仕om 也e temperature on the return side.
To calculate temperature rise across the heat exchanger, subtract the
return side temperature from the supply side temperature.

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UNIT 3 COOLING COILS

Measuring
pressure drop Measuring the pressure drop across the cooling coil is one way of checking
across coil the operation of the system. If the measured pressure drop is too great, the
cooling coil unit may need to be cleaned or the blower may need to be
adjusted. The manufactur町、 manual describes the acceptable pressure
drop for the unit.

Pressure drop across the coil can be measured with a magnehelic gauge or
a manometer.

The static pressure check must be done on a coil that is dry and free of
condensate. To measure the pressure drop using a manometer:
1. Find the quarter-inch holes in the inlet and outlet of the cooling coil
unit provided for measuring pressure drop and temperature differences.
Drill holes in the cooling coil cabinet, if none are provided. Take care
not to drill into the cooling coil. The holes should be on the centreline
of the coil.
2. Tum on the blower only.
3. Insert an awl or screwdriver into the measurement holes and open up
the insulation behind them.
4. Level the manometer.
5. Check the rubber hoses 仕om the manometer for leaks.
6. Insert the hose into the holes in the cooling coil cabinet so that about 说
inch extends into the cabinet. Seal around the hole wi也 pu时. The hose
企om the lower end of the incline manometer should go into the
downstream hole. The pressure differential between the press田e of the
air entering and leaving the coil is the pressure drop through the coil
(Figure 3-3).
7. Refer to the manufactur町、 manual for the correct pressure drop and air
volume.
8. Clean the unit and retest before adjusting blower speed. Then, if
necessary, adjust the blower speed to obtain the correct pressure drop
and air volume.

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COOLING COILS UNIT3

Downstream
air flow

舍 Pressure
taps

舍
Manometer

Figure 3-3 Check pressure drop across coils

Importance of
coil Internal and external surfaces of the cooling coil must be clean. Several
cleanliness problems can result from a di此y coil.
• During the cooling season, the coil will not deliver its full cooling
capacity.
• Air flow to the building will be reduced.
During the heating season, both temperature nse across the furnace and
stack temperature will be increased.

The coil should be checked visually for cleanliness when the furnace is
cleaned. In cases where the coil is located in a cabinet, an access door is
provided. If the coil is mounted in the plenum, it may be necessary to cut
an inspection port. Care must be taken to ensure that the coil is not
damaged if a port must be cut.

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 UNIT3 COOLING COILS

Cleaning the
cooling coil The cooling coil must be cleaned when it is dirty. For the gas technician,
this involves cleaning the exterior of the coil itself, and the fins through
which air is forced over the coil. Cleaning of interior surfaces of the coil
(inside the lines) is us阳Uy done by an air conditioning specialist.

Exact cleaning procedures vary depending on the unit that has been
installed. Consult the manufacturer ’s instructions for specifics. The
following is a typical cleaning procedure.
1. Check the fins for accumulated dirt or dust. If the fins are clogged or
di向r, clean them with a vacuum cleaner, wire brush or a fin comb. Use
the vacuum, brush or comb carefully so as not to damage the coil.
2. Inspect the tubing and connections for signs of oil leaks. Spots of oil
indicate a leak which must be repaired by the air conditioning
technician.
3. Outer surfaces of the lines can be brushed or cleaned with a vacuum
cleaner. If necessary, they can be washed with low-pressure water and
mild detergent. If grease and dirt have accumulated, it may be
necessaηr to remove the coils and wash off the accumulation with
steam, compressed air and water, or hot water.

Note:
飞、、－
This should be done by an air conditioning technician.

4. Check and clean the condensate drain system. Clean the drip tray of
accumulated dust or dirt. Probe the drain hole with a screwdriver to be
sure it is not clogged. Pour a small amount of water in the drip tray and
watch to ensure it drains properly.

＼卢

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UNIT 3 COOLING COILS

Assignment 3
When you have completed the following questions, ask your instructor for the
Answer Key.

1. Why would a cooling coil be added to a forced air furnace?

2. List four problems that might develop in a central 臼mace if the cooling coil is not kept clean.

3. If there are no viewing ports allowing the technician to view the coil, what must be done?

4. Why should static press町e across the coil be measured?

5. Where should the test holes for measuring static pressure be drilled?

6. What devices are used to meas旧e pressure drop across the coil?

7. What adjustments should be made if the pressure drop across the coil is too great?

8. What does an oil leak 企om the coil indicate?

9. How can the external surfaces of a coil be cleaned?

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COOLING COILS UNIT3

10. 认That additional kind of cleaning must be done if untreated water is used as the cooling
medium?

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© Canadian standards Association