MODERN HYDRONICS 2019 SPRING
THE BENEFITS OF INTERNALLY CLEAN SYSTEMS THERMAL ENERGY METERS: AN UPDATE
THE CASE FOR SYNCHRONIZED LOOPS PRODUCT SHOWCASE SMALL SCALE HYDRONIC COOLING
PROPOSED EFFICIENCY REGS PROMPT INDUSTRY REACTION MASTERING THE ART OF ZONING
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CONTENTS
Modern Hydronics
MH4 COOLING
MH12 REGULATORY NEWS
Small scale hydronic cooling
Industry reacts to NRCan proposed equipment efficiency regulations
A market sector with growth potential. BY JOHN SIEGENTHALER
MH16
PRODUCT SHOWCASE
MH8 SYSTEM DESIGN
The case for synchronized loops
MH22 ZONING
Mastering the art and science behind ideal environments
A system composed of synergistic components enhances the efficiency of the entire loop.
There are solutions to the thermal problems often associated with bad buildings.
BY JOHN SHEFF
BY ROBERT BEAN
MH10 METERING
In-service accuracy is key to uptake Measurement Canada to approve thermal energy meters within the year.
MH28 CORROSION Clean your pipes
Establish physically and chemically “clean” surfaces inside piping and other components. BY JOHN SIEGENTHALER
MODERN HYDRONICS
a supplement of Heating Plumbing Air Conditioning Magazine
111 Gordon Baker Road, Suite 400, Toronto, ON M2H 3R1 TEL: 416.442.5600 FAX: 416.510.5140 www.hpacmag.com EDITOR ASSISTANT EDITOR ASSOCIATE PUBLISHER ACCOUNT MANAGER ACCOUNT COORDINATOR ART DIRECTOR CIRCULATION MANAGER PUBLISHER VICE PRESIDENT PRESIDENT & CEO
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MODERN HYDRONICS
SPRING 2019
MH3
COOLING
SMALL SCALE HYDRONIC COOLING A market sector with serious growth potential. BY JOHN SIEGENTHALER
MH4
SPRING 2019
MODERN HYDRONICS
All piping and components conveying chilled water mus be insulated and vapor seale
COOLING MODE entire system filled with propylene glycol antifreeze solution
INSIDE
nology. Geothermal water-to-water heat pumps, as well as air-to-water heat pumps, stand ready, willing and able to supply warm water for low temperature radiant panel heat systems in all areas of North America. In many areas of North America, geothermal heat pumps currently enjoy generous subsidies that cover their higher installation cost. Air-to-water heat pumps, although currently not subsidized in most markets, can still hold their own on the basis of cost competitive performance, even in cold climates. The icing on the cake: In addition to their ability to serve as high performance hydronic heat sources, nearly all currently available geothermal water-towater heat pumps, and air-to-water heat pumps, come with refrigerant reversing valves and associated control logic that allows them to function as chillers. That’s a game changer when the question “but what do I do about cooling” comes up with prospective clients. A typical hydronic heat pump (waterto-water or air-to-water) can produce chilled fluids with temperature down to about 40F. Those temperatures are very sufficient for both sensible and latent cooling. All that’s needed is a way to interface this chilled fluid with interior space in a way that produces comfortable air temperatures and humidity levels. That interface should also take advantage of the benefits offered by hydronic delivery system, such as zoning, high distribution efficiency, and minimal invasiveness.
OUTSIDE
H
ydronic heating has long been known for providing superior cold weather comfort. Even so, the question that often comes from potential clients who are already convinced about of the benefits of hydronic heating, is: “What do I do about cooling?” In the days when nearly all hydronic heating systems were supplied by boilers, the answer to this question was to install a separate cooling system. It might be a standard ducted system where an outdoor condenser unit supplied a single air handler in the building. The cooled and dehumidified air was then routed through a ducted forced air system. The potential customer’s argument was typically: Why should I pay to install a hydronic heating system and then pay several thousand dollars more for a fully ducted cooling system, when the ducted system could also be used for distributing heated air? In some cases the allure of superior comfort, especially that provided by a hydronic radiant panel heating system, was sufficient justification for this “two separate systems” approach. However, when the construction budget was the controlling factor, the “ducts can do both” option typically doomed the hydronic heating system in favour of a furnace topped with an A-coil for cooling. Today, there are many indicators that point to heat pumps gaining a greater share of the hydronic heat source market. There is also a significant overlap between heat pumps and hydronic tech-
spr che val
(P1) air-to-water heat pump (HP)
flexible connectors
There are several possibilities. Let’s take a look. One approach is to set up a zoned distribution system serving multiple fancoil units, such as depicted in Figure 1. This system, shown in cooling mode operation, uses an air-to-water heat pump to supply two zones of radiant panel heating, or two zones of cooling. To ensure freeze protection of the outdoor heat pump, the entire system operates with a 30 per cent solution of inhibited propylene glycol antifreeze. Some manufacturers also offer “split system” air-to-water heat pumps that only contain refrigerant in the outdoor unit. This eliminates any concern for WWW.HPACMAG.COM
Modern Hydronics
(FC1)
high wall air handler
OFF (ZVH1) (ZVC1)
(FC2)
s st ed
high wall air handler
(ZVC2)
(P2)
ring eck lve
(ORC)
(S2)
(S1) (S3) temperature sensors
(SPC)
buffer tank
Figure 2 High wall unit
from migrating into the radiant panel zones by a combination of a closed zone valve on the supply pipe and a check valve on the return side piping. A variable speed circulator provides flow to the radiant panel manifold stations, or the air handlers, depending on operating mode. Zone valves determine which manifold or air handler receives flow. The circulator automatically adjusts speed as zone valves open or close. The buffer tank prevents the heat pump from short cycling when only one zone is operating.
TERMINAL VARIATIONS Figure 1 Zoned distribution system
freezing in the outdoor unit. All piping carrying chilled fluid must be insulated and vapour sealed to prevent condensation. Although this is a simple concept, it remains a challenge in practice, especially for installers not used to insulating piping in hydronic heating systems. When piping insulation is not properly done condensation on piping, valves, and circulators is sure to occur. That condensate can drip onto drywall surfaces and produce stains in short order. If you are not willing and able to do the insulation system right, do not get involved with any chilled fluid cooling system. In Figure 1, chilled water is prevented WWW.HPACMAG.COM
The fan-coils depicted in Figure 1 are called “high wall” units. Figure 2 shows an example of such a unit installed about six inches below ceiling level. High wall hydronic fan-coils are virtually identical to the air handlers used on many mini-split heat pump systems. The only significant difference is that the hydronic air handler has a water coil, rather than a direct expansion (refrigerant) coil. Hydronic high wall air handlers are currently available from several North American suppliers. They are typically turned or or off using a remote, and sport features such as vertically oscillating air diffusers, variable speed blowers, and different control modes for cooling, heating, and dehumidification. MODERN HYDRONICS
PHOTO COURTESY JAGA
(ZVH2) OFF
Figure 3 Console fan-coil
These air handlers come with condensate drainage tubes that can either be routed through an exterior wall, or connected to 3⁄4 inch plastic drainage piping routed through partitions. It is also possible to use “console” fan-coil units such as the unit shown in Figure 1. Console fan coils can be surface mounted or recessed into wall cavities. The later arguably looks better, but requires coordination with wall framing to ensure the recessed cavity is located and sized correctly. Yet another possibility is one or more ducted air handlers. These are widely available with both vertical or horizontal cabinet configurations. An example of the latter is shown in Figure 4. Some ducted air handlers are designed Continued on MH6 SPRING 2019
MH5
COOLING
Figure 4 Ducted horizontal air handler
to connect to standard ducting systems. Others are designed as “high velocity” units with blowers that generate high static pressure. the latter are typically configured with a single trunk duct that supplies several flexible two-inch diameter branch ducts. These small branch ducts can be snaked through partitions or along framing cavities. They terminate in a small orifice mounted on a ceiling or wall. Typically there needs to be six or seven branch ducts per ton (12,000 Btuh) of cooling capacity. The branch ducts are typically limited to runs of 25 feet from where they connect to the trunk duct. Figure 5 shows an example of a horizontal air handler mounted within a conditioned attic space. The small two-inch flex ducts supplied from the single trunk are seen fastened to the insulated roof surface. If you look closely you will also see a secondary drain pan under the air handler. It is there in case the drain pan within the air handler develops a leak, or the piping from that drip pan somehow gets plugged. A secondary drain pan is cheap insurance against the possibility of a condensate leak that could damage expensive interior surfaces under the air handler.
PAY ATTENTION Whenever a fan-coil or air handler is used for chilled fluid cooling it is important to understand, respect, and implement several details: 1. Always be sure that the air handler or fan coil is equipped with a condensate drip pan and drain tube. 2. Be sure to plan for how electrical power, an insulated supply and return pipe, and a condensate drain tube will be routed to each air handler or fan coil. 3. When a recessed fan coil is used be sure to provide framers or other construction contractors with information on the size and exact location of the wall cavity. 4. Be sure to pitch the condensate drainage tube to allow gravity drainage. 5. If the condensate drain is connected to the building’s DWV plumbing system be sure to install traps that prevent MH6
SPRING 2019
Figure 5 Air handler in conditioned space
sewer gas from reaching the air handler or fan coil. Follow applicable code requirements for the trap details. 6. Place air handlers or fan coils so that air discharge is not directly aimed at areas where occupants are seated. Drafts create discomfort. 7. Always get a wiring diagram for the specific air handler or fan coil being used so that it functionality can be coordinated with other control functions such as turning on the distribution circulator and heat pump.
COOL SURFACES Another option is radiant panel cooling. This technology enjoys a more developed market in Europe, but is currently in its infancy within North America. It involves circulating a chilled fluid (water or an antifreeze solution) thorough radiant panel tubing circuits embedded in ceilings, walls, or floors. Of these, radiant ceilings are ideal for cooling. A key concept is to regulate the chilled fluid temperature to the radiant panel so that it remains just above the dewpoint temperature of the space being cooled. This is critically important in avoiding condensation on the panel. The May 2014 HPAC article “I Need This Controller” covers the details and possible piping/control designs for radiant cooling. Check it out in the HPAC archives for more information. <> John Siegenthaler, P.E., is a mechanical engineering graduate of Rensselaer Polytechnic Institute and a licensed professional engineer. He has over 34 years experience in designing modern hydronic heating systems. Siegenthaler’s latest book is Heating with Renewable Energy (see www.hydronicpros.com for more information).
SEE JOHN AT THE MODERN HYDRONICS SUMMIT 2019. CHECK MODERNHYDRONICSSUMMIT.COM FOR UPDATES.
MODERN HYDRONICS
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SYSTEM DESIGN
THE CASE FOR SYNCHRONIZED LOOPS
A system composed of synergistic components enhances the efficiency of the entire loop. BY JOHN SHEFF
A
building’s hydronic HVAC system is rarely just the sum of its parts. The system is comprised of chillers, boilers, pumps, variable frequency drives (VFDs), air handling units (AHUs) and valves that create a loop through which water is circulated to control the building’s temperature and its occupants’ comfort. In this loop, each component is a node that has an effect not just on the one next to it but on every other one, regardless of how far they are from each other. In fact, the nodes furthest from each other may impact each other the most. Variable speed pumps, for example, surrender much of their part-load efficiency if the wrong balancing valves are installed at the terminal units. Too often systems are designed and components specified as though this loop is made of discrete nodes. Consequently, building owners continue to install inefficient systems and then struggle to find lasting solutions to chronic problems like hot spots, high utility bills and constant maintenance calls. A system composed of synergistic components, on the other hand, enhances the efficiency of the entire loop.
Pressure independent control versus manual balancing.
Pressure independent control valves (PICVs) installed at the AHUs tightly control the water temperature entering and exiting the unit’s coils, allowing the chiller’s oil-free variable speed compressor to work as efficiently as possible. VFDs on the pumps supply only as much water as is demanded to take advantage of part load conditions to save energy. All the while, each component collects valuable data on energy usage, flow, pressure and temperature for the building management system to aggregate and use to make decisions about predictive maintenance, fault detection and comfort.
Investing in a synchronized hydronic loop made of synergistic components ultimately offers solutions to the following common problems associated with conventional hydronic HVAC systems: • Occupant comfort • Design efficiency versus installed efficiency • Degradation of efficiency over time These problems are often symptoms of an unbalanced system but are frequently misdiagnosed as issues with individual components. Those disconnected components, however, are operating as best they can in a system not at equilibrium.
A system composed of synergistic components. MH8
SPRING 2019
MODERN HYDRONICS
WWW.HPACMAG.COM
Modern Hydronics
pumps and oil-free variable speed compressors to match the system’s energy consumption to that demand, allowing the system to achieve design efficiency in all load conditions.
SUSTAINED EFFICIENCY OVER TIME
Hydronic pumping strategies.
Left, how much oil is common? Right, how oil impacts performance.
PRECISE COMFORT CONTROL A traditional HVAC system is designed using manual balancing valves to provide proper flow to all coils during the hottest and coldest days of the year, which typically occur just two per cent of the time. These balancing valves, however, possess a fixed orifice that remains in the same open position the other 98 per cent of the time, allowing the system’s differential pressure to change, and thus flow to the coils to shift even as loads remain constant. Ideally, flow should vary only in response to changes in load. This improper flow at constant load creates a situation known as “hunting,” which causes inefficient heat transfer, spikes in chiller and pump energy consumption, dramatic swings in discharge temperatures and, ultimately, chronic hot and cold spots in the occupied space. The pressure independent control valves (PICVs) in a synchronized hydronic loop, on the other hand, continuously adjust their differential pressure orifice poWWW.HPACMAG.COM
sition in response to dynamic load conditions, maintaining consistent differential pressure across the valve. This means the flow into the coils only varies in response to changing loads, allowing for efficient heat transfer and precise comfort control in the occupied space.
DESIGN EFFICIENCY IN ALL LOAD CONDITIONS It is easy to assume that achieving maximum efficiency in an HVAC system means sacrificing comfort. After all, conserving energy at home usually means adjusting the thermostat past the point of comfort. When it comes to hydronic HVAC systems, however, comfort and efficiency are two sides of the same coin. As the PICVs at the air handlers continuously adjust to current load conditions to optimize heat transfer and comfort, they’re also minimizing flow into the coils. This means the system is only heating, cooling and pumping as much water as is necessary to meet demand. A synchronized hydronic loop utilizes variable speed MODERN HYDRONICS
Regardless of where a system starts out, its efficiency will decline with time. Chillers with traditional compressors degrade at a faster rate, as oil from the chiller mixes with the refrigerant and contaminates the system. That could lead to an immediate efficiency decrease of seven per cent, eventually climbing to a peak of around 20 to 30 per cent efficiency loss. However, a synchronized hydronic loop utilizes oil-free chillers, completely avoiding these issues. Instead of oil, these chillers use magnetic rotors to eliminate friction. This technology is designed to not only allow the system to maintain a high level of efficiency, but to also significantly reduce maintenance costs. The synchronized hydronic loop offers solutions to many of the problems associated with conventional hydronic systems. It also proves that a systems-based approach, as opposed to selecting components individually, is necessary to maximize efficiency, decrease downtime and, ultimately, improve occupant comfort and the bottom line. The efficiency of each component in the synchronized hydronic loop is superior to the efficiency of that same component in a system without the other components. In this way, the synchronized hydronic loop is truly greater than the sum of its parts. <> John Sheff is a business development manager focused on utility programs and end user strategy at Danfoss. Previously, he worked as an energy and sustainability policy analyst in the office of Maryland’s governor. SPRING 2019
MH9
METERING
IN SERVICE ACCURACY IS KEY TO UPTAKE
Measurement Canada to approve thermal energy meters within the year.
T
WHAT ARE THERMAL ENERGY METERS? Thermal energy meters measure the amount of heat energy given up or absorbed by a liquid in a heat exchange circuit such as a radiator. These meters are used to measure the amount of heat energy used by a customer for the purpose of billing. Thermal energy meters can be used with:
Thermal energy meters consist of three main parts:
• Gas-fired boilers • District heating systems • Sub-metering configurations • Other systems
• A flow sensor • A temperature sensor pair • A calculator
MH10
SPRING 2019
Thermal energy meter installed.
“in service” accuracy (to protect consumers from erroneous billing) are what is needed to advance this technology.” In 2017 with the intention of developing technical requirements, input was sought from owners of thermal energy meters in use used within Canada; industry members and associated organizations; and consumers who were billed for heating or cooling on the basis of the measurements provided by a thermal energy meter.Following those consultations, Innovation, Science and Economic Development Canada tells HPAC that technical requirements have been formalized and MC will continue to expand its knowledge in this field by visiting partner laboratories across the world to learn best practices. It is expected that MC will issue its first approvals of thermal energy meters before the end of 2019. Devices installed prior to the requirement to use an approved meter (tentatively, 2021) will be allowed to remain in service until 2026. After that date, MC will begin requiring their removal and replacement with an approved meter. In the interim period from 2021 to 2026, MC reserves the right to perform inspections of all installed thermal energy meters, whether or not approved. If an unapproved meter is inspected, it will be allowed to remain in service until 2026, provided that its performance is satisfactory. For background and more information on this topic see "A Shot in the Arm" by Evans in HPAC August 2015 (digital archives at www.hpacmag.com). <>
MODERN HYDRONICS
WWW.HPACMAG.COM
PHOTO COURTESY ONICON
hermal energy meters, also known as Btu meters and heat meters, are moving from the realm of simple measurement into use as billing devices, which raises some regulatory questions on the municipal, provincial and federal levels. The issue is analogous to a gas pump that is measured and calibrated in accordance with the prescriptive requirements governed by Industry Canada–Measurement Canada (MC) under the mandate of the Weights and Measures Act. Previously, there was no specific legislation or guideline in place from MC to govern the suitability or certification of Btu meters in Canada, meaning the devices were not regulated under the Weights and Measures Act. This is unlike electricity, water and gas, which have regulated measurement (metering) practices in place to ensure fair measurement for both suppliers and consumers. Without accurate measurement systems installed, thermal energy systems will not be able to allocate costs effectively. This could potentially result in lower returns on investments for suppliers, increased end-user consumption (waste), or unfair bills to end consumers. As HPAC columnist Mark Evans noted in a 2015 article, “We have a long way to go before Btu metering becomes ubiquitous and hydronic heating/cooling are mainstream. A fully-vetted, consensus Standard, along with guidelines requiring manufacturers meet a single stated accuracy level to ensure ongoing
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REGULATORY NEWS
Limited product offerings for replacement applications is expected to be just one result of proposed increased NRCan efficiency requirements that are not in harmony with U.S. regulations.
INDUSTRY REACTS TO NRCAN PROPOSED EQUIPMENT EFFICIENCY REGULATIONS
I
n October 2018 Natural Resources Canada (NRCan) published new proposed energy efficiency regulations for heating equipment in the Canada Gazette Part 1. These proposed regulations are part of Amendment 15 to the Energy Efficiency Act and introduce new or increased efficiency requirements to a range of products including commercial water heaters, household and commercial boilers, mobile home furnaces and gas fireplaces. Publication in the Canada Gazette Part 1 is the last step the government takes prior to passing these new requirements into law. After publication of the proposed regulations, NRCan provided for a final comment period, which ended on December 29, 2018, that allowed all stakeholders to provide feedback. The proposed regulations are controversial, with several of them being opposed by heating industry associations. The Canadian Institute of Plumbing and Heating (CIPH), the Heating, Refrigeration and Air Conditioning Institute (HRAI) and the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) represent manufacturers and distributors in the plumbMH12
SPRING 2019
ing and heating industry. These three associations presented a joint submission to NRCan outlining their concerns regarding the proposed regulations. The submissions by CIPH-HRAIAHRI covered two separate product categories: water heaters and boilers. The water heater regulations being proposed by NRCan cover commercial electric, gas and oil-fired storage water heaters, and residential and commercial tankless water heaters. For electric and oil-fired storage water heaters, NRCan is harmonizing energy efficiency requirements with those already in place in the U.S. For gas-fired storage water heaters NRCan is taking a new approach with two different efficiency requirements, which cover new installations and retrofit installations. New installations will require condensing level efficiency equipment, while retrofit applications can still use non-condensing equipment. The industry associations endorse most of the proposed water heater regulations and are very supportive of the concept of separate requirements for new construction and existing construction for
MODERN HYDRONICS
WWW.HPACMAG.COM
REGULATORY NEWS commercial gas fired storage water heaters. The associations have however raised objections to the proposed regulations for non-condensing gas-fired storage water heaters that are more stringent than current United States Department of Energy (DOE) regulations. “The industry objects to the increase in the efficiency requirements being proposed for non-condensing equipment that can be used for retrofit applications. NRCan is raising the thermal efficiency requirement for this category from 80 per cent (current DOE requirements) to 82 per cent for this category and this is extremely problematic for the industry,” explained Robert Waters, technical consultant for codes and standards for CIPH. The industry associations claim this increased efficiency requirement will not be in harmony with U.S. regulations and will result in the elimination of the majority of the models currently utilized for replacement applications in Canada. The result will be a very limited product offering for consumers, as most models currently available would not meet the new efficiency requirements. There are also some technical and safety concerns with possible flue gas condensation in existing venting systems with the proposed higher efficiency equipment. CIPH-HRAI-AHRI do not object to the proposed new water heater efficiency regulations for the new construction category, but have recommended the requirement for non-condensing equipment be harmonized with the current U.S. DOE regulations for those products, ensuring availability of a wide range of products and a smooth transition in the market. They have also asked NRCan to push back the proposed implementation date to allow more time for industry to react to the changes. The boiler regulations being proposed by NRCan cover residential and commercial, gas and oil-fired boilers. For oilfired boilers, NRCan is harmonizing MH14
SPRING 2019
“The proposed regulations are controversial, with several of them being opposed by heating industry associations.” efficiency regulations with current DOE regulations. For gas-fired boilers, NRCan is deviating from current DOE regulations and proposing only condensing level efficiency equipment can be used for all applications. These proposed gas-fired boiler regulations are much more contentious. “The majority of our members are not in support of the new gas fired boiler regulations being proposed by NRCan,” stated Waters. “Members are very disappointed dual level efficiency requirements for replacement and new construction applications are not being proposed for gas-fired hot water boilers. “NRCan has proposed this approach for commercial water heaters, but have not applied this same approach to boilers, even though similar technical and other issues apply to both categories of products,” added Waters. NRCan commissioned a Cost-Benefit Analysis (CBA) study to look at the economic impact for consumers of the proposed new regulations. NRCan’s CBA report has been used to justify its proposal to increase efficiency levels to condensing technology for all gas hot water boilers. CIPH-HRAI-AHRI believe there are many issues with the CBA study and feel that it contains errors and inconsistencies as well as incomplete and/or incorrect data. The industry associations state the market for household and commercial condensing boilers has grown significantly over the last 15 years without having any minimum efficiency regulations in place. CIPH-HRAI-AHRI believe that condensing boilers are being utilized extensively where they are economically justified, but feel there will be MODERN HYDRONICS
significant financial and technical burdens for consumers by forcing condensing boilers into all existing installations. The associations have also stated there continues to be many retrofit applications where condensing boilers cannot be justified and non-condensing boilers are still the best option for consumers. “There are many existing buildings that will have to incur huge costs to install new venting and mechanical room repiping to accommodate a condensing boiler,” said Waters. “There are also many applications that only use high system water temperatures, resulting in minimal condensing in the boiler. These applications will see minimal if any fuel savings from a condensing boiler, but may have to spend huge amounts to install the boiler.” CIPH-HRAI-AHRI have recommended that NRCan implement dual level standards for household and commercial gas-fired water boilers for new installations and retrofit installations, similar in concept to the proposed efficiency regulations for commercial storage water heaters. None of the new proposed equipment efficiency regulations are finalized yet, as NRCan is currently reviewing all of the final comments received. Once they finalize their review NRCan will then have to decide the final version for the new regulations. This is expected to be published sometime in the next few months in the Canada Gazette, Part 2, at which point the regulations will become law. Waters noted that these regulations will have a big impact on what type of equipment Canadian mechanical contractors will be allowed to be installed in the future. <> WWW.HPACMAG.COM
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an external sensor connected directly to the TPE3 allow the pump to
systems. Key provisions of the 2018 USHGC and changes from the
take charge of the systemâ&#x20AC;&#x2122;s need for flow based on differential tem-
2015 edition include new: insulation and fasteners provisions for radi-
perature. Wireless technology enables the TPE3 to connect with up to
ant and heating/cooling systems; snow and ice melt system controls;
four single TPE3 pumpsâ&#x20AC;&#x201C;they can be controlled jointly in either cascade
slab penetration tube and joint protection used in hydronic systems;
mode, alternating mode or duty/standby without the need for any other
listing requirements for ground coupled and water source heat pumps;
pump controller unit. www.grundfos.com
Continued on MH18
certification of DX heat pumps; and more. www.iapmo.org MH16
SPRING 2019
MODERN HYDRONICS
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PRODUCT SHOWCASE
Beacon Morris has released panel radiators and towel warmers, which are engineered to Hydro Shark radiant floor panel systems from
perform in all types of applications including
Stiebel Eltron feature a closely spaced tee to
low temperature systems. Available in 1,472 to 18,355 Btuh, the radiators have valve in-
SpacePak’s Solstice Extreme low ambient
create hydraulic separation between the boiler
serts for thermostatic head. Maximum work-
heat pump is suited to residential and light
loop and emitter heating loop. Panels are
ing pressure is 145 PSI. Maximum operating
commercial primary heating and cooling ap-
available with or without the electric boiler in-
temperature is 200F. The radiators are fin-
plications in severe weather climates. The
tegrated on the panel. Features of the Pro and
ished with a decorative grille, rounded edges
heat pump utilizes enhanced vapour injection
Master models include powder coating, quick
and can be installed anywhere with six differ-
technology and a high efficiency condenser.
mount rails, heavy duty copper pipe and fit-
ent connection points. The panel radiators
Solstice Extreme provides up to 48,000 Btuh
tings, and precision solder joints. Panels are
combine both radiant and convection heating.
at 0F.
pre-plumbed, pressure tested and pre-wired.
www.beacon-morris.com
www.spacepak.com/Solstice.html
www.stiebel-eltron-usa.com
Bacharach’s PCA 400 may be used for spot-
EC Power micro CHP systems can operate as
checking and tuning boilers. It has a high-
one single stand-alone engine, or in a larger
KN-Series Plus cast iron condensing boilers
range CO sensor and available sample condi-
connected group with a central control system
from Advanced Thermal Hydronics utilize a hy-
tioner. Features include a 4.3 in. colour touch
to monitor all engines and maximize efficiency
drophobic coated finned stainless steel heat
screen with enhanced viewing options to eas-
to match base loads of thermally led systems.
exchanger to work in concert with the existing
ily see readings. Bluetooth wireless technolo-
Overall efficiencies are able to reach 96 per
high efficiency cast-iron heat exchanger.
gy allows for live streaming of data to PCs and
cent (thermal and electrical) when operating
Finned stainless steel tubes increase heat
mobile devices. A rugged all-in-one probe con-
at full capacity. The units can be tied into ex-
transfer area to maximize efficiency while
nection offers durability and easy setup. NOx
isting boiler loops, and operate as a “first on
maintaining a small footprint. The unit is a full
and SO2 sensors with Viton probe tubing for
and last off” approach, which provides more
variable flow water-side condensing boiler, al-
emissions testing are optional. The dilution
heating redundancy. Popular sizes in Canada
lowing integration into variable flow primary
mode protects sensors and allows for use in
are 19 kW and 25 kw per unit. Applications
boiler systems. It is certified for use with PVC
harsh conditions. The portable combustion
include
facilities,
and Polypropylene vent materials and comes
and emissions analyzer runs on rechargeable
commercial laundry, car wash, university cam-
in sizes from 600,000 to 3,000,000 Btuh.
Lithium-Ion battery pack or four ‘AA’ batteries.
puses, swimming pools, and snow melt sys-
www.knseries.com
www.mybacharach.com
tems. www.aquatech-canada.com
MH18
SPRING 2019
healthcare, correctional
MODERN HYDRONICS
Continued on MH20 WWW.HPACMAG.COM
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Each building is its own puzzle. By taking a holistic approach to your entire hydronic system, the experienced team at Bell & Gossett will help you solve for true energy efficiency. Now’s the time to take advantage of the most complete product range in the industry, including Bell & Gossett highly energy efficient e-series pumps. Spec your job today with the only integrated, online selection tool at esp-systemwize.com.
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PRODUCT SHOWCASE
Bell & Gossett’s ecocirc wireless hot water system uses an electronically communicated Weil-McLain’s AquaBalance Series 2 combi
motor to operate at 20 watts. It is intended
and heat only boilers feature stainless steel,
for potable plumbing systems without a recir-
With its minimalist design Ideal MD055 in
titanium-infused heat exchangers. The units
culation line. Installed under the sink, the
chrome from Vogue UK is a contemporary
are designed for retrofits or new construction
system’s
towel dryer with a polished finish. Made from
in single-family homes, apartments or condo-
equipped with an onboard temperature sen-
stainless steel, the Ideal is available in three
miniums. AquaBalance is available in three
sor and wireless RF transceiver, communi-
sizes: 1500 mm. (10 rails), 1200 mm. (8
sizes (8,120 and 155 MBH input). The 155-
cates with the circulator pump mounted to
rails) and 900 mm. (6 rails). Electric models
size combi-boiler products a constant supply of
the hot-water source to deliver temperature-
are also available. www.vogueuk.com
hot water up to 4 gpm. www.weil-mclain.com
controlled hot water. www.bellgossett.com
battery-operated
paired
valve,
The 60V MAX In-Line Stud and Joist Drill with E-Clutch System from Dewalt is a high torque right angle drill. The drill has a mechanical clutch for control in high or low speed. In high and low speed, the EClutch system is designed to sense tool motion and eliminate the V-10 touch screen controller is available on all VFC and SL series
torque when binding is detected by stopping the motor. The user is
condensing boilers from IBC. Boilers may be programmed with an in-
notified the system has been activated through an illuminated LED
terview style and quick start menu. The controller offers up to four-
light. The drill also features the two-speed Quick-Shift, which allows
zone pump control and simplified load pairing. Internet connectivity is
the user to easily shift between two speeds without having to feather
built-in and a USB port simplifies programmability. Features include an
the trigger. The drill also includes a two-position side handle, a shallow
intuitive alert system, built-in notification relay, reverse flow detection,
nose to get into tight spaces, a ½ in. keyed chuck and chuck key
automatic altitude adjustment and pre-programmed values for all load
holder, an LED to illuminate work areas and a knuckle guard to help
types. www.ibcboiler.com
protect the user’s hand. www.dewalt.com
MH20
SPRING 2019
MODERN HYDRONICS
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ZONING
Inconsistency in space and surface temperatures can occur where multiple elevations exist off a single floor plate.
MASTERING THE ART AND SCIENCE BEHIND IDEAL ENVIRONMENTS There are solutions to the thermal problems often associated with bad buildings. BY ROBERT BEAN
T
his continues to shock many readers but as I have said repeatedly the construction industry does not exist to employing building professionals. The industry exists to create spaces for humans because without shelter for protection we would not be able to populate many parts of the world. When it comes to buildings it all comes down to MH22
SPRING 2019
Maslow’s hierarchy of needs where food and shelter are basic essentials and the final stage manifested through self-actualization. In architecture, self-actualization is expressed through creative forms and interior finishes. But here’s the thing, creative forms and interior finishes are not sufficient for creating ideal environments–supplementary solutions are most always necessary to condition indoor spaces. This explains the existence of lighting and HVAC systems. These take on many forms from meeting mandatory minimum requirements established by building codes, to voluntary compliance to higher requirements identified by proMODERN HYDRONICS
grams such as Well, Living Building Challenge or Active House.i In the former neither comfort nor energy are the priority, being trumped by basic needs of safety and reducing risk of illness. In the latter it is assumed the former is a prerequisite to support much higher aspects of human factor design (self-actualization) and earth stewardship. When it comes to zoning, most design practitioners carrying out HVAC load calculations to minimum code compliance often follow a single or minimal approach ignoring many of the factors which contribute to occupant discomfort and system inefficiencies. As I have discussed before, HVAC load calculaWWW.HPACMAG.COM
Modern Hydronics
tions are not comfort calculations and should never be represented as such.ii Alternatively the designer could lead the client to a multi-zone system, which based on good practice, considers the space dynamics due to wind, precipitation, solar loads and enclosure performance; and occupant’s metabolic rate and clothing and tactics which promote adaptive strategies.iii If compliance to comfort standard ASHRAE 55 is desired (and why wouldn’t it be) then separate calculations according to the Standard are necessary. To precede with comfort calculations two approaches are considered. Use a multizone systems approach or design and construct a building of such high performance that single or minimal zoning is sufficient. Zoning is both an art and science, which strategically must consider the
representative occupant, competing representative occupants, their individual and collective authority over controllability, system operation, and economics. Tactically it considers the following as good practices:
ARCHITECTURAL ELEMENTS How a building is orientated on a parcel of land will affect precipitation, wind and solar loads on exposed above grade surfaces or unexposed below grade surfaces. These mass and energy loads are then transmitted to the interior spaces through differentials in moisture, pressure, and temperatures. Surfaces and spaces that receive extraordinary loads ought to have their own comfort controls. Examples of these are southern facing rooms with large window to wall ratios and finished with interior blinds and
without exterior shading. These southern surfaces will receive relatively large amounts of shortwave radiation which depending on solar heat gain coefficients could influence the space conditions differently than other spaces. If the southern space had the only thermostat and was combined with (for example) northern facing rooms it is possible that under heating could occur in the north spaces during some periods. This is due to the thermostat shutting down the heating system due to a rise in temperature from the solar load. Likewise, if the north space had the thermostat it is highly likely that the southern spaces will overheat. This is due to the thermostat remaining on to satisfy the setpoint but can’t pick up the temperature rise in the south facing rooms. It is important for designers to develop this, Continued on MH24
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MODERN HYDRONICS
SPRING 2019
MH23
ZONING TABLE 1: ZONING STRATEGIES BASED ON ROOM FUNCTION, TYPES, MOISTURE LOADS, TEMPERATURE SETPOINT, CLOTHING (CLO) AND METABOLIC (MET) RATE Space function
Typical room types
Moisture load
Temperature setpoint
Typical clo values
Typical met rates
Socializing, entertaining
Living, family, kitchens, break rooms, lounges, solariums, atriums
Steady state
Normal
Low to medium
Low
Food preparation and consumption
Kitchen, dining, pantries, break rooms, lounges
Variable
Normal to low
Low to medium
Low to high
Hygiene
Bathrooms, powder rooms, change rooms, laundry
Variable
Above normal
Low to medium
Low
Rest, sleeping
Bedrooms, dens
Steady state
Below normal
Low to medium
Low
Study, work
Offices, study, libraries, reception, meeting, copy/print
Steady state
Normal
Low to medium
Low to medium
Personal
Hobbies, music gyms, greenhouses, solariums
Variable, steady state
Varies
Low to high
Low to high
Media
Theatre, music
Steady state
Normal
Low to medium
Low
Pool/wet rooms
Swimming, hot tubs, steam, sauna
Med to high
Above normal
Low
Low to high
Cellars
Wine, food
Steady state
Below normal
na
na
Storage
Household goods, office supplies, janitorial
Steady state
Below normal
na
na
Any space with an extraordinary source of heat such as fireplace, stoves, theatre equipment, kilns, solar loading etc. Should be on separate controls. Any spaces with extraordinary low heating or cooling loads with similar function, moisture loads, temperature set points and where occupants are doing similar activities and wearing similar clothing should be combined for simplifying systems and reducing capital costs. Mixed spaces should permit adaptive strategies (clothing, shading) and accommodate personal devices such as desk fans and heaters.
â&#x20AC;&#x153;if/thenâ&#x20AC;? understanding and herein (in part) lays the art of zoning.
CHANGES IN ELEVATION OR GEOMETRY Any time there is changes in elevation such as in a multi floor building there could be thermal consequences due to stack effect. This will result in stratification where warmer air temperatures accumulate in the higher floors and colder temperatures at lower floors due to convective flows. There can also be inconsistency in space and surface temperatures where multiple elevations exist off a single floor plate (ex. vaulted ceilings mixed with flat ceilings) or where floor plates change direction (L-shaped rooms exposed to different solar loads) or are sepMH24
SPRING 2019
arated (for example) by stairwells or elevator shafts. For these reasons floor plates of different geometry, separation or with different elevations should not be combined, as a single thermostat cannot accurately represent the different conditions that may exists.
SPACE FUNCTION/PURPOSE AND CONTROL There is frequent control conflict when rooms of different use and purpose are assigned to a single control point. Consider the metabolic rate, clothing and pattern of an occupant in a specific space relative to occupants in other spaces; and consider what heat and/or moisture sources might be present in one room but not in another. Also conMODERN HYDRONICS
sider the location and types of control employed in one space but not others this includes shading, fans, heaters and building management systems. In addition, there could be any number of mixtures of spaces, people, lights and equipment operating at any time. Any combination of the above could cause conflicts if the entire building is treated as a single zone. Good practice suggests rooms of unique characteristics and use each be considered for separate controls as described in Table 1.
INTERIOR DESIGN AND FINISHES The importance of interior systems on indoor environmental quality and energy use cannot be overemphasized. This Continued on MH26 WWW.HPACMAG.COM
ZONING includes effects of short wave radiation and moisture on finishes (outgassing) and effect of surface treatments on heat transfer.iv The latter has significant consequences for designers of radiant floor systems. For this reason zones of similar flooring conductivities with similar fluxes should be grouped together. Another way of stating this is zones with different floor conductivities and fluxes should not be controlled with the same control system. In practice the radiant system (tube spacing) along with the flooring conductivities (U values) and enclosure design (ACH and U values) should be manipulated to harmonize the necessary fluid temperatures to the least number of required profiles.
GOOD BUILDINGS There is in practice a conflict between zoning, controllability and economics. Consider the entry level, two-storey home with a single furnace and thermostat. In a “built to code” house it is almost impossible to comply with ASHRAE Standard 55 due to the thermal dynamics in the home. The same applies to poorly designed and constructed commercial spaces with single roof top units. Even multi-zoned balanced air systems will have noncompliance issues such as
Complete solutions for energy production, storage, and distribution
MH26
SPRING 2019
HPAC_Aug_Roth.indd 1
cold floors, radiant asymmetry, drafts and stratification simply because of climate inappropriate architecture, poor choices in finishes and inadequate enclosure designs. Solving the non-compliance issues by zoning and enclosure improvements often makes the building uncompetitive relative to the market for entry level structures. Until the benchmark for entry level products changes, industry will always have non-compliance complaints. Simply put if the industry wants to reduce the complaints stop doing bad buildings. Good buildings with flexible policies around adaptive strategies can have simple single or simpler multi-zone systems because the occupants, building and finishes solve many of the thermal problems often associated with bad buildings. Zoning in and of itself is not a single solution to comfort problems. Anyone making this suggestion does not fully understand the relationships between people and buildings. Understanding how spaces respond to exterior and interior stimuli and how these relate to occupant needs and preferences for space conditions helps develop the designer’s art of zoning but the art first must be based upon the sciences of physiology, psychology and buildings.v <> REFERENCES
i Bean, R. 2018. Human factors and their influence on building perfor-
Radiant, Snowmelt, Oil Storage and Solar
www.Roth-America.com Call 800-969-7684
“Zoning in and of itself is not a single solution to comfort problems.”
mance and comfort. HPAC Magazine Canada ii Bean, R. 2012. Built to code: What does it mean for consumer thermal comfort? < http://www.healthyheating.com/Built-to-code.htm> iii Bean, R. 2016. It is time HVAC system design grew up. HPAC Magazine Canada iv Bean, R. 2012. Together Forever. HPAC Magazine Canada v Bean, R. 2014. Integrating Elements to Improve Comfort Design. HPAC Magazine Canada
Robert Bean is a Registered Engineering Technologist in building construction (ASET) and a Professional Licensee (Engineering) in HVAC (APEGA). He is president of Indoor Climate Consultants Inc. and director of www.healthyheating.com; a past ASHRAE Distinguished Lecturer; recipient of ASHRAE’s Lou Flagg Award and ASHRAE Distinguished Service Award; and a member of ASHRAE technical committees 2.1 (Physiology & Human Environment) 6.1 (hydronics), 6.5 (radiant), 7.04 (eXergy) and SSPC 55 (thermal comfort). Bean is also the author of numerous industry courses and seminars covering the building sciences, indoor environmental quality, energy, and radiant-based HVAC systems. MODERN HYDRONICS 2018-07-17 3:06 PM
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CORROSION
CLEAN YOUR PIPES Establish physically and chemically “clean” surfaces inside piping and other components. BY JOHN SIEGENTHALER
W
ater is the “life-blood” of hydronic systems. Its chemical characteristics can make the difference between a system that lasts for decades, versus one that develops expensive corrosion issues within months of commissioning. We discussed the advantages of establishing and maintaining good water quality in hydronic heating and cooling systems in the March 2016 issue of HPAC. Part of that discussion focused on removing dissolved ions created by calcium and magnesium salts, which are commonly found in groundwater. The resulting “demineralized” water would ideally have a total dissolved solids (TDS) reading between 10 and 30 parts per million (PPM). This gives the water just enough electrical conductivity to allow low water cutoff safety devices to function properly, but not enough to support galvanic corrosion. It also high enough to prevent the water from scavenging ions from piping materials, which can happen when the water’s TDS number approaches zero. Although demineralization is the primary method for improving water quality in hydronic systems, its effectiveness is dependent, in part, on establishing physically and chemically “clean” surfaces inside the piping and other components of a closed loop system. Although it is easy to think of a new crafted hydronic piping system as being internally clean since it was built with all new materials, this is seldom the case. To begin with, think about how copper or steel tubing makes its way from the mill to a newly assembled system. Those materials are typically handled, transported, and stored multiple times and at different locations before they make it to your job site. During that time they can be exposed to dust, rain, wind, pollen, road salt, insects, birds, mice and more. It is inevitable that contaminants from some of these sources will get into piping that is not capped at both ends. These contaminants aside, there is also likely to be some residual of lubricants used during manufacturing. When copper MH28
SPRING 2019
Figure 1. Recommended setup
piping is soldered together there is going to be residual flux inside the piping. Threaded steel piping is also going to contain some cutting oil. Cast iron components, especially those that are not internally painted, or that have been stored in high humidity conditions, are going to have internal surface oxidation. There is also likely to be small pieces of metal inside the pipe from sawing, deburring, reaming, grooving, or other metal cutting operations. These contaminants should be physically removed, to the extent possible, as the system is assembled. In some cases, this is as simple as wiping down components with a clean rag before they are joined together. I know one experienced hydronics pro who pushes and pulls a small wad of clean cloth through every piece of copper tubing that is four feet or less in length, before joining them into the system. After physical cleaning has done all it can, the next step is chemical cleaning–giving systems a healthy and thorough internal bath before filling it with demineralized water. Internal washing is done by filling the system with water, adding a “hydronic detergent” formulation (now available from several suppliers) and circulating this blend through the entire system, with the heat source operating at normal temperature, for at least one hour. Suppliers of these hydronic detergents typically avoid giving out their proprietary formulations, which break down oils and greases within the system and suspend them in the circulating fluid. At the end of the wash cycle the wash water is completely drained from the system and disposed of based on the detergent supplier’s directions. Most of the currently available hydronic detergents are biodegradable and can be disposed
MODERN HYDRONICS
Continued on MH30 WWW.HPACMAG.COM
February 2019
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CORROSION
MH30
SPRING 2019
ON
partially closed open
inlet purging valve
water sample valve open outlet purging valve
demineralizer
of in sewer drains. The piping should get a final rinsing flush and drain to remove as much of the wash water as possible. I recommend use of a double-ported purging valve, along with a sump pump and a clean five gallon pail for getting the mixture of water and hydronic detergent into smaller systems. The setup is shown in Figure 1. The inline ball within the double-ported purging valve is closed during this process. A hose from the sump pump carries the mix of water and hydronic detergent into the system, the other hose returns it to the pail after it has passed through the system. A clean white pail lets you see what gets flushed out. Keep the fluid level in the pail high enough and the end of the return hose far enough away from the sump pump to reduce entrained air bubble entry into the system. After the system has been internally washed it can be filled with demineralized water–assuming a source of that water is available. Alternatively, it can be filled with clean on-site or trucked in water and then demineralized using a “sidearm” assembly as shown in Figure 2. Demineralizing cartridges or carts are now available from several North American suppliers. Each time some of the system water passes through the demineralizer ions are removed. Water leaving the cartridge gets mixed back into the remaining system water. Thus, with this method of demineralizing it is necessary to draw small periodic samples of the system water to check its TDS reading. Maintain the demineralizing process until a TDS reading between 10 and 30 PPM is reached. After demineralizing, best practices call for adding a film-forming hydronic system stabilizing formulation. Again, several such products, with proprietary chemical combinations, are available in North America. These products form extremely thin protective films on the inside of the piping and components that help isolate the water from the raw metal sur-
TDS testing
Figure 2. Sidearm assembly
face. They also stabilize the pH of the water, and help protect the system against the slow but unavoidable oxygen entry that occurs over the system’s life. To keep the system clean you should include high performance air and dirt separation devices in every system. These functions can be achieved with separate devices, or a single device. If the system contains any ferrous metals such as cast-iron or steel, as most systems do, the dirt separating device should include a magnet to capture ferrous oxide particles. I also highly recommend dirt separation for systems containing high efficiency circulators with permanent magnet motors. Internally clean hydronic systems help maintain peak component efficiency and lengthen service life. You wouldn’t take a bath in dirty water. You would not MODERN HYDRONICS
(knowingly) put contaminated fuel in your vehicle and you probably would not eat with a rusty fork. Treat your hydronic systems with the same respect and enjoy their benefits for decades. <> John Siegenthaler, P.E., is a mechanical engineering graduate of Rensselaer Polytechnic Institute and a licensed professional engineer. He has over 35 years experience in designing modern hydronic heating systems. Siegenthaler’s latest book is Heating with Renewable Energy (see www.hydronicpros.com for more information). SEE JOHN AT THE MODERN HYDRONICS SUMMIT 2019. CHECK MODERNHYDRONICSSUMMIT.COM FOR UPDATES. WWW.HPACMAG.COM
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