Modern Hydronics Autumn 2015

MODERN HYDRONICS 2015 AUTUMN

LESS IS MORE

Distribution Piping Strategies

Big Loads, Good Building Strategies to make it work

A PUBLICATION OF

How to simplify system design

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CONTENTS

Modern Hydronics

MH4

SIMPLIFICATION

Systems do not have to be complex to be sophisticated.

By John Siegenthaler

MH12

HOW TO DEAL WITH RAMPED UP LOADS

Jevons’ paradox is alive and well in high performance houses.

By Robert Bean

MH14 A SHOT IN THE ARM

Point-of-use energy consumption measurement. By Mark Evans

MH16

TIPS FOR SUCCESSFUL INSTALLATIONS How to integrate SIM into almost any outdoor surface.

By Lance Macnevin

MH20

WHAT ARE YOUR OPTIONS?

Knowledge is power when it comes to distribution piping design. By Mike Miller

MH24

MODERN HYDRONICS-SUMMIT 2015 PRODUCT SHOWCASE

MH38

HELLO BOILER, IT'S WI-FI CALLING A wireless future for the mechanical industry.

By Curtis Bennett

MH44 I CAN’T SEE ANY AIR

But it is likely still there. By John Siegenthaler

MODERN HYDRONICS a supplement of Heating Plumbing Air Conditioning Magazine

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MODERN HYDRONICS

AUTUMN 2015

| MH3

>> Design

Simplification Systems do not have to be complex to be sophisticated.

D

Image courtesy Harvey Youker

o you ever feel that there are just too many pipes, circulators, controls and other gadgets in the hydronic systems you install? Why is it that many well-organized two-dimensional schematics – systems that look so good on paper – turn into a dizzying array of hardware when installed?

At times the finished product presents much differently than the schematic it originated from.

Many of us have seen “prize winning” hydronic systems displayed in trade journals and other publications over the years.

Most of these systems are one-of-a-kind installations. With proper design, documentation and scheduled maintenance, they can serve their owners well. Take away any of these requisites and you have a very expensive collection of hardware that nobody seems to understand, or is willing to service.

The latter scenario is a serious issue. The last thing the industry needs is for the average consumer to think that hydronic heating has to be complex to be correct. Or, that hydronic systems that go beyond a boiler, a circulator and a series loop of fin-tube baseboard cannot be easily maintained by a reasonably competent HVAC technician.

To help avoid such situations it is important to look at ways MH4 | AUTUMN 2015

of simplifying residential hydronic heating systems. The goal is to trim away at design concepts, as well as hardware that in many cases do not need to be included in the system for it to deliver efficient operation and superior comfort.

LESS MULTI-TEMPERATURE SYSTEMS A recurring situation in planning radiant panel heating systems is the need for multiple supply water temperatures. An example would be a system that heats the basement slab, as well as the wood-framed floor areas of a house. The latter type of floor heating is often accomplished using a tube and plate system installed above or below the subflooring.

A common approach is to set up a separate mixing assembly for each type of radiant panel construction. Some designers will specify separate mixing assemblies for every area with different types of floor covering (e.g. ceramic tile versus padded carpet). Sometimes a separate mixing assembly is also specified on a floor level basis, even when the water temperature requirements of the panels being supplied are the same.

I have designed residential systems with three different mixing assemblies and I have seen systems having at least five independent mixing assemblies. Do these systems work? Yes. Is this complexity necessary? Not necessarily.

The following is a procedure that can be used during the design process to help decide if multiple water temperatures are needed: 1. Add up all of the circuit supply water temperatures calculated for design load conditions.

2. Calculate the average of these supply temperatures.

3. If the supply temperature for a given circuit is more than 10F above or below this average temperature identify that circuit.

4. Consider modifying any of these identified circuits through changes in tube spacing to increase or decrease their required supply water temperature at design load conditions.

Try to bring that temperature within +/- 10F of the average temperature of all circuits. Remember to calculate a new average each time a circuit supply water temperature changes. In basements consider tube spacings of up to 18-inches, or even 24-inches if the basement is infrequently occupied and floor surface temperature variations are not deemed to be a problem.

AN EXAMPLE Suppose you are planning tubing for a bare concrete slab and need 20 Btu/hr/ft2 of heat output at design load conditions. The space is to be maintained at 70F under these conditions. Figure 1 shows that if 12-inch tube spacing is used,

MODERN HYDRONICS

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Modern Hydronics

the average circuit water temperature needs to be about 27F above the room air temperature (e.g. 27+70=97F).

Assume the same building has a gypsum thin-slab with embedded tubing for heating the upper floor, and at design load those circuits need 115F average water temperature.

Increasing the tube spacing in the concrete slab portion of the system to 18 inches increases the average water temperature to about 104F. Assuming a nominal 20F circuit temperature drop, the supply temperatures for these circuits would be about 97+20/2=107F, and 104+20/2=114F respectively. These supply temperatures are within 10F of each other and thus could very likely be supplied from the same system. In this case the controls could be set to produce a supply temperature midway between these two values (around 110F).

In this situation, one could also argue that it is better to decrease the tube spacing on the higher temperature circuits and thus bring the average system water temperature down to promote efficiency gains at the heat source. This is a valid Figure 1 Tube spacing and circuit water temperature

Figure 2 Homerun distribution system

proposition for systems using mod/con boilers, geothermal heat pumps or solar collectors as heat sources.

Only a life cycle cost comparison that factors in the changes in heat source efficiency versus the higher installation cost of more tubing can provide a substantiated answer to this point. When a conventional (non-condensing) boiler is used, the changes in boiler efficiency are likely to be minimal and the cost savings are largely derived by not installing multiple mixing assemblies.

5. If variations in tube spacing are not enough, discuss the possibility of different finish flooring with the client before giving up on use of a single supply temperature.

I have found it possible to combine slab-on-grade systems with both thin-slabs and even underfloor tube and plate systems in certain circumstances. Eliminating the need for multiple mixing assemblies in these situations can reduce installation cost by hundreds of dollars.

When a single supply water temperature is possible consider zoning manifolds using zone valves, or individual circuits using valve actuators. Another possibility is to mix in non-electric thermostatic valves for zone control. This approach sets the stage for a simple delivery system using a single variable speed pressure regulated circulator. An example of such a “homerun� distribution system supplied by a mod/con boiler is shown in Figure 2.

LESS ZONES The ability to divide a system in several independently controlled zones is one of the most cited benefits of hydronic heating. There are several techniques for providing multiple zones in almost any modern hydronic system. In most cases, zoning can be accomplished at a significantly lower cost than an equal number of zones in a forced air system.

However, just because you can set up every room in a building as a separate heating zone does not mean you should.

This is especially true when installing wired zone controls. By the time all the transformers, valve actuators, relay centres and thermostats are connected you may have installed a couple miles of thermostat cable, as shown in Figure 3. It is tedious Continued on pMH6 Figure 3 Lots of thermostat cable adds to cost

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MODERN HYDRONICS

AUTUMN 2015

| MH5

>> Design continued from pMH5 Figure 4a System utilizing parallel primary loop

Figure 4b System with a hydraulic separator

work that can easily add a couple thousand dollars to installed cost. Even when money is not an issue, all those thermostats may only be used to balance heat flow within the building rather than for continuous readjustment of temperature.

In keeping with the theme of simplification I think it is important to not get carried away with “over-zoning.” Look for open areas in a building when selecting zones. Such areas “communicate” as far as heating is concerned and seldom need to be on separate zones. Also, look for areas that receive significant solar heat gain and put them on separate zones from non-solar gain areas.

If you really like the idea of room-by-room zone control take a good look at thermostatic control valves. They are available for use in baseboard and panel radiator systems, as well as in wall-mounted boxes for site-built radiant panel systems and offer the benefits of no wires and fully modulating control.

LESS PRIMARY/SECONDARY (P/S) SYSTEMS Primary/secondary (P/S) piping does work. We have designed many systems around this piping method. However, there are simpler and less expensive ways to achieve the benefits offered by P/S piping.

Two approaches for achieving hydraulic separation of all circulators and equal supply water temperature to each load are contrasted in Figure 4a and b.

The system shown in Figure 4a uses a parallel primary loop to connect the boiler with each load. A dedicated primary circulator is required to move flow through the primary loop.

Figure 4b shows a system with a hydraulic separator replacing the primary loop. This eliminates the need of a primary circulator. It also eliminates the need for dedicated air and dirt separators, since these functions are handled by the internal coalescing media in the hydraulic separator.

LESS TRANSFORMERS Have you ever been in a mechanical room where there is a half dozen or more transformers mounted on 4x4 J-boxes and buzzing away 24/7? The photo below shows an example of Each of the red clouds indicates a transformer.

MH6 | AUTUMN 2015

MODERN HYDRONICS

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>> Design continued from pMH6 such a situation. There is a transformer located within each of those red clouds.

Put your hand on any active transformer and it feels warm.

That is because they are sitting there converting electricity into heat through their primary windings, regardless of whether there is an active load on their secondary winding. The installed cost of multiple transformers is certainly more than the transformers themselves. Each needs a J-box and associated wiring.

Multiple transformers also set the stage for problems if connected in parallel without proper “phasing.”

Consider using a single larger transformer, such as one with a 100 VA rating, rather than several smaller transformers.

Also, strive for control arrangements that turn off transformers when the portion of the system they serve is not needed.

Why let the transformer(s) in a cooling system operate during the heating season and vice versa? The electrical energy you save through reductions in control transformers is probably not going to be huge, but every little bit helps.

FEWER FITTINGS Years ago, I thought of a box full of fittings and shut-off valves as incidental to the overall cost for a hydronic system. That has changed since copper fittings started being delivered in Brinks’ trucks.

A recently published cost estimating manual puts the installed cost of a one-inch copper x male adapter fitting at $13.25.

That adds $26.50 to the cost of

Image courtesy REMS

Figure 5 Fabricated bends

installing a one-inch valve you might have nonchalantly purchased with FPT connections. My advice is to get away from installing threaded adapter fittings whenever possible.

You might also want to consider buying a quality tube bender and fabricating bends in tubing rather than installing elbows, as shown in Figure 5.

LESS ANTIFREEZE I have a saying about antifreeze: “The only good thing about antifreeze is that it doesn’t freeze.” Glycol-based antifreeze deMH8 | AUTUMN 2015

creases the heat capacity of the fluid relative to water. This requires increased flow rate for the same heat conveyence. The higher viscosity of glycol-based antifreeze also adds significantly to head loss. At 120F a 50 per cent solution of propylene glycol increases head loss (at the same flow rate) by about 24 per cent.

When the flow rate is increased to compensate for reduced heat capacitance, the head loss goes up by 47 per cent. That translates to more pumping power and higher operating cost.

As many of you have discovered, glycol-based antifreeze also has a propensity to weep through threaded fitting joints and create surface oxidation where water would either not leak or would quickly evaporate without scaling. Last, but not least, filling a system with a 50 per cent glycol solution can easily add a few hundred bucks to the installed cost.

So, where should antifreeze be used? Snowmelting systems and closed loop solar collectors obviously need the protection it offers. In Northern climates we also specify glycol in residential garage heating circuits and in homes that will be unoccupied for several consecutive winter days.

We used to specify antifreeze for floor heating systems in large slab-on-grade facilities such as highway garages.

However, many of these buildings now have emergency generators that can keep running during a prolonged power outage. With constant circulation “stirring” heat around in a large concrete slab, it could take several cold days before water in the slab circuits would be in danger of freezing, even if the boiler was not operating. Given these favourable odds, we now avoid antifreeze in this type of facility.

WHY LESS IS MORE Writing about hardware being removed from systems is always a bit precarious. That hardware produces income for individuals from the manufacturer right down to the professional who installs it.

What prompts this discussion is to help ensure that average consumers view hydronic heating as an affordable, efficient and understandable technology; something that they want in their home or place of business.

That goal requires periodic “self-examination” of what we do as individual professionals and as an industry. We want to build market share, not parts count. Why build the space shuttle when our clients need a Cessna? <> - JOHN SIEGENTHALER 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. He is also an associate professor emeritus of engineering technology at Mohawk Valley Community College in Utica, NY. See John at Modern HydronicsSummit 2015 (for more information see p42) on September 10 at the International Centre in Mississauga, ON.

MODERN HYDRONICS

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T E C H N O L O G Y

>> Design

How To Deal With Ramped Up Loads Jevons' paradox is alive and well in high performance homes.

T

he industry's public relations and marketing campaign to push higher performing homes appears to be working, at least for a percentage of the population, but even consumers adopting “green” and sustainability are proof that W.S. Jevons was right–at least on some scale. Jevons was an economist and philosopher who foreshadowed several developments of the 20th century. He argued that technological progress was not to be counted on to reduce society’s energy consumption.

There are many examples of Jevons’ paradox at work in housing, including disproportionate floor areas (relative to needs), inaccurate or no load calculations,1 oversized equipment/components and the increasingly common monstersized kitchen range hoods.2 Well thought out energy paths are frequently trumped by ramped up cooling and dehumidification loads, heating of make up air for kitchen exhaust or unique potable water heating demands.

The following is an example of a project where comfort, durability and low maintenance objectives were a top priority, and where the philosophy of sustainability was headed in the right direction until it took a slight detour.

The 4500 ft.2 (418 m2) home and carriage house, which is located in the Great Lakes area, is constructed with insulated concrete block with an additional layer of exterior insulation.

Accounting for the windows and doors, the vertical enclosure is a weighted R=18 hr■ft2■F Btu (RSI=3.17 K■m2/W), the slab is insulted to R=10 hr■ft2■F Btu (RSI=1.76 K■m2/W) and the attic to R=60 hr■ft2■F Btu (RSI=10.57 K■m2/W).

Working with the client, we were able to base our loads for east, south and west windows on triple pane, argon filled with a Cardinal glass coating configuration of LoE‐366/clear/ LoE‐180, U value=0.14 Btu/hr■ft2■F (0.79 W/m2■K), solar heat gain coefficient (SHGC)=0.24 and visible transmittance (VT)=0.54. North side windows had LoE‐180/clear/LoE‐180 glass to allow for greater visible light transmission of a VT=0.67, U=0.15 Btu/hr■ft2■F (0.85 W/m2■K) and SHGC=0.51. In similar buildings the builder has demonstrated leakage rates of 1.5 ACH50 (approximately 0.1 ach) or lower.

Sensible heating flux from the radiant panel averaged approximately 11 Btu/hr■ft2 (35W/m2) and cooling sensible flux was at approximately 7 Btu/hr■ft2 (22 W/m2). Additional sensible cooling is provided by the ventilation system (see Figure 1).

The flooring is to be light carpet in the basement, tile for all wet areas and wide wood plank flooring in all other areas.

The occupant conditioning system is embedded radiant either in concrete or subfloor/wall panel systems. From the first run of calculations, the weighted return fluid temperature MH10 | AUTUMN 2015

Figure 1 Air System (Mechanical Room One)

for outdoor heating design conditions at 6F (‐14C) was set to 94F (34C) and at minimum load to 76F (24C) to enable higher boiler efficiencies and minimize VOC emissions from subflooring.3 Flow velocity was established based on conservative delta ts and pipe diameter selections for the cooling approach so that the circulator saw similar head losses in either the heating or cooling mode.

The cooling system was set for mean fluid temperatures of approximately 53F (12C) for dehumidification at outdoor design conditions of 87F (31C) and 72F (22C) WBT and then mixed up to 66F (19C) for the radiant floors. Wherever rogue zones needed higher or lower temperatures radiant walls were added to increase the surface area. This prevented the system from operating unnecessarily at higher or cooler temperatures and eliminated the need for additional control systems.

A 118 MBH (34.6kW) wall hung high efficiency boiler (B‐1 in Figure 2) connected to a 25 USg (97L) buffer tank (Tk‐2), will deliver heated fluid for the radiant floors and heating coil (HC‐1) for the kitchen exhaust and make up air (F‐1 and F‐2 in Figure 1). Likewise a five-ton (17.6kW) reverse cycle air cooled chiller (CH‐1, Figure 2) will be used to maintain 50F (10C) in a 50USg (189L) buffer tank (Tk‐1) to feed the radiant floors and walls and for the cooling coil (CC‐1, Figure 1) for the kitchen make up air.

Due to the deliberate low operating fluid temperatures in heating and somewhat higher temperatures in cooling, both of the coils in the kitchen make up air system are ‘oversized’ relative to traditional coil selection procedures. This oversize is a one‐time capital cost with the lifetime benefit of lower operating costs.

As a result of HVAC configurations and building geometries, mechanical room one, which contains the boiler, is located in the main house. It is approximately 75 ft. (15 m.) away from mechanical room two in the carriage house, which holds the cooling equipment. The two pipe changeover system uses a four way reversing valve (RV‐1) to flow a 40 per cent propylene mix either from the boiler and buffer tank to mechanical room

MODERN HYDRONICS

Continued on pMH12 WWW.HPACMAG.COM

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>> Design continued from pMH10 two in heating or from the chiller and buffer tank to mechanical room one in cooling.

The space ventilation system is a three speed HRV (HRV‐1) that pulls its outdoor air (O/A) through the heated and chilled water coils (HC‐1, CC‐1), which are installed as part of the kitchen make up air system. In the normal space cooling and ventilation mode, the cooling coil provides dehumidification of 150 cfm (71 L/s) of OA. The cooled, lean and filtered (MERV 11) supply air (S/A) is reheated via the exhaust air (E/A) passing through the heat recovery core in HRV‐1 before being distributed directly to each space. EA is extracted either directly from each room or via undercut doorways or jump ducts depending on design flow rates and room use. Timers in the bathrooms and kitchen/dining room engage the HRV's high speed capacity (400 cfm [189L/s]).

A few items to note: as the home is to be very tight, the infiltration load and thus the latent load is essentially limited to the incoming ventilation air plus moisture released to the space from the occupants (two adults, two children), plus moisture released during meal preparation, home cleaning and bathing. Since the cooling coil’s primary purpose is to dehumidify make up air for the 900 cfm (425 L/s) kitchen exhaust fan, space cooling and ventilation air passing over the coil even at high speed will be at a low velocity of approx. 150 fps (46 m/s) and even lower during normal operation. Because of the chosen fluid temperatures and wide operational band on the coils, constant fluid flow with a modulating two way injection control valve with actuator having a wide rangeability were selected. A linear valve is preferred for heating due to the low mean fluid temperature and larger delta t; and an equal percentage valve for the cooling coil due to the somewhat higher mean fluid temperature and smaller delta t.

The design challenge of significance was integrating the 900 cfm (4256 L/s) kitchen exhaust into the system. There were two approaches. The first was for separate heating and cooling coils in a make up air unit independent from the HRV. The second, and chosen method, was to size the make‐up air coils for the kitchen exhaust system and use the same coils for the space ventilation systems. In the latter application the cooling coil provides dehumidified air to both systems. If necessary, the heating coil can provide wintertime pre‐heat for the HRV. Additionally, if aggressive dehumidification is required when the occupants are entertaining or during unusually extended wet outdoor conditions, the HRV can be switched from its 150 cfm (71 L/s) to 400 cfm (189 L/s) capacity with 250 cfm (118 L/s) air bypassed (R/A Bypass), and recirculated across the cooling coil. The analysis of three air flow rates over a single coil is necessary to understand the space ventilation supply air and kitchen make up air conditions and the necessary valve/ damper/control strategy to achieve the designed performance.

After it was all said and done, the make‐up air heating coil MH12 | AUTUMN 2015

Figure 2 Hydronic System (Mechanical Room One and Two)

load was 83 MBH (24.3kW) and the cooling coil was 48 MBH (14.1kW) compared to the 48 MBH (14.1kW) space heating load and 39 MBH (11.4kW) space cooling load (figures are approximates). As is the case with many modern projects, it is not the space load driving the plant size but rather the make up air for the kitchen.

Why would the client not drop the big gas fired range and its required monster exhaust hood, which would allow for a smaller induction unit with a smaller hood at about a third of the load?

We asked the same question. The family frequently entertains large groups of people. They struggled in their previous home to prepare meals for large gatherings and their hearts were set on gas. C'est la vie.

On other projects we have been able to convince clients to drop the big gas ranges, which tightens up the entire mechanical system. As they say, some days you are the pigeon and other days the statue. More often than not we are finding we have to set aside our personal objectives for sustainability and meet the subjective needs of our customers. But given the choice between a poor building with extraordinary loads and a good building with extraordinary loads – we will always take the latter over the former. <> - ROBERT BEAN Robert Bean, who is president of Indoor Climate Consultants Inc., is a Registered Engineering Technologist in building construction through the ASET and a Professional Licensee in mechanical engineering through APEGA. See Robert at the Modern Hydronics-Summit 2015 on September 10, 2015. For more information visit www.modernhydronicssummit.com 1 See HPAC Feb, 2015 (www.hpacmag.com, archives), Heat loss/heat gain considerations.

2 See HPAC June, 2013 (www.hpacmag.com, archives), The unintended consequences of monster-size range hoods.

3 See HPAC January 2012 (www.hpacmag.com, archives), VOC Emissions Modelling

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>> Technology

A Shot In The Arm Point-of-use energy consumption measurement removes bias against hydronic systems.

T

he terms BTU metering and energy metering are used interchangeably in the context of buildings with central production of hydronic heating or hydronic heating/cooling energy. Effectively, BTU metering is the downstream measurement of energy consumption at pointof-use, functioning as a sub-set measurement for the purpose of user-pay billing (pay per use) in private, closed-loop mechanical systems. This is opposed to the traditional arrangement where total energy consumptive costs as billed by the public utility (gas or electric), are apportioned based on a per cent of the total square footage, or some other equal cost sharing formula.

HOW IS THE MARKET EVOLVING IN CANADA? Recent BTU metering projects in British Columbia were carried out on the authority of the BC Utilities Commission (BCUC). Fortis Energy (FEI), along with other industry stakeholders, made application to BCUC to permit the use of BTU meters for billing purposes. This was necessary as private companies providing billing services are acting as “Private Utilities” and must operate under exemption from the Provincial Utilities Commission.

On June 14, 2007, the Commission issued Order No. G-6507, which approved amendments to the FEI general terms and conditions to include definitions to allow for thermal metering. This opened the door for non-utility energy consultants to supply and monitor BTU meters for billing purposes. Further to this, Commission Order No. G-65-07 directed FEI to file reports annually on the Thermal Metering Pilot project by July 15 each year starting in 2008 and each year thereafter through 2012 inclusive. Subsequent to that, on November 5, 2012 the Commission received an application- Application for a Certificate of Public Convenience and Necessity for the TELUS Garden Thermal Energy System and for Approval of the Rate Design and Rates to Provide Thermal Energy Services to Customers at TELUS Garden Development. This was the first of what are now many projects that include the use of BTU meters for billing purposes. It should be noted that an application was made to BCUC and the initial pilot project received an extension through 2017.

WHAT IS DRIVING THIS TECHNOLOGY IN CANADA? Design knowledge and the product supply chain have both evolved and these functions are no longer concentrated solely within the traditional plumbing and heating or HVAC supply chain. This has opened the door for new companies to enter into the design and supply of heating/cooling products and MH14 | AUTUMN 2015

systems. Further, a new emphasis on evolved green building methods (more efficient building envelopes as an example) and design Standards such as LEED are contributing to this trend.

The drive to conserve energy and penalize over-consumption or waste was motivated by rising energy costs. Those factors now bear significant influence in making life-style choices or purchasing decisions. The next evolution in this is an awareness of the capability to facilitate equity in billing for consumers, homeowners and tenants who share common spaces in public and private buildings. The development community see this as an opportunity to increase the profitability of their projects. Energy utilities see it as an opportunity to encourage conservation, increase system (especially distribution) efficiencies and manage demand.

Fortis Energy noted the following in its 2011-2012 Thermal Metering Annual Report dated July 13, 2012: “Through consultations with developers and property managers, the Company has discerned that the use of central hydronic systems is often discouraged by property managers and developers of vertical subdivisions in favour of electric baseboard heating, to more easily allow for the individual metering and billing of heating costs.

The bias is driven by consumer demand to manage and control their own energy use (and discourage free-ridership within a complex), as well as the perceived competitive advantage that comes through reducing the costs that must be included in monthly strata/condo fees. Many complaints and disputes brought to property managers are a result of the inability to individually meter each suite’s energy usage. The introduction of thermal metering to strata developments provides the Company and consumers with a natural gas solution for individual metering within strata units. Further, providing sustainable energy management and encouraging conservation and demand side management continue to be key values for FEI. Thermal metering will provide British Columbians with a sustainable and conservationist approach to residential development by providing them with an option to take control of their energy use."

These observations point to a great opportunity for hydronic heating, including combined radiant heating and radiant cooling to move into the popular lexicon. The challenge for our industry is to ensure that we have a seat at the table as new regulations and requirements are developed to bring this technology into the mainstream. To date, this has not been the case.

MODERN HYDRONICS

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Modern Hydronics

REGULATORY AND PRODUCT APPROVAL LANDSCAPE What is new here is that BTU meters are moving from the realm of simple measurement into use as billing devices. That 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 under the mandate of the Weights and Measures Act. There is no specific legislation or guideline in place from Measurement Canada to govern the suitability or certification of BTU meters in Canada, thus these devices are not currently regulated under the Weights and Measures Act. To help clarify, Carl Cotton, manager–weighing and measuring division, Measurement Canada, explained: “Regulation of trade measurement is a federal jurisdiction set out in section 91 of the Constitution Act. Consequently, Measurement Canada will not be required to enact new legislation in order to implement the recommendations that came out of the trade sector review for the Steam and Thermal Energy Sector. Some regulatory amendments (specifications related to this type of technology which will likely be based on existing international requirements like OIML or EN) will need to be put into place. Many of the provinces may have legislation/requirements related to utilities and metering. It is possible

REFERENCE PROJECTS IN THE GREATER VANCOUVER AREA: MC2 Towers 443 Units • Designed to meet LEED GOLD equivalency • Energy efficient, European-style heating throughout homes. European designed JAGA Briza passive cooling units in all bedrooms • Individual suite energy metering •M otion sensor lighting in parkade and common area hallways • High water efficiency plumbing fixtures • High energy efficiency lighting • ENERGY STAR appliances • Low emitting materials, adhesives, sealants and paints • ‘Green’ podium roof in North Tower TELUS Garden 428 units • LEED Platinum encompasses combined radiant heating/cooling First Avenue Athlete’s Village Housing Co-operative • LEED Gold family-oriented co-op is part of a vibrant community designed to be sustainable with buildings that include features like green roofs, individual energy monitoring and a passive building design.

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Figure 1 CSA C900 Standard for Heat/Energy/Thermal meters C900.1-13 General Requirements C900.2-13 Construction Requirements C900.3-13 Data Exchange and Interfaces C900.4-13 Pattern Approval Tests C900.5-13 Initial Verification Tests C900.6-13 Installation, Commissioning, Operational Monitoring and Maintenance

that some of these requirements are more stringent than Measurement Canada’s. Our position has been not to interfere with the provincial authorities in these instances, so long as their requirements do not contradict Measurement Canada’s or attempt to set laxer requirements. It looks like BC is using the notion of pilot projects in order to allow the introduction of thermal energy metering. I am not familiar with the British Columbia Utilities Commission Act and regulations so I couldn’t comment on whether this is within the commission’s purview. Part of what we will need to look at when we begin our work on implementing the trade sector review recommendations will be what each province is doing to allow/prohibit the use of this type of device and ensure that our requirements do not conflict with provincial approaches."

It should be noted that CSA has published the C900 Standard for Heat/Energy/Thermal Meters (see Figure 1), which is based on the European CEN-1434 2007 standard. There are six major components to the Standard. C900.1-13 and C900.6-13 appear to be relevant to the involvement of our industry, most likely represented by the Canadian Institute of Plumbing and Heating through the Canadian Hydronics Council.

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 “in service” accuracy (to protect consumers from erroneous billing) are what is needed to advance this technology. Engineers, contractors and ultimately consumers would trust that they have a reliable range of products to choose from and can choose what best suits their needs. <> - MARK EVANS Mark Evans has held positions of increasing responsibility at the regional and national level of the wholesale supply, rep agency and manufacturing sectors of the plumbing and heating industry.

See Mark at the Modern Hydronics-Summit 2015 on September 10, 2015. For more information, see www.modernhydronicssummit.com

MODERN HYDRONICS

AUTUMN 2015

| MH15

>> Snow and Ice Melting

Tips For Successful Installations How to integrate SIM into almost any outdoor surface.

A

pplying radiant heating technology to outdoor surfaces, (hydronic snow and ice melting (SIM) systems) provides a safe and reliable way to keep surfaces clear of snow and ice. With proper design and installation, these systems offer long-term performance and reliability as well as saving the time and energy spent on traditional snow and ice removal using mechanical equipment.

SIM systems operate in a variety of outdoor areas such as sidewalks, steps, driveways, ramps, parking lots, loading docks, carwashes, roadways, bridges, and even helicopter landing pads.

INSULATION Whether the system is always on or uses a moisture sensor, a significant amount of heat can be conducted to the frozen earth below the SIM surface if appropriate insulation is not installed.

In some cases, downward losses can exceed 50 per cent of all the energy supplied to the SIM area. CSA B214 requires at least R-5 insulation below SIM areas, but many designers specify R-10, since insulation also improves response time.

The type of insulation may be extruded polystyrene (XPS), polyurethane (PU) or even expanding foam that is sprayed onto existing concrete or the earth to Outdoor concrete surface with embedded PEX tubing.

MH16 | AUTUMN 2015

follow contours. Be sure the insulation is rated for outdoor use and meets the expected compressive loading from vehicles, or settling can occur.

TUBING SIZE AND SPACING SIM systems require high flow rates to deliver lots of heat in demanding winter conditions, so ¾ in. nominal PEX tubing is the most popular size. Larger projects may even require one-inch tubing, while ½- and ⅝-in. tubing are used when tighter spacing or low profile is a consideration. To help with rapid and even melting most designs use 20 to 23 cm. (eight to nine inch) tube spacing. While some special cases use tighter spacing, going wider than 23 cm. runs the risk of snow strips between tubes.

(four to six inches) of structural concrete. A great technique is to pour the structural slab first, cover it with insulation, then install the SIM tubing within a 7.5 cm. (three inch) concrete overpour. By placing the tubing closer to the surface, the heated slab thickness is reduced, making the system more responsive.

POURED CONCRETE In poured concrete the PEX tubing is simply embedded within the concrete, strongly resembling slab-on-grade radiant heating installations. This is very popular in stained concrete. It is recommended that the tubing be located five to 7.5 cm. (two to three inches) below the surface for faster response time, but this is not always practical.

Tubing is often stapled directly onto the insulation board or tied to rebar or wire mesh within the 10 to 15 cm.

INTERLOCKING CONCRETE PAVERS The most common technique for installing SIM with pavers is to embed the tubing in the sand bed above well-supported insulation. The sand bed should be laid approximately 40-mm. (1 ½-in.) thick, or 28-mm. (1 ⅛-in.) after compaction. More sand than this will slow down heat transfer and may allow too much movement of the pavers.

According to Robert Bowers, P. Eng., director of engineering with the Interlocking Concrete Pavement Institute (ICPI), insulation used under pavers must be very rigid to prevent movement under load. ICPI does not recommend stone dust media under pavers, as it interferes with drainage, loses strength as it holds water, and can refreeze when wet, potentially heaving.

Technical specifications and drawings of SIM systems with pavers can be found at www.icpi.org.

Pavers installed over sand bed with embedded heating tubing.

Tubing within stone dust below asphalt.

MODERN HYDRONICS

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ASPHALT When heated above 120C (250F) most PEX tubing will soften and flatten if compressed. This would surely happen if hot asphalt, which can be more than 175C (350F), is placed directly around the tubing. The tubing must be protected in two ways: 1. Tubing is installed within a 7.5 cm. (three inch) thick compacted bed of stone dust below the asphalt to prevent direct contact with the asphalt. Tubing is usually stapled to insulation laid beneath the stone dust. The stone dust conducts heat well and allows paving equipment to drive above it.

2. Cold water is flushed through the distribution manifold and all tubing circuits to carry the heat away from the tubing until the asphalt cools. The flow of fresh water is regulated to be below 65C (150F) at the manifold outlet. If it is hotter than that the flow rate must be increased and the water just goes to a drain.

On a hot, sunny day, this flushing may take more than 12 hours to cool the asphalt.

STAIRS Obviously, outdoor stairs are dangerous in winter, so well-installed SIM systems increase pedestrian safety. Just as there are different Tubing fastened to concrete stairs and insulation before an overpour.

H2O Demineralizers Engineered Hydronic Fluid

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Special PUROPAL mixed bed resin

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MODERN HYDRONICS

AUTUMN 2015

| MH17

>> Snow and Ice Melting continued from pMH17 ways of building outdoor stairs, there are different installation techniques for the tubing. It is important that the tubing is within five cm. (two inches) of the surface and the nose of each step, and that it is not buried deep inside concrete, as this could lead to icy spots.

Tight tube spacing is also crucial for even melting and rapid response. Due to the low profile and tight spacing requirements, ½-in. PEX tubing is often

used in steps. When concrete stairs are poured in place, the tubing needs to be held in place using rails or other fasteners so it is properly positioned after the concrete is poured.

It is even possible to retrofit SIM tubing above existing stairs. When concrete steps are pre-existing or pre-cast, tubing can be anchored on top of the structural concrete and embedded within an overpour. Insulation is sometimes sprayed onto existing steps before the tubing is placed, for better efficiency and response.

DRAINAGE When snow and ice melt, the resulting water must drain. Otherwise, the SIM system must also evaporate the moisture, which requires more energy than simply melting snow. Allowing gravity to carry the water away to landscaping or a drain will improve safety and reduce

Above, remote manifold in an outdoor vault with warm glycol supplied by pre-insulated flexible piping (below).

operating costs. Drains are especially important at the bottoms of steps or ramps. Water left standing can refreeze, so be sure that any installed drains have heating tubes nearby and direct the run-off to avoid creating hazards or ice dams on unheated areas. Drains may be connected to drain tile piping or storm sewers, where regulations allow, or even to a ditch or pond, if there is one nearby.

MANIFOLD PLACEMENT The location of distribution manifolds for supplying warm glycol to the SIM piping circuits may be a conundrum, since the designers want the manifolds close to the SIM area, yet the SIM area is often far from the heat source location or mechanical room. Therefore, SIM manifolds are often installed in remote cabinets or vaults designed to protect the manifold and pipes from sun, vandalism and accidental damage, while allowing good drainage through an open bottom. Various styles of utility boxes have successfully been used. Warm glycol may be transferred to the manifolds through buried pre-insulated PEX pipes, to deliver the heat with minimal heat loss and high reliability.

SUCCESSFUL INSTALLATIONS Hydronic snow and ice melting systems are effective, efficient and reliable.

There are many situations where public and private buildings require this level of protection outdoors. Being aware of the tips presented here and working with an experienced designer will help to ensure that installations go smoothly. <> - LANCE MACNEVIN Lance MacNevin, P.Eng., is manager of REHAU Academy where he is responsible for training across North America.

With over 20 years of hydronic experience, he is on the technical committee for CSA B214.

MH18 | AUTUMN 2015

MODERN HYDRONICS

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Maximum VITALITY

with fire tube heat exchanger

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ntiboilers.com

>> Piping

What Are Your Options?

Knowledge is power when it comes to distribution piping design.

S

everal options are available when approaching residential and commercial distribution piping design.

The options are generally: direct return, reverse return or one pipe primary/secondary. Understanding each of them will help you determine which one will provide the best overall results in specific circumstances.

DIRECT RETURN A direct return, two pipe system is the most commonly deployed piping strategy. It has direct piping for supply and return lines to and from the heating terminal unit or zones as shown in Figure 1. The supply and return lines are usually of equal distance. Each branch or terminal unit or zone uses a two-way control or zone valve as a means of enabling or disabling flow to that heating or cooling load.

A proper means of flow balancing should be installed per load in order to achieve adequate flow to each. Fluid will otherwise flow through the shortest distance or the zone offering the least resistance. Flow balancing can be achieved with balancing or globe valves, or better yet, flow setters. If two-way control valves are used, the primary pump is sized for the full building requirement.

A proper means of pressure bypass must be installed to allow for flow to be bypassed when any terminal unit is not calling. If zone pumps are used, each one provides the necessary flow to each load along with the associated pressure drop, therefore balancing may not be needed. The primary piping size is dependant on the loads downstream, so the further down the primary loop you get, the smaller the remaining pipe sizing will be.

Benefits: • Same supply fluid temperature across all loads • Easy to follow Compromises: • Improper balancing can cause compromised efficiency • System needs to be balanced (if using two-way control valves) • Close attention needs to be given during the installation on reduced piping sizes REVERSE RETURN A reverse return, two (or three) pipe system is one that has separate piping for supply and return lines to and from the heating terminal unit or zones as shown in Figure 2. Depending on the building structure, this may require a longer return line than that of the supply, as the ultimate requirement being that the first load's supply is the last return in the system (see MH20 | AUTUMN 2015

Figure 1 Direct return, two pipe system

Figure 2 Reverse return, 2 or 3 pipe system

Example A, three pipe). Unless, of course, the primary supply and return come in at opposite sides of the building (see Example B, two pipe).

This piping strategy, however, is inherently self-balancing if all loads are equal, or the piping is sized adequately throughout based on the loads. The additional piping can result in savings on mechanical hardware such as balancing and globe valves. The primary piping size is dependant on the loads downstream, meaning that the further down the primary loop you get, the smaller the remaining pipe sizing will be. Note that the inverse is true on the return piping.

Benefits: • Same supply fluid temperature across all loads • Self-balancing • Less mechanical components needed due to self-balancing Compromises: • Typically requires more primary loop piping • Close attention needs to be given during the installation on reduced piping sizes ONE PIPE PRIMARY/SECONDARY A one pipe primary/secondary distribution system consists of just a single pipe primary loop as shown in Figure 3. All heating terminal units or zones come off through a means of hydraulic

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SECURITY CHIMNEYS

SECURE SEAL

Figure 3 One pipe P/S system

SINGLE AND DOUBLE WALL GAS VENT

separation. Hydraulic separation can be achieved via closely spaced Tees or specially designed fittings. Every load would have a zone pump on it, and its return fluid mixed with the primary loop, causing a cascading of supply fluid temperature throughout the primary loop. The cascading of the primary supply temperature can and should be calculated in order to properly size the zone pumps and terminal units downstream. Note: Upsizing the terminal units downstream is not necessarily required, as the deltaT across the terminal unit can be accommodated for in order to keep the terminal unit size the same (GPM = Btuh/deltaT x 500). This system is also inherently self-balancing as the primary loop is hydraulically separated from the secondary or load loop.

Benefits: • Self-Balancing; • One pipe distribution (less pipe) • Same pipe size throughout primary loop • Cascading of fluid temperature can improve high efficient heating source by creating larger differential (i.e. condensing boilers) • Labour/installation savings • Reduction on primary pump horsepower Compromise: • May not be ideal in all applications Note: Closely spaced Tees require the centre-to-centre measurements to be a maximum of four times the primary pipe diameter.

CASE IN POINT The goal in a project involving a five-storey multi-family dwelling with four units per floor was to eliminate any surface piping with the terminal units located inside the closet spaces.

Unit layouts from floor to floor were identical, therefore the closet spaces in each unit provided the most ideal location for the installation of the riser distribution piping.

Figure 4 shows this design using the direct return distribution piping method. This particular design would have the supply and return lines brought to the top of the building where they would split into the four risers, one per wing, picking up all apartments in that part of the building in parallel. The primary pump is sized to accommodate the flow for the entire building. Not shown in this drawing is a pressure bypass valve that would be required if the primary pump was constant volume. DeltaT or deltaP pumps, as well as self sensing pumps, could be used instead to

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Secure Seal features a smooth weld seam inside and out, which is completely shielded during the welding process.

For more information scan QR Code, follow us on social media or visit securitychimneys.com

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800-361-4909 US 800-667-3387 Canada Security Chimneys © 2015

Continued on pMH22 WWW.HPACMAG.COM

MODERN HYDRONICS

AUTUMN 2015

| MH21

>> Piping continued from pMH21

Pipe, hydronic, Quantity steel, standard weight

Total

0.75" x 21'

30

630 ft

1" x 21'

4

84 ft

1.25" x 21'

11

231 ft

1.5" x 21'

2

42 ft

2" x 21'

12

252 ft

primary pump

1

1.5 Hp

regulate flow when not all zones are calling. Please refer to Figure 4's table for the make-up of distribution piping needed based on line sizes. Also, note the need for individual balancing valves per zone in order to balance each load.

Figure 5 shows this design using the reverse return distribution piping method. This particular design would only have to supply the top of the building where it would then split into the four risers, one per wing, picking up apartments in that part of the building in parallel. The returns are fed down back into the basement or mechanical room level in order to eliminate the need for a third pipe and to still achieve self balancing of the system by essentially making the fluid travel distance equal for all loads (first supply â&#x20AC;&#x201C; last return). The primary pump is sized to accommodate the flow for the entire building.

A pressure bypass valve (not shown) would be required if the primary pump was constant volume. DeltaT or deltaP pumps, as well as self sensing pumps could be used instead to regulate flow when not all zones are calling. Refer to Figure 5 for the make-up of distribution piping needed based on line sizes. Offsetting the supply and return on opposite sides of the building allowed for less two-inch piping as shown in Figure 5. Note the need for individual balancing valves per zone in order to balance each load.

zone valves

20

20 EA

Figure 6 Primary/secondary distribution

balancing valves

20

20 EA

Figure 4 Direct return distribution

1239 ft

Figure 5 Reverse return distribution

Pipe, hydronic, steel, standard weight

Quantity

Total

Pipe, hydronic, steel, standard weight

Quantity

Total

0.75" x 21'

30

630 ft

0.75" x 21'

20

420 ft

1" x 21'

4

84 ft

1" x 21'

12

252 ft

1.25" x 21'

13

273 ft

1.25" x 21'

2

42 ft

1.5" x 21'

4

84 ft

1.5" x 21'

2

42 ft

2" x 21'

10

210 ft

2" x 21'

4

84 ft

primary pump

1

1.5 Hp

primary pump

1

2/3 Hp

zone valves

20

20 EA

zone pumps

20

20 EA

balancing valves

0

0 EA

balancing valves

20

20 EA

MH22 | AUTUMN 2015

1281 ft

MODERN HYDRONICS

840 ft

1/25 HP ea

WWW.HPACMAG.COM

Modern Hydronics

Figure 6 shows this design using the primary/secondary distribution piping method. This particular design is similar to Figure 5 but picks up all apartments in that part of the building with a form of hydraulic separation. The returns are fed down back into the basement or mechanical room level also. The primary pump is sized to accommodate the flow only with very little resistance in the primary loop.

Each load, being hydraulically separated from the primary loop, now has its transformers and zone valves replaced by a small wet rotor circulator. As a result, the primary pump can be significantly smaller than those needed in Figures 4 or 5.

DeltaT pumps would be ideal for the primary pump as it would modulate its flow based on the overall load in the building.

In that scenario, a two-way balancing valve is used per riser in order to set the required flow based on full design conditions at the commissioning stage.

Constant volume pumps can also be used.

Taking this a step further, a two-way modulating valve operated by a deltaT controller could modulate the flow through each riser based on riser deltaT instead of fixed balanced flow. Self sensing pumps could increase system operating efficiency by reducing the primary pump's power consumption when the riser modulates down due to reduced building load. Figure 6 shows the piping needed based on line sizes.

Through the slightly larger deltaT (30F) in the distribution piping, additional savings could be picked up by us-

ing smaller pipe sizes for the majority of the building. Even if the deltaT per riser were to be kept at 20F, each riser size would go from the current one- to 1Âź inch.

No single option will be the best fit for all applications but in either of those two scenarios, the primary/secondary distribution piping option could provide not only material but also labour savings.

Determine the best piping option for each project based on the desired overall system design, installation and efficiency outcome. You may find a scenario where it is advantageous to combine a couple of those options within one system. <> - MIKE MILLER

SNOW AND ICE MELTING SYSTEMS Increase Safety and Control Over the Elements

Mike Miller is director of commercial sales, Canada with Taco Canada Ltd., and chair of the Canadian Hydronics Council (CHC).

He can be reached at hydronicsmike@ taco-hvac.com.

See Mike at Modern Hydronics-Summit 2015 where he and Steve Goldie will present on this topic. For more information, see www.modernhydronicssummit.com.

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Melting t 1st begins a ow sn sign of or ice

MODERN HYDRONICS HPAC Ad 7 2015.indd 1

Using the latest controls technology, hydronic SIM systems are more capable and cost effective than you might think. We answer your questions about controls, installation and operating costs at na.rehau.com/sim Š REHAU 2015 | MH23 7/20/15 2:13 PM

AUTUMN 2015

>> Modern Hydronics-Summit 2015 Product Showcase

Puropal 300, 500 and 1000 disposable cartridges

from

Axiom

Industries

Ltd.

demineralize fill water for closed loop hydronic Aquatherm Blue Pipe features a faser-

systems. Demineralized water meets water

composite layer and heat stabilization. During

quality requirements from boiler and glycol

the manufacturing process the pipes are

manufacturers. Aggressive salts, such as

extruded with a middle layer where glass fibres

chlorides, sulphates and nitrates, which

are blended with the PP-R to reinforce the pipe

specifically attack stainless steel, copper and

and

contraction.

aluminum, are removed. Scale producing

Designed to be safe to use in applications

restrict

expansion

and

ions, such as calcium and magnesium that

from -5F to 200F, based on pressure rating,

damage components and block heat transfer,

the pipe is available in ½ in. to 24 in. sizes.

are also removed. The media in the Puropal

There is an option of flexible 100m coils for

300 changes from blue to beige when spent.

sizes one-inch and smaller. The lightweight

Maximum pressure is 58 psi at 140F.

pipes are in accordance with CSA.

Accessories include a flow and conductivity

www.aquatherm.com

meter, and hose kit. www.axiomind.com

Extrol ASME commercial expansion tanks are suited for use in closed, non-potable hydronic heating and chilled water systems. Featuring a replaceable, full acceptance heavy-duty butyl bladder, the tanks are freestanding on integral welded ring base. They are factory pre-charged to 12 psig and have a maximum operating temperature of 240F. www.amtrol.com

Lochinvar’s Knight wall mount heating boiler models are available with 55 000 to 399 999 Btu/Hr. They operate on natural or L.P. gas and are capable of full modulation, firing down to 20 per cent of rated input with a turndown

Compass high-efficiency wet rotor circulators

ratio of 5:1. The fire tube design boilers

from Armstrong Fluid Technology have an

feature an automated weld heat exchanger

“auto” algorithm that adapts to system

assembly and a 439 stainless steel self

demand to simplify setup. Features include a

cleaning combustion chamber. A built-in

broad operating range, producing up to 20 ft.

stainless

allows

of head and 20 USgpm flow, variable speed

condensation to drain from the heat exchanger

operation, an easy to read display and eight

assembly into the external condensate trap.

different modes of operation. The circulators

The control system has an electronic display

have a large wiring chamber and front-

for boiler set-up, boiler status and boiler

mounted terminal block, and are available in

diagnostics. All components can be accessed

cast iron (Compass 20 -20ci) and stainless

and serviced from the front and top of the

steel (Compass 20-20ss).

jacket. www.lochinvar.com

www.armstrongfluidtechnology.com

steel

MH24 | AUTUMN 2015

flue

collector

MODERN HYDRONICS

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Modern Hydronics

dahl’s globe style radiator valves in sizes from ½ in. to 1 ¼ in. have Bosch’s 95 AFUE Greenstar FS Series is

the same rough-in dimensions they have had for 50 years and the

geared to the replacement boiler market. The

current replacement assemblies (cartridges) still fit, meaning

low loss header is pre-piped and connection

contractors do not have to modify the rough-in. Replacement

boxes (both high and low voltage) are located

assemblies feature a unique spring-loaded self-adjusting packing

on the back of the boiler for quick and easy

system and a heat resistant handle. Heavy pattern models now come

connection. Venting options include two-inch

standard with a Hi-Temp Disc for low-pressure steam.

polypropylene (PP), flexible PP chimney liner,

www.dahlvalve.com

concentric PP kit, PVC or CPVC. The boilers offer floor and wall models with up to 5:1 modulation in five heat-only and three combi

Olsen’s OLSSV Series of gas-fired, wall hung modulating

sizes. An integral pump is standard on all

condensing boilers has vertically mounted helical fin tube heat

models. Other features include a simplified

exchangers, which are made of 316L/444 stainless steel. A top

control with no programming required, coated

pipe connection with a built-in drip leg saves material and time.

heat exchanger, DHW output of up to four

The 95 per cent AFUE boilers are approved for PVC, CPVC and

GPM DHW output on combi models based on

polypropylene venting. A smooth coil design eliminates sediment

ΔT at 72F. A large flat-plate heat exchanger

collection.

allows for lower operating temperatures and

programming with text display, outdoor temperature sensor and

larger ΔT in DHW mode.

an easy access, protected terminal strip. www.olsenhvac.com

Other

features

include

5:1

turndown

ratio,

www.boschheatingandcooling.com

Amvic’s AmPEX insulated radiant PEX panels are designed for interior and exterior use in residential and commercial applications.

Jaga’s Clima Canal and Clima Canal Hybrid

They are available in R10, R12 and R14.

pre-assembled low water temperature infloor

Usable size is 48 by 24 in., with the overall

heating units can be topped with one of seven

The RedZone air handler features a Grundfos

size being 49¼ by 25¼ in. The thickness

wood-grain or aluminum grills to match the

circulator, advanced four-row copper tube, a

ranges from 3⅜ to 4⅜ in. PEX pipe

floor design. They are comprised of a 0.39 in.

heating coil with aluminum fins, one-inch

accommodation is ⅜-, ½-, ⅝-, ¾- and one-

thick duct of Sendzimir galvanized steel plate

insulation and an ECM motor. For cooling, this

inch. The panel nubs form a “mushroom”

and a telescopic height adjustment with

made in Canada product is designed to

shape to lock the PEX piping in place. The

stainless steel grille holder, coated with a

accept most brands of evaporator coils.

PEX piping is inserted into the panel by

scratchproof lacquer. Fans are tangential 24

Suited to new construction or retrofit, the unit

walking on the tube. Once inserted the pipe

VDC. Units can be installed as a continuous

has an electronic control board and a knock

will be properly positioned and seated into

product with open spaces filled with empty

out on both sides and the bottom. It requires

the panel. The patented panel design ensures

ducts. The Hybrid model, which has a build-in

no venting or gas lines so it can be placed in

that the tube will be completely encased in

height of 3.94 in. > 5.71 in., also offers

a closet, crawl space, attic or basement.

concrete and not pushed to the bottom.

cooling. http://jaga-usa.com

www.redzone-products.com

www.amvicsystem.com

continued on pMH26 WWW.HPACMAG.COM

MODERN HYDRONICS

AUTUMN 2015

| MH25

>> Products continued from pMH25

Eco-Con low temp radiators from Hydronic Heating

Roth

Technologies Inc. offer low mass, fast acting heat

X-PERT S5 hydronic tubing

transfer along with low-pressure drop in the

is a five-layer polyethylene

Industries

Inc.’s

convector. Standard measurements are from two

of raised temperature (PE-

to eight feet, a depth of three to 3¾ in. and a

RT) oxygen barrier tubing. The pipe consists

height of 8 to 8.1 in. Cover accessories allow the

of an oxygen barrier layer of ethylene vinyl

units to be joined to accommodate different space

alcohol

polymer

configurations. The radiators are offered in white

between

two

and white with black grille and sides. Other colours

Polyethylene Copolymer Resin and two layers

are available at a surcharge. www.hhtsystems.com

of adhesive. www.roth-america.com

(EVOH)

layers

of

encapsulated DOWLEX

2344

The Grundfos Comfort PM pump range has a low noise, permanent magnet motor for reduced energy consumption. It is available with constant operation mode. Maximum head pressure is 3.9 ft. and maximum flow rate is 2.2 GPM. Features include an integrated external sensor cable, insulation shells for faster installations, lead free brass housing and a compact design. www.grundfos.ca

The V-10 touch screen boiler controller from IBC is available on the VFC and SL series. It allows for quick setup and has built-in internet connectivity. Features include an intuitive alert system

Myson’s

with plain English warnings and error messages, the ability to

radiators offer decorative styling with finished

contractor

series

steel

panel

manage up to four different loads and five pumps, and pre

top grille and side covers. The radiators are

programmed values for all load types.

packaged with EZ fit wall brackets, air-vent,

www.ibcboiler.com

blind plugs, an internal valve with control cover and ½ in. male BSP to ½ in. sweat fittings. www.mysoncomfort.com

continued on pMH28

Online Learning – from the masters Integrated HVAC Engineering Expert Instructor: Robert Bean • Online: September 14 - December 18 INTEGRATED HVAC ENGINEERING

Run thermal comfort calculations, submit designs for a radiant-based HVAC system with DOAS, and make recommendations to improve IEQ and energy efficiency through architectural, building, and interior systems. During Integrated HVAC Engineering, you will study the complex interaction of room air temperature, humidity, mean radiant temperature, ventilation rate, lighting, sound, and even odours that determine the true quality of an interior environment. Numerous calculation and modeling exercises will allow you to immediately apply what you’ve learned. The course includes a variety of Excel tools for performing critical calculations, such as: the inside surface temperature of walls, ventilation rates for the current and previous version of ASHRAE Standard 62.2, exergy, and much more.

For more information and to register visit www.hpacmag.com/bean MH26 | AUTUMN 2015

MODERN HYDRONICS

Powered by

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simply radiant

Systems for life.

It’s all about you. Smart comfort, pre-programmed by you to meet your individual heating and cooling needs…this is HeatLink’s radiant hydronic system. In-tune with your schedule, and yet flexible enough to go with the flow, it would almost seem as if there was a genius…or genie, in your mechanical room. Effortless, efficient, and understated…literally! HeatLink’s radiant hydronic heating and cooling systems are engineered to create a comfortable, affordable and energy efficient environment for living. Designed for peace of mind, they are easy to use and have a full warranty. For more information please visit: www.heatlink.com

>> Products continued from pMH26

Spirovent from Spirotherm is a line of air eliminators and dirt separators with the Spirotube at their core. Designed to trap the smallest micro bubble, it offers little resistance to flow. Threaded (¾ in. to 4 in.) or flanged (2 in. and up) connections are available. The drain plug is also suitable for connecting a valve or temperature sensor. The automatic air vent is guaranteed not to leak and can only be closed by the installer for a pressure test. It is constructed of welded steel for longevity. www.spirotherm.com

The Prestige Solo condensing high efficiency gas boiler from Triangle Tube offers multiple venting and termination options. Five models from 60 to 399 MBH are available. A Next Generation Fire Tube Heat Exchanger is designed to provide maximum reliability with low thermal stress and improved water flow for maximum heat transfer. The boilers incorporate TriMax Control, which manages two separate reset curves for high and low

The Wilo Stratus GIGA high efficiency inline

Navien’s NHB condensing boilers are available

temperature zones, controls up to four

circulator has a temperature range of -4F to

in 55, 80, 110 and 150 Btu/Hr sizes. They

circulators and manages two space heating

284F. Maximum ambient temperature is 104F

feature an advanced burner system, turndown

zones and one DHW zone without an external

and maximum operating pressure is 232 psi.

rations of up to 15:1, adjustable Delta T

zone control panel. www.triangletube.com

It has maximum flows of 275 USgpm and

ranges, two inch PVC venting up to 60 ft. and

maximum head of 167 ft. Multiple control

three inch PVC venting up to 150 ft. An

modules are available for the compact pump.

integrated smart control provides a timed

It is constructed of cast iron with a high-temp,

hydronic

high-pressure engineered composite impeller

adjustable

and stainless steel pump shaft.

adjustable minimum burner time setting.

www.wilo-canada.com

www.navien.com

supply turn

water down

boost ratio

feature,

timing

and

HeatLink has released a line of preengineered hydronic control panels designed for use with Weil McLain’s ECO, Viessmann’s Vitodens 100, and Creatherm interlocking radiant floor panels

Lochinvar’s Cadet series of high

are

expandable

efficiency wall mounted boilers. The

polystyrene (EPS) and Neopor. The floor

manufactured

out

of

panels are complete with 24V (ac)

panels are two by four feet and they are

plug-in transformer and simple wiring

available in 1.8 in., 2.8 in. and 3.3 in.

connections. No assembly is required

thicknesses. A staggered snap-tight grid

and there is a single warranty for all

allows optimal tube spacing. On-centre points

components. www.heatlink.com

exist every three inches. www.creatherm.com MH28 | AUTUMN 2015

continued on pMH30 MODERN HYDRONICS

WWW.HPACMAG.COM

>> Products continued from pMH28

Models of the bth ULTRA electric boilers from Thermo 2000 are available from seven kW to 36 kW with multiple voltage options. Suited to single and multi-family as well as commercial, the compact boilers may be installed in new or retrofit applications. The boiler may be combined with an auxiliary heater for a dual-energy system. Temperatures are adjustable between 50F and 190F and a safety control limits excessively high temperatures. www.thermo2000.com Uponor code-listed, commercial-grade, PEX-to-PEX, fullHamilton Engineering Inc.’s 3VO water heater

port ball valves are available in ½-in. to 2-in. sizes and

or heating boiler features a 316L stainless

are appropriate for non-potable PEX piping applications.

steel heat exchanger, modulating stainless

They are listed to ANSI/NSF 14 and cNSFus-rfh and

steel burner (6:1 turndown), self-diagnostic

tested to ASTM F877, ASTM F1960, CSA B137.5 and NSF

microprocessor controls and externally and

359. The valves, which are compatible with systems

remotely adjustable settings. Available in

containing up to 50 per cent propylene glycol, feature

sealed combustion or room air; venting

blow-out-proof stems and are available with stem

options for the 3VO are AL 29-4C stainless, PP, CPVC, or PVC. Capacity ranges from

extension kits to accommodate up to 2 in. of insulation in

79 000 to 8 000 000 Btu/Hr. www.hamiltonengineering.com

insulated piping applications. www.uponor.ca

continued on pMH32

Z-DENS

TM

CHIMNEY & VENTING SOLUTIONS

P O LY P R O P Y L E N E

VENT

SYSTEM

FOR

CONDENSING

APPLIANCES

FOR ME IT’S ABOUT “TURN AROUND TIME” YOU MAKE THE CALL IT’S IN STOCK AND Z-FLEX DELIVERS Z-FLEX “Its worth the call”

Z-DENS™ Polypropylene Venting System, designed for quick and safe installation

ADVANTAGE Z-DENS! NO MESSY GLUE! BETTER BY DESIGN! USA T. 1.800.654.5600 F. 1.888.889.3539

ZDENS_25july.indd 1 MH30 | AUTUMN 2015

Self-sealing factory installed gaskets dramatically reduce installation time

CANADA T. 416.679.0045 F. 416.679.0051

sales@z-flex.com

MODERN HYDRONICS

www.z-flex.com

2015-07-27 3:43 PM

WWW.HPACMAG.COM

Viega press systems

Multiple materials, many solutions One provider

Copper

Stainless Steel

Black Iron

Polymer

Meeting and exceeding industry standards with every installation For more than 115 years, Viega has been the global leader in pipe joining technology.

Our press fitting systems can be joined without soldering, making us the clear choice for new and existing piping applications.

By combining different materials and sealing elements, Viega systems are approved for use in gas, compressed air, flammable fluids or hydronic applications including everything from natural gas and hydrogen, to diesel fuel and chilled water. With secure connections made in less than seven seconds, installation time is reduced by 60%. Find peace of mind on the job with Viega products that include the Smart Connect速 feature, allowing installers to easily identify unpressed connections during pressure testing.

For more information, call 800-976-9819 or visit www.viega.us T H E

G L O B A L

L E A D E R

I N

P L U M B I N G ,

H E AT I N G

A N D

P I P E

J O I N I N G

S Y S T E M S

>> Products continued from pMH30

Webstone and Aquatherm have developed a line

of

brass

valves

with

integrated

connections for PP-R pipe, compatible for use with Aquatherm PP-R piping systems.

PP-R Pro products include lead free ball valves, The Isolator, with multi-function drain

The HBX Wi-Fi zoning system allows your

and the Pro-Pal ball drain. Available in

clients to control multiple zones within their

nominal sizes of ½ in. to 2 in., the valves are

living space. It incorporates a new ZON-0550

NTI’s Vmax vertical firetube boiler has a

guaranteed for life.

along with a two-wire THM-0300 thermostat

stainless

www.webstonevalves.com

and Wi-Fi communication module. Each zone

steel

heat

exchanger

and

a

maximum operating pressure of 30 psi. It is

can be viewed and configured from a

available in floor standing and wall mount

smartphone. ZON-0550 has the capability to

models. There is a built-in primary loop, three-

have up to four THM-0300s connected, with

speed

spark

the possibility of expansion. Designed for

ignition. The fully modulating burner has 6.5

quick and simple installation, the ZON-0550

turndown ratio. Integrated control provides

connects to a two-wire HBX thermostat

low water pressure cut-off and an easily

making it suitable for retrofits, as well as new

programmable display. www.nythermal.com

installs. www.hbxcontrols.com

circulator

and

high-energy

Suited to retrofit or new installations in The Eco-King Supreme offers up to 95 per

residential and small commercial applications,

cent AFUE and has a fully modulating,

Viessmann’s Vitocrossal 300 gas condensing

condensing 6-1 turn down ratio and stainless

boiler offers high temperature capability, high

steel heat exchanger. Three boiler sizes are

mass and stainless steel construction. A

The ManaBloc plumbing manifold system from

offered: 100, 140 and 200 000 Btu. The

vertical stainless steel Inox-Crossal heat

Viega is suited to commercial applications. It is

boiler is available in two models, one of which

exchanger with wide water passageways

a high-efficiency, parallel water distribution

provides heating and DHW via indirect tank

allows for simplified system piping with full

system with a range of ports from 14 to 36.

with priority, and a combi unit, which provides

system flow. This eliminates the need for a

The fully assembled system incorporates

priority on-demand hot water with hydronic

dedicated boiler pump or primary/secondary

integrated quarter-turn shutoff valves for each

heating. Features include an adaptive gas

piping. The Vitotronic 200, KW6B control

fixture, offering centralized control over the

valve and separate CH and DHW connections

manages

Features

entire plumbing system. Available with ⅜-in. or

to simplify piping. An outdoor sensor, variable

include control of up to three heating circuits,

½-in. connections, the system features a 1

speed Grundfos pump and 12L expansion

intelligent DHW control, a variable speed

¼-in. internal reservoir to maintain constant

tank are included with all boilers.

pump output (0-10V) and multiple setback

temperature and pressure.

www.ecokingheating.com

timers. www.viessmann.ca

www.viega.us

the

heating

system.

continued on pMH34 MH32 |

AUTUMN 2015

MODERN HYDRONICS

WWW.HPACMAG.COM

>> Products continued from pMH32

Taco’s ECM, wet rotor high efficiency Viridian commercial line includes VR1816 (18 ft. of head and up to 16 gpm flow), VT2218 (22 ft. of head and up to 18 gpm flow) and the VR3452 (34 ft. of head and up to 52 gpm flow). The VR1816 is available in infinitely variable fixed speed, constant pressure or proportional pressure operating modes. The Viridian VT2218 comes with two temperature sensors, a LCD screen and push button navigation. The VR3452 variable speed wet rotor ECM circulator offers up to 34 ft. of shut-off head and 52-gpm flow. www.taco-hvac.com The Mascot FT from Laars is available as a wall hung heating only boiler or as a wall hung or floor

The RAUBOARD from REHAU

standing combi model. The fire tube heat exchanger

is a lightweight plywood

is stainless steel with aluminum core fire tubes,

panel designed for above-

rated for 30 psi (207 kPa) working pressure. The

floor installations. Installed

boiler has a fully condensing design with built-in

between the finished floor

condensate drain and trap. At 77F (25C)

and the subfloor or on walls

temperature rise, domestic hot water flow rates

under gypsum board, the

through an integral stainless steel domestic water

plywood panel features a

indirect tank are 140 MBH = 3.5 gpm or 199 MBH

0.5-in. profile. These low-

= 4.7 gpm. An integral DHW indirect tank holds a

profile panels are offered in

minimum of three gallons of DHW. www.laars.com

double

groove

or

single

groove panels and expand the applications for radiant to include retrofitting options, as well as new construction. www.na.rehau.com

Security Chimney’s Secure Seal single wall,

Low Temperature Convector

•

double-wall

and

double-wall

insulated gas vents feature laser buttwelding, built in lock systems, AL29-4C stainless steel and standard adjustable

Ideal for Modulating Condensing Boilers, Geothermal, Heat Pumps and Solar Heat Sources

vent length. The Secure Seal double-wall system is fully interchangeable with the Secure Seal single-wall system. www.securitychimneys.com

The

flanged

DIRTMAG

commercial

dirt

separator from Caleffi continuously removes ferrous and nonferrous impurities. The dirt separating action uses the internal element with

Also as free standing radiator available

concentric

diamond

pattern

mesh

surfaces. The element offers little resistance to the medium flow. Dirt particles are collected Made in Canada

www.hhtsystems.com Phone 519-624-6623

in a large collection chamber where they can be flushed, even while the system is in operation. The connector on top of the dirt separator can be used for installation of an automatic air vent valve. www.caleffi.us

continued on pMH36 MH34 | AUTUMN 2015

MODERN HYDRONICS

WWW.HPACMAG.COM

A better way to make ends meet.

Professionals who specify and install Uponor PEX plumbing and hydronic piping report faster installation times, savings on materials costs, fewer callbacks and greater peace of mind.

Exceptional products, tools and support. Uponor. Tested in the lab and proven in the field.

Connect with Uponor.

Connect with confidence.

See more case studies at www.uponor.ca

PEX PLUMBING RADIANT HEATING & COOLING HYDRONIC PIPING PRE-INSULATED PIPING

>> Products continued from pMH34

Z-Dens polypropylene vent systems from Z-Flex

Schluter-BEKOTEC products

are for use with high efficiency boilers and

are

lightweight

modular

water heaters. Z-Dens does not require

systems that are used to

glue and catalyst and is available in

create continuous screed

diameters of 2-, 3-, 4-, 5-, 6-, 8- and

surfaces

10-in. It is fully compatible with

joints

Z-Dens

They

Flex

Concentric.

and

The

Z-Dens

systems

without

or

control

reinforcement.

produce

permanent

are

flooring assemblies that are

pressure tested to 20 in. W.C. and

free from internal stresses by confining the shrinkage and curing

are ULC S636 certified for flue

stresses to smaller modules. The floating systems can be

temperatures up to 230F.

customized. The products are suited for use with ceramic tile, natural

www.z-flex.com

stone, or other surface coverings. www.schluter.com

December 2014

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Weil McLain’s Evergreen 95 per cent AFUE

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◻1-4 ◻5-9 ◻ 10 - 19

◻ 20 - 49 ◻ 50 - 99 ◻ 100 - 199

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exchanger and can be floor or wall mount. It is

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HPAC Magazine

80 Valleybrook Dr., Toronto, ON M3B 2S9

boiler has a stainless steel fire tube heat

◻ Hydronic Heating ◻ Fire Protection ◻ Other––––––––––––––––––– (please specify)

FAX: 416-510-5170

Publisher reserves the right to determine qualification & limit distribution.

available in three sizes: 220, 299 and 399 000 Btu/Hr and up to eight boilers may be lead/lag and rotated. Features include 10:1 turn down, control wizard for easy set-up and built-in Modbus with BacNet options available. http://weil-mclain.ca

MH36 | AUTUMN 2015

MODERN HYDRONICS

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Our new 3D i-see Sensor gives you

752 reasons to choose Mitsubishi Electric.

M-Series | MSZ-FH • Industry-leading SEER rating of 30.5 • Available in 4 sizes, including a new 18,000 BTU/h unit • Absence Detection provides greater energy efficiency

Introducing another brilliant advancement from the leader in comfort innovation. The 3D i-see Sensor from Mitsubishi Electric analyzes the temperature profile of a living space to identify human presence and deliver optimal comfort. By dividing the entire room into 752 zones, the 3D i-see Sensor locates people based on their unique body temperature. With this thermal data, the MSZ-FH then directs the perfect amount of heating or cooling towards those who need it.

That’s comfort innovation in action.

*When installed by an Authorized HVAC (Heating, Ventilating, and Air Conditioning) Installer.

SmartHVAC.ca

>> Controls

Hello Boiler, It’s Wi-Fi Calling

W

A wireless future for the mechanical industry. ires have historically connected our lives.

Power wires, cable wires and telephone wires are everywhere but a less restrictive communication technology is becoming increasingly prevalent in people’s day-to-day lives. And they are understandably embracing it.

Think back to when you got your first “cordless phone.” I bought mine in grade 12 and I remember every detail about that phone. The reason I bought it was freedom. Not the “Braveheart” kind, but the freedom from that pesky telephone cord. I did it so I could wander from room to room while talking to my girlfriend and avoid having my mom overhear the conversation.

Back then I did not see the big picture and would not have guessed how far the technology would advance in a short period or time. I, along with most people, did not envision the world we now know as “cordless.” At least the term “cordless” has evolved into a far better one known as wireless.

TERMINOLOGY TUTORIAL What does wireless really mean and what do people think when they hear it? Many people confuse the term wireless with Wi-Fi and they do it with good reason. It is similar to when you ask for a Kleenex. Because they are very good at branding, everyone calls tissue paper Kleenex. When was the last time you heard someone say, “Can you pass me a Puffs?"

A similar scenario has happened with Wi-Fi and wireless.

Wireless is a term for something without wires. Wi-Fi is a protocol designed to work on wireless networks that connect us to the internet. Wi-Fi is not the only wireless protocol out there but like the Kleenex scenario, it is what we think of.

Protocol basically means the structure something takes when communicating but not the communication itself.

Wireless protocols are just different ways to structure the information going back and forth. Some might be very small with no error checking and some, such as Wi-Fi, can be very big and have many layers to them. Both have advantages and disadvantages in certain situations.

There are many things out there without wires such as radios or walkie-talkies, or even satellites. But the term wireless as we know it now, really has to do with the wireless communication. Exchanging data without wires. We are in the information age and data exchange is at the very heart of that.

Where is the most data? It is on the internet and to get there almost all computers, cell phones, cars and fridges have Wi-Fi. The term is everywhere, hence the reason people intertwine the terms Wi-Fi with wireless.

MH38 | AUTUMN 2015

OTHER PLAYERS Wi-Fi is not the only protocol out there but by far the most well known. Bluetooth is also a very popular protocol that you probably know running on the same frequency as Wi-Fi, at least for the most part. There is also mesh and star network protocols. These networks run on small protocols like Zigbee or chopped up “Zigbee like” protocols and are designed to connect many devices together in a relatively small space.

Devices like these could connect temperature sensors to thermostats and thermostats to boilers or zone controls. There are also some very large associations out there for wireless protocols in our industry. EnOcean is one company that is trying to make a push to be at the front of our industry. They offer a good protocol, as well as power saving features for remote devices. Many companies have signed on and are making their devices EnOcean compatible by licensing its technology. Honeywell is another big company that uses a proprietary protocol called RedLink for its wireless devices.

Everyone has a phone, not just at home but literally with them at all times. Apple knows it, Samsung knows it and that is why they are making more and more devices to connect our world. We are heading toward a time when everything will be connected to something else with Wi-Fi. The Internet of Things or IoE as it is called, is coming.

MODERN HYDRONICS

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Modern Hydronics

ried to its devices.

Apps give us ease of use, which is my favourite part. The hardest part of consumer devices is to put all the information on a display and make it easy to use. But with apps we can put more of that information, settings and features in a format that we are very used to using.

If you cannot navigate through it all, being connected and having all the information at your fingertips means nothing.

Making an app where people can understand the information they are seeing is key. It is not just techie guys that want this stuff in their house, it is everyone. You have probably stumbled upon end users that get a little too deep into the control and mess up the settings. I have certainly seen my fair share.

We have a task to figure out – how much information is enough? Luckily, with connected devices we can actually get more information in their hands and more easily. It is easier to make an interface on a device such as a telephone for end users as it is very familiar to them and they will use it. It is our job to make it simple and comfortable for them. Or else why are we doing it?

Wi-Fi connects devices together and allows us to see what

WHERE DO WE COME IN How and where does all this fit with the HVAC industry? Well, in one word: NEST! While there are other similar products, this thermostat was the one that really opened our eyes and changed our world. Nest Labs, Inc. proved that people would pay a premium for connectivity to the internet.

The increasing number of devices that can be connected to the internet has created more terminology confusion. People do associate “wireless” with Wi-Fi but they are starting to also do something else. Wi-Fi is being associated with Apps. It is becoming more and more common for people in our industry to talk about Wi-Fi when they really mean the device can be controlled by an App. We have all heard “there’s an app for that.” People want to see everything on their telephone, from their alarm system, to the amount of steps they take in a day, to the current temperature in their house. It is all about information at their fingertips. So, I say give it to them.

Wi-Fi offers convenience. As much as it pains me to say this, I am among those who would rather get up and get their telephone to change the temperature on their thermostat rather than just walk to the thermostat. We are a society that is mar-

Continued on PMH40

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MODERN HYDRONICS

Peak-performance heating systems

AUTUMN 2015

| MH39

>> Controls Continued from PMH39 is going on all the time. We live in a world where things are instant and our industry is no different; except that we are just entering this world. Companies are rushing to get connected products to market and many are coming out with great ideas.

What it comes down to at the end of the day is that boilers, pumps, controls, thermostats and other devices in our world are “coming on line.” This will really change everything.

Our customers are expecting this because even their fridges are Wi-Fi connected so why can’t they see their boiler or thermostat? We need to give it to them.

Thermostats have been relatively the first HVAC devices to be Wi-Fi enabled. We are starting to now see boilers and pumps be connected. The next step in the controls world is to try to connect it all together. Having a central device that talks to everything is something that needs to happen. People do not want 14 different apps for each item in their system, they want one or two. So the natural progression is to have Wi-Fi enabled systems coming out.

Wi-Fi allows for the possibility of literally keeping us up to date. When devices, such as thermostats, are connected to the internet they can be updated remotely. This would keep

the thermostat or connected device always up to date with the latest software without you even knowing it. Another big positive of having devices connected to Wi-Fi is it allows contractors to peer into these devices from anywhere and solve problems then and there. This will save travel time and add a big value added service for customers.

Wouldn’t it be good as a contractor to know ahead of time that your customer’s boiler needs servicing because of something failing inside? Of course it would. What about being able to let customers know they have a problem before they even know they have a problem?

These are just a few of the possibilities when we connect these devices to the internet using Wi-Fi. The evolution is apparent. The question is, do we play catch-up or is the mechanical industry a leader in this whole new world? <> - CURTIS BENNETT A graduate of Southern Alberta Institute of Technology (SAIT), Curtis Bennett, C.E.T., is operations manager and a product developer at HBX Control Systems in Calgary, AB. He can be reached at curtis@hbxcontrols.com.

CHEMICAL SINCE 1981

Established in 1981, Hood Chemical supplies Dow Chemical glycol (propylene and ethylene) with inhibitors. We offer free analysis and supply a written report advising the freezing point, pH, concentration of inhibitors, and appearance.

“Who’s Your Glycol Expert”?

Contact Us for our Full List of Products and Services

1-800-567-9791

www.HOODchemical.com

HiTech Dispensing Inc. MH40 | AUTUMN 2015

MODERN HYDRONICS

WWW.HPACMAG.COM

BOILER CONTROL FROM ANYWHERE. Now you can take peace of mind on the road, with the Lochinvar CON·X·US™ mobile application. From anywhere, anytime, your smartphone or tablet keeps you in communication with a standalone boiler, or boiler plants in multiple locations. CON·X·US gives you control and monitoring capability at a lower cost compared to expensive building management systems. And the CON·X·US application provides two-way communications so you can make required adjustments and receive status alerts from around the corner, or halfway around the world.

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Look who will be at Modern Hydronics-Summit 2015

John Siegenthaler

Robert Bean

Steve Goldie

Mike Miller

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Register today at

Mark Evans

www.modernhydronicssummit.com Need help? Call Kim at 416-510-6794

>> Air Separation

I Can’t See Any Air But it is likely still there...

MH44 | AUTUMN 2015

due to their small size and rather infrequent use once the system has been initially purged. Float-type vents are ideal at the top of thermal storage tanks or central air separators.

ALONG FOR THE RIDE Entrained air bubbles are simply bubbles moved along by water flowing through the piping. Experience has shown that piping with average flow velocities as low as two feet per second can entrain air bubbles, even in vertical piping with downward flow. Entrainment can be helpful in dislodging air from remote portions of the system and then bringing it back to a central air separating device. This assumes ample water circulation in the system to provide the conveyor belt. Again, a good forced-water purging driven by a pressure source other than the system’s circulator(s) is the best way to entrain air and eventually route it out of the system.

PRESENT THOUGH UNSEEN Perhaps the least understood form in which air can exist in a hydronic system is as dissolved air. Molecules of the gases that make up air including oxygen (O2) and nitrogen (N2) can exist “in solution” with water molecules (H2O). These molecules cannot be seen, even under a microscope. Although water may appear perfectly clear and free of bubbles, it can still contain a significant quantity of air in solution.

The amount of dissolved air that water can hold depends on Figure 1 Air gases in water

Gauge pressure 5.5 30 psi

45 psi

60 psi

75 psi

90 psi

105 psi

5.0 4.5 4.0

15 psi

3.5 3.0 2.5

0 psi

2.0 1.5 1.0 0.5 0

MODERN HYDRONICS

32

65

100

135

170

205

240

275

310

345

Water temperature ( !)

Courtesy Caleffi North America

Max amount in gallons of dissolved air per 100 gallons of water

A

ir bubbles in water are as common as clouds in the sky, or waves on a lake. Most people take them for granted. However, those working with hydronic systems quickly learn that air in their systems is undesirable and seek ways to get rid of it.

My “attitude” on air in hydronic systems has changed over the years. I used to fear situations where air could get trapped in system piping and create problems such as loss of flow, noise and the (justified) complaints that would follow. Part of that fear was based on my inadequate understanding of how air behaves in hydronic systems.

Today, I know that proper system design, including provisions for forced water purging in combination with residual methods of air elimination, can quickly rid just about any hydronic system of air and keep it that way.

Air in hydronic systems can be categorized into three groups: • Stationary air pockets • Entrained air bubbles • Air dissolved with the fluid Since air is lighter than water, it migrates toward the high points of the system. These points are not necessarily just at the top of the system. Stationary air pockets can form at the top of heat emitters such as radiators, even those located low in the building. They can also form in horizontal piping runs that turn downward following a horizontal run. A common example is where a pipe is offset upward to cross over a beam, and then dropped back to its previous level.

Stationary air pockets within piping can usually be eliminated through forced-water purging. A stream of water flowing at a high velocity through the piping will push air along much like a piston moving through a cylinder. The air is eventually pushed out through an open valve near the end of the circuit.

Forced water purging is best driven by water pressure from the building’s domestic water supply system, that is water main pressure or pressure from a well pump. The high velocity flow needed can also be created using a swimming pool pump rated for at least one horsepower and supplied from a large/ clean plastic trash barrel filled with water. Do not count on the flow created by a properly-sized hydronic circulator to displace stationary air pockets, especially when that circulator has a mixture of air and water passing through it.

Stationary air pockets within radiators, or at the top of components such as thermal storage tanks and heat exchangers, are best eliminated through a vent. Hardware choices range from manually operated vents, to fully automatic float-operated vents. Manually operated vents are suited to radiators

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the water's temperature and pressure. At higher temperatures, the ability of water to contain dissolved gases decreases, and vice versa. As the pressure of the water increases, so does its ability to hold dissolved gases in solution.

Have you ever popped the cap on a bottle of beer and instantly seen the bubble forming and rising? It happens because the pressure on the liquid was reduced, which allows some of the carbon dioxide (CO2) molecules that were dissolved in the beer to merge together into tiny bubbles.

LIKE SQUEEZING A SPONGE Think of water as a “sponge” for dissolved gases such as those in air (mostly O2 and N2). Certain conditions allow that sponge to soak up additional molecules, while other conditions effectively “squeeze” the sponge and thus rid the water of some of these molecules. This “sponge” effect is driven by temperature and pressure.

The contours in Figure 1 show the maximum amount of dissolved air gases contained in water over a range of temperatures and pressures (expressed as a percentage of total volume).

For example, at 15 psi gauge pressure and a temperature of 65F, up to 3.6 per cent of the molecules in a container of water can be dissolved gases (oxygen, nitrogen and other trace gases). Water in this condition can be thought of as a sponge that has soaked up a significant amount of air molecules.

If the temperature of this water is raised to 170F while the pressure remains constant, its ability to hold dissolved gas is reduced to 1.8 per cent of its volume, half the previous level.

This change in air solubility is typical when cold water is first heated to a relatively high temperature in a boiler. The “sponge” has just been squeezed.

As the pressure of the water is reduced, so is its ability to Figure 2 Piping arrangement with air separator close to heat source

hold dissolved gases in solution. For example, Figure 1 shows that reducing the pressure of 170F water from 15 psi to 0 psi reduces the amount of dissolved gas it can contain from 1.8 per cent to about 0.6 per cent of its volume. This is another way to squeeze the “sponge.”

GROUND ZERO The best location for capturing air bubbles is where the ability of water to hold dissolved air is lowest. This is where the combination of temperature and corresponding pressure produce the lowest point on the graph in Figure 1.

The piping arrangement shown in Figure 2 places a central air separator close to the heat source where the water temperature is at or close to its highest value within the system.

The expansion tank is connected to the bottom of the air separator. This establishes the point of no pressure change (PONPC) in the system. When the circulator is operating, the pressure at this location will not change. It may not be the lowest pressure in the system (based upon the elevation changes in the piping), but the combination of temperature and pressure at this location is likely to produce a point on the graph in Figure 1 that is either the lowest, or very close to the lowest point. This is where the molecules of oxygen and nitrogen in the water join together to form very tiny “microbubbles.” This process is called coalescence.

Individually, microbubbles are too small to be seen by the human eye. However, dense collections of microbubbles can make otherwise clear water appear cloudy. A common place to see temporary clouds of microbubbles is in a drinking glass just filled with water from a faucet having an aerator device as seen in Figure 3.

Continued on pMH46

Figure 3 Temporary clouds

Figure 4 Cross section of a modern air separator and the coalescing media insert cap, (sealed when closed)

microbubble! air separator

air outlet ports

spring-loaded stem valve seat & O-ring linkage

point of no pressure change

make-up water

air

float continued on pMH6 guide pin baffle plate upper! chamber

exp.! tank

Courtesy Caleffi North America

coalescing! media (insert)

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MODERN HYDRONICS

water

lower bowl

expansion tank connection! (or drain valve)

AUTUMN 2015

| MH45

>> Air Separation continued from pMH45 If you watch the glass of water carefully, you will see the cloud of microbubbles slowly rise and disappear from the surface of the water. At that point the water might look air free, but it is not. There are still molecules of O2 and N2 mixed in with the water molecules. Fortunately we have modern devices to coax them out of hiding.

Modern air separating devices contain a mesh-like insert made of engineered polymers or metal. This insert is called a coalescing media. Figure 4 shows the cross section of a modern air separator and the coalescing media insert.

The coalescing media contains thousands of small sharp surfaces throughout its three-dimensional structure. These surfaces create tiny vortices; that is regions of reduced pressure, as water passes by them. The reduced pressure encourages molecules to coalesce into microbubbles. This is the first step toward the goal of capturing this dissolved air and ejecting it from the system.

Microbubbles are very easily entrained by moving fluids. This characteristic makes them more difficult to capture compared to larger bubbles. However, the surfaces of the coalescing media provide shielded vertical pathways along which microbubbles can rise above the active flow stream moving through the separator. Once they are above this region it is almost “game over.”

The microbubbles merge into larger bubbles that eventually form an air pocket in the upper chamber of the separator.

When sufficient air has accumulated, the float in the upper portion of the separator drops down and a small linkage attached to it opens a valve. This allows the accumulated air to be ejected from the system. The pressure difference between the inside of the separator and the surrounding air is what pushes the air out as this valve opens. As the air leaves, the float rises and the valve closes to prevent all but a tiny loss of water. The automatic make-up water subsystem responds by adding a small amount of water to replace the ejected air.

The water stream exiting the air separator and heading into the circuit is said to be in an “unsaturated” state. This means it is capable of absorbing more molecules of oxygen and nitrogen as it passes through the circuit. Thus, whenever the water is moving through the circuit, there is an ongoing process whereby air molecules are absorbed into the water stream, conveyed back to the air separator, scrubbed out of the water by the coalescing media, ejected from the system and replaced by equivalent volumes of water. This process can eventually reduce the dissolved air content of the system’s water to less than 0.4 per cent. This small residual air content does not adversely affect system operation.

PAY ATTENTION TO DETAILS For optimal performance it is best to keep the flow velocity of water entering an air separator no higher than four feet per second. Placement of the air separator as shown in Figure 2 provides the air separator with an excellent hunting ground for capturing dissolved air. Be sure to place purging valves near the end of branch circuits so that each of these circuits can benefit from a forced water purging when the system is commissioned. Follow these details and it is easy to rid even complex piping systems of air and keep them that way. <> - JOHN SIEGENTHALER 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. He is also an associate professor emeritus of engineering technology at Mohawk Valley Community College in Utica, NY. See John at Modern HydronicsSummit 2015 (for more information see p42) on September 10 at the International Centre in Mississauga, ON.

Online Learning – from the masters Mastering Hydronic System Design

Expert Instructor: John Siegenthaler • Online: October 6 - December 12, 2015 MASTERING HYDRONIC SYSTEM DESIGN

Learn how to design state-of-the-art systems for residential and light commercial buildings that deliver unsurpassed comfort, efficiency and reliability. During Mastering Hydronic System Design, John Siegenthaler provides a detailed discussion of the design elements underlying modern hydronic heating systems. It presents both design concepts and design tools for optimizing hydronic heating systems in a variety of contemporary applications.

For more information and to register visit www.hpacmag.com/siggy

MH46 | AUTUMN 2015

MODERN HYDRONICS

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