October 2013

Publication Mail Agreement #40063170. Return postage guaranteed NEWCOM Business Media Inc. 451 Attwell Drive, Toronto, Ontario M9W 5C4

Hot Water Heating Keep customers happy with reliable efficient hydronic systems

Inside ■ It is the weather after all!

■ N.S. gas rebate program causes concern ■ Oil tank installation rules ■ Getting paid and maintaining cash flow

OCTOBER 2013

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â– Contents

Hydronic Heating Issue

Departments Hot Seat .........................................4 The ethics of door knocking

Industry News ..............................7 It is the weather, after all

People & Places............................59 Taco introduces distribution partner

Coming Events.............................61 All-trades show gears up

Shop Management......................62 Happiness is steady cash flow

Products & Technologies Building Green.............................10 Hot Water Heating ......................13 Heating ........................................25 Ventilation ...................................33 Refrigeration ...............................35

College makeover

$60-million upgrade geared to construction trades

Features

Pipes, Valves & Fittings ...............45 Trucks for the Trade.....................49 Tools & Instruments ....................55

Planned maintenance

13

Keeping customers and their systems happy

Cover: Careful commissioning will ensure a new water heater achieves the performance and efficiencies that it is designed for. Please see our article on page 18. (Bradford White photo)

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Variable speed pumping The gradual evolution of high-rise booster systems

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Unique approach

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Hot water heating with forced air

October 2013 – Plumbing & HVAC

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■ Hot Seat

October 2013 Volume 23, Number 7 ISSN 1919-0395

Publisher Mark Vreugdenhil (416) 614-5819 mark@plumbingandhvac.ca Editor Simon Blake (416) 614-5820 simon@plumbingandhvac.ca Design and Production Tim Norton production@plumbingandhvac.ca Production Manager Lilianna Kantor (416) 614-5815 lily@newcom.ca Circulation Manager Pat Glionna Corporate Services Anthony Evangelista

PLUMBING & HVAC Magazine is published eight times annually by NEWCOM Business Media Inc. and is written for individuals who purchase/ specify/approve the selection of plumbing, piping, hot water heating, fire protection, warm air heating, air conditioning, ventilation, refrigeration, controls and related systems and products throughout Canada.

High pressure The plague of door-to-door high-pressure sales people pushing equipment traditionally supplied by our industry in recent years threatens to give every contractor a black eye.

In fact to refer to the approach that homeowners find themselves dealing with on their doorsteps as “sales” is misleading. It often involves outright lies and fraud. Dressed in a uniform and bearing identification making them look like a representative of the local utility or some official government body, the individual tells the homeowner that they need to change their “illegal” water heaters or HVAC equipment – containing “illegal refrigerant” – because it doesn’t meet current “government regulations.”

The practice seems to be getting more widespread – despite some provinces introducing legislation to curb it – and has become a regular topic at meetings of contractors.

The question always comes up: what about legitimate contractors that send their employees out to knock on doors when business is slow? An honest employee making an honest presentation isn’t usually a problem, except for one thing.

They are selling something that most people don’t want. (They might need it, but that’s besides the point.)

The HVAC system may be 20 years old, but it works fine and if there was a problem, the homeowner would call a contractor.

But it’s the scammers that are at issue. There have been a number of incidents reported where a relatively new high efficiency system was replaced after the doorknocker convinced the gullible home owner – often an elderly woman – to do so.

At the recent annual meeting of the Heating, Refrigeration and Air Conditioning Institute of Canada,

contractors division members got into a heated debate over a relatively new phenomenon – the rental of the entire HVAC and hot water systems in new homes.

Builders love this because they don’t have to buy anything.

However, it’s not generally good value for the homeowner because they pay much more than the value of the equipment. As if that isn’t bad enough, many new home buyers are unaware that they are buying a home with rental equipment. This is certainly not the first thing the salesman points out, if he mentions it at all.

So one has to ask, are these issues strictly “buyer beware,” or does the industry have a responsibility?

Some would argue that it’s not the industry’s responsibility to protect homeowners from “their own stupidity.” But we’ve all been taken advantage of in some sleazy deal at one time or another. We’re the experts in this situation – the homeowner isn’t – and the scammers go to great lengths to appear legitimate.

As these scams become more and more widespread there is a very real risk that the reputation of the entire industry may suffer.

In my view, the industry needs to take a stand. Any association that represents contractors needs to spell out appropriate sales tactics in their code of ethics.

Many contractors have spent years building a solid reputation for quality work and honest business practices.

They need all the help they can get to distance themselves from the fast buck fraud artists that are quite literally stealing business and giving the industry a black eye.

NEWCOM Business Media Inc. 451 Attwell Drive, Toronto, Ontario, Canada M9W 5C4 Tel: (416) 242-8088 • Fax (416) 614-8861 POSTMASTER: Send all address changes and circulation inquiries to: Plumbing & HVAC Product News magazine, 451 Attwell Drive, Toronto, Ontario, Canada M9W 5C4. Canadian Publications Mail Sales Product Agreement No. 40063170. Postage paid at Toronto, ON. Annual Subscription Canada: $40.00 plus applicable taxes, single copy $5.00 plus applicable taxes. Annual Subscription United States: $60.00 U.S. Annual Subscription foreign: $90.00 U.S.

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Copyright 2013. The contents of this magazine may not be reproduced in any manner without the prior written permission of the Publisher.

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

A member of: Canadian Institute of Plumbing & Heating Canadian Circulation Audit Board Mechanical Contractors Assoc. of Canada Ontario Plumbing Inspectors Association American Society of Heating Refrigerating & Air Conditioning Engineers Heating Refrigeration and Air Conditioning Institute of Canada Refrigeration Service Engineers Society of Canada

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■ Industry News

So much for science!

Analysis of past sales offers little help in predicting future, HRAI delegates hear

By Simon Blake It is the weather after all! A recent study by Ryerson University in Toronto demonstrated that scientific analysis of HVAC/R sales is pretty much useless when it comes to predicting future sales.

“They found that none of the data had any impact on HVAC/R sales… that temperature variations were the key motivator,” reported David Morden, chairman of the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI) in his opening address to the group’s 45th Annual General Meeting and Conference.

“In some ways we are better to consult the Farmer’s Almanac rather than rely on scientific sales data,” he added.

However, he noted that the industry is changing rapidly as tighter homes – more even than the need for energy efficiency – are driving changes to equipment.

“Innovations have become less about energy efficiency and more about properly distributing the air in the house,” he told 240 delegates and companions attending the meeting, held at the Westin Bayshore Hotel in Vancouver Aug. 21-24.

In fact HRAI is in the process of upgrading its SkillTech training programs due to changes to the CSA F280 standard in which heat/loss gain calculations have been dramatically altered to reflect modern home design, reported HRAI education director Joanne Spurrell at the group’s industry update, held on the first evening of the conference.

As usual, the HRAI conference was jam packed with educational sessions, meetings and speakers.

Keynote speaker Peter Legge, CEO of Canada Wide Media in Vancouver, gave delegates a step-by-step howto class on leadership. “Great leaders make decisions slowly and stick to them,” he says.

Contractors debate rentals Discussions became heated in the HRAI Contractors’ Division meeting with some smaller contractors complaining about unscrupulous business tactics by some larger contractors in the leasing of residential HVAC equipment, particularly in new homes.

“The new home buyer doesn’t realize they have a rental HVAC system,” remarked Tom Vasilak, Hamco Heating and Air Conditioning, Hamilton, Ont. “(The young people) buying homes are so wrapped up in the excitement of buying a home, they are not seeing the scam.” The rental rates are “exorbitant,” he added.

However, other contractors said it’s up to the buyer to be careful. “How you market your business inside a home is no business of this contractor’s board,” said Bob McKeraghan, Canco Climatecare, Newmarket, Ont.

www.plumbingandhvac.ca

“There are already government regulations.”

Contractor’s chair Marc Gendron, Les Enterprises MLG & Fils, Montreal, suggested the association could look into the issue further.

Progress on hydrocarbons HRAI is finally beginning to make progress on preventing the sale of do-it-yourself hydrocarbon refrigerant kits through retail stores, reported Jim Flowers (Linde Canada Ltd.), Manufacturer’s Division chair, at the group’s National Assembly.

“We are finally getting some traction on the issue with support from the Ontario Fire Marshal’s Office,” he reported. HRAI has been contacting fire marshals after failing to get much support from government or the retail outlets after these highly flammable hydrocarbon DIY refrigerant kits started appearing on store shelves a few years ago.

Gendron was elected chairman, replacing Morden who has completed his term.

He said his first priority is to build on the work of the HRAI Careers Committee in attracting youth to the industry. As well, he hopes to boost HRAI membership across Canada, he urged contractor’s to take advantage of the group’s marketing tools and he would like to see

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Tracey Bell, aka “Marilyn,” spiced up the traditional handing over of the gavel from David Morden, right, to Marc Gendron.

HRAI become more involved with the Canadian Hydronics Council (a division of CIPH) to give hydronic heating a boost.

The next HRAI Annual Meeting will take place in Montreal Aug. 20-23, 2014. For more information, please visit www.hrai.ca.✚

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■ Industry News

Industry steps up efforts against N.S. gas incentive program It’s no secret that the natural gas industry has had a difficult time establishing itself in Nova Scotia. A strong oil heating industry along with the high cost of conversion has discouraged many home and business owners from making the switch where natural gas is available.

As a result, there was little surprise that Heritage Gas – the gas utility – rolled out an incentive program designed to make the transition easier and less expensive for homeowners. But the conditions of that program have members of the Nova Scotia Natural Gas Association (NSNGA) and its parent body, the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI), hiring a lawyer to take the issue to the Nova Scotia Utility and Review Board (NSUARB). They are also consulting with an expert on competition law to consider a complaint to the federal Competition Bureau.

The program “crosses the line by intervening too directly in the HVAC marketplace,” reported Martin Luymes, director of programs and relations for HRAI, in the group’s newsletter.

The problem is that Hertage gas is buying the products from its sources and having them installed by its approved dealers on a rotating basis, effectively shutting out manufacturers and contractors that are not part of the program. Available products include boilers, furnaces, water heaters and conversion burners. Margins and product installation allowances are also set by the utility.

“Local (HRAI) members believe this program will seriously curtail competition in the marketplace by giving the utility too much power over product selection

and pricing, not to mention determining which contractors will get the work generated by the marketing program,” said Luymes.

HRAI met with Heritage Gas in April with solutions that would make the program more inclusive for industry. However, those ideas were rejected, said Luymes.

A number of HVAC manufacturers pledged financial support for the HRAI/NSNGA legal challenge at the HRAI Annual Meeting in Vancouver in August.✚

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NTCCC sets new priorities The National Trade Contractors Coalition of Canada (NTCCC), which has been leading efforts to get prompt payment legislation, added two new priorities at a meeting in Vancouver Sept. 4. The group, which is made up of trade contractor organizations including MCAC and HRAI, will examine the state of tender documents within the construction industry and find solutions. It is also looking at “ways and means” to have the entire industry, design community and contractors alike understand the quantitative impact of changes on a construction project and how to address them in a responsible and fair manner.

For more information, visit www.ntccc.ca.

Energy use measurement system Natural Resources Canada (NRCan) is introducing the Energy Star Portfolio Manager in Canada. This online tool is used to track energy, water consumption and greenhouse gas emissions. It can benchmark the performance of one building or a portfolio of buildings. It is available at http://oee.nrcan.gc.ca/commercial.

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Counterfeit refrigerant settlement DuPont has won a small victory in the battle against counterfeit refrigerants after police in China seized 300 containers of counterfeit DuPont SUVA 134a refrigerant and packaging in a raid against Hangzhou Sporlan Heating and Refrigeration Company, Ltd. in Hangzhou province, China. A settlement requires Hangzhou Sporlan to apologize in writing, pay damages, and agree to cease to use DuPont trademarks and word marks.

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■ Building Green

Large pizza,

LOADED

Or how the University of Windsor over-engineered its engineering centre

By Bruce Nagy Like everything in the world, university education is changing quickly. So when designing the Ed Lumley Centre for Engineering Innovation (CEI), the University of Windsor knew it was important to satisfy some forward-looking objectives.

Universities must teach skills tied to real work, like the extensive automotive engineering undertaken in neighboring Detroit. They increasingly position themselves as specialists in a few specific disciplines. And they need to attract top students by creating a balance between essays, pizza and beer.

The project’s engineering will be microscopically scrutinized as a teaching exercise, explains Kevin Stelzer, principal at B+H Architects and the lead designer on the project. Seasoned engineering professors and some of the brightest young minds will be meticulously reviewing it for many years to come. (No pressure!)

“Everything is exposed, labeled and monitored. We’re tracking for the building automation system, plus we added a couple hundred more sensors and measuring devices for energy usage, temperatures, pressure, water flow, occupancy, CO2, illumination and so on,” added Stelzer.

A living wall provides air filtration.

High tech Stelzer and his group considered the Internet and other pervasive education technologies, mobile devices, video streaming and electronic teaching aids. They planned for teamwork and hands-on experiences. And because it was the engineering department, the structural, mechanical and other engineered systems they selected are state-of-the-art.

The centre has the largest vehicle crash wall in North America, a wind tunnel, specialized laboratories for robotics, fluid dynamics, health care engineering, waste water treatment and so on. A huge lecture theatre can live-stream video from the tech labs. Designed like a comedy club with tables on cascading levels, it accommodates lectures and group breakouts in the same room. Executives from Detroit’s automakers are impressed. Enrollment has jumped.

Hollow core wall technology fulfills ventilation and energy storage needs

Sustainable The LEED Gold project includes a 10,000 square foot green roof, a three storey living wall, heating and cooling generated by a campus central plant that feeds an energy-wise Termobuild air delivery system. Five of the 13 air handlers are equipped with energy recovery wheels operating at 20,000 cfm. Classrooms benefit from displacement ventilation and the centre also demonstrates grey water recycling, modern building envelope features, and a modern storm water management system.

The central plant consists of three gas-fired steam boilers, one combined heat and power steam turbine, one centrifugal chiller, and one absorption chiller running on waste heat from the co-generation plant. It provides 4800 tons of chilled 7ºC (450F) water for 28,800 square metres (310,000 ft²) in the CEI. In winter it provides 121ºC (250F) steam at 120 lbs. per square inch.

Hollow core concrete Stelzer says the building’s energy savings are 32 percent and cost savings about 42 percent over a conventional building of the same size. Air volume and fan power are drastically reduced using the Termobuild system.

Hollow core concrete Termobuild planks act like a rechargeable battery.

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Plumbing & HVAC – October 2013

The Ed Lumley Centre for Engineering Innovation at the University of Windsor is expected to withstand scrutiny.

Work proceeds in the civil engineering lab.

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“It’s an energy storage reservoir as well as an air duct technology,” says Stelzer. It permits low level, low velocity air-flow from a pressurized under-floor plenum.

“Our fans are about 66 percent what they would be normally. A full wet lab usually consumes 850 kilowatts per square metre. We’re at 280.” Usually Termobuild uses hollow planks plus two inches of concrete to add thermal mass. “This time we used three inches and we put sensors in some of the cores.”

Algorithms had to be adjusted for higher humidity and a building that’s open 24 hours, seven days a week. But the university is still spending less than $2.00 per square foot on energy. “Usually a university costs $3.25 or $3.50,” reported Jack Laken, Termobuild Canada president.

permeable paving surfaces. Rooftop rainwater overflow is directed into bio-swales.

“We built a 200-metre long tank – dug it out, poured crusher and wrapped it in filter fabric,” reported Mark Beaulieu of Windsor’s J.P. Thomson Architects Ltd., who served as project manager for the building. “And we do first level storm water treatment for phosphates before water returns to the sewer.”

Beaulieu says the biggest challenge was not the construction on the project. “We had a team of professionals who knew what they were doing, so nothing was difficult.” He reports it was more daunting to move a huge amount of equipment from the old

engineering building during a relatively short period.

“There are no more three-month down periods at universities, so it felt like we moved everything in about a week. But it was worth it. The students love this building. It’s like a pizza with everything on it.” ✚ Bruce Nagy is a Toronto-based freelance writer that reports on green technologies and solutions. He can be reached at bruce.nagy@rogers.com.

Green roof monitored In addition to being a great place to munch on pizza at lunch time, at 3,048 square metres (10,000 square feet) the green roof is formidable and possibly the most monitored patch of foliage in the world. “We have thermocouples everywhere. We’re measuring temperatures at the top of the plants, at the deck, plus rainfall, relative humidity, wind strength, wind direction; and we have a flow metre into the cistern drain,” says Stelzer.

“The weather station tells us how much rain fell and the computer calculates how much remains in the soil.”

Windsor data is still being analyzed, but a comprehensive 2004 University of Michigan study showed its gravel roof was about 20ºC warmer than its green roof and reduced heat flux through the envelope by an average of 167 percent.

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The plants must be continuously watered from above.

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■ Hot Water Heating

Technicians Marcus Gedak, left, and Tyler Hoffos of Bruin’s Plumbing & Heating in Red Deer, Alberta do a boiler check.

PLANNED MAINTENANCE, PART II

Not just a

programs – things that are often not really looked at, came to the surface – stuff you can only really understand fully if you have actually “lived the life” as it were (I really have been doing this for a long time).

So here they are; and next month I will explain in detail what the technician needs to look for and what types of things should raise red flags, along with some examples of the types of issues I’ve run into over the years.

cash cow

Setting up a comprehensive preventive maintenance program for your customers

By Roy Collver

www.plumbingandhvac.ca

ast month, I talked about the business case for a contracting firm to develop a comprehensive planned maintenance (PM) program as an important part of their business strategy. This follow-up was intended to cover just the nuts and bolts stuff you actually have to do during a maintenance check on a hydronic system but, as often happens once I get deep into a topic, I realize I have a whole bunch more information to pass on.

Some other really important aspects of PM

L

Not simply a cash cow

When it comes to your PM customers, keep in mind that the worst thing you can do is treat them simply as a cash cow. One of the main goals of these programs is to help you become a trusted partner to your customers. You have to give them more than their money’s worth. Don’t expect to just plump up your margins and keep your apprentices busy in the slow times, but rather use it as an extension of your sales and marketing efforts. Save money on those phone book advertisements and put it toward developing customer satisfaction.

It is so easy for your customers to just do an internet search and dig up all kinds of information on PM contracts. One site I looked at, for fifty dollars, will sell the homeowner a DVD with “complete” video instructions on “everything they need to know” to do an annual maintenance check on their gas furnace or

Please see ‘Developing’ on page 15

October 2013 – Plumbing & HVAC

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■ Hot Water Heating

Developing the program Continued from page 13 air-conditioner. I didn’t see a hydronic system version, but I’m sure some hero is out there working on it.

Scary stuff for sure - so don’t be surprised if your customer comes back at you with very focussed and difficult questions. Be ready with the answers and teach your techs how to respond to them as well – it will make it much easier to get them to buy into the program if they have easy answers as to what is involved in a PM check and what the benefits are to the customer.

Looking for trouble One of the most important aspects of a PM check is that you are looking for trouble. This is a big deal. It’s called preventive maintenance for a reason.

Yes they are going to check the usual basic components and clean and replace the bits that normally need to be cleaned and replaced, but they also have to figure out how the system is supposed to work. They then have to take it for a spin to see if it does indeed work the way it is supposed to – maybe even push it hard enough to almost break something (ever had a cardiac treadmill stress-test?) – all the while documenting everything important about the system for future reference.

These calls help your techs develop customer communication skills. If they see something wrong, they have to explain it to the customer in terms the customer can understand. Ideally they will build a rapport with the customer and establish a sense of trust for your company.

Demand that your technicians to be scrupulously honest at all times. Not only is it the right thing to do, it is the only thing to do. Your reputation will be solid, your customers will be your best source of advertising and new business and you will sleep better at night.

Choosing the right steps Lets look at the steps in a full-blown PM check for a hydronic system. Most programs have various levels of maintenance performed, at various prices. You have to decide what your company will charge, and how many levels you offer.

Maintenance requirements will vary with the equipment involved. You must ALWAYS check the manufacturer’s installation

www.plumbingandhvac.ca

and operation manuals for each piece of equipment installed in the system for detailed service instructions – for example, do you lubricate the circulators, or not? – you have to look it up.

If the instructions are missing – and you are not already familiar with the equipment – get the instructions from the manufacturer, rep. or wholesaler. It has never been easier in this day of the internet.

Make the appointment with your customer and be reasonable. “Tuesday sometime” is not reasonable. “Tuesday morning, or afternoon” is getting better.

Asking the customer when they would like to see you there, and then doing your best to try and fit it in – “Tuesday at 10:00 a.m. it is then,” for example, and you just made a friend.

Explain to the customer what you are going to do, and how. If it is a new customer, tell them that you need to have a look at the system for a few minutes, and then stop and show/tell them what you think needs to be done, and how long you think it will take.

This gives you an opportunity to introduce them to the idea that there may be some extra work needed, and to assure them that you will inform them and give them an estimate before proceeding. If you discover a total disaster, you have to stop and have that chat sooner rather than later. They may get upset, they may want to run you off the job – if so, don’t argue – it happens.

Cut your losses, and give them your business card on the way out so they can call you back when they cool off.

The basic system functions need to be looked at one-by-one. Consider yourself a hydronics physician – it’s simple then.

Boiler – check, piping and fluid flow – check, terminal units and heat transfer – check, controls – check. For really elaborate “boutique” systems, you may have to refer the patient to a specialist. If there are eight fancy controls on the wall and a rat’s nest of wiring and you have no idea how it works, be honest about it and phone a friend.

done, explain to the customer what you did. At this point, you should warn them about anything that looks a bit dodgy, stuff that they might want to replace before it breaks.

Back to being honest – if it is a good, clean, simple and easily maintained system, advise them that they may not need to get the full meal-deal every year.

If you do anything extra (throw in a free fan belt or filter – clean a burner that wasn’t included) make sure you tell the customer you did them a freebie, don’t go all “aww shucks” on them and keep it to yourself; they should know what good guy you are.

Make sure you sign them up for next year (or whenever you think it should be done again) and leave lots of signs of you having been there – GOOD signs.

This is the most cost effective advertising you can do – appliance stickers, flyers, customer service satisfaction survey, fridge magnet, business card, etc. A little gift with the company logo, web site, phone number,

goes a long way. And, last but not least, thank them for the business and make sure they know how to contact you 24/7 – that you are there for them if anything goes wrong.

Lately, I have been reviewing my 17 years of articles written for this publication with the idea of compiling the better ones into a book. I came across four articles between 2004 and this year on preventative maintenance. If you keep your back-issues, please reference the following issues of P&HVAC Magazine: Nov/Dec 2004, Sept/Oct 2005 and Nov/Dec 2009. I also covered commercial boiler water and fire-side maintenance in April and May/June respectively this year. If you don’t have the back issues – I hope to be able to have a nice, useful and entertaining, reference book to sell you soon! ✚ Roy Collver is an author and consultant on hydronic heating based in Peachland, B.C. He can be reached at hoth2o@shaw.ca

Meeting expectations Once you have figured out what is included in the PM contract and had the customer agree – do it. Clean, check and replace what you said you would and give any old parts back to the customer.

Document as you go and when you are

October 2013 – Plumbing & HVAC

15

■ Hot Water Heating Radiant floor package Radiant Ready 30E and Fast Trak systems from Uponor are designed to speed up radiant floor heating installations. The Radiant Ready 30E is a complete radiant mechanical room designed in a compact, preassembled, easy-to-install panel. The installer simply hangs the panel on a wall and connects the tubing, thermostat and electrical power. It includes a 30,000 Btu/h electric boiler, heating manifold, pump, expansion tank, pressure-relief valve, isolation valves, thermostat and air vent — all preassembled and prewired. Fast Trak knobbed mats provide a faster, easier method for installing PEX tubing in overpour applications.

Uponor u www.uponor.ca

Energy Star certified

Multi-purpose tank

A.O. Smith has announced that its high efficiency condensing Vertex residential gas water heaters are now Energy Star certified. These units operate at up to 96 percent thermal efficiency with up to 100,000 Btu/h input thanks to an advanced heat exchanger design inspired by the company’s Cyclone commercial water heaters.

A.O. Smith Canada u www.hotwatercanada.ca

Taco’s commercial MPT (multi-purpose tank) line incorporates features of Taco’s buffer tank, 5900 and standard in-line air separator lines within a single product. Tank sizes range from 50 to 1050 gallons across 16 sizes with nozzle connections from two to 10 inches. Each unit includes four flanged nozzles, a two-inch full port blow down valve and a factory installed air vent.

Each tank is designed for 125 psi at 240° F. Taco Canada u www.taco-hvac.com

WATCO

INTRODUCING

Efficient commercial boiler The compact new P-K SONIC boiler from Harsco Industrial Patterson-Kelley uses a stainless steel heat exchanger design with two segments working together to optimize efficiency and improve reliability. This allows each section to be engineered independently using different composite stainless materials for better heat transfer and higher reliability through the condensing process, reports the manufacturer. The boiler operates at 96.5 percent efficiency with a 5:1 turndown and ultra-low emissions.

Harsco u www.harscopk.com

Condensing tankless heaters The Greentherm C 1050 ES and C 950 ES condensing gas-fired tankless water heaters from Bosch are Energy Star rated models that achieve up to 10 percent improved energy efficiency over non-condensing models, with an energy factor up to 0.94. An automated and fully modulating bypass provides temperature stability. There are multiple venting options, including concentric PP up and out, and up to four units cascaded and vented together with the company’s new polypropylene common venting system.

Bosch u www.Boschheatingandcooling.com

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Boiler for tight spaces The SlimFit condensing boiler from Weil-McLain Canada is a lightweight, compact design requiring minimal clearance featuring a modulating burner with 6:1 turndown, aluminum heat exchanger, AL294C or PP venting for direct vent and direct exhaust and LCD touch screen. It is available in 1,000,000, 1,500,000 and 2,000,000 Btu/h sizes.

Weil-McLain Canada u www.weil-mclain.ca

www.plumbingandhvac.ca

OR

Watco Manufacturing Company

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WATCO

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Patented and Patents Pending See www.watcomfg.com for details

October 2013 – Plumbing & HVAC

17

■ Hot Water Heating

UP TO 99% EFFICIENCY UP TO 25:1 TURNDOWN 1.5 MILLION TO 5 MILLION BTU/HR 30 GPM TO 350 GPM FLOW RATES DIRECT-VENTING UP TO 100 FEET

Technicians learn about the new water heater technology at a Bradford White training session.

WITH MODBUS PROTOCOL, CASCADING SEQUENCER AND FRONT-END LOADING CAPABILITY

Commercial DHW Working with the new condensing water heater technology

By John Vastyan

300 Maddox Simpson Parkway Lebanon, Tennessee 37090 P: 615-889-8900 / F: 615-547-1000

www.Lochinvar.com

18

Plumbing & HVAC – October 2013

In the past few years, the arsenal of commercial water heaters and associated technology has grown considerably, availing a wide range of fuel, venting and combustion air options. There are also many new application-friendly components and techniques to enable trouble-free specification and installation, although – with the new, green systems – a few new needs emerge.

Higher efficiency, condensing systems are great for end-users in terms of reduced energy use, chiefly because they harvest heat from waste condensate. The energy advantage requires modest design and installation changes to meet the need for condensate treatment and drainage.

This may translate to an inability to use existing venting if the original water heater was atmospherically vented. The availability of electricity is another concern. Some systems require hard wiring; other commercial systems need only a simple wall plug-in.

Acidic condensate strategies Condensate drainage is a likely necessity. Often, fluids to be drained are too acidic for metal drain lines. Condensate typically has a pH of 4.0, about that of Coca-Cola – just enough to attack any metal it connects with. Over time, the cumulative effect of

www.plumbingandhvac.ca

are now just as well served with sidewall venting.

Constant change New codes are forcing all of us to be attentive to a broad range of emerging requirements. National, provincial and local codes are changing in the wake of the green movement’s more stringent environmental policies and initiatives.

Historic settings are commonly guarded by restrictions that regulate the presence and appearance of modern building systems and attachments (i.e., wire, regulators, transformers and venting). In fact, the presence of old and unsightly or loud venting systems has

actually encouraged the replacement of aging atmospheric water heaters in many of these buildings. ✚

John Vastyan is president of Common Ground, a trade communications firm based in Manheim, Pennsylvania that specializes in the hydronic, mechanical and HVAC industries. He can be reached at cground@ptd.net.

All facets of a commercial water heater installation are checked during the commissioning process. exposure to acidic runoff threatens the integrity of the drain lines.

Routing the condensate through a simple, lime-bed acid neutralizer is the typical solution. And CPVC or PVC drain lines can handle the acidity.

Venting options If new, high-efficiency water heaters are planned as a retrofit, existing venting must be upgraded to comply with the ULC S636 Standard for Type BH gas venting systems, which typically means either PVC or polypropylene venting. The majority of venting lines are three or four inches in diameter, precisely matched to the design requirements of new blower motor assemblies that discharge from the top of water heaters.

Some new water heater systems have the ability to vent through the roof and pull air in for combustion through the wall; this is a big advantage. The need to improve flexibility of installation and placement has driven the development of power, power direct vent; through-the-roof and sidewall venting options.

Finally, if the application offers abundant atmospheric combustion air, some water heater models require only one pipe: for venting.

Multi-story and high-rise installations challenge traditional venting. High efficiency water heaters often can often accommodate long venting runs. However, often there’s no need to run vertical venting all the way to the roof, requiring a roof penetration. Many systems

www.plumbingandhvac.ca

October 2013 – Plumbing & HVAC

19

TOP QUALITY WATER HEATERS FOR TOP NOTCH CONTRACTORS John Wood products are manufactured with the highest quality in mind to ensure ease of installation and trouble free operation.

Check out the latest Atmospheric Vent, Electric and Power Vent models!

Visit www.johnwoodwaterheaters.com for new product information and updates.

NEED HELP AT A JOB SITE? Call the John Wood DEDICATED CONTRACTOR LINE for First Call, Final Resolution Service: 1-866-208-8367

■ Hot Water Heating Drywall covers the radiators in what had what had previously been a frigid Saskatchewan basement.

Hydronic heating with

FORCED AIR

By Bruce Nagy here’s been considerable discussion in the industry about the benefits of combining forced air and hydronic heating technologies. These “combo” systems typically take the form of a boiler providing heat through a fancoil, which is often also equipped with an air conditioning coil.

A couple in Regina wanted to heat their basement without changing out their existing high efficiency forced air furnace. They came up with a unique solution, which basically involves installing a hydronic heating coil in the warm air stream.

“It’s new found real estate,” says Aura Lee MacPherson, CEO for RadiantLink Heating Services in Regina. MacPherson rediscovered her 1800 square foot previously ‘cave–like’ frigid Saskatchewan basement, by renovating the space and having the unique hydronic heating system installed.

Designed with help from her husband Murdoch and others at his engineering firm, the hybrid radiant/forced air system offers a solution for certain

T

Installation required replacing a piece of the duct with the special supplied plenum.

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Unique approach offers straightforward way to add comfort to basement applications. It’s an economical option that can be installed quickly without ripping up the floor; and it connects to the existing gas furnace rather than a separate boiler.

How it works The heart of the hydronic heating system is a multi-row fin-tube coil installed in a special plenum downstream from the furnace. The coil maximizes heat transfer to the hydronic glycol mixture while being designed for minimal supply air pressure drop.

A wall mounted control panel includes a circulating pump, expansion tank, air vent, relief valve and zone controller. The supply duct coil is piped through the control panel circulator to the manifold for the hydronics. PEX or copper piping from the manifold is then routed through slots in the radiant wall panels, which are then covered in drywall.

“We also installed panels near our shower enclosure, basement bathtub enclosure and in the walls of two bedrooms on the main floor that were furthest from the furnace,” added McPherson The experience turned into a start-up business after the system was also installed in two Saskatchewan office buildings.

Please see ‘Office’ on page 23

October 2013 – Plumbing & HVAC

21

The Evolution of High EfďŹ ciency Condensing Boilers High efďŹ ciency stainless steel boiler Hr Models from 46,000 to 151,000 BTU/Hr Available in a combi version Fully modulating with 5:1 turndown Advanced outdoor reset control Low NOx operation Venting to 150' 2" venting on all models up to 100'

■ Hot Water Heating

Office building retrofit recognized Continued from page 21

Straightforward installation Installation is comparatively easy.

Openings are cut top and bottom in the supplied plenum according to airflow needs, and a piece of the top supply ductwork is removed and replaced with the new plenum, directly above the furnace. A flexible connection is installed between the coil cabinet and supply air ductwork and turning vanes even the airflow across the coil and reduce static pressure drop. The plenum unit is then sealed in. An air conditioning coil can also be added.

After the control panel is mounted to the wall, the plenum coil inlet and discharge are connected, plus a relief valve discharge and manual air vent.

Next, the control panel discharge and return are piped to the radiant manifold.

A low voltage thermostat can be added to one of the zone terminals in the panel, or alternatively a jumper wire can be used to keep the pump operating continuously.

For air condtioning, a default jumper wire is removed and replaced with connections to the AC controls and/or a snap-disc-style, low limit pipe temperature sensor is installed, surface-mounted on the AC liquid line. It should break the circuit when the AC system starts and pipe temperature drops below 10ºC. After that the technician flushes, pressure tests everything to 30 psi, fills it

Multiple units have been used to bring radiant heat to office buildings. with propylene glycol, plugs the unit into 120V outlet, turns on the pump via the thermostat, and bleeds the system.

Economical hydronics The system is inexpensive relative to other hydronic options. “You can use the available heat more effectively without affecting the 92 percent high efficiency of the gas furnace,” says Murdoch, chief technical officer for the new company.

When compared with supplemental electric heat, the MacPhersons say they save about $350 each year. In addition, they say, maintenance is easier.

The company has recently shipped two systems to North American Trade Schools (NATS) in Ontario to be tested by the students and instructors there. “We are going to try it out, but I like what I know about this system because you don’t have to buy a separate boiler or heat pump,” says Lanny Metcalfe, instructor at NATS in London. “People should save money and they are not burning extra energy. Plus many homes don’t have room for hydronic equipment. So the space saving angle could be impressive.”

condensing furnaces, plus this special hybrid combo and the hydronic low wall heating system.

“It provided a reduced cost system with more redundancy than an alternative that would have involved

condensing boilers,” says Murdoch.

The ceilings (and diffusers) were 12 feet high, so the hydronic wall panels provided supplemental desk level warmth and allowed the original floor slab to be preserved and polished as an architectural feature.

The LEED Gold building saves about $4000 annually in energy costs, compared with its Model National Energy Code for Buildings (MNECB) model reference building, and has an Energy Star performance rating of 86, reported Murdoch.

The second office building in Regina used 12 of the hybrid packages to condition 20,000 square feet of space.

The architects cited the comfort of infloor heat, space savings, as well as reduced capital and maintenance costs, when choosing the system.

Although radiant floor heating might be considered a better quality alternative than the radiant wall system, Aura Lee points out that more than 60 percent of new homes are still built with forced air systems. Her hybrid gas furnace hydronic system is designed to bring the comfort of hydronic heating to the basements of these homes. ✚

Makes the competition look soft.

PEX-Flex may take a little more to put in the ground but the extra effort pays off in long lasting durability.

High system compressive properties keep the carrier pipe(s) centered under shallow buried live loads and along even the shortest radius turns. The smooth wall outer casing does not ‘catch’ obstacles or debris during installation. The UV Stable PE Jacket, eco-friendly PUR insulation and PEX pipe(s) are mechanically bonded

Commercial applications

Using radiant wall heating brought comfort without tearing up the existing floor.

www.plumbingandhvac.ca

Lest this all sounds a little gimmicky, the system was installed in a Saskatoon office building that went on to win an ASHRAE Technology Award, First Place for Existing Commercial Buildings, in 2011.

A Saskatoon architecture firm that was growing and needed new offices used multiple units in its new building.

The firm retrofitted a chilly 13,000 sq. ft. former egg warehouse with seven

creating a completely watertight system.

If you’re looking for a tough flexible pre-insulated pipe system – choose

PEX FLEX 1-866-PEX-COIL (739-2645) | pexflex.net

October 2013 – Plumbing & HVAC

23

What One Canadian University Learned About Zuba-Central.

And how this new study can lead to more satisfied customers.

Every HVAC system claims to be energy efficient. But how many of these claims are backed by science? Ours is.

An independent study*conducted by Ryerson University in Toronto proves that Zuba-Central: SAVES ENERGY With a COP ranging from 1.4 to 3.19, Zuba-Central delivers energy savings of up to 60% annually over conventional heating and cooling systems.

OPERATES EFFICIENTLY AT LOW TEMPERATURES Our advanced system design and innovative compressor technology ensures effective and efficient operation in temperatures as low as -30°C. IS MORE AFFORDABLE THAN GEOTHERMAL Zuba-Central delivers similar energy efficiency at a fraction of the installed cost of a geothermal system.

Get the facts for yourself and see why Zuba-Central by Mitsubishi Electric is the proven choice for energy efficiency and cost savings. *Study conducted by Toronto and Region Conservation Authority (TRCA) and Ryerson University: Performance Assessment of a Variable Capacity Air Source Heat Pump and a Horizontal Loop Coupled Ground Source Heat Pump System

*When installed by an authorized HVAC (Heating, Ventilating, and Air Conditioning) installer. Certain conditions, restrictions and/or limitations apply. See warranty terms and conditions for complete details.

ZubaHome.ca

photo courtesy of TRCA

■ Heating A professional installation will give the customer confidence in your company. Note the fresh air intake.

Efficient oil heating Keeping up with evolving technology is critical

By Bob Bettles and Brian Guttormson “Wet test” steady state efficiency levels were much higher and, at the time, AFUE numbers were not part of the equation. As such, while the steady state numbers were impressive they did not take into account the short cycling of the thermostats or the fact that to achieve these high numbers the furnace involved had been on full fire for up to half an hour or more! This is not a true heating cycle that the homeowner would ever see unless the heating season was 20F or more below the design conditions of the day.

Internal changes

The technician raised this high efficiency unit off the damp floor.

www.plumbingandhvac.ca

T

oday’s oil furnaces have evolved immensely from the original burner in a drum design of the past!

Current products, with their sealed combustion direct vent designs and high pressure burners, will squeeze the fuel dollars much better than the original units.

Unfortunately many of the oil burner mechanics have been slow in coming up to speed with these new units.

In the past the burner service man would adjust air gates and overfire draft settings by eye or, in some cases, a wet finger! Eventually the smoke spot test came into play and a Fyrite wet test was done to check CO2 and O2 values of the flue gases. Burners were interchangeable depending on the serviceman’s preference. Conversion burners were readily available to convert older equipment to “higher” efficiency levels.

These aftermarket burners truly brought the title of ‘mechanic’ into the industry. In the early years a onegallon or larger burner nozzle was the fuel input of choice. Insulation in homes was scarce, fuel was inexpensive and the burners were quite forgiving in setup and adjustment.

Oil-fired equipment available today while, in most cases, is similar to the older products visually; internally times have changed! Today we have oil fired products rated in excess of 94 percent, vented with ULC-636 plastic materials and with condensate drains to boot! While the efficiency results are similar to the current gas-fired products, commissioning does require a few more tweaks and fine tuning.

Even the current units rated at the minimum Energy Star levels will produce high efficiency values if the time is taken to do the proper setup. Our friend above with the “wet finger and the good eye” is now from the dark ages.

Many times we have spent too much time on the telephone with a service tech (?) questioning our directions and suggestions regarding his problem of the hour. Usually after several minutes our “pro” on the phone will state: “I have been in this business for “X” number of years and that is not how I do it!” The reply he will receive is “Yes sir, you have been in the business for “X” years of experience, but unfortunately because you weren’t willing to learn and keep up with the improvements, you have repeated the same year “X” times over!” This will usually end with a hang-up and several @#$%^&*()(*&^% comments regarding our knowledge and talents!

Not to sound like a broken record (remember

Please see ‘Smaller’ on page 27

October 2013 – Plumbing & HVAC

25

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■ Heating

Smaller market hampering development

The technician needs to know his stuff to install complex modern oil systems like this. (Photos by Bob Parsons) Continued from page 25 them?), the equipment manufacturers today spend many hours testing and retesting the products. We are asked regularly the question: “When are you going to build a 95 percent oil furnace?”

The answer is not a quick and easy response! From the time the design process starts to the final product release may be as much as two years.

The unit has to be tested and certified by the approval agencies along with vent lengths, clearances, diameters, high limit checks, pressure switches, tests, and more tests, etc. An installation manual must be written and included with the documents

but also pump pressures and nozzle size and spray patterns at various rates. If more than one burner has been approved the complete model number of the approved burner(s) will be included.

Temperature rise (min/max) through the unit is also approved.

http://www.warmingupcanada. hvacrheritagecentre.ca http://www.beckettcorp.com/ http://www.riello.ca/the-brand/history ✚

Bob Bettles HVAC author and trainer Robert (Bob) Bettles is technical service adviser and product trainer for B&B Trade Distribution Centre. He can be reached at bbettles@bandbtrade.com.

Brian Guttormson HVAC author and trainer Brian Guttormson is technical service advisor for Trent Metals Ltd. (Supply). He can be reached at techsupport@tmlsupply.com.

Declining market

We are limited to using oil burners from outside suppliers for new products that are slowly declining in numbers as well. Too many of the original entrepreneurs of the early days have come and gone; names like Fess, Gurney, Inglis, Gar Wood, John Wood, and Conroy, among many others, have been absorbed or folded due to readily available natural gas products.

Today we are down to two or three well known suppliers of Current products, high pressure oil burners. R.W. Beckett was one of the original with their sealed combustion North American manufacturers direct vent designs and high and has survived the several pressure burners, will squeeze downturns in oil usage and has kept up with demands for higher efficiencies. the fuel dollars much better During the oil crisis of the than the original units. seventies Riello came into our North American market. They since have become one of the provided with the furnace. Within this preferred burners of many oil burner manual, over-fire and chimney drafts, as installers in Canada. well as CO, CO2, O2, and smoke values are produced. These numbers are not Fuel storage challenges picked out of the blue, but as part of the The next challenge we are seeing is the agency approvals they must be storage of fuel at the equipment locations. documented prior to any of these units Oil tanks have recently received too much hitting the streets. bad press with leaks and spills. The oil, The approval agency labels now which initially came from under the include not only min/max firing rates, ground, may not be expected to return to

www.plumbingandhvac.ca

its source from a spill. It can contaminate many acres of land as well as any water course within many miles of the spill.

Clean-up is an expensive operation. Along with changes within the fuel code books, insurance companies are requesting additional inspections, sometimes with tighter than code requirements.

The bottom line, gang, is to take some time to read the documents provided with the equipment you are selling and installing. Take the time to research the products you are working with before the sale and installation date. If your customer finds you in a dilemma in his furnace room having to read the instructions or phoning us for tech support for help while the cold winds and snow are blowing outside, no matter how glossy your sales presentation was, you will be put to the curb for any referrals with this and any future sales!

Below are some links with some interesting history of the development of oil burner manufacturing and earlier solutions!

There’s more than one way to

make the connection Providing HVAC/R Distributors with a complete line of approved electrical wiring accessories. www.wiringpro.com 1.800.690.9266 IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII October 2013 – Plumbing & HVAC

27

■ Heating

FOLLOWING THE

RULES

Oil tank installation requirements vary across the country

By Art Irwin

Getting every last drop of oil out of the soil following a spill is an expensive process.

There are a number of variations in the regulations regarding residential oil tank installation across Canada.

Historically, residential oil containment has had a rather bumpy ride for a number of reasons. Costly oil spills have cost insurers big dollars ranging from $3,000 to over one million dollars per claim. There have been instances where the cost of remediation was greater than the value of the home and, in a few cases, the home was demolished.

In jurisdictions where strict guidelines have been developed and enforced, the number of oil spills has been greatly reduced. Many feel the cost of clean-ups following oil spills is often absurd. If the oil spill affects a water source it is understandable that the utmost of care must be followed. But oil is biodegradable and it is not toxic. In many instances, they dig for days and remove every possible bit of contaminated soil, which is probably unnecessary.

that it has been constructed to the national standard, ULC-S602, along with the year of manufacture, metal thickness, serial number and the name of the manufacturer. As an option, the label might show Underwriters Laboratories of Canada’s ULC/ORD C80, which is for above ground, non-metallic tanks.

Following even a small spill, a truck and excavator are on site and the costs skyrocket immediately.

The CSA B139-09 code specifies it is no longer permissible to install the conventional single wall steel tank above ground outdoors. It must have a secondary containment designed for outdoor use or a double bottom with a monitoring device between the steel walls, unless the tank is non-metallic and complies with ULC ORD-C80.1.

The oil heating code The Canadian Standards Association (CSA) first developed the standard – Installation Code For OilBurning Equipment – in 1957. The latest version was published in 2009. The standards are developed through a consensus process approved by the Standards Council of Canada by a group of volunteers that represent various aspects of the oil heating industry, including equipment manufacturers, inspectors and marketing representatives. This committee currently has 32 members.

All provinces have adopted the CSA B139 oil heating code and several have developed provincial regulations that vary, but come under the CSA B139 umbrella.

Ontario, for example, regulates oil tank installations under their Technical Standards & Safety Authority (TSSA) and has made a number of amendments.

All oil tanks must have a certification plate showing

28

Plumbing & HVAC – October 2013

Oil tank options There are a number of alternatives to the standard oil tank. It makes sense to offer these to homeowners as they are not that much more expensive and the homeowner may get a break on their insurance.

Granby manufactures a steel tank with a double bottom that has the company’s Ecogard polyurethane coating. Granby offers $2 million liability insurance coverage for these tanks, which also include a leak detection system and a 25-year warranty.

Vilco and ZCL manufacture a non-metallic tank in

Some oil tank installations are a disaster waiting to happen. Filling this tank is not worth the risk.

Please see ‘Oil’ on page 31

www.plumbingandhvac.ca

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â– Heating

HVAC & HYDRONICS

Oil code changes proposed Continued from page 28 Waverley, Nova Scotia, Quebec and Alberta . These fibreglass tanks are made from UV and fire resistant resins to ensure the safe storage of fuel oil. They are available with side or top feed, have a 30-year warranty against leaks caused by corrosion and can be installed indoors or outdoors. They are available in single or double wall construction.

Roth manufactures a double-wall tank that consists of an outside galvanized casing that can hold more than the volume of the inner tank in the event of a leak. The inner tank is made of high density polyethylene. These tanks are available in 400, 620 and 1000-litre volumes and include a leak alarm. The warranty is 10 years for outside installation and 15 years for indoor use.

Roth provides $5 million insurance coverage against product failure.

Stainless steel tanks were also available for a short time but the quality of steel was not as good as the conventional steel tank and many had a short lifespan.

Province by province Every province has slightly different rules concerning oil storage tanks. Following are a few highlights:

BRITISH COLUMBIA All underground tanks that have been out of service for two years must be removed. A permit must be obtained.

If a property is being sold with an underground oil tank, it is the responsibility of the homeowner to have the tank removed.

by the Technical Standards and Safety Authority (TSSA).

As of Jan. 1, 2013, all new indoor and outdoor tanks must have double bottom, double wall or secondary containment. Tanks must have protection around both ends of the tank and leak detection between the double-bottom must be visible above the highest level of the tank.

Note: For a complete listing of new code requirements, see Edition 3, CSA-B139ON-06.

PRINCE EDWARD ISLAND Indoor tanks must be double-bottomed or non-metallic.

Outdoor tanks must be non-metallic unless otherwise approved by the department. Installers must have a home heating tank licence and must report new tank installations to the Department of Environment. Tanks must be located at least five metres (16 ft.) from a well.

All tanks must be tagged and an inspection form completed and submitted not later than five business days after the end of the month in which the inspection was made. The shelf life of the tank must appear on the tag at installation.

One should contact the authority having jurisdiction in their province for further details regarding oil tank installations, maintenance and guidelines.

Consumers should study their insurance policies and discuss details with their insurance agent to be better educated regarding their coverage. There are differences in the coverage by many insurers and many homeowners assume they are fully covered which is not always the case.

Oil code changes proposed ONTARIO Fuel oil distributors are not permitted to deliver fuel to an underground tank that is not registered and approved

Oil heat in Canada Province/ Territory

Households Heating With Oil

Percentage of Households Heating With Oil

Newfoundland

55,210

28%

Prince Edward Island

36,132

68%

Nova Scotia

207,282

55%

50,313

17%

Quebec

350,828

11%

Ontario

318,852

7%

New Brunswick

Manitoba

8,078

1.8%

Saskatchewan

24,003

6.2%

Alberta

22,612

1.8%

British Columbia

82,158

5%

Yukon

7,821

62%

Northwest Territories

9,908

69.6%

Nunavut

7,831

99%

1,181,007

9.5%

CANADA TOTAL

The CSA B139 Installation Code for Oil-Burning Equipment is currently undergoing major changes. The present plan is to divide it into two parts with large equipment being separated from smaller residential equipment.

Part I will include installation requirements for large oil-burning equipment for multi-unit residential, larger commercial buildings, as well as industrial and institutional buildings. It also includes requirements for diesel fuelled stationary engines and miscellaneous specialty oil systems.

Part II concerns low capacity boilers, furnaces, air heaters, domestic water heaters and similar residential type appliances including the associated ancillary equipment installed in residential and small commercial buildings.

Users should note that the design of fuel systems anticipated in this part may not require sealing of the design and provision of construction and review services by a professional engineer. ✚ Arthur A. Irwin operates Irwin Energy Consulting Services in Halifax. He can be reached at irwin.a@ns.sympatico.ca.

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OPCMF DB t

Source: Statistics Canada

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October 2013 – Plumbing & HVAC

31

Freezeless AND Anti-Rupture? What’s the difference? A freezeless faucet has the shut off mechanism well within the heated portion of the home – but what if a garden hose or other device is inadvertently left connected to a faucet during freezing temperatures? Water in the tube fails to drain, this water then begins to freeze and pressure in the tube is increased as ice forms and tries to compress the water trapped in the tube. The tube ruptures and the next time the faucet is used the wall fill with water. Woodford Model 19 Freezeless Faucets have a patented pressure relief valve which allows for expansion during freezing temperatures, saving the faucet and preventing a costly repair or call back. With Woodford’s Model 19, you’re protected – even from other people’s mistakes!

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â– Ventilation

INDUSTRIAL

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The Model QEI-L inline mixed flow fan from Greenheck is designed for low pressure applications. It is available in 11 sizes for wheel diameters 12 through 36 with a performance range up to 40,000 cfm. A flanged connection is standard with companion flanges available for slip fit connections. AMCA certified for sound and air performance, it is recommended for low pressure ventilation applications requiring low sound levels and high fan efficiency including office buildings, concert halls, educational facilities, libraries and parking garages.

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Compact low profile fans The Broan LP80 and NuTone LPN80 ventilation fans are especially designed for installations where conventional ventilation simply won’t fit. This unit is narrow enough to be installed in a wall between 2� x 4� studs. And yet the LoProfile fans are Energy Star approved, providing 80 CFM of ventilation at a sound level as low as 1.1 sones. In retrofit applications, they can often fit without having to move plumbing or electrical obstructions found behind the drywall.

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Geothermal IAQ accessories A new line of IAQ accessories from Bosch Thermotechnology Corp. is designed to work with Greensource geothermal heat pumps or any other HVAC system. The line consists of a humidifier, photocatalytic oxidizer, carbon and potassium-permanganate filters, smoke detector, fresh air dampers and touchscreen thermostats. All are designed to improve indoor air quality while also helping to save energy.

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Standard and custom fabricated pipe, delivered straight to your location.

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Inline belt-driven fans The new CTB Tubular Inline Belt Driven fans from S&P Canada Ventilation Products are designed to offer one of the widest ranges of sizes, horsepower and performance in the industry and are ideal where space is limited. They can handle static pressures up to 2� w.g. and provide air performances up to 20,000 cfm. Features include continuously welded and epoxy painted steel housing, aluminum centrifugal wheel, extended lubrication lines and a two-year fan housing warranty.

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Duct hanging solution Erico has expanded its range of specialty end fittings for its Caddy Speed Link universal support system with six new end fittings for greater flexibility and time savings when installing ductwork and conduit. It offers an alternative to using threaded rod, strut and strut nuts, and it installs without drilling into the building structure. A selection of locking devices is available for different applications and load requirements.

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We know your business.

It’s our job.

PLUMBING | HVAC | HYDRONICS | INDUSTRIAL FIRE PROTECTION | BUILDING MAINTENANCE

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■ Refrigeration

This system uses a fixed set-point manual reset pressure control.

A typical coil TD of a walk-in cooler is 10°F, a reachin or smaller walk-in can be as high as 15°F or 18°F, but it is rarely lower than 10°F unless the box or case was designed specifically for a product that requires a high humidity like a floral cooler. Table 1 shows the settings for a cooler pressure control using R404a for different TDs and temperature.

Also be aware that almost all low pressure controls are physically installed near the compressor and there is a pressure drop in the suction line between the evaporator and compressor that should correspond roughly to 2F saturated suction temperature.

Smooth operation Using low pressure controls to keep refrigeration systems humming along

By Greg Scrivener Unlike the high pressure controls we discussed last month, there is no code requirement for low pressure safety controls, but they are so useful in operating and preventing damage to the system that a low pressure control (close-on-rise or open-on-fall) of some description is included with almost every commercial refrigeration system installed today.

These controls are not always used simply as a safety control; they can be used as defrost termination and temperature controls as well. The two most common uses are as a loss of charge safety control or as a temperature control.

Loss of charge safety controls are simply set to a pressure low enough that they shouldn’t trip off unless the system has lost a significant amount of refrigeration.

The setting of this control is not really crucial, but care should be taken to set the control to cut out at a setpoint lower than any normal operating suction pressure.

The differential should be large enough that the control doesn’t short cycle the compressor.

This can become a little tricky as the box or case warms up because if there is any liquid refrigerant in the evaporator the pressure will be roughly equivalent to the case temperature, so as the case warms up the pressure can increase, causing a quicker cycle of the compressor. The

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danger of the system operating at a low suction pressure isn’t usually the pressures themselves. It’s a combination of a lower mass flow of refrigerant – recall that in all hermetic and most semi-hermetic compressors the refrigerant is what cools the motor windings – and short cycling that causes the compressor windings to overheat.

When you approach a compressor that’s been operating low on refrigerant, it will almost always be hot to touch and occasionally will even be off on an internal temperature safety. Manual reset low pressure safety controls are available, but aside from a fixed setting type control in packaged air conditioning equipment, I don’t recall ever having seen one used.

Temperature control There are two ways that a low pressure control can be used as a part of the temperature control system. The first is to actually use the pressure control as a temperature control. This is fairly common in older reach-ins and small walk-ins.

In my experience, this practice is not being applied to very many new systems but, regardless, it is important to understand how to set these pressure controls as it is critical to the proper operation of the unit.

These controls work based on the fixed saturation temperature and pressure relationship; you will need a PT chart to set one. The key piece of information we are usually missing is the coil temperature difference (TD) – the difference between the saturated refrigerant temperature in the coil and the box or case temperature.

If you are fortunate enough to know the design or have this information available, it can give you a better starting point and take less time to get the setting right.

Barring that, you will have to make an educated guess.

Evaporating Temperature (°F)

TD (°F)

Cut-out Setting (psig)

Corrected Setting (psig)

28

7

68

65

25

10

64

61

20

15

56

54

15

20

50

48

Figure 1: Approximate cut-out settings for a R404a 35F cooler for different TDs - corrected settings incorporate suction line pressure drop Once you have picked a cut-out setting you must simply watch the unit and make small adjustments to the cut-out based on the box temperature when it cycles off. In larger cases or boxes this can take a very long time.

On a cooler, once the cut-out set-point has been determined the differential should be set to ensure that the evaporator rises above freezing during the off-cycle so that the coil is defrosted between each cycle.

In small boxes and cases this usually works well. In cases with large product loads and larger walk-in boxes, the air temperature often gets too high between each off cycle and the differential will need to be turned down and a time clock will need to be used for defrost.

Obviously a freezer uses a time clock for defrost so the differential setting only needs to be set to prevent short cycling.

Caution required The other method that a low-pressure control is used in a temperature control system is in combination with a liquid line solenoid and a temperature control. In this case the temperature control de-energizes the liquid line solenoid, which stops the flow of refrigerant to the evaporator. The compressor continues to operate until the low pressure control opens and the compressor is shut off.

By far, this is where the setting of a low pressure con-

October 2013 – Plumbing & HVAC

35

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■ Refrigeration

Different low pressure strategies Continued from page 35

Fig. 3: Operating Envelope trol is most neglected. Often the pressure control is simply set to cut out at zero psi or even in a vacuum. It’s true that a lot of compressors will operate in a vacuum perfectly fine, but you must be cautious. Scroll compressors and medium-high temperature reciprocating compressors can be susceptible to damage.

The best method to determine the cutout set-point for a low pressure control being used in this situation is to find the compressor performance charts. Examples are shown in Figure 2 and Figure 3.

The R404a reciprocating compressor from Figure 1 has not been rated below -10°F evaporating. This temperature is equivalent to 24 psig suction pressure. So, if possible, the minimum cut-out setpoint you would want to use in this situation is 24 psig.

Similarly, the lowest rating point in Figure 3, which is the operating envelope for a small medium temperature scroll compressor, corresponds to a cut-out set-point of 30 psig.

Practical considerations Admittedly, there are practical applications in which this is not possible.

Very cold freezers and compressors that are already operating at the edge of their performance envelopes present a challenge. In these cases, you will have to set the low pressure control cut-out outside of the operating envelope using experience and your judgment. And one final caution – a lot of scroll compressors will be seriously damaged by operating

in a vacuum and you must be particularly cautious with them.

The cut-in/differential setpoint for these controls can again be used to ensure a proper defrost for cooler evaporators by setting the cutin to approximately 40°F. While I have seen this done successfully, it does not work when the refrigeration condensing unit is outside or in an ambient temperature lower than the evaporators. The benefit of a reduced risk of flood-back associated with a pumpdown type control system is negated because large amounts of liquid refrigerant can sit in the evaporator for long periods of time. I prefer to set the differential in such a way that the unit always turns on when the temperature control opens the solenoid. This means that a defrost clock will almost certainly be required.

There are many more uses for all

different types of pressure controls and we likely will touch on those in a future article. The high and low pressure control are ubiquitous in commercial refrigeration systems and yet still present a challenge in achieving the proper setpoints, not only for proper operation and code compliance, but also for prevention of as much equipment damage as possible when things go wrong as inevitably they always do. ✚

Greg Scrivener is a Saskatchewan based refrigeration consultant specializing in education and energy analysis.

He is a journeyman refrigeration mechanic, holds RSES CMS designation in commercial refrigeration and is a mechanical engineer in training. He can be reached at greg.scrivener@colddynamics.com

Fig. 2: Performance Chart

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October 2013 – Plumbing & HVAC

37

Electronic Gauge with Vacuum Sensor

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■ Refrigeration Leak detection kit The Spectronics EZ-Ject leak detection kit pinpoints refrigerant leaks in small to medium size air conditioning and refrigeration systems. Leaks are revealed by a bright fluorescent glow picked up with a rechargeable violet light LED flashlight with an inspection range of up to 25 feet. Also included are a dye injector, two multi-dose 0.5 oz (14.8 ml) dye cartridges, hose assembly, dye cleaner, three drip plugs, an AC/DC charger and fluorescence-enhancing glasses.

Spectroline u www.spectroline.com

Efficient cooling tower Baltimore Aircoil (BAC) has improved it’s Series 3000 open circuit cooling towers with up to 16 percent increase in thermal capacity, improved energy efficiency and enhanced payback analysis. These units meet or exceed new efficiency requirements set out in ASHRAE 90.1. They offer superior winter operation, and they are easy to maintain with direct access to the fan drive system, cold water basin and water distribution system.

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Unitary control The Simplicity Intelli-Comfort II unitary control from Johnson Controls now incorporates variable air volume (VAV) technology utilizing a variable frequency drive (VFD) and the company’s new “IntelliSpeed” multiple speed airflow control technology. It is factory or field configurable to operate from a field installed thermostat or zone/space sensor. It offers energy savings through the intelligent control of fans, economizer, compressors and other functions Johnson Controls u www.yorkhvacdealer.com

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■ ICI Mechanical

Effective project management, Part II Putting the theory into practice in a rooftop retrofit

By Michael McCartney, P.Eng.

Planning and communication meant the crew knew exactly what they had to achieve.

In the last issue I talked about how using a military system for mission orders also works well in project management. In the military, one is taught to follow SMEAC, an acronym for: ‘SITUATION,

became: Carry out the replacement in as little time as possible.

The mission was made all the more urgent by the need to do all of the hoisting from a busy city street with a

MISSION, EXECUTION, ADMINISTRATION, COMMUNICATION.’ In project management, this system can and will lead to smoother operations in the field.

A good example of a project we handled at Techaire (Brampton, Ont.), where SMEAC came in handy, had to be a high-rise condo project in Mississauga, Ont. where a retrofit of most major HVAC items was called for.

The building was of mid-1980’s vintage and in 2004 we quoted on and were awarded the contract to go ahead and replace a chiller, cooling tower and 17 small (two-ton) rooftop packaged units that served the penthouse suites.

The chiller was an older, outmoded

and non- convertible R-11 machine that featured a gear-driven impeller and made a hellish howl when operating.

Because one of the members of the condominium corporation’s board of directors had his bedroom located directly beneath the chiller room and found sleep to be unattainable in summer, the project had a sense of urgency.

The cooling tower showed signs of age and neglect, with moss growing in and amongst the media and signs of leakage around the joints in the pan. The spring vibration isolators were rusted and bottomed-out.

The heating/cooling units serving the penthouse units were experiencing frequent breakdowns, some of which required compressor replacements, and a few of them had cracks in the heat exchangers. As anyone familiar with two and 2-1/2 ton units can tell you, swapping out a heat exchanger in such a small unit usually costs about the same as replacing the entire unit.

Setting the stage

New equipment arrived at the allotted time, minimizing expensive crane time.

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All of this was explained to the crews who would do the work well in advance of the project being carried out.

The SITUATION was, therefore, made clear to our employees: the systems were old, the equipment had to be replaced, and our MISSION

very expensive 340-ton crane and to include all elements of the job – cooling

Please see ‘Assembling’ on page 43

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October 2013 – Plumbing & HVAC

41

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■ ICI Mechanical

Assembling the pieces Continued from page 41 tower, chiller and the packaged rooftop units – in as little time as possible. It all had to be done in one hoist and within regular working hours.

We EXECUTED the project initially by changing out one of the old rooftop units. This entailed moving a new unit, by hand, up the stairs from the penthouse level corridor to the roof, measuring and fabricating a roof curb adapter, manually lifting out the old unit and putting the new one in place.

This allowed our sheet metal bench man to start fabricating the remaining curb adapters out of 16gauge galvanized sheet metal with weatherproof, soldered steel joints.

Because of the backbreaking nature of using the ‘Hercules’ method of hauling a 500-lb unit up stairs, it was decided, with the approval of all concerned, to use labourers from a demolition company to do that part of the job. We had our supplier send all of the remaining packaged units to the site at one time and off-loaded them, stacked two-high, with an eight-ton boom truck.

The units weren’t so heavy that four men couldn’t lift them; however their bulk made them tough to handle.

As the new units were hoisted up, the old ones were taken down.

with the rubber mats underneath it all. This would dampen any low-frequency vibrations caused by fluid flows within the chiller and associated piping, with the rubber mats accounting for the higher notes emitted by the new chiller, which had screw compressors.

When the time came to do the heavy lifting, all the new packaged heat/cool units were set beside the old ones, the curb adapters were ready in our shop and the items used for setting in place the chiller and tower (steel spring vibration isolators, a heavy steel mounting base and some ¾inch rubber pads) were set to be delivered to the site on the appointed day of the hoist, as was much of the pipe and a Victaulic machine used for re-working the condenser lines.

The fact that all items were ready on the day of days can be attributed to good ADMINISTRATION of the project. The sheet metal crew knew what they had to fabricate, having gotten measurements ahead of time and acted on them. Shop drawings of the chiller, tower and rooftop units were provided to all Manhandling the new rooftops up two flights of stairs also parties: the Techaire crew, the people from the crane company, and the heavy reduced the requirement for crane. machinery moving company who took Our subcontractors sent a crew of four men to handle out the old chiller and moved the new one in place on the units, but carrying four units per day up those flights top of the mounting base, as well as the electricians of stairs and across the roof left them exhausted. It took engaged for the power hookup. four days to get the new units up and set aside from the We even arranged to have the old units taken away old ones they were to replace. by a company that re-sells used A/C units, thereby saving the time and labour required to remove the Careful preparation Freon from them.

We prepared, ahead of time, drawings of all four walls of the chiller room, clearly marking the centers of all Good communication critical piping penetrations. This enabled us to get an accurate COMMUNICATION on site was left to the Techaire price on the replacement of the rusted-out condenser foreman, the late Mike Colledan, a superb man who piping. We designed a very heavy steel base for the knew what had to take place and how best to do it. He chiller, comprised of a 6x6 box steel frame set atop two made sure the crew on the roof were tied off with proper foot-wide quarter-inch plates, all of which were to sit fall protection or kept inboard at a safe distance, atop several ¾-inch mats of recycled rubber. The idea communicated with the crane operator via cell phone was to have the chiller sit on steel spring vibration and, in short, brought the mission off faultlessly. isolators, which would be mounted onto the heavy base, In the space of four hours from when the crane was

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counter-weighted and ready to hoist to when it was broken down again for transport, Mike saw to it that the old chiller was removed, the new one set outside the machine room for the heavy equipment movers to handle the next day, the tower set in place on new springs, the old rooftop units taken away and the new ones with their plenums set in place and made ready to be powered, gas-piped and started.

It was a triumph of good planning, swift execution and, in the end, a profitable job carried out by smart, competent people who knew their jobs because they were well led by a foreman who really knew his stuff.

The following summer, that board member was able to sleep at night with a chiller running overhead….finally. ✚

Michael (Mike) McCartney is a mechanical engineer and project manager. After 28 years with Techaire and E.S.Fox Ltd., Mike is with MCW Consultants as consulting engineer/project manager at their Toronto office.

He can be reached at MMcceng77@aol.com.

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www.raptorcutting.com October 2013 – Plumbing & HVAC

43

top performer

Industry-leading Genetron® Performax™ LT refrigerant is the clear leader in its field.

If your bottom line is a better bottom line, no other supermarket refrigerant comes close.

From keeping fresh food fresher longer to energy savings to eco-friendly performance, the list of reasons to choose Genetron ® Performax™ LT over R-438A or R-407A refrigerants goes on and on. Genetron Performax LT offers industry-leading capacity, industry-leading efficiency and low GWP values versus other popular supermarket refrigerants. This saves money in new installations and in R-22 retrofit projects. Plus, a mass flow that identically matches R-22, eliminates expensive expansion valve changes and adjustments in retrofit applications while maintaining superheat performance which protects costly compressors. So go with the gold standard. Go with Genetron Performax LT. Maximize Performance with Performax LT.

Brenntag Canada Inc. Exclusive distributor of Genetron® refrigerants in Canada Ontario & Western Canada: Tel. No. (416) 243-9615 Fax: (416) 243-9731 Quebec & Maritime Provinces: Tel. No. (514) 636-9230 Fax: (514) 636-8229 To learn more, call 800-631-8138 or visit www.genetronperformaxlt.com. © 2010 Honeywell International Inc. All rights reserved.

■ Pipes, Valves & Fittings Fig. 1: State-of-the-art in the 1970s, variable frequency drives offer much better efficiencies than this triplex boosting system.

Variable

speed

pumping

The gradual evolution of high-rise booster systems By Bill Hooper, C.E.T. Was everything better in days past? For some things, like fishing, I would agree! I am not so sure, however, when it comes to pumping system technology. I have been selling pressure booster systems since 1989 and recall that constant speed systems like the triplex unit shown in Figure 1 (1970’s vintage) were the staple of engineering practice.

Pumps shared the load, starting and stopping and working together up to 100 percent load. Controls for this were normally based on amp draw and it was rare that all pumps would be on at the same time. If there was only a small load in a large building, one pump was engaged and would run at full speed against a pressure reducing valve.

Yes, way back in the old days, say about 15-20 years ago, we used to work really hard to sell variable speed pressure booster systems. I was considering asking for a special plaque and a tree to be planted to commemorate such a sale.

We had to justify the very concept that we would even remotely consider applying frequency drives to pressure boosting.

That was crazy talk. Energy was relatively cheap, so we had to bring out the heavy artillery; we had to bring up things like fluctuating suction pressures, where to locate the sensor so we took advantage of

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variable friction losses in the system, and how much easier variable speed was on the piping, valves, and related equipment.

Despite all of those considerable benefits, we still had to justify a variable speed unit with a simple payback of less than three years, or you were out of luck.

After all, constant speed systems were doing the job, providing water to the building. Before it was retired to move to a variable speed system, the vintage booster set shown in the picture had three pumps, a lead pump and two lag pumps with 63,167 hours, 62,388 hours, and 48,433 hours of run time respectively.

Other than routine maintenance, this unit went about its business without a second thought over many years.

to provide full load when it is needed, it happens very rarely. The majority of run time is below 50 percent of full load and, depending on the building type, the majority of running hours can be less than 25 percent.

Matching the load

“Fudge factors”

While it is true constant speed systems work to deliver water and pressure, it is like having your foot on the gas and the brake at the same time driving down the road. Variable speed matches flow and pressure to actual load, so oversized pumps can be managed with the right controls, and optimized with the right pressure sensor placement.

The main drawback with constant speed booster systems is that pump selections are oversized to account for full load conditions that happen very rarely. It is part of the design process to estimate how many of the plumbing fixtures will be in operation simultaneously. The load profiles on page 47 indicate the required running time and percent of full load capacity.

It is easy to see graphically, that although the system needs to be designed

Rules of thumb and estimates for full load (with “fudge factors” – and don’t pretend you don’t know what that means) only make the situation worse, as they are too conservative. Constant speed systems can accomplish the task, but with a degree of energy waste; pumping to create pressure and trying to produce flow that is not always needed in the system. Pressure reducing valves would keep excess pressure from being realized in the system (another waste of energy).

Based on these issues and findings, having a way to control a pressure boosting system with intelligence is important. To do this right, we need the finesse to take a system large enough to provide full flow during high demand and turn it all the way down to provide as little as 10 percent or less of the design flow effectively.

We also need the flexibility to use all the pumps in the system to accomplish the appropriate flow and discharge pressure with parallel, or individual pumping. We need the pumping know how to interpret sensor input in the form of a feedback signal to give us a process variable to pump to as a set-point.

Adoption slow I would estimate that about 10-15 years ago, consulting engineers started to warm up to the idea of placing drives on booster systems. Variable frequency drives were getting smaller and more affordable and they were beginning to apply them in other HVAC and closed loop pumping systems. I started to see the possibilities… a world with variable speed pumping for pressure boosting applications!

Matching flow and pressure to load… WOW! Over time, it became more and more viable. In these last 10 years, we have seen installations go from one variable in every five systems to practically the inverse.

Please see ‘Better’ on page 47

October 2013 – Plumbing & HVAC

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■ Pipes, Valves & Fittings

Better boosting with variable speed Continued from page 45 The math becomes much more interesting. If you narrowed the price tag gap between the two systems and understood the operational inefficiencies of constant speed systems, you could see the benefits in a new light.

ASHRAE 90.1 is now an engineering design standard and it encourages using variable speed as a best practice. The vintage system above was converted to the variable speed system shown in these pictures.

New mindset In fast forwarding to the present, we are finding that booster systems designed for small residential to large municipal and industrial applications have variable

speed as the system of choice.

The engineering has not changed, nor the rationale to justify variable speed pressure boosting, but the mindset of the decision makers sure has. The ASHRAE 90.1 standard has been a catalyst for the new design of larger projects, and has been an example to emulate for system retrofits. Many contractors and building owners are also seeing the benefits to the point where even design-build projects are using variable speed pressure boosting from small to large systems.

A lot has changed since those good old days. In truth, variable speed pressure boosting has always been a good idea from a performance perspective and

remains so today. It was interesting to have seen the progress of this technology over the years and I look forward to the next advances in pumping system effectiveness and efficiency. ✚

Bill Hooper, C.E.T., has been in engineering sales since 1989 working for a manufacturers rep, and then for Bell & Gossett directly since 1995. Based in New Brunswick, he can be reached at bill.hooper@xyleminc.com.

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■ Trucks for the Trade

McKeown & Wood technicians sometimes carry extra propane and fuel oil to help their customers make it through the night.

All season radials with aggressive tread patterns help Arpi’s technicians through the Calgary winters

Service van

winter prep

With modern vehicles, communication systems, is it really necessary?

By Simon Blake

T

here was a time when contractors went to considerable effort to get their vans and trucks ready for winter. However, modern vehicles, tires and communications technology have reduced the burden somewhat.

That, however, can lull a contractor or his technicians into a false sense of security. Maintaining vehicles in excellent operating condition is critical to avoid winter breakdowns.

“At the end of the day, it’s all about trying to do the same thing (with your vehicles) that you do with rooftop units – make sure the oil is changed regularly, filters are changed, the air filter is clean. In general, just be on the technician’s cases to treat the vehicle like their own.

When there’s small repairs, they need to take care of them before they become major,” remarked Walter

Please see ‘Different’ on page 51

www.plumbingandhvac.ca

Things like vacuum pumps need to be brought indoors at night to prevent freezing.

October 2013 – Plumbing & HVAC

49

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â– Trucks for the Trade

Frontier technicians plug their trucks in to ensure they start during cold Manitoba winters.

Different regions, different issues Continued from page 49 Lehmann, president of Frontier Refrigeration in West St. Paul, Manitoba.

And that, perhaps, is the biggest challenge. Cold weather means HVAC/R equipment is more likely to break down, pumps and pipes can freeze. Contractors become busy and just finding time to perform routine maintenance can be a challenge. This makes it critical to reduce, not just breakdowns, but wintertime maintenance to the absolute minimum.

Different regions, different challenges Winter truck preparation varies depending on typical winter weather conditions in each region.

Lehmann knows a thing or two about cold weather operation. It’s not unusual for Manitoba night-time winter temperatures to drop below -40C. Technicians take their vans home at night and they typically plug in the block heaters. “Being rooftop service techs, at the end of the day when they come back from a service call they know how cold it is,� he remarked. “I think for the most part they all routinely plug them in. Nobody wants to be out there and hear ‘click, click, click.’�

www.plumbingandhvac.ca

Battery care is critical. “Suspect batteries are replaced before the cold weather and block heaters are tested. We use fuel conditioners and overall proper maintenance provides a service vehicle that is ready to go when called upon,� reported Jim Wood, president of McKeown & Wood Fuels in Napanee, Ont. None of the contractors that spoke to P&HVAC are using specialized snow tires, but they all emphasized that tires must be new or in very good shape. It’s not a place to cut costs. “We run a more aggressive tire on our vehicles compared to what is supplied by the manufacturer. They are all-season tires that can run year round, but have good winter traction due to tread design� reported Frank Kipke, in-house mechanic for Arpi’s Industries in Calgary.

A little extra weight in the back can help with traction, but with the tools and supplies that plumbing and HVAC/R vehicles typically carry, it’s typically not an issue. Employees at Hamco Heating & Cooling Ltd. in Hamilton, Ont. sometimes put a few sandbags in the back of pickup trucks during the winter, said operations manager Andrew Vasilak.

In southern Ontario, extreme cold is not typically an issue but snow can be

A few sandbags help Hamco pickups find traction in Hamilton.

heavy at times. Moist air, temperatures that vary widely, and a whole lot of salt on the road tend to dictate the required preparation. “The road salt is usually the biggest culprit for damage to the bottom of trucks,� added Vasilak.

The company’s pre-season fall truck checkup typically consists of pulling the parts and tools out, cleaning inside and out, having a mechanic do a full

Please see ‘Keeping’ on page 52

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■ Trucks for the Trade

Keeping the technician safe

backup cameras that are a huge help to techs backing in and out of tight spots, added Vasilak.

Continued from page 51

Freeze protection

mechanical inspection and checking for rust and having the vans rust-proofed.

Things like brakes need to be checked and not-so-obvious things like seat belts should also be checked, he added.

Hamco keeps its vehicles in the shop at night. That substantially reduces the likelihood of trucks or equipment freezing up.

Arpi’s has a year-round preventative maintenance program that requires each truck to undergo a minor service and inspection at 5,000 kilometres and a major service and inspection at 30,000 km, said Kipke.

This includes fluid changes and a gravity check on the anti-freeze to ensure

it won’t freeze. Batteries are checked.

Block heaters are tested. Tire tread depth is measured. By following a detailed scheduled maintenance program, when winter comes there is no need to bring the trucks in for special preparation, added Kipke.

Special safety equipment Thirty years ago it was common to carry things like tire chains, flares and blankets.

“Our biggest safety device today is the cell phone,” says Lehmann. And Frontier Refrigeration subscribes to a service that calls every technician every hour. “It’s a work-alone requirement. You can’t take any chances.”

Arpi’s technicians use both iPhone work-alone monitoring “apps” and the

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company also has an after-hours workalone protocol that keeps technicians in regular contact with an answering service, reported company president Julie Berdin.

If the van is left outside overnight, obviously anything that might freeze must be brought inside. This includes things like vacuum pumps, glues and sealants for piping, battery powered tools, etc.

The glue for System 636 HVAC vent pipe seems particularly susceptible to freezing, noted Vasilak. Letting a vacuum pump freeze causes the oil to thicken and means “you’ll be burning out vacuum pumps left right and centre,” remarked Lehmann.

Water jet drain cleanContractors must ensure their employees can reach ing machines should, if at all possible, be brought the jobsite safely. From left are Apri’s technicians inside at night, advises Olivier Bergeron-Gelinas, Jami Fawcett and General Pipe Cleaners Simon Stunell. (www.drainbrain.com).

McKeown & Wood has a similar If that’s not possible, they should be system. “They all have cell phones and flushed with anti-freeze and then the we utilize a vehicle GPS tracking system anti-freeze should be drained prior to the so we know where the trucks are 24 next use. hours a day. There is always someone on Operating in a rural area with many call in addition to themselves so that customers using propane or oil to heat they can call for assistance if required,” their homes, McKeown & Wood said Wood. technicians carry extra propane Training in workplace safety along cylinders and cans of heating oil to with common sense on the part of emensure the customer will have heat ployees goes a long way too. Frontier Rethrough the night. frigeration is COR certified (Certificate However, no matter how well of Recognition), a health and safety prepared one is, there will be times when management program that is often reit just won’t be possible to reach the quired for public and private sector concustomer. Twice in the past 10 years, struction projects.

Hamilton has been snowed in and Room for extra safety equipment in a nothing was able to move, reported service van is typically limited. Some Vasilak. In other regions of Canada, such Arpi’s technicians carry chains if they are occurrences are more common going into remote areas, said Kipke. Laws No service call is important enough covering chains and studded tires vary to risk injury to staff, says Wood. “Most across the country. often I leave it to the service tech to A set of booster cables in colder assess the road and weather conditions regions can be lifesaver, in addition to and if they deem it safe they proceed, regular safety equipment like first-aid although there have been times when I kits and fire extinguishers. Of course, it’s have called the on-call staff person and critical to ensure these are maintained. requested that they do not go out, And while it’s not specific to winter, effectively grounding them until Hamco outfits its service vans with conditions improve.” ✚

www.plumbingandhvac.ca

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■ Tools & Instruments

High-Efficiency Appliance Venting

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Serious cordless grinding A good disk grinder is essential for anyone that works with metal. But there are good grinders and then there are grinders that stall when you put your weight into it. And that’s with conventional corded grinders.

So we were a little skeptical when Milwaukee Tools introduced an 18-volt cordless grinder. But we had an opportunity to try one at the company’s annual media day in Milwaukee last June and we This cordless grinder provides the grinding/ couldn’t stall it in either grinding or cutting cutting power of a good corded unit. applications. Milwaukee’s claim that the new M18 Fuel grinder delivers “true corded performance without the cord” proved accurate.

“The new FUEL Grinders effectively grind, cut and surface prep, while existing cordless tools are only effective as cut-off tools,” said Andrew Plowman, group product manager.

Milwaukee has combined three technologies to achieve this performance – lithium ion batteries, a brushless motor and “REDLINK Plus” intelligence, which is basically a computer built into the battery pack that communicates with the tool and optimizes power delivery, run time and charging.

The cordless grinders feature the same metal housing and gears found in the company’s corded grinders. Disk changes can be made without tools. A slim compact structure makes it easy to handle.

While this cordless grinder may not replace corded units in the shop, it would certainly be useful to have in the truck or on the jobsite.

Milwaukee Tools u www.milwaukee.com

Durable HVAC gauges The new Hilmor Aluminum Manifold is designed to be durable in the field. It is available in two- and four-valve models and includes easy-to-read gauges with high-contrast colours and clear graphics, rubberized handles for easy turns and

Economical thermal imaging The new FLIR E-Series line of thermal cameras is designed to track down overheating, moisture ingress, missing insulation, air leaks, and a host of other issues at an economical cost. They feature a vivid three-inch color LCD display, wide-angle focus-free lens, intuitive oncamera button controls, on-board digital camera, and the company’s Multi-Spectral Dynamic Imaging technology, which integrates visible details from digital camera photos onto IR images for a clearer picture.

FLIR Imaging Systems u www.flir.com

faster vacuum pulls with a true 3/8-inch bore on the four-valve. Other features include replaceable stainless steel valve seats, protective gauge boots, front-mounted hose positions and a permanent location for temperature clamps.

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Self-levelling camera RIDGID has announced a new self-leveling camera head for its SeeSnake Max rM200 camera system. The new head was added to help take the guesswork out of inspections. Users can now count on a clear, right-sideup image or video in even the most complicated lines. The company is offering a free self-leveling camera head to existing rM200 owners.

RIDGID u www.ridgid.com

Sees behind walls The Boroscope from General Tools is designed to let the technician to see behind walls and in other areas that can be difficult to inspect. Using the instrument’s Wi-Fi hotspot capability and a free app, the technician can instantly and wirelessly view and save high-definition inspection video and images to their smartphone or tablet. This eliminates the need for an integral monitor or a wired connection to an external monitor, reports the manufacturer.

General Tools & Instruments u www.generaltools.com

www.plumbingandhvac.ca

Power pressing tool The new Slim-line power press tool from HeatLink is designed for increased efficiency and reduced fatigue when making larger diameter PEX connections. It has interchangeable jaws ranging from ½” to 1 ½”. It offers short pressing cycles of 3-4 seconds and a quick charging time of just 15 minutes. The tool is built using Makita lithium ion battery technology.

HeatLink u www.heatlink.ca

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October 2013 – Plumbing & HVAC

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■ Training

The Right Tools

For HVACR Professionals

Laminated beams dominate the new atrium and provide a learning experience.

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Construction school upgrade at SAIT Polytechnic tudents in the construction, manufacturing and automation trades returned to a newly renovated state-of-the art classrooms and labs at SAIT Polytechnic in Calgary this fall.

Originally opened in 1952, the Thomas Riley building has undergone $60 million in renovations to 162,000 square feet of learning space.

This comes just a year after SAIT, formerly known as the Southern Alberta Institute of Technology, opened its world-class Trades and Technology Complex.

Updated spaces in the Thomas Riley building include a home lab that can accommodate the construction of two 1,200-square-foot homes simultaneously and a brand new millwright and natural gas compression lab.

“Students are our top priority and we wanted the new spaces in Thomas Riley to be designed to enhance the curriculum and ensure our students are highly trained for their current and future employers,” said Scott MacPherson, dean of the School of Construction. “The new Founding Builders Home Lab will allow us to build six houses a year with students — invaluable experience to take with them to their first job.”

The renovation has added 40 years to the life of the building and was focused mainly on improving the student learning experience — classrooms, labs, and study space — and giving it the same interior look and feel as the other new buildings on campus.

S

www.plumbingandhvac.ca

A new atrium space for students to gather and study has also opened. Large laminated wooden beams that are stronger and more dimensionally stable then traditional heavy timber construction materials and were included with learning in mind.

“Construction students can look up in the atrium and see the materials they will be working with on projects both in class and later in industry,” said Boris Dragicevic, associate vice president of facilities management and campus expansion.

For more information, visit www.sait.ca. ✚

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■ People & Places

Taco Canada welcomes new rep A dinner cruise around Toronto Harbour on Sept. 18 introduced about 130 Taco Canada customers to the company’s new Canadian manufacturer’s representative, Emerson Swan, on Sept. 18.

The two companies have a long history in the U.S. Emerson Swan has been representing Taco – formerly the Thermal Appliance Company – since 1934, reported Parker Wheat, CEO for the rep agency, headquartered in

Randolph, Massachusetts.

“The relationship between Taco and Emerson Swan is more than just a business relationship,” added Taco president John Hazen White Jr. via video feed.

Emerson Swan Canada has 20 Parker Wheat employees at its Toronto location. “We are in this for the long haul,” said Wheat, noting that it takes time to build relationships. The company intends to distribute Taco products through wholesale channels, he added.

Customers and friends gather on the Toronto waterfront for an evening boat cruise with Taco.

Trade-only showroom marks successful year Staff at the Kitchener, Ontario Desco Water Closet plumbing showroom invited their friends to celebrate its first anniversary on Sept. 19.

“It’s been a successful year for Desco’s newest showroom and we wanted to thank our loyal customers and invite some potential new customers to join us in the celebration,” reported branch manager Melanie PeetWinkfield.

“Our trade only policy – we don’t sell retail – in this

showroom has really helped define us in this market and gain the loyalty of our contractor and trade customers both in our showroom and wholesale operations,” she added.

Over 100 people joined in the celebration, which was sponsored by American Standard.

The showroom is located at 241 Shoemaker Road in Kitchener. Call (519) 743-6827 or visit www.watercloset.ca for more information.

From left, Matthew Cloyd, Desco HR, Anne Jamieson, Watercloset sales, Kathryn Holman, showroom supervisor and Brian Ruetz, Western region sales manager, celebrate the anniversary.

The

People Michael Warne has been appointed Canadian sales manager for Flow Design Inc., based in the Toronto area.

BMI Canada Inc., Boisbriand, Que., has named Alexandre Laroche vice president, information technology Michael and innovation and Rachel Bouthillette as vice president, procurement.

Warne Brad Diggens, MJS Mechanical Ltd., Calgary, Alta. has been appointed chairman of the National Trade Contractors Coalition of Canada replacing Bob Hoare, Adelt Mechanical Ltd., Mississauga, Ont., who has retired from the chairman’s role.

The Canadian Institute of Plumbing and Heating (CIPH) has appointed Shamus A. Allidina as its technical advisor for codes and standards.

The

Companies Trane Newfoundland has moved into a new 3,800 sq. ft. office and parts centre at 22 Beclin Road, Mount Pearl. The new location has already been drawing more traffic, reports area manager Jon Hare. The new location can be reached at (709) 753-9807.

www.plumbingandhvac.ca

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THE WORLD’S LARGEST HVAC R

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JAN UARY 21-23 JAV ITS CON V E NTION CE NTE R A H R E X P O.C O M /AT TE N D54

■ Coming Events NOV. 14-15: Ontario Geothermal Association Annual Conference, Hockley Valley Resort, Orangeville, Ont. Contact Heather GrimoldbyCampbell at 1-800-267-2231 or hgrimoldby@hrai.ca or visit www.ontariogeothermal.ca.

DEC. 4-6: Construct Canada, Metro Toronto Convention Centre, South Building, Toronto.

Visit www.constructcanada.com for more information.

JAN. 18-22: ASHRAE 2014 Winter Conference, New York Hilton Hotel, New York City. Visit www.ashrae.org for information.

JAN. 21-23: AHR Expo, Javits Center, New York City.

Call (203) 221-9232, e-mail info@ahrexpo.com or visit www.ahrexpo.com for more information.

MARCH 8-14: Canadian Construction Association 96th Annual Conference, Westin Playa Bonita Panama, Panama City, Panama. Call (613) 236-9455 or visit www.cca-acc.com for more information.

INDEX to

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www.plumbingandhvac.ca

All-trades show marks milestone Canada’s largest all-trades show will mark 25 years when it returns to the Toronto Convention Centre this year.

Construct Canada is scheduled to take place in the South Building Dec. 4-6.

Billed as “seven shows in one,” Construct Canada is held concurrently with PM Expo, Design Trends, Concrete Canada, Home Builder & Renovator Expo and the National Green Building Conference.

The show typically draws a number of plumbing and mechanical industry exhibitors scattered amongst other exhibitors displaying everything from aluminum siding to hardwood to concrete products. Organizers expect about 1,050 exhibitors this year.

There is also an extensive seminar program with 450 speakers and over 200 presentations. Seminar topics were unavailable at press time.

For more information, visit www.constructcanada.com.

AHR returns to New York The AHR Expo, North America’s largest HVAC/R trade show, will return to New York City in January. This year’s event – the 66th annual – will take place Jan. 21-

Mitsubishi Electric .....................24 Mobilio .......................................4 Napoleon ..................................26 Noble ............................29, 31, 33 Noritz........................................16 NTI ............................................22 *Ontario Power Authority .........56 RaptorCutting Tools ..................43 Rheem Canada .........................46 RIDGID ......................................64 Rinnai........................................34 Saniflo.......................................40 Taco Canada ...............................2 Testo Inc....................................59 Uponor .....................................36 Urecon ......................................23 Victaulic ......................................9 Viega ........................................63 Viessmann Mfg. ........................11 WatcoMfg.................................17 Wiring Pro.................................27 Woodford Mfg..........................32 Worx.........................................52 Zurn Industries ..........................51

Zurn was among the mechanical industry exhibitors at Construct Canada in 2012.

For more information, please visit www.ahrexpo.com.

Geothermal conference 23 at the Javits Convention Centre.

Pegged as “Sustainability Central,” the event will feature numerous seminars and hundreds of products geared to energy efficiency in buildings. This year’s event is expected to draw almost 2,000 exhibitors from around the world.

The Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI) is an honorary sponsor.

The Ontario Geothermal Association will hold its 2013 annual conference at the Hockley Valley Resort, east of Orangeville, Ont., Nov. 14-15. A full day of business sessions is planned, along with a gala dinner.

For more information, please contact Heather Grimoldby-Campbell at 1-800267-2231 or hgrimoldby@hrai.ca or visit www.ontariogeothermal.ca.

Knowledge is power.

And empowering HVACR professionals is what HRAI is all about.

HRAI’s technical manuals have become the leading source of HVAC best practices in the country.

They’ve helped thousands of industry professionals maximize their knowledge of HVAC fundamentals, design and installation.

They can help you too.

Visit hrai.ca/manuals

HRAI Technical Manuals Your ‘go-to’ source for best practices.

*Ontario only

October 2013 – Plumbing & HVAC

61

■ Shop Management

Getting paid Managing your accounts receivable effectively is one of the most important traits of a successful contractor. The average HVAC contractor in Canada made six percent operating profit last year. That means to recover $100,000 in bad debt takes over $1.6 million in sales; even a $10,000 write-off requires $160,000 in additional sales and that hurts. Profits are no good until they are turned into cash. Most companies that go broke do so because of failure to manage their cash flow.

There are certain guidelines that should always be followed: Never work for a customer without checking his payment history with other contractors. Also, find out how fair he is in dealing with extras. Go to your association meetings and ask about the payment history of people you are quoting to. Suppliers often trade information about which contractors are slow to pay their bills.

Never let your lien rights expire. It is very easy to remove a lien once you get paid. Each province has different lien legislation. Have your lien filed using a lawyer to ensure that you

Happiness is a healthy cash flow

By Ron Coleman

have completed it correctly.

When a general contractor receives payment from his customer he receives it in “trust” for the benefit of wages, suppliers and sub trades. If that money is not apportioned correctly the general may be liable for “breach of trust,” which is a criminal offence.

Never get concerned about arguing with a client who doesn’t pay you promptly.

Their response that “we won’t ever give you any more work” should be a relief to you.

If a job is bonded then file a complaint with the bonding company. Bonding companies get very upset when their clients are being accused of nonpayment. Even if you are a sub-trade you should check to see if your client has given the owner a “labour and material bond”.

You would likely be protected under it.

“Sub-subs” are not likely to be protected. Get a copy of the bond so that you know exactly what procedure to use in case you have to file a claim.

For more information on the various types of bonds available and how they work go to http://www.jml.ca/wp-content/upl o a d s / p u b l i c a t i o n s / Co n s t r u c t i o n BondsWhatEveryContractor.pdf (see page 16 for labour and material bonds).

Difficult customers Where a job is not bonded, go over the head of your client to the owner and tell them you are considering putting a lien on the job to protect yourself. Never get concerned about arguing with a client who doesn’t pay you promptly. Their response that “we won’t ever give you any more work” should be a relief to you. Tell them that you will hold them to that commitment.

Where possible get all changes approved in writing before proceeding. If you are obliged to proceed “under protest” do so, but tell them in writing that you are doing so and document your claim fully and keep your client informed. Not billing a legitimate change order is the same as writing off a bad debt.

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Plumbing & HVAC – October 2013

Small claims court is the simplest way to collect on smaller amounts. Each province has its own limit. For example, the limit in British Columbia is $25,000. So, if you were a B.C. contractor having a dispute for $30,000, I would recommend reducing the claim to $25,000 and going after it in small claims court.

Getting deposits is also an effective way of reducing bad debts. Keep the deposit and offset it against the final claim.

Do not give portions of it back with progress draws.

How do you keep accounts receivable out of the 90-day column? By not letting them get into the 60-day column in the first place. There should be someone within your organization who has as their primary responsibility the collection of accounts receivable. They should be staying on top of collections every day. This can’t be left to someone to do after their other tasks are done.

Make sure that you claim back the HST/GST and (in some provinces) the PST on amounts not collected.

Always try to use arbitration before bringing in lawyers.

Another approach is to use a company that specializes in dealing with construction claims if it is a dispute rather than a collection issue (Revay & Associates, for example).

Try to stick to recognized contract documents such as CCDC 2. Also, ask your clients if they comply with the code of ethics of the Canadian Construction Association.

The Ontario General Contractors Association has a code of ethics. It can be viewed at http://ogca.ca/members/code-of-ethics. Many other construction associations have adopted similar documents.

Where the owner is an individual you may be able to put a black mark against their credit rating. But take legal advice on this first as I don’t want you getting countersued for libel.

There are two main reasons contractors don’t get paid.

Firstly, they work for clients who either can’t pay or have a reputation for not paying and secondly because they have not documented their claim completely. Check out the former before you quote them and follow the following for the latter: documentation, documentation and documentation are the three most critical elements of any claim.

Always sign a contract before starting on a project; relying on common law to get paid is fraught with dangers. Be prudent in who you deal with and stay on top of collections on a regular basis.

I do have a booklet on this topic and if you email me your request I will email you a copy of it. ✚ Ronald Coleman is a Vancouverbased accountant, management consultant, author and educator specializing in the construction industry. He can be reached by e-mail at ronald@ronaldcoleman.ca.

www.plumbingandhvac.ca

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