• Tag Archives ECM
  • SUBMISSION FOR NON-PROVISIONAL (UTILITY) PATENT PROTECTION

    BoilersOnDemand.com via its Principal, Paul D, Mercier, Sr., has filed for Non-Provisional Intelligent Property Protection (Utility Patent) in the United States of America and Canada on the: ENHANCED CONVECTION, DIFFERENTIAL TEMPERATURE MANAGED, HYDRONIC HEATING APPLIANCE.

    We deem this to be the first, truly integrated, free-standing, simple, durable Hydronic (FHW) Heating Appliance in the Market. Enabled by recent advances in Delta-T ECM Hydronic Distribution, the major elements of energy generation and distribution augmented by our optimization of natural convection (Gravity Heating) comprise the highest efficiency product available ….. bar none!

    A true “appliance”, merely coupling it to site utilities and radiation effects a completed hydronic (FHW) heating installation. Dramatic reductions in materials, labor & skill content, floor-space and maintenance have been realized. A truly “Value Engineered” product.

    Further detail will be made available on our web site www.BoilersOnDemand.com as we finalize our patenting process.


  • DELTA-T ECM HYDRONIC DISTRIBUTION – Really “Raising The Bar”!

    Heating and moving water (hydronics) is recognized as the most efficient method of creating and distributing warming energy. From the Roman Baths to Gravity Piped Hot Water Systems of a century ago natural convection of heated water provided a simple, if seemingly temperamental solution.

    Adding pumps (circulators) to heating water distribution has forever improved comfort an flexibility. However, their application has been less than ideal, utilizing only fixed-speed/capacity circulators, typically poorly applied to residential heating in particular. Using a “one size fits all” approach and swapping sizes to effect results has been a thorn to the trade suppliers.

    Applying switchable, multi-speed circulators has provided an interim solution to poor matching options. Further, measuring actual circulator zone supply and return temperature differentials with an infrared thermometer while selecting speed(s) has provided a more efficient solution. It’s still a less-than-ideal result, with a cost premium.

    The Delta-T (Differential Temperature Sensing) Variable Speed Circulator has been around for some years now, providing the idealized solution to heating distribution flow management. It has arguably fallen far short of its potential, burdened by high initial cost, audible operational “whine” and low speed “growling”. Occasional high load torque stalls further contributed to its unknown nature.

    Enter the ECM (Electronically Commutated Motor), the latest iteration of the “intelligent” Delta-T Variable Speed Circulator. The “heir apparent” is whisper quiet yet powerful, dramatically reduces power consumption with no “torque stalls”, displays great functional data and at a palatable cost. Taco® Comfort Solutions of Cranston, RI also claims up to 15% fuel savings along with an 85% energy drop with their 00e Series VT2218 ECM Circulator, pictured.

    Author’s Note: We former High-Tech Process Engineers were applying “Stepper Motors”, the ECM predecessors to Machine & Process Control over 40 years ago. Finally, the Heating World is getting some real tools to work with!

    The Delta-T Circulator is and has always been marketed as an enhanced replacement for a fixed or multi-speed circulator. Have a zone performance issue? Substitute a Delta-T and “tweak” it in. Problem fixed, within the constraints of the zone design and a 3X cost premium of course. This latest (and supplier exclusive) Taco® VT2218 is being very well received, breaking the “Cost-Performance Stigma” of its predecessors and counterparts. We love it!

    VT2218+ZV ultra-oil-1 HTPSuperstor

    As “High-Tech” Process and Manufacturing Engineers with a Heating Discipline we (Mercier Engineering) have further projected the Taco® Delta-T ECM VT2218 as a Dedicated System Circulator, the acknowledged INDUSTRY FIRST to do so! Reviewing its Technical Specifications the VT2218 is ideally suited to residential/light-commercial heating system applications, given that operational attributes can be accommodated. These are namely:

    1. Providing uniform heating performance under normal multi-zone demands.
    2. Simultaneously servicing an Indirect Water Heater (IWH) to optimize both domestic hot water (DWH) and heating water generation.
    3. Prioritizing DHW generation within varying area heating demands.
    4. Accommodating differential temperature branching such as radiant zone(s).
    5. Satisfying both current and future (planned expansion) demands without an efficiency penalty.
    6. Providing beneficial System Service & Reliability projections.

    Over the past fifty (50) years we have installed and monitored “conventional” hydronic (FHW) heating systems, focusing on component selections, their performance and service levels. This continual qualification process has yielded a set of Premium American Components with “zero-fail” histories, at the expense of other NAFTA, Euro & Chinese products.

    Recognizing the potential of Delta-T Hydronics Distribution as previously noted, about five (5) years ago began a concerted effort to select and qualify the dedicated system circulator application. Our independent work using three (3) successive iterations of Taco® VDT, HEC and VT/00e Products has yielded not only a viable, but a superlative Packaged Delta-T ECM Hydronic Heating Appliance™. Its performance is principally based on our Proprietary Near-Boiler Piping System that constitutes the basis of our Non-Provisional Intellectual Property Protection Submission (Patents Pending – USA & Canada).

    So what began as an “evolutionary” effort to apply a newly available “tool” in the resultant has approached a “revolutionary” one. Our Packaged Delta-T ECM Hydronic Heating System™ is actually a FHW Heating Appliance, an industry first! Placing the Delta-T ECM Circulator into a full hydronic (FHW) heating system we slogan as “Putting an ‘Automatic Transmission’ on a Boiler”. Coupling “intelligent” Taco Zone Sentry® valving (pictured), a “high-mass” boiler (Weil-McLain UO – pictured) and an integrated IWH (HTP SSU45 – pictured) dramatically reduce complexity and idealize hydronic system performance.

    In our introduction we referenced the “natural convection” (gravity heating) used by the Romans, et al that prefaced our “modern” hydronics. Our optimized Delta-T ECM System exhibits exceptional gravity convection qualities, continuing heating upon circulator disablement or with zone valve manual operation. Short of a full electrical outage significant gravity convection heating continues, providing a useful fail-safe protection feature.

    Now let us really “Raise The Bar”. Here is performance data taken from two (2) similar “beta test sites” in our grouping.

    100,000 BTUH System, Oil-Fired, 3-Heating Zones + IWH

    Attribute “Conventional” System Delta-T Hydronic System Comments
    System Efficiency (Est.) 87% (Boiler Only) 90++% (Aggregate) Combined Hydronic Efficiencies
    Mean Operating Temperature > 145°F (Est.) 132-140°F (Observed) Normal Heating Operation
    Distribution Power 165 Watts (Est.) 11-12 Watts (Observed) Equates to Taco® Claims
    Distribution Fuel Efficiency  N/A – 15% Consumption Per Taco® Claims
    Natural Convection  Minimal to Moderate Very Significant (Observed) Very Installation Dependent
    System Footprint < 35 Sq. Ft. 12 Sq. Ft. (Actual) Very Installation Dependent
    Construction/Life Low-Mass C.I. or Stl. + Copper High-Mass C.I. & Stl. Only  10 to 20 vs. 30+ Yrs. (Est.)
    Complexity/Maintenance/Skill Higher/Annual/Specialized Low/Bi-Annual/Standard Standard Controls Only
    System Installed Cost (Est.) $10,000+ (Est.) $7,500 (Quoted) Southern NH Region

    This is the new “Bar Height”.

    We challenge ANY Tradesman or System Installer to raise it.

    To Summarize:

    1. Delta-T ECM Hydronic Distribution is singly the most significant and cost-effective contemporary heating advancement.
    2. This technology is applicable to any fueled hydronic heating system with substantial packaging and cost benefits.
    3. System configuration using a Dedicated Delta-T ECM Circulator further reduces physical and technical complexity while idealizing hydronic performance.
    4. Our Packaged Delta-T ECM Hydronic Heating System™ is the first, true Hydronic Heating Appliance, considering its intrinsic architecture, performance and as-installed economics.
    5. This is the new Standard of Measure in Hydronic Heating.

    Author’s Note: Updated 06/12/2017


  • THE DELTA-T ECM CIRCULATOR — The “Automatic Transmission” for Boilers

    After speaking on-site  with a local customer about his system, he inquired as to what else we were doing. A mistake on his part.

    Both of us having differing technical backgrounds I launched into an inspired dissertation of our application of Delta-T ECM Circulation to Residential FHW Heating Systems. Obviously very interested, a running Q & A exchange of increasing technical depth ensued to the point of my noting he was developing that “deer in the headlights” look of incomplete understanding.

    We engineering types have a terrible habit of technically overloading our audiences, not as an “ego-trip”, but to inform as effectively as possible — we think!

    Needing to salvage the situation I paused, desperately searching for that inspired “bolt of lightening” to strike and clarify the atmosphere. By seeming grace, it came immediately! “I’m putting Automatic Transmissions on Boilers.” Yeah”, he responded, “that makes complete sense. Good idea!” Our further conversation became an analogy of FHW Heating Systems to Automobiles, surprisingly clearing our technical disparages. To expound …..

    After all, hot water boilers and automobile engines are both truly “heat engines”. An automobile engine must convert as much fuel combustion energy into mechanical propulsion power as possible via pistons, crankshafts, etc. Less than 60% becomes useful power, the remainder is dissipated as waste heat. The hot water boiler on the other hand necessarily converts its fuel combustion energy directly into useful heat at up to 97% efficiency!

    The automobile uses a transmission to adapt its mechanical power to control vehicle propulsion. A variety of gears, pumps, valves, etc. are used to accomplish this. The hot water boiler conversely needs only to move heated water (via a pump) exactingly to ideally acclimate our heated areas and (optionally) our domestic hot water (DHW).

    The Delta-T ECM (Differential Temperature) Variable Speed Circulator (Pump) is that ideal “boiler transmission” that delivers heated water most efficiently to maintain our comfort. So efficiently does it do so as to reduce system fuel consumption by up to 15% and electrical consumption by up to 85% as documented by Taco, Inc. Published Testing Results.

    No longer is heating system efficiency measured solely (and inaccurately) by the Boiler AFUE (Annual Fuel Utilization Efficiency) Rating, but the aggregate of Boiler, Distribution and Radiation Efficiencies. There are THREE (3) Elements in a hydronic heating system! Just as in Sulky Racing, it’s the combination of the horse, the jockey and the buggy that wins races.

    Even more exciting  is the opportunity provided by the Delta-T ECM Circulator to most efficiently configure a FHW Heating System, which we have done very effectively. Refer to our other, recently published Delta-T Blogs on this site that detail our development, field testing and observations of our systems.

    Our “Packaged Delta-T ECM Hydronic Heating Appliance™” (Patents Pending) exhibits the following attributes in direct comparison to the typical “conventionally installed” system:

    1. Has a higher Combined Boiler AFUE and Delta-T ECM Distribution (System) Efficiency than achievable with any “conventional” system configuration.
    2. Consumes less fuel and electrical power than any equivalently sized system.
    3. Our Integrated Boiler/Indirect Water Heater System occupies 1/3 to 1/2 the floor-space of others.
    4. Our proprietary Fully-Iron & Cast near-boiler piping maximizes durability and distribution performance using fewer materials.
    5. Further combining a High-Mass Boiler with an All-Stainless Indirect Water Heater assures a dramatically projected economic life (30 years or more?).
    6. A truly universal, multi-fuelable Appliance. Just change the burner and not the system!
    7. Provides, Simple, Durable, Efficient and Cost-Effective FHW Heating.

    So yes, we do put “Automatic Transmissions” on Boilers!

    Author’s Note: Updated 07/23/2018


  • THE HYDRONIC REVOLUTION – THE INTELLIGENT DELTA-T ECM CIRCULATOR FHW SYSTEM

    We have witnessed many technological breakthroughs in the past fifty (50) years or so. My engineering career began manufacturing the first transistors, through integrated circuits, personal computers, parallel-processing supercomputers and their logical applications. Now witness the plethora of personal, mind-bending “high-tech” devices available to almost everyone. Similarly there are advances in energy, transportation, communications, etc. that will derive our future.

    OK. So what’s this Hydronic Revolution? Hydronics is the use of water as a medium in heating (or cooling) systems. Thus a Forced Hot Water (FHW) System is more correctly a hydronic system. As simple as they seem, Hydronic Systems need to be carefully designed to maximize their performance, both heating-wise AND electrically! Unfortunately most applications are incorrect hydronically and virtually all electrically, nor can they be using dated components and methods in particular.

    Heated water generated by a boiler must be pumped through “radiation” (baseboard, radiators, heaters, etc.) at an idealized rate to suit the heating demand. Pump it too slow and you have a wide temperature variation and “lazy” performance. Pump it too fast and you waste power and can create hydronic circulation noise. In both cases you waste energy, particularly electrical. The pump (circulator) either runs too long, or too hard.

    Enter the Variable Speed “Delta-T” Circulator some years ago. It measures the input and output temperatures of radiation piping and adjusts its pumping rate (speed) to maintain a “Delta-T” (temperature differential), usually set to 15-20°F with further adjustment to suit varying applications. It was a great advance from Taco® Comfort Systems, the premium American Hydronics Manufacturer with variants produced by others (U.S. & Foreign). It has never really “taken off” though, finding a niche in process control, radiant heating and other problem solving but little else to date ….. until now.

    Taco® has again “upped the ante”, and really upped it this time! Their newest offering, the Taco® VT2218 00e Series Delta-T ECM (Electronically Commutated Motor) Circulator is a marvel of Applications Engineering. An “Intelligent Circulator” is now an apt, if not a modest description. Kudos to our fellow engineers!

    Referring to the Taco® VT2218 00e Series Circulator Specification Sheet you can appreciate the sophistication of this device, and its flexibility to suit varied applications. It can do so much in fact that we must limit our discussion to its application as a simple Delta-T system circulator, its predominant application and the objective of this blog.

    Of equal or greater importance is what is not explicitly referenced in the Taco® specifications, how it attains its intelligence. Simply stated, the circulator’s logic “learns” its application pattern over a period of time, placing it in memory and executing it in the successive period. While executing, it continuously “observes” the pattern variations and adjusts its memory accordingly. Thus your programmable thermostat(s) cycles and heating load variations can be patterned and thenceforth satisfied efficiently.

    Similarly, observing pattern changes such as the length of a heating demand allows the Taco® VT2218 to empirically determine the relative outside temperature, emulating an Outdoor Temperature Sensor Option function. Being a passive measure, it would lag the correction time of an outdoor sensor, but to what overall effect?

    Utilizing a single system and/or distribution circulator such as the VT2218 Delta-T ECM vs. multiple fixed-speed circulators does require controlling individual thermostat demands via Zone Valves. Here again Taco has met the challenge. Again a little background is helpful.

    Taco® is the undisputed giant of the residential hydronic zone valve market. Their “Heat Motor” Zone Valve has dominated for decades and is available in most hardware and “box” stores as is their Model 007 Circulator. The combination of these power and control most residential hydronic systems, however poorly executed they may be. Referencing our Blog Library on this site (and on the internet in general) will evidence how much print is given to addressing hydronic distribution issues!

    The new Taco® Zone Sentry® Series Zone Valves are the “next generation” product to replace the old “Heat Motor” (energy hog) valves and be the ultimate companion to the VT2218 Delta-T ECM Circulator. They are both energy-efficient and intelligent by design as well. Whereas the old “Heat Motor” and “007” dominated and created their renowned application difficulties, the new Taco® Duo of Zone Sentry and VT2218 are their long awaited and performing successors (pictured).

    VT2218+ZV

    We among many other heating bloggers have derided simple “Zone Valves+Circulator Systems” as being an arguably cost-effective alternative to individual circulator zoned systems, and with justification. We in fact chide that zone valves+circulator systems “do nothing well”. True for the old, but not for the new generation!

    Thus, the titled “Intelligent Delta-T Circulator FHW System” consists of a Taco® VT2218 Circulator and Taco Zone Sentry® Valves coupled to a high-efficiency hydronic boiler for maximum performance. We have now and for over a generation specified and used Weil-McLain® Boilers in our applications with absolutely no regrets. Weil-McLain® is recognized as the premium All-American Manufacturer, with a growing market share. Their Warranties are fabled.

    So, to quote the old adage, “How do we get there from here?” From our perspective it’s all about education, particularly within the residential and light commercial market sector. You, the now hopefully more informed consumer, DIY (Do-It-Yourself-er), contractor, “week-end warrior”, tradesman, property manager or developer must drive this point forward in your interest.

    System specification is now relatively simple:

    1. Your total heating demand as determined by a heat loss calculation.
    2. A boiler selection by size and fuel type to suit.
    3. An intelligent Delta-T ECM Circulator(s) sized to your total heating demand.
    4. Energy-efficient Ball Zone Valves for your systems distribution controls.

    Notes:

    1. If your boiler selection has a “system loop circulator” you will employ the Delta-T System in series with it, per the manufacturer’s specification. (High-mass boilers typically don’t require a system loop.)
    2. If you wish to generate DHW (Domestic Hot Water) with your system, an Indirect Water Heater will be required. We exclusively specify and install the HTP® SuperStor Ultra, all-stainless and Lifetime Warranted.
    3. The new generation Zone Valves typically have built-in diagnostics and indicator lamp(s). Therefore you don’t need a Zone Valve Controller, as long as you can see the individual lamps. Significant redundant cost avoidance.

    Quoting Cesar Chavez 1927-1993 (American Activist and Labor Organizer): “We have seen the future, and the future is ours!”

    Mercier Engineering has seen its future as well. We have and are developing a series of “Intelligent Delta-T Circulator FHW Systems” PRODUCTS built upon Weil-McLain® Boilers, Taco® VT2218 Circulator and Taco® Zone Sentry® Valves that will provide the user with a very significant cost-performance advantage to built-on-site alternatives. They are a pre-built, assembled hydronic boiler package, ready for expedient on-site installation, with proven performance.

    Our dedicated website www.BoilersOnDemand.com is currently under complete re-construction to incorporate the latest technological innovations. It will be a significant resource to this end. Meanwhile please excuse us while we work by also taking advantage of our site’s extensive Heating Blog Library.

    Hopefully we have made you aware of hydronic FHW Heating progress and how it will definitely affect our immediate futures.

    Author’s Note: This Blog updated 08/18/2016 to reflect Taco’s new VT2218 Delta-T ECM 00e Series Circulator, replacing all prior.


  • “PLUMBING GUYS PLUMB, HEATING GUYS HEAT” — AN OBSERVATION

    You have doubtless noted the “Plumbing & Heating” Logos on Trade Vehicles. Both disciplines are related, specifically to FHW (Forced Hot Water – Hydronic) Heating Systems, but not necessarily synonymous. They share similar tools and some materials, but not the same techniques — and it shows!

    At the risk of categorization and classification we can readily identify with surety who installed your heating system, i.e. a plumber, your brother-in-law, a DIY (Do-It-Yourselfer) or a heating specialist. The levels of knowledge, application skills and techniques define the end product, and its net performance and efficiency. To quote the axiom “the devil is in the detail” certainly applies to this observation and how the details affect system operation, efficiency and maintenance.

    Ideally you want a FHW System that is finely tuned for performance, notably:

    1. The highest economically efficient energy producer (boiler)
    2. Hydronic components selected for operational efficiency and life cycle cost
    3. Circulation and radiation options complimenting your structure and lifestyle
    4. Complimentary, efficient DHW (Domestic Hot Water) Generation
    5. Optimized hydronic distribution (piping) and zoning

    Prefacing our remarks, do not do a thing until you know your aggregate needs for heating energy! There is no excuse or recovery for not knowing this up front. A Heat Loss Calculator (see other blogs) is not outside the capability of a homeowner or DIY’er, not to mention the professional. Also the Calculator is a great tool for playing energy improvement scenarios prior to making money decisions. Git-er-done!

    Boiler sizing is usually our first observed misapplication, virtually always too large for the current application. In fairness to the original installer and dating of an aging boiler, the existing structure and boiler inefficiencies were a factor as well, along with over-sizing practices at the time. Unfortunately the resultant of subsequent energy improvements and old indiscretions combine to make the boiler now substantially over-sized and an even greater stand-by loss energy robber. (See other blogs)

    Additionally there are the “plumber’s boilers”, as called in the trade. Same so-so boiler, same techniques for decades. Even this “old dog” has had to learn some “new tricks”. The new Triple-Pass (Oil) and Condensing (Gas) Boilers offer us very efficient new tools — with new rules!

    Near-Boiler Plumbing (includes the boiler and Distribution (Zone) piping) is the next focus area. Indicative poor practices are:

    1. Bushings in boiler supply and return outlets, reducing outlet piping sizes at the peril of high stress and corrosion prone fitting failures at the boiler. (We use Heavy Series Nipples and Reducing Elbows, Tees or Couplings to avoid this structural risk.) Such failures are so much fun!
    2. Continuously hard-piped (supply and return) manifolds, with too many fittings and no repair or boiler removal provisions. (More fun!)
    3. Extended length manifolds with high cantilevered loads (weights), sometimes anchored to the floor, wall(s) or overhead construction for support. (Here’s our “Compact Steel Hydronic Header” – Patents Pending that addresses this problem)
    4. Poor (or no) manifold flow proportioning.
    5. Lowered return manifold and piping.
    6. Lots of copper piping vs. iron.
    7. Misplaced, excessive or insufficient valving.
    8. Circulation and/or Zone Valve application and placement.

    The added Indirect Water Heater installation is virtually always “hacked”, i.e. however neatly installed it is thermally compromised. Too much, inappropriately sized, and somewhat under-insulated piping usually stretched from existing boiler manifolds contribute to unnecessary seasonal stand-by losses. (Our “Secret”: We “close-couple” Indirect Water Heaters directly to the first-off-the-boiler fittings to minimize heat loss. The system manifolds are unheated seasonally, save a little convective heating under the insulated riser piping.)

    The guy who has to service a boiler knows best where to place service components (water pressure regulator, circulators, valving, relays, service switch or clean-out accesses)! We position all of ours within an arm’s reach for servicing efficiency.

    A point to ponder: Every extra foot of piping, every elbow, foot of water head-height and gallon of water, through every fitting and valve consumes more energy to accomplish the heating task. Distribution efficiency is totally disregarded by every contemporary hydronic (FHW) heating system installer!

    Example: A past “boiler swap” in an apartment house yielded an excess of 35 feet of copper pipe lengths, many shorter “cuts”, fittings, etc. The new Triple-Pass Weil-McLain Ultra Oil Boiler fires @ 70% of the prior 30 year older Weil with new, appropriate wet-rotor circulators uses 40% less fuel and supplies endless DHW through an 80 Gal. Indirect Water Heater. Every little bit counts — and counts up!

    If it’s any consolation, many of the “old dog” plumbing guys are closing out their careers. Now we other “old dog” heating guys that are determined to continue adapting and applying our skills and experience using the new heating tools have our days in the sunlight. Problem is, we have a lot of consumer educating to do. Hope that jabbing our plumbing brothers a bit makes this ever more apparent.

    To emphasize this point look at our Enhanced Convection Delta-T ECM Hydronic (FHW) Heating Appliance – Patents Pending (USA & Canada) and our supporting website www.BoilersOnDemand.com.

    If our fellow “Plumbing & Heating” Tradesmen need assistance in efficiently applying the latest in hydronic distribution technology, perhaps we can help them ….. or you, the consumer directly with America’s First Hydronic (FHW) Heating APPLIANCE™!

    Updated 08/01/2018 P.D.M., Sr.