Publisher: Bruce Meacock, C 416-457-9563 bruce.meacock@mechanicalbusiness.com
How to properly drain a system
Bob “Hot Rod” Rohr 48CHC CONFERENCE PREVIEW
Exhibitors, schedule, speakers
HYDRONIC CONTROL VALVES: PART III
BALANCING AND THE EFFECTS OF LOW DELTA T
Control valves used in the HVAC industry have evolved into more than just a mechanical device. Smart valves can dynamically balance a hydronic loop, improve system performance, and save considerable energy.
Rick Mohammed
ROAD WARRIOR: THE MULTI-TASKER
Plumbing and HVAC/R technician Dallas Blatkewicz especially enjoys the hydronic projects undertaken by Bald Eagle Plumbing & Heating Ltd. in Drayton Valley, AB.
Carolyn Cooper
A
Match the correct definition or meaning to the terminology you hear in the field and enter for your chance to win a Yeti cooler from NIBCO.
ENERGY EFFICIENCY
MAKING THE CASE FOR ZONING
The reasons to support or design in a zoned type of system are incredibly easy to see and understand.
Matthew Reid
Photo: Carmen Williams, Carmen Rae
By Rick Mohammed
Hydronic control valves Part III CONTROLS
Rick Mohammed, A.Sc.T., is a regional application consultant with Belimo. He can be reached at rick.mohammed@ca.belimo.com.
Balancing and the effects of low Delta T
InPart I of this series (Mechanical Business Sept/Oct 2023), we reviewed the different types of control valves found in hydronic systems. In Part II (Mechanical Business March/April 2024) we learned how to size and select a control valve. In Part III, the final edition, we discuss the challenges with balancing many control valves on a hydronic loop, and the drastic effects an unbalanced system has on system performance and energy consumption. In almost all hydronic systems the flow of water is unevenly distributed throughout the piping system. In some areas closer to the pumps there will be higher pressure and too much flow, and in other areas farthest away from the pumps there will be lower pressure and too little flow. We see this often in buildings when we ask operators about their pumps. Often, we are told the pumps are running at high speed, and they have to manually turn the speed down when loads are low.
FIGURE 1
DELTA T (ΔT) is the difference in water temperature entering and leaving a coil, heat exchanger, or supply and return lines to the plant.
There is a relationship between pressure, flow, and Delta T (ΔT). A low ΔT below the original design at the AHU and at the cooling or heating plant, is a big indicator a system is using too much energy and not delivering its maximum load.
The process of balancing flow in a hydronic system includes opening all the valves in the loop, increasing the pump to full speed, and adjusting a balancing valve to get the maximum design flow for the coil in an AHU, FCU, reheat coil, or perimeter rad. We can see right away that the system is only balanced at full load and since all HVAC systems are oversized, it will operate below the maximum flow setting 99 per cent of the time. In other words, the system is unbalanced 99 per cent of the time.
Figure 1 shows a coil with a balancing valve set to 100 GPM. As soon as the modulating valve is below 100 per cent open the balancing valve is no longer offering balancing. This allows for excess flow to pass when demand is at part load and pressure is high.
As flow passes through a coil of an AHU too quickly, the heat transfer between the water and the air is not maximized. This is apparent in the measurement of the ΔT. Figure 2 shows the relationship between flow and ΔT. The red points create a power or heat transfer curve of the coil, and the blue points represent the ΔT of the coil. We can see the difference between 65 GPM and 55 GPM on the X axis correlates to a 5 KBTU/hr change in coil power. That is a 15 per cent change in flow to get only a one per cent change in coil power. We also can see that the difference in ΔT shown on the right-hand axis increases from 10⁰F to 12⁰F as the flow drops to 55 GPM. That means 65 GPM of flow is too high which leads to a lower ΔT, and very little change in coil power.
When ΔT is low at the various coils or heat transfer devices, the temperature of the water returning to the chiller or heating plant is not at design. This limits the load the chiller or boiler was designed to generate. The result is an overworked system, high energy consumption, and compromised occupant comfort.
In Figure 3 we have a chiller rated at 200 tons. The chiller generates 42⁰F water that is sent to the AHU cooling coil and it needs a 54⁰F return water temperature for a 12⁰F ΔT. When the flow through the coil is too high the heat exchange between the water and air is reduced. This is shown in the delta measurement at the supply and return of the coil. It also causes the return water temperature to be colder at 48⁰F. The chiller is now getting a six-degree ΔT and its capacity drops from 200 tons to 100 tons.
By eliminating the overflow at each AHU we can achieve equal distribution of flow throughout the hydronic loop, and correct the underflow in other areas at the same time. This will in effect correct the ΔT at each coil. But what does that mean for the plant?
Let’s look at a typical primary/variable secondary loop system. Figure 4 (page 30) shows a system with 3 chillers each rated at 200 tons on the primary side. Each chiller has a dedicated constant flow pump. On the secondary side there is a secondary pump with a variable frequency drive that is driven by a differential pressure sensor installed after the last air handling unit, AHU 3. Each AHU has a standard two-way valve and a balancing valve to vary the flow as the load changes in the space being cooled.
Let’s recall the limits with balancing flow mentioned earlier. The pressure and flow through each AHU is unbalanced. This causes overflow through some cooling coils of the AHU, and underflow through others. As the flow of water passes through the coils too quickly it does not pick up enough heat from the air. This reduces the ΔT between the supply water and return water temperatures, and it also decreases the return water temperature going back to the chiller plant.
Just like in the earlier chiller example, the chillers are selected to provide a supply water temperature of 42⁰F and they require a return of 54⁰F to give a 12⁰F ΔT for the chiller. A 12⁰F ΔT allows the chiller to operate efficiently and deliver 200 tons of cooling. AHU 1, AHU 2, and AHU 3 have return water temperatures of 45⁰F, 46⁰F, and 52⁰F. When these temperatures are mixed in the return line going back to the chiller plant, we can see a resulting return water temperature of 48⁰F. The ΔT at the chiller plant is now only 6⁰F causing the chiller to deliver only 100 tons of cooling. As the load of the building increases, chiller 2 must come on earlier to make up for the lost chiller capacity.
Many building operators tell us they have to add a chiller because they cannot cool the building when outside temperatures are high. Usually, we find the ΔT at the plant is significantly below the design ΔT.
FIGURE 3
To fix the balancing, over pumping, and low ΔT problem we can apply the use of smart valves as shown in Figure 5. The standard two-way valve is replaced by a smart valve and the traditional balancing valve can be removed or simply fully opened. The smart valve can be set up with a position, flow, or coil power set point depending on the system. It can also be set up with a ΔT setpoint. This way flow and ΔT can be customized for the AHU which will then correct the return water temperature, and improve chiller operation. The same concept can be applied to a heating plant where condensing boilers are not condensing and causing excessive gas consumption.
Control valves used in the HVAC industry have evolved into more than just a mechanical device. They can include a flow meter, temperature sensors, BACnet communication to collect useful data such as energy use, and built in algorithms to manage flow accuracy, ΔT, and power output.
Smart valves can dynamically balance a hydronic loop, improve system performance, and save considerable energy. This concludes the three-part series on control valves. We hope it has given you a new appreciation for control valves, and how control valve technology has evolved.
A smart valve is a component that can automatically adjust its position or flow rate. It uses data from sensors or a programmed control system. Sensors in smart valves can detect changes in temperature, water pressure, and flow. This can be used by technicians to adust balancing operations.
FIGURE 4
FIGURE 5
Higher Turndown Hydronics
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Camus
HYDRONICS
Fluidity fixes: How to properly drain a system
In my working definition, hydronics indicates the system will be based on a fluid to transfer the energy. As such, commonly seen systems that could be considered hydronic are radiators, fin tube, air coils, radiant, solar thermal, GEO loops, and A2WHP. I’d put steam systems in the hydronic category also.
There may come a time when one of these hydronic systems needs to be drained. It could be for a service call to fix a leak, or to replace a component, for example. It could be the system just needs to be flushed, cleaned and refilled from years of service. Water quality and the maintenance of the fluid has a lot to do with the need to drain occasionally. Non-barrier pex tubing used in hydronics is another example of a system that will need to be drained and serviced at some point. I have never witnessed crystal clear hydronic fluid, but dark coloured sludge in any hydronic system indicates a problem worth investigating.
If a component fails or ages out, the system needs to be drained.
In some cases, a drain down is a super simple task. A boiler or solar tank below all the piping would just need a valve at the low point to accomplish a drain down. Many of the cast iron boilers come equipped with boiler drains at the bottom. So, connect a short hose and open the drain and an air vent to get a good quick drain.
Personally, I prefer a ball valve to a compression type boiler drain to ease draining and flushing. Consider this upgrade on a new or repair installation. A handful of hose caps on your service vehicles can be helpful also. Eventually you will come across a valve that will not seal off. If it has a hose connection, a cap and washer is a quick, maybe temporary, fix.
By Bob “Hot Rod” Rohr
Bob Hot Rod Rohr has been a plumbing, radiant heat and solar contractor and installer for 30+ years. A long-time columnist, he is involved with training and education at Caleffi North America. You can reach him at bob.rohr@caleffi.com.
In addition to a good wide open flow path for draining, a ball valve is best when pumping fluids back into the system. This will be handy if you want to pump in cleaners, conditioners, and possibly glycol for freeze protection.
When you pump backwards through a typical washer type boiler drain, you run the risk of pushing the washer off the bib screw. This will make it hard to seal off that valve. A typical compression type bib washer valve is intended for flow in one direction. There are plenty of options for ball valves with a garden hose connection. This is always a nice upgrade for a drain valve on a system. It offers higher flow rate and bi-directional flow options.
Systems with the components or piping below the boiler will be more of a challenge to drain. For a complete 100 per cent drain down of a system like this you pretty much need some compressed air. Compressed air with adequate volume will help push all the water out.
Come to the job prepared with several drain/purge tool options.
Fin tube circuits blow out fairly easily. Thousands of feet of pex tubing in a slab, for example, will take more time and patience to completely drain. Ideally a manifold with isolation valves will allow you to blow out one or two loops at a time.
On small residential systems, a wet vac can do a good job of getting all the water or fluid out. A wet vac is also handy for cleaning up spills of the work area after you complete the job. There are a number of good cordless vacs available if you roll without power corded tools these days.
It’s not a bad idea to purge the system fluids out into buckets or a plastic barrel to get a good idea of the system’s capacity. With a total water content measurement, you make easy work of adding glycol, cleaners, or inhibitors. I like to see what flushes out, too. Flushing out solder balls, Teflon tape shards, copper reams, etc. tells a lot about the previous installer or service contractor skillset. And, the more shrapnel in the system, the more potential damage you might uncover.
Old glycol or other unknown fluid blends should go to a recycler. Check your city or town website for recycling options.
A fill cart with at least a ½ hp pump can also be handy for flushing and refilling as well as injecting chemicals or glycols. On larger, more piping-intense systems, you may need to cut in some isolation or drain valves to speed or complete the drain down project. Break the system into manageable circuits.
Press-type valves and tees are great for cutting into systems. I believe there are press systems for copper, stainless, and schedule 40 piping now available. You can also use grip type valves and fittings, if you are comfortable with that type of connection.
If you are a tool buff, a pipe freeze kit can be a job, or reputation, saver.
Some valves come with dual purge ports and a ball valve in between.
These can be handy for flushing two directions.
It is worth spending a few dollars more to get a quality valve. The low-priced, lowquality valves tend to have small diameter stems, thinner forgings, and no packing nut. They look and feel cheap. You want the valve to last more than one cycle.
When you do add valves, think about how they can be installed to serve multiple functions. As an example, consider pump isolation flanges. These can function to isolate and replace or repair a pump, and to purge or drain those points in the system.
In a perfect world, a valve would be exercised from time to time. Left untouched for years, valves can stick in the open or
There are many valves available for residential, commercial or industrial use with water or oil. This valve is specifically designed for filling and draining glycol/antifreeze from any point in a hydronic system.
closed position. “Forcing” them to operate can result in a broken stem. Or worst case, a valve that moved partially through its stroke, and then the stem broke. If you spend years in the field, you will come across many of these issues, so be prepared.
The combination of a freeze kit and a press valve or fitting can certainly turn a problem job into a quick simple win for a service technician. This repair can also be a unique money maker.
That’s just my short list of fluidity fixes – if you have a tip or trick, let me know and I can share it in future columns and podcasts.
Bob Rohr’s May/June 2024 column stated: In these horizontal tanks there is a diaphragm or separation between the fluid and the air bubble. It should read: In these horizontal tanks there is no diaphragm or separation between the fluid and the air bubble.
Lochinvar
HYDRONIC PRODUCTS
Zero-emissions boiler
Aerco’s Benchmark E is a zero-emissions electric boiler with new technology such as peak load management and hybrid plant capability. The boiler is designed to maximize system efficiency, allowing up to 16 boilers to be sequenced, including gas-fired Benchmark boilers for a hybrid plant. Peak loads are managed to optimize electricity usage and lower costs. Benchmark E also pairs with AERCO’s SmartPlate EV indirect water heater for a fully electric heating and hot water plant solution. The unit is available in five sizes from 216 kW to 684 kW, roughly equivalent to 750 MBH to 2,400 MBH, with a maximum water flow of 350 GPM for all sizes.
www.
aerco.com
High-efficiency electric boiler
The EBX modulating electric boiler from IBC is suitable for primary and secondary heating in applications operating up to 87°C. Features include compact design, easy set-up for either set-point or outdoor reset operation; modulating electric elements for better temperature control; and built-in three speed boiler pump, flow sensor and high limit safeties.
www.
ibcboiler.com
Hydronic flooring
Air-to-water heat pump
The Advantage monobloc air-towater heat pump from Enertech is a turnkey solution for heating and cooling, and offers complete air-source solution to offer radiant heating, up to 100 per cent of domestic hot water heating, and forced air heating and cooling. Available in 2.5 and 5 tons, the heat pump doesn’t need refrigerant lines between outdoor and indoor units. With its variable-speed vapour injection scroll compressor, the unit is designed to produce heat in temperatures down to -25°C.
www.
enertechusa.com
Legend Hydronics’ VersaTherm floor system, available from Ontor, is a low-profile, high-output, snapfit radiant panel system suited to new construction and retrofits. The panels snap together quickly, saving labour costs. The 3/4-in. thick panels are pre-insulated and water resistant. One-half-in. tubing allows for greater circuit lengths. The tubing is 100 per cent protected by metal and the entire surface transfers heat. www. ontor.com
Recyclable tubing
CB Supplies’ VIPERT potable and radiant PE-RT tubing offers performance with improved flexibility, a low greenhouse gas emission footprint, and 100 per cent recyclability. It is compatible with various joining methods, including crimp, push-fit, and cold expansion fittings. Tailored specifically for hydronic systems, including radiant heating and cooling and snow/ice melt, the tubing is available in 100 to 1,200 ft. coils, with diameters of between 3/8 and 2 in. www.
cbsupplies.ca
Bradford White
HYDRONIC PRODUCTS
Electric hydronic boiler
The Cleaver-Brooks LVR electric hydronic boiler is available from 90 to 540 kW in three compact footprints. The LVR has carbon steel construction with a 160-psig designed pressure vessel. It features SCR control providing full modulation and infinite turndown, integrated controls for maximum operating efficiency in a variety of system applications, and a user interface with built-in power metering and limiting functions. The LVR can be provided as a skidded turnkey boiler room solution, and is suitable for applications such as healthcare facilities, universities, and multi-family housing. www.
cleaverbrooks.com
Buffer tank
The Flexcon Argosy is a pressurized composite buffer tank that works for hot or chilled potable and nonpotable water. The unit includes a high-strength noncorrosive plastic outer shell, a lightweight reinforced continuous strand fibreglass inner tank, and High R value injected closed cell foam insulation to minimize temperature loss and maximize efficiency. The tanks come in volumes of 22, 40, 55, 80 and 119 gallons, and have threaded stainless steel water connections. www.
flexconind.com
Gas heat pumps
Flexible boiler
Weil-McLain Canada’s Ultra Series 4 boiler is designed for residential and light commercial installations. The boilers now feature an UltraArmor nano-coated heat exchanger to maximize efficiency and extend longevity. Available in both natural gas and propane, and floor or wallmount versions, the Ultra’s six sizes, from 80 to 399 MBH, deliver up to 94.1 per cent AFUE. The units provide direct exhaust or direct vent and 5:1 modulation, and a water inhibitor and pump are included. www. weil-mclain.ca
Distribution manifolds
Anesi branded heating products for residential and commercial customers are now available in Canada. The air-to-water heat pumps run on natural gas, propane, or renewable gas as the primary fuel source. The Anesi gas heat pump and all refrigerants, combustion processes, and venting are located outside, and a warm water/food-grade glycol mixture enters the interior through standard PEX or copper piping. www.
anesicomfort.com
HeatLink’s 1-1/4 in. stainless steel distribution manifolds are suitable for residential or commercial hydronic radiant heating or cooling systems. A lockable 0-2 U.S. gpm (0-7.5 L/min) flow meter on the supply manifold permits fine tune balancing of the flow rate for each loop. A zone valve on the return manifold provides on/off manual control to allow isolation of individual loops. Isolation ball valves, thermometers, hose bibs, and mounting brackets are included. PEX to manifold connectors are available in 1/2-, 5/8-, and 3/4-in. sizes and in both compression and F1960 expansion styles. www.
heatlink.com
CANADIAN HYDRONICS CONFERENCE
CIPH/CHC
Transforming a Century-Old Brand into a Market Leader
Celebrating 100 years, Milwaukee Tool, a subsidiary of Techtronic Industries Co. Ltd. (TTI), has been refined and transformed over its time. Innovation isn’t just a buzzword for the heavy-duty power tool manufacturer–it takes years of leadership and culture to get there.
Here’s how Craig Baxter, group president of TTI Canada, transformed Milwaukee tool in Canada to bring it to where it is today.
How do you transform a 100-year-old brand like Milwaukee Tool, taking it from the back of the pack in market share to the leading maker of professional power tools and equipment?
“You don’t do it by setting goals you know you can achieve,” says Craig Baxter, group president of TTI Canada. “Very little that’s great has ever been achieved by setting easily achievable goals. I’m a strong believer in audacious goals,” adds Baxter. “I love that word. An audacious goal changes everything. It changes the way you think, the way you plan, the way you behave. It changes your entire approach.”
Sixth in a Five-Horse Race
If anyone would know from experience about the power of audacious goal-setting, it’s Baxter. In 2007, when he first joined Milwaukee Tool, the company’s products were barely on the radar as a job site solution.
“We were sixth in a five-horse race in terms of the market share of professional cordless tools,” Baxter recalls. “My first audacious goal was committing back in 2007 to make Milwaukee the number one brand of professional power tools in Canada by 2017. To achieve that meant we had to grow at least 20 percent a year for 10 straight years.”
Under Baxter’s leadership, Milwaukee Tool didn’t just achieve that goal—they smashed it. “We’ve compounded at 24 percent for the last 16 years,” he shares.
Leading by Inspiration
But while Milwaukee Tool’s continuous innovation is critical, Baxter credits his workforce—and the incredible spirit of teamwork and collaboration he set out to foster—for these incredible results.
Having taken the company from less than 100 employees in 2007 to almost 800—“We have single-digit turnover,” Baxter notes—he’s determined to build the best possible team and the best possible work culture.
“My job is to create an environment where talented, ambitious people can flourish,” he says.
For Baxter, that all hinges upon leadership. “The predominant leadership style today is command and control,” he adds. “But that style is never going to lead to extraordinary results over the long term. And that’s because great people simply don’t want to be controlled.”
Baxter continues, “If you don’t understand how to get the best work out of individuals, then extraordinary results will be incredibly difficult to achieve,” he says.
Great leaders are able to inspire people to become the absolute best version of themselves, and in so doing, they’re able to stretch for audacious goals.
Po wering the Job Sites of th e Futu re
T hi s f o cus o n lead ersh ip i s a formul a Baxter believes can power
Mi l waukee Tool for t he ne xt 1 00 years. As it leads to empowering each prod uct t eam to con ti nu e d eliver i ng di sruptive innovations. Speaki ng on these innovations, Baxter highlights three systems t ha t t ou ch u po n t he pro wess and commitment of Milwaukee Tool to con t in ue d eve lop in g & d el i veri ng innovative jobsite solutions.
T hese b ei ng MX FUEL™, NITRUS CARBIDE™, & FORGE™.
“O ur MX FUEL™ Equipment System is designed to take on gas and corded equipment, addressing common hazards and f rustrations. This system eliminates the need for gas, oil, or eng i ne m aintena nce, reducing tripping hazards on site, and preventing the need for corded solutions or extension cords,” he adds.
P rod uc ti vi ty c omb ined with execution is at the forefront for all syste m s. “With our NITRUS CARBIDE™ Blades, we’re providing o ve r 2X fa ster cuts and 2X longer life than traditional carbide teeth p rod uc t s. Ou r Ex t re m e Metal and Extreme Material options are the b es t -perf ormi ng c ut ti ng products on the market, and professionals need a blade that can stand up to the wide range of heavy-duty m aterials they face in a day” Baxter shares.
Speaking of battery systems, our new REDLITHIUM™ FORGE™ batteries are the most powerful, fastest charging, and longest life batteries within our cordless systems.
“ ”
With the MX FUEL™ REDLITHIUM™ FORGE™ XC8.0 and HD12.0 battery packs, we ensure our tools deliver peak performance and extended runtime, enabling professionals to tackle demanding tasks without interruption,” he notes.
Baxter acknowledges. “Our vision is a cordless job site—and by that I mean everything from a small renovation to building a tower downtown. Our vision is to have every single application on that job site powered with a lithium-ion solution brought to you by Milwaukee Tool. We want to replace other batteries, replace hydraulics, replace pneumatic air, replace gas and cords. Any source of power on the job, we want to replace it with one of our solutions. In five years, I see us providing solutions that are beyond anybody’s imagination on a job site,” Baxter shares.
With such a great team and strong leaders on his side, it’s yet another audacious goal Baxter believes is within reach. “Just look at what we’ve brought to market so far. You can only imagine how many solutions and the type of capabilities we will provide in the future. We are just getting started.”
Craig Baxter, group president of TTI Canada
HYDRONIC PRODUCTS
Energy efficient pump
The Wilo Stratos Maxo smart pump offers easy installation and operation, making it suitable for hotwater heating systems of all kinds, air conditioning systems, closed cooling circuits and industrial circulation systems. Features include EC motor, Green Button Technology with LED colour touchscreen display, Bluetooth interface, and energy-saving functions such as Multi-Flow Adaptation and No-Flow Stop. The pump provides a flow rate of 281 GPM, and 52 ft. max. head. www. wilo-canada.com
A2W heat pump
The Quantech QTH1 AWHP features inverter scroll design for a broad operating range, delivering up to 60°C water in heating capacities up to 443 MBH (heating only mode) and 546 MBH (in simultaneous heating and cooling mode). The units feature two-pipe or four-pipe design, with a COP up to 8.1 in simultaneous heating and cooling. The 35-ton modules use low GWP R-454B refrigerant, and are scalable up to 140 tons. The units offer part-load performance year-round and have a cooling EER of 10.2. www.
master.ca
Z-Vent
Baseboard cover
Baseboarders’ Premium Series of baseboard heater covers offers a clean, modern aesthetic for hydronic baseboard heaters, and is available in every common panel length and accessory configuration. The covers are easily installed without the use of tools, and are made of 22 and 18 gauge galvanized steel. Panels can also be cut to customized lengths. Covers are available in four colours: white, oil rubbed bronze, cast iron black and cool grey. www.
baseboardheatercovers.com
For the safety of both property and occupants proper venting of condensing gas-fired appliances is critical
Over time, scaling, poor combustion, elevated temperatures, and lack of maintenance can cause appliance fl ue gas temperatures to rise above safe operating temperatures of plastic vent material
For an added safety margin and peace of mind install Z-VentBLU®
Pressure sensor
Xylem’s optimize Bluetooth pressure sensor measures differential pressure to identify potential equipment problems before they occur. The sensors are installed in the piping, and are available for pressure ranges of up to 100, 250, and 500 psi. Using condition monitoring technology, they detect any system issues and send automatic alerts, data and insights to building operators through Xylem’s Avensor app. The sensor is part of the enhanced optimyze modular conditioning monitoring solution, which can be added to any Bell & Gossett pumps. www.
xylem.com
HYDRONIC PRODUCTS
Heavy duty water heater
The Bradford White ElectriFLEX HD commercial electric water heater is designed to provide water at a thermostatically controlled temperature greater than 180⁰F/82⁰C for highuse commercial applications. Features include Incoloy lowwatt density elements, field conversion kits to fit demanding application needs, proprietary Vitraglas lining with Microban antimicrobial product protection, and a Hydrojet sediment reduction system. The units are available in voltages of 208, 240, 277, 380, 415, 480 and 600 volts.
www.
bradfordwhite.com
Low water cut offs
McDonnell & Miller introduces updates to its electronic low water cut off product line, including the GuardDog RB-24SE low water cut-off and RB-122E low water cut-off for hot water boilers. The units each feature a self-cleaning probe to minimize scale build up, leak-free metal-to-metal seal, and a push-to-test button to confirm proper operation. The enhanced series is compact with a reduced footprint. The RB-24SE has 15,000 ohms probe sensitivity, and the RB-122E has 20,000 ohms probe sensitivity.
Precision factory formed pipe and fittings, with fusion welded seams
HYDRONIC PRODUCTS
Drain strainer
The Pro-Pal ball drain strainer from Webstone is a combination Y-strainer, ball valve, and high-flow hose drain. Its forged brass construction takes the place of eight individual components. A flexible design allows users to install it in a vertical or horizontal orientation, depending on the system’s needs. Available in 1/2- to 1-1/4in. press or FIP connections, it features lead-free dezincification resistant forged brass construction, 20 mesh screens, and a O-ring sealed and plugged strainer port for easy removal of the filter and installation of the drain valve.
www.
webstonevalves.com
Smart controls
Tekmar’s smart boiler control 294 saves time and labour by controlling boiler systems anytime, anywhere, with instant alerts via telephone, text or email. It provides a solution for boiler monitoring across different properties, and can control up to 16 boilers regardless of brand as part of a new system or a retrofit. Boiler settings can be remotely viewed and adjusted in real-time via Watts OnSite web or mobile app. It operates both condensing and non-condensing boilers that are either modulating, single-, two-, three- or four-stage, and comes with outdoor reset controls.
www. watts.ca
Condensing boilers
Air-to-water heat pump
Viessmann’s Vitocal 100-AW is a residential airto-water heat pump system for heating, cooling, and domestic hot water that includes an outdoor unit, indoor unit and a 20-gal steel buffer tank. The kit is delivered on a single pallet. The heat pump is available in three different sizes, 1.5, 3, and 4.3 tons for cooling and 20.5, 34, and 58 MBH for heating (nominal capacities), which allows for flexible applications. The buffer tank can be physically mounted on top of the domestic tank for additional space savings.
www.
viessmann.ca
Conforto’s high-efficiency condensing MAC wall-mounted or MACF floor standing combi gas boiler is controlled with Adaptive Intelligence. It provides hydronic heating and on-demand domestic water heating (DWH). The unit automatically modulates the gas input, using more gas when needed to provide heat or DWH when necessary, and less gas when usage is low. Models include the MAC-115 with a 6.9:1 turndown modulation ratio in DHW mode, and the MAC-150 and MAC-205, with a 7:1 turndown modulation ratio in DHW mode. www.
confortohvac.com
Fan coil
The Astra Beam non-ducted hydronic fan coil from Jaga Climate Systems uses chilled water to extract heat from the indoor air. The fan coil circulates air through a high-capacity hydronic coil, and delivers up to 1.5 tons of cooling using 43°F chilled water, using 54 watts of 24 VDC power, and an efficiency of 0.08 watts per CFM. It is quiet and does not require line voltage electrical connections. www.
jaga-canada.com
Coil kit
Caleffi’s Flowmatic Express coil kit is a pre-assembled connection and regulation kit for terminal units that helps reduce pipe connections and installation time. With flow rate regulation up to 16 GPM, the coil kit provides flow control, balancing, bypass, filtering and isolation functions for maintenance and flushing of the terminal unit. It comes complete with pressure independent control valve, three-way shut-off valves, integrated by-pass, Venturi device with pressure test ports, filtering cartridge, and pre-formed insulation shell. It is compatible with Caleffi’s 145 and 6565 series actuators. www.
caleffi.com
After two decades, our Ultra Series 4 condensing gas boiler is still going strong, bringing the heat to residential and light commercial installations across Canada. Available in 6 sizes, from 80 to 399 MBH, delivering up to 94.1% AFUE and 5:1 modulation.
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Dallas Blatkewicz
Dallas Blatkewicz The multi-tasker ROAD WARRIOR
Situated about 145 km southwest of Edmonton, Drayton Valley, AB is known for its beautiful surrounding wilderness, as well as its booming oil fields. So it wasn’t surprising that Dallas Blatkewicz initially planned to work in the oil industry in instrumentation. But the industry is known for its boom and bust cycles, so when Blatkewicz graduated high school and was unable to find a job, his father Dale, owner of Bald Eagle Plumbing & Heating, suggested he come work for him.
“I just kind of fell into a job,” Blatkewicz recalls. “The job where I wanted to go, nobody was really hiring, but he needed workers so I helped them over the summer. And I promised him I would get my ticket for plumbing, and then I was going to go back to instrumentation.”
He found he enjoyed the work, and enrolled at NAIT, graduating as a journeyman plumber in 2015. Since then, he’s also taken on a refrigeration and air conditioning program, and is currently in his fourth year.
“We hired a few refrigeration guys, but they didn’t really stay long, and I got a taste for that so I said, I’ll just go to school and do it. Now I prefer the furnaces, the boilers, the heating and air conditioning side of my trade.” Blatkewicz is also the company’s installer for private sewage systems.
Servicing and repairs are the company’s bread and butter, with residential comprising about 80 per cent and commercial 20 per cent. Bald Eagle also does installations and renovations, particularly hydronic systems, something Blatkewicz also enjoys.
“They’re just a nicer system to work on. Pulling it apart, doing a little troubleshooting to make you think a little bit, that’s always fun. Pretty much all our apartment building [customers] have hydronic heating, and there’s a lot of homes with hydronic heating, or a combination
Name: Dallas Blatkewicz
Nickname: D, Dally
Company: Bald Eagle Plumbing & Heating Ltd.
Job Title: Plumbing and HVAC/R technician
Born/Lives in: Drayton Valley, AB
Age: 34
of both a furnace and hydronic heating, especially newer homes in the region,” he says. “Our winters are fairly cold, so it is nice to have a second source of heat if something breaks down so you’re not completely stranded in the cold.”
Blatkewicz and the team at Bald Eagle are currently rebuilding a customer’s hydronic system around an older boiler which will eventually be replaced. “We’re redoing all the piping and the boiler loops and everything, we do that fairly frequently. We’re pretty much cutting out his old system, leaving the old boiler in there for now and then redesigning it as we’re putting the new high-efficiency system in.
“The way we’re doing it is helping extend the life of his current boiler as secondary heating. When he needs to change that boiler, it will be a lot easier for him and a lot less expensive. I’m a big proponent of if we’re allowed to take apart everything, like we’re doing with this customer, we can redesign the whole system and keep the older boiler a lot of times. There’s newer technology in hydronic systems, new ways of doing stuff. So doing the install, doing the piping layout, there’s so much that can make your boiler work so much better, even an older boiler.”
Blatkewicz says educating new customers about the system can sometimes be a challenge. “If somebody moves to a home with hydronic heating, they don’t always understand it’s a different type of heat, it’s a slower reacting heat. Another big thing would be service – it needs to be checked, it needs to be looked at. I try to educate them on having somebody come out and take a look at it every year, servicing their equipment and not just letting it run until it finally breaks. So, catch the small stuff before it turns into a big problem and you’re freezing in the middle of winter.”
In the mechanical industry since:
By Carolyn Cooper
Best advice you’ve ever received: KISS – Keep it simple stupid
Advice for young people considering entering the trades: Don’t be afraid to ask questions – jumping in and getting your hands dirty is the best way to learn
The current work ride: RAM 3500 ProMaster
Service area: Drayton Valley and the surrounding area
Any area you like to get dispatched to, and why: Elk River Road on nice days for the good views of the mountains
The most useful tool in your toolbox: Multimeter
Tool that you wish you had: Bluetooth refrigeration gauges
Favourite performer: Kevin Hart
Last book you read: The Empire’s Corps by Christopher Nuttall
Best concert you ever attended: Green Day
Favourite TV show: The Big Bang Theory
Favourite movie: Any old western
Favourite sport: Beer Darts
Favourite season: Summer
Schools and programs: Frank Maddock High School, 2009; NAIT for plumbing and gas fitting, 2015; and NAIT for refrigeration and air conditioning, currently completing fourth year
Favourite teacher: Mrs. Neigraf
Favourite class: Construction class in Grade 11 and 12
Fishing and hunting
Around a campfire
Favourite restaurant or local lunch hang out: Khal’s Steakhouse & Lounge
Chicken stir fry
Smarties
ast movie you saw: Godzilla vs. Kong
world you would like to visit:
CONFERENCE PREVIEW
Event brings together hydronic pros from across the country
TheREGISTER CANADIAN HYDRONICS CONFERENCE
CIPH Canadian Hydronics Conference is presented by the Canadian Hydronics Council (CHC), a council of the Canadian Institute of Plumbing & Heating (CIPH). This two-day trade show and conference will bring together industry experts, manufacturers, wholesalers and more for keynote presentations, a series of technical sessions/workshops (see page 50), and an exclusive group of hydronics exhibitors presenting the latest products in the hydronics industry.
CHC is holding the 2024 Canadian Hydronics Conference in Enoch, AB at the River Cree Casino & Resort on September 25 and 26. The theme for the event is “Igniting a sustainable future by thriving and growing in a changing market.”
The conference venue offers many amenities for attendees after a day of networking and learning.
In 2022, CHC announced that the Canadian Hydronics Conference would be an annual event, and that it would move across the country to various regions. The conference was launched in 2014 at CIPHEX West in Calgary, AB. The first expanded format of the Canadian Hydronics Conference took place in Ottawa, ON in 2019 and had more than 300 participants over two full days of educational sessions.
Online registration is open until September 11 at ciph.com/ events. One and two-day passes are available. Attendees may also register onsite.
ciph.com
September 25 & 26, 2024
Edmonton, Alberta
Educational Seminars & Trade Show
Theme:
Igniting a sustainable future by thriving and growing in a changing market.
SEPTEMBER 25 CONFERENCE HOURS 9:30 a.m. - 5:00 p.m.
TRADE SHOW HOURS 7:30 a.m. - 7:00 p.m.
SEPTEMBER 26 CONFERENCE HOURS
9:30 a.m. - 4:30 p.m.
TRADE SHOW HOURS 7:30 a.m. - 4:30 p.m.
River Cree Casino & Resort
CARING FOR WATER. WITH PASSION.
SCHEDULE
Wednesday, September 25
7:30 a.m. – 9:30 a.m. Breakfast/Trade Show
9:30 a.m. – 10:30 a.m. 5.8M units of housing needed by 2030 to avoid crisis
10:30 a.m. – 11:00 a.m. Break/Trade Show
11:00 a.m. – 12:00 p.m. Breakout Sessions
Newcomer Hydronics as a profession
Educational opportunities include breakout technical sessions, panel discussions and keynotes.
Experienced Selling hydronics versus air systems Speaker: Erin Deibert, Robinson Supply
Established Proper redundancy in commercial hydronic engineering Speaker: Thomas Heckbert, Rheem
12:00 p.m. – 1:00 p.m. Lunch/Trade Show
1:00 p.m. – 2:00 p.m.
2:00 p.m. – 2:30 p.m.
2:30 p.m. – 3:30 p.m.
3:30 p.m. – 4:00 p.m.
4:00 p.m. – 5:00 p.m.
Hydronics and how it fits into modular construction
Break/Trade Show
Breakout Sessions
Newcomer Outdoor reset; how it works and why it’s so critical Speaker: Thomas Heckbert, Rheem
Experienced Application of air-to-water heat pumps and buffer tanks Speaker: Michael Ridler, Eden Energy
Established Hydronic controls; options and why are they needed Speaker: Sean Giberson, Taco
Break/Trade Show
Panel discussion: Building energy efficiency and the track to net zero
Moderator: Jerry Leyte, Viessmann
5:00 p.m. – 7:00 p.m. Trade show and reception
Thursday, September 26
7:30 a.m. – 9:30 a.m. Breakfast/Trade Show
9:30 a.m. – 10:30 a.m. 5.8M units of housing needed by 2030 to avoid crisis
10:30 a.m. – 11:00 a.m.
11:00 a.m. – 12:00 p.m.
Break/Trade Show
Breakout Sessions
Incoming CHC chair Alan Zanidean of Axiom Industries (L) with past chair Jerry Leyte of Viessmann Manufacturing Company Inc.
Newcomer How does a hydraulic separator actually work? Speaker: Thomas Heckbert, Rheem
Experienced Inspection process/Enforcement Speakers: Sid Manning/Paul Chang, Alberta Municipal Affairs
Established Thermal storage and PCM batteries Speaker: Michael Ridler, Eden Enegy
12:00 p.m. – 1:00 p.m. Lunch/Trade Show
1:00 p.m. – 2:00 p.m.
Hydrogen as a replacement for natural gas Speakers: Spencer Burchett & Michael Leung, ATCO
2:00 p.m. – 3:00 p.m. Break/Trade Show
3:00 p.m. – 4:30 p.m. Panel discussion: What is the future of hydronics in Canada?
Moderator: Jerry Leyte, Viessmann
CANADIAN HYDRONICS CONFERENCE
September 25 & 26, 2024
To see coverage of the recent Canadian Institute of Plumbing & Heating Annual Business Conference visit mechanicalbusiness.com.
Edmonton, Alberta
& Trade Show
Theme:
Cintas
ENERGY EFFICIENCY
By Matthew Reid
Making the case for zoning
Whenwould it be advantageous to a homeowner to have one centralized system all controlled by one thermostat? After all, the occupied areas can and should be kept at a different temperature than the unoccupied areas in order to save energy. The reasons to support or design in a zoned type of system are incredibly easy to see and understand.
Consider a two-storey house. The main level will be the living room, kitchen, dining room, and a bathroom. The second storey will be all bedrooms. Let’s also say it’s winter and we are talking about heating. During the daytime, the main level (occupied) can be kept at a warmer temperature than the second storey bedrooms (unoccupied). The second storey can be allowed to cool slightly thus saving energy.
Now is as good of time as any to explain how temperature turndown/setback works and how it saves energy. For all those readers who say setback thermostats don’t work or end up costing more in energy to reheat the area after being set back, please keep reading.
DOING THE MATH
Let’s say we have a heat loss of 100,000 BTU/hr. Our design temperatures are going to be -20⁰F outdoor design temp (-29⁰C) and inside design temp is 70⁰F (21⁰C). Using the formula Q=AxUxΔT (Delta T), let’s break it down and then we can start filling in the numbers we know.
Q is the required quantity of BTUs to heat an area at design temperatures over the course of an hour.
office. He can be
house is unoccupied for most of the day, presenting an opportunity for energy savings through zoning.
ΔT (Delta T) the differential between the heated area versus the outdoors.
The Q = 100,000 (pulled out of thin air for easy math). The A for this scenario will be 22,222 sq. ft. of exterior wall. The first floor is identical to the second storey (again picked so the math would work) and the U will be an insulation value of 0.05 (R20). Delta T will be 70⁰F indoors versus -20⁰F outdoor so ΔT is 90.
Formula: 100,000 = 22,222 x .05 X 90
100,000 BTU/hr is the total heat loss, 22,222 is the total exterior envelope area, .05 is the U factor or insulation factor and ourΔT is 90. The thing to keep in mind is that this number is based around 60 minutes. We use 100,000 BTUs in one hour to keep this house at 70⁰F.
A is the surface area of exterior walls able to perform heat exchange when there is a temperature differential between indoors to outdoors.
U stands for the U factor. To calculate U, you must first know the R value of the insulation and then use the formula U=1/R. In some cases, such as windows, the U factor is given instead of R value.
What happens though if we create two zones; the main floor and the second floor. Let’s decrease the indoor temperature to 60⁰F in the second storey bedrooms but let’s only do it for one hour. We will have two calculations: second storey Q = 11,111 X .05 X 80 which equals 44,444 BTU/hr, and the main floor Q = 11,111 X .05 X 90 which is 50,000 BTU/hr for a grand total of 94,444. A saving of
Matthew Reid is an outside sales representative at Enviroair’s Richmond Hill, ON
5,556 BTUs worth of energy in an hour. The argument goes that you will lose the energy savings when you turn the temperature back up so let’s do that math and see if it’s true.
First, we have to turn the temperature back up. We are at 60⁰F and we want the temp at 70⁰F Delta T, therefore Delta T is 10⁰F. This is called the pickup load. Q = 11,111 X .05 X 10 or Q = ~5555 After that you must add back in the 50,000 BTU/hr to maintain that 70⁰F for the next hour making the total 55,555. We saved 5,556 BTU/hr by turning the thermostat back and used about the same to turn it back up. This is true, but what happens if we can set the temperature back for multiple hours?
Remember in this case we are zoning the unoccupied bedrooms of a house, which can be vacant for up to eight hours out of the day or more. Hopefully more to all the Nintendo diehards out there. It will always only cost you an additional 5,555 BTU/hr to bring this zone back up to temperature but you only need to do it once, so the longer you can leave it in setback, the more energy you can save. In one hour, we save 5,556 BTU/hr worth of energy. In two hours 11,112, over the course of a day or eight hours, we saved 44,448 BTU/hr worth of energy.
It’s only with quick temperature setbacks that the occupant may be losing or breaking even on energy consumption and even then, there were some variables that I didn’t include into the calculation to simplify the math. The long and the short of it is, your customer will save money and energy by turning down the temperature and the longer they can keep the number down for, the more energy they will save.
WHEN DO YOU WANT ZONING AND WHERE?
In theory, zone wherever the system will allow you to do so. The only issue would be if the system equipment can’t really handle zoning. For zoning to work properly, the heat output of the heat source (furnace or boiler) should be able to mimic, match or buffer the zone load.
If you have a 100,000 BTU/hr modulating furnace with a 10:1 turn down, the lowest possible BTU/hr output of this unit is 10,000 BTU/hr.
This would mean that without doing any serious duct alterations your smallest zone should be no smaller than 10,000 BTU/hr. Same for boilers. There are some work arounds for both systems either forced air or hydronics. For forced air you can put in a supply air bypass and for boilers you can put in a buffer tank. These act as workarounds to the minimum firing rate and help mitigate the possibility of short cycling or overheating.
There is no argument than can be made against the efficiency of a zoned system − it will save energy. Which leads to the question as to why doesn’t everyone do it? The easiest culprit is price of equipment to install. It does cost something to put in dampers and valves. Is it apathy towards comfort in some systems that keeps us from making zoned systems the norm? I don’t think so.
I think the reason we shy away from zoned systems is a misunderstanding on complexity of the zones themselves and its incorporation with the equipment. As stated above, the operating characteristics of the heat source may limit the ability to zone even though there are workarounds in nearly all cases. They are simply not well talked about, taught or understood by installing contractors.
When it comes to selling zoned systems, we know it saves energy and we know it can be done so why don’t building owners scream for zoned systems to be installed everywhere?
In the commercial world there is zoning on nearly every single job. The exception being warehouses and self-storage joints. We zone in nearly all custom residential. In fact, we zone nearly everywhere with the exception being residential construction and even then, we are seeing it more in some of the higher end new construction homes with hydronic hi-v air handlers becoming more common place. The issue seems to be with residential furnaces. That’s where we seem to fall off the scale and unfortunately the most common way of heating a home at this time in Canada is a forced air furnace.
Buffer tanks help mitigate the possibility of short cycling or overheating.
Photo Cory Pitman
JOBSITE JARGON WIN!
Match the terminology you hear in the field to the correct definition or function by August 30, 2024 and enter for your chance to win a Yeti cooler from NIBCO. This contest is open to Mechanical Business subscribers in Canada. Send your answers to kerry.turner@mechanicalbusiness.com or enter online at mechanicalbusiness.com.
JOBSITE JARGON
5) Hydronic I) Of or relating to a heating or cooling system that transfers energy by circulating fluid through a system of pipes Answer 5,I
A) Piping is sealed at all points from the atmosphere and contains non-potable solution
B) Increase in space temperature to occupied set-point after a period of shutdown or setback
C) Point at which the desired temperature (°C) of heated or cooled space is set
D) Regulate and maintain a constant flow to the coil or branch regardless of pressure fluctuation within the system
E) Difference in temperature between the outdoor mean temperature over a 24-hour period and a given base temperature
F) Throttling devices designed to regulate the fluid flow through hydronic components
G) Reducing the setpoint or increasing the setpoint during hours when a building is unoccupied or when lesser demand is acceptable
H) Regulate the flow of liquid by controlling the distance between a plug and seat in the valve body
I) Of or relating to a heating or cooling system that transfers energy by circulating fluid through a system of pipes
J) Heat-distribution loop or system of loops with a control means independent from control means of other distribution loops for automatically regulating heat output
Thank you for participating!
K) A measure of water heater overall efficiency
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