• Tag Archives Packaged
  • 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 UOpictured)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


  • MERCIER ENGINEERING INTRODUCES “PRE-BUILT, PRE-PACKAGED BOILER SYSTEMS”

    This Blog, originally written in 2008 has been superseded by our subsequent development activity, culminating in a Non-Provisional Intelligent Property Protection Submission (Utility Patent) in the USA & Canada in April, 2017.

    The original blog crossed out text following has been retained to witness our efforts in both timeline and content. The final submission attributes:

    1. A true hydronic appliance vs. the partially pre-built, conventional system described therein.
    2. New Delta-T ECM Hydronic Technology is fully integrated, dramatically reducing component content, increasing distribution efficiency and system performance.
    3. Gravity (Convection) Heating is optimized and provides innate, additional performance.
    4. A flexible, modular design, it is readily manufactured and provides excellent value with predictable performance.
    5. Prior and further proprietary design features have been fully integrated. Example: The “Iron Cross Manifold” has evolved into the “Compact Steel Hydronic Header” – Patent Pending.

    The ENHANCED CONVECTION, DIFFERENTIAL TEMPERATURE MANAGED, HYDRONIC HEATING APPLIANCE™ Product Brochure on our BoilersOnDemand.com website will further detail our effort. 

    Amended 07/07/2017 P.D.M., Sr.

    Modern, high efficiency hydronic (hot water) heating systems necessarily incorporate technological features that sophisticate them, particularly in the areas of controls and distribution. Whereas in the past one could make a few wiring connections and connect a few pipes, now the task may appear daunting. However, organizing these functions logically and employing selected hydronic and control components can result in both a sophisticated, yet simple system.

    Mercier Engineering is dedicated to advancing hydronic heating applications by applying the benefits of over 50 years of “being in the trenches”, so to speak. As such we recognize that there are skilled DIY’s (Do-It-Yourselfers) and Contractors who have access to skills complimenting heating installations. Our contribution is to reduce the task to a manageable one in cooperation with our customer by providing a very cost-effective, packaged forced hot water heating system.

    Since the introduction of Weil-McLain’s Ultra Series of Gas and Oil Boilers (click on our site links) and applying Taco’s renowned hydronic components and relays to them, we recognize the opportunity of readily “packaging” these products. This is further highlighted by the recent announcement of our “Iron Cross Manifold” (TM) System that efficiently configures multiple circulators and valving. Furthermore as service people ourselves this configuration is a serviceman’s pleasure, providing ready access and diagnostics for future eventualities. Note that this service is available ONLY on and limited to the Weil-McLain Ultra Series Products.

    From client supplied site detail we build the boiler systems on the Weil-McLain Pallets, then knock them down for re-shipment. All shipments are F.O.B. Antrim, New Hampshire. Note that packaging limitations may preclude commercial freight and require arranging local pickup by the client.

    To complete the installation the client will have to:

    1. Transit, de-palletize and position the system.
    2. Exhaust the boiler per manufacturer recommendations.
    3. Assemble the burner to the boiler (oil only).
    4. Extend fuel connection (gas piping or oil line) to the system.
    5. Extend 1/2″ water service to the input pressure regulator/backflow preventer.
    6. Connect the heating zone supplies and returns as applicable.
    7. Connect the thermostats to the control relay.
    8. Extend 110V 15A power service from the overhead thermal switch to the boiler service switch.
    9. Execute system fill, purge and start up procedures.

    Also note that all permits, code compliance and inspection(s) are the responsibility of the client.

    So, if you have been hesitant to upgrade and thought you just couldn’t afford a top-end Energy Star System, but have complementary skills at your disposal, this may be an answer to your dilemma.

    Contact us to discuss your particular situation. As usual there is NO OBLIGATION.