• Tag Archives (Patent Pending)
  • WEIL-MCLAIN CASE STUDY SUBMISSION – Our Beta #3 Site Delta-T ECM Heating Appliance™

    A Case Study Submission has been made to Weil-McLain for their publication.

    It details our Beta #3 Site early Delta-T ECM Hydronic Heating Appliance operation with the testimonial of our client. Focus is on the rapid, seamless installation and resulting performance of our system. It is the first, true Hydronic (FHW) Heating Appliance and is currently under Patent Pending in both the USA & Canada.

    Look for it in an upcoming Weil-McLain Newsletter publication.

    Thanks as well for our client’s participation and his resounding endorsement!


  • BOILERS ON DEMAND LLC

    Be advised that as of April 10, 2017 Boilers On Demand is now registered in the State of New Hampshire as a Limited Liability Corporation.

    This is necessitated by our intent to provide our “ENHANCED CONVECTION, DIFFERENTIAL TEMPERATURE MANAGED, HYDRONIC HEATING APPLIANCE” (Patents Pending – USA & Canada) to in particular the Residential Hydronic (FHW) Heating Market.

    Fully integrating Delta-T ECM Hydronic Distribution Technology by Taco Comfort Solutions® with our proprietary near-boiler piping system enables a functional Hydronic (FHW) Heating Appliance. Further incorporating our experience with Natural Hydronic (Gravity) Heating with a Weil-McLain® UO Series (very) High-Mass, Triple-Pass Boiler provides a simple, durable and efficient heating system.

    Our modular, application-specific appliance capability provides the heating market with a value engineered alternative to the contemporary loose-piece, build-on-site trade practices. The predictable price-performance of a multi-fuel capable “Made In America” appliance is particularly attractive to the heating consumer.

    We are currently marketing our product via our dedicated website www.BoilersOnDemand.com and to Fuel Dealers, Trade Institutions and Journals, Tradesmen and Contractors in the USA and Canada. Extensive planning, installation and maintenance resources are currently available on our website along with a deliverable Power Point Presentation on our technological effort.

    There is now a real alternative in the Residential Heating Market and we encourage you as a consumer or trade participant to explore “The Hydronic (FHW) Heating Revolution”.

     


  • SIMPLE, DURABLE, EFFICIENT FHW HEATING ….. PERIOD!

    Our Motto is “Simple, Durable, Efficient FHW Heating ….. Period!”. Boilers On Demand LLC has achieved this seemingly noble objective by fully integrating Advanced Taco Delta-T ECM Hydronic Distribution Technology into Forced Hot Water (FHW) Heating . The unstated result of our “Convection Enhanced Delta-T ECM Hydronic Heating Appliance” (Patents Pending – USA & Canada) development is it being highly cost-effective as well. Can we “have it all”, so to speak? Let’s look at our effort in further detail …..

    Hydronic (FHW) Heating to the layman and consumer has always had a certain mystique, evidenced by witnessing a tradesman or plumber configuring a system, piece-by-piece into a seeming maze of piping and components. The results vary from the mundane to aesthetically impressive, but we must realistically note in fact that the hydronic performance of any system is less than ideal. The residential and light commercial heating markets in particular have not had the tools nor the general expertise to optimize a hydronic heating installation. Consequently the end user has suffered with an over-installed, under-performing, energy-consumptive system over its lifetime ….. knowingly or not!

    Note: We can’t excuse our like personal participation for now sixty (60) years in hydronic heating. Our guilt is shared ….. but no longer!

    Now a true “hydronic revolution” is upon us, not yet generally known and even less appreciated, nor applied. Hydronics have thankfully been somewhat forgiving to all of us applying it, but now there’s a new day, and a new benchmark.

    By explanation, there are three (3) basic elements to hydronic heating: Energy Creation, Distribution and Radiation. Put more simply:

    1. A Hydronic Boiler to create energy by burning a fuel, as efficiently as possible.
    2. Moving (distributing) heated water to points of use with “pipes and pumps” (circulators).
    3. Warming an environment by passing air over hot piping, as simply and effectively as possible.

    We have progressed quite well in creating and utilizing energy via boilers and radiation, but that is where it has stagnated far too long. Given the limitations of fixed or selectable speed circulators and valving we have managed without addressing the true potential of improving hydronic distribution efficiency to complete the heating equation. The intelligent, variable speed Delta-T (ΔT) ECM VT2218 00e Series Circulator by Taco Comfort Solutions® has changed it all ….. and none too soon!

    We have been experimenting with Taco® Variable Speed Delta-T VDT’s, “BumbleBees”, Viridians and now 00eSiries ECM Circulators for years, utilizing them as direct substitutes for their fixed-speed predecessors. They have worked particularly well as radiant zone circulators as our fellow tradesmen have also discovered. The Taco BumbleBee® in particular has gained trade notoriety both by its appearance and performance. However, our personal technical efforts have gone well beyond the obvious in pursuing a dedicated boiler system circulator application. It has neither been promoted nor seeming anticipated, yet its implications are very significant when achieved.

    Utilizing a Delta-T, and in particular an ECM (Electronically Commutated Motor) based circulator as a single, dedicated system hydronic “distributor” offers near-ideal efficiency potential. We slogan it as “putting an ‘Automatic Transmission’ on a boiler”. It greatly simplifies both near-boiler piping and control complexity, but must necessarily possess several operational attributes:

    1. First and foremost is reliability! A dedicated (single) system circulator failure is a potential “show-stopper” after all.
    2. Performance Flexibility. It must adapt to and accommodate all system energy demand patterns with minimal, if any effect.
    3. Accommodate an Indirect Water Heater as a prioritized and an incrementally higher energy demand accessory.
    4. Significantly improve system efficiency and performance while reducing energy requirements, both fuel and electric.

    Zone Valves are a necessary compliment to manage individual zone demands when using a single circulator. New generation valving and in particular the Taco Zone Sentry® Valve provide outstanding performance and value with self-diagnostics. The “Zone Sentry” in fact delivers three times the heating capacity of its popular “Heat Motor” predecessor, and uses dramatically less power. Combine these with its physical packaging attributes the “Zone Sentry” provides a unique configuration opportunity further addressed in this writing.

    The hydronic distribution function is composed of two elements:

    1. “Near-boiler piping” as generally referred includes circulators, valves, air elimination and expansion devices that prepare and present heated water or “hydronic energy” to points-of-use.
    2. Distribution piping that extends and presents this heated water energy to radiation components.

    We offer that considering these two distribution tasks without differentiation or distinction is fundamentally flawed, and yet is standard trade practice. As initially stated, Delta-T Distribution Technology changes this assumption, and dramatically! Consolidating hydronic flow within a single, intelligent system level circulator packaged with complimentary, intelligent zone valves packages into a true, efficient FHW Heating Appliance. Further, “hydronic convection” (gravity heating), the natural attribute of heated water to rise and convect within distribution piping is idealized as well. Witness the need to install “flow-check” valves in conventional systems piping, into circulators or using properly sited zone valves to control convection (gravity) heating. By incorporating natural convection total circulation energy is measurably reduced beyond that of Delta-T. A simple analogy would be “like paddling your canoe with the current, rather than against it”.

    Hydronic convection performance is at the core of our Proprietary Near Boiler Piping System. Included as a standard, recommended option for idealized system and DHW (domestic hot water) creation efficiency is an Indirect Water Heater (the HTP SuperStor Ultra Series). Close-coupled within our near-boiler piping, its integrated supply architecture becomes a physical, gravity flowing extension of boiler capacity, particularly in circulator fail-mode operation. Yes, we had a “fluke” 1st Generation Taco Viridian® VT2218 failure on our “Beta #3” site that was not discovered for an estimated 2-3 days of heating operation. DHW generation was never affected!

    Ideally complimenting our hydronic system is the highest-mass boiler for its rated output (the Weil-McLain UO Series), extending system energy storage capacity and potential fail-mode convection performance. Its supply and return rear porting compliment near-boiler piping by compactly and efficiently packaging all hydronics within its footprint plus an approximate 1 ft. rear piping and exhausting space. Adding the Indirect Water Heater uses under 12 sq. ft. of combined space, up to 2/3 less than a typical currently installed system while reducing system valving and near-boiler piping by up to 1/2. Integrating with domestic all-steel piping, malleable fittings and brass/bronze valving compose a free-standing system architecture of innately superb strength, chemical resistance and field proven longevity.

    Now applying our paralleled “High-Tech” Manufacturing Process expertise to Hydronic Heating, we have modularized, value engineered, methodized and tooled our Delta-T ECM Hydronic Heating Appliance to include several additional components in our Intellectual Property Protection (Patent Pending) Submission. Our cooperating customers on multiple “Beta Sites” are also providing us valuable data to optimize our system design and performance with the goal of providing an unbeatable cost-performance product.

    Taco Comfort Solutions® publishes that its Delta-T ECM VT2218 00e Series Circulator provides up to 15% fuel and 85% electrical power reductions in applications. We certainly concur! Our dedicated VT2218 system circulators are using 8-13 Watts in heating maintenance mode. Cold system warmups begin at 25-35 Watts (half the rated power) then reducing toward acclimation temperatures.

    At the extreme of our experience is our “Beta #1″ Site upgrade, badly mis-piped with three hidden, seriously undersized 1/2” radiation zone supplies & returns that exhibit high head pressures (obviously). A pre-existing integral IWH is also under-sized piped, adding to delivery issues. Yet, this system cold starts @ 65 Watts, decreases rapidly to 35 Watts, then slowly acclimates to 22-25 Watts running. (A single Taco® 007 draws up to 80 Watts by comparison. It had four operating three heating and the IWH zones.)

    Additionally by using the High-Mass Weil-McLain UO Series (Oil) Boiler(s) we see system operating temperatures lowering to 132-140º F, regulated by its integral Hydrolevel “Fuel Smart” HydroStat® 3250-Plus Aquastat. System demands are readily “cushioned” by the thermal mass provided in the total system architecture. It responded very positively to the prior noted prototype system circulator failure, ramping up system temperature toward maximum with zone duty cycle duration detection & response, maintaining radiation heating in degree. Boiler burner cycles are infrequent and brief, further reducing equipment maintenance levels while extending system operating life.

    We have more recently offered the appliance-specific Carlin EZ-PRO Gas (NG&LP) vs. the Beckett NX Oil Burner in the Weil-McLain UO Boiler. Now it’s a Universal Hydronic (FHW) Heating Appliance! Change fuels ….. swap the burner only!

    Total Hydronic  (FHW) Heating System Efficiency is  the AGGREGATE  of Boiler AFUE, Delta-T ECM Hydronic Distribution & Radiation Efficiency Gains! We further claim that the reduced operating system temperatures and hence stand-by losses of the very high mass Weil-McLain UO Boiler further increase overall efficiency. Thus we can confidently claim the highest efficiency heating system available!

    System Comparison

    “Conventional” FHW Heating System         vs.         The Delta-T ECM Hydronic System

     

    Identically Specified 100KBTUH, 2-Heating Zone + IWH, Oil-Fired Systems

     

    Attribute"Conventional" System"Delta-T" SystemComments
    Boiler TypeWelded Steel Plate (Example Unit)Cast Iron "Triple-Pass"15 years +/- vs. 30 Years +
    Boiler Weight270 Lbs.625 Lbs.Very High Mass - Durability
    Oil Burner TypeVarious OfferedBeckett NX (Pressure-Fired)Flexible, stable operation
    Gas Burner TypeFixed, Appliance-SpecificCarlin EZ-PRO (NG/LP) (Pressure-Fired)Appliance-Specific Interchange
    CirculationMultiple Fixed Speed Circulators onlyA Delta-T Variable Circulator w/ Intelligent Zone Valves>/ 15% Fuel Savings
    >/ 85% Electrical Savings
    Piping/FittingsCopper (Typically)All Iron & Cast ConstructionSuperior Strength/Durability
    Indirect Water HeaterVarious Mfrs. & TypesAll Stainless Steel OnlyA Lifetime of Service
    Floor Space UtilizationInstaller-dependentOptimized Package DesignMinimum Space Requirement
    Energy PerformanceInstaller-dependentOptimized Energy DesignPeaked Hydronic Efficiency
    Component SourcesU.S./Foreign Mix (Typical)"All-American" (US/Canada)Quality and Serviceability
    Installed Cost (Oil example shown)"Over $10,000" (Oil, as shown)$7,000 (Oil, as shown)Price, Performance, Value

    To Summarize:

    Taco® Delta-T ECM Hydronic Distribution changes everything! The “Plumber’s Playground” of conventional, inefficient hydronic distribution piping “free expression” is gone as well! We must now look at Hydronic (FHW) Heating in totality, no longer as a an aggregation and assemblage of parts by personal preference. Technology has provided we heating guys with some new working tools. Let’s learn how to use and apply them well!

     Author’s Note: Updated 10/01/2018


  • 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


  • “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.