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COMFORT STILL MATTERS
When it comes to superior indoor thermal comfort, hydronics is the premium solution homeowners should be willing to pay for.
BY JOHN SIEGENTHALER
Aside from the fact that they are all used in hydronic heating systems, what do the following items have in common? a) PEX tubing, b) ¾-in. copper elbows, c) boilers, and d) ball valves.
Answer : They are all commodities in the North American hydronics market. There are dozens of choices for all these items from a wide variety of manufacturers. You can buy all of them at traditional wholesalers , big box stores, or online.
Price is often the major determinant of which brands sell the most, and the majority of your clients don’t know enough to specify which brands of these commodities they want in their system. Most don’t care. Instead, they trust you to make
the right selection. After all, you’re the industry professional.
Which of the following would you also label as commodities? a) Ford Focus, b) Tesla Model S, c) Plymouth Voyager minivan, or d) Ford F-350 6.7L PowerStroke.
I suspect many of you probably consider the Ford Focus and the Plymouth Voyager as the commodity vehicles to be found in this list.
But wait, aren’t all four of these vehicles available from hundreds of dealerships? Can’t they all get you from point A to point B? Aren’t they all capable of easily exceeding speed limits? Don’t they all have heating, cooling, power windows, anti-lock brakes, and radios? So, in some sense, aren’t they all commodities?
But why would someone pay upwards of $100,000 for the BMW, and not much less for a fully loaded F-350, when for about 1/4 of the price they could get the Ford Focus, and still drive to and from where they need to be? Why would anyone pay so much more when all the basic functions can be had for far less?
The potential answers span quite a range: luxury interiors, superior performance (the Tesla model S does 0-60 mph in 2.3 seconds), heated seats, huge touchscreen panels, Apple CarPlay, Bluetooth… and perhaps even superior ride comfort.
Surely, it’s no surprise that there’s a huge spectrum of features and associated prices when it comes to purchasing automobiles.
ACCEPTABLE VS. AWESOME
If only more people could translate this discernment when it comes to home comfort systems.
A basic 20-year-old furnace connected to an adequate ducting system can keep the thermostat in a typical modern house satisfied.
In most cases it can do this even when the air temperature at the ceiling is 20F higher than at the floor. Even when the sound of air whistling through registers requires the volume on the 85-inch flat screen TV to being cranked up. And even
when a photo of what has accumulated inside the ducting would quickly spoil most peoples’ appetite.
Many North Americans apathetically accept what their heating and cooling system does or doesn’t do.
During winter they cope by wearing “hoody footies”, or buying room humidifiers, electric space heaters, and WiFi thermostats that promise to reduce their fuel consumption (which they do by reducing indoor temperatures and further degrading already marginal comfort).
In recent years I’ve watched the market for those “little white boxes on the wall” (A.K.A. ductless mini-splits) increase exponentially.
Walk the floor at trade shows like CMPX and you’ll see many offerings for these systems. Surf the web and you’ll find many government-funded incentive programs for installing these systems. Listen to the radio in the morning and you’ll hear advertisements touting the “free” money offered by government and utility incentive programs, and that most of your neighbours qualify for that free money.
Ask a contractor if they would rather attempt to unravel an existing heating system that’s been buggered up by various contractors over several decades, or just abandon that system and drill a few three-inch holes though the exterior wall for refrigerant tubes to connect the little white boxes to the mothership outside.
Several market forces have aligned to boost the market for these systems. Most of them involve concepts such as easy, fast, plug-and-play, remote control, and photos of happy people with bare feet sitting on couches as one of those little white boxes on the wall lovingly watches over them.
THERE ARE CHOICES
Imagine an experiment in which a typical family is first situated in a home, in Regina, conditioned by several little white boxes on the wall.
They live in that house for a couple of
years and get to experience all the nuances of air-side heating and cooling.
Then they move to another nearly identical house next door in which a heat pump supplies properly installed radiant floor panels or panel radiators during winter, and a central chilled water air handler supplies summer cooling.
After a couple years they’re asked which system provided better comfort, including evaluation of thermal comfort, acoustical comfort, and respiratory comfort.
What’s your bet as to which system gets the better evaluation?
“True comfort is a luxury, not a commodity”
Suppose you then told them that the hydronic system cost about 20% more than the little white boxes on the wall, and both systems have about the same operating cost.
In effect you’re offering them the Tesla or the F-350 for about 20% more than the Ford Focus. Which option do you think most of them would choose?
STAY ON MESSAGE
As a professional in the hydronics industry, you should never lose sight of what you’re selling (e.g., comfort).
Never take the attitude of all’s well when a thermodynamic balance of Btus in = Btus out is achieved. Doing so is like the Tesla dealer conceding that it’s pointless to compete against those dealers selling the Ford Focus.
Do you see that capitulation happening in the auto industry?
Of course not!
Superior comfort has been, and continues to be, the primary reason that informed owners choose hydronic systems.
Most of that demographic has taken some time to understand the differences in what’s available, and most are willing to pay a reasonable premium to have years of unsurpassed comfort.
Unfortunately, that demographic remains a relatively small percentage of North American households. Most of the lesser informed majority don’t know what’s possible or what they’ve been missing. Instead, they put on a sweater and move to a different chair to avoid the drafts.
Hydronic pros have access to a technology that can - allow me some sarcasm here - “blow” the doors off the heating comfort delivered by air-based systems.
Don’t squander the possibilities or “apologize” for a reasonable premium to achieve those possibilities.
Don’t capitulate to a one-size-fits-all plug-and-play approach.
Use your knowledge to create simple, repeatable, serviceable systems that are compatible with future energy trends and capable of delivering superior comfort.
We live in a world full of commodities. Those little white boxes on the wall are but one example.
With a myriad of choices when it comes the heating (and cooling), many homeowners believe that any HVAC system available to them could do the job. Perhaps from the standpoint of a simple thermodynamic balance between Btus in versus Btus out they’re right.
But comfort - true comfort - in a North American home, is a luxury, not a commodity. Professionally crafted hydronic systems are the pathway to that luxury. Understand it, believe it, and sell it! <>
John Siegenthaler, P.E., has over 40 years of experience designing modern hydronic heating systems and is the author of Modern Hydronic Heating (4th edition) and Heating with Renewable Energy. To learn more visit: hydronicpros.com.
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AFFORDABLE HOUSING USING HYDRONICS AND HEAT PUMPS
The True North development in Dartmouth, Nova Scotia, benefits from the electrical efficiencies of heat pumps for space and water heating.
BY DOUG PICKLYK
Nationwide, Canadians are being faced with an affordable housing crunch. For years the combination of rising demand for homes and a limited housing supply has led to rapidly rising prices. Stagnant wages have made keeping up impossible, and as a consequence, individuals and families are struggling to find affordable places to live.
But the challenge of meeting the demand for affordable housing for economically challenged Canadians isn’t a new
phenomenon. Groups from coast to coast have formed to help provide shelter for local citizens. One such group is the Affordable Housing Association of Nova Scotia (AHANS), a not-for-profit that has been actively involved in building affordable housing and upgrading existing housing stock since the mid-1980’s.
Part of the group’s aim is to build resilient housing with a vision towards netzero-ready infrastructure, and one of their latest projects combines the benefits of passive design with hydronics and heat pump technology to deliver an optimized and efficient housing solution with no gasburning appliances.
The True North project in Dartmouth consists of a multi-phase multi-unit rental housing development funded by the Federal Rapid Housing Initiative and built on land received from the Halifax Regional
Municipality. The goal of the project is to offer a variety of affordable rental rates for three- and four-bedroom townhouse units in a family-oriented mixed income community.
The initial 18-unit apartment complex made up of two buildings in an L-shape, designed by Passive Design Solutions, features a tight building envelope and a solar PV array on both rooftops making it Net Zero ready.
“We are heating 18 units, and producing all of the domestic hot water, using two five-ton heat pumps,” notes Benoit Maneckjee, founder of ThermAtlantic, the Newfoundland-based developer of air-towater heat pump components and controls. With a focus on affordability and simplicity, without sacrificing comfort, the mechanical engineer on the project, William Marshall, president of Equilibrium
Overview of the 18-unit affordable housing development on True North Crescent in Dartmouth, NS.
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Engineering, part of LMMW Group in Dartmouth, specified the ThermAtlantic products for the build.
Designed as split system air-to-water heat pumps, the ThermAtlantic direct expansion to water (DX2W) module is located indoors and can pair up with various outdoor air-source heat pumps to supply refrigerant into the building.
Although designed to work with reversible heat pumps for heating and cooling, for this affordable housing project the design called for a heating only mechanical room, and instead of in floor heating they elected to go with low temp radiators in the units.
The outdoor design temperature for the Halifax/Dartmouth area is -18C, and based on modeling for passive design of the building the design temperature for the space heating is 105F [40.5C].
HEATING ONLY
“The ThermAtlantic product is cool because you can hook anything to it,” says Scott Carvery, owner of Scotia Mechanical, who handled the HVAC installation, working alongside Blackburn Bennett Plumbing and Heating on the project.
In the trade for 20 years, Carvery incor-
porated Scotia Mechanical in 2013. After years as a chiller mechanic, now his company works more on high-end residential and medium to light commercial jobs along with a lot of service work.
Something of a fluid mechanics specialist, Scotia Mechanical has worked on a lot geothermal and an increasing number of air-to-water systems.
“The biggest difference from what we’re used to doing, is we basically bought a heat exchanger with controller from ThermAtlantic, and we were able to buy any appropriate heat pump. At True
North we went with a two-stage Trane XL outdoor unit with a nice roof cover on it. There are two outdoor units, so it’s got some redundancy,” notes Carvery.
The mechanical room is located in the middle of the L-shape project design. From the DW2W modules the heated water flows through a 120-gallon buffer tank then through a back-up 15 kW electric boiler for supplemental heating if required.
“The supply temperature is 105F and we have the capacity to put it up to 115F if we really need to,” say Carvery, noting that the backup boiler will not engage unless supply water drops to 95F.
In the first year of operation the boiler only came on when a heat pump was down, and another time when a power surge in the area took out the controls, a situation that was remedied within a few days.
The buffer tank satisfies the space heating demand for the complex with one Wilo smart circulator in constant pressure mode feeding the space heating supply with a zone valve for each apartment.
HOT WATER CASCADE
The heat pumps are not only supplying the space heating but also providing preheat for the DHW. “What’s really important, is that once you get into the multi-unit
The two 5-ton Trane XL heat pumps to supply space heating for the 18-unit apartment complex.
The two DX2W indoor split air-to-water heat pump modules connected in parallel, with back-up electric boiler and circulator.
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residential market, you start to realize that domestic hot water is a huge portion of the energy bill,” notes Maneckjee. “With the systems I’ve been doing since 2018, we are fully electrifying domestic hot water production.”
It’s a design he calls “airdronics,” a play on hydronics. The True North system uses a two-stage cascade, with the outdoor air source heat pumps used for pre-heating the water through a 120-gallon double coil indirect tank, and then feeding two 80-gallon Rheem hybrid heat pump water heaters which lift the temperature to the desired output.
The design also includes a fan coil located in the mechanical room to heat the air in the colder months to assist the heat pump water heaters.
“Normally one of those heat pump water heaters is recommended for a family of four, and in conventional applications it’s responsible for bringing 45 to 50F cold water up to 125 to 130F. But when you feed it 105F water, it has a lot less work to do,” explains Maneckjee, “So we are able to maximize the capacity of those two heat pump water heaters so they can service the roughly 80 people that live in those units.”
Carvery was also impressed with the water heating design. “We’re not only preheating our domestic water with a heat pump, but then we’re actually heating it a with heat pump. We’re really able to leverage the electricity substantially.”
The multi-unit complex also takes advantage of hot water recirculation, which is monitored and optimized.
CONSTANT MONITORING
ThermAtlantic has been installing air-to-water systems for over a decade, and every one of its systems comes with an Internet monitoring service. And with the advancement in technology, now installing contractors and building managers can also access an online dashboard through an app that can send alerts to their phones, and if something goes awry they also have a real-time view and can make adjustments to the system.
For this project, the dashboard keeps track of kWh consumption, output, net efficiency, and breaks it down between the heat pumps, the heat pump water heaters and the auxiliary electric boiler.
According to Maneckjee, one of the benefits of monitoring is an 80% reduction in call backs. “The sad reality is that with the increased complexity of HVAC systems now that heat pumps are becoming prevalent, people must get used to the fact that there are going to be more call backs.
“And the next problem is that your technicians are going to have to be more experienced on this technology than most are today.”
He suggests that any HVAC company that is going to offer monitoring is going to need people who understand the very systems that they’re monitoring — eventually he foresees AI being able to monitor and regulate systems, but for now it requires expertise.
Carvery is impressed with the tracking features: “It was cool being involved in that and hopefully, a sign of things to come with engineers and designers putting a little more emphasis on energy efficiency and monitoring.” He also sees real value in finally getting a monitoring system like this for lower-budget smaller builds.
The mechanical system for True North was commissioned in August of 2023, and the next phase of the development is underway. Carvery was happy to be part of the project. “This area in Dartmouth has seen next to no growth in the last 30 years. To say we need housing is an understatement, and it’s an exciting time to be a part of this,” says Carvery.
“There’s just so much innovation, so much change in the trade right now. I really think the sky is the limit when it comes down to what’s possible and who’s out there really putting rubber to the road with making this change.”
“It’s this type of work that will get the next generation interested in the industry as well.” <>
The 120 gallon buffer tank and 120 gallon double-coil indirect tank.
PHOTOS: BENOIT MANECKJEE
The two 80-gallon hybrid heat pump water heaters supply all 18 units.
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CAST-IRON TO CONDENSING
Considerations for retrofitting to new efficient boiler systems.
BY DAN RETTIG
The hydronic heating industry has seen a broad adoption of high-efficiency condensing boilers in all retrofit applications. Frequently, the previous boiler that served a building was a conventional, standard-efficiency, cast iron model. This is true among older commercial and industrial customers.
The switch from high-mass cast iron to low-mass condensing technology is being driven by several factors, including energy efficiency mandates. In most instances, the benefits include lower energy expense, quieter operation, and increased space in the mechanical room. There are, however, several considerations that installers should consider before making the conversion.
VENTING
The most common hurdle to overcome during a high-efficiency retrofit is boiler venting. Mechanical rooms are often in a
When
difficult location with limited access and space. At times, this may require some creativity to get the vent installed within the requirements of the new boiler.
Masonry chimneys and existing steel venting cannot be re-used when retrofitting with a condensing boiler for two reasons. First, many of the cast iron or steel boilers being removed are atmospherically vented, meaning the flue did not need to be sealed. Modern high-efficiency boilers (and some conventional boilers) are designed for induced draft, meaning the flue operates at a static pressure higher than the atmosphere in the boiler room. This means the venting must be sealed.
Second, the heat exchangers in condensing appliances are so efficient that flue gases are cooler and can be vented in multiple materials if the manufacturers have tested and certified the appliances with each type of vent material. The common materials are stainless steel, polypropylene, CPVC and PVC. The condensate is corrosive and will destroy other vent materials. Each appliance will
have different venting requirements so the installation and operation manual should be referenced before each job.
SYSTEM PIPING
When replacing a conventional boiler with a condensing boiler, it’s important to look at the existing system piping. Is the existing system a full-flow or primary/ secondary layout?
In terms of flow rate, the current system must offer what the new boiler requires. If the system can’t facilitate sufficient flow, it must be re-piped.
Not all condensing boilers can be installed with a full-flow piping arrangement. Even if permitted, full-flow systems can be problematic because multiple zones with different flow rates can make it difficult to maintain the minimum flow required at the boiler.
Primary-secondary arrangements can still present water flow issues, so installers must fully understand the requirements. Proper installation of closely spaced tees is critical. The system circulator must pump away from the point of
converting from standard to high-efficiency boilers, it’s important to understand the differences between the technologies.
Venting and gas supply considerations are different and proper combustion analysis is critical.
no pressure change, and the system flow must always be greater than the boiler flow.
SYSTEM CLEANING
Cleaning a hydronic system before any boiler retrofit is good practice, but it’s especially important when converting from a conventional boiler to a high-efficiency boiler, or when the existing system includes old cast iron rads or black pipe.
This is because the channels within a high-efficiency heat exchanger are much smaller than those inside a cast iron boiler and are more likely to clog when decades’ worth of sludge is introduced.
Additionally, many high-efficiency hydronic retrofits include the use of permanent-magnet ECM circulators. These circulators are prone to collecting black iron oxide sludge around the wet rotor, causing early failure.
The best way to clean the system is to
use a cleaning solution, like those produced by Fernox, Sentinel, or other hydronic water treatment brands.
Some installers prefer to circulate cleaning fluids and flush the system before the old boiler is removed, but this can be problematic because it exposes the entire system to the debris that was resting at the bottom of the cast iron boiler sections.
Other installers prefer to wait to flush the system until the new boiler is installed. This removes the dirt inside the old boiler, but now exposes the new boiler to the dirt that had been dormant within the system piping and radiation.
The best way is to either isolate or move the existing boiler, introduce cleaning additive, circulate and flush. After a thorough flushing the new boiler can be installed.
It’s also good practice, and sometimes a requirement, to install a magnetic sep -
Z-Vent
arator in a high-efficiency hydronic system, especially a system that has been exposed to black pipe or cast-iron components.
CONDENSATE DISPOSAL
Condensing boilers generate flue gas condensate as a byproduct of efficient combustion. In rough numbers, condensate is produced at .75 gallons per hour per 100,000 Btu/h of gas fired capacity. This fluid has a pH range of 3.2 - 4.5, making it acidic.
Anything downstream of the mechanical room can be damaged, including drains, cast iron sewer lines, and on-site septic systems.
As a result, flue gas condensate must be neutralized by a properly installed and maintained neutralizer and disposed of via a drain. Depending on the location of the boiler, a condensate pump may be needed in addition to the neutralizer.
THERMAL PERFORMANCE
VENTING
For the safety of both property and occupants proper venting of condensing gas-fired appliances is critical
Over time, scaling, poor combustion, elevated temperatures, and lack of maintenance can cause appliance fl ue gas temperatures to rise above safe operating temperatures of plastic vent material
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GAS SUPPLY
It’s considered best practice to replace the existing gas regulator when converting a hydronic system from conventional to condensing technology.
Older regulators may not be able to facilitate the changes in gas pressure as a result of modulating burner turndown ratios. In some instances, old regulators can’t adjust rapidly enough and could potentially create gas supply issues.
With the introduction of turndown ratios above 5:1, the industry learned that not all regulators respond the same. There are lock-up and non-lock-up type regulators. Lock-up type regulators are very effective at eliminating spikes in gas pressure, but these units can also have slower response times, creating problems for modulating burners.
Some gas valves won’t open if there’s too much pressure. A utility line gas pressure spike could result in a no-heat situ -
ation. Also, some regulators don’t respond rapidly enough to provide the gas pressure needed by the boiler as it quickly modulates up.
It’s critical to follow the instructions supplied with a new regulator, especially the vent line sizing. Some regulator manufacturers require an increase in the vent line diameter as lengths increase.
Never assume the connection size on the boiler will work for each job. Static and dynamic gas line tests are best practice before any retrofit and are definitely the first thing to be checked if there are ignition issues or loss of flame.
RETURN WATER TEMPERATURE
Over the years, it’s amazing how many times I’ve heard that a high efficiency boiler retrofit didn’t yield the energy savings expected. The problem is that the return water temperatures are too high to permit condensation of flue gases. If
condensation never occurs, the savings potential will never be achieved.
Return water temperatures depend almost entirely on the amount and type of radiation installed relative to the heat load of the space. Return water should be roughly 130F for proper condensation. Without low enough return temperatures, a condensing boiler will operate at similar efficiencies as a cast iron boiler. That said, the condensing boiler has the advantage of firing rate turndown, which could be enough benefit without the unit operating in condensing ranges.
Mod-con boilers are no longer new technology, are not difficult to install, and the retrofits become business as usual after one or two projects where best practices are followed and all factors are taken into account. <>
Dan Rettig is a product manager with Thermal Solutions.
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HELP ME, HELP YOU
Technical support is here to solve your problem, let’s work together.
BY CURTIS BENNETT
If you have read anything I have written before you will know that I have had a few electrical mishaps. Working in the field of hydronics control systems, I do a lot of testing while designing new products. I have all the static safety mats and wrist straps to make sure I don’t shock the controls when they are out of an enclosure. Well, one day I was doing some testing on a raw board, meaning it was out of the case, and of course there was 120VAC needed to power the board. Testing the board includes hooking up sensors and then hooking up the power. The unit turns on, thing are fine, and then I did something dumb. I pressed on the connectors. Now the back of the connectors are pointy and sharp, so when I
pressed on the board the connectors broke the surface of my static mat.
Now you may or may not know, but static mats are conductive. When you touch one or are connected to it, the conductivity will “absorb” the potential difference between you and the mat. The mat is usually grounded so it will protect the electronics.
I hope you noticed that I said “conductive”. Well, when I pressed on the connectors and they pierced the static mat, can you guess what happened? A very large flash and a nice electrical pop. It scared the living “beep” out of me.
I now live with a reminder on my desk, because I have a static mat with a discolored burn mark on it. I have found that I learn more by messing up because usually I get shocked from messing up, and it imprints in my brain. Anyways enough of my stupidity we need to move on.
Today’s topic is one near and dear to my heart. Tech support.
START WITH THE BASICS
I don’t take as many tech support calls as I used to, but I do get pulled into the complex ones—but those are not on the agenda today.
For this article we will talk about product support. Seems a bit boring, but it’s a big topic at most manufacturing companies. Now keep in mind this comes from my perspective as a “small” company where we do not outsource our tech support. Not saying anyone else does, just saying we do not.
I want to start with a few ways to get you the best support possible. This can be a delicate subject, because the first part of receiving great customer support put the onus (responsibility) on the person needing the support, you.
I understand there can be frustrations, I do, but remember that the person on the other end doing the support is a person too.
Ok… so, the first point is ‘Be Concise.’
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The job of tech support is to help you with your problem, not redesign your system.
Yes, we need to know certain items in your system, and we will pull that information from you if we need it, but often customers will just start talking about their issue without explaining which product they are calling about—in our case “Which control is it?”
So, always start with the basics: What control is it? What is not working on the control? Notice I said, “on the control.” Calling in and saying, “My boiler does not work,” may not be enough information to get started.
The second point is do a little ‘due diligence.’ It’s frustrating to receive a call and nothing has been tried already. Once again, we are here to help, we want to make your support experience the best it can be, but we need you to know a few things about your system, items like: What pumps are connected to the con-
“99.8% of WiFi connectivity issues are that the SSID and/or password have been entered wrong. Double check the spelling.”
trol? How many and what types of boilers are they? Two-stage boilers or single stage? Is the DHW connected to our control or is it just on an aquastat?
I think I have said this in a previous article (thank you Jerry Maguire): “Help me, help you.”
Here’s where things get a little delicate: “Take a look at the manual.”
Like many other manufacturers out there with components that supply the hydronics industry, we have a QR code on the front of our products that link directly to the manual. Take a quick look.
If you are looking for what certain op -
tions do, the manual for all products will explain that. You will save yourself time and frustration by reading the manual.
We have so many customers call in, and the answer was on page 18. Ok, probably not on page 18, well maybe it was, but you get my drift.
The third point is when checking the control, ‘disconnect the wires from the control.’ For example, if you think the boiler is not turning on because of the control; disconnect the wires going to the control and test right at the control. This will tell you if it’s the control or the rest of the system very quickly.
We will ask you to test continuity anyway, it’s one of the first tests we like to do. Continuity is a test for a short or an open. Most meters will beep, but you still should look at the meter.
Most continuity tests will beep and give you the resistance of the test. The beep will indicate anything below, let’s say 100 ohms, but if the test is at 89 ohms and you should have a perfect short (which is 0 ohms) then this can also show an issue. Ok, this is slightly off topic, sorry for that.
BAD CONNECTION
One of the main issues we run into is bad reception. This is not anything we can solve. You call in, don’t get support right away, so you leave a message. We call you back, but you are back in the basement and do not get the call because of bad reception. In most cases we do not keep calling back. We must move to the next call.
This can be extremely frustrating to the customer, and we get that, but it’s out of our hands. At HBX we have imple -
mented a good chat feature on our website, and I know other companies have as well. This helps a lot, because with chat our support team can be doing more than one support service at a time, so problems get solved faster for you.
Another issue involves products being “connected”. All of our controls come with Wi-Fi built in. This comes with its own set of issues. You are going to think I’m exaggerating, but 99.8% of Wi-Fi connectivity issues are that the SSID and/or password you are entering are wrong.
Spending 20 minutes on the phone only to find out that you did not capitalize one of the letters in the network name is really a waste of time for both sides. So, confirm the SSID and password. It will solve most of these issues. No joke.
The other part of the Wi-Fi connectivity is the difference between 2.4GHz and 5Ghz. Just because your phone sees the network does not mean the control can. Most controls are still 2.4GHz. A lot of routers provide a dual frequency broadcast, but IT guys often shut off the 2.4GHz portion. Keep that in mind. We see it all the time.
Last, but not least, it’s important to have some prior knowledge of what the control you are using can do. I know, it’s a lot to ask, especially when it comes to controls that pack a lot of options into them. I will say it again because I have not said it enough: “Read the manual.”
I am a huge culprit here too, so don’t get me wrong. But just do it. By reading the manual you will find other items that the control can do, that may not only help with the current installation but will help out with future installations and make your life easier with wiring and determining how to control a system.
Looking back on what I wrote here it seems like I am putting a lot back on the customer, and I am.
This may be my final article after all of the complaints come in. But believe me, supporting products is not an easy task. I know controls have bugs, parts fail,
they are shipped across the country and then ride in a parts van for 400 kms. Things can go wrong, and they do.
All manufacturers want to solve your problems as quickly as possible. Your time is valuable, and to spend hours on the phone is not a pleasant experience. I hope you can use a couple of these tips to make that easier for all parties, and, oh yeah… read the manual. <>
Curtis Bennett C.E.T., product development manager at HBX Control Systems in Calgary, co-founded HBX with Tom Hermann in 2002. Its control systems are designed, engineered and made in Canada to accommodate a range of hydronic heating and cooling needs.
SETTING UP SERVICE PLANS
Leverage manufacturer manuals to design and sell maintenance.
BY MATHEW POTTINS
Ithink we know that for most small to medium-sized plumbing and HVAC companies the value of the business is tied very closely with the owner. These service companies ride the tide of how much business the owner/salesperson/installer (usually all the same person) can drum up.
In the last few years, through a lot of conversations, watching, listening, and learning, I’ve realized it doesn’t always have to be this way.
It is possible to create deep and lasting value in an HVAC company, so that when it’s time to retire, move on or simply take a vacation, the company still generates plenty of income on a recurring basis to feed the business and grow.
And what’s even better, for those in the hydronics design, installation and servicing business, you will find that the manufacturers of the appliances and parts you use everyday are actually (secretly/not so secretly) trying to force you to do this— and all you have to do is … read the manual.
I know, I know, these are the most annoying three words in all of HVAC, but I'm here to tell you that there is more to these documents than safety precautions, installation instructions and charts and graphs.
TAKE THE TIME
Look, I get it. These days as soon as I open a book I’m basically sleeping, but when it comes to making money and building my company, I’m always wide awake. That’s how I would view reading the manuals that come with the products you work with, and so should you.
So where am I going with all of this? As the title of this article suggests, Service Plans!
Not only can building a service plan help your company in the long run, but it will help you sell jobs, earn new customers and grow your business.
We know that hyrdonic systems are complicated. We know these systems require routine maintenance. We know that sys -
tems are expensive and need to be sold to end users. So how do you do that?
PLAN OF ACTION
Believe it or not, we can leverage the product manuals to help sell systems and design and develop comprehensive service plans. As you are trying to sell a project or a service plan you can open the manual of any boiler manufacturer, circulator maker, air bleeder or condensate neutralization kit supplier and highlight key points. For example:
• NTI Boilers Maintenance: “Perform annual maintenance inspection of the boiler’s heat exchanger, combustion chamber and burner. Check and adjust the flue gas composition to ensure efficient combustion. Clean the condensate trap and ensure the drain is clear to prevent blockages and corrosion.”
• Caleffi Air Bleeders: “Manually or automatically bleed the system to remove trapped air, which can cause inefficiencies and noise. Inspect and replace seals to prevent leaks.”
• Taco Circulators: “Regularly check for leaks and ensure bearings are lubricated (not as common with new magnetic motors but still relevant). Ensure the impeller is free from debris to maintain flow rates. Inspect and tighten all electrical connections to prevent malfunctions.”
• JJM Neutralization Kits: “Regularly replace the neutralizing media to maintain effectiveness in neutralizing acidic condensate. Check the housing for any signs of damage or leakage.”
These are only a few of the components of the overall hydronics puzzle, I didn’t mention magnetic dirt filters, feed valves, glycol systems, etc. The point is, your service plan is al -
ready built for you in the content supplied in all of these manufacturers’ manualsl. You simply have to read the manuals and 'borrow' the best parts.
“Manufacturers’ manuals are goldmines.”
SOFT SELL
I do know for some technicians, the idea of selling and promoting doesn't come naturally, but with a little effort it can make a huge difference. Here’s the sales pitch: “By following the (insert manufacturer’s name) recommended maintenance schedule, our service plan ensures that your heating system operates at peak efficiency, reducing your energy bills and extending the life of your equipment. Regular checks and adjustments outlined in the manual not only keep your warranty valid but also provide peace of mind knowing your system is safe and reliable. Sign up for our compre -
MEET THE HEET!
hensive service plan today and enjoy the benefits of a well-maintained hydronic heating system.”
What homeowner is going to say no to that? It builds trust and shows you know what you’re doing.
Manufacturers’ manuals are goldmines, not just to learn how to install, service and troubleshoot products, but they actually help you to sell.
It’s just a matter of how you look at it and then how you present it.
All you have to do is READ THE MANUAL! <>
Mathew Pottins has worked with HVAC manufacturers and suppliers for over a decade, and his passion is in growing the industry. He runs Laylan Hydronics and HVAC Sales and can be reached at mathew@laylanhvac.com.
HYDRONICS PRODUCTS
The Vitocal 100-AW from Viessmann is a residential air-to-water heat pump system including an outdoor unit, an indoor unit and a 20-gallon buffer tank. The system comes in three sizes, 1.5, 3 and 4.3 tons for cooling/20.5, 34 and 58 MBH for heating. An optional indirect storage tank allow for DHW and comes in three sizes, 53, 66 or 79 gallons. The indoor unit features auxiliary heat, or the unit can be paired with a furnace or boiler using a dual fuel switch. The heat pump uses the low GWP R32 refrigerant Viessmann.ca
The Pro-Pal E-Tank Service Assembly from Webstone simplifies the installation and service of a hydronic expansion tank. Its forged brass design features isolation valves for the system, a dedicated drain valve, and a union connection at the expansion tank to provide control during installation. An automatic air vent, pressure gauge, and steel mounting plate are also included. The dual union-ended ball valves provide isolation for cold water supply and the system. The assembly supports tanks up to eight gallons. webstonevalves.com
NTI Boilers new Compass is a condensing floor mount, fire tube boiler with a new user interface for set up and troubleshooting. The unit features independently reversible plumbing connections, as well as a built-in ECM pump. With its field reversible left- or right-hand piping and built in primary/secondary, it makes retrofitting to existing piping systems easier than a wall hung. The heat exchangers are made of Chromium stainless steel. The boiler maintains 95-96% AFUE and is available from 85-199 MBH. Systems can be designed to cascade up to eight boilers, and are available in both combi and non-combi models. ntiboilers.com
Johnson Controls new YORK YMAE 575 V air-to-water inverter scroll modular heat pump is compliant with the Canadian Registration Number (CRN) requirements for pressurized equipment in certain provinces. The unit features variable speed electronic vapour injection (EVI) scroll technology to expand heating capacities. Available in two- and four-pipe configurations, the YMAE 575 V can deliver 60C (140F) water in heating capacities up to 443 MBH while in heating-only mode, and 546 MBH during simultaneous heating and cooling using recovered energy. The YMAE 575 V uses the lowGWP refrigerant R454B. Up to four modules can be factory-kitted. york.com/commercial-equipment
Caleffi’s 149 Series FLOWMATIC Express is a compact pre-assembled terminal unit coil kit, which contains a 145 Series FLOWMATIC pressure independent control valve (PICV). The multifunction device simplifies a complex task to four pipe connections. Assembled from individual components, the kit provides flow control, balancing, bypass, filtering, isolation and flushing functionality. Optional on/off or modulating actuators add automatic control for connection to a local controller or BAS. caleffi.us
McDonnell & Miller, a Xylem brand, updated its electronic low water cut off (LWCO) product line, including the GuardDog RB-24SE and RB-122E for residential hot water boilers. Both updates share the company’s selfcleaning probe that minimizes scale buildup and protects users from potential boiler shutdowns or water overfill. The updated line also features a leak-free brass metal-tometal seal and a push-to test button that quickly confirms proper operation. xylem.com
The new Calbalance 4-in-1 hydraulic separators from Calefactio separate water, air, dirt and ferrous debris while also isolating the primary circuit from the secondary circuit for heating and snow melting applications. The unit improves system efficiency by preventing corrosion, blockages, noise, and excessive energy consumption. The easy to install 4-in-1 hydraulic separator product line is offered with 1-in. to 2-in. NPT connections including a wall support, the new model is available with a 2-½-in. to 4-in. flange. Preformed polyurethane insulation is also available as an option. calefactio.com
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ThermAtlantic, the Newfoundland-based manufacturer of air-to-water heat pump components and controls, new DX2W-EX3 series of indoor control offers native support for most heat pumps using cold climate inverters using enhanced vapour injection (EVI) technology. The third-party heat pump outdoor units supported now includes central split inverters with 24VAC thermostat support including those manufactured by Gree or Midea. Units using the latest EVI inverters extend the operating envelope down to -25C and broaden the heating capacity by as much as 60% compared to the previous generation of conventional heat pumps. thermatlantic.com
Jaga Climate Systems’ Astra Beam is a non-ducted fan coil that can use chilled water to extract heat from indoor air. Equipped with a tangential fan, it circulates air through a high-capacity hydronic coil. The unit can deliver up to 1.5 tons of cooling using 43F entering chilled water, for heating and cooling efficiency. It operates on 54 watts of 24VDC power for .08 watts per CFM. An integrated condensate tray manages condensation. The unit features a single grille that handles the supply and return air as well as access to the fan coil. jaga-canada.com
Viega is growing its portfolio of press products with the addition of 21 valves across its ProPress, MegaPress and PureFlow systems to satisfy and broader spectrum of residential, commercial and industrial projects. Key new products include swing check valves and strainers for ProPress and MegaPress systems, brass ball valves and a complete hydronic balancing valve offering. The update also includes a ProPress 3-way mixing valve and a ProPress 3-piece ball valve. Users are able to press multiple system fittings and valves with the same tool, for improved efficiency and reducing overhead costs. viega.us
The VoltMax range of electric boilers from Thermo 2000 has been developed to power hydronic heating systems in commercial, institutional and industrial applications. Available in a range of voltages to adapt to single-phase or three-phase electrical supply, the units’ electronic controllers enable precise temperature, power and dual-energy management to optimize performance. Units can deliver from 22.5 kW up to 408 kW. The controller can modulate the power of the unit from 0 to 100%, based on heating demand. Compact in size, they fit into small spaces and require little clearance. thermo2000.com
Our NEW wall-hung & floor standing boilers, the perfect fit for commercial needs. Solutions offered as a boiler or a volume water heater.
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HeatLink has a new line of 1-¼-in. and 1-½-in. stainless steel manifolds for residential and commercial applications. Offering pre-assembled configurations from two to 12 loops, the 1-¼-in. manifolds include integrated 1-in. FNPT isolation valves and hose bibs. The 1-½-in. manifolds (pictured) include ball valve isolation for each supply loop and hose bib on supply and return manifold. The larger manifolds are suitable for large commercial, snow melting and as a distribution header handling a max. trunk flow rate of 50 gmp and max. operating pressure of 145 psi. heatlink.com
Taco Comfort Solutions enhanced its line of switching relays and zone valve controls adding priority zoning for circulators and pumps, or fan controls. The NextGen Zone Controls offer: simple wiring and grounding; priority protection, postsurge, pump exercise timers; diagnostic lights for all outputs; five programmable outputs to control circulators, boilers, heat pumps, ventilation and more; DHW recirculation; and mobile app connectivity. Applications can include 2-, 3- or 4-wire zone valves. The controls are fuse-protected, compatible with universal thermostats, and offer 24-volt output for hard-wired thermostats. tacocomfort.com
Weil-McLain’s ECO Tec stainless steel fire tube family of modulating condensing boilers feature a 95% AFUE and include heating models in four sizes (80, 110, 150 and 199 Btu/h) and combi models in three sizes (110, 150 and 199 Btu/h). There is a built-in circulator for both heating and combi models, and they come in a wall mount design with optional colourmatching floor stand. The models include the company’s new colour touchscreen control and the cabinet design allows for easy service accesss. weil-mclain.com
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STRETCH IT OUT
Consider using extended manifold designs where possible to use less tubing, less drilling and less fastening.
BY JOHN SIEGENTHALER
Several years ago I had the opportunity of visiting the Mostra Convegno Expocomfort show in Milan, Italy. The international trade show ranks right up there with the famous ISH show in Frankfurt, Germany, as a “bucket list” event for those who are passionate about hydronic heating and plumbing.
After spending a couple days walking the show, one of the folks at the huge Caleffi booth asked me; “What are your impressions of Mostra?”
I gave a rather off-the-cuff response: “Does the world really need more manifold systems?”
SO MANY MANIFOLDS
There were dozens upon dozens of manifold offerings. They were made of copper, brass, stainless steel, polypropylene, and other engineered polymers.
Some had balancing valves, along with trim such as isolation valves, air vents, fill/drain provisions, temperature gauges, electric valve actuators, and spaces for labeling each circuit.
Some manifold station systems even included circulators, mixing valves, insulation shells, and provisions for hydraulic separation.
Much of this technology is now available in North America, with dozens of suppliers and a wide range of options.
Manifold stations, in some sense, have become a commodity in the global hydronics market.
They are most widely used in radiant panel systems for heated floors, walls, and ceilings. It’s common to see mani -
fold stations that can accommodate from two to 12 individual circuits. These circuits are typically “gathered” together as they approach the location of the manifold station, as shown in Figure 1.
I like to “fan out” the circuits in the vicinity of the manifold station, as seen in Figure 1. This reduces “hot spots” or weak points in a slab due to many tubes running in parallel lines at very close spacing.
STRETCHING THE CONCEPT
Fundamentally, all manifold systems are just a way to divide an entering flow in multiple parallel paths. This provides the same supply water temperature to each path. It also allows for individual circuit flow adjustments.
The latter is “enhanced” by the fact that head loss along the length of a typical short and larger diameter manifold is very small relative to the head loss
PHOTO COURTESY OF PETER GASPERINI
Figure 1. Manifold stations make sense for heated floors, walls, and ceilings.
through individual parallel circuits.
There are situations where a classic manifold station collecting multiple parallel circuits, although possible, may not be the best option.
One example is a homerun distribution system that serves many panel radiators that are spread out all over a relatively large building.
In theory each radiator could be supplied and returned to a single manifold station, but doing so would probably require several hundred feet of small (3/8-in. or ½-in. PEX , PERT, or PEX-AL-PEX) tubing, along with many holes drilled through framing, clips where the tubing runs along the framing, and possibly hundreds of feet of tubing insulation if some of the tubing is routed through unconditioned space.
Insulated or not, all this piping emits heat into spaces that are not where the radiators being served are located.
The goal is to get the heated water from the manifold station to each of the heat emitters being served with minimal amounts of materials and labor. Poorly planned or located manifold stations, such as the one shown in Figure 2, can “waste” a lot of tubing.
EXTENDED MANIFOLD
An alternate approach is what I call an extended manifold. It’s basically two straight runs of rigid piping with several tees located as close as possible to where the flexible tubing circuits begin and end. Figure 3 (next page) shows the concept for one extended manifold that serves several panel radiators and two floor heating circuits.
This assembly is for a house with a design heating load of 36,000 Btu/h. In total it serves 10 panel radiators and two small floor heating circuits. Flow through each of the 12 parallel circuits is regulated by thermostatic radiator valves. Ten of the thermostatic valve operators are mounted directly to integral valves on the panel radiators.
The two floor heating circuits use a valve mounted in an accessible location and connected to a wall-mounted adjustment knob via a capillary tube. Heat output from each of the 12 circuits can be individually adjusted.
A small variable-speed pressure-regulated circulator operates 24/7 during the heating season. Its speed automatically
increases or decreases as the flow requirements of the heat emitters change. At full speed this circulator requires a power input of just 44 Watts. Under more typical partial load conditions it operates between 20 and 30 Watts.
Over 24 hours, and operating at an average power input of 30 watts in a location where electricity costs $0.20/kWhr, the operating cost of this circulator is about 15 cents per day.
The extended manifold consists of two runs (supply and return) of ¾-in. copper tubing. Each branch connection is made using a ¾-in. x ¾-in. x ½-in. tee (sweat or press).
The ½-in. side port on each tee transitions to a ½-in. PEX-ALPEX compression fitting. Figure 4 (next page) shows the fittings at one of these “take-off” points.
“Poorly planned or located manifold stations can ‘waste’ a lot of tubing.”
The project in which this particular distribution system was installed had a 12-in. deep laminated veneer lumber (LVL) main girder running the length of the building to support the floor joists. The ¾-in. tubing that forms the extended manifold just runs straight along this girder. After pressure testing the copper tubing was covered with ½-in. thick elastomeric foam insulation.
You’ll notice some short stubs of ½-in. copper that are soldered to the brass adapters connected to the ½-in. PEX-AL-PEX tubing. This was done because there was no source (at the time) for ½-in. PEX-AL-PEX x ½-in. FTG adapters, which, if avail -
Figure 2. Not an ideal manifold station location.
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NEXT Supply along with industry experts will guide attendees towards enhancing their hydronic knowledge on the following topics:
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• Hydronic Controls 101
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able, could have been directly pressed to the ½-in. side ports on the tees.
The total flow rate to the extended manifold, at design load conditions, is only about 4 gpm. So each ¾-in. tube is only operating at approximately 2 gpm (assuming the mains tie in at the midway point between all the heat emitters, and with all heat emitters operating).
Because the extended manifold piping was insulated there was very little tem perature drop from where the mains con nect, to the outer end of each ¾-in. tube. Thus, each heat emitter receives water at about the same temperature.
Individual flow adjustments (e.g., bal ancing can be done at each of the radiator valves).
The buffer tank allows the “microzoned” distribution system to operate without short cycling the heat source. This project used an air-to-water heat pump as the primary heat source, but it could just as easily be a boiler or a combination of a heat pump and a boiler.
The control logic is simple: operate the heat source(s) as necessary to maintain some specified temperature range in the buffer tank. It could be a setpoint range such as 100F to 120F, or based on outdoor reset control. The latter will typically improve the performance of heat pumps
as well as mod/con boilers.
Extended manifolds trade a few feet of rigid piping (typically type M copper, or fused PP-R) for what otherwise would be many more feet of ½-in. flexible tubing (PEX, PERT, or PEX-AL-PEX) along with a manifold station to connect all that flexible tubing to.
They can greatly reduce the amount of drilling and fastening required to install the distribution system. They represent an alternative to “classic” homerun distribution systems, where all circuits begin and end at a single compact manifold station. Keep them in mind when the right building layout comes along. <>
John Siegenthaler, P.E., has over 40 years of experience designing modern hydronic heating systems and is the author of Modern Hydronic Heating (4th edition) and Heating with Renewable Energy (visit hydronicpros.com).
Figure 4. Example of a fitting at one of the “take-off” points on the extended manifold.
Figure 3. Schematic showing the concept of an extended manifold serving several panel radiators and floor heating circuits
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