Our singular observation in over 50 years of hydronic (FHW) heating systems installation and service is this: Given any similar application, no two heating systems are configured the same, nor do they consequently service the same. Need they be? We argue that they definitely should be alike for both operational and service efficiencies.
The impairment to maximizing hydronic efficiency and service lies within the heating market itself. Manufacturers supply components and installers apply them to the customer application employing their accrued experience. The obvious result is the installation variations we observe – “the good, the bad and the ugly” to apply the popular quotation.
The problem is that even the good is not good enough efficiency-wise, and the installers get little help from their component suppliers, representatives and technical services in this regard. Specific to hydronic boilers, the “building block” of all FHW Systems, the manufacturer provides a generic installation guide with plumbing diagrams and wiring schematics that cover all the bases. No effort is given to efficient component sizing, placement or utilization. Much like an artist that is given a clean canvas with an image theme, the installer creates his own picture as he sees it.
Ironically, there is an innate need for plumbing and heating guys to paint their own canvas. The daily tedium of fixing “leaks and squeaks” gets old very quickly. The opportunity to become creative by building a heating system on-site and making it look seemingly neat and pretty is a strong draw, not to mention a great payday as well. LEGO’s for Big Kids! Problem is, the customer pays for it up front, and continues to pay over the lifetime of the system in fuel, maintenance and operational costs, knowingly or not.
From an engineer’s perspective the solution is quite simple, a designed and configured PRODUCT built specifically for the application. The quandary however is: How can you possibly accommodate so many applications and individual variations? There is seemingly an endless possibility of pipes, circulators, controls and valves to idealize an application. This has been the traditional dilemma — until recently. Technology to the rescue!
Hydronic systems are undergoing a true design revolution with the development of “smart” circulators and zone valves. The combining of these reduces virtually any common residential or light commercial hydronic application to a single circulator and compliment of zone valves to suit. The resultant is a very efficient, flexible and yet simple system. We strongly recommend viewing our companion blog THE HYDRONIC REVOLUTION – THE INTELLIGENT DELTA-T CIRCULATOR FHW SYSTEM for further descriptive and technical details.
Now to define a typical residential or light commercial system you only need to:
- Calculate the total heat loss of the structure.
- Specify a hydronic boiler and fuel type with suitable capacity.
- Select either a natural draft or forced exhaust venting.
- Qualify the use of an indirect water heater, if applicable.
- Determine the number of heating zones and their respective supply and return points.
Note: These comments apply only to a Hydronic Boiler Packaged Product. Heating distribution compliments and completes the system, either as a new or in a replacement application.
There are currently, to the best of our knowledge, no pre-built, assembled FHW Boiler Package Products applying the latest technologies, assembly methods, materials and logistics to support this emerging market. We are defining the attributes of this market to be providing:
- Hydronically optimized boiler package providing exceptional performance.
- Intelligent, ideal energy delivery and control.
- Complimentary supply zone distribution.
- Complimentary zone returns with service enhancements.
- Quick, simple on-site preparation and fitting.
- Ideally, availability on-demand.
- Expedient delivery to site, as required.
Given the attributes and performance of this product, it will lend itself to service ease by any reasonably skilled personnel. The challenge remains to break the customer from the current norm of “one-stop shopping” for heating installation and service, the intent of this writing. It is only by providing and displaying the performance of such a product will we break the status quo — for the benefit of the consumer, and as an asset to the installer as well!
We (Mercier Engineering) have participated concurrently in both high-technology manufacturing and the heating trades for over fifty years. An opportunity is now provided to us to participate in developing and marketing this Hydronic Boiler Product. Our career skill-set strongly compliments this task and thus we will be introducing a series of products to develop this emerging market.
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Our “Mission Statement” therein defines us and our goals..