Reference · physical-layout anchor images

Anatomy & pictorials

The "what it looks like when you open the thing" view. Every electrical concept in this book eventually has to land on a real component in a real cabinet — these are the bridges.

A career plumber knows what a boiler room looks like before they read about one. A career tech reads a schematic and sees the cabinet in their head. For someone crossing trades, the missing piece is the second habit — the mental picture that turns a symbol into a part you can touch. These pictorials exist to build that habit.

System-level view — the big picture first

Before any component-level diagnosis, the reader needs to mentally place everything: the stat on the wall, the air handler in the basement closet, the condenser in the yard, the thermostat wire that connects them, the line-voltage feed that powers them. This is the picture every chapter implicitly assumes you already have.

Residential split system — thermostat to condenser 2nd-floor thermostat · basement air handler · outdoor condenser · cross-section view 2ND FLOOR 1ST FLOOR BASEMENT 72° thermostat 18/8 thermostat wire LED evap coil air handler / furnace supply 30A load center 240V · 30A · 10-3 w/ground disconnect CARRIER 24ANB7 condenser · 2-ton refrigerant line set · suction + liquid 24V Y+C to outdoor contactor 1 Thermostat on interior wall · issues call · R→Y 2 Air handler board · xfmr · blower · evap 3 Main electrical panel 240V 2-pole breaker dedicated to outdoor 4 Outdoor disconnect fused pull-out · last control before condenser 5 Condenser contactor · compressor · fan · run cap 6 Refrigerant line set insulated suction + bare liquid Stat (1) closes R+Y · signal reaches air handler (2) via 18/8 · board energizes 24V Y to outdoor · contactor at (5) pulls in · 240V from panel (3) flows through disconnect (4) to compressor + fan
A typical residential split system in cross-section. Thermostat on an interior wall, air handler with evaporator coil in the basement, outdoor condenser on a pad, panel and disconnect in between. The thermostat wire traces from wall to equipment to outdoor contactor.

Gas furnace — what's inside the cabinet

The single most-referenced piece of residential equipment. Everything in Part 5 — ignition modules, gas valves, flame sensors, limits, pressure switches, blower motors — lives inside this cabinet. Memorize where each component sits and half the chapters turn from abstract into concrete.

90%+ condensing gas furnace — upflow cabinet, cutaway view HSI ignition · single-stage · 80–100K BTU class · ECM or PSC blower 3" PVC vent M PS HONEYWELL ON/OFF LIM R ROL secondary HX · condensing INTEGRATED FURNACE CONTROL PN: CNT06711 · REV C R W Y G C W2 Y2 DHUM LED 3A 40 VA ECM CFM 1200 5µF 370V DOOR SW 120V IN MODEL G8N80H 1 Inducer motor 120 VAC · establishes draft first 2 Pressure switch proves inducer draft to IFC 3 Hot surface ignitor 120 V · silicon nitride, glows red 4 Gas valve 24 V solenoid · Honeywell / WR 5 High-limit switch bimetal NC · opens on overtemp 6 Heat exchanger primary (steel) + secondary (condensing) 7 Flame sensor rod µA DC rectified signal to IFC 8 Rollout switch one-shot bimetal · manual reset 9 Integrated furnace control IFC · the board that orchestrates the call 10 Transformer 120 → 24 VAC · 40 VA typical 11 Blower motor PSC (speed tap) or ECM (PWM signal) 12 Run capacitor PSC only · µF value on nameplate 13 Door interlock kills 120 V when blower cover off Call sequence: stat R→W · IFC starts inducer (1) · PS (2) proves draft · HSI (3) glows · gas valve (4) opens · flame sensor (7) confirms · blower (11) delayed on · limits (5) (8) (13) can interrupt
A 90%+ condensing upflow gas furnace with the cabinet cut open. Call sequence numbered on the callouts: inducer → pressure switch → ignitor → gas valve → flame sensor → blower. Everything else protects or powers that sequence.

AC condenser — what's inside the outdoor unit

Opening an outdoor unit for the first time is disorienting. The layout looks different from the furnace: compressor and fan motor dominate the volume, the control components are crammed into a small access compartment, and almost everything is 240 V hot the instant the disconnect is in.

RUN CAP 45 / 5 µF · 370V ±6% · 60Hz H C F COPELAND SCROLL R-410A · 24K BTU RLA 13.2 · LRA 71 C·S·R AC condenser — access panel cut away single-stage residential · Copeland scroll · dual cap · 24K BTU class 1 Condenser fan motor PSC · 1/4–1/2 HP · pulls air up through coil 2 Fan grille / shroud directs airflow · supports motor frame 3 Condenser coil aluminum fins over copper tubes 4 Contactor 24V coil · switches L1/L2 to compressor + fan 5 Dual run capacitor HERM + FAN + C · failure #1 in AC service 6 Scroll compressor single-phase · C / S / R under cover 7 Crankcase heater prevents liquid refrigerant migration 8 Whip from disconnect 240V L1/L2 · flexible conduit Order of failure: cap → contactor → fan motor → HPS → compressor (last to fail)
Residential condenser with the access panel removed. Control box at top-right contains the contactor and dual run cap. Compressor sits in the center with its terminal cluster covered. Pressure switches tie into the line set. The fan motor hangs from the grille above the coil.

Boiler room — job-site view

Boiler rooms read chaotic until you've seen a few. The electrical story is surprisingly simple — one service switch, one aquastat, zone controls, one or more circulators — but the piping hides the wire runs, so the pictorial has to show both. This diagram traces the thermostat call from wall to pump through the physical layout every tech sees on arrival.

Boiler room — 3-zone hydronic install, job-site view cast-iron gas boiler · zone-valve distribution · Taco-style zone relay panel burner access HONEYWELL 180°F HI LO T/P WEIL-McLAIN CG-5 IBR 140K flue air sep AMTROL #30 ext tank TACO 007-F5 circulator · 120V ZV1 zone 1 ZV2 zone 2 ZV3 zone 3 TACO SR503 ZONE STATUS Z1 · running Z2 · idle Z3 · idle T1 T1 T2 T2 T3 T3 TT TT Z1 R Z2 R Z3 R X X 3A FUSE PWR SW service WATTS feed / PRV 1 Service switch 120V disconnect · first check 2 Aquastat (L8148) HI / LO setpoints · relay coil inside 3 Gas valve (behind door) energized by aquastat burner circuit 4 Air separator removes dissolved gas · has auto vent on top 5 Expansion tank absorbs thermal expansion · bladder type 6 System circulator 120V · driven by zone panel TT 7 Zone valves 24V motor · end switch back to panel 8 Zone relay panel Taco SR503 · stat input → circulator out 9 Feed valve + PRV auto-fill at 12–15 psi · backflow preventer Call path: stat → zone relay panel (8) → zone valve (7) opens → end switch closes → panel TT energized → circulator (6) runs → aquastat (2) calls burner (3)
A 3-zone hydronic boiler install as you'd see walking in. Service switch, aquastat, zone valves on the supply manifold, zone relay panel on the wall, circulator on the return. The dashed heat-colored line is the thermostat call physically routed through the system.

Probe-placement pictorial — µA flame signal

The most commonly-run test on a gas furnace, and the one where probe geometry matters most. Getting this pictorial into the reader's head prevents the classic mistake of trying to read flame signal as an AC voltage across R and C. The meter goes in series with the sensor's wire — not across it.

Flame signal probe test — measuring rectified µA DC meter in series between IFC flame sensor terminal and the disconnected rod wire STEP 1 · METER IN SERIES INTEGRATED FURNACE CONTROL FLAME SENSE R W Y G LED IFC · Flame Sense highlighted spade lug wire to flame sensor → 4.2 µA DC AUTO V~ V⎓ mV Ω µA⎓ mA VΩmA COM FLUKE · 87V red → flame sense black → wire SETUP 1. Disconnect the flame sensor wire from the IFC "FLAME SENSE" terminal. 2. Red probe → board terminal. Black probe → disconnected wire end. 3. Meter in series. Dial on µA DC. Call for heat. Expect 2–6 µA. STEP 2 · WHAT THE FLAME DOES HSI flame rod to meter ↑ µA flow THE PHYSICS Flame conducts electricity — but unequally. More ions flow from the grounded burner → tiny rod than the reverse. Net DC current = flame proof. EXPECTED READINGS (µA DC) < 1 µA dirty rod / weak flame / bad ground 2–6 µA healthy — typical field reading No flame → 0 µA → IFC shuts gas valve in ~0.8 sec. Weak flame (< 1 µA) → intermittent dropout. Only DC component proves a real flame — AC leakage can't fool it.
Flame signal µA DC test. Spade lug pulled off the IFC's FS terminal — meter in series between that terminal and the spade. Red probe in mA/µA jack, black in COM, dial on µA DC. Burner relit and reading taken after flame stabilizes.

Photo annotations — for your own job-site images

The drawn pictorials above explain how systems work in the abstract. But there's no substitute for a real photograph of a real piece of equipment when you want to say "this is what a Copeland scroll compressor actually looks like sitting on a pad in a Jersey driveway." The <PhotoAnnotation> component takes any image and overlays numbered technical callouts — same visual language as the pictorials, but with your photos underneath. Drop in a photo from your phone, a licensed stock image, or a Wikimedia Commons shot, specify where the callouts anchor in percent coordinates, and the component handles the rest.

Demo — replace the placeholder with a real photo

Placeholder demonstrating the PhotoAnnotation component 1 2 3 4
  1. 1
    Inducer motor — establishes draft before ignition
  2. 2
    Pressure switch — proves inducer draft to IFC
  3. 3
    Burner tubes — manifold + 4-tube array
  4. 4
    Blower assembly — PSC or ECM · scroll + wheel

Coordinates are percentages of the image dimensions, so the callouts scale with the photo. The placeholder here shows how the labels flow; a real photo just drops in as the src.

Placeholder · replace /public/demo-furnace-photo.svg with your own image

USAGE

import PhotoAnnotation from "@/components/illustrations/PhotoAnnotation.astro";

<PhotoAnnotation
  src="/photos/condenser-interior.jpg"
  alt="Carrier condenser with access panel removed"
  title="Service call — 8/14/2026"
  annotations={[
    { x: 72, y: 38, num: 1, label: "Run capacitor",
      detail: "swollen top · failed", side: "right" },
    { x: 45, y: 52, num: 2, label: "Contactor",
      detail: "burn marks on L2 lug", side: "right" },
    { x: 40, y: 78, num: 3, label: "Compressor terminals",
      detail: "C/S/R under cover", side: "left" },
  ]}
/>

Coordinates are percentages (0–100) of the image's rendered width/height. side places the label column ("left" or "right" — defaults to right). On narrow screens both columns collapse below the image as a numbered list.