July/August 2010 by Mechanical Business

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F E A T U R E S 20PLUMBING Wet Vents Spell Savings Rainier Bratsch-Blundel

63TOOL TIP It’s all about the PEX

72OIL TANK CORROSION Five Keys to Safer Storage Systems Michael Freill

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31We return with another helping of Wet

Heat Applications & Technology, WHAT, Canada’s hydronics publication. Check WHAT it is all about in this issue of Mechanical Business.

80EVENT IN PICTURES

50COVER FEATURE

COHA Oilheat 2010

Jason Hawes & Grant Wilson: Plumbers by day; Ghost hunters by night Dave Bowden

88PLUMBING Lime Scale: The Energy Thief David A. George

82HVAC/R

Making the Most of Your Multimeter Carol Fey

P E R S O NA L I T I E S 18HVAC/R HE Furnace Venting: The full picture Gord Cooke

24REFRIGERATION Keeping your systems running trouble-free Phil Boudreau

28ASK ROGER It’s Five O’Clock Somewhere Roger Grochmal

38PIPING Serious about Series, and Pumped about Parallel Bob “Hot Rod” Rohr

66MARKETING Are you talking to your most important customer - your employee? Doug MacMillan

97WORLD VIEW Cloudy with a chance of windmills Jeff Patchell

74PVF REPORT

Instability in Resin Supply and Pricing Dave Bowden

P R O D U C T S 62,71Hydronics 78Plumbing 94HVAC/R 96Stuff you need

86REFRIGERATION

Keeping supermarket systems running smoothly Greg Swiercz

D E P A R T M E NT S 04From the editor’s desk 06News 15Letters 16Profile: Alain Lanthier 90The Info Page 93Calendar 98By the numbers

On the cover: Jason Hawes & Grant Wilson, a pair of plumbers with Roto-Rooter, use their mechanical knowledge to help sort out what really goes bump in the night. Catch their television show Ghost Hunters on OLN.

FROM Content Media Group Inc. 19 – 1525 Cornwall Road Oakville, ON L6J 0B2 CANADA Tel: 905.465.2919 Fax: 905.465.2913 www.mechanicalbusiness.com July/August 2010 Issue Published 6 times per year. Editor: Adam Freill, ext. 224 adam.freill@mechanicalbusiness.com U.S. Sales Manager: David Gerchen (314) 878-3939 david.gerchen@mechanicalbusiness.com Office Manager: Chris McKay, ext. 227 chris.mckay@mechanicalbusiness.com Controller: Liz Mills, ext. 221 liz.mills@mechanicalbusiness.com Art Direction: JJM Graphic Ltd. davem@jjmgraphic.com Circulation Manager: Shila Naik (905) 272-4175 shila.naik@mechanicalbusiness.com Publisher: Bruce Meacock, ext. 222 bruce.meacock@mechanicalbusiness.com PM:41536047 ISSN 1916-0674 MB (Print) ISSN 1906-0682 MB (Online)

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The past few months have been marked with a number of significant announcements that stand to affect the ability to attract and retain bright young people to the mechanical trades. In the west, the Mechanical Contractors Association of Saskatchewan has successfully lobbied to alter the journeyman-to-apprentice ratio in the province. In Ontario, eight individuals have been named to the Appointments Council of the Ontario College of Trades, a professional regulatory body with a structure similar to the colleges in place for teachers, doctors and nurses. Saskatchewan is not alone in adjusting its apprenticeship ratio. Several provinces have adjusted their ratios to either one-to-one or multiple apprentices per journeyman as the result of marketplace pressure to keep construction projects moving. While there may be concerns about Mechanical Business now has safety – for both employees and a training calendar. Visit customers – the need for spaces to www.mechanicalbusiness.com to see what courses are train the next generation of available in your area. journeymen is something that does have to be addressed. And while the noise coming from the HVAC/R and plumbing sectors is not as loud as that seen in the electrical trade, our sector is also faced with the prospect of turning good people away simply because companies are handcuffed by what can be, at times, a limiting ratio structure. The establishment of Ontario College of Trades should help address this issue as industry will now have a non-governmental structure within which to plead its case for a re-examination of the existing ratio formulas used in the province. With a growing need for certified staff, and a very real threat of a looming shortage of skilled tradespersons steps like these are going to be necessary to ensure that we are not turning away bright young minds simply because we have no place available to train them. Until next time,

Adam Freill, Editor

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Goodman goes mobile Goodman recently launched the SmartContractor mobile application, designed to provide HVAC service technicians with the ability to look up parts, product information and specifications on the go. Accessible by any mobile phone or computer capable of internet browsing, the program is designed to negate multiple trips to a distributor by providing information on Goodman and Amana products remotely. mobile.goodmanmfg.com goodmanmfg.com

Distributor earns Red Cross Order Kai Tao, president of Dragon Fire Distribution, was recently presented with the Order of the Red Cross by the international non-profit organization, in recognition of outstanding humanitarian service, dedication, and achievement. Kai was honoured for his work establishing a relationship between the Chinese Canadian community and the Canadian Red Cross Society. Among other causes, Kai has worked to help victims of mass floods, cyclones, earthquakes and tsunamis. edragonfire.com

OS&B updates website OS&B recently renovated its website, adding a news blog and searchable product catalogue, among other features. Completely redesigned, the new site also features downloadable product spec sheets, an FAQ section and industry links.

$70K raised for heroes The first annual Renos for Heroes golf tournament, held in June in Copetown, Ont., raised $70,000 for the charity, which helps renovate homes for disabled military personnel. The organization was founded by Jim Caruk in 2009 (see Mechanical Business, July/August 2009), host of HGTV's Real Renos and Handyman Superstar Challenge to help wounded Canadian soldiers make necessary changes to their homes while minimizing the expense and stress on them and their families. “Everyone recognizes the sacrifice that our soldiers are making overseas,” he explains, “and the Canadian military takes care of its wounded men and women with great compassion and significant resources. But there are specialized building skills and materials that the Canadian home improvement industry should be offering, from the grassroots level, to these veterans. That's what Renos for Heroes is all about.” Pictured at the tournament are Mechanical Business contributor Roger Grochmal of AtlasCare (left), Jim Caruk, and Al Caruk – Jim's cousin, and an employee at AtlasCare.

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HIP seeks eyes In an effort to get consumer media outlets engaged in the topic of indoor air quality, and as part of its Clean Air Day activities, the Healthy Indoors Partnership (HIP) delivered View Master slide viewers, pre-loaded with images of some of the dirty-air culprits that exist in indoor air, to numerous news editors across the country.

Students show their skills

“Healthy indoor air is a major concern for many Canadians, and the problem is getting worse, but it doesn’t get a lot of coverage,” explained Craig Jobber, an indoor air consultant, and the president of HIP. “This partnership is a collaboration of industry and government, with a focus on spreading the word. We thought a fun gimmick like the slide viewers would get the conversation started, and encourage homeowners to speak with contractors about indoor air quality.” healthyindoorspartnership.ca

Solar milestone hit Alberta’s Drake Landing solar community recently became the first thermal solar community in the world to have 80 per cent of its annual space heating requirements provided by solar thermal energy. The neighbourhood in Okotoks, Alta., features 52 single-detached homes that integrate solar collection with short-term energy storage, a thermal energy storage system, a district heating system and homes certified to R-2000. The community has a goal of having 90 per cent of its annual space heating requirements provided by solar thermal energy. dlsc.ca

AHR on record-setting pace Organizers of the AHR Expo expect the show’s 2011 edition to be one of the largest in its history. Scheduled for the Las Vegas Convention Center at the end of January, organizers report that more than 1,360 companies have already reserved over 300,000 square feet of exhibit space for the show’s inaugural Vegas bow.

Skills Canada recently held multiple HVAC/R and plumbing skills competitions across the country. In Waterloo, Ont., plumbing apprentices had 12 hours over two days to complete the “plumber’s SUV” challenge. Peter Coughlin of Durham College took home the gold, before going on to capture gold at the national challenge. Michael Layman of Humber College and Daniel Levin of George Brown College took home the Ontario silver and bronze medals, respectively. HVAC/R and plumbing contests for Atlantic provinces were held in conjunction with MEET 2010 in Moncton, N.B. Six students competed in the HVAC/R competition, with Nathan Hoar of Apprenticeship Moncton capturing gold, Jeremy Gould of NBCC St. Andrew’s taking silver and Matthew Harvey, also of Apprenticeship Moncton, receiving bronze. Eight students competed in the plumbing competition at MEET, which saw Apprenticeship Saint John’s Tyler Moffat take home gold, Aaron McCoy of Apprenticeship Fredericton (pictured) grab silver and Nick Driscoll of NBCC Saint John receive bronze. skillscanada.ca

2,000,000 kg As of June 15, 2010, Refrigerant Management Canada (RMC) had collected and safely destroyed more than 2 million kilograms of environmentally damaging refrigerant waste. Initially established in 2000 to destroy the surplus CFC inventory, RMC opened the program to HCFCs in January 2004.

The president of the International Exposition Company, which manages and produces the show, attributes the strong early numbers to an improved economy and a desire for innovation. “The recession has created pent-up demand for new equipment and energy-savings solutions,” says Clay Stevens. “We are expecting close to 50,000 HVAC/R professionals from over 120 countries to seek these solutions at the 2011 AHR Expo.”

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0U[YVK\JPUN V\Y ,ULYN` :[HY :[\KKLK 3PUL\W Mitsubishi Electric is shining bright for 2010 with the introduction of fourteen – yes, fourteen – new Energy Star certified units. You now have a world of options when it comes to specifying highly efficient heating and cooling systems for your clients. Also available for 2010 is a new, smaller-sized 6000 Btu/h indoor unit, extended heating operation range down to -25°C and a new, improved 6-year parts/10-year compressor extended warranty.

>L»YL [OPURPUN IS\L ILJH\ZL ^L ^HU[ `V\ [V [OPUR NYLLU Visit ^^^ ZTHY[/=(* JH for more information.

+<*;,+ +<*;3,:: :730; :@:;,4: ;/052 .9,,5 *When installed by an Authorized HVAC Installer.

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Viessmann garners innovation award CIPH recently presented Viessmann with an innovation award in recognition of the company’s intelligent combustion management system in its Vitodens 200 boiler. The Lambda Pro system electronically adjusts the Vitodens 200 boiler altitude, gas type and quality. viessmann.ca

Boating adventure targets cancer OS&B’s Brent Cornelissen was part of a four-man crew that embarked on an adventure around North America to help raise funds for cancer research. The group, All of Us, started their journey from the coast of Vancouver, and while the original plan was to travel through the Panama Canal, rough weather and the oil spill in the Gulf of Mexico forced them to adjust their path to complete the final leg of the trip from Jacksonville, Fla. to Oakville, Ont., as planned. The trip itself helped raise $25,000 for cancer research, and the charity is still accepting donations. For information on how to donate, or to find out more about the trip, visit www.allofus.ca. allofus.ca

Heading for the Hill

Re-Booted in Niagara Outgoing CIPH Ontario Region president Michael Kotyck, of Kotyck Bros., receives a gavel from incoming president Jon Leeson of Desco Plumbing and Heating Supply during CIPH Ontario’s Re-Boot Camp, held in Niagara Falls in May. More than 170 delegates, companions and guests attended the event, which focused on business management.

It didn’t take long for Helene Gagnon, winner of the new truck at this year’s CMX-CIPHEX show, to make good use of her wheels. The admin officer of Cardinal Contracting in Bourget, Ont., has taken her 2010 Nissan Titan to the street – in this case, Ottawa’s Wellington Street, directly in front of Parliament Hill. cmxciphexshow.com

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Enerworks receives government grant Southern Ontario’s Enerworks Inc. recently received a government investment worth nearly $2.5 million. Bestowed by the federal government as part of its economic action plan, the investment will be used to improve existing production facilities, new facilities, engineering solutions and other operational improvements. enerworks.com

See page 20

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People in the news www.mechanicalbusiness.com Maax Bath Inc. recently appointed MARK GOLD as the companyâ&#x20AC;&#x2122;s new president and CEO. Formerly the president and CEO of Western Forge, a manufacturer of transportation products, Gold brings 20 years of sales, marketing and management experience to the position.

Goodman Canada recently announced the appointments of two new sales managers.DAN LABELLE(Right) is commercial sales manager in Calgary. He brings more than 16 years of experience in commercial HVAC sales and management to the position, having worked in both western and eastern Canada. Meanwhile,CHRIS CHUDLEY(Right) is the new territory sales manager for Northern Ontario, Manitoba and Saskatchewan.

KEN TOMIHIRO recently became CIPHâ&#x20AC;&#x2122;s permanent program manager, after assuming the duties on an interim basis in February. Ken brings 25 years of management experience related to the business world and the nonprofit trade association environment to the position. He has previously worked with TSSA, CSA, and multiple Ontario Government ministries.

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ANTON WOLMARANS has been promoted to vice-president and general manager of the Heating, Ventilation and Air Conditioning Division of Mitsubishi Electric Sales Canada Inc. Wolmarans has more than 20 years of experience in the HVAC industry and joined Mitsubishi Electric Sales Canada Inc. in 2001. Independent plumbing and electrical distributor Bartle & Gibson recently appointed a pair of new directors of operations. REG WONG is now the director of operations for Northern Alberta. RICK MARCH is the director of operations for Southern Alberta. Between the two of them, they bring a combined 60-plus years of experience at the company to the positions.

B.A. Robinson recently made a number of personnel announcements. TIM KIST (pictured) has joined the company as director of sales and marketing. Working out of Winnipeg, he brings more than 19 years experience in senior sales and marketing to the position. Also in Winnipeg, MATT ROBINSON was appointed manager of business development, moving from the company’s Calgary office. KAREN CHERNESKY was recently hired as director of business operations, where she’ll handle supply chain management. And JASON KUSS will take over branch manager responsibilities in Surrey, B.C., after nine years as branch manager at the company’s Light and Bath Centre in Vancouver. G.F. Thompsonrecently added two new sales representatives to coincide with the opening of new warehouses in Western Canada. PATRICK MOIR will work as the company’s Alberta rep in Calgary while MIKE CUMMINGS will represent British Columbia.

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BRYAN MULLET was recently promoted to president of plumbing fixtures with Bradley Corporation. Mullett will focus on driving the company’s lean manufacturing, supply chain, and total quality management. His responsibilities will include overseeing the Canadian market. RON WRIGHT has joined Enertech Manufacturing as Canadian sales representative serving all of Canada. An active promoter of the geothermal market since the technology was first introduced to Canada in the early 1980s, he brings more than 35 years of HVAC experience to his new role. He will work from his office in the London, Ont., region. M e c h a n i c a l

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Movers and Shakers www.mechanicalbusiness.com

Watts acquires Blue Ridge Watts Water Technologies recently acquired Blue Ridge Atlantic Enterprises, a provider of engineered rain water harvesting solutions that operates in the commercial, industrial and residential markets. The addition of Blue Ridge will extend the products offered under the Watts Drainage platform and provide the company with a source of knowledge on national and local codes.

Noble acquires LGC Noble Trade recently acquired the assets and operations of Montreal-based LGC Plomberie Inc., a distributor of plumbing and heating products. The purchase continues Noble’s acquisitions in the Quebec market and follows on the heels of its recent acquisition of Plomberie Payette & Perrault. The company has also just undergone a rebranding, emerging as Noble. The company recently unveiled a new logo and website as part of the rebrand.

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Peerless Pump moves in with Grundfos

noble.ca

Peerless Pump recently relocated from its office in Burlington, Ont., into the Oakville, Ont., headquarters of Grundfos, its parent company. Chris Halton, general manager of Peerless Pump Canada, said the move is a first step in presenting the two entities as one company and increasing Peerless’ brand recognition in Canada. “The advantage of doing this is that we will be able to grow our business a lot quicker by utilizing distribution networks and selling our products through existing Grundfos channels,” he said. peerlesspump.com

HPSI acquires WarmRite assets Hydronic Panel Systems Inc. has purchased the assets and production equipment for the Ipex Warmrite lineup of hydronic manifolds. President Tibor Kovacs, a key engineer in the development of the WarmRite line while he was with Ipex says the line will be marketed across North America under the brand Hydronic Panel Systems. WarmRite production staff have joined HPSI and continue in their R&D and production roles. hydronicpanels.com

G.F. Thompson expands

New office, appointment for HPG

G.F. Thompson recently opened two new warehouses in British Columbia and Alberta. In addition, the company has hired a new sales rep to work in each province. (See People, page 12.) “This will ensure our high standards of service, ontime delivery and fill rates,” said national sales manager Grady Taylor. gfthompson.com

Hydronic Parts Group recently expanded into Ottawa with a new office, located at 2620 Lancaster Rd., units C&D. “It’s our fourth branch, following Toronto, London and Hamilton,” said advertising and marketing coordinator Christa Mader. “Ottawa is a good market and pretty untouched for us.” In addition to the new office, HPG was recently named representative for RBI Water Heaters Inc., becoming an RBI boiler and hydronic parts specialist. Contact info is Tel.: 877-633-0334. hydronicpartsgroup.com

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editor

Clearing up controls Dear Editor, Carol Fey’s article in the March/April edition titled “Clearing Up Controls” addressed simplifying the task of wiring up zone valves. However, a very important issue was overlooked, the fact that a large number of zone valves are low-voltage (24V) controls, which require separation from line voltage (120V). The powering of line voltage circulators directly through the end switch of a class 2 (24V) zone valve (and thereby avoiding the use of a relay) may indeed simplify a wiring task, but exposes the installer to a potential code violation. Though the end switch and motor wiring are indeed electrically isolated on most zone valves, Caleffi and other manufacturers do not advise taking this short cut. A primary reason is due to code requirements stating that the valve design would need “compartmental segregation” between line voltage wiring and class 2 wiring. A quick glance at any major brand valve in the market shows this cost prohibitive design is not incorporated. Another concern is the electrical characteristics of the class 2 zone valve end switches themselves. The end switches in Caleffi 24v zone valves for example, feature a patented reed switch design as is used in most new automobiles. The switch has been optimized for use with relays, especially in dirty environments. Directly switching a high voltage load from a switch of this type would not only violate code, but it would also void the warranty. Other manufacturers likely have additional reasons for specifying the use of relays. As such, you will see them recommend wiring through a relay. Respectfully, Mark Olson – General Manager Caleffi North America, Inc.

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A life in plastic Alain Lanthier recently retired from the industry, but his contributions have been significant. His story lives up to the line from the movie The Graduate, where a family friend of the main character, played by a young Dustin Hoffman, explains, “There's a great future in plastics.” We caught up with Alain at his home in Lorraine, Que., to discuss his career in the pipe industry.

Q A

How did you get started in the industry? In 1971, I worked at a private golf course, Green Valley, for my summer job and one of the members, Phil Ruvman, was president of Craig Plumbing, a division of Westburne Industrial Enterprises, and he approached me to join the company. I started off in the shipping department. That was my first job.

Q A

When did you join IPEX?

Q A

In January of 1978, I joined a company called Canron Plastics. Plastics back then were just starting to gather some momentum in the plumbing business. In 1992 the two largest plastic pipe manufacturers in Canada, Scepter Manufacturing and Canron Plastics, merged and became IPEX.

Q A

What do you enjoy most about the industry? It is all about people. The industry has had some wonderful and very talented people – and some characters. The relationships and solid friendships always enticed me.

Can you share a story from your years in the mechanical industry? Back in 1993, we introduced the IPEX name. We put together a meeting in Quebec City, at the Chateau Frontenac. There are three huge flags that float over the main entrance. We replaced the Union Jack with an IPEX flag. It was white with our colours. I think the hotel management definitely noticed, but they left it up there for three days nonetheless.

have to do one thing in life: treat people the way you want to be treated.”

Words of Advice “At the end of the day, it is a people business where solid relationships will never be out of style.”

Who have been some of your mentors over the years? Bill Hopkins was a very charismatic leader. Paul Graddon is a strong and efficient leader with exceptional business scope. And Jacques Robert had probably the most exceptional strategic mind that I ever came across. My number 1 mentor of all time though was my dad. It all started there. He had a very strong set of values, and at the top of those values was respect for others. He always told me, “You

BIO Name: Alain Lanthier Title: Senior vice-president of sales and marketing, IPEX (retired) Location: Montreal Age: 62 Born in: Lachute, Que. Currently resides in: Lorraine, Que. Family: Wife, Micheline, and three boys, Patrick (34), Francois (33) and Nicolas (29) Joined the industry: 1971

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FAST FACTS • Alain and his wife are subscribers to the Place des Arts for theatre. • Alain has had two hole-in-ones, both with the same club, a 6-iron. • Alain has a keen interest in Quebec-based artists. • Alain collects matchboxes – and estimates his collection to be a few thousand.

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*Water-efficient lavatory flow rates compared to ASME A112.18.1/CSA B125.1 industry standard of 2.2 gpm @ 60psi, 8.3 L/min @ 414 kPa.

HIGH PERFORMANCE HVAC

HIGH-EFFICIENCY

FURNACE VENTING:

B y Go r d C o o ke

THE FULL PICTURE I

was conducting an indoor air quality audit in an older modest duplex just a month or so ago. As I was reviewing the old natural draft furnace in the basement, the homeowner mentioned to me that she had just had a quote for a new midefficiency furnace from her HVAC contractor. The contractor had said now was a good time to buy because he had stockpiled a bunch of mid-efficiency furnaces before the 2010 regulation changed and he was soon to run out of them. Of course, the owner had asked about other high-efficiency options, but the contractor insisted that mid-efficiency was her best option for three reasons: • The existing furnace location was in the centre of the small finished basement on the common wall side to the attached dwelling, thus making it “impossible” to vent a high-efficiency furnace. • Installing a high-efficiency furnace would mean her gas water heater would be left to vent into the large, old WANTED: VENT SPACE chimney and therefore he would have to line the chimney At this customer’s home, the existing natural draft furnace and at an extra cost. water heater were jammed into a small room that included the clothes washer and dryer. According to the homeowner, the • He noted that she had a small home and therefore there furnace filter was almost impossible to access. On the day of my would be very little “payback” to installing a high-efficiency visit, there was a collection of clothes and boxes close enough furnace. The contractor was being respectful of what the to the furnace to make me nervous. homeowner described as a very limited, tight budget. You may well wonder why I felt compelled to write this article The basement was totally finished, including ceilings, so indeed, given that efficiency regulations have changed, so it is just a at first glance it would take some work and require opening up matter of time before everyone has to comply regardless of the ceiling to vent a high-efficiency furnace. circumstances. Of course, professional contractors will know that there would It turns out this particular case demonstrates well the have been a possibility of passing the sealed vents up the opportunities we sometimes miss by not looking at the bigger existing chimney, assuming something could be done with the picture of helping consumers make wise energy decisions. water heater (more on that in a minute).

One simple question to the homeowner was very revealing, however. “What are your plans for the basement?”

Talk yourself

She was hoping to make some modest changes to the basement so that she could create a small basement apartment and rent it out to her niece. However, she had noticed mould in the basement bathroom and that prompted her call for an indoor air quality investigation.

The trends and regulations towards continual improvement of energy efficiency require HVAC contractors to be more creative – not only in finding technical solutions to ever more complex installation requirements, but also in finding the best overall solution for clients.

The mould turned out to be relatively minor but in as much as it stemmed from a small intermittent leak from the bathroom above, it required removal of small sections of the ceiling in the bathroom and an adjoining closet. This left an obvious path to the back wall that was clear for venting.

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This case reinforces the value of asking more questions to uncover the real needs of clients. Since I wasn’t there specifically to address the furnace venting issue, I ended up asking a wider range of questions than a contractor might otherwise be inclined to ask. This proved to be very valuable in finding the best overall solution.

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• Wor k in t h e f i n a n c e s • B ackd r aft avo id an ce t ech n iq u es Gord Cooke is a professional engineer who has spent 20 years helping builders and HVAC contractors implement innovative technologies into high-performance homes. He has particular expertise in IAQ and air flow management in houses, and can be contacted at gcooke@airsolutions.ca.

BACKDRAFT AVOIDANCE TECHNIQUES

NEW PROBLEM;

NEW SOLUTIONS

WORKTHE FINANCES The homeowner had indicated a limited budget and, in fact, you may argue that the switch to new appliances, the ceiling modifications needed and the higher energy rates for an electric water heater increased her financial burden. However, she was able to gain space, create rental income and improve the air quality and safety for the basement apartment in her home. Not only that, but I am able to report after doing a quick energy simulation with HOT 2000 software, the savings associated with the incremental improvement from a mid-efficiency furnace to a high-efficiency furnace, including the switch to an electric water heater, in even this small, older duplex would be $230 per year in a Toronto climate. It would be $320 in a Calgary climate, and $410 in a Saskatoon climate. These savings applied to a loan payment amortized over five years at today’s interest rates empower her to finance an additional $1,000 to $1,800 at no additional monthly cost.

Certainly there are numerous options when faced with near-impossible venting restrictions. You could switch to all electric options, such as heat pumps or thermal storage units, or you could combine heating and hot water functions with an air handler and a highefficiency water heating option, such as a tankless or condensing tank-type water heater, or even a small wall-hung boiler. These newer technologies provide an up-to-date HVAC contractor with more tools to solve the issue of venting limitations.

It was of little surprise that a quick look at the existing chimney system in this home uncovered an obvious backdrafting concern. The B-vent chimney was water stained and rusted, and there were brownish scorch marks on top of the water heater by the draft hood. A natural draft appliance in an enclosed area with a clothes dryer is, of course, not a safe or healthy option. We needed to help this homeowner address this health and safety issue, regardless of cost. Two questions provided great insight to possible creative solutions. “Tell me about your household with respect to hot water needs?” and “What, if any, plans do you have for the laundry area and equipment?” The owner noted that since her own children had grown, it was just her and, with luck, her niece. The appliances were old, took up a lot of room and were far bigger than she really needed or wanted. She had already been looking at new smaller appliances. Options to consider: • Why not a well-insulated electric water heater? The hot water needs are small, the cost of a doubleinsulated water tank would be lower than a power-vented unit (and if she was renting the water heater the rental would be lower), and the chimney could be used for venting or could be decommissioned. • How about the new combined clothes washer and dryer units? These are condensing and require no venting. She gains space, the equipment operates more safely, and the old dryer vent becomes an opportunity for venting. In fact, both of these options were implemented. They were able to reorganize and create more space, turn the furnace for better access and provided an opportunity to insulate the room so as to reduce sound from the mechanical area.

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PLUMBING

b y R ain ier B r at sch - B lu n d el

VENTS SPELL SAVINGS When installing a rough-in within a building, there are methods aimed at saving material and labour costs. One such method for plumbing systems is wet venting. This form of venting uses a fixture’s soil or waste pipe to act as a vent pipe for fixtures connected downstream on the same branch or stack.

How a Wet Vent Works Waste water will cling to the side wall of piping, leaving the centre core of the wet vent open to maintain atmospheric pressure.

When defining the wet vented portion, what we are really looking at is the portion of the vent that starts at the most upstream fixture served by a continuous vent, ending at the most downstream fixture or symmetrically connected fixtures.

Sizing a wet vent The size of the wet vent is determined by how many fixture units discharge into the wet vented portion, in accordance with the limits shown in Table 1. The size is further determined by whether or not a water closet, or a maximum of two water closets, are being wet vented. It is important to note that the most downstream fixture or symmetrically connected fixtures are not included in sizing the wet vent.

The most common form of single-storey wet venting is a bathroom group where a water closet is wet vented by a bathtub and a basin. The two-inch wet vented portion (with a maximum of three fixture units, as per Table 1) extends from the downstream end at the connection of the water closet, and upstream through the bathtub connection to the sanitary T (also known as a TY) at the basin forming a continuous vent. All of the requirements from single-storey wet venting apply to multi-storey wet venting, but there are some differences that result from extending up a floor (or more). A wet vent may pass through more than one storey,

Table 1

Maximum Permitted Hydraulic Loads Drained to a Wet Vent Maximum Hydraulic Load, Fixture Units

Size of Wet Vent inches

continued on page 22

Not Serving Water Closets

1 1/2”2N/A 2”43 3”128 4”3614 5”N/A18 6”N/A23

See page 48

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Column 1Column 2Column 3

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Serving Not More Than Two Water Closets Fixtures Other Than Water Closets

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PLUMBING

continued from page 20

forming a soil or waste stack. In this case, a cleanout will be required at the base of the stack. Above the first storey, the total number of fixture units connected to the wet vent must not exceed four per storey. A multi-storey wet vent is permitted to have one nominally horizontal offset, but no connection is permitted in that offset. The maximum length of this offset can be 1.2 metres for a two-inch or smaller wet vent, and 2.5 metres for a three-inch or larger wet vent. When a multi-storey wet vent passes through more than four storeys, the stack vent must be sized to be the same size as the wet vent.

Wet Venting Restrictions The number of water closets cannot exceed two. When two are connected, a symmetrical fitting must be used. The water closet(s) must be installed downstream of all other fixtures. Trap arms and fixture drains connecting to the wet vent must not exceed two inches in size, except if a three-inch emergency floor drain is installed. The size of the continuous vent only includes the fixtures being vented by the wet vented portion. The size of the wet vented portion may not reduce in size (except for the installation of a three-inch emergency floor drain). he length of the wet vented portion is not limited, but must have a minimum slope of 1:50.

Adding on It is permissible to add onto a wet vent. A separately vented branch or fixture drain may connect to a wet vent or a wet vented water closet trap arm. For calculation purposes, the separately vented branch or fixture drainâ&#x20AC;&#x2122;s hydraulic load is included in the size of the wet vented portion, but is not included in sizing the continuous vent. Keep in mind, the separately vented branch could be a separate wet vent itself.

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WET VENTING RULES The size of a wet vent must conform to National Plumbing Code of Canada (NPC) Table 2.5.8.1., Ontario Building Code (OBC) Table 7.5.8.1., or British Columbia Building Code (BCBC) Table 7.5.8.1. These tables all contain the same instructions, and are summarized in Table 1 (See page 20). The table is divided into three columns. The first column gives the size of the wet vent. The second states the hydraulic load of a wet vent where the lowest connected fixture is served by a p-trap â&#x20AC;&#x201C; meaning that it is not a water closet. The third column states the allowable hydraulic load, in fixture units, when the lowest connected fixture is a water closet, or two symmetrically connected water closets.

Rainier Bratsch-Blundel is a plumbing professor and the plumbing and steamfitting programs coordinator for apprenticeship and skilled trades at George Brown College. He is also an executive committee member with the Ontario Plumbing Inspectors Association. He can be contacted at rblundel@georgebrown.ca, or visit OPIA online at www.opia.info.

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REFRIGERATION

B y P h il J. B o u d r eau

KEEPING YOUR SYSTEMS RUNNING TROUBLE-FREE U

nwanted liquid in suction lines and the compressor; concerns with the presence of too much oil, or not enough oil; particulate/ moisture/acids in the system - there are a plethora of things that can go wrong in a refrigeration system. Knowing the potential perils that exist can help with troubleshooting procedures on emergency calls. Better yet, it can be useful in ensuring that components are addressed properly and that problems do not develop down the road, or prematurely. This article continues on the topic of oil separation as it relates to the servicing of equipment.

Working with oil

Some manufacturers recommend the use of coalescing oil separators on low-temperature compound compressors due to their very high efficiency. While these separators are very efficient, system problems may be encountered if certain factors are overlooked.

In systems that contain an excessive amount of solid contamination, the screens and coalescing elements may become plugged. In extreme cases, it may become plugged to a point where a hole could be created as the compressor overcomes the restriction. If this happens, the oil separator will permit excessive amounts of oil to circulate throughout the system. This is especially important to keep this in mind when applying an oil separator to a system that has been converted to an alternative refrigerant/oil combination. The oil separator may have to be replaced when the pressure drop across it increases to a dangerous level. A blown element is likely present if the pressure drop across the oil separator is significantly less than what is considered normal for that particular system. The key is proper system clean up and maintenance. Modern POE lubricants do a thorough job of cleaning

LUBRICATION BREAK-DOWN Most refrigeration lubricants tend to break down and/or carbonize at temperatures above 300°F, or 150°C. The life expectancy of an oil separator depends largely on the cleanliness of the system, and on the ability of the system to operate at discharge temperatures that are not excessive.

up system interiors, and the oil is not only cleaning up older machinery. Even some new systems may contain an unacceptable level of solid contaminants – flux and cutting oils used during manufacturing may be present after the system has been assembled. Always specify good suction filters and liquid line filter/driers, especially on systems containing polyol ester lubricants. One equipment manufacturer I spoke with also recommended to do at least one oil change within a

continues on page 26 24

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REFRIGERATION

continued from page 24

Check your oil return lines

day or so after initial startup. This may be seen as a costly step, but it is something worth considering.

Most oil separators incorporate a float assembly which automatically returns oil as the level rises in the oil separator. A system operating under normal conditions will have an oil return line which is alternately hot and cool.

Some systems are more vulnerable than others to damage due to the presence of liquid refrigerant and/or oil. For example, direct suction compressors will tolerate very minute amounts of liquid refrigerant and oil at the suction inlet and must be protected accordingly. This includes two-stage compressors.

If the oil return line remains hot, the float valve may be stuck open, or the system may be overcharged with oil. When this occurs, the discharge temperature will also increase. Alternatively, an oil line that remains cool may indicate a blockage at the valve port that is restricting oil flow back to the compressor.

Periods of heavy loading and defrost will bring back large amounts of oil that may have accumulated as the load dropped off and/or excessive evaporator frost accumulated. Properly sized accumulators should be used on these systems with care taken not to oversize them. Remember that oil will eventually make it out to the system and all modes of operation must be considered during the system design process.

If the oil return line remains cold or frosts up after startup, liquid refrigerant is present. When liquid refrigerant is permitted to enter the crankcase lubricating difficulties will take place. Insulation or heat may help solve the problem. A check valve between the oil separator and condenser is a very effective method of controlling liquid migration during the off cycle. Make sure that all electricity is disconnected for this test.

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• C h e c k y o u r o i l r e t u r n lin es • S izin g o il sep ar at o r s

Sizing oil separators Oil separator sizing is a crucial part of the system design process. Oversized or undersized separators will result in an excessive amount of oil leaving the separator, along with other problems. It is not acceptable to simply size a separator based solely on discharge line size. As with the suction line, it is not uncommon to reduce or increase a size depending on line lengths and operating conditions. Manufacturers list capacities for their oil separators in nominal tons or discharge flow rate (dcfm). Nominal tonnage should be used as a guide only – and horsepower should never be used. Capacity listings for tonnage are based on very specific operating conditions and are not necessarily accurate enough for the particular system you are designing or servicing.

AFTER THE BURN

After a compressor burnout, the separator will have to be cleaned or replaced. Serviceable separator types may be cleaned and repaired while hermetic separators should always be replaced after a burnout to help eliminate future problems.

It is always best to determine the discharge cfm or the actual tonnage of the compressor at the specific conditions at which your compressor will be operating. Most oil separators can operate within a very wide range, which helps simplify the selection process. The amount that an oil separator may be undersized or oversized depends greatly on the type of separator used. When compressors are used in conjunction with capacity control methods such as slide valves, unloaders, multiple compressor cycling and variable frequency drives, always ensure that the oil separator will be effective during part- and full-load.

PHIL’S FIELD TIP If your dcfm or BTUH per ton capacity rating falls between two separators, the larger of the two is generally recommended. However, be sure that the oil separator will not be too large during operation at minimum load.

Phil Boudreau provides sales, training and technical support for Bitzer Canada Inc., and is the instructor of a refrigeration course at Humber College in Toronto. He can be contacted at pboudreau@bitzer.ca.

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with Roger Grochmal

It’s Five O’Clock Somewhere Okay, I’m jealous. A buddy of mine, who is also in the plumbing and heating game, just booked yet another vacation to the Bahamas. I don’t know where he gets the time. I’m working 60+ hours a week. What do I have to do to go from constant overtime to hitting a beach in the sun? Mike K., Oshawa, Ont.

Excuse #1

“I’m the only one who knows

This is a great question every contractor how to do it. No one else can needs to ask himself. We make all kinds of do what I do.” excuses for not taking time off to balance Everybody wants to be needed, including our lives. The ones who suffer most are our business owners, so we make ourselves indisfamilies. We make a lot of excuses to allow pensible. I once suggested to a contractor, us to rationalize our behavior, but it would that if she wanted be beneficial to to know how examine our excusmuch she’d be Excuse #2 es and come to missed after she “With computers, BlackBerrys grips with the facts was gone, she and cell phones, I am just as – it is the only way should put her to avoid repeating busy working when I am away the excuse cycle. hand in a bucket on vacation so I might as well The sidebars conof water, pull it not go.” tain three of the out and see how I am old enough to remember what it was more common big of a hole was like before electronics. Things still got done. excuses I hear, and left. I have all the toys and I use them to my my thoughts on We are not indisadvantage, but I have made the decision to them. pensible. Others be connected to the world on my own can do what we terms. I decide how often I take calls and In the end, we are do. It’s called not the centre of emails. Being real-time in the world is just the universe, and delegating and it not that important. our businesses takes training. I have also made it a habit to not call my should not revolve The result is well staff when they are on vacation unless it’s a around us. worth it. real emergency. I expect them to do the same for me. A while back I came across a great saying: “Dream as if you will live forever, live as if you will die tomorrow.” I got a practical lesson in this from my late, good friend Craig McCarty who sold his business and lived in the moment after he was diagnosed with cancer and given only a couple of years to live. He created a charitable foundation, accomplished so much and got the most out of every day he had

M e c h a n i c a l

Excuse #3

“I’m a perfectionist. I like to be in control and make all the decisions.” Because the buck stops with the owner, this is pretty common. It often comes down to what goals you have set for yourself. Most people I meet haven’t invested time defining their goals. They spend more time planning a one-week vacation than planning their lives. You will never escape your reality unless you make a plan to change and then execute it. This process will also spill over into how you design your business. Is it to provide maximum lifestyle, a job, maximum profitability, growth, community service or some combination of all of the above? This type of owner or manager tends to have big trust issues with their people. Chances are they know it, too.

because he knew how many he had left. Make the most of your time, don’t squander away your days. Empower your coworkers, live in the moment and you and your family will achieve all your goals - including that trip to the Bahamas.

? 28

“The E Myth” by Michael E. Gerber is a great book every contractor should read and refer to regularly.

B u s i n e s s

You need to have good people around you who can make decisions and free you up to work on your business instead of in it.

Roger Grochmal is the president of AtlasCare in Oakville, Ont. To submit a question about your company, business practices, or the industry in general, send an e-mail to Mechanical Business Magazine’s editor, Adam Freill, adam.freill@mechanicalbusiness.com. 0 8 . 1 0

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w h a t

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W H A T

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C O NT E NT S

F E A T U R E S 38PIPING Serious about Series, and Pumped about Parallel Bob “Hot Rod” Rohr

Making Gil Proud

40FIELD NOTES

36GUEST COLUMN

“Did you turn off the gas?” Mike Breault

Ken Webster

44HYDRODYNAMICS Resistance is Futile Rod Brandon

EXPANSION TANKS Expanding your hydronic horizons

48QUIZ

54EXPANSION TANKS

Test your Hydronics IQ David Hughes

Bob Barbour

56RADIATORS Sizing It Up Christopher Makarewicz

61WEB PROFILES 63TOOL TIP 66MARKETING Are you talking to your most important customer - your employee? Doug MacMillan

68HVAC/R HERITAGE MOMENT The Automatic Air Vent Gary Burger

50COVER STORY

Jason Hawes & Grant Wilson Dave Bowden

P R O D U C T S 62Hydronics

D E P A R T M E NT S 34Welcome 52Find the Fix 60Road Warrior: Donavon Giesbrecht

On the cover: Donavon Giesbrecht is a partner with Southern Comfort Mechanical in Winnipeg, a firm working on geothermal and other hydronic projects in the region. Photo: John Woods

Content Media Group Inc. 19 –1525 Cornwall Road Oakville, Ontario L6J 0B2 CANADA Tel: 905.465.2919 Fax: 905.465.2913 www.mechanicalbusiness.com Editor: Adam Freill, ext. 224 adam.freill@mechanicalbusiness.com US Sales Manager: David Gerchen (314) 878-3939 david.gerchen@mechanicalbusiness.com Office Manager: Chris McKay, ext. 227 chris.mckay@mechanicalbusiness.com Controller: Liz Mills, ext. 221 liz.mills@mechanicalbusiness.com Art Direction: JJM Graphic Ltd. davem@jjmgraphic.com

THE

EDITOR’S

Publisher: Bruce Meacock, ext. 222 bruce.meacock@mechanicalbusiness.com

Notice: Mechanical Business is published for owners, managers and decision makers with mechanical contracting firms and the sector's supply chain partners in Canada. While every effort is made to ensure the accuracy of the information, Mechanical Business, Content Media Group Inc., its staff, directors, officers and shareholders (‘The Publisher’) assume no liability, obligation or responsibility for advertised claims, for errors and/or omissions, or for the results obtained from the use of this information. Manufacturers’ instructions take precedence over published editorial. The publisher reserves the right to publish a printed correction in a subsequent issue for editorial errors, omissions and oversights.

Are your basics covered? While attending the Canadian Oil Heat Association’s annual symposium, Oilheat 2010, I could not help but be impressed with the amount of technology that continues to be pushed forward. For example, we are about to see a bit of movement in the condensing oil-fired boiler offerings in the North American marketplace. This technology is notoriously difficult to harness, since sulphur in oil turns condensate into sulphuric acid, and the dew point of 47°C (versus 60°C for gas) makes it more difficult to make the water vapour in the flue gas condense.

Add to that advances in radiator design, pump design, controls, and so forth and it can be easy to forget about some of the basics, like good piping practice, but overlooking the basics can be perilous in business, so while you scour this edition for the latest and greatest the world of hydronics offers, I also invite you to stop by Mike Breault’s article on page 40 to see if you are dotting your i’s and crossing your t’s, and to peruse the finer points of series and parallel piping schematics with our resident hydronics go-to guy, Hot Rod Rohr on page 38. And don’t forget to try your hand at our Find the Fix puzzle (page 52). Knowing your basics could land you a nice prize, or at least some bragging rights. Until next time,

Adam Freill, Editor

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W H A T

DESK

But those details have been figured out, and movement towards lower sulphur levels in fuel oil (including ultra-low sulphur fuel oil) is making this a viable option.

Circulation Manager: Shila Naik (905) 272-4175 shila.naik@mechanicalbusiness.com

PM:41536047 ISSN 1916-0674 MB (Print) ISSN 1906-0682 MB (Online)

FROM

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Making Gil Proud T

o be recognized by leaders in this industry with the CarlsonHolohan Industry Award of Excellence is very special. Hydronic heating is a great industry to work in. Keeping people warm and comfortable in a cold climate while also helping protect their environment is rewarding enough, but to be recognized for the time spent sharing knowledge and helping others when I have been able to, that is a true honour. Hydronic heating technology has excelled over the past few years with the introduction and refinement of condensing boilers, ECM pumps, digital controls, and renewable technologies like biomass, solar and heat pumps. Education and training of the industry is paramount to our future success, building on the foundation of a number of educators and mentors, like Gil Carlson. In Canada, progress has been made through a number of key initiatives from the Canadian Hydronics Council (CHC) with the support of Canadian Institute of Plumbing and Heating (CIPH). The CSA B 214 Installation Code for Hydronic Heating Systems is now an enforceable standard referenced in the 2010 National Building Code. And we are moving ahead with the Certified Hydronic Designer and Certified Hydronic Installer designations at colleges across Canada. The final frontier â&#x20AC;&#x201C; marketing hydronic heating to the public â&#x20AC;&#x201C; may become a reality for us by early next year. In 2004-2005, I had the privilege to co-chair the CIPH Habitat for Humanity Committee with Paul LaChance (Wolseley Canada). Case de Jong (Franke Kindred Canada Ltd.), who chaired several Habitat for Humanity campaigns for CIPH, recruited me to this committee in 2000. He told me then that this would be good for my heart, and he was right. Those who have participated in Habitat for Humanity build projects and home dedication ceremonies know what I mean.

Ken Webster is the director of sales and marketing for Viessmann Canada. Earlier this year, he was presented with the CarlsonHolohan Industry Award of Excellence, named for Gil Carlson and Dan Holohan and presented in recognition of contributions to the industry through education, mentoring and volunteerism.

WHAT

Supplement

It is a great time to be in this exciting industry. We are poised for growth, and we are surrounded by great people doing good things. Water is still the best heating medium. We have what everyone wants. And we have dedicated people who are willing to share what they know for the betterment of the industry. Gil Carlson would be proud!

08.10

Photo: David Chidley

My task was to raise donations from CHC members of CIPH, and to coordinate equipment and installers at build sites. I received positive support and am pleased to say we have hydronic heated Habitat homes in every province in Canada, and will outfit 12 hydronically heated homes every two years.

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Piping Serious about Series and

Pumped about Parallel

Without the pipe, it doesn’t matter how much heat is generated by the boilers, or how much a pump can pump, but when was the last time you stopped to consider the type of piping circuit you were putting together?

SOLAR DHW CONNECTIONS

Series piping can be used for connecting the multiple tanks used to store hot or chilled water. Series connections remain the most common way to connect a solar storage tank into an existing water heater. On low solar gain days, the solar tank may just act as a pre-heat tank. On some days it may just add a few degrees of temperature to the incoming water. On high solar gain days, however, with a properly sized array, it could supply 100 per cent of the DHW needs. And on “best condition” days it may supply temperatures of 140°F (60°C) or higher to the second tank. Under those conditions the second tank would not need to operate to provide DHW as it flows through from the solar tank piped up-stream in series. It is imperative that a listed thermostatic valve be installed at the outlet piping of the second tank. Most plumbing and mechanical codes require a listed thermostatic valve be installed. Be sure to check your local code to chose the proper valve with an appropriate listing.

Series, parallel, reverse return, home run, primary/secondary, are some of the choices. Which is the best method? Well that depends on your job design, control-ability, and desired end result. On some installations you might need or encounter a combination of methods, since each brings with it certain plusses and minuses. There is a place for each. The installer needs to consider the job, and the desired end result, to select the best method for the application

WHAT’S BEST FOR SOLAR? One question that keeps coming across my desk has to do with the best piping for solar thermal installations. Very often solar thermal installers have crossed over from the photovoltaic, roofing, or other related trades. Interestingly, all of the mentioned trades bring good techniques and products to the mix.

Bob “Hot Rod” Rohr has been a plumbing, radiant heat and solar contractor and installer for 30 years. A long-time RPA member and columnist, he is manager of training and education with Caleffi North America. You can reach Hot Rod at bob.rohr@caleffi.com.

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by Bob â&#x20AC;&#x2DC;Hot Rodâ&#x20AC;&#x2122; Rohr

DIVIDE AND CONQUER Parallel piping differs from series in that the flow is divided amongst two or more pathways. With two water heaters or boilers the goal is to pipe the heaters so they are both used equally. Remember with series piping, the first tank sees all of the incoming cold water, sediment and the majority of the heating load. This is not the case when they are piped in parallel.

Diagram 1

EXPLORING SERIES PIPING

The shortest distance between two fittings is the pipe, and series circuits use this to their advantage. This method is often used by hydronic installers to install fin tube baseboard convectors and panel radiators. The supply flow enters the first baseboard or radiator in the loop and flows through that emitter before moving onto the rest of the baseboards in the circuit.

When working with a parallel piping array, the pipe lengths and fittings should be as close as possible to the same since this helps maintain balanced flow in the system. Since you are essentially turning multiple tanks or boilers into a single unit, this will tend to equalize the life of each individual tank or heater.

When implementing series piping for baseboard, the installer needs to calculate the total length of the loop and size the emitters so the last emitter on the series loop can still transfer enough heat to the room. Fluid temperature drops as it gives up energy to the emitters it passes through, so the emitters at the end of the circuit may need to be increased in size to compensate for the temperature drop of the fluid as it transfers energy. Look for a series baseboard simulator in your system design software package. This is a very effective way to see the effect of series piping on fluid temperature, and on temperature delivery. For example, Iâ&#x20AC;&#x2122;m impressed with the knowledge and methods that experienced roofers bring to the game when it comes to mounting and sealing piping penetrations. And the PV experienced installers generally understand controls, grounding and wiring. Proper piping tends to be the main challenge. Hopefully this article, and our next in the series, will help you determine what will work best with your specific solar project

As the example in Diagram 1 shows, the software program I use has adjusted the baseboard length to accommodate the diminishing fluid supply temperature along the loop. Notice the delta T from the first baseboard to the temperature exiting the last radiator.

Watch for other piping options, including reverse return, primary/ secondary, and home run piping in future issues of Mechanical Business.

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It also ensures that you can use tanks whose outside dimensions will fit through doorways and down basement stairways. Installers may choose tanks with capacities below 120 gallons to avoid the more expensive listed, large capacity tanks. It might be worth checking your local code requirements when specing DHW tanks, since multiple tanks piped in parallel might save time and budget. Looking over the parallel piping schematic for the boiler installation in Diagram 2, you can see how it differs from series piping. Flow setters have been added to the installation to ensure that every emitter receives the correct flow rate.

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Service ABC’s

by Michael Breault

“DID YOU TURN OFF THE GAS?”

o goes the classic movie line as a young couple heads off on a vacation, complete with cheesy fake countryside in the background of the fake car. “Yes dear.” And the somewhere off in space, usually right after these words are uttered, an explosion rocks the scene. “Okay, so maybe I forgot,” the guy laments. Isn’t this the way it goes? We do things the same way, over and over, time and again. Often we begin discarding the things that take a little time but don’t appear to be worth worrying about. If it wasn’t done last time and no one noticed, those little things get us out the door faster and create an illusion of “I saved time, and time is money.” You think we know the routine, but we almost always overlook something, either in the quote, the installation, or the follow up. So, what are we forgetting?

PUSH THE SERVICE CONTRACT One of the biggest benefits to a longer-term, five or 10-year, service contract with one company (yours) is that you will have all documentation available to them if a manufacturer demands proof of service should a warranty claim be necessary. Two ways to help push this length of contract are to have them pre-pay (at today’s rates), saving annual price increases; and if you are working with an oilfired unit, perhaps the contract can be tied into fuel sales – “Buy our fuel for five years (or 10) and you will not have to put out a penny for anything for the next five or 10 years (other than the cost of the install, and fuel to run it).”

PRICE IT RIGHT Sales is where we start our relationship with potential customers. But going straight into a low price pitch is a long-term problem. The low price can indeed get you the work, but are you forgetting something? Yes. The future. Anyone can undercut the competition. Getting the job at a higher price is harder, but it is infinitely more desirable. Trunk slammers and unemployed tradesmen looking to make a buck can always be lower priced than you. While pricing a job and quoting it completely might make your quote higher, the trick is selling it. Say you are quoting a boiler install and have five ball valves listed on the quote for serviceability. The other guy has none. At 50 bucks a pop, you have to tell your customer that this is an investment. By installing all these “extra” valves you can replace any component in less time without having to drain the system. The other guy can’t do that, so your way will mean that future labour costs will be much lower. That extra $250 can save many times that in the future.

DON’T FORGET YOUR TOOLS Before we even start installing, we should verify we have all the equipment and tools needed. This seems pretty basic, but you would be amazed at how often this comes up. Not too long ago I had a tile guy at my place, and I had more tools than he did. It instills a feeling of professionalism to the customer if you are prepared, and quite the opposite if you are not. Other tips to put forth a professional image include: • Calling before your appointment to remind your customer of the appointment. • Installing drop cloths. This shows respect for the customer’s property. • No swearing or smoking. • Keeping your workspace clean. This can be particularly tough when removing an old oil-fired boiler filled with 30-year-old water, but plan before you start so that you have the means to deal with it.

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continued on page 42

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continued from page 40

APPLIANCE CHECKS Modern appliances are very different from those of yesteryear. Some basic checks should include: • Is the power supply polarity correct? Many new units are polarity sensitive. • Are all wiring connections tight? • Are all switches in the correct position for start up? • Any visible leaks? • Are all clamps tight?

CHECKLIST: A professional checklist can easily be done up on a word processor. It can be reviewed by the tech to make sure the installation is complete. It should be reviewed with the customer as well.

Michael Breault is the product manager for the Radiant and Hydronic Specialties Division of Watts Water Technologies (Canada) Inc. He can be reached at mbreault@wattscanada.ca.

• Are the panels in place? If these basic items are all set, check the system. Are valves opened or closed as required? Has the system been filled, purged and pressurized? Did you set the proper pressure in the expansion tank before installing it? Once the system is ready use the thermostat to initiate a call for heat. Do not use a jumper since we want to verify that the stat and associated wiring is okay. Many new appliances require combustion analysis to set up the burner properly. Verify and adjust the combustion to match the manufactures specs. If a combustion analysis is not required, you should at the very least verify that the manifold pressure is to spec to ensure proper firing rate. Once the appliance combustion is tuned in, then we can then start tuning the heating system. The combustion must be done first, otherwise it will throw off all other set up steps. Start at the appliance and work your way out. Verify the system’s delta T, and adjust if required. Check the system design spec. While 20°F was the norm, it is not unusual to see higher delta Ts of 30 or 40°F. It can be even higher in a mini-tube distribution system. And note, this applies to the main or primary loop. The secondary can have a different design delta T. Next is the distribution. The flow rate in the loops can be set and balanced. A well designed system will tell you gpm for each part of the system. Once the system is dialed in and running properly, clean up. Put all the tools out in the truck, remove materials and debris. Bring in a cleaner and a rag and wipe down the equipment. Sweep the floor where the installation was done. Even if the homeowner says they will do it. It shows respect and professionalism and that will impress them.

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AFTER THE JOB Someone should call your customer within five days to see if they are satisfied with the way the installation was done. If the system will not operate for a while (heating system install in June) call after the heating system starts to make sure it is operating properly. If you successfully sold a maintenance agreement, schedule it at this time, and book it for one of those times of the season when business is usually slow. If you can and they seem positive, ask for referrals, or better yet an endorsement. If the installation was particularly good, request permission to photograph the installation, and permission to use them as a reference. This is all ammunition in the sales gun for the next target. Don’t forget the next customer.

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Hydrodynamics

by Rod Brandon

IN THE PIPE

RESISTANCE IS FUTILE

n our first article of this series, titled Water, Water Everywhere… (See Mechanical Business, Jan./Feb. 2010), we learned that there is no more efficient medium for the distribution of thermal energy throughout an HVAC system, than simple water.

In a pipe or tube, the liquid in the centre is moving fastest, while the liquid touching the walls is almost stationary. The rate at which fluid flows through a tube increases proportionally to the pressure applied.

parts of the HVAC system, such as we do with balancing valves, and to shift the system resistance curve to a more energy efficient point on a pump performance curve, but alas, we are getting ahead of ourselves.

An increase in resistance decreases the flow rate of fluid through a pipe. This resistance depends on the diameter, length, and type of the pipe, whether flow is turbulent or laminar, and the viscosity of the fluid.

This article is all about the elements of an HVAC system that oppose water distribution, and which contribute to the total system resistance.

Fluid resistance decreases with an increase in pipe diameter, and increases with pipe length. If the length of the pipe is doubled, the resistance is doubled.

In many cases, system resistance is inevitable but undesirable. System resistance is what must be overcome, generally by throwing pump horsepower and energy dollars at it, so that we can get the required flow through the HVAC system.

Fittings Size (inches)

90 Tee

Ball (full port) Gate Globe Check

90°

45°

Side branch

Straight run

1.4 1.6

0.7 0.8

3.0 3.1

0.9 1

0.2 0.3

0.3 0.4

16 18

4.0 5.2

2.3

1.1

4.1

1.4

0.4

0.6

6.9

2.7

1.4

5.3

1.8

0.5

0.7

8.7

3.6

1.8

6.9

2.3

0.6

0.9

Dynamic head loss varies dependant on flowrate,

4.5

2.2

8.1

2.7

0.7

1.1

5.4

2.8

10.3

3.5

0.8

1.4

based on the quadratic equation H = R x F1.75, where:

2 3

6.5 8.5

3.3 4.1

12.3 15.3

4.1 5.1

0.9 1.0

1.7 2.0

70 87

21 26

5.0

7.2

1.2

2.4

116

In some cases, we can use resistance to our advantage to force flow to other

DYNAMIC HEAD LOSS

3/8

PIPE LENGTH EQUIVALENCE

H = head loss (ft) R = hydraulic resistance F = flowrate (US gpm)

Elbows

Valves (Wide Open)

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Calculating the equivalent pipe length allows a complex piping layout to be discussed in much simpler terms, making analysis of the pipe network much easier. By using a chart of equivalent pipe lengths for components, which will be based on the size and type of pipe being used, like the above chart, a theoretical head loss and discharge can be calculated that will estimate the head loss and discharge for the real pipe system.

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CALCULATING THE RESISTANCE There are various formulas for calculating total system resistance, but for general pump sizing, a common approach is to just consider the equivalent length of piping for the most disadvantaged circuit.

In this example, the most disadvantaged circuit is highlighted in red. For simplicity, we will assume the tube is all 3/4” type M, (risers and multi-branch feeders would typically be larger). For a design flowrate of 5 gpm, the equivalent length would be:

For the sample system shown in Diagram 1, the most disadvantaged circuit is shown in red. It has an equivalent length of piping of almost 200 feet. To make matters even simpler, some take the length of actual pipe in a circuit, and just multiply it by a factor of 1.5 to estimate the equivalent length, including all fittings and Diagram 1 devices. For the example in Diagram 1, this would have resulted in a length of 120 feet in estimated equivalent length and total head loss of 7.3 ft. However, as we see in this case, the resistance estimate would be almost 40 per cent too low. While it is necessary to be in the correct galaxy, attempting to calculate system resistance to high levels of precision is futile, as many resistance values used are averages, pipe lengths are typically estimates, and routings may deviate from plan.

Pipe = 15 + 20 + 3 + 18 + 4 + 15 + 5 = 80 ft 7 x tees (straight) = 7 x 1.4 ft = 9.8 ft 4 x 90 degree elbows = 4 x 4.1 ft = 16.4 ft 1 x 20 ft of fan coil (straightened) = 20 ft 1x full port ATC = 0.4 ft 3 x CBV (wide open) = 3 x 23 ft = 69 ft Total equivalent length = 195.6 ft. 3/4” Type M tube at 5 gpm US has a pressure drop of 0.061 ft / ft. Therefore, total head loss = 195.6 x 0.061 = 11.9 ft. Continued on page 46

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Hydrodynamics

continued from page 45

WHAT IS RESISTANCE? System resistance can be defined as the total resistance to fluid flow that the HVAC system presents to the pump(s), as created by fluid friction of the piping system, and the hydraulic resistance of fittings and devices such as heat exchangers, terminal units and even heat sources and chiller plants. For a closed loop circuit, as is common for HVAC systems (except cooling towers), we only have to concern ourselves with dynamic head loss, and not static head to be overcome. In more common vernacular, this is the lift required.

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Rod Brandon is a technical marketing specialist with S.A. Armstrong Limited, a global supplier of HVAC and fluid flow equipment and solutions for residential, commercial and industrial applications. He can be reached at rbrandon@armlink.com.

TURBULENT TROUBLE Restrictions and changes in pipe direction cause turbulence, which increases dynamic resistance as compared to laminar flow. For minimum system resistance and maximum energy efficiency, system distribution pipe runs should be kept as short and straight as possible. In contrast, thermal energy transfer tubes often have lots of bends to induce turbulent flow for maximum energy transfer to the occupied space.

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HVAC system resistance tends to increase over time, due to corrosion and build-up within system piping, fittings, terminal units, and other devices. For this reason, designers tend to over-estimate system resistance, as it is far easier to throttle a valve, trim an impeller, or turn down a variable frequency drive (VFD) than to add more pump later. Some extra care is usually exercised for larger systems, where the cost impact of over-estimating resistance becomes increasingly significant.

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Test Your Hydronics IQ The World Cup has just wrapped up, but fans of soccer are not the only ones looking to gain bragging rights (not to mention a fancy golden trophy). So, gather your co-workers together and test your mettle to see who’s got the golden touch with the latest Mechanical Business Hydronics IQ Quiz. No fair diving to the ground clutching your ankle if you whiff on an answer though. Pick yourself up, dust yourself off, and get onto the next question on the list. Top performer earns bragging rights. If that’s you, feel free to pick up a trophy on your way home tonight. The answers can be found on page 64.

CHALLENGE QUESTIONS

5. What method of joining is common to all types of PEX tubing? A. crimp rings B. compression C. expanding tool D. solvent cement 6. What is the correct definition of "net rating"? A. heat available at the boiler outlet B. heat available at the burner C. heat available at stack D. heat available at heat transmission units 7. What is the flow rate required to satisfy a heating load of 75,000 Btu with a ΔT of 15 degrees: A. 9 US gpm B. 10 US gpm C. 11 US gpm D. 12 US gpm

1. Which of the following represents the correct reference material that should be used when joining PEX tubing?

8.What is the pressure exerted by 15' of head of water. (1 psi = 2.31' of head)

A. plastics code B. tubing manufacturer’s specifications C. heating code D. plumbing code

A. 6.49 psi B. 12.69 psi C. 17.31 psi D. 34.65 psi

2. To conduct an accurate heat loss calculation for a building which of the following sources of information should the designer review?

9. The ventilation/flue effect can result in which one of the following dangerous conditions?

A. foundation and plan drawings B. elevation and section drawings C. specifications D. all of the above

A. over humidification B. exfiltration C. infiltration D. appliance back drafting

3. Which statement below relates to a boiler that has a yellow flame at the burner?

10. If grading pipes in a heating system, what is the recommended slope and in which direction?

A. primary air shutter needs to be opened more B. airborn contaminates are being drawn into the burner C. primary air shutter needs to be closed more D. gas line was not properly cleaned

A. 1/4 inch per foot down in the direction of flow B. 1 inch in 20 feet down in the direction of flow C. they should always be put in exactly level D. 1 inch in 20 feet up in the direction of flow

4. What is the change in temperature of the boiler water if the reset ratio is 1-1/2 and outdoor temperature dropped 212°F? A. 48°F B. 32°F C. 21.33°F D. 16°F

See page 88

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So, how did you do? 0 to 4 correct: Red Card! Hit the showers. 5 to 6 correct: Yellow Card – Warning, you may soon find yourself on the sidelines. 7 to 8 correct: It’s a shootout! So close. Great effort. 9 or more: GOOOAAAAAAAALLLLLLLLLLLLLL!

With thanks to Dave Hughes, chair of the Plumber and Gasfitter Programs at the Northern Alberta Institute of Technology. www.nait.ca

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Hunters or debunkers? Though Jason Hawes (left) and Grant Wilson both claim to have had experiences with the paranormal, they’re not exactly on a wild goose chase. “We actually had a different view about the paranormal and how it should be approached,” Wilson explains of their method. “We went in and tried to disprove the claims that the people had.” With a team that includes HVAC professionals and other technical and construction professionals, they set out to explain things that go bump – or flush – in the night. “Eighty per cent of what we come across, we can debunk, and a lot of times that’s due to our plumbing knowledge,” Wilson says. “Don’t forget the flapper valve that makes everybody think their uncle Fred who used to be a plumber is telling them that he’s there by flushing the toilet at 3 a.m.,” Hawes offers as an example. “Really, they’re going to bed at 11 and the flapper valve is leaking, so it’s likely that it takes that long before the toilet kicks back on.” Cases they can’t explain become more credible, Wilson says, because they withstand the expert scrutiny. “Our goal is to help people and find out the truth,” he says. “If you find something odd, it stands the test because you’ve already tried to disprove it.”

Cover Story

By Dave Bowden Jason Hawes and Grant Wilson are like thousands of other tradesmen. The two New England plumbers got into the field at the encouragement of family and friends, and ended up falling in love with the rewarding nature of the work. “My favourite thing about working in plumbing is that every day is something different,” Hawes says. “The harder you work, the smarter you work, the more you make. You’re really out there making a difference,” adds Wilson. Of course, Jason Hawes and Grant Wilson are also very different from most tradesmen. After about a decade in plumbing, the two now spend most of their time traipsing the continent in search of the otherworldly. As the stars of Ghost Hunters, Hawes and Wilson ply their trade by trying to disprove reported paranormal activity. (See sidebar above: Hunters or debunkers?)

M e c h a n i c a l

B u s i n e s s

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Ghost hunting gear Tools in the TAPS arsenal include: • Tape recorder and digital video camera • Infrared camera with DV recorder • Digital thermometer • EMF detector • Ion generator • White noise generator

Getting Ghostly Airing in 171 countries around the world, including on OLN here in Canada, Ghost Hunters has become somewhat of a phenomenon itself since it launched in 2004. It recently aired its 100th episode, and has already spawned two spin-offs, Ghost Hunters International and Ghost Hunters Academy. So, how did two plumbers from New England become the world’s most famous ghost hunters? By having their own close encounters. And a modem. “We both had our own personal experiences (with the paranormal) that we just always kept private,” Hawes explains. Though the two friends have never divulged the nature of their “experiences” to the public, it was enough to prompt them to found Rhode Island Paranormal, which became The Atlantic Paranormal Society (TAPS) in 1990. From there, TAPS established a website and found a home within a budding community of internet users and paranormal enthusiasts. “TAPS really excelled on the internet,” Hawes says. “Before the show, we got 30,000 hits per day. Since the show, last year alone we did 96 million hits.”

FROM TAPS TO TV STARS The success of TAPS caught the eye of TV producers, who started pitching Hawes and Wilson on the idea of turning their company into a television series. After turning down initial offers, the pair negotiated a deal that would allow them to launch the show on their own terms. “We told them, if you want to spend millions of dollars making a TV show and you want us to catch ghosts, then we’ll leave right now,” Wilson recalls. “But if you want to spend millions of dollars and you don’t care if we catch a ghost or not, then let’s do it.” Of course, television can be a fickle business. There was no guarantee the show would be successful, and the guys weren’t about to quit their day jobs. “When the show started, for the longest time we were working our normal work week for Roto Rooter and we were also doing the show,” Hawes explains. “We were literally working somewhere in the vicinity of 100 to 120 hours per week.” Once the show took off, the pair was able to transition into ghost hunting full time. But with six seasons and more than 100 episodes under their belts, they still find the time to ply their trade in a more traditional manner. “When production (on the show) slows down, it goes back to the norm where we can go help out on jobs and check on things and price out things for people,” Hawes says. Despite their success, neither Hawes nor Wilson has let the whirlwind of the past few years go to their heads. At the end of the day, they’re still tradesmen who take pride in their work.

OPERATING IN OTHER WORLDS As if hunting ghosts, hosting TV and radio shows and squeezing in the occasional plumbing job weren’t enough, Hawes and Wilson have ventured into the literary world as well. They’ve written two books, “Ghost Hunting” and “Seeking Spirits,” which both placed on the New York Times’ bestsellers list. Their next venture? A series of youngadult novels to be released this fall, titled “Ghost Hunt,” which they’re working on with the wife of famed children’s author R.L. Stine.

This Month’s Quiz: THE PROBLEM INSTALLATION

1 1/4” Boiler Fitting

It all seemed so simple. A new house, equipped with a boiler plus a hot water air handler with air conditioning, and DHW supplied from the tankless coil inside the boiler. The boiler was rated at 140,000 BTUH, and the manufacturer said the tankless coil would deliver five gallons per minute. The heat loss was 86,567 BTUH, so the 93,000 BTUH air handler was a perfect fit. The boiler fittings were 1-1/4”, and the air handler fittings were 3/4”. It was simple, just run 3/4” piping to and from the air handler, and run 1/2” cold water supply and 1/2” hot water supply for the DHW. The system didn’t deliver enough heat, nor did it deliver five gallons per minute of hot water. Sometimes, simple isn’t the answer. What For more puzzles from our archives, happened? visit us on the web, (Hint: Do the www.mechanicalbusiness.com. math.)

93,000 btu Air Handler 140,000 btu High Mass boiler c/w Tankless DHW Coil

Answer and win! ARE YOU A CUT ABOVE IN THE HYDRONICS GAME?

Get your fix online

Send us your solution to this month’s puzzle by August 27 and you could find yourself with something to keep you on the cutting edge – An M12 Cordless PVC Shear for cutting PVC, CPVC and PEX, courtesy of Milwaukee Electric Tool.

What’s Better About tekmarNet® House Controls? • Supply water temperatures are calculated using a combination of indoor & outdoor temperature readings. This saves more energy than traditional outdoor reset when the sun or occupant activities add heat to the building. • They work with thermostat models 527 to 530 that provide a backlit, dual temperature display, two-conductor wiring & simple, up/down adjustment. • Zone start times are synchronized to reduce boiler short cycling.

Occupied (Comfort) Unoccupied (Economy) Away (Best Economy & DHW Suspend)

Saving Energy is Easy With a User Switch 479! With the touch of one button, all zones in a tekmarNet ® system can switch between Occupied, Unoccupied & Away temperature settings. While homeowners are away, DHW operation is suspended to save even more. 400, 401, 402

527, 528, 530

479

tekmar Control Systems Ltd. 5100 Silver Star Road, Vernon, BC, Canada, V1B 3K4 Tel. 250-545-7749 www.tekmarcontrols.com

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The May/June Quiz: THE PROBLEM: This recent job was installed in a large service bay with approximately 11,000 sq. ft. of in-floor heating. The system was working and delivering heat to the area, however, boiler software caused numerous lockouts. Once the boiler was reprogrammed, other issues appeared. If Zone 1 called, the boiler would short cycle, so an anti-short cycle device was added. When Zone 2 called, all four secondary circulators would fire, and the temperature to each manifold was different. The last manifold in the line would see temperatures almost 30°F lower than the first. So, what caused the short cycling? What was the supply temperature at each circuit if the supply started at 115°F?

THE FIX:

Congratulations to Ivan Tochev of Eli-T Design & Prototyping Ltd. in Vancouver, B.C., our May/June winner. He’s the proud new owner of a Milwaukee Laser TEMP-GUN M12 Cordless Thermometer. Be sure to pick up the next edition of Mechanical Business to see who claims the next prize, and for the next edition of Find the Fix!

Even when it works, that does not mean the system is correct. Zone 1 was so small that even on the lowest firing rate (80,000 BTUH) the boiler water would come to temperature and shut off. When Zone 2 called, the temperature in each secondary loop would drop as the load was shed into the floor. Here is the math [{Fa x Ta} + {Fb x Tb}] = {Fc x Tc} Assume a 20°F delta T at each manifold. Using this, when Zone 2 came on, the temperature going into the second manifold would be about 105°F. To see the cumulative effect, continue the math to the last manifold. The room was large (11,000 sq. ft.) so it was hard to notice the temperature difference throughout. The simplified drawing shows an easy way to correct and deliver the same temperature water to all manifolds. There is no way to correct Zone 1 completely, since it is so small, but you could use a relay and bring on another manifold on the coldest side just to keep the boiler firing on the minimum rate. A short fat header is a great way to simplify installation material and labour. A small change in piping can make a great difference on system efficiency.

2”- 3” dia. Vertical Header With Close Coupled S/R T’s

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EXPANSION TANKS Expanding your hydronic horizons

still encounter an old steel expansion tank from time to time, often suspended above an ancient boiler and topped by 30 or 40 years of dust. The expansion tank was simply a vessel, larger than the pipe it was connected to on each side. Many of those heat plants, and the early expansion tanks that kept them company, have found their way to the recycling pile.

NO DRAIN PLEASE

New technology has changed these systems dramatically. Elastomeric diaphragms within the tank now – by design – separate the water and (pressurized) air. One side is connected to the pipe work of the heating system filled with system fluid; the other side contains pressurized air to provide a prescribed level of resistance.

Temperature versus density Thermal expansion of water in a closed system can create a number of annoying and potentially dangerous problems. These include the build-up of unusually high pressure in a system (even when a pressure reducing valve is installed); pressure surges; and the chronic or continuous dripping of temperature and pressure relief valves. The threat of more serious problems can arise due to thermal expansion. When dangerous pressures build within a water heater, such internal parts as the internal flues, fittings or water connections may fail. If a flue way collapses it can lead to the potential release of toxic gases, such as carbon monoxide into living spaces.

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Through the years, one thing has remained the same: when heated water (or glycol solution) expands within a closed-loop system, it needs a place to go. And for this reason, modern expansion tanks remain on guard as reliable risk managers.

Perhaps 80 per cent of expansion tank problems stem from the installation of a drain at the base of an expansion tank. Diaphragm or bladder-style tanks often have a drain plug, though it’s not recommended that a drain be attached in the field. Too often, these drain assemblies are unable to contain the pre-charged air which needs to remain in the tank. Even a very gradual leak will cause a loss of pre-charge which can result in system over-pressurization and bladed/diaphragm problems.

WATCH THE PARTIALS The ratio of bladder/diaphragm volume within a partial acceptance tank varies between manufacturers. The typical range is between 30 to 60 per cent of total tank volume. So, a 100gallon partial acceptance expansion tank may, in actuality, permit a storage volume of only 30 to 60 gallons. A fullacceptance tank (with bladder size equal to the internal tank volume), on the other hand, permits storage volumes much closer to the tank’s actual size.

DON’T MAX OUT

Size it UP! Expansion tank sizing is based on the total system volume, minimum and maximum allowable system pressures and the minimum and maximum design temperatures at which the system is expected to operate. Often multiple tanks can be used to increase a system’s capacity.

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It is not recommended to use the maximum system pressure when sizing or selecting expansion tanks. Design engineers should select expansion tanks using a maximum system pressure of no more than 90 per cent of the system’s relief valve setting. The main reason for this: relief valves may begin to weep. As pressures rise to within 10 per cent of the relief pressure setting, weeping can cause loss of system fluids.

by Bob Barbour

Water line Water fills upper half of expansion tank Internal rubber diaphragm at middle seam

Air fills lower half of expansion tank

A BALANCED APPROACH TO SAFETY

Re-charging a DIAPHRAGM-STYLEexpansion tank If a diaphragm expansion tank has excess water and inadequate air, there’s a remedy, assuming the membrane, diaphragm or bladder is intact.

Expansion tanks are designed to absorb the increased volume of water created by thermal expansion and to maintain a balanced pressure throughout the closed-loop hydronic system. They’re also used to prevent boiler damage and unnecessary relief valve discharge caused by excessive pressure from thermal expansion.

Diaphragm-type expansion tanks are easy to maintain. In fact most incorporate an air charging valve at the tank’s base. The diaphragm tank has a diaphragm separating the upper half from the lower half of the tank to contain system-expanded hot water in the upper half and pressurized air in the lower half.

An expansion tank must be installed on the suction side of the circulating pump typically found on the discharge side of the boiler and properly charged with air to prevent water in the system from boiling.

Expansion tank Q&A Q

Should I connect a drain to the bottom of my captive air (CA) expansion tank?

Without provision for expansion, heated water would burst a joint or weak point in the piping, valves, or fittings. Modern expansion tanks incorporate a rubber bladder that separates the air and water. We know that air must be kept from entering the water: air within a pump can shut it down, and air within the system may lead to corrosion or noise issues.

No. Doing so could cause an air leak at each pipe joint, packing gland, ball seat or valve seal. Unlike the old, plain-steel type tanks, the CA tank doesn't need to be drained. How do I check the air charge pressure in a captive air expansion tank? Q Isolate the tank from the system and break the connection to it so that A any fluid inside is allowed to escape. The true air charge can't be determined until all the fluid is removed. What is the correct air charge pressure for my captive air expansion tank? Q The air charge pressure should be equal to the system fill pressure or the pressure relief valve setting A if the tank is at the same elevation as the PRV. If the tank is located at any other elevation in the system, the charge pressure in the tank should be the cold pressure of the system at that elevation. How do I determine the pressure needed for the air side of the tank? Q The correct pressure is dictated by the minimum fill or operating system pressure. The only water A that should enter or exit the tank is the result of thermal expansion or contraction of system fluids. The tank pre-charge pressure should equal the minimum system operating pressure, giving you system equilibrium. Why do I need an expansion tank in my chilled water system? Q A chilled water system is filled with water at a temperature between 50ºF and 60ºF. When the A chiller is turned on, the temperature of the water drops to 45ºF. When the water contracts, the

As water temperature increases, expanded water is received by the tank. As the water and pressure reaches its maximum, the diaphragm flexes, compressing the air cushion (air being compressible) to allow for increased water expansion.

system pressure drops, and the fill valve allows more water to enter the system to maintain the system pressure. If the chiller shuts down and the water in the system warms up to room temperature, the rise in temperature from 45ºF to ambient will cause the water in the system to expand. Without an expansion tank, the relief-valve would blow. W HAT

Bob Barbour is the business development manager, heat transfer division, at Taco, and can be reached at bobbar@taco-hvac.com.

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Radiators

by Christopher Makarewicz

IDENTIFYING THE RIGHT RADIATOR FOR THE JOB Using the right size radiator is critical to any project. Go too small, you risk installing an under-performing system that leaves building occupants cold. Too large and you will easily overshoot temperature set points, reduce comfort and increase energy consumption. From building age to the number of doors and windows in a room, there are numerous variables that affect the load requirement for any radiator installation. Today’s buildings are built better and are engineered to significantly reduce the amount of heat loss which greatly affects the type and operation of heating systems installed. UltiToday’s radiators can work on low mately, sizing up a radiator may not be as water temperatures easy as it used to be. down to 110°F.

TIP

In order to appropriately size a radiator, highly complex calculations are required since the system design depends upon many variables. The best calculations take every measurement of every room, especially window size and outside wall sizes, number of windows, doors and construction materials used. HVAC designers can design to specific temperature requirements and incorporate these materials to calculate “U” values to get an accurate radiator size. Some contractors select radiators certified for performance output qualified by the Institute of Boiler and Radiator Manufacturers or more stringent regulations, such as Europe’s EN442. These standards define procedures for determining the standard thermal output of the heating radiators and convectors fed with water or steam at temperatures below 248°F. This certifies the performance in the literature is equivalent to actual output performance. In addition, this will also ensure guidelines from ASHRAE are easily met. In the past, buildings typically used a cast iron boiler to generate heat. Designed to do

continued on page 58

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Sizing considerations: 1) What yearly climate design conditions is the building subject to? 2) What is the building’s spatial orientation? How does this affect glazed surfaces? 3) Is it possible to use solar loads to your advantage? 4) What volume is the space? 5) What internal loads are in the space (appliances, electronics, lighting, people, etc.) or located in adjacent spaces? 6) What is the purpose of the space, and how often will it be occupied? 7) How many exterior windows/doors are there, and what materials are these made from? 8) What type of radiator will you be using? Is it a one-pipe or two-pipe system? Is it a traditional panel radiator or a baseboard?

Simple. Smart. Now e! Availabl Murelle HE

The Intelligent Combi - DHW on demand & central heating in one unit - Condensing design with up to 97% efﬁciency - Sophisticated pre-mix system - World-class stainless steel heat exchangers - Built-in circulator, expansion tank and air eliminator - Intelligent pcp board is "Solar Ready"

SIME.

Tomorrow’s Choice... Today One of Europe’s most established and trusted names in the boiler business is now in North America. Sime, the 8th largest boiler manufacturer in the world (yes, the world), is now available across Canada. Sime boilers and systems are built to the exacting standards of European craftsmanship and are foremost designed with efficiency and the environment in mind. When you install Sime, you install confidence. Every one of Sime’s extensive range of intelligent boilers leaves the factory fire-tested, component checked and ready to meet even the most stringent environmental regulations. For more information on our complete line, contact us or visit us M

online at: www.simenorthamerica.com

E IN ITA L

Murelle HE is a versatile and eco-friendly boiler. It’s also very smart. Every Murelle HE features a built-in interface that dedicates one eight-button keyboard to intuitive end-user input, and a second four-button keypad to system operating parameters. The latter also features a PC data acquisition port thast ensures speedy diagnostics for servicing technicians. Add in a range of intelligent remote controllers, and the Murelle HE redeﬁnes customer satisfaction

Control Panel ®

Service Keypad & Data Port

NORTH

AMERI CA

North American Distribution by:

Intuitive End-User Keypad

S U P P L Y L T D .

101 Sharer Road, Woodbridge, Ontario L4L 8Z3 Tel: (905) 265-1527 Fax: (905) 265-9739 www.thermalhydronics.com

D I S T R I B U TO R O P P O R T U N I T I E S AVA I L A B L E !

continued from page 56

one thing, provide hot water, efficiency wasn’t a concern. However, in an increasingly energyconscience society, low-temperature heating solutions are key to project success where heat can be generated by low-temperature condensing boilers, geothermal systems or solar.

It pays to know the building, application and occupancy habits. Once you consider these specific requirements of the building, you can assess the radiator size. Ultimately, the size of the radiator will be the success of a sustainable design, providing the proper level of heat at an economical price, while adapting to ambient changes to keep occupants comfortable under any condition.

FREE HEATING SOURCES

Christopher Makarewicz, Dipl.T, B. Eng, is an engineering advisor for Jaga Climate Systems, a manufacturer of radiator systems. For more information about radiators, visit www.jaga-canada.com.

ENERGY-EFFICIENT RAD OPTIONS In our energy conscious society, the most efficient systems will be a result of in-suite or in-room products that accommodate energy-efficient system designs. Products designed to operate and perform with low-flow rates and low temperature fluids will enable engineers to minimize system components (pipes, pumps, insulation, etc.), while promoting the use of other energy-efficient products (condensing boilers, geothermal, vacuum tube solar collectors, etc.) will result in a total energy-efficient system.

PROPER PLACEMENT: WHERE THE RAD GOES Where should a radiator be placed? Exterior walls and below window openings are ideal locations for radiator placement. Today’s modern designs and creatively engineered products can often be blended into a rooms décor without being noticed. In-floor canals are easily placed beneath large windows or sliding doors. Wall products can be hung to appear as cabinetry or fashioned in exotic materials (wood, stone) to become architectural staples. Ideally, every room with external walls will have a radiator mounted within it. This promotes zoned heating controls, enabling unoccupied rooms to maintain lower set points. In zoned systems, setbacks will promote additional energy saving in rooms not used. Even a washroom with spectacular views and external walls could benefit from radiators fashioned for practicality as towel warmers.

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The key to this is two-fold: 1. Select a radiator with low thermal inertia. 2. Select a radiator that can perform with low entering fluid temperatures. Low-inertia radiators minimize the thermal loading time before the radiator begins to heat the space. This results in rapid comfort while minimizing energy consumed by the boiler.

DESIGN NOTES: In a retrofit scenario, changing to a condensing boiler without changing to a low-temperature radiator will not achieve full energy savings.

Low-temperature radiators promote maximum efficiencies in condensing boilers or enable an alternate source of heat such as geothermal or solar to be used. A product that promotes these characteristics will ensure the maximum potential of all system components is achieved. Pipes and pumps will be minimized, and insulation will be reduced to a minimum. Boilers will operate at their highest efficiency levels, while pumps will ramp down to low operating levels. Additionally, a product with these characteristics will deliver superior comfort levels when ambient temperatures fluctuate. It will begin to heat the space much sooner and dissipate its heat very rapidly once set point is met. This enables boilers and pumps to ramp down to lower set points. A two-pipe system is also a good solution. These systems enable accurate fluid temperatures through all radiators, can simplify system balancing, and promote rapid and uniform heating techniques.

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h For every 5 boilers you buy, we’ll give you our top-quality stainless steel S40 Trin & Stor Tank

With unmatched quality and ultra efficiency, NTI’s Trin & Stor sets the new standard for indirect water heaters and storage tanks. The Trin & Stor line comes in stainless steel and stone-lined options, with 13 models to choose from. It’s the perfect tank solution for every situation. NTI will provide one free Trin & Stor S40 tank to the installing contractor for every 5 boilers they purchase from July 1st-Dec. 31, 2010. *Some terms and conditions apply.

The Future in Heating Technology and Home Comfort

www.nythermal.com

ROAD WARRIOR

by Dave Bowden Favourite thing about your job: “Getting in contact with people. I really enjoy pleasing people with quality workmanship.” And what brought you to the plumbing and heating trade? “I started working for my uncle as a way to pay for university. But as I started working here, I loved the people and really enjoyed the work.” Time behind the wheel per day: 2 to 3 hours Makes and model of service vehicle: ’98 Savana

Photo: John Woods

Kilometres logged per day: 100 to 200 Favourite place to get dispatched to: “A little town near Niverville called New Bothwell. Bothwell Cheese comes from there. Anytime I get to drive through there I buy some cheese – my wife really likes it when I do that.”

Latest job site: “A 52unit life-lease project, Mapleton Lane, in Selkirk, Man., which has a geothermal system with a ground loop.”

Last book read: Rule Number One by Phil Town. Biggest pet peeves: “Slow drivers really get to me. I know you shouldn’t speed, but...”

Favourite movie: The Game Favourite magazine: “I don’t read a whole lot of magazines, but I do read Mechanical Business for all the technical input.” Place to hang out: “Tony Roma’s for wings with my buddies.” Drive-thru restaurant: “I don’t do drive-thru. Subway’s the closest I would get.” Local haunt for lunch: “The Empress of China. Anytime there’s a special occasion, my wife and I order in from there.”

Place on wish list to visit: “Egypt to see the pyramids.” Farthest place travelled to: Costa Rica The real you: “Most people wouldn’t know I’m a bit of a nerd when it comes to science stuff. Sometimes I’ll Google stupid science stuff and learn about the stars and stuff like that.” If you could meet anyone, alive or dead, who would it be? “I would definitely go back in time to meet the guy who invented the standard screwdriver – and just beg him not to.” Favourite tool in your toolbox: “Magnetic nut driver. Almost every unit I open needs a 5/16” nut driver.” My rule of thumb is... “Do it right, do it once.”

Name: Donavon Giesbrecht Company: Partner, Southern Comfort Mechanical Trade school: Red River College Resides in: Winnipeg, Man. Age: 27 Family: Wife, Ashley Pets: Standard schnauzer, Maggie Service Area: Primarily Winnipeg and surrounding area

Favourite car: Audi R8 60

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WEB Reviews

Bell & Gossett website

ITT’s Bell & Gossett website offers a wealth of helpful information for HVAC and plumbing professionals. Installers and specifiers can easily access detailed information on Bell & Gossett pumps, circulators, valves, hydronic specialties, heat transfer and packaged systems. This comprehensive resource centre includes specification bulletins, installation and maintenance manuals, parts lists, training manuals, videos and tutorials on many aspects of hydronic system design and installation. Plus interactive features such as online product selection and system sizing programs, as well as BIM content files in Revit.

www.bellgossett.com

Geothermal Contractor Software

GeoComfort’s website features tools to help you design a system, and make the sale. Version 1.2 of GeoComfort’s proprietary GeoAnalyst® software offers built-in consumer friendly sales proposal modules that allow dealers to customize each presentation with their company logo and information. Advanced dealer-only options offer advice on complete system design, including pressure drop, pump-sizing and more. Completing the package, GeoComfort now also offers exclusive Canadian payment plans with TD Financing Services.

www.geocomfort.com

Complete Contractor Support

Contractors who regularly visit the Camus website know exactly what they can expect to find. Everything. Every product in the Camus portfolio is cleanly and clearly presented. Detailed technical specifications for every boiler are provided and complete Engineering Submittal Sheets are available for easy download. Information on the company’s Camus Certified program, links to participating Green Programs, FAQ’s and an easy-to-use rep finder round out this user-friendly website. Be sure to visit today.

www.camus-hydronics.com

The Hydronic Pro’s Geothermal Choice

Hydron Module’s website offers contractors a complete resource for all their geothermal projects. In addition to comprehensive consumer information, dealers have exclusive use of the industry’s leading geo-design software – GeoAnalyst® – that allows contractors more time to focus on the job at hand, and less time on administration. Comprehensive sales support materials, including a custom proposal generating module, complete this contractor-friendly website. Be sure to ask about Hydron Module’s recently introduced Canadian payment plans through TD Financing.

www.hydronmodule.com

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Zoning system Uponor’s Climate Control zoning system consists of a radiocontrolled base unit, an interface module and wireless thermostats. Designed to connect up to 12 wireless thermostats, the unit can also accommodate and control up to 14 thermal actuators. Wireless thermostats offer battery status indication and run on two standard AAA batteries.

uponor.ca

Circulator The Alpha from Grundfos Pumps is an energy‐optimized, 115‐volt circulator featuring a permanent magnet motor designed to minimize power consumption. The pump can modulate its performance to match system demand. It features a flow range of 0 to 21 GPM and a head range from 0 to 19 ft. It can handle fluid temperatures from 2ºC to 110 ºC with a maximum working pressure of 150 psi.

grundfos.ca

The Kerr GreenFlame wood pellet-fired boiler has a water volume of 84 litres (22 gallons) and outputs up to 100,000 BTUH. It has storage system capacities ranging from 400 to 1,000 pounds, and has a five-inch chimney vent and a four-inch pellet vent.

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The Bisque Hot Spring radiator from Runtal is available in two models, ranging in height from 26” to 73”. At 82°C (180°F), the 26” model outputs 1,975 BTUH while the 73” model outputs 6,681. Both models come with a pair of chrome angle shut-off valves and have a maximum working pressure of 100 psi.

runtalnorthamerica.com

Wood-fired pellet boiler

Radiator

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Zone control panel Recirculating zone control panels from Hydronic Panel Systems Inc. are available in three sizes, ranging from 30” to 42” in length, with five- to 11-loops. They are designed to provide circulation in the floor piping system and maintain the average space temperature.

hydronicpanels.com

TOOL TIPS

It’s all about the PEX H High efficiency gas boiler The Trinity Lx gas boiler from NTI features a touchscreen display, and a 316litre stainless steel heat exchanger. Ranging in size from 142,000 to 383,000 BTUH, it offers efficiencies up to 97 per cent AFUE and is available in floor and wall-mount configurations.

nythermal.com

ydronic heating contractors have to make pipe connections in many different applications, under a variety of conditions, so the ease of use, reliability, and availability of professional ergonomic tools is eminently important. They should look for tools and fitting systems that make their lives easier by making PEX connections quickly, easily, and reliably. PEX is very tough yet flexible, but as with any type of pipe, there are some attributes that should be considered when working with it. PEX generally has a bend radius of eight times its outside diameter. Often it arrives on a jobsite in a large 300-foot coil. The use of a coil unroller may help avoid kinks in the tube.

Working with MLC pipe Multi-layer composite pipes, like PEX-Al-PEX, required higher cutting forces due to the aluminum layer, and can be difficult to cut with a plastic shear. Often these are cut with metallic tubing cutters.

While connection systems are not universal, all PEX connections demand a straight clean cut for proper fitting application. The tubing should not be crimped, kinked or misshapen by the cut. When cutting PEX larger than 1” in OD, many contractors will use a ratcheting device. More recent options include a battery-powered cutting tool designed to cut all dimensions of PEX.

Differential pressure controller Designed to ensure the correct pressure is delivered to the coil and circuit balancing valve, the TA Series 793/794 differential pressure controller from Victaulic is capable of stabilizing differential pressure ranges of 1.5 to 8.7 psi, 2.9 to 11.6 psi and 5.8 to 23.3 psi, depending on the controller series, size and spring option.

victaulic.com

Sponsored by Milwaukee Electric Tool – a proud partner with Mechanical Business. Look for video tips, tools and reviews at www.milwaukeetool.com. Be sure to visit mechanicalbusiness.com for your chance to win valuable Milwaukee products and merchandise!

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The solar pumping station from Taco features a variable-speed circulator designed to continually optimize the flow through the collector. The unit has a maximum flow rate of 12 litres per minute, a maximum working temperature of 120ºC (250ºF), and pressure relief setting of 87 psi. The 25-lb. unit measures 12.1” wide, 17” high and 6.6” deep.

taco-hvac.com

Hydronic radiator

Pump controller

The Aplano Plus radiator from Jaga’s Iguana line has an output range between 1,221 and 13,432 BTUH with 18.3°C (65°F) entering air. Designed for use in either residential or commercial buildings, it is available in lengths ranging from 12” to 33.5” and heights from 71” to 94.5”. A towel rack, hat rack and two sizes of shelves are available for mounting to the radiator.

The Bell & Gossett Technologic 502 from ITT allows control of up to four parallel pumps. The pump controller has four analogue inputs for a combination of zone, flow and suction sensors. It uses customized algorithms to handle various pumping applications, including secondary, tertiary, hot water, chilled water and pressure boosting.

jaga-canada.com

bellgossett.com

Hydraulic separator Designed to combine dirt removal and hydraulic separation, the Hydrocal hydraulic separator from Caleffi is available in two- to six-inch sizes. With a maximum operating pressure of 150 psi, flow rates range from 140 litres (37 gallons) per minute to 1,400 litres (376 gallons) per minute. Operating temperatures range from 0ºC (32ºF) to 120ºC (250ºF).

caleffi.us

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Answers from page 48 1b, 2d, 3a, 4c, 5b, 6d, 7b, 8a, 9d, 10d

Solar pumping station

Commercial boilers Ultra Commercial Boilers from Weil-McLain are up to 94.7% efficient and come in two model sizes, 550,000 and 750,000 BTUH. The boilers feature direct vent or direct exhaust options, with 20 to 100 per cent modulation, 11 pre-set applications, fully integrated multiple boiler control and real text LCD display.

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PEX-to-wire tool Hydronic controls

The Malco PEX-to-wire tool and clip system is designed for securing a PEX tubing infloor radiant heating layout to a wire grid. It features a 25-clip capacity magazine with 12-gauge (2.5 mm) steel clips, and is designed for use with all brands of PEX tubing from 3/8” (10 mm) to 3/4” (19 mm) diameters.

The Optima series of hydronic controls from Triangle Tube is engineered to work with the company’s Prestige boilers. The boiler controls are designed to connect and control up to 16 boilers with full modulation, outdoor reset and lead stage rotation. The series features four boiler controls and four valve and pump controls.

malcoproducts.com

triangletube.com

Electronic pressure independent valve Belimo’s ePIV two-way valve ranges in size from 2-1/2” to six inches and is designed to measure flow by combining a magnetic flow meter and a two-way control valve. The actuator features an algorithm that modulates the control valve to maintain the flow setpoint set by the controller.

belimo.us

Save time and save money. That’s what HPSI hydronic manifolds do. We take the guess work and manifold fabrication time out of every job, leaving you time to get the system up and running smoothly ... and on to the next project. Every CSA-certified HPSI panel is predesigned, pre-assembled and fully tested to meet your specifications. Whether you choose one of our many standard-engineered stations, or a custom design, our panel systems give you professional looking results and no manifoldrelated call-backs to worry about.

Talk to us before your next project, and be sure to visit us online. HPSI – Hydronic Panel Systems Inc. 12A – 50 Paxman Rd. Toronto, ON M9C 1B7 Tel: (416) 845-2587 Fax: (416) 622-5127

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by Doug MacMillan

Recently, a technician was at my home to take care of my spring HVAC tune-up. It was perhaps a week after the Feds unceremoniously yanked the ecoEnergy program, and the subject made for great small talk with the service chap. Except he wasn’t quite sure what I was talking about. He knew of the program - kinda - but didn’t know a lot of the details. Now, I realize his job isn’t to memorize the specifics of the myriad rebates and grants that are floating around right now. I’d much rather that he know everything there is to know about how my furnace and air conditioner work. But I was surprised he wasn’t a little better informed about a topic generating a lot of talk in the HVAC circles, and occasionally in basements with customers. A simple, inexpensive communications program from employers can ensure everybody in the organization has a basic understanding about what’s going on in the industry, in the business, and with the customers.

Internal communication is a good thing Any business of any size should communicate with its employees regularly. The return on investment looks something like this: • Employees at all levels of the organization are informed about important news and issues affecting the industry and the customers, and can participate in informed conversations with customers. • Management can build awareness and confidence amongst staff of its business decisions and goals, leading to a stronger base of support and understanding of where the company is heading, why, and what staff can do to take it there. • Sales promotions, ad campaigns, and new websites are tested with an internal audience to work out the kinks and enhance the chance for success. • People know what their coworkers and peers are up to or perhaps dealing with. People make better decisions and tend to get along a little better when they see a bigger picture. • People are featured regularly in the company’s success stories as told in various communications. As a result, they feel valued and appreciated.

Doug MacMillan is president of MacMillan Marketing Group in Guelph, Ont. To reach him, e-mail dmac@macmillanmarketing.com.

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A LOW COST MORALE BOOSTER In my company, over the past few years we’ve introduced a few specific employee communication activities that have made an amazing difference. We’ve seen improved morale, significant reductions in “politics” or bickering, and a boost in ideas and suggestions on how to improve the business. The costs? Practically zilch, if you don’t count the occasional lunch we’ll spring for.

Doug’s “Hardly Cost Anything” internal communications tactics 1)

E-newsletter – Send it weekly or biweekly, with updates from management, spotlights on what’s new or coming soon, and a few fun things like home-spun recipes.

Video – One of our clients, a reasonably small company, actually has an employee-run TV network. It’s all done online, using YouTube.

Staff meetings – Yes, obvious. But these tend to focus on micro-stuff like scheduling and vacations. Once a month, update staff on how the company is doing.

Peer recognition awards – Set up an online nominating system using Survey Monkey (cost: next to zilch) so employees can nominate one another.

Mailed letters – One company I know mails a two- or three-page letter to employees and their families. It talks about how the company is doing, and specifically acknowledges that employee’s contribution.

Team-building events – Toss the stale holiday dinner out. Shake it up with some fun and active team-building events. These let people break out of the box and connect at a different level.

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The LG ArtCool™ products allow owners to customize the look and feel of the unit in their home. From the ArtCool Pic model that allows custom artwork or photos or the ArtCool Mirror with its changeable panels and incredibly modern design. LG offers many design options for the most discerning home owner.

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AN HVACR HERITAGE CENTRE MOMENT

b y Gar y B u r ger

THE AUTOMATIC AIR VENT One of the first domestic air vents was patented in 1930 by Ervin Mueller. It was a finely crafted winged tee handle manual valve that would not look gaudy on any home radiator. In 1935, John Miller received a patent for a float operated, radiator air vent. His automatic air vent replaced the top pipe plug of a cast iron sectional radiator. William Woolley received patent #2106512 in 1938. It looked like a big horizontal sausage shaped device mounted on the end of the radiator. He would later develop a vertical design vent, much like what we use today.

Quietly on guard for thee Air in a heating system manifests itself as a heat transfer problem that prevents circulation. In early systems, air had to be frequently removed manually. Like proverbial beach sand, that pesky air continually builds and gets into everything, hence the importance and emergence of the automatic air vent.

In 1940, Alexander Rose received patent #2224929 for a comprehensive air vent and water make up system that used several components installed in various locations throughout the system. Today, these units are considered standard hydronic system components.

In 1943, Edward Zelnis developed a hygroscopic air vent in which the flow rate was adjustable. This was a revolution in design. As long as water was in contact with the hygroscopic washer, it would swell shut. Once air accumulated, the washer dried, shrank and vented air. Waterâ&#x20AC;&#x2122;s presence again made it swell closed. It also incorporated a ball check to prevent water flow if misadjusted. In 1950 Ramon Jimenez received a patent for a vertical air vent that had no float but used a piston instead. In March 1953, Woolley received a patent improving his air vent. The patent included Maid-O Mist as an assignee in June 1953, Woolley received patent #2642078 for a hygroscopic air vent which reduced the size of radiator air vents to about the same size as Muellerâ&#x20AC;&#x2122;s manual valve. Warren Ferguson took a step further with patent #2655170 in 1953, a combination manual and hygroscopic air vent. One could manually release a large quantity of air at the twist of a key. Small quantities of air would be automatically expelled by the hygroscopic section. Henry Persha received a patent in 1953 for a large high capacity air vent that looked more like a steam trap. In 1974, patent #3796227 was issued to Katsuji Fugiwara of Japan for an air vent that discharged when the weight of the ball float tilted a synthetic rubber valve plug off its seat. It was economical to produce and needed very little precision to manufacture. This little device is rarely thought about, but its importance to hydronic efficiency is unquestionable.

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Dating as far back as 1913, patent #1075780, held by Earl Gibbons, shows one of the earliest air vents. It was quite large and intricate with lots of finely machined parts suited more for the large equipment of its day. Gary Burger is the vice-president of HVACR Heritage Centre Canada, and is the retired chief engineer of Stevenson Memorial Hospital in Alliston, Ont. He can be reached at burgergary@hotmail.com. The HVACR Heritage Centre Canada is a small group of HVACR professionals working to keep the history of the trade alive with its private collection of artifacts and by documenting old systems that are still out there. Visit them online at hvacrheritagecentre.ca

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Water-to-Air Applications

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Water-to-Water Applications

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Simply Controls At Uponor, we believe that our controls offerings provide the most innovative solutions in the industry. This commitment is reinforced by the people who represent our product. People like Mike Miller, a controls expert who shares his extensive knowledge and experience with our customers. It’s that commitment to customers and innovation that helps to ensure we deliver results that exceed your expectations. That’s because at Uponor we offer Simply More.

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Air separator

Zone valves White-Rodgers’ Z-series line of zone valves is designed for two-way straight through positioning and features a onepiece, solid brass body with a raised ball seat and stainless steel return spring. It also sports a plastic cover to protect against moisture and a rotating ball valve for even wear of ball surface.

white-rodgers.com

Designed to require no minimum inlet/outlet piping length for proper operation, the AS-MB micro-bubble air separator from Watts features forged brass body construction in flanged, 3/4”, 1" and 1-1/4” FPT sizes. It also has polyphenylsulfone coalescing media operating temperatures up to 116°C (240° F).

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Wall-mounted condensing boiler With a rated input ranging from 31,000 to 370,000 BTUH, the Vitodens 200 WB2B gas-fired wall mount condensing boiler from Viessmann has an efficiency rating of 96 per cent AFUE. It features the company’s Lambda Pro combustion management system, designed to automatically adjust for gas type and quality.

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Mixing valve kit The AMX300 mixing valve kit from Honeywell includes a mixing valve with a 3/4” mixed water outlet and hot water inlet, and 1/2” alternate hot water outlet and optional recirculation inlet. It also includes a cold water tee with 3/4” inlet and outlet, and stainless steel flex connectors in 8” or 11” sizes.

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Boiler control system Lochinvar’s Smart System boiler control system comes standard on its Knight residential and commercial boilers, as well as the Armor commercial water heater. The control features a built-in cascading sequencer designed to allow up to eight boilers or water heaters to be installed and accessed through a computer via a standard USB cable.

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OIL TANK CORROSION

B y M ich ael Fr eill

FIVE KEYS TO A SAFER STORAGE SYSTEM The industry must move forward with changes in order to protect homeowners, technicians, fuel supply companies and the environment. The following five-point program will help the industry reduce the risk posed by leaking storage tanks.

1 INSTALL TANKS INDOORS Storage tanks that are located outside are the number one problem for the industry. Tanks located outside will collect condensation, in some cases daily, which leads to MIC corrosion. Prior to 1992, oil storage tanks were required to be inside based on the CAN/ULC S602 standard. Back then, we had fewer incidents with tanks failing from corrosion. Keeping the water out was a key component to this success. The new CAN B139 code requires new outside tanks to be either non-metallic or have a double bottom with interstitial monitoring.

2 EQUIP OUTSIDE TANKS WITH TOP OUTLETS ONLY

Due to line breakage, freeze-ups and vandalism some U.S. states have banned the use of bottom or end outlets on tanks located outside. All outlets must come off the top. If the tank cannot be located in the house, installing it outside should be the last choice. Instead of the fuel line coming off the bottom or end, as has been the standard for years, a single supply line should come off the top of the tank. Note: a dearator will need to be installed inside the home at the burner. Avoid using a two-line system as this promotes condensation in the tank and causes premature filter failure.

4 INSTALL A PERMANENT CONTAINMENT DEVICE UNDER FILTERS AND BURNERS

Some proactive heating oil companies have already started this process. As part of their risk reduction process all home heat accounts are retrofitted with a permanent containment tray under the filter. The fuel today is changing (ULSD and Bio-fuels), thus gasket leaks are becoming more common. Should the filter leak during or after servicing, the tray catches the spill and provides time for a technician to return and tighten the filter or fitting or replace the gasket.

5 ADD CORROSION INHIBITORS

Photo: www.bushman.cc

Inside tanks do not corrode as frequently as outside tanks, however they do fail. A containment device is designed to catch pinhole corrosion failures, common overfills, spills, and connection and filter leakage. These devices can be installed under new tanks or retrofitted under existing ones. Audible alarms can be installed on the containment devices in areas where daily traffic is not common providing remote monitoring.

In March, I conducted a training session for field inspectors from the Technical Standards and Safety Authority (TSSA) in Toronto on the subject of domestic oil storage system failures. Based on the feedback from the inspectors, who were from different areas of Ontario, it was not uncommon for them to respond to a domestic oil system failure at least once per week. In some cases the frequency was higher and this has become a major concern.

In many cases the filters are located at the burner thus a single tray under the burner can provide protection for both of these areas.

3 USE CONTAINMENT DEVICES UNDER INSIDE TANKS The Fire Marshalâ&#x20AC;&#x2122;s Office of PEI has recommended every inside storage tank be installed over a containment device. It is not just the environmental issues they are concerned about. If a spill or leak from a tank migrates under the heating appliance the fuel is heated above its flash point where a fire can easily occur.

Stunning Revelations

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There are a number of additives currently available which can be added on an individual bases. Additives will not eliminate corrosion concerns completely, however in combination with other measures, they will reduce the risk of corrosion failure, bringing the issue to a more manageable level. With the current increase in internal corrosion failures it would be prudent to start the process of having corrosion inhibitors added to heating oil at the refinery or distribution level.

• Ul t ra l o w s u l p h u r d i e s e l • M icr o b io lo gical in flu en ce co r r osion

Dealing with microbiologically influenced corrosion The largest source of oil tank failures can be attributed to internal corrosion. Internal corrosion failures are often associated with microbiologically influenced corrosion, or MIC. This aggressive form of corrosion appears in the bottom of steel tanks or filter canisters and is confined to areas where water is present.

In the mid 1950’s the use of corrosion inhibitors in heating oil was tested and found to be useful in reducing internal corrosion.

Ultra Low SULPHUR Diesel It is speculated that the growing problem of internal corrosion failures is due to the changes in the furnace fuel specification, resulting in the reduction of sulphur. Ultra Low Sulphur Diesel (ULSD) is now being used in more domestic home heat storage systems. The effects of ULSD fuel on the storage system have not been fully proven, however there are a number of studies underway to determine what effect if any ULSD is having on the corrosion process. The New England Fuel Institute (NEFI) is currently completing a study on the effect of ULSD on filter plugging and corrosion issues.

MIC is not a new phenomenon, however changes in the fuel sulphur specification, along with the introduction of bio-fuels, has provided a more attractive environment for bacteria to grow in storage tanks. As far back as 1953, studies concluded that water from any source, even a few drops of it, will eat through a tank over time if the water is allowed to stay in one spot. Data from PEI gives a clear picture of where the industry must focus if it wants to solve this issue. With incidents becoming quite costly events – in some cases costing over one million dollars to clean up – we need to work swiftly to find solutions that work. Data collected by the Prince Edward Island Department of Environment on domestic oil storage systems provides a better idea where systems are failing. It is certainly not just a tank corrosion issue. We have to look at all types of failures and plot a course that will eliminate all these common events.

–

Michael Freill, P. Eng, is the president of Mark 1 Engineering Company and has 28 years of engineering experience with petroleum storage systems. He can be reached at mark1eng@accesscable.net

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PVF REPORT

B y Dave B o wd en

PVF TOP STORIES: RESINS AND PRICING T

he Canadian dollar seems to be on a trampoline this year, bouncing up and down between 90 cents and parity as Canada recovers from recession. Unfortunately, no industry is immune to its effects, including the pipes, valves and fittings sector. “The biggest concern in the industry right now is probably the instability in the pricing of our products. They seem to be fluctuating up and down,” says Kevin Fullan, vicepresident and general manager of Mueller Flow. Adding to that challenge is the demand coming from construction sites. “Last year, Kevin Fullan through the first half, PVF products had a relatively strong first half. Even though everybody was kind of mired in a fairly significant slump, we enjoyed a good first half last year, and I think a lot of our competitors did as well. Then the second half really slowed down pretty significantly for our market. The opposite is happening this year,” reports Fullan. “We’ve had a very weak start to the year and don’t anticipate any kind of strength until the summer months, or maybe even into the fall. So it’s the flipside of what happened last year.”

Worldwide, roughly half of the polyvinyl chloride resin manufactured is used for pipe production.

Metal not out of the woods? Though the recession is behind us, Bob Lynch, vice-president, Eastern Canada at CCTF Corporation, says the metal pipe sector needs to tread cautiously going forward. The price of steel is driven by the cost of raw materials and energy, as well as supply and demand, and historically, the price of steel has been volatile. How supplier companies manage to absorb or pass along price changes to customers will be a challenge for the foreseeable future.

Bob Lynch

“I think that the steel PVF industry's major concern at this point is what could be a return to high price inflation of products,” he says. “A 100 per cent increase in iron ore will inevitably affect all carbon steel product costs. This increase, if it occurs too rapidly, could stifle future growth and complicate an already fragile market.”

continues on page 76

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New Name. New Look. New Branches. New Products. Same Guarantee: They say the more things change, the more they stay the same and that couldn’t be more true of us today. We’ve recently changed our name from Noble Trade to Noble. We’ve also introduced a new logo and launched a new website. And it doesn’t stop there. From our 23 strong branch network, to our staff, to our product offering — everything is growing. Noble is so much more than plumbing — we now carry an extensive line of HVAC, Hydronics and Industrial products. What’s driving these changes? As always, the needs of our customers, your suggestions and feedback. Noble’s original goal back in 1993 was to guarantee better service in the wholesale industry and all these years later it’s still all about you and our guarantee: making sure you get what you need, when you need it.

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PVF REPORT

continued from page 74

Reclusive resins

“Thermoplastic resins have been in tight supply in early 2010 due to lower than normal inventories to start the year at resin plants, an upstart in construction activity in Canada for late 2009 and early 2010, and an unstable supply of key resin components such as ethylene and styrene,” he says.

The plastic sector of the industry faces a particular challenge as the availability of resins essential to manufacturing those products has declined. “Concerns within the plastics segment of the PVF market today would be unstable resin costs, service levels due to low inventories and ensuring full compliance to codes and regulations,” explains Gordon LeFort, Ipex Ontario sales manager for mechanical products.

While some companies have stocked up on plastic products in anticipation of a shortage, Fullan warns that contractors can expect back orders for these products as the year progresses. The cost of neither steel nor resin can be controlled from within a single sector, leaving the PVF industry to react to such forces rather than dictate the market. However, business opportunities will exist for those who keep from getting caught up in doom and gloom.

Gordon LeFort

“The one thing that can be done is try to be consistent in the pricing to the marketplace. Ride it out and hope that everybody else in the industry is doing the same,” suggests Fullan. “Service levels will correct themselves over time as post-recession inventories catch up to current demands,” LeFort adds.

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If you know of something that’s new and interesting, become a MB Insider and let us know. You can e-mail your tips directly to our Director of Intelligence (code name – “The Editor”), Adam Freill, at adam.freill@mechanicalbusiness.com. Why have a secret when you can share it with 19,000 people?

â&#x20AC;˘ Re c l usi v e r e s i n s

â&#x20AC;˘ I n n o vat io n in t h e m ain s â&#x20AC;˘ Ou t lo o k o p t imistic

Outlook is optimistic

Innovation in the mains

The first half of 2010 was weak when compared to the industryâ&#x20AC;&#x2122;s 2009 start, but a convergence of factors has PVF forecasts looking up.

Though the PVF sector generally presents what Fullan calls â&#x20AC;&#x153;a pretty stable or static group of products,â&#x20AC;? it is not without innovation. A modified PVC pipe similar to the widely used AWWA C900 water pipe presents new technology for underground water mains. â&#x20AC;&#x153;The new product is called Molecular Oriented PVC, or PVCO for short,â&#x20AC;? LeFort says. â&#x20AC;&#x153;It provides a higher impact and superior flow capacity pipeline for four-inch through 12-inch water lines or sewage force mains.â&#x20AC;?

Most widely produced plastics: 1. Polyethylene 2. Polypropylene 3. Polyvinyl Chloride

Molecular Oriented PVC

The process of molecular orientation has long been used to strengthen materials. Molecular Oriented PVC, or PVCO, is manufactured by a process that reorients the molecules of conventionally extruded PVC pipe. The pipe, which starts out at approximately half the diameter and twice the wall thickness of the finished product, is placed inside a mould that matches the proper outside diameter of the finished pipe. During the expansion process, the molecular orientation is changed and the physical properties of the finished pipe are established. Through the process, the pipe gains a higher impact strength, and greater cyclic and hoop strength.

NEW LOOK

NEW PRODUCTS

â&#x20AC;&#x153;Domestic inventories are now at appropriate levels and pricing is on the rise, rather than dropping,â&#x20AC;? Lynch notes.

In addition, the industry derives optimism from the federal governmentâ&#x20AC;&#x2122;s stimulus spending. While infrastructure money has so far focused on â&#x20AC;&#x153;shovel-readyâ&#x20AC;? projects like roads and highways, the industry expects the next wave to be geared more toward ICI construction. â&#x20AC;&#x153;Larger government infrastructure projects such as hospitals and treatment plants announced up to two years ago seem to be in full motion here in 2010,â&#x20AC;? LeFort says. â&#x20AC;&#x153;We are anticipating that the infrastructure money is going to be hitting the marketplace in the second half of the year,â&#x20AC;? adds Fullan.

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Recharging electronic commercial faucet Delta’s four-inch cast electronic faucet is outfitted with the company’s HydroPower system that’s designed to power the faucet and also recapture power to recharge its battery pack. The faucet’s flow rate of 5.7 litres per minute at 60 psi is identified by the powering system, which adjusts the generator’s charging capability. The faucet’s battery pack also contains an on/off switch.

deltacommercialfaucets.com

Pull-down faucet Featuring a dual pull-down spray, the Bistro kitchen faucet from Riobel has a maximum flow rate of eight litres (two gallons) per minute and contains a ceramic cartridge. The solid brass faucet has a 3/8” compression speedway, a two-jet spray feature and a nylon/metal hose.

riobel.ca

Macerator Designed for a half bathroom, the Sanitop Quiet Range macerator from Saniflo features vibration absorbers and specialized rubber interior components designed to keep the unit operating at less than 35dB of sound. An external macerating unit, it features two inlets: one for a toilet and one for a sink.

saniflo.ca

High-efficiency toilet The WETS high-efficiency toilet system from Sloan, distributed by Dobbin Sales in Canada, requires 6 litres (1.6 gallons) per full flush and 4.2 litres (1.1. gallons) per reduced flush. The floormounted bowl features a 91/2” x 8-1/4” water spot area and a 2” fully glazed trapway. It features a solar-powered flushometer designed to feed off incandescent or fluorescent light and provide approximately 100 per cent power with 650 illuminance (lux).

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Root cutter General Pipe Cleaners’ Metro-Rooter root cutting machine has 75 ft. of 5/8” wire, coiled around 49-strand aircraft-type wire rope. Designed to clear roots and stoppages in 3” and 6” pipe and manoeuvre into tight spaces, it also has 100 ft. of 1/2" cable for smaller jobs.

drainbrain.com

Reclaimed water tubing Designed for grey water systems, Uponor’s AquaPEX reclaimed water tubing is PEX-a crosslinked polyethylene tubing that is coloured purple to designate it for systems that supply non-potable, reclaimed water to laundry, toilets and irrigation systems. It is available in 1/2", 3/4" and 1" sizes in 300-ft. coils.

Join The Green Scene

uponor.ca

Thermal storage tank The Marathon two-port thermal storage tank from Rheem comes in capacities ranging from 50 to 105 U.S. gallons (189 to 397 litres). Models range in height from 67” to 71” and in weight from 100 lb. to 152 lb. The units feature a maximum test pressure of 300 psi and maximum working pressure of 150 psi.

rheem.com

Gooseneck faucet Finished with chromeplated cast brass, the Z812B1-XL faucet from Zurn’s lead-free line features quarter turn ceramic disc cartridges and a 5-3/8” centerline rigid or swing gooseneck spout. The Z812B1-XL has an eight-litre pressure compensating aerator, 2-1/2” colour-coded metal lever handles, mounting hardware and 1/2” NPSM coupling nuts.

New WatcoFlex Bath Waste ...installs faster/easier TM

Special patent pending PVC flexible tubing. Eliminates four field joints. Innovator overflow parts assemble by hand. No screws. Approved by IAPMO. It’s green. You’ll get used to seeing it. Just ask your wholesaler

WATCO

The Bath Drain Company WATCO MANUFACTURING COMPANY 1220 South Powell Road, Independence, MO 64057-2724 Phone 816-796-3900 • FAX 816-796-0875 www.watcomfg.com A Division of WCM Industries, Inc.

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COHA

PHOTO OPPORTUNITIES

Canadian Oil Heat Association 1

Celebrating Oil on the Island Lobster was on the menu and all aspects of the oil heat industry were topics of discussion as the Canadian Oil Heat Association brought its 27th annual symposium, Oilheat 2010, to the Delta Prince Edward in Charlottetown, PEI in June. The theme for the conference was, “It’s Your Future. Be There.” and speakers covered a wide range of topics including oil tank corrosion, insurance, new and emerging technologies, and business management. coha.ca

1. Viessmann’s Ken Webster discusses oil-fired condensing boilers. 2. The conference had numerous sponsors, as pictured here. 3. Russell Noonan of Noonan Petroleum displayed his 1937 International Fuel Truck during the conference. Noonan Petroleum was founded in 1924. 4. Outgoing COHA chairman Steve Wilson (Kerr Heating Products) impresses with his Highland Fling. 5. Gary Bischof, president of Irving Oil Commercial GP, discusses ultra-lowsulphur fuel. 6. Sean Giberson (Taco), COHA’s technical committee chair, shares a laugh during the event. 7. Bill Sanford, president, CEO and partner with Bluewave Energy discusses the emergence of his company as one of the nation’s largest independent petroleum delivery companies. 8. Seanna Callaghan, partner with the legal firm Gowlings, discusses land contamination claims. 9. Consultant and educator Bob Hedden talks about the future of oil heat. 10. Duane and Pat Walton enjoying a lobster dinner. 11. Conference sessions were well attended. 12. COHA introduced the first of its GreenTech Certified technicians. Standing with COHA president Veronica Yu (left) and technical committee chair Sean Giberson (right) are Calvin Bell, Ken Carmichael and Gary Boucher 13. Several COHA members received Delivering the Goods awards during the conference, including Patty Bell (left), who received her award from Jonathan Beckett, of R.W. Beckett Canada.

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HVAC

B y C ar o l Fey

MAKING THE MOST OF YOUR METER A

popular HVAC myth is that each piece of equipment or control is its own unique troubleshooting challenge. But the fact is that the same basic troubleshooting techniques can be applied to anything electrical. You need one simple tool: a multimeter. This somewhat complex looking device is as basic to an HVAC professional as a stethoscope is to a doctor, but it is far more handy than the simple listening device.

Carol Fey is a technical trainer who has been in the HVAC and hydronics industries for over 20 years. She can be reached at carol@carolfey.com.

The two basic measurements that are necessary when looking at the electrical circuits at work in an HVAC system are voltage and continuity. There are many other measurements that can be taken, but let’s start at the basics before working our way up into those.

V IS FOR VOLTAGE Voltage is indicated by the letter V on the meter. We call the voltage part of the meter a voltmeter. Set your meter for the highest possible AC voltage setting. Do not select DC. Always start with the highest setting in order to protect the meter. After the meter tells you what the voltage is, you can then move down to the appropriate voltage range for the system.

TECH TIP

On your meter, you’ll find two leads or probes. One is black and one is red. For our purposes it doesn’t matter which you put where. Make absolutely certain that your fingers touch only the coloured, insulated part of the probes, however. You can get shocked if your fingers stray onto the metal tips. Often we’re most interested in confirming that there simply is voltage (Yep, we got power!) rather than exactly how much. To check for line voltage coming into an electrical outlet, put one lead into each slot.

If you’re new to using a meter, or if you’re using a meter you don’t know well, begin by measuring things you already know, for example, a wall outlet.

The outlet voltage should be around 120 volts. Actual voltage delivered by the utility can vary depending on time of day, time of year, or location. When there is a greater overall demand (e.g. during high air conditioning demand), your voltage may be lower. Controls are often 24V – called low voltage – rather than 120V.

continues on page 84

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HVAC

continued from page 82

What’s that beep?

A transformer is a control that changes the 120V from the utility to 24V for HVAC controls. When checking a transformer with a meter, expect to find about 120V when you touch the meter probes to the two terminals connected to incoming electricity. Expect 24V on the other two terminals – the ones connected to the control circuit. As the incoming voltage varies from the utility, so too does the voltage going to the controls.

Making the meter beep is a quick way to make sure that a control or circuit has continuity. This means it is electrically good – with no broken windings or wires. The meter sends out a bit of electricity from its battery. If the electricity makes it all the way through the electrical pathway and back to the meter, the meter beeps. For example, if you put the meter probes on each of the two wires on a simple motor, the beep means that the motor is good. If you put the probes on the two terminals of a switch, a beep means that the switch is closed (turned on). For this function, set the meter for “continuity” –)))) –or “ohms” – Ω . Make sure that all electricity is disconnected for this test.

WHY IS IT CALLED A MULTIMETER?

A meter is called a multimeter because it has multiple functions. With one device you can measure volts (V), amps (A) and ohms (Ω). The ohms function is also what is known as continuity. Depending upon the meter, you can measure volts and amps for either alternating current (AC) or direct current (DC). You select the function you need.

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• W h a t ’ s t h a t b e ep ? • W h at ’s t h e b ig clam p fo r ?

What’s the big clamp for? When a meter has a clamp on the top, the real purpose is not for hanging it on a pipe. The clamp is intended as a convenience option for measuring amperage. Amperage is not one of the two basic measurements for HVAC but it can prove useful. An ordinary meter, without the clamp, can still measure this as long as it has the function “AC amperage.” Disconnect two circuit wires from each other, connect each to one of the meter probes, and wait a minute or so for the amp reading to stabilize. With a clamp you don’t have to break into the circuit. Just put the clamp around any wire and wait for the reading.

CAUTION! If you measure an AC circuit with a DC amperage setting, the meter may die.

HEARD THAT METERS ARE EXPENSIVE AND HARD TO USE? That’s an old story that’s been made inaccurate through technological advances. Today’s digital electronic meters are simple and durable. For a resaonable price you can get a nice digital meter that will let you easily test the basics – AC voltage and continuity. That’s all you need to get started. For more money you can add more features.

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customer’s needs and satisfaction. With over 30 years of manufacturing home comfort products, Napoleon® entered its 4th year with a full residential HVAC product offering along with 30 years of expertise. Built on established practices, traditions and customs with cutting–edge technologies, Napoleon® combines the strength of the past with the resources of the future. We offer ﬂexible payment plans, local support and training, expedited shipments, up-front payment value, advertising packages including co-op, one of the best warranties in the industry and technicianfriendly products all to make your job easier than ever and so much more! Time for change, time for Napoleon®

To become a Napoleon® HVAC dealer call: 1-800-461-5581. To discover the full line of proﬁt-making HVAC products, visit napoleonheatingandair.com

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REFRIGERATION

B y Gr eg S wier cz

Keeping supermarket systems running smoothly T

oday’s supermarket operators must look for aggressive cost savings in order to perform and compete effectively in the market. Equipment maintenance is an important area of focus because in most cases, it represents one of the largest operational expenses, second only to energy costs. In no other component of the refrigeration system is there greater potential for reduced maintenance costs and increased energy savings than the compressor.

IT’S TOO HOT IN HERE When the heat in a compressor reaches a high enough temperature, the oil begins to break down chemically to the point where it loses its ability to lubricate. Major reasons for overheating include: low suction pressures, high condensing pressures, high compression ratios and high return gas temperature.

When a technician or contractor arrives at the scene, it is crucial to know which problem the compressor is experiencing so it can be corrected before a failure occurs. A high number of compressors returned under warranty to the manufacturer are classified as NDF – or “no defect found.”

To prevent low suction pressures, check to make sure that there has not been a pressure drop in the suction line, and the evaporator coils are not restricted. Light load operating conditions and incorrect pressure switch settings can also cause low suction pressures.

So, let’s look at some of the common problems that can affect compressors in supermarket refrigeration systems.

LOSING OIL Loss of oil occurs when oil leaving the compressor does not match the amount of oil returning to the compressor. This is problematic, because in order to run properly, all systems require an adequate amount of oil. Loss of oil is usually a result of inadequate return of oil from the system. To address this problem, technicians should review the refrigerant piping, accumulator, oil reservoir, evaporator superheats, defrost scheme and oil floats.

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High condensing pressures can be caused by inadequate airflow through the condenser, which is generally a result of dirty condenser coils. Other causes of high condensing pressures can be an overcharge of refrigerant, non-condensables in the system, or an undersized discharge line or condenser. High compression ratios are a combination of low suction pressures and high condensing pressures. To avoid this condition and resulting problems, care should be taken to ensure the compressor is operated within the manufacturer’s guidelines. It is a good idea to monitor the discharge line temperature to determine if the compressor is in danger of overheating. Check with the compressor manufacturer for the recommended discharge line temperature.

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Floodback occurs when liquid refrigerant returns to the compressor while the compressor is still running. This can be caused by low evaporator loads, improper refrigerant charge, improper or malfunction TXV, or sudden changes in load. Prevent floodback by installing properly selected components, precise expansion valve sizing, ensuring proper air flow, air distribution and refrigerant charge.

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Flooded starts happen when the compressor starts up with liquid in the shell or crankcase. The longer a compressor is off, and the cooler the ambient temperature while it is off, the greater the opportunity that exists for liquid migration. The temperature difference between saturated refrigerant in the evaporator and the oil in the compressor can also affect migration. To control a flooded start, locate the compressor in controlled ambient, maintain minimum refrigerant charge, maintain adequate oil levels and use a crankcase heater or a pump down cycle.

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Greg Swiercz is the manager of engineering and technical services with Emerson Climate Technologies Canada. He can be reached at greg.swiercz@emerson.com.

Please visit us at www.colemanac.com, or call Toll Free:

1-800-668-2389 ext. 5486

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PLUMBING

B y David A . Geo r ge

SCALE: A POOR CONDUCTOR

The thermal conductivity of a material is measured in BTUH/ft²/in/°F. As measured on this scale, copper has a heat transfer rating of 2,680 BTUH/ft²/in/°F and steel has a heat transfer rating of 460 BTUH/ft²/in/°F. Lime scale has a heat transfer rating of between 3 and 7 BTUH/ft²/in/°F, a rating so low it works more as an insulator than as a viable heat transfer material.

David A. George is a product manager in the marketing department for Lochinvar Corporation, a manufacturer of highefficiency water heaters, boilers, pool heaters and storage tanks. www.Lochinvar.com.

LIME SCALE: The Energy Thief F

rom the smallest hair salon to the largest industrial process, commercial operations invest a significant portion of overhead in the cost of fuel to heat water. Lime scale buildup on the surfaces of water heaters reduces heat transfer, decreases fuel efficiency and ultimately leads to equipment failure.

The simplest and most common design of a water heater is a tank or vessel of water with a gas fired burner underneath. The heat is transferred from the flame through the steel wall of the tank, either along the bottom of the tank or the flue tubes running up through the tank.

M e c h a n i c a l

Water contains dissolved minerals such as calcium carbonate or lime, magnesium, silica, iron and phosphate, in microscopic quantities. Not only are these minerals not harmful to your health, they are actually beneficial to human health, but not to your water heater. When water is heated, these minerals precipitate out as solids that can build up on the surfaces of water heaters overtime. On Day 1, the tank type water heater will enjoy its highest heat transfer rate or thermal efficiency. Most have a first day thermal efficiency of approximately 80 per cent. B u s i n e s s

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• Sol u t i o n s f o r l i m e s c ale • C o st in cr ease wit h lim e scale Over time, mineral solids precipitate out as the water is heated. The solids fall to the bottom of the tank or drawn by the attraction of heat to cling to the flue tubes.

Commercial water heaters should be serviced at least once a year, which is a perfect time to schedule a de-scaling program. In areas with hard water, or if the unit operates at high temperatures, or has considerable use, more frequent maintenance is advisable.

The lime and other particulates cling together, build up over time and bake into a hard crust - a solid barrier to the heat transfer process.

The best defense is to consider options before scale becomes an issue. There are water treatment options on the market that will pre-treat water to help limit scale formation. Another advance against the scale concern has been the introduction of water heaters with heat transfer systems located outside the tank, avoiding lime scale buildup altogether.

The lime scale builds up between the metal wall and the water, thus blocking the efficient transfer of heat. In fact, a 1/4" layer of lime scale will block heat transfer so much that it can increase fuel costs by as much as 38 per cent. Eventually, the scale will inhibit the heat transfer process to the point where the steel can overheat, become brittle and crack, causing tank failure.

So what’s a contractor to do? Well, once scale is present, the task falls to scale removal. This can involve the use of de-liming products, such as acids that will dissolve the scale. In some cases, these products are not enough and physical scraping may be necessary. Be sure to check with the manufacturer for their recommended procedures and products though.

Cost Increase %

Solutions for lime scale

Cost increase with lime scale

Scale Accumulation in inches

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Multi-split zone system Featuring inverter technology and a SEER rating of 19.1, the Flex multi-split zone system from LG has a capacity of up to 42,000 BTUH. Designed to cool up to four rooms on a single unit, it features room-by-room temperature controls.

lg.ca

Heat pump Modulating anywhere from 40 to 118 per cent of capacity, the Frigidaire iQ Drive heat pump offers cooling capacities of 10,000 to 52,000 BTUH at 35ºC (95 º F) and heating capacities of 6,000 to 49,200 BTUH at 8 ºC (47 º F). Using inverterdriven rotary technology to achieve up to 22 SEER, it operates at sound levels as low as 59 decibels.

18-SEER heat pump The Affinity YZH split series heat pump from York is an outdoor unit with two to five ton capacity. Running on R-410A, it has a maximum cooling capacity of 36,000 BTUH and a rated CFM of 1,245 when operating at 18SEER. It features a metal coil guard designed to protect the coil from debris and other damage.

yorkhvacdealer.com

frigidaire.net

Ductless wall mount split system heat pump With optimal operating temperatures of -18°C (0°F) for cooling and -15°C (5°F) for heating, Fujuitsu’s 24RLXS is a 24,000 BTUH ductless wall mount split system heat pump. It has efficiency ratings of 18 SEER and 10 HSPF, and a line set maximum of 165 lineal feet.

fujitsugeneral.com

Ductless air conditioner Napoleon’s ductless air conditioner runs on R-410A and offers output ranges from 9,000 to 24,000 BTUH. The units feature directional vanes that move both vertically and horizontally to direct cooling, automatically restart after power failure, and are available in heat pump and dual-head models.

napoleonheatingandair.com 94

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According to an ecobee study, 30% of North Americans program non-WiFi enabled thermostats. This compares to 82% of users who program their Smart Thermostats

Thermostat Designed to allow remote access from any computer, the Smart Thermostat from ecobee connects to a standard WiFi wireless network and can be programmed remotely.

ecobee.com

Ductless heating and cooling systems

Infrared heater Designed for commercial and industrial use, SRP’s Series U gas-fired infrared tube heater is available in rates from 40,000 to 220,000 BTUH, lengths from 10 to 70 feet and natural gas or LPG. It features a jet stream burner designed to maximize radiant output and parabolic aluminum reflectors.

superiorradiant.com

Heat recovery ventilators Airia Brands has introduced the RNC 84-TPF and RNC 85-TPF top ported heat recovery ventilation (HRV) units to its Lifebreath RNC product line. The units deliver 35 to 95 CFM, and are well suited to condo and apartment applications.

lifebreath.com

The Mr. Slim M-series line of heating and cooling systems from Mitsubishi includes heat pumps that range from 2,800 to 36,400 BTUH in cooling, and from 3,000 to 43,000 BTUH in heating. With systems rated up to 26-SEER and 10-HSPF, the line also includes wall-mounted inside units with a sensor designed to measure radiant hot and cool spots in the room and help direct airflow.

mitsubishielectric.ca

heatfab

SGV/DGV

NEW 4X3

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Special Gas Vent The industry leader in Special Gas Vent introduces new alternative alloy SGV/DGV Special Gas Vent Systems. Available in both Single Wall and Double Wall designs, SGV/DGV features a proprietary stainless steel alloy - 4X3™ that offers superior corrosion resistance at an economical price point. These new systems feature installer-friendly connections and built-in silicone seals, so field applied RTV is not required. • 3 & 4 inch sizes for residential applications • Single Wall / Double Wall Systems • Listed to UL1738 and ULC S-636 5030 Corporate Exchange Blvd. Grand Rapids, MI 49512 Toll Free: 1.800.433.6341

heatfab

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M e c h a n i c a l

P.O. Box 526, Depot 1 Hamilton, ON L8L 7X6 Toll Free: 1.888.SELKIRK (735.5475)

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Torch kit The Deluxe Portable Torch Kit from TurboTorch is designed to hold two disposable gas cylinders and tools needed for soldering and brazing. Consisting of a lightweight tool bag with pockets, a shoulder strap and a metal sleeve for hot-tip storage, the kit contains two self-lighting tips for propane or MAP/Pro fuel, a torch handle, gas regulator, 12-ft. hose and heat shield.

turbotorch.com

Clamp meter Extech’s EX845 clamp meter is a 1,000-amp AC/DC CAT IV unit with a built-in infrared thermometer. The true RMS meter features a 43 mm (1.7") jaw opening designed for conductors up to 750 MCM or multiple conductors, such as two 500 MCM conductors. In addition, the unit works in conjunction with Flir infrared cameras via wireless technology.

extech.com

Metal-cutting circ saw blades Hand-held torch The hand-held Quickfire torch from Bernzomatic features an adjustable flame-control knob and lock button for finger-free use. Fuel cylinders load into the torch’s handle and are designed to provide enough fuel to solder 200 fittings.

Available in seven sizes ranging from 6-3/4” 40T to 14” 80T, metal-cutting circular saw blades from Irwin feature lasercut vents designed to prevent vibration and keep the blade cool. Also featuring an anti-kickback tooth shoulder designed to reduce dust and sparks, blades cut various steels, including black pipe, angle iron, threaded rod or aluminum.

irwin.com

bernzomatic.com 96

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W RLD VIEW Jeff Patchell

Cloudy with a chance of windmills Several new technologies designed to produce drinking water and take up the fight against water shortages have been tested in recent years. From windmill technology to cloud seeding, a line in the sand has been drawn to come up with solutions that stop the dissipation of the precious resource commonly known as H 2O.

Cloud seeding Many countries are having varying degrees of success with cloud seeding techniques. The science of cloud seeding is not new. People have been investigating ways of getting rain clouds to part with their moisture bounty for more than 50 years. Alex Nazarov is principal scientific officer for Hydro Tasmania (Australia) and has been working mostly in the field of hydrology since 1979. “Successful cloud seeding needs a special ingredient – clouds,” he says. “More specifically, clouds with a large water vapour content and a low temperature.” In the natural rain-making process, warm, moist air rises into the atmosphere, begins to cool and forms droplets of water. Cloud droplets form around cloud nuclei – tiny particles of dust, salt, or soil that are constantly present in the atmosphere. Cloud droplets then group together into clouds (it takes millions of cloud droplets to form one raindrop), which can precipitate as rain, snow or hail. Cloud seeding is not as basic as it sounds – in fact, it’s a complex process. In the simplest terms, it means introducing other parti-

WINDMILL TECHNOLOGY Dutch Rainmaker is currently working on a new concept for the production of fresh water. Windmill technology is being used to produce drinking water from air, and it can also be used for the desalination of sea water. A wind turbine directly drives the compressor of a fully integrated compression cooling system. The inlet air is cooled through the compression cooling system so that the water in the air condensates. The condensate water is then collected and preserved to be used as drinking or irrigation water.

Air at 20°C with 50% relative humidity contains approximately seven grams of water per kilogram of air. Air at 30°C and 50% RH contains almost 14 grams of water per kilogram of air.

cles into a cloud to serve as cloud condensation nuclei and help in the formation of precipitation. Nazarov says cloud seeding has several applications, including precipitation enhancement, reduction in hailstorm damage, fog dispersal and even firefighting. More than 30 countries, including the United States, Australia, Morocco, Burkina Faso (West Africa), Thailand, Indonesia and China are using or trialing cloud seeding for a variety of reasons. Most are investigating the option to help fill storages for irrigation, potable water supply and electricity generation.

Depending on local ambient temperatures and humidity, air always contains a certain amount of water. This makes it possible to make water from air almost anywhere in the world.

Warm ambient air, in particular, may contain large amounts of water. Lowering the temperature of air requires relatively little energy. By doing so a large volume of water becomes available by condensation.

Jeff Patchell is managing director of Connection Magazines Pty Ltd. He has recently launched www.worldplumbinginfo.com, an online plumbing industry knowledge bank. M e c h a n i c a l

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BYTHENUMBERS Compiled by Dave Bowden

MORE WATER REDUCTION ON ITS WAY Consumers intend to install more high-efficiency fixtures and faucets over the next two years. Here’s what they want:

SEER STILL LAGGING Despite government grants and incentives, most A/C systems in Canada are still under

78% 73% 72% 67% 64% 45%

high-efficiency lavatory faucets high-efficiency urinals high-efficiency showerheads high-efficiency toilets dual-flush flush valves flush-free urinals

13 SEER.

YOUTH NEEDED!

4.35 million Total A/C units 77% under 13 SEER 52% under 10 SEER 46% 15 years old or older

1 million

workers anticipated by 2020

152,000

who will need to be replaced by 2017

HEAT PUMPS ON THE RISE

50% of Canadian non-apartment

2.9% Canadian households using a heat pump as their primary heat source in 1993

homeowners retrofitted their homes to make them more energy efficient between 2003 and 2007.

4% Households using heat pumps as their primary heat source by 2003

Top retrofitters were: Prince Edward Island: 60% Ontario: 58% Manitoba: 55%

M e c h a n i c a l

B u s i n e s s

Number of skilled

workers in Canada’s construction sector

REGIONAL RETROFITS

PLUMBING LINE... COMING SOON

Shortage of

SOURCE: HRAI, Statistics Canada, Natural Resources Canada, Sloan Valve, Skills Canada PM# 41536047 Postmaster: Please send all address changes or undeliverable copies to: Mechanical Business, 19 – 1525 Cornwall Road, Oakville, ON L6J 0B2

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