HPAC February 2024

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WHAT IS PFAS?

‘FOREVER CHEMICAL’ CONCERNS
FEBRUARY 2024 HPACMAG.COM Follow Us On @hpacmag GRINDER PUMPS REFRIGERANT EVACUATION DUCTLESS ACCESSORIES
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15

FEATURES

10 COVER STORY

HVAC

NAVIGATING THE PFAS LANDSCAPE

Understanding the evolution and potential challenges of forever chemicals in the HVAC/R industry.

15

DUCT FREE ZONE

NECESSARY ACCESSORIES

Take advantage of the new mini split installation and service aids available on the market.

52 PLUMBING PUMP AND GRIND

Taking care of the unflushables and reducing call backs.

58 REFRIGERATION

EVACUATION PLAN

Mastering the vacuum pump, the technician’s key to efficient system charging.

COVER PHOTO: TYLIM/GETTY IMAGES
CONTENTS
10 52
P4 FEBRUARY 2024 / VOL. 98 NO. 1
CONTINUED ON
HPACMAG.COM FEBRUARY 2024 | HPAC 3

CONTENTS

MH6

HEAT PUMPS

WHEN ONE ISN’T ENOUGH

Details for piping multiple hydronic heat pumps together in one design.

MH14

PROJECT

OPERATIONAL NET ZERO

Carmichael Engineering’s new branch office in Belleville, Ontario provides a template for the company’s future net zero projects.

MH18

BUSINESS

THE MAINTENANCE PLAN

Ensure long-term customer satisfaction by removing the confusion and offering service plans and more with every installation.

MH20

30 MECHANICAL MINUTES

ELECTRIC BOILERS:

WHEN AND WHERE?

John Seigenthaler joins HPAC to talk about how electric boilers work and where they make sense.

MH24

DUAL FUEL

THE BIG SWITCH

Modern controls can optimize hybrid gas/electric hydronic heating solutions, here’s why it matters.

MH26

HYDRONICS PRODUCTS

MH28

DESIGN

MATHEMATICS VS. REALITY

Exploring the non-proportional relationship between heat output and flow rate.

4 HPAC | FEBRUARY 2024 HPACMAG.COM DEPARTMENTS 6 UPFRONT 8 NEWS FEATURE Report supports geothermal and thermal storage to offset Ontario grid loads. 8-9 INDUSTRY NEWS 49 MECHANICAL SUPPLY NEWS 50 PEOPLE 61 THE SOURCE 62 CALENDAR
FEBRUARY 2024 / VOL. 98 NO. 1 MODERN HYDRONICS SPRING 2024 BUILDING TO OPERATIONAL NET ZERO New construction in Belleville DUAL FUEL MULTIPLE HEAT PUMPS FLOW RATE AND BTUS a publication of MH 26 MH 18

BREAKTHROUGH TECHNOLOGY

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Flexi-Rooter ® featuring ClogChopper ® Cutters

Flexi-Rooter uses ClogChopper six-bladed cutters along with carbide-tipped chain cutters to break through the toughest clogs, scale and roots. The cutters then grind up the stubborn stoppages and scour the pipe walls clean.

The rotating shaft is 10 times faster than traditional shafts, yet easy to handle. It’s extremely exible for clearing 2" lines, yet strong enough to cut roots in 4" lines up to 75 feet long. Plus, the foot pedal leaves both hands free to guide it into the drain.

To learn more, visit www.drainbrain.com/Flexi-Rooter, or call the Drain Brains ® at 800-245-6200.

Visit us at CMPX Booth #1702

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< UPFRONT

GAME TIME

THERE IS NOTHING QUITE LIKE THE FEELING YOU EXPERIENCE IN A PACKED

STADIUM OR ARENA WHEN THE HOME TEAM IS PLAYING AN IMPORTANT GAME. The crowd energy is palpable, you can feel it in your bones, there is real excitement in the air. Well, when walking the halls at the AHR Expo in Chicago on the first two days of the show this year, that's what I was reminded of. It wasn't quite playoff game energy, but it was definitely a very important regular season game and the attendees were excited and happy to be there.

Despite near zero temperatures outside on day one, crowded hallways and packed booths were a welcome sight for the exhibitors and the show organizers. The annual expo for the HVAC/R industry hadn’t been in Chicago since 2018, and the strong attendance was a great sign, revealing great interest from the contractor community to see the latest products available and gain insights on industry trends.

It's an interesting time in the industry with such a strong global push on environmental issues and reductions in carbon emissions. The HVAC/R sector is facing significant change from technology applications to refrigerant phase downs and restrictions that are coming on board soon.

It was no surprise to see a strong heat pump presence across the major heating equipment manufacturers, and this was a significant show for hydronics as air-to-water heat pumps begin gaining more traction based on the number of products revealed, some serving as previews of what’s to come.

Yes, electrification and decarbonization continue to be popular themes at exhibitor presentations, and although the concept of artificial intelligence (AI) was being thrown around and attracting interest, it’s still a challenging subject to communicate in terms that make sense, so it wasn’t a main topic of discussion for most of the presentations I saw.

During an engaging State of the Industry panel discussion on Tuesday, the key messaging for contractors centered around the need to encourage ongoing training among HVAC techs and the ever-important role of contractors as the conduits of educating homeowners and building owners on the new technologies coming out and how these new solutions can best provide comfort while meeting efficiency or environmental goals.

The upcoming refrigerant phase downs was also a hot topic, and keeping up to date on what is happening with refrigerants is very important for contractors. One panelist, Talbot Gee from HARDI insisted that the transition to A2L (mildly flammable) refrigerants is going to be unlike any other transition the industry has experienced before.

Steve Yurek of AHRI stressed the need for more industry training around that topic, and he emphasized the growing importance of R410a recovery and reclamation going forward to support the large existing installation base.

Like I said, this year's trade show energy was high, and I expect the Canadian crowds will bring that playoff level excitement to CMPX next month in Toronto. I look forward to seeing you there.

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REPORT SUPPORTS GEOTHERMAL AND THERMAL STORAGE TO OFFSET GRID LOADS IN ONTARIO

A new report commissioned by the Ontario Clean Air Alliance recommends incentives to boost the installation of more ground source heat pumps, thermal storage solutions, electric batteries and two-way electric vehicle chargers to help offset the demand on the province’s power grid.

Prepared by McDiarmid Climate Consulting, the study, An Analysis of the Impacts of All-Electric Heat Pumps and Peak Mitigation Technologies on Peak Power Demand in Ontario, did the research to determine how the shift to using heat pumps to heat and cool homes in Ontario will affect peak period electricity demand.

It’s widely acknowledged that Ontario and other provinces will need to increase grid capacity as more sectors of the economy electrify, and this report analyzes specific solutions for reducing peak power draws from single family homes that adopt all-electric heat pumps.

The conclusions reveal that solutions such as thermal storage, batteries and pairing with electric vehicles can reduce demand more cost effectively than building additional electricity generation.

It shows how installation of ground source heat pumps (GSHP) instead of air source heat pumps (ASHP) can reduce the power demand from all-electric heat pumps on winter peak hours.

Therefore, it recommends that utilities and governments incentivize the adoption of all of these solutions for single family homes.

The entire report can be viewed at the Clean Air Alliance website. cleanairalliance.org

NEXT PHASE OF DEPARTMENT OF ENERGY COLD CLIMATE HEAT PUMP TECHNOLOGY CHALLENGE UNDERWAY

The U.S. Department of Energy (DOE) has announced that four additional heat pump manufacturers (Bosch, Daikin, Midea, and Johnson Controls) have successfully produced heat pump prototypes as part of the DOE’s Residential Cold Climate Heat Pump (CCHP) Technology Challenge, and their prototypes will join products from Lennox, Carrier, Trane, and Rheem in the next phase of the Challenge, which is to involve the installation and monitoring of more than 23 prototypes in various cold-climate locations throughout the U.S. and Canada over the next year.

First announced in May 2021, the Challenge — launched in partnership with Natural Resources Canada (NRCan) and the U.S. Environmental Protection Agency (EPA) — was enlisting manufacturers of residential, centrally ducted, electric-only heat pumps, and the Challenge had two segments: one for a CCHP optimized for 5F (-15C) operation (“the 5F challenge”) and the another for a CCHP optimized for -15F (-26C) operation (“the -15F challenge”).

In the Challenge Specifications, published in September 2021, manufacturers could choose to participate in either one or both segments of the Challenge.

The first six industry partners announced in Fall 2021 included: Carrier, Daikin, Johnson Controls, Lennox, Mitsubishi Electric and Trane. In February 2022 three more companies joined the Challenge: Midea, Rheem and LG. And subsequently Bosch also joined the Challenge.

In June 2022 it was announced that Lennox had developed the first prototype that achieved the Technology Challenge’s lab testing standards, delivering 100% heating at 5F (-15C) at double the efficiency, and 70% to 80% heating at -5F (-20C) and -10F (-23C).

Now there are eight companies (Bosch, Carrier, Daikin, Johnson Controls, Lennox, Midea, Rheem and Trane) participating in the field testing phase of the 5F challenge. It’s still to be determined if product commercialization can be achieved in 2024. energy.gov

FEDERAL PROMPT PAYMENT LEGISLATION NOW IN EFFECT

To ensure all construction workers on projects contracted by the Government of Canada are paid in a timely manner, the government has announced that federal prompt payment legislation has come into force as of December 9, 2023

The Federal Prompt Payment for Construction Work Act states that the federal government will have 28 calen -

dar days to pay after the contractor submits a proper invoice.

The contractor will then have seven days to pay its subcontractors; subcontractors will have another seven days to pay their sub-subcontractors; and so on down the contracting payment chain.

The federal prompt payment legislation aims to ensure that payment for the construction is predictable and timely.

Any existing construction contracts will

8 HPAC | FEBRUARY 2024 HPACMAG.COM SEE THE LATEST NEWS @ HPACMAG.COM INDUSTRY NEWS
CCHP technology challenge timeline.

have one year, as of December 9, 2023, to comply with the new Act.

Also, any federal construction work being done in provinces or territories that have already enacted a similar prompt payment and adjudication regime (which currently includes only Ontario, Saskatchewan and Alberta), in those designated provinces contracts will by default be under the prompt payment regime of the province. canada.ca

COLD CLIMATE HEAT PUMP PROTOTYPE BEING DEVELOPED IN TORONTO

Terravis Energy, a subsidiary of New York-based Worksport Ltd., is testing a working prototype of a cold climate air source residential heat pump in a specialized climate chamber in Toronto.

“We are engaged in this rigorous and severe testing protocol because Terravis’s mission is to offer a zero-emission residential heat pump that sets new standards in cold-weather performance,” commented Terravis Energy’s CEO, Lorenzo Rossi in a company press release. “Our heat pump’s goal is to provide heat to homes in as low -31F (-35C), which we believe will make us the most effective heat pump technology in the market.”

The testing chamber conducts cold weather trials across a range of temperature points from 14F (-10C) to -31F (-35C). These tests include checking four refrigerant pressure zones, airflow, and the energy consumption of each component with an aim of optimizing the heat pump’s efficiency and performance at various temperatures.

The Terravis heat pump is being designed to offer an easy-to-install modular design permitting different ways of mounting depending on the space.

MECHCAN EXPANDS INTO B.C.

MechCan Inc., the Canadian company that has been partnering with and rolling up mechanical services companies, has expanded beyond Ontario with its acquisition of Pro Ace Heating & Air Conditioning of Vancouver.

This marks MechCan’s seventh transaction since the business launched in January 2022. Its other acquisitions have all been in southern Ontario and the Ottawa area.

“Since its inception in 2005, Pro Ace’s success has been driven by our commitment to customer satisfaction,” said Ali Soroush, Pro Ace’s owner-operator.

Pro Ace will continue to operate under its brand and retain its team. mechcan.ca

ASHRAE ENHANCES PERFORMANCE STANDARD FOR EXISTING BUILDINGS

ASHRAE has released the latest version of its energy efficiency standard for existing buildings, with an expanded focus to incorporate building decarbonization.

Standard 100-2024, Energy and Emissions Building Performance Standard for Existing Buildings is a codeready building performance standard that provides processes and procedures for reducing energy consumption and carbon emissions through improved energy efficiency of all types of existing buildings, including residential, commercial, institutional, and industrial.

The latest edition of the standard includes carbon emissions performance requirements for existing buildings, as well as emissions targets for dozens of building types. ashrae.org

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NAVIGATING THE PFAS LANDSCAPE

Understanding the evolution and potential challenges of forever chemicals in the HVAC/R industry.

You may not hear much about this topic during your average workday, but in the grand domain of HVAC/R systems, the pervasive and ubiquitous presence of per- and polyfluoroalkyl substances (PFAS) has become a topic of increasing concern and scrutiny.

This family of synthetic chemicals, which some refer to as forever chemicals, was developed by several companies, 3M being a major pioneer starting production of the compounds back in the 1940’s.

The first major product was perfluorooctanoic acid (PFOA) widely used in non-stick coatings such as Teflon, introduced into the market by DuPont in 1945. Highly desirable for their waterand grease-resistant properties, PFAS compounds have been instrumental in a variety of industrial applications, including firefighting foams, non-stick cookware, and, notably, as key components in certain HVAC systems.

While their initial incorporation into these systems brought about unparalleled advantages in terms of performance and efficiency, the dark side of PFAS has gradually surfaced. Some members of this chemical family, known for their persistent nature and resistance to degradation, have been identi -

fied as posing potential risks to human health and the environment, leading to regulatory actions that have banned or restricted their usage in certain regions.

In 2016, the government of Canada banned the manufacture, use, sale, and import of PFOA, its salts and precursors throughout our country.

As we try to reconcile the complexities surrounding PFAS, it becomes imperative for the HVAC industry to examine these challenges carefully, striking a delicate balance between maintaining the beneficial aspects of these chemicals and safeguarding the well-being of our customers and the ecosystems in which HVAC systems operate.

10 HPAC | FEBRUARY 2024 HPACMAG.COM TYLIM/GETTY IMAGES < HVAC Continued on p12
Teflon and plumber’s tape are known products using PFAS chemicals.
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PFAS compounds are now regarded worldwide as “emerging contaminants” as more information about their toxicity and environmental impact becomes known. Fluorination makes PFAS compounds exceptionally durable and slow to break down and thus are persistent in the environment.

PROPOSED TOXIC LABEL

PFAS, or forever chemicals, meet two criteria for being listed as toxic under the Canadian Environmental Protection Act, according to a draft assessment from Environment and Climate Change Canada (ECCC) and Health Canada. Those criteria include their potential long-term effects on human health and environmental biological diversity.

“To reduce the immediate and longterm harmful effects on human health and the environment, important measures are needed to control the use of PFAS,” Canada's Health Minister JeanYves Duclos said in a statement in May of 2023.

This past spring ECCC published a Risk Management Scope for Per – and Polyfluoroalkyl Substances (PFAS) for a 60-day public comment period. The Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI) assembled a panel of experts to address the government’s Risk Management Scope and submitted a lengthy and comprehensive document detailing Canada’s HVAC/R industry’s desire to base any regulatory outcomes on a weight of the evidence approach using the best available science.

Other groups such as the Chemistry Industry Association of Canada took exception to the proposal in which all PFAS would be treated as an entire class, noting: “It is neither scientifically accurate nor appropriate to regulate as one class,” and, “Canada will not be able to meet climate goals without fluorinated chemistries,” said the associa -

tion’s policy manager Danielle Morrison.

To date there has not been any indication as to the regulatory route ECCC and HC intend to take, however, ECCC has, no doubt, received numerous and complex briefs from other industries that will be affected as well.

“PFAS compounds are now regarded worldwide as “emerging contaminants”

REFRIGERANTS & COMPONENTS

It should be noted that PFAS compounds represent a diverse and wideranging group of synthetic compounds valued for their strength, versatility, and durability.

We are learning about the need to limit or to even prohibit certain PFAS compounds from certain applications, however, many other PFAS composites have well-known properties that do not pose unreasonable risks to human health or the environment when used properly.

The U.S. Environmental Protection Agency (EPA) has developed a working definition of PFAS in which chemicals must have at least two adjacent carbon atoms that are fluorinated, and at least one of those must be fully fluorinated. The EPA characterization means approximately 6,500 chemicals used throughout North America would fall under their definition.

Even so, the EPA’s definition makes it difficult to determine which substances might fall under any new regulation. The HVAC/R industry depends upon fluorinated gases such as Hydrofluorocarbons (HFC) and Hydrofluoroolefins (HFO) to provide heating, cooling, and refrigeration to meet societal needs that include

preserving agricultural produce and dairy products, pharmaceutical cold chains, and human comfort.

Potential PFAS restrictions could include a comprehensive list of currently used pure refrigerants, such as: R-125, R-134a, R-1234ze and R-1234yf, and many others.

Blends such as R-410A, R454B, R-513A, R-448A also fall under the EPA’s definition of PFAS.

R-32, also an HFO, is not on the list as it is outside of the proposed EPA definition, at least for now.

A U.S. industry group, known as the Sustainable PFAS Action Network (SPAN) is a “non-profit organization representing stakeholders that responsibly produce and utilize PFAS compounds in a wide range of commercial products,” according to their website.

SPAN membership includes: Arkema, Daikin, Honeywell, AHRI, and the Aerospace Industries Association (AIA), among others.

SPAN argues that HFO’s do not show any of several characteristics frequently cited as most concerning when related to PFAS compounds; they are not persistent, bioaccumulative, nor toxic. In fact, SPAN noted EPA’s proposed Toxic Substances Control Act does not include HFO’s.

SPAN advocates for a science-based management policy noting how a blanket restriction that treats all PFAS compounds the same would have devastating economic and safety consequences for our and many other industries.

As there are currently no alternatives to HFO’s, an all-out PFAS ban leaves only the “natural refrigerants” such as CO2, ammonia, and the A3’s left to work with.

The European HVAC/R industry association, EUROVENT, has expressed similar concerns about banning PFAS and fluoropolymer refrigerants, noting, “For

Continued on p14

12 HPAC | FEBRUARY 2024 HPACMAG.COM < HVAC Continued from p10

SETTING A NEW INDUSTRY STANDARD IN HYBRID HEATING PRODUCTS.

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*Time of use rates is currently only available in Ontario, Canada.

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Continued from p12

those components a time unlimited derogation for both fluoropolymers and non-fluoropolymers should be developed that also reflects the availability of spare parts for repair in the sense of Ecodesign (e.g. is not acceptable to scrap a compressor due to unavailability of an PFAS free O-ring with interchangeable design).”

Fluoropolymers are used in many devices because of their chemical inertness and durability—these are the same characteristics that also make them undesirable.

You are going to find PFAS in a wide variety of components and tools used every day by about everyone, everywhere in our industry. Here is a small sampling: compressor oils and components; air filters: anti-drip additive in flame retardant plastics; coax cables; electronic components – diodes, capacitors, sensors, motors and switches; exterior cabinet paints and coatings; foam cleaning and firefighting agents; heat exchanger tubes –hydrophilic coating (potential); high temperature and/or chemically resistant O-rings/seals/gaskets; lithium-ion batteries – electrode substrate and in the electrolyte; plumber’s tape (PTFE / Teflon); printed circuit board coatings (potential and likely); and pumps (using PFAS O-rings, seals, gaskets).

EUROVENT describes the fundamental importance of PFAS on the properties of air filters, namely the ability to remain durable in high humidity applications along with providing superior dust holding capacity.

Air filters typically contain a PFAS compound known as C6 (PFHxA) providing water and oil repellency. C6 is added to the filter during manufacturing preventing the media from absorbing bonding adhesives that would otherwise plug the air passages and reduce the filter efficacy. There is no alternative to C6 at this time.

In a pathogen-anxious world, the po -

tential loss of air filtration media could leave many people feeling vulnerable, although I would be just as worried about our unfiltered HVAC equipment suffering damage from accumulated contaminants.

WHAT IS THE PROBLEM?

Scientists, citing the precautionary principle, are studying the effects of PFAS compounds, especially those that might contribute to developmental defects in fetuses and infants.

Some are suggesting a potential link between certain PFAS compounds and an increased risk of cancer.

PFAS has been shown to accumulate in the liver over time, potentially leading to liver damage, and exposure to PFAS compounds may suppress the immune system; metabolic issues might be caused by PFAS induced thyroid damage; some PFAS exposures are potentially linked to reproductive problems including decreased fertility and hormonal imbalances.

Some scientists, like Professor Miriam Diamond of the University of Toronto Department of Earth Sciences said in a recent interview by CBC’s Marketplace program, “we can’t afford to wait for more studies.”

Governments are studying proposed legislation to ban PFAS chemicals, for example, the European Chemical Agency (ECHA) suggests chemicals and mixtures along with articles (complex goods) having 25 parts per billion (ppb) or more of any particular PFAS compound, or 250 ppb of a combination of PFAS ought to trigger a potential ban. If finalized, the ECHA proposal would be one of the most all-encompassing chemical bans ever enacted.

This kind of proposal puts all PFAS chemicals in the same class despite a hierarchy of significant differences. Certainly, expect a ban on the low hanging fruit such as any PFAS compounds

that have immediate alternatives combined with toxic labelling of complex goods and chemical preparations.

There is also no question about restricting manufacturing, use and marketing of products potentially contaminating food or drinking water.

In late November 2023, the 6th U.S. Circuit Court of Appeals dismissed a class action lawsuit against PFAS manufacturers 3M and DuPont. The judge decided the suit filed by the lead plaintiff was too broad and failed to show how the PFAS detected within his body could be linked to the manufacturers.

Such a finding does not mean we can rest on our laurels, certainly more studies are needed so that a solid database of credible facts about any harmful effects to humans and to the environment caused by PFAS can be compiled.

As if the coming transition to A2Ls will not be stressful enough, there is little doubt that every industry could be affected by the PFAS regulatory process.

Businesses may well have to reexamine the composition of their products and potentially institute redesigns free of PFAS fluoropolymer compounds costing untold billions of dollars.

In the meantime, learn more by visiting the SPAN website (span.org) and monitor the Environment Canada and Climate Change website (canada.ca/ en/environment-climate-change). And of course, continue to use personal protective equipment (PPE) when appropriate and dispose of chemicals according to the manufacturer’s instructions and local regulations. <>

Ian McTeer is an HVAC consultant with over 35 years of experience in the industry. He was most recently a field rep for Trane Canada DSO. McTeer is a refrigeration mechanic and Class 1 Gas technician. Reach Ian at imcteer@outlook.com.

14 HPAC | FEBRUARY 2024 HPACMAG.COM
< HVAC

NECESSARY ACCESSORIES

Take advantage of the new mini split installation and service aids available on the market.

Mini splits have become so popular that their sales and installations increase annually by double digits, and as a result an onslaught of mini split installation/service aids and accessories have hit the market—some good, some not so much. But there are a few I now consider necessities for anyone in the trade.

The first essential product has to be a surge protection device. I’m always shocked (pun intended) when I’m conducting a mini split training class and find out many installers and technicians have never considered surge protection or even heard of it as it relates to HVAC equipment.

A surge protection device will protect equipment and the control boards within equipment from damaging voltage surges, whether man-made in the form of something internal to the grid or an act of God like a lightning strike.

In a home my wife, Patricia, and I owned in New York state, we had an older inverter mini split that heated a four-season room (a glass enclosed deck if you will). The compressor fried on its own, but because I had a surge protector on the system it did not take out the board along with it.

How do I know the surge protector saved the board? Easy, the surge protector has a little green LED light that illuminates as long as the surge protector is not spent (most are one and done). In my case, the surge protector was spent, clearly sacrificing itself to save the board when the compressor fried—impressive!

Those of you who know me, or read my articles regularly, know that I preach to small business owners that we must always do everything we can to limit our liability. Do all we can to isolate and insulate ourselves and our businesses from liability. A surge protector, a component that in most cases nets out to less than $125, can save you thousands of dollars in lost equipment and liability expenses.

We all put little stickers on equipment that we have installed that say, “When you need service, call ACME Heating & Air.” It’s how we get repeat business, and it’s something all contractors have done since time immemorial. But that sticker has the potential to take you from being the installer to the defendant when that equipment is destroyed by a power surge.

We need to protect ourselves from that potential, and a surge protector does just that!

I have used the Intermatic AG3000 for many years, and recently I used the Rectorseal RSH-50. I see where my friends at Diversitech have introduced the Surge-Trap surge protector. Any one of these products should be included in every mini split installation no matter where that installation is taking place.

FLAIR FOR FLARING

My second item would be a proper flaring tool. Because today’s mini split systems use R410A refrigerant and run at higher pressures than R22, the diameter of the flare needs to be larger to compensate for the higher pressures the connection will experience.

That said, we need to use a flaring tool specifically designed to create the

Continued on p16

HPACMAG.COM FEBRUARY 2024 | HPAC 15
PHOTO CREDIT: WITSAWAT/ADOBE STOCK
DUCT-FREE ZONE >
Mini split evaporator cleaning could be new revenue potential.

Continued from p15

R410A flare. I like the Yellow Jacket Deluxe 45-degree flaring tool.

The key to this tool is that it has a tubing stop; if used properly it won’t allow you to over or under flare the tubing. Now, I won’t say the tool is idiot-proof, because idiots try real hard, but if the tubing stop feature is used as designed the flare diameter and depth will be perfect each and every time.

Now, I’m an old guy so I tend to do things “old school,” but my friend Jeremy Torra of Centric Sales, the NAVAC tool representative, has turned me onto their battery powered flaring tool, the NEF6LM. Besides being “state of the art” technology it also has a tubing stop—brilliant!

Now, a flaring tool alone does not guarantee a perfect, non-leaking flare, but one more element will.

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will assist in creating a seal between the two mechanical components of the flare. I’m a huge believer in Nylog and preach its value in every training event I conduct.

“The exponential growth of the mini split market in Canada provides an opportunity to find new revenue streams.”

CLEAN CLEANING

The last item I want to address is a service-related item. It’s a product that makes cleaning the mini split evaporator coil and blower wheel relatively simple and easy.

The SpeedClean Mini Split Bib Kit, the Rectorseal Desolv Cleaning Kit and the Nu-Calgon Complete Care Mini Split Kit all allow for the cleaning of an indoor unit coil and blower wheel without extensive disassembly of the indoor unit and without any damage to finished walls and floors.

The three products are very similar in that they provide what I call a mini split diaper. The diaper essentially creates a basketball hoop effect around the bottom of the indoor unit.

The bottom of the diaper is then directed into a five-gallon bucket in which the kit was packaged, and then the cleaning process begins. The three products are a bit different in how the diaper attaches, but they all provide a watertight seal that allows power washing of the coil and blower wheel with all fluids being directed into the bucket— Ingenious!

I have heard horror stories from service techs of how they essentially completely disassembled a mini split indoor unit in order to clean it. “No more,” I say. These products are inexpensive, and a single kit allows for multiple uses.

TOOL YOU CAN USE

The exponential growth of the mini split market here in Canada provides an opportunity for service companies to find new revenue streams like mini split evaporator cleaning. All the companies I mentioned and others are producing low-cost service products to help us reap some of the benefits of this extraordinary growth. <>

Gerry Wagner is the vice president of business development for Bathica in Canada. He has 43 years in the HVAC/R industry working in manufacturing, contracting and training. You can contact Gerry by email: GerryWagner@Bathica.com

16 HPAC | FEBRUARY 2024 HPACMAG.COM
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HPAC_Intertek_Feb24.indd 1 2024-01-17 2:44 PM
FOR MORE INFORMATION

MODERN HYDRONICS

SPRING 2024
BUILDING TO OPERATIONAL NET ZERO
FUEL
HEAT PUMPS FLOW RATE AND BTUS a publication of
New construction in Belleville DUAL
MULTIPLE
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HEAT TRANSFER FLUID - INHIBITED PROPYLENE GLYCOL COMPARISON CHART HEAT TRANSFER FLUID – INHIBITED PROPYLENE GLYCOL COMPARISON CHART ***Based on information provided on respective manufacturers’ websites* **Subject to change Brand Chem Frost 100% Eco Frost Brand O Brand R Brand H Brand U Brand D Pail Size 20L 18.9L 18.9L 18.9L 20L 20L 18.9L PG % 95/5 94/6 N/A 92/8 94/6 95/5 95/5 Aluminum Safe YES NO NO NO NO NO NO Solar Compatible YES LIMITED Temp LIMITED Temp NO NO NO NO Geothermal Compatible YES YES N/A N/A N/A N/A N/A Temperature Rating 325F 250F 250F 275F 250F 250F 220F Viscosity @ 50% 100F 5.5cP N/A N/A N/A N/A N/A N/A Boiling Point @ 100% 417F 370F 370F 370F 370F 370F 370F CFIA Approved YES NO NO YES NO YES NO Raw PG Grade FOOD INDUSTRIAL INDUSTRIAL INDUSTRIAL INDUSTRIAL INDUSTRIAL INDUSTRIAL Purity of Propylene Glycol 99.94% 99.7% 98% N/A N/A N/A N/A Phosphate / Nitrate NONE YES YES YES YES YES YES Inhibitor Type PDT NON-TOXIC DKP DKP DKP DKP DKP DKP LEED YES NO NO NO NO NO NO Energy Savings Up to 60% None None None None None None Based on information provided on respective manufacturers’ websites* **Subject to change**

MH6 HEAT PUMPS When One Isn’t Enough

Details for piping multiple hydronic heat pumps.

MH14 PROJECT Operational Net Zero

Carmichael Engineering’s new branch office in Belleville, Ontario provides a template for future projects.

MH18 BUSINESS

The Maintenance Plan

Ensure long-term customer satisfaction by offering service plans with every installation.

MH20 30 MECHANICAL MINUTES Electric Boilers: When and Where?

John Seigenthaler joins HPAC to talk about how electric boilers work and where they make sense.

MH24 DUAL FUEL The Big Switch

Modern controls can optimize hybrid gas/electric hydronic heating solutions.

MH26 HYDRONICS PRODUCTS

MH28 DESIGN Mathematics vs. Reality

Exploring the non-proportional relationship between heat output and flow rate.

MODERN HYDRONICS WWW.HPACMAG.COM MH4 SPRING 2024 CONTENTS COVER PHOTO COURTESY CARMICHAEL ENGINEERING
HPAC Magazine receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. HPAC Magazine, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. NOTICE: HPAC Magazine, Annex Business Media, their staff, officers, directors and shareholders (hence known as the “Publisher”) assume no liability, obligations, or responsibility for claims arising from advertised products. The Publisher also reserves the right to limit liability for editorial errors, omissions and oversights to a printed correction in a subsequent issue. HPAC Magazine’s editorial is written for management level mechanical industry personnel who have documented training in the mechanical fields in which they work. Manufacturers’ printed instructions, datasheets and notices always take precedence to published editorial statements. Contents Copyright © 2024 by Annex Publishing & Printing Inc. may not be reprinted without permission. Proud member of: We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities. 111 Gordon Baker Road, Suite 400, Toronto, ON M2H 3R1 TEL: 416.442.5600 FAX: 416.510.5140 www.hpacmag.com MODERN HYDRONICS a supplement of Heating PlumbingAir Conditioning Magazine Doug Picklyk (416) 510-5218 DPicklyk@hpacmag.com David Skene (416) 510-6884 DSkene@hpacmag.com Amanda McCracken (647) 628-3610 amccracken@hpacmag.com Kim Rossiter (416) 510-6794 KRossiter@hpacmag.com Emily Sun esun@annexbusinessmedia.com Urszula Grzyb (416) 442-5600, ext. 3537 ugrzyb@annexbusinessmedia.com Peter Leonard (416) 510-6847 PLeonard@hpacmag.com Scott Jamieson EDITOR ASSOCIATE PUBLISHER NATIONAL ACCOUNTS ACCOUNT COORDINATOR MEDIA DESIGNER CIRCULATION MANAGER PUBLISHER PRESIDENT/COO Modern Hydronics

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WHEN ONE ISN’T ENOUGH

Details for piping multiple hydronic heat pumps.

Multiple boiler systems have been used for decades.

They allow full heating capacity to be delivered when necessary, while also retaining high efficiency under partial load conditions compared to a single large boiler.

They also increase the resiliency of the overall heating plant. If one boiler is down for service at least one other boiler is likely ready to supply at least partial capacity.

All the benefits of multiple boiler systems also apply to multiple heat pump systems. If the set up is configured to supply heating-only, or cooling-only, the generic system piping is identical to that of boilers, as shown in Figure 1.

Each “source device”, be it a boiler or heat pump, is piped in parallel with the others. Each has its own circulator that operates only when that source device is on. Each source device branch contains a check valve, purging valve and at least

one means of isolating the source device from the remainder of the system if it has to be removed or replaced.

The headers that supply and collect flow from the source devices should be short and generously sized (e.g., max flow velocity of two feet per second).

They lead back to a hydraulic separator that isolates the pressure dynamics of the source device circulators from that of the load circulator. The hydraulic separator also provides air and dirt separation.

It’s also possible to pipe a multiple boiler, or multiple heat pump system, using a single variable- speed pressure-regulated circulator along with motorized ball valves on each source, as shown in Figure 2 (page MH 8)

The variable-speed pressure-regulated circulator is set for constant differential pressure mode. It automatically adjusts speed up or down as one or more of the motorized ball valves opens or closes.

In theory, the number of source devices could vary from two up to whatever is needed to meet the design load capacity. However, there are diminishing returns on incremental gains in plant efficiency versus the added cost for piping, as well as space in a mechanical room tends to lead to a “practical” limit of four source devices.

Several manufactures now offer “modular” heat pump products that reduce the external piping requirements. In some cases the header segments are built into each heat pump.

SIMULTANEITY

Many commercial buildings, as well as some large custom homes, can require simultaneous heating and cooling. A common scenario is when the perimeter areas require heating while the “core” areas (e.g., those without exposed exterior

MODERN HYDRONICS WWW.HPACMAG.COM MH6 SPRING 2024
HEAT PUMPS
IMAGES: JOHN SIEGENTHALER
Continued on
Figure 1. Piping plan for multiple energy sources.
MH8
Modern Hydronics

surfaces) require cooling due to internal heat gains. Another scenario is when the building contains large glass areas that receive solar gains on sunny winter days.

There are several ways to design HVAC systems that provide simultaneous heating and cooling. They include variable refrigerant flow (VRF), variable air volume (VAV), four-pipe hydronic systems supplying air handlers or fan-coils, and water loop heat pumps.

Monobloc air-to-water and water-to-water heat pumps are another option for applications requiring simultaneous heating and cooling. Systems can be designed that allow any heat pump to operate independently in either heating or cooling mode.

In addition to space heating and cooling, such systems can be configured to heat (or pre-heat) domestic water or add heat to a pool through a heat exchanger. The piping configuration for such a system, based on monobloc air-to-water heat pumps, is shown in Figure 3 (page MH10)

This design use four risers, two for heated water supply and return, and two for chilled water supply and return. Although shown vertical in Figure 3, these risers can be in any orientation that suits placement of the heat pumps.

Flow in the risers is handled by a single variable-speed circulator set for con -

stant or proportional differential pressure regulation, depending on the length and size of the risers.

If the risers are relatively short and generously sized for a maximum flow velocity of 2 ft/sec., the circulator can be set for constant differential pressure control.

If the risers are long, and represent a significant part of the head loss through the heat pump assembly, proportional differential pressure control can be used.

In either case, the circulator automatically adjusts speed and flow rate as individual heat pumps turn on and off.

Each heat pump uses a pair of threeway diverter valves and a single two-way ball valve. The latter only opens when its associated heat pump is running. It ensures that there is no possible “short-circuiting” through inactive heat pumps.

Without this two-way valve the flow path through the heat pump remains open to either the heating or cooling risers when the heat pump shuts off. This creates a flow path, but with no heating or cooling input.

For example, if the heat pump shuts off in heating mode, the two three-way diverter valves remain in the heating position, which allows cooler heating water to flow through an inactive heat pump and then on to the hot water riser. This

“thermally dilutes” the temperature in the hot water riser.

Each set of risers leads to a buffer tank, one for heated water and the other for chilled water. For the system shown in Figure 3, heated water from the buffer tank is routed to multiple radiant panel manifold stations, and chilled water is routed to multiple fan-coil units.

These emitters are only examples. The heated water could also go to panel radiators, chilled beams, or even satellite air handlers.

Flow on the load side of the buffer tanks is also handled by variable-speed circulators set for proportional differential pressure mode. Each crossover between the distribution supply and return pipes has a zone valve that opens when that crossover is active and closes at all other times.

In addition to thermal buffering, each buffer tank provides hydraulic separation between the circulator supplying the heat pumps, and the load circulator.

The two three-way diverter valves and single two-way valve shown for each heat pump in Figure 3 could be replaced by four two-way valves. However, this likely adds to piping cost and also creates more points of potential failure.

The controls for this system would

Continued on MH10

MODERN HYDRONICS WWW.HPACMAG.COM MH8 SPRING 2024
PUMPS
HEAT
Modern Hydronics
Figure 2. Multiple heat sources using a single variable-speed pressure-regulated circulator and motorized ball valves.

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monitor the temperature of both buffer tanks. Since there is a limit to both heating and cooling capacity, and since any heat pump can only operate in one mode at a time, the control logic must prioritize heating over cooling, or vice versa.

In winter it’s likely that the priority would be heating, and thus operating the heat pumps to maintain the temperature in the heated buffer tank based on some

setpoint or outdoor reset schedule.

Cooling operation might only be allowed when the temperature in the heated buffer tank is within some differential of the target temperature.

During summer the priority would likely switch to cooling. The only heating load might be domestic water heating (if present), or early morning warming of select spaces using low mass heat emitters.

VARIATIONS

Air-to-water heat pumps with variable speed “inverter” compressors are becoming more common. It’s possible to leverage their modulating capacity control with staging to improve the load tracking ability of a plant. Doing so is analogous to how modulation and staging are now commonly combined with boilers.

Continued on MH12

MODERN HYDRONICS WWW.HPACMAG.COM MH10 SPRING 2024
buffer tank temperature sensor (S2)
Chilled
buffer tank
entire system filled with antifreeze solution All piping and components conveying chilled water must be insulated and vapor sealed VS ∆P circulator VS ∆P circulator VS ∆P circulator Air separator Air/dirt magnetic particle separator
Heated
Fan-coil
Zone
Balancing valve
valve
Purge valve
Balancing
Purge valve
Zone valve
valve
isolation valves PRV PRV Heat pump 1
VS ∆P circulator Dirt & magnetic separator
feeder diverter valves
motorized ball valve Heat pump 2 Heat pump 3
feeder
Balancing valves Purging/
Fan-coil
Fluid
2-way
Fluid
HEAT PUMPS
Modern Hydronics
Figure 3. A multiple heat pump set up for simultaneous space heating and cooling.

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A heat pump with a variable speed compressor can reduce its capacity to about one-third of its rated output. If two were combined the overall turn-down ratio would be approximately 6:1.

This range of capacity modulation can eliminate the need for buffer tanks. Hydraulic separators would take their place, as shown above in Figure 4 System controls would monitor the supply on both the heating and cooling distribution system and operate the heat pumps based on load priority of the desired “target” supply water temp.

Another option is based on two threeway diverter valves at each heat pump,

but those valves must have three position settings: one to connect to the heating risers; another for connecting to the cooling risers; and a third that blocks flow through the heat pump when it’s off. This approach eliminates the need for a two-way motorized ball valve to block flow through a heat pump that is off.

Most three-way ball valves could provide the necessary positions. What’s missing (at least from my inquiries) is a three-position actuator. If anyone knows of a source I’m all ears.

The piping concepts shown can also be applied to water-to-water heat pumps sourced from a common earth loop. It

would also be possible to combine heat pumps with one or more boilers.

The market for heat pumps as alternatives to fossil fuel boilers is growing rapidly. Designers need to have concepts for deploying multiple heat pumps ready to roll. <>

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).

MODERN HYDRONICS WWW.HPACMAG.COM MH12 SPRING 2024
HEAT PUMPS
system filled with antifreeze solution
piping and components conveying chilled water must be insulated and vapor sealed
∆P circulator hydraulic separator PRV
VS ∆P circulator entire
All
VS
Balancing valves Purging/
isolation valves Heat pump 1 diverter valves
∆P
2-way motorized ball valve
Heat pump 2 VS
circulator
temperature
VS ∆P circulator supply temperature sensor supply
sensor hydraulic separator
Fluid feeder
Modern Hydronics
Figure 4. Heat pumps with inverter compressors could eliminate the need for buffer tanks.

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OPERATIONAL NET ZERO

Carmichael Engineering’s new branch office provides a template for future projects.

From modest beginnings as a Montreal-based plumbing and heating business, over the past 100 years the family-owned Carmichael Engineering company has embraced an adventurous entrepreneurial spirit and developed into a nationwide commercial, industrial and institutional HVAC service, maintenance and designbuild contracting organization.

Founded by Ray Carmichael Sr. in 1922, today the company is led by Carmichaels’ grandson, Ray Jr., and has 23 branches and over 700 employees across the country.

In 2022 the business celebrated its centennial, while at the same time it was undertaking an ambitious project—designing and overseeing a ‘smart’ operational net zero building to serve as the new branch office for its Belleville, Ontario location.

WALK THEIR TALK

Carmichael made its name in service and maintenance and added Building Automation, Energy Services and DesignBuild divisions over the years. Although the company performed energy projects for clients, designing the new branch was their opportunity to walk the talk.

“We’ve been preaching this is the way to go,” says Carmichael’s Eric Rockarts, “Now we had to put our money where our mouth is by developing a building for our own team.” Rockarts, a 30-year employee with the company, launched the Belleville location in 1998 and served as branch manager for 24 years. He formally retired in June 2022, and then re -

MODERN HYDRONICS WWW.HPACMAG.COM MH14 SPRING 2024
PHOTO: DOUG PICKLYK
PROJECT
PHOTO COURTESY CARMICHAEL ENGINEERING The two 20-ton heat pump air-cooled chillers provide heating and cooling. The new Carmichael Engineering branch in Belleville, Ont. has been designed to generate as much energy as it consumes in a calendar year. PHOTO: SEAN HAMMOND The building has enough solar to generate 125 kW of energy.

joined as part of the Engineering and Project Management group.

The goal for the new office was an energy efficient building that would produce as much energy using solar panels as it would consume in a calendar year with almost no reliance on carbon-burning fuels. And through its own building automation team it will be able to monitor and optimize the building’s operations. The project was a true team effort.

MECHANICAL SYSTEM

The new branch is around 22,000 sq. ft. in total, with Carmichael occupying 4,000 sq. ft. of office space in the front along with 6,000 sq. ft. of warehouse, and the building has two additional tenant spaces available for lease.

The warehouse and tenant section of the building is made up of pre-formed, pre-insulated, wall panels, and a double roof with about nine inches of insulation

and materials. The south facing office space has well-insulated walls, a lower roof surface and tinted high-efficiency double paned windows, all providing a tight building envelope.

Rockarts explains how the project’s mechanical design evolved over time.

“We wanted to add solar panels, so the energy group ran the models, balancing cost versus achieving the goal of operational net zero.”

The solar installer was able to accommodate all the panels on the building’s high roof, with the ability to generate 125 Kw of electrical energy. All the modeling is based on that capability.

Initial design options included using geothermal or VRF, but ultimately the team selected LG air-cooled inverter scroll heat pump chillers for an air-to-water system, the first installation of these units in Canada.

They installed two 20-ton chillers on the lower roof to provide heating and cooling. Using a glycol/water mix to prevent freezing, four pipes lead from the chillers into the building to satisfy either the hot water or chilled water buffer tank. The hot water tank is maintained at

Continued on MH16

MODERN HYDRONICS WWW.HPACMAG.COM MH15 SPRING 2024 Modern Hydronics
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Glycol loop from heat pumps to buffer tanks.

and the

When there are calls for heating or cooling in the building, the system draws from the tanks to a heat exchanger, where the distribution system for the occupied spaces is then fed a water-only supply of hot or cool water.

As Rockarts explains, “In January both chiller units would be in heating mode, and then come the shoulder seasons we can have chilled water and hot water working simultaneously. And, of course, cool water in the summer.”

A back-up gas-fired Lochinvar boiler is in place for supplemental heating if required, and it will only kick in below -15C.

HEATING/COOLING DISTRIBUTION

The system is designed using low temperature in floor radiant as the primary heating and hot water fan coils for zone tempering. The fan coils are also equipped with chilled water coils for water-based cooling.

Using all ECM-driven fan coils, it is designed with heating coils downstream from cooling coils, so they can provide dedicated dehumidification.

“We’re controlling plus or minus 0.1F of set point in all spaces,” says Rockarts. The systems are all controlled by Belimo electronic valves, and the building’s mechanical system is fully automated courtesy of Carmichael’s building automation system design using ABB-based controls.

“We also have Belimo Btu meters on everything,” notes Rockarts. “We know exactly where all of our energy is at, at all times.” As the generator of solar electrical power, plus heating and cooling energy, they can monitor all the energy heading to the tenant spaces to charge for consumption.

Because it’s an industrial site the demand for domestic hot water is very low, so instead of incorporating DHW off the heating water loop the team is using a 40-gallon domestic hot water electric heater to manage demand.

VENTILATION

The building operates a dedicated outdoor air system with ERV. “We wanted to precondition the outside air before it hit the fan coils, so it’s got an SCR controlled electric pre-heater on the incoming air to take the chill off, but then it has post heating or cooling from the heat pump chillers,” explains Rockarts.

The system design provides preconditioned constant ventilation with CO2 reset, whereby for all zones it calculates average CO2 and decides if it needs to increase fresh air or decrease to a minimum rate. “When there is no one in the office it will go down to a minimum ventilation rate to bring fresh air in, so the building starts fresh every day,” says Rockarts.

GRAND OPENING

The basic build was completed in June 2023 followed by commissioning. The BAS system operations are monitored by the company’s secure cloud-based Performance Analyzer platform. It was the joint forces of the Carmichael Divisions [DesignBuild, Engineering & Project Management, Building Automation and the Energy Group] that brought the project to life.

The Belleville team moved into the building in mid-October and celebrated a grand opening on November 21 st with the Mayor participating in the ribbon cutting along with Maddie Carmichael, the Vancouver branch manager and the fourth generation of the family to continue the legacy.

“As part of the new generation of Carmichael, we’re aiming to pioneer solutions that not only elevate the operation, efficiency and comfort of indoor spaces, but to pave the future for a greener world for generations to come,” said Carmichael, adding, “This building, in itself, represents the importance of, and our commitment to, sustainability.”

The Belleville branch is creating a template for future Carmichael facilities, and its Ottawa division is already working on a new space. <>

MODERN HYDRONICS WWW.HPACMAG.COM MH16 SPRING 2024
114F (45.6C) chilled water at 44F (6.7C).
PROJECT
The entire building has in floor heating. Buffer tanks in the mechanical room, one for hot one for cold. PHOTO: DOUG PICKLYK
Modern Hydronics
PHOTO COURTESY CARMICHAEL ENGINEERING

CANADA’S HYDRONIC INSTALLATION CONTEST

WIN ONE OF THREE $2000 BUYING SPREES FROM EMCO!

Get your cameras ready. Be a part of Canada’s hydronic installation contest. Proud of your work? Better than the rest? It’s time to bring it on!

THERE WILL BE A WINNER IN EACH CATEGORY: COMMERICAL, RESIDENTIAL NEW-BUILD & RESIDENTIAL RETROFIT

ENTRY IS SIMPLE - send us pics of your installation. Include a brief description of the particular challenges that you faced with this installation and how you overcame the obstacles. Submissions are limited to one per contractor. Deadline to enter is July 31, 2024. All submissions will be shown at the Modern Hydronics Summit 2024. The three winners will also be announced by John Siegenthaler at the Summit. In addition to having your winning entry shared across our social media channels you’ll also be interviewed by HPAC’s editor and featured on the cover of the October edition of HPAC –

SEND ENTRIES OR QUESTIONS TO DPICKLYK@HPACMAG.COM WITH THE SUBJECT LINE “SWEET HEAT CONTEST”
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THE MAINTENANCE PLAN

Ensure long-term customer satisfaction by offering service plans with every installation.

Hydronic systems are often praised for their efficiency and comfort. As we all know, these systems are an intricate network of components piped together to create a seamless heating experience in homes and commercial buildings.

However, their complexity can pose challenges for homeowners and contractors when it comes to maintenance and upkeep. A new system installation shouldn’t be a one and done with that customer.

In the world of HVAC services, unlike some other industries, contractors face a unique opportunity to not only retain customers but also expand their business. They can do this by offering comprehensive maintenance and service plans tailored specifically for the hydronic systems they install.

It’s understood, but it’s also important

to reflect on the many key components of a hydronic system and to educate your customer on the different parts and their proper servicing requirments:

Boilers or heat pumps: these are the heart of the system, responsible for heating the water or fluid before circulation and a source requiring regular inspection.

Pumps and valves: these components facilitate the movement of the heated liquid throughout the system, ensuring even distribution to the radiators, underfloor heating or other heat exchange points. Are they doing their job? (Let’s not get into the zoning with pumps or valves argument right now)

Radiators or heat emitters: these are the key devices that release heat into the occupied spaces. You might think radiators are as easy as install and walk away, but once you’ve introduced thermostatic radiator valves and auto air bleeders things start to change, homeowner education is always welcome. Or maybe you’re installing air handlers or fan coils which now have electronics involved.

Expansion tanks, makeup water

feeds and pressure regulators: these essentials are vital for maintaining proper pressure levels within the system and preventing damage.

Piping and insulation: the network of pipes through which the heated water travels, often concealed within walls or floors, require periodic checks for leaks, corrosion, or insulation integrity.

Condensate kits: providing a condensate neutralization kit and keeping the neutralizer fresh to ensure there is no corrosion in the plumbing and following local codes.

These are six major elements of a hydronics system that need to be maintained, and the average homeowner doesn’t want that servicing burden. So, let’s dig into how to make more money in hydronics while keeping your customer happy for the next 20-plus years.

CUSTOM PLANS

Every hydronic system can be a little unique, and this can be overwhelming to the common homeowner, which also means service plans can be specifically tailored to the heating system installed

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in each and every location.

Regular maintenance not only keeps your company fresh in the face of the homeowner. but it allows you to keep that system running smoothly for the long haul.

I recently installed a boiler with an air handler and in-floor heating in my house, and the first thing my wife said was: “This looks pretty complicated, what if something goes wrong?”

I replied: “I know a guy.”

OPPORTUNITY

There is no question that maintenance and service plans will benefit your customers, likely extending the life of their systems. And of course providing service plans offers benefits to your business as well:

Predictable revenue stream: service plans provide a consistent source of income, ensuring a steady cash flow.

Customer loyalty: by offering regular

service, you build trust and loyalty with end users, increasing the likelihood of repeat business and referrals.

Reduced emergency calls: regular maintenance helps identify and address potential issues before they escalate, reducing the number of emergency service calls for your team (how about we sleep on the weekends).

Extended system lifespan: proactive maintenance leads to a longer lifespan for system components, reducing the constant replacement of parts.

Market differentiation: contractors offering comprehensive service plans stand out in the market, attracting homeowners who prioritize the long-term health of their hydronic systems.

Upselling opportunities: during routine service visits, contractors can iden tify opportunities for system upgrades or improvements based on customer feed back, leading to additional sales (I know

we are a humble trade, but you have permission to do this).

BUSINESS VALUE

The addition of a comprehensive service plan with scheduled visits that you initiate by reaching out to customers annually, will not only keep your customer happy, safe, and lower their stress levels, but it will give you (the contractor) the opportunity to hold on to that customer.

And that’s what really increases the value of your company.

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

MODERN HYDRONICS MH19 SPRING 2024 Modern Hydronics
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• 5,000 TIES PER CHARGE • HALF A SECOND PER TIE SAVE TIME SAVE MONEY WITH A ® OnSite_MaxUSA_Dec23.indd 1 2023-11-28 10:08 AM

ELECTRIC BOILERS: WHEN AND WHERE?

John Seigenthaler joins HPAC to talk about how electric boilers work and where they make sense.

The latest installment of HPAC magazine’s 30 Mechanical Minutes, the free webinar series, took place January 31st and focused on electric boilers. In this episode, HPAC editor Doug Picklyk was joined by regular contributor and hydronics expert John Siegenthaler to discuss how electric boilers work, their advantages and drawbacks and some installation considerations.

This edition of 30 Mechanical Minutes was sponsored by Conforto, a division of Granby Industries.

ELECTRIFICATION

To begin, the discussion opened with comments about the recent AHR Expo that had taken place in Chicago just one week prior. The trend towards decarbonization and electrification was very evident on the trade show floor, with both

the host and Siegenthaler noting the large presence of new air-to-water heat pump demonstrations. But they both also commented on the growing number of electric boilers being shown, particularly products for the commercial segment of the industry. “Electric boilers were a hot topic at AHR Expo this year, and thus a great time for us to be talking about them here on 30 Mechanical Minutes,” said Picklyk.

In explaining just exactly how the technology works, Siegenthaler began by describing the electric boiler is a “relatively simple device.”

The units convert electricity through some type of a resistance element, similar to the elements in an electric water heater. “Typically, a residential electric boiler has a small pressure vessel, and there could be anywhere from one to as many as four heating elements,” says Siegenthaler. “While some of the large commercial electric boilers have more—I actually looked at one at the show that had, I believe, 15 different elements.”

All of these elements are controlled, and he acknowledged that in the past they were just turned on and off with con -

tactors, but today most of the electric boilers control the current that goes through the element, and they do that with solid state devices.

“So an electric boiler, unlike a fossil fuel boiler, can basically regulate heat output anywhere from 0 all the way to 100%,” says Siegenthaler.

He also explained how the controls within these boilers have progressed, some can not only maintain a pre-set boiler outlet temperature, even though the inlet temperature varies, they can also control based on outdoor reset, so as it gets warmer outside the supply temperature is reduced.

The devices can also be relatively small compared to fossil fuel boilers because they don’t need to accommodate the combustion chamber and gas assemblies.

PANEL CONSIDERATION

Something to beware of with electric boilers is the wattage that is being converted to heat. Siegenthaler provided a simple equation to convert kilowatts (kW) to Btu/h: just multiply kW by 3,413. For example, a 15-kW boiler is just over 51,000 Btu/h.

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30 MECHANICAL MINUTES
Doug Picklyk (left) editor of HPAC and hydronics expert John Siegenthaler discussed what applications are a great fit for electric boilers. The complete video is available at youtube.com/@hpacmag.

“That would be high enough capacity to heat a house, and it’ll be served by a single phase, 240-volt circuit, and that would require almost 63 amps,” he says.

This is why the circuit panel is one of the very first things a contractor will want to check, especially in a retrofit situation where some older houses, especially those already using fossil fuel heating systems, might have 100- or 150-amp services.

“I don’t want to say that you can’t install an electric boiler with 100-amp service, but if that panel is pretty much filled up with breakers, you’d probably reach the limit.”

For new construction, using an electric boiler with enough capacity to heat a 2,500 sq. ft. modern house will require at least a 200-amp service, and that’s especially true if an electric vehicle charger is being added to the home.

TYPICAL USES

Electric boilers can be used for any hydronic distribution system that you would supply with a gas-fired or oil-fired boiler including radiant floors, panel rads, hydronic baseboard, etc. And an advantage of the electric boiler is no combustion, so there’s no issues with fuel supply or venting, and it doesn’t generate carbon monoxide (CO), so that’s one safety concern that’s eliminated.

In addition, Siegenthaler says that short cycling is really is not an issue at all with an electric boiler, plus they make very little sound. “You may hear a very small amount of sound coming from it, but that might be just the water moving through it.”

One of the unique potential advantages of an electric boiler over a fossil fuel boiler is the ability to coordinate their operation with time-of-use utility rates.

“You could easily set up controls that would allow an electric boiler to operate under the lowest-cost electricity,” suggest Siegenthaler.

Also, an electric boiler can take advan-

tage of solar photovoltaic systems. “If you’re dealing with net zero houses and you have photovoltaics, some of the energy that you’re producing can go directly into the boiler,” he says. “And if you have net metering, where any surplus electrical energy generated by the solar array would simply go back out through the meter at the same rate that you buy it at, essentially the utility becomes a battery for you.”

DRAWBACK

Aside from the high current draw, Siegenthaler touched on the thermodynamic efficiency concept called exergy, the idea that we can do a lot of things with electricity to maximize its thermal output. “We can run a compressor, for example, in a heat pump, and in effect, we get three or four times as much low-

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Continued on MH22

grade heat into a building compared to just dissipating the energy into heat with an electric boiler.”

WHERE’S THE FIT?

When asked where he’s seen electric boilers in operation, Siegenthaler pointed to net zero and low energy houses or apartments as a possibility. “We’ve used electric boilers in very low load houses, in areas that have low-cost electricity or for clients that want photovoltaics and an all-electric solution.

“We’ve got a project in Minnesota that only has a 6-kW electric boiler that heats the entire house, and it does that with radiant floor heating in the basement and some panel radiators on the main floor. It’s not a large house, about a 1,500 sq. ft., but it’s extremely well insulated.”

Those homeowners asked, “Why not just put electric base board in versus a hydronic system?” His reply was about flexibility. They can use a low-cost electric boiler now, and switch to an efficient heat pump down the road.

“So electric boilers definitely have a niche. We like to use them as backup to air-to-water heat pumps, or even geothermal water-to-water heat pumps.”

He then shared details of a research project in Northern Maine where they are looking at off-peak rate structures and want to grab off peak electrical energy when it’s available and store it.

“It’s kind of a unique situation. They have a lot of wind turbines, and when they have a strong wind event the local utility has more energy than it needs, so they’re looking for ways to dump some of that capacity without curtailing operation of the turbines. I’ve actually been told that at some times they have negative utility rates, which means the utility would pay you to take this energy,” he says.

The project is using a prototype heat pump unit that can generate high water temperatures up to about 175F, where most air-to-water heat pumps are limited to about 130F.

In this case they can be tied into thermal storage, but most heat pumps really can’t get the temperature as high as an electric boiler, which could easily do 180F.

Siegenthaler shared a schematic where a heat pump and electric boiler are piped in parallel, and that enables either heat source, or both heat sources, to operate at the same time (Figure 1).

“If the heat pump wasn’t able to keep up with the load, or if the heat pump was down for service, the electric boiler could come on automatically.”

He adds that the controls in this system are designed to charge the thermal storage tanks up when the low-cost electricity is available, and then discharge those tanks back into the header, and ultimately to the hydraulic separator and the heat distribution system.

“The system is set up so energy can go into thermal storage from either heat source or it could go directly to the load.”

Some heat pumps can automatically

signal the electric boiler and its circulator would turn on.

He adds that heat pumps are much more complicated than electric boilers in terms of controls and sensors, and he suggests that there’s a better chance that a heat pump could go down for some service requirement.

“So we like to build electric boilers into systems as a backup to make sure the building has heat, especially in remote locations where you know that service may be much more than two hours away.”

In that situation, he sees an electric boiler as an ideal and relatively low-cost option compared to putting a fossil fuel boiler in as a backup.

The webinar closed with great questions asked by the live audience. To see the entire webinar visit hpacmag.com/ tech-pulse, where you can also find past editions of 30 Mechanical Minutes. All episodes are also available on the HPAC YouTube channel @hpacmag. <>

MODERN HYDRONICS WWW.HPACMAG.COM MH22 SPRING 2024
30 MECHANICAL MINUTES
Modern Hydronics
Figure 1. An air-to-water heat pump and electric boiler piped in parallel enabling either heat source to operate, or both at the same time.

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THE BIG SWITCH

Modern controls can optimize hybrid gas/electric hydronic heating solutions.

Well, it’s a good thing I’m a huge procrastinator otherwise I wouldn’t have an electrifying story for you today. So, yes, regular readers of my articles, I shocked myself again.

While downstairs working on a project for SAIT in Calgary I needed to test a control that has 120VAC. Easy enough you might think, but all I had around was a circuit board. Well, I found the power cord with the proper connector on it and plugged it onto the board.

The stupid part was that I had plugged the cord into the wall first. Normally this is not an issue, and I am careful, but as I was plugging the connector onto the board I touched the fuse. As you can imagine I yelped a bit.

It was not a huge shock, but enough to let me know how dumb and careless I can be sometimes when I am rushing. I went upstairs and asked my daughter, “Did you guys hear me yelp?”

Both my daughter and wife shrugged and went on about their evening. I don’t get much sympathy for being dumb in my house.

The focus of today’s article, like some others I write, can be a touchy subject in some areas of the country. I realize not everyone may agree with my point of view, and I’m ok with that. Our subject today involves bringing together new and shiny heat pumps with the now passé gas-fired boilers.

I say this with tongue in cheek, of course, although this topic is dividing not only our industry but also our nation. Now I won’t get into the politics, but we will see how these seemingly opposite sources of energy can be united and work together.

Decarbonization and electrification are the buzz words, and electrification of heating products in HVAC is accelerating to a crazy point. It does seem like all companies are trying to build heat pumps for the hydronics industry, whether these are water-to-water or air-to-water. And it seems like a new company is popping up every week.

Don’t get me wrong, I am all about saving the environment, but I am not about electrification at all cost. Like most things in life, we need a little balance here and the Big Switch can help.

The Big Switch is an idea of using the lowest cost energy resource available at a specific point in time.

Let’s start with a few statistics to realize the potential here:

• Space heating and/or cooling accounts for the most energy used in a building.

• DHW alone accounts for about 25% of the energy used in a building.

• Colder climates use more natural gas than hotter climates.

• Hotter climates use more electricity than colder climates.

• In Canada the average household uses about 10GJ of gas and about 830kWh of electricity per month.

• Return on investment (ROI) is important.

Controls in our industry are becoming more savvy and cost effective. By this I mean we can gather more information and not break the bank. Without this information gathering, our topic today would be a moot point. We need information to make the proper decisions on sav-

MODERN HYDRONICS WWW.HPACMAG.COM MH24 SPRING 2024
DUAL FUEL

ing energy and saving money.

In this Big Switch hydronic heating scenario I’m layout out, primarily we would be switching between an electrically operated device, usually an air-to-water heat pump, and a gas-operated device, usually a boiler.

Now you can have an electric element in this equation, but in the next issue of HPAC look out for PART 2 where I do all the calculating and you will see that model does not work out well, but it can.

The first question you are probably asking is, “Why the heck would we even bother with this switching business?” Good question reader!

I think the number one reason is money, but it’s a tie. Money and a greener planet are tied for first.

I am a huge proponent of ROI. If you put in a system that costs $50k for a hybrid or $20k for gas-fired only, how much gas can you buy for $30K? I know this is

a bit glib, but these are the facts.

And this scales up as well, because the cost of the installation also goes up with more equipment. I’m only pointing it out like this to show the monetary side of the equation.

Now there are financial incentives to install heat pumps, which is a good thing, and there are some other incentives to maximize efficiency of your house as well. So this all needs to be taken into account when making decisions.

Ok back to reality. How can we cost effectively use both electric and gas heating.

“Be green and save money?” you ask, “not possible.” Well, yes it is.

Now as the installations get bigger, so does the energy usage. Especially in the cases of DHW in commercial or large residential buildings. These loads are big, and they are predictable. Perfect for any number cruncher. Or perfect for any number crunching control in our case.

Electricity utilities everywhere are switching to Time-of-Day pricing, if it hasn’t hit your area yet it will.

What this means is when demand is low on the grid the price for electricity is low, and when the demand is high the pricing is high.

Most of the time this would not really work in our favour, but with the onset of energy calculating controls we can calculate the cost of running the gas side compared to running the electric side.

To do this we need utility data, the time-of-day gas pricing (which really does not change much) and time-of-day electricity pricing. We also need to know the Btu output vs input of the boiler and the total COP of the heat pump.

I will get into more specifics in Part 2 of this article, but for now just know we can figure out these values using thermal energy meters (like the ones that we make at HBX Controls) and with a little extra electrical input we can accurately calculate COP’s.

The reason we need to know these in real time is that Btu output and COP’s

change. Not so much for the boiler Btu output, but the heat pump COP changes with outdoor temperature.

So, by calculating in real time, or close to real time, we can know which system gives us the best value. By knowing this, and knowing the time-of-day pricing, we are then able to make the best decision possible.

Another factor here when using large DHW loads (as I said above, they are fairly predictable) is that we can precharge the tanks.

Why would we want to do this? Well, yes, I know the tanks will lose heat when just sitting there with no usage, but if we pre-charge the tank and actually “over charge” them when the time-of-day pricing is very low over night, there is significant savings that can be made.

In some jurisdictions the time-of-day pricing for overnight periods is 10 times less than peak hours. So, you can see even the small amount of heat loss you may have from pre-charging the tanks is far outweighed by the savings you can have.

We know that from around 6AM to 8AM is a huge load for DHW in large residential buildings. So, by pre-charging and overcharging the tanks before that happens can save a lot. We can only do this by knowing all the information, COPs, Btu’s and time-of-day pricing. They are all important. If you are missing one, the equation breaks down.

Ok, that’s a lot to chew on, so I’ll stop there. In the next article we will get into the math, so you can see the potential savings by making the Big Switch. <>

Curtis Bennett C.E.T is product development manager with HBX Control Systems Inc. in Calgary. He formed HBX Control Systems with Tom Hermann in 2002. Its control systems are designed, engineered and manufactured in Canada to accommodate a range of hydronic heating and cooling needs.

MODERN HYDRONICS WWW.HPACMAG.COM MH25 SPRING 2024 Modern Hydronics
IMANTSU/GETTY IMAGES PLUS

Taco Comfort Solutions expanded its light commercial ECM pump offering with the 1911ecm and 1915ecm. The 1911ecm is a 425-watt, selfsensing, close coupled, mechanically sealed pump with a high-efficiency volute, ECM motor and an integrated frequency drive. It provides a maximum 50 ft. of head and 105 gpm. The 1915ecm operates at 650 watts provides a maximum 65 ft. of head and 120 gpm. Both have control options that include constant pressure, constant speed, proportional pressure, 0-10Vdc and parallel pump alternation. Both pumps are both available in ductile iron for closed loop hydronic heating and cooling systems or stainless steel, NSF/ANSI/CAN 61 & 372 Commercial Hot Certified for domestic hot water applications. tacocomfort.com

RBI has expanded its Torus line of watertube boilers and water heaters to include smaller sizes from 300 to 1,000 MBH. The full line is now available from 300 – 4,000MBH. The boilers still include the HeatNet 3.0 digital touchscreen control and Tru-Flow fuel/air coupling system. Torus uses a pressure-driven air/fuel mixing system to provide up to 10:1 turndown. This pressure-driven system has no moving parts and eliminates common nuisance failures including ignition lockouts. An exclusive telescoping burner door system slides outwards offering full access to thecombustion chamber for easy annual inspection and service rbiwaterheaters.com

U.S. Boiler Company has introduced its Ambient air-to-water hydronic heat pump, a 5-ton capacity (rated at 60 MBH) unit that provides space heating at temperatures as low as -13F/-18C. Offering a COP of up to 3.95 and delivering supply temperatures of up to 140F, the Ambient monoblock heat pump uses R-32 refrigerant for high efficiency and low global warming potential, and its DC inverter enhanced vapor injection (EVI) technology is quiet, with operating sound levels as low as 39 decibels at two-foot distance. The Ambient Heat Pump is available with an optional dual-fuel controller for applications in extremely cold climates.

usboiler.net

WILO’s new EC motor-driven circulator, the WiloStar E 21, is a four-speed circulator with three HD modes of operation for proportional control as well as an auto mode where the pump will automatically adjust to the system resistance to reach its best efficiency point with an LED display and adjustment buttons for easy set-up. Designed in a cast iron HT 200 pump body, it incorporates an advanced composite impeller and ceramic shaft. An optional check valve is also provided for parallel pumping applications. The fluid temperature range for the new Wilo-Star E 21 is 36°F to 230°F, with a maximum operating pressure of 145 PSI (10 Bar). wilo.com

Grundfos has introduced its new-digital ALPHA high-efficiency ECM circulator. Its most efficient solution, the pump offers enhanced AUTOADAPT, Bluetooth connectivity and a touch-screen interface showing flow, power, and head for faster troubleshooting, and it offers guided setup, firmware updates, and with its functionality the company claims it is able to replace 95% of pumps in its performance space. It has also achieved a Hydraulic Institute Energy Rating of 193, demonstrating its improved energy efficiency. It also features improved system air venting for faster setup and can show trend data and and event log for easier system troubleshooting.

grundfos.com

Johnson Controls has launched the York YVWH water-to-water dual variable speed screw heat pump, the first screw heat pump in North America to use R-1234ze refrigerant which has an ultra-low global warming potential (GWP) of 1. The YVWH can be operated in three modes: heating only, cooling only or simultaneous heating and cooling. It is the first screw heat pump that can provide water up to 176F (80C). The unit can provide 4,050 MBH of heating while simultaneously providing 200 tons of chilled water cooling at 41F (5C). The YVWH also features variable-speed drive and has excellent turndown that allows it to run with as low as 25% of the design-heating load.

york.com

MODERN HYDRONICS WWW.HPACMAG.COM MH26 SPRING 2024 HYDRONICS PRODUCTS

Now in Canada, BOW-branded Oxy-PERT and Oxypex tubing options offer benefits for a range of hydronic applications. Part of Orbia’s Building and Infrastructure business, Wavin, the BOW Oxy-PERT and Oxypex oxygen-barrier plastic pipes are designed to prevent the ingress of oxygen and are manufactured from recyclable ecofriendly materials. Both pipes provide noise and water hammer resistance. Oxypex PEX B can be used for both potable water and hydronic heating, while Oxy-PERT is a high-temperature flexible plastic pressure pipe suited for radiant slab heating systems for concrete, snow-melting applications, and baseboard heating. wavin.us

AERCO has introduced Sequoia, a high voltage immersed electrode boiler series for large commercial and industrial applications that require a virtually 100% energy efficient, emission-free heating solution. Available in seven sizes from 2,500 kW to 60,000 kW, the boiler family is simple to operate, its automatic controls provide operation over an output range of 10% to 100% (10:1 modulation) to optimize demand fluctuations while reducing operating personnel. Users can take advantage of lower energy rates during off-peak periods to reduce energy costs. Sequoia matches the capacity of large gas- or oil-fired boilers (up to 60 MW) in a much smaller footprint. aerco.com/sequoia

Bell & Gossett introduces the TECHNOFORCE HVAC package system, a stock skid system ready for installation in commercial HVAC and pressure booster applications. Offered in 40 pre-configured standard stocked models that come fully assembled, the package system consists of two to three e-1531 pumps, valves and control drives. Most models will fit through a standard 36-in. doorway. Flow ranges from approximately 200 to 3,400 gpm and each preprogrammed station is fully tested for flow and pressure up to 175 psi boost. A, LED colour touchscreen interface provides navigation of the system. bellgossett.com

The Hydronic Industry Alliance-Commercial (HIA-C), which promotes the use of water-based hydronic systems in buildings, has released version 6.2 of its Building Efficiency System Tool (BEST), an interactive commercial building HVAC system efficiency comparison application. The latest version focuses attention on energy use, including up to four selected HVAC system types in one life-cycle comparison report using historical design temperatures to determine peak energy demand and the energy utilization index (EUI). This free tool can help determine the return on investment for building owners when comparing different styles of HVAC systems. iapmo.org/hiac/

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MATHEMATICS VS. REALITY

Exploring the non-proportional relationship between heat output and flow rate.

When thinking mathematically, most people use proportions. For example, if someone is brewing coffee, and needs two scoops of granules for six cups, they intuitively know they need four scoops to make 12 cups.

So, if a person who thinks that way was told that a 100 horsepower (hp) engine, at full throttle, could make a certain car go 100 miles per hour (mph), and then was asked how fast would a 200 hp engine make the same car go, they’d likely answer 200 mph.

Unfortunately, nature doesn’t always work in proportions. Car racing fans know that it takes a lot more than 200 hp to push a race car around the track at 200 mph. It takes close to 800 hp to produce that kind of speed. Most of that power goes into overcoming the aerodynamic drag at those high speeds.

DISPROPORTIONATE

Hydronics also has its share on non-proportional relationships. One is how the

heat output and temperature drop across a heat emitter is affected by the flow rate through it.

For example, suppose a given length of residential fin-tube was yielding a heat output of 5,000 Btu/h when operating at a flow rate of 1 gallon per minute (gpm).

If asked what would happen when the flow rate was increased to 2 gpm, while all other conditions remained the same, many people, including plenty who work with this hardware every day, would say that heat output would double. That answer might seem intuitive, but it’s not correct.

How about if the flow rate was increased from 1 to 4 gpm?

Surely a 400% increase would at least double the heat output.

To answer this just look at some Institute of Boiler and Radiator (IBR) output ratings from baseboard manufacturers. They’re given for a wide range of water temperatures, and for flow rates of 1 gpm and 4 gpm.

You’ll find the rating at a flow rate of 4

gpm is about 6% higher than the rating at 1 gpm, all other conditions remaining the same.

The reason lies deep in the workings of natural convection and thermal radiation between the outer surface of the fin-tube element and its surroundings.

It’s also effected by the forced convection between the water and the inner surface of the tube. The theory is complex, but the results are simply a reflection of how nature behaves.

MODERN HYDRONICS WWW.HPACMAG.COM MH28 SPRING 2024 DESIGN
Figure 1. A simple hydronic circuit using fin-tube baseboard heating.

MAKING SOME MEASUREMENTS

Suppose you made up a hydronic circuit like the one shown below left in Figure 1.

This circuit contains 50 feet of residential fin-tube baseboard, along with a variable speed circulator, flow meter, two temperature gauges and a heat source. That heat source is always controlled so the supply water temperature into the fintube element remains at 180F.

You turn on the circulator at full speed, and the flow meter indicates 8 gpm. The water temperature entering the fin-tube baseboard is steady at 180F, and after a short time the outlet temperature of the fin-tube element stabilizes at 174F.

Knowing the flow rate and temperature drop along the fintube, you can calculate the rate of heat dissipation.

Where:

q = rate of heat output (Btu/h)

D = density of the fluid (lb/ft3)

c = specific heat of fluid (Btu/lb/F)

f = flow rate (gpm)

∆T = delta-T, temperature drop (F)

8.01 = a number that makes the units correct

You now have a measurement of the heat output at a flow rate of 8 gpm. Next, you reduce the speed of the circulator so

the flow rate drops by 1 gpm, wait for the outlet temperature from the fin-tube baseboard to stabilize, and write down the measured flow rate and outlet temperature.

You keep doing this for flow rates all the way down to 0.5 gpm, while the heat source always maintains the inlet temperature to the fin-tube baseboard at 180F.

Now that you’ve captured all this data, you can use it to calculate the temperature drop across the fin-tube element (e.g., delta-T), as well as the heat output rate from that element.

You then create graphs for heat output and temperature drop as a function of circuit flow rate.

They should look similar to the graphs in Figure 2 (next page)

IT IS WHAT IT IS

The graph of heat output (q) versus flow rate is probably not what you expected—especially if you think proportionally. It shows that heat output from the fin-tube element drops off rather slowly as flow rate decreases, until you get down to a flow rate of about 2 gpm. Below 2 gpm the heat output drops quickly with any further reduction in flow rate.

Although it might not be what you expected, this non-proportional relationship between heat output and flow rate is reality.

Continued on MH30

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DESIGN

This characteristic is shared by all hydronic heat emitters: fin-tube, convectors, panel radiators, and even radiant panel circuits.

Heat output changes very quickly at low flow rates, but very gradually at higher flow rates. This trend also holds true at other supply water temperatures.

Next, look at the temperature drop across the fin-tube over the same range of flow rates.

First, it’s obvious the temperature drop doesn’t remain constant as the flow rate changes. The ∆T happens to be at the commonly assumed value of 20F when the flow rate is just a bit over 2 gpm.

As flow increases above 2 gpm, the delta-T keeps dropping, and at 8 gpm it’s only about 6F. When the flow is only 0.5 gpm the ∆T is slightly above 55F.

These delta-T values are the direct result of heat output. There’s nothing in this setup that forces the delta-T to stay at any particular value. There’s also nothing “wrong” with the fact that the delta-T is changing. It just goes where the physics takes it.

Another take away from this experiment is that there’s nothing special about operating a hydronic heating circuit with a temperature drop of 20F.

In Europe it’s common to see panel radiator circuits designed for design load delta-T of 30F or perhaps even higher.

European designers do this because it reduces flow rate, and reduced flow rate means small pipes and small circulators.

It also means lower operating cost. Over there, every watt counts. They won’t operate a circulator at 45 watts if it can create the necessary flow at 35 watts.

They care, and so should we, especially with increasing emphasis on mechanical systems for net zero buildings.

Radiant floor heating circuits can also be designed for different design load delta-T values. I like to design around 15F for floor circuits in areas that are expected to have “barefoot friendly” floors. The

smaller delta-T reduces variation in floor surface temperature a bit compared to what it would be at a delta-T of 20F.

However, in an industrial building, I may push the design load delta-T for the circuit up to 25F. That’s because heated concrete slabs in most industrial buildings don’t need to be “barefoot friendly.”

Slightly wider variations in floor surface temperature are hard to notice through a pair of work boots. Designing around slightly larger circuit temperature drops also reduces flow rate, which in turn decrease circulator size requirements.

IT’S NOT ALWAYS INTUITIVE

The relationship between the heat output of a hydronic circuit and the flow rate passing through it is not proportional.

Neither is the relationship between the circuit’s temperature drop and the flow rate through it.

Be sure to examine this relationship as you design future systems. Opportunities abound for reducing both installation and operating costs based on reduced flow rates and operating circuits at higher temperature drops. <>

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).

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Figure 2. Heat output and temp drop/flow rate.

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CARRIER COMPLETES VIESSMANN ACQUISITION

Carrier Global Corp. announced on January 2 that it had completed its acquisition of Viessmann Climate Solutions from the Viessmann Group.

“The combination with Viessmann Climate Solutions creates the most comprehensive and differentiated suite of sustainable climate technologies and services in the industry today,” said Carrier chairman/CEO David Gitlin in a company release.

Viessmann’s 12,000 team members were added to Carrier’s global family, positioning Carrier within the residential and light commercial (RLC) space in Europe. Thomas Heim, who previously led Viessmann Climate Solutions, now leads Carrier RLC HVAC in Europe, the Middle East and Africa, which includes Viessmann and Carrier’s RLC business in those regions.

Max Viessmann, CEO of Viessmann Group, joins Carrier’s Board of Directors. corporate.carrier.com

LAARS ACQUIRES ELECTRO INDUSTRIES

Laars Heating Systems, a subsidiary of Bradford White Corp., has acquired Electro Industries of Monticello, Minnesota, a manufacturer of electric boilers, air-to-water heat pump technology, electric duct heaters and controls.

The acquisition includes all company assets, including the Electro Industries facility in Monticello.

As a result of the acquisition, Electro Industries will be organized as a division of Laars Heating Systems. laars.com

MECHANICAL SUPPLY NEWS

MANUFACTURERS • DISTRIBUTORS • WHOLESALERS

REHAU CELEBRATING 75 YEARS

The REHAU Group, initially founded in 1948 in the German Bavarian town of Rehau, marked its 75th year in December of 2023 and will continue its celebration throughout 2024.

Today’s REHAU Group remains an independent family-owned company operating in more than 190 locations with more than 20,000 employees.

Still based on its foundation of working with polymer-based solutions, the group develops, manufactures, and markets products and solutions for the construction, automotive, furniture, materials, medical and industrial sectors.

In 1987 the company introduced its compression-sleeve fitting for connecting pipes, and it has sold a billion units since. rehau.com

OSO HOTWATER GROUP OPENS CANADIAN OFFICE

OSO Hotwater Group, a Norwegianbased maker of stainless steel hotwater tanks has opened a Canadian operation, OSO Hotwater Inc, in Saint John, New Brunswick. “We are excited to open a subsidiary in Canada as a result of our continued growth in the Canadian market,” said said Sigurd Braathen, thirdgeneration owner of the OSO Hotwater Group, in a company release.

The company’s solutions for smart water heating technology include connected electric tank water heaters with smart controls for monitoring hot water activity, along with indirect tanks for connecting with boilers and heat pumps. osohotwater.ca

DISTRIBUTION

>> O’Dell Associates, a manufacturers rep in the HVAC industry, has expanded into the Sudbury and has named Eric Berube as the business development lead for HVAC sales in Northern Ontario. odellassoc.com

>> Philippe Jolicoeur and Patrick Péladeau have launched a new manufacturers rep agency, Prospect Agent Manufacturier, covering the plumbing industry in the Quebec and Eastern Ontario. The agency is representing Bélanger-UPT products. prospect-agent.com

>> Conforto, part of Granby Industries, has added two sales representative agencies, RJS Sales responsible for Saskatchewan, and Marwin Agencies covering Manitoba and northwestern Ontario including Thunder Bay. confortohvac.com

>> Wolseley Canada is acquiring Yorkwest Plumbing Supply, a distributor of plumbing, hydronics, HVAC and industrial products in the Greater Toronto Area. Each of Yorkwest’s four locations (Woodbridge, Toronto, Barrie and Stoney Creek) includes a kitchen and bath showroom branded as Atlantis Bath Centre. wolseleyinc.ca

>> Montreal-based rep agency Enviroair Industries has announced that nine years after its acquisition of Ontario-based Smith Energy the two companies will now fall under the Enviroair umbrella and the Smith Energy brand will cease to exist. enviroair.ca

HPACMAG.COM FEBRUARY 2024 | HPAC 49
on p50
Continued

Continued from p49

150 YEARS OF WATTS

In celebration of its 150th anniversary, Watts has launched its “Learn Today, Lead Tomorrow” sweepstakes, a year-long contest open to customers of any brand in the Watts family across Canada and the U.S., offering an opportunity to “learn and earn” prize packages and gifts all year long.

The sweepstakes runs through December 31, 2024, offering monthly and quarterly prizes, along with a grand prize trip to Boston.

Create a free account with Watts Works Online and earn tickets through any of Watts’ professional training opportunities. watts.com/150sweepstakesrules.

< PEOPLE

TRANE OPENS THIRD PLANT IN GRAND RAPIDS

Trane has expanded its commercial manufacturing operations in Grand Rapids, Michigan, opening a third facility focused on producing aircooled chillers for the data centre and high tech markets.

According to the company, the demand for these products is forecast to grow by approximately 20% by 2027.

The company first established manufacturing in Grand Rapids in 1998, and in 2021 a second plant was opened to focus on manufacturing air-cooled chillers for data centres and other large commercial applications, such as hospitals, municipalities and universities.

The new plant will produce Ascend air-cooled chillers and essentially doubles the location’s air-cooled chiller manufacturing capability and nearly quadruples the site’s total manufacturing footprint. trane.com

Caleffi North America has named Rolf Fischer as national sales manager for Canada. With extensive sales experience, Fischer previously worked with Prier Products, Independent Mechanical Supply and OS&B. In his new role he will drive growth in the plumbing and hydronic industries across the country.

OS&B appointed Kristy Ryan as vice president of sales and marketing. Ryan joined OS&B in 2019 and most recently served as national sales manager for Canada. In her new role, she will oversee Canadian sales and marketing teams.

CB Supplies named Paul Agapito as its senior marketing manager. Combined with previous ad agency and building products industry roles, Agapito brings over 15 years of experience in marketing, advertising, branding, communications, and support of product development.

Equipco added Jasmeet Singh as technical sales specialist in Ontario and Ronald Rouse as outside sales representative for the greater Toronto

area. Most recently Singh was with Emco Burnaby. In his new role he will be assisting specifying engineers and assisting with technical sales. Rouse, a trade plumber and a member of Local 46 for the past 13 years, was previously with Wolseley in national accounts.

Independent Mechanical Supply has named Dinesh Sethi as hydronic and HVAC technical support specialist. In this newly created role, Sethi will be in the field working with vendors and supporting customers on site.

Morden National Sales and Marketing has appointed Luke Sim director of sales. Sim brings a track record of sales success and team leadership across technical equipment industries and will be expanding representation of Morden’s product offerings across Canada.

Madison Air has appointed Joe Patterson as vice president and general manager of its newly formed Heat Group, bringing together unit heater manufacturer Reznor and infrared heating maker Roberts-Gordon, both owned by Madison. Patterson has been Reznor’s general manager for eight years.

50 HPAC | FEBRUARY 2024 HPACMAG.COM PHOTO CREDIT
< MSN
Fischer Ryan Agapito Rouse Sethi Sim Patterson Singh
CONNECTIONS
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PUMP AND GRIND

Plumbing pros have options when working against gravity with sewage lines.

We’ve all heard the expression, “What goes up must come down,” but what goes down doesn’t always go up. At least that’s the lesson many plumbing pros have learned when dealing with below grade sewage ejection.

Plumbing works best when gravity plays a role. Ancient Greeks and Romans, inventors of the earliest toilets and sewage systems, understood the principle of moving wastewater downhill. But inevitably today plumbers are faced with sewage systems in new developments, home renovations or simply challenging situations where the main municipal or septic system drain leaves no option but to pump it up.

For residential basement washroom installations in homes where no gravity sewer lines exist, manufactures have designed macerating up-flush toilet systems for easy installation without needing to break open concrete floors. These systems include a toilet that flushes into a pump tank which macerates sewage waste and pumps it up and away through discharge pipes. A tidy solution for simple residential applications.

However, for renos with additional plumbing demand—adding a complete basement suite, kitchen and laundry for example—a more robust solution is required and that involves the installation of a sewage ejection pit. This process involves breaking concrete to install drainage piping that will feed into a prefabricated packaged pit system.

Within these packaged systems, will be a sewage, or solids, pump that will trigger to turn on with a float system once reaching a set volume. The pump

will lift the wastewater away often through a 2-in. discharge pipe. The package systems include an access cover with outlets for venting and discharge, along with alarm system options to warn of any malfunction. These systems offer a standard ½-horsepower (hp) solids handling sewage pump which is suitable for many simple residential applications. But not all applications are simple.

THE GRINDER

The greatest challenge for standard sewage pumps come from unintended objects ending up in the sewage pit. “People tend to treat the toilet like a garbage can these days, and it’s getting worse and worse,” says Steve Ritsema, Liberty Pumps national sales manager for Canada. He notes that for most homeowners a regular sewage or solids pump is going to run fine, but if it’s a basement rental suite, he recommends putting a grinder pump in the pit from the start.

“Airbnb is a huge issue,” says Ritsema. “There are a lot of basement suites and many of those renos have to put in a pump to get sewage up to the city sewer. That’s where we recommend

the grinders.”

A grinder pump, like it sounds, has rotating cutting blades designed to macerate and grind solid waste into smaller particles before pumping it through the plumbing system. These powerful pumps, starting at 1-hp, will grind waste into a slurry and provide enough pressure to keep it moving to the main drains.

“We’ve always made grinder pumps for residential as well as municipal applications, and where you’re going to want a grinder is where you’re not going to be in control of what’s going to be flushed down the toilet,” says Jeremiah Brodie, director of training with Little Giant for plumbing and HVAC in Canada and the U.S.

“We all think we have control,” says Brodie, “Until you have children or elderly parents living with you and you may find things going down the drain that are not great for a sewage ejector.”

Both Ritsema and Broadie site the emergence of “flushable” wipes as a problem for basic solids pumps, as well as a long list of items they’ve seen or heard of plumbers discovering in failed ejector systems. They both agree that flushable wipes and other common usually unflushable disposables are no challenge for a grinder.

There are multiple grinder pump options on the market from manufacturers including: DAB, Liberty Pumps, Little Giant (Franklin Electric), Goulds (Xylem), Pentair Myers, Saniflo, Zoeller and more. The grinders are available in higher levels of horsepower to accommodate sewage lifting from small residential to larger commercial and municipal pumping applications.

Continued on p54

52 HPAC | FEBRUARY 2024 HPACMAG.COM
< GRINDER PUMPS
A cutaway example of the Pit+Plus Jr. sewage pump package system from Little Giant.

OPIA Information Session at CMPX 2024

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Date: March 20, 2024 | 1 PM to 4 PM

Location: Metro Toronto Convention Centre, South Building, Room 703

< GRINDER PUMPS

Continued from p52

“The one horsepower grinders are enough for residential or light duty com mercial, but once it’s a true commer cial facility like a quick service restaurant, a hospital or a school, it’s recommended to start off at the two horsepower grinders,” suggests Ritsema. Liberty and some other manufacturers make grinders up to 15 horsepower for applications like high-rise apartment buildings and municipal services.

SERVICE CALLS

“We demonstrate our grinder pump at trade shows and plumbers will say, ‘I wish I had put this in because I’m sick and tired of servicing sewage pumps,’” says Ritsema.

Speakers

Rainier Bratsch-Blundell Plumbing Professor George Brown College

Kevin Wong Canadian Codes Manager Uponor

Replacing domestic ½-hp sewage ejector pumps with a 1-hp grinder pump is an area where Little Giant sees a lot of sales, notes Brodie. And he’s heard from many contractors in the field that going out to fix a sewage ejector is their least favourite job, noting they will charge a minimum of $1,000 for those service calls. “For roughly that cost you can purchase a grinder pump and not have to worry about it,” he says.

And while Ritsema admits grinders may not be entirely perfect for everything that may get flushed—they are only machines after all—they will reduce call backs in 90% if not 100% of the cases.

For some plumbers that effectiveness could be seen as a blessing and a curse. Ritsema recalls one trade show where a plumber approached him after a grinder pump demo and was clearly upset. “That’s a good pump,” he said, shaking his head, “But, you know, I installed 60 of them around a lake and I put myself out of a job.” He wasn’t getting any of his regular service calls.

Thinking about the pump replacement market, pump makers are working to make the pumps more plumber friendly. Little Giant has outfitted its 1-hp grinder with a 1-1/4-in. discharge as well as a 2-in. flange, “so it can easily be retrofitted and not have to be re-plumbed,” says Brodie, noting that typical grinder applications have 1-1/4-in plumbing, where a sewage ejector is going to have a 2-in. or 3-in. discharge.

These pumps also can weigh around 80 lbs., so they are made with attachments for lowering the pumps into a pit. These immersible grinder pumps can also be serviceable.

54 HPAC | FEBRUARY 2024 HPACMAG.COM
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Continued on p56
The ProVore 1-hp residential grinder pump from Liberty Pumps uses the company’s V-Slice cutter technology and can
be
used as a replacement pump in 2-in. discharge systems.

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Continued from p54

Some coming with replaceable electrical cords and other replaceable parts including cutter blades, impellers and the adjustable rubber feet on the bottom of the pump.

New to the market is a retrofit pump kit from SFA SaniFlo that offers a built-in 1-hp grinder motor and cover that is designed to fit most existing 24-inch pits.

“As sewage pumps have been a largely unchanged and problematic part of the plumbing industry for over 50 years, this solution is poised to disrupt the North American market by offering a hassle-free and high-performance option for replacing faulty sewage pumps,” says Regis Saragosti, CEO of SFA Saniflo North America.

Beneath its cover, this retrofit solu tion creates a dry working area within the pit keeping the components and the motor separate providing a cleaner ex

perience for service technicians. It includes a 2-in. discharge rubber adapter

quired, sewage pits with two grinder pumps are available. “Once we go into a commercial application, it’s almost always by code, the design engineer will require duplex with an alarm and a backup pump built in,” says Ritsema.

Other common uses for grinder pumps include pressure sewer systems, this includes entire communities where the sewage needs to be pumped to higher ground. All homes and buildings will be equipped with grinders to move the wastewater with ample pressure.

And more commercial applications, where solids pumps were specified now

56 HPAC |
< GRINDER
PUMPS
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EVACUATION PLAN

Mastering the vacuum pump, the technician’s key to efficient system charging. BY DAVE DEMMA

One of the more valuable tools in the technician’s arsenal is the vacuum pump; its function is to remove air and water vapour from the system prior to charging it with refrigerant.

During evacuation the vacuum pump accomplishes the following: (1) creates a pressure differential between its inlet and the higher vapour pressure inside the system, allowing for the vapour to flow to the pump inlet, and (2) reduces the system pressure to a point where any water that might be present will boil into a vapour. (Keep in mind that a vacuum pump is a vapour pump only; it will not remove water in the liquid form).

PRESSURE MEASUREMENTS

Every fluid has a distinct pressure-temperature relationship whereby the saturation (boiling) temperature can be precisely determined for a given pressure. It becomes more complicated when discussing air pressure (in relation to system evacuation) as there are several pressure scales that must be used.

Figure 1 shows the pressure-temperature relationship for water, with the pressure being expressed in the various units of measurement described below.

PSI: The technician’s gauge manifold set consists of a high side gauge and low side (compound) gauge. The high side gauge and the portion of the low side gauge at 0 or above are expressed in psig (pounds per square inch gauge). The gauge pressure reading is simply that, the pressure which the gauge is reading; a partial pressure which shows how far above atmospheric pressure the reading is. Converting psig to psia (pounds per square inch absolute) is done by adding atmospheric pressure to the gauge pressure reading; 14.7 psi at sea level.

Inches of HG: A barometer is a device used to measure atmospheric pressure. It is constructed from a glass tube sealed at the top, open at the bottom, with the bottom sitting in a mercury puddle. A vacuum occupies the portion of the glass tube above the mercury. Atmospheric pressure at sea level will support a column of mercury 29.92 inches high in the tube. This is where the term inches of mercury (Hg) comes from.

Inches of Vacuum: The portion of the compound gauge below 0 psig is used to express a system pressure less than atmospheric pressure. Its unit of measurement is inches of Hg, but is expressed as inches of vacuum. Rather than being a measurement of pressure above absolute vacuum, it is a mea -

surement of where the pressure is in relationship to 0 psig or atmospheric pressure. A reading of 10-in. vacuum on the compound gauge would indicate that the system pressure is 10-in. Hg. below 0 psig (atmospheric pressure). The conversion between psi and inches Hg is roughly 2:1; 10-in. Hg is equivalent to 5 psi, meaning that the system pressure is approximately 5 psi below whatever atmospheric pressure is.

58 HPAC | FEBRUARY 2024 HPACMAG.COM
< REFRIGERATION
Continued
Figure 1. Pressure temperature relationship for water.
on p60
PSIA Inches of HG mm Hg Microns (mm Hg x 1000) Compound Gauge in Hg. Vacuum H2O Saturation Temp. (F) 14.6960 29.9210 759.999 759,999 0.000 212.00 14.0000 28.5040 724.007 724,007 1.418 209.56 13.0000 26.4680 672.292 672,292 3.454 205.88 12.0000 24.4320 620.577 620,577 5.490 201.96 11.0000 22.3960 568.862 568,862 7.526 197.75 10.0000 20.3600 517.147 517,147 9.617 193.21 9.0000 18.3240 465.432 465,432 11.598 188.28 8.0000 16.2880 413.718 413,718 13.634 182.86 7.0000 14.2520 362.003 362,003 15.670 176.85 6.0000 12.2160 310.289 310,289 17.706 170.06 5.0000 10.1800 258.573 258,573 19.742 162.24 4.0000 8.1440 206.859 206,859 21.778 152.97 3.0000 6.1080 155.144 155,144 23.813 141.48 2.0000 4.0720 103.430 103,430 25.849 126.08 1.0000 2.0360 51.715 51,715 27.885 101.74 0.9000 1.8320 46.543 46,543 28.089 98.24 0.8000 1.6290 41.371 41,371 28.292 94.38 0.7000 1.4250 36.200 36,200 28.496 90.08 0.6000 1.2220 31.029 31,029 28.699 85.21 0.5000 1.1800 25.857 25,857 28.903 79.58 0.4000 0.8140 20.686 20,686 29.107 72.86 0.3000 0.6110 15.514 15,514 29.310 64.47 0.2000 0.4070 10.343 10,343 29.514 53.13 0.1000 0.2040 5.171 5,171 29.717 35.00 0.0000 0.0000 0.00 0.00 29.921
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REFRIGERATION

Continued from p58

mm Hg/Microns: The compound gauge is only accurate down to 29-in. Hg (at best) and should never be used to determine the system pressure while evacuating. The English Standard system of measurement is not particularly convenient when discussing vacuum; the inch is too large of a measurement. When discussing deep vacuum (between 29-in. Hg and 30-in. Hg) the unit of measurement used is mm Hg. At sea level, atmospheric pressure will support a column of mercury 760 mm high (there are 25.4 mm per inch). To further simplify the small measurements required in reading accurate vacuum, mm is broken down to 1/1000 of a mm, or a micron.

Conversion between units of measurement:

• 1 inch equals 254 millimeters

• 1 millimeter equals 1,000 microns

• 1 psi equals 2.036 inches of Hg

• 760 millimeters Hg equals 29.92 inches Hg

• 29.92 inches Hg equals 14.696 psig

• 29.92 inches Hg equals 0 inches vacuum

VACUUM MEASUREMENT AND PARAMETERS

“Blow and Go,” the practice of purging newly installed piping (or a recently serviced system) without evacuation is never an adequate method of ensuring that air and/or water have been removed from the system.

Evacuation is required, and the triple deep evacuation method is generally considered to be best. This will ensure any water present in the system will boil into a vapour and be removed along with any air that is present.

Deep evacuation means a final reduction in system pressure to 500 microns (some recommend 250 microns). Triple evacuation means three steps of evacuation: (1) down to 1000 microns, breaking the vacuum with dry nitrogen and a trace amount of refrigerant for leak testing; (2) again reducing system pressure to 1000 microns, and similarly breaking the vacuum once again; and (3) a final evacuation down to 500 microns.

A true electronic micron gauge should be used to measure the pressure in the system during evacuation. It should be vertically connected to the top of the piping and should never be exposed to large bursts of pressure.

While the vacuum pump should be connected to the low and high side of the system to minimize evacuation time, the micron gauge location should be some distance from either of these connections.

This will ensure that an accurate system pressure is being measured.

Once 500 microns is achieved, the vacuum pump should be valved off and shut down. The system should sit anywhere from 15 minutes (for a small system with short piping runs), to

System Size Pump Size

Up To 10 Tons 1.2 CFM

11 - 30 Tons 4 CFM

31 - 50 Tons 6 CFM

51 - 70 Tons 10 CFM

several hours for a large commercial/industrial system.

If the pressure rises to the 1500 micron level it would suggest that water is still present in the system, with the increase in pressure the result of that water boiling.

If the pressure increases to something near atmospheric (or at least to a pressure higher than the corresponding pressure for a saturation temperature equivalent to the ambient temperature) this would suggest that the system has a leak, with the pressure increase a result of air entering the system.

STARTING THE EVACUATION PROCESS

The vacuum pump will only reduce the pressure in the system to the pump’s minimum pressure achieved less the pressure drop in the connecting line between the pump and the system piping. Therefore, the path between the system piping and the vacuum pump should be as unrestricted as possible.

In addition, pressure drop experienced in the connection between the vacuum pump and the system piping extends the required time to reduce the system pressure to 500 microns.

Since a micron gauge is in use there is no need for a gauge manifold set; it will offer restriction to vapour flow to the vacuum pump. Consider using copper tubing (3/8-in. ODF or larger) to connect the vacuum pump to the system piping and keep them short as possible. (If using hoses, make sure they are large diameter, suitable for evacuation, and free of leaks).

Never connect the vacuum pump to an access fitting with a Schrader Valve; remove the Schrader Valve during evacuation and replace when complete.

A vacuum pump capable of reaching 500 microns is in good shape; a vacuum pump incapable of reaching 500 microns needs attention.

All line valves, compressor service valves, etc. should be opened.

Any normally closed control valve (solenoid valve or pressure regulator) should be manually opened before starting the vacuum pump.

Do not attempt to leak-check the system while it is in a vacuum. Leaks will be difficult to locate, and if present they will allow air into the system.

If you plan to run the vacuum pump overnight, install a full port direct acting solenoid valve in the piping between the vacuum pump and the system. Use a 120 V coil and plug it into a wall outlet. If a power failure occurs, the solenoid valve will close, allowing the state of vacuum to remain.

A vacuum pump that is too small for the size of the system will

60 HPAC | FEBRUARY 2024 HPACMAG.COM <
Figure 2. Vacuum pump sizing recommendations.

result in an extraordinarily long amount of time to complete evacuation. For proper vacuum pump sizing based upon system capacity, refer to the recommendations in Figure 2

Never base whether system evacuation is complete on the amount of time the vacuum pump has been operating. Evacuation is complete only after the pump has reduced the system pressure to 500 microns, and the system maintains that pressure after the pump has been shut down.

VACUUM PUMP MAINTENANCE

Contaminants removed during evacuation will be trapped in the vacuum pump oil. On large systems requiring extended time for evacuation, vacuum pump oil should be monitored during evacuation. If it becomes noticeably discoloured or appears watered down, it should be replaced.

Use only certified vacuum pump oil; it is specifically designed to have a low va -

“Evacuation is complete only after system pressure is at 500 microns.”

pour pressure (5 microns) at 100F (at a pressure of 5 microns the oil boils at 100F. The vacuum pump cannot achieve a pressure lower than the vapour pressure of its own oil.

In a perfect world the vacuum pump will receive the following maintenance: (1) pump oil drained immediately after each use (while the oil is warm); (2) refill with new oil and run for 2-3 minutes; (3) drain again, and refill; (4) close pump inlet valve and replace all pump seal caps.

Every time a system is opened for service, the liquid filter-drier should be replaced.

The vacuum pump will only remove contaminants such as acid if they are

present as a vapour. After a hermetic motor burn, you should expect that the majority of acid will still be present after replacing the compressor and evacuating the system. Appropriately sized filter-driers will be required to remove these destructive contaminants.

With the system leak free, contaminant free, evacuated, and equipped with the appropriately sized suction filters and liquid filter-driers, it is now ready to be charged with refrigerant, started, and commissioned.

And with the proper maintenance, a long healthy life should ensue. <>

Dave Demma holds a degree in refrigeration engineering and worked as a journeyman refrigeration technician before moving into the manufacturing sector where he regularly trains contractor and engineering groups. He can be reached at ddemma@uri.com.

HPACMAG.COM FEBRUARY 2024 | HPAC 61
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FOR THE LATEST EVENT NEWS, SEE HPAC'S NEWSLETTER @ HPACMAG.COM

KBIS

February 27-29

The Kitchen & Bath Industry Show (KBIS), North America’s largest trade show dedicated to all aspects of kitchen and bath design with displays from the industry’s largest names in faucets and fixtures, returns to Las Vegas. kbis.com

MEET Show

May 1-2

The Mechanical Electrical Electronic Technology (MEET) show is returning to Moncton, taking place at the Moncton Coliseum Complex. This will be the 25th edition of the biennial event that features the latest equipment, products, and technology all on display for contractors in Atlantic Canada and beyond. meetshow.ca

ASHRE Annual Conference

June 22-26

The global Society of Heating, Refrigerating and Air-Conditioning Engineers will be holding its five-day annual conference in Indianapolis. The program will cover how legislation, electrification, AI and other factors are affecting the industry.

ashrae.org

Canadian Hydronics Conference

September 25-26

The Canadian Hydronics Council hosts its now annual conference this year at the River Cree Resort and Casino in Edmonton. This will be a two-day conference including keynote presentations and a series of break-out technical sessions and workshops. There will also be a hydronics tabletop trade show. ciph.com/page/hydronics_council

Hot Air & Hot Water Forums

March 12-14

The American Council for an Energy-Efficient Economy (ACEEE) presents its second Hot Air Forum, focusing on decarbonizing space heating in buildings, and the Hot Water Forum, a technical conference dedicated to producing, distributing, using, and reusing hot water. Both are being held at the Hilton Atlanta in Georgia. aceee.org/events

Building Lasting Change

June 5-6

The Canada Green Building Council (CaGBC) annual Building Lasting Change conference takes place June 5-6 in Toronto. The conference agenda includes a technical stream which will explore real-world solutions from design and materials selection, to construction, operations and renewal.

cagbc.org

Modern Hydronics Summit

September 12

HPAC magazine’s annual Modern Hydronics Summit lands at the Paramount EventSpace just north of Toronto with a day filled with learning opportunities and displays of the latest in products and technologies that are pushing the hydronics industry forward.

modernhydronicssummit.com

ASHRAE Decarbonization Conference

October 21-23

This edition of the Decarbonization Conference will be held in New York City and will focus on an information and idea exchange on the topic of reducing carbon emissions from existing tall buildings in cold climates.

ashrae.org

CMPX

March 20 – 22

The Canadian Mechanical & Plumbing Expo is moving to the south building at the Metro Toronto Convention Centre in downtown Toronto. CMPX is Canada’s largest event for the plumbing and HVAC/R industry with over 500 exhibitors along with educational seminars and workshops.

cmpxshow.com

CIPH Annual Business Conference

June 16-18

The 2024 CIPH Annual Business Conference will take place in Kelowna, B.C. This marks the 91st anniversary of the national association for manufacturers and distributors of products and services for Canada’s plumbing and heating industry.

ciph.com

HRAI Annual Conference

September 22 – 24

The Heating Refrigeration and Air Conditioning Institute of Canada 2024 Annual Conference will take place in Vancouver. As always, the yearly gathering will include a variety of social and networking events along with a series of informative and thought provoking sessions on topics of interest for this evolving industry.

hrai.ca

MCAC Annual National Conference

November 27-30

The Mechanical Contractors Association of Canada takes its annual national conference to the capital city of Texas, Austin, which is well known for its live-music scene centered around country, blues and rock.

mcac.ca

62 HPAC | FEBRUARY 2024 HPACMAG.COM
2024
Planning an event? Send the details to editor@hpacmag.com Visit event websites for the most current updates and registration details.
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