< Previous10 JULY 2023HIGH-PERFORMANCE HVAC TODAY A Commercial Hydronic System TAB Process You Can Use By Kevin P. Heikkila TECHNICAL W hen you find yourself in a position where you can’t seem to achieve an air or water flow specification, that, in my opinion, is when the fun begins. You must ask yourself, “Why.” Our company excels at analytical testing to dis- cover the reason why. Going the extra mile to find the reason for poor performance has greatly en- hanced our reputation in the industry. We follow this process at Integrity Test & Balance, Inc. As TAB (Testing, Adjusting, and Balancing) contractors, we come in after the me- chanical contractor has completed his work and test the system to ensure it operates as designed. Feel free to use this process in your business to help determine why commercial system perfor- mance isn’t what it should be. CHECKING THE SPECIFICATION REQUIREMENTS After securing a project, we examine the spec- ification requirements and compare them to our hydronic test and balance plans. We do this to en- sure we can achieve the flow specifications. The first step is to compose the required test and balance reports with the design documents. We gather all the design documents, including the project specification booklet, addendums, and any bulletins to date, along with a complete set of re- viewed and approved equipment submittals. The key here is to verify that the equipment sub- mittals have the “Reviewed and Approved” stamp on it. This is very important. If you use equipment submittals that don’t have the “Ap- proved” stamp, you risk the possibility that the equipment was rejected, and the supplier had to “Re-Submit” per the engineer’s correction notes. That means there may be changes to the equip- ment that you need to know about. I can’t emphasize enough the need for an up- to-date set of mechanical plans. I’ve known of some construction management companies who will confiscate outdated project prints. If this happens, it will set you back because you must acquire the latest prints approved “FOR CON- STRUCTION.” Don’t ever let that happen. PUMP TEST REPORTS We start by composing Pump Test Reports by viewing both the hydronic equipment schedule pages and the approved pump and hydronic sub- mittals. We list all the required design informa- tion on the pumps, including flow rate (GPM), operating head differential (DP), voltage, rated horsepower (HP), and brake horsepower (BHP). We also include design pump speed (RPM) and operating frequency (HZ) if the pump is con- trolled by a variable frequency drive (VFD). We review both the hydronic equipment sched- ule and approved submittals to see if there are any significant discrepancies between the two. The design operating DP and the submitted op- erating DP should be the same. The design en- gineer calculates the DP, and the pump suppli- ers should base their pump selection on the same, along with the pump model number. HYDRONIC LOAD TEST REPORT Next, we review our TAB estimate and the me- chanical schedule pages to determine the count for hydronic equipment and loads. We also check each hydronic load and the specified flow rate (GPM). We then start to mark up our hydronic draw- ings and number each load starting with the first heating load from the supply heating main to the connected load. Another possibility is that the design team did not confirm the connected load before selecting the pumps. You may have to increase the pump size and flow rate. You’ll need balance valves for each hydronic load. The mechanical detail pages should illustrate such. Should you find any balance valves missing on a hydronic detail, say so in the TAB Submittal. More on that below. TAB SUBMITTAL Most TAB specifications require you to send a “TAB Plan” submittal to the design team for review and approval before commencing work. This sub- mittal is your opportunity to flush out any questions or concerns. We start by being upfront with our understanding of the specified TAB work. Being upfront means listing all the systems and equipment to be tested and balanced on the inside page of our TAB submittal. Should we be missing anything, the design team can note that correction when they review and return our submittal. We also list in our TAB submittal any issues that would prevent us from properly testing and balancing the hydronic system. What am I talking about? Here is a list of some problems we commonly identify. zNo balance device is illustrated on the hydronic detail or the hydronic floor plan prints z Balance valves listed on the me- chanical prints may no longer be functional z It is missing a balance device for the secondary pumped circuit that typi- cally has two to three zIncorrect piping layout zExisting loads without a flow spec- ification or a balance valve are illustrated JULY 2023 11HVACTODAY.COM Sample analytical test report pages used by Integrity Test and Bal- ancing . Courtesy of Kevin Heikkila last load on the system. We number each hydronic load in our Hydronic Test Report. After tallying the entire hydronic system, we fill in each load’s specified flow rate. It may get confusing with discrepancies between the flow rates listed on the mechanical schedule and those recorded in the approved equip- ment submittal. If the two flow rates differ, we list the specified flow rate from the approved equipment submittals. We add a note to that hydronic load indicating which flow rate we used for clarification. This is common when engineers specify mechanical equipment based on a particular manufacturer. When other manufacturers bid on the equip- ment, flow rates may differ based on providing the same required heating or cooling Btus. Always review equipment submit- tals to verify the required flow rate (GPM). Now add up all the hy- dronic loads and the listed re- quired flow rates to determine your “connected load.” A pump size is typically based on the required flow rate and cal- culated operating DP. The design pump flow rate and the “connect- ed load” are usually nearly equal on most hydronic systems. If the pump design flow rate is less than the connected load, verify if this system is based on a diversi- ty factor. If that is not the design intent, there is a good chance that the pump will still be able to provide the flow rate for the 12 JULY 2023HIGH-PERFORMANCE HVAC TODAY12 JULY 2023HIGH-PERFORMANCE HVAC TODAY bridge gauge connection at the inlet of the suction strainer. This situation can add unwanted pressure drop and thus provide an unreliable reading. Another common error is that we find a bridge gauge was either not spec- ified and/or not installed. When we run into that situation, we shut the pump off, then isolate it from the system by closing the shut-off valves on the suc- tion and discharge sides of the pump. We then remove the plugs at the flanges and install a Pete’s Plug fit- ting at each side of the pump. We can test the pump with our digital hydron- ic manometer by inserting the test nee- dles into the Pete’s Plug fittings. Next, we perform a “Deadhead no- flow” test on each pump. We start by measuring the pump differential at “NO FLOW” by closing off the pump’s discharge valve. Doing this lets us veri- fy the pump impeller size on the manu- facturer’s pump curve. Should the deadhead reading be slightly different than what the manu- facturer’s pump curve indicates at no flow, we plot a new pump curve next to the original one and use that curve to verify the total pump flow. Read the rest of this article on our website at ncilink.com/KHeikkila4 work on a hydronic system, verify the system piping is fully installed, that all mains and isolation valves are in the open position, that all control valves are toggled open, and that all the air is purged from the system. If this is a multistory building, you must calculate a minimum primary pump suction pressure so that the up- per levels do not operate with a nega- tive suction pressure. Operating a hydronic system in a negative pressure risks drawing in air. If automatic air bleed devices are in- stalled in the system, they not only bleed unwanted air from the system but can also allow air into it. Ensure the system is filled properly to prevent op- erating at a negative suction pressure. PRIMARY PUMP PRELIMINARY TESTING When water balancing a hydron- ic system, start by testing the primary pumps. Begin by confirming whether one pump or two pumps are designed to operate. Typically, dual pumps are for redun- dant backup. If a single gauge is in- stalled to measure pump DP, we will use the bridge gauge installed at each pump. Should that gauge have too low of a pressure range and/or we think it is unreliable, we will temporarily install our own gauge to take the DP readings. Note: Only install one gauge with ball valves to take all the pump mea- surements. Gauges are like snowflakes. No two are alike. For every one PSI of incorrect reading, that dictates 2.3-in. of incorrect head DP. Also, note that bridge gauges must be installed at each pump flange on the supply and return connections. A common mistake is to find the suction zRequired “Loop Balance Valves” not illustrated on hydronic drawings for hydronic sub-loops. This is especial- ly important for multi-level projects, major sub-loops, and phased com- pletion schedules. PRELIMINARY HYDRONIC TEST & BALANCE After receiving the approved TAB Pre-Submittal, we can note any clarifi- cations from the design team and pro- ceed with pre-testing the main pumps. First, we coordinate with the Tem- perature Control Contractor so they can make a “global command” on the DDC (direct digital control) network to toggle all the hydronic heating con- trol valves to the fully open position. This allows us to measure the pump’s operating DP with all valves open to de- termine the required flow rate (GPM). This process is commonly known as a “full call” for heating and cooling. We record all the motor data and specifications on the pump rail tag in the field. Some of this information may vary slightly from the equipment submittals. We typically verify low- load amperage specifications for the motor in the field. Note: Before beginning the pre-TAB TECHNICAL Kevin Heikkila owns I n- tegrity Test and Balance, Inc ., of Traverse City, MI. His 21-year-old company specializes in commercial system testing, adjusting, balancing, and commis- sioning. They conduct air and hydronic measure- ments on HVAC systems, then adjust flows to achieve optimum performance. You can reach Kevin with any questions about this article at ncilink.com/ContactMe .JULY 2023 13HVACTODAY.COMopportunity to install the very first R-32 mini- split in the United States in January 2022. I want to share what I’ve learned from the experience so that other HVAC professionals can know what to expect. I’ll focus primarily on R-32 because it’s the cur- rent leading A2L (over 160 million systems al- ready installed worldwide), and I have the most experience with that refrigerant. However, the service and installation procedures outlined here will apply to most A2Ls. A2L-CERTIFIED VACUUM PUMPS Based on my first R-32 experience, installa- tions only require minor changes. Among those, first and foremost, you must purge refrigerant lines with nitrogen when doing retrofits. In fact, it makes a lot of sense to flush out the system and install a new line set with any R-32 mini-split installation. If you are servicing an R-32 system, be sure any vacuum pump you use is rated for A2Ls. Most newer vacuum pumps from Fieldpiece, Appion, and other manufac- turers are A2L certified. This certification is no different than consider- ing exhaust fans in combustible areas. They, too, must be certified combustion-proof, meaning they can have no motor windings or anything electrical exposed to the atmosphere. That’s the same type of rating given to vacuum pumps that are A2L certified. There is nothing in the compression or recovery machine process that would create a spark within that machine that could ignite A2L refrigerant. A s of January 1, 2022, the United States officially entered the world of A2L refrigerants for residential HVAC applications with the first installation of a Daikin ATMOSPHERA ductless system, with R-32 refrigerant. I installed that new system into a home in the Orlando, Florida area. The introduction of A2Ls will soon be the new refrigerant standard in the United States. Why? Because A2L refrigerants have an improved ozone depletion rating – Global Warming Pro- tection (GWP) – and a better ability to offset the dangerous greenhouse effects of currently used HFC-based refrigerants. For several years, discussions focused on A2L refrigerant’s slight flammability characteristics. The key word here is “slight.” The bottom line is, yes, A2Ls can ignite, but it takes a lot of ef- fort to make them ignite. With proper training, HVAC technicians who follow existing OSHA reg- ulations and manufacturer guidelines, can install and service A2L HVAC systems without concern. I was a mechanical contractor in the state of Florida for seven years and recently returned to that market after working for Daikin Com- fort Technologies. I was fortunate to have the 14 JULY 2023HIGH-PERFORMANCE HVAC TODAY A2L Refrigerants: Contractor Knowledge is Power By Roman Baugh TECHNICAL A2L refrigerants aren’t new – there are more than 160 million HVAC systems installed worldwide that use the A2L refrigerant R-32.who works on your vehicle equipped with A2L-based air conditioners. The liability aspect is very low if you follow OSHA regulations when doing installations. It’s very low if you fol- low the manufacturer-recommended guidelines. Do those things, and you limit your liability. DIFFERENCES BETWEEN R-410A AND R-32 Before we talk about the differences between R-410A and the A2Ls that are slated to replace it, we need to establish that not all A2Ls are the same. Even though the A2Ls are all similar from a flammability standpoint, they’re made up of different chemicals. A2L R-32, is a non-blend refriger- ant. R-410a, on the other hand, is a 50-50 blend of R-125 and R-32. In a way, technicians have already been us- ing R-32 since the adoption of R-410A as the standard. Other refrigerants, like R-454B, are HFO (hydrofluoroolefin) blends. R-454B is what we call a “low-glide” blend, just like R-410A. Like R-410A, you will need to charge blends like R-454B in the liquid state. When charging A2L-based equip- ment with R-32, one of the significant differences will be using different en- thalpy and saturation charts than those used for R-410A. But in essence, you’ll be looking for the same numbers. Other A2Ls, like R-454B, also have pretty similar discharge pressures to R-410A despite having different charts. Still, you’ll want to make sure you’re using the right charts and re- sources for the refrigerant you’re working with. Don’t rely on an R-410A or R-454B chart for an R-32 system because there are differences. Another difference is due to the chemical properties where A2L-based mini-split systems will use much less R-32 than their R-410A counterparts. For example, in an R-410a-based system, the full refrigerant charge may be four pounds, while an R-32-based system, designed to deliver the same capacity, will only use around 2.8 pounds. In other words, A2L-based systems require less refrigerant. Furthermore, R-32 performs bet- ter than R-410A in low ambient con- ditions, providing better heat pump performance with greater capacity in LIABILITY ISSUES? From a service standpoint, there are many questions about liability. The fact is if your technicians are trained in proper refrigerant handling and prop- er system charging protocols, your lia- bilities are no different. As high-performance profession- als, you always want to check for cor- rect system operation. When it comes to charging systems, you always want to verify proper airflow on the return or supply side of the system. Super- heat is still superheat; subcooling is still subcooling. Every piece of A2L-charged equip- ment has a label highlighting the re- frigerant’s flammability so that con- sumers will know this immediately. If they have concerns, it might make sense to point out that any automo- bile manufactured and sold in the U.S. today uses A2L refrigerant for the air conditioning system, which is in- stalled next to a combustion engine. These slightly flammable refriger- ants are already here. And not just in cars. A2Ls are in some residential kitchen refrigerators, so they are al- ready in people’s homes. The stigma or fear of causing dam- age or harm is no different for HVAC equipment than for an appliance service professional who works on your refrigerator that uses propane. It’s no different than the mechanic JULY 2023 15HVACTODAY.COM Different A2L refrigerants have different properties, so pay attention to the charge on the data tag and your temperature and pressure readings to be sure you charge the system correctly.16 JULY 2023HIGH-PERFORMANCE HVAC TODAY TECHNICAL practices are we supposed to be doing? Again, many things have not changed: pressure testing with nitro- gen, pulling a proper vacuum, and so on. Technicians should isolate with the vacuum to ensure the equipment pass- es decay tests without leaks. Then, they charge the system. Outside of that, ev- erything is the same. The refrigerant hose connections are the same, and there are no counter-thread connec- tions – these are just false rumors. And finally, the most common ques- tion I hear is about how to carry and handle A2L refrigerants. The EPA, OSHA, and other government entities have a lot of material about how you carry and store A2L-based refriger- ants, which is different from how you may have done so previously. These refrigerants require that technicians and contractors need to change their mindset. Previously, you could leave tanks of R-410A in your trucks all day, no mat- ter the temperature outside. However, if you do that with a tank full of A2L re- frigerant, there would be severe reper- cussions. A2L tanks must be stored in cooler areas – like a truck’s cab, a stor- age compartment, or a shaded area. You can’t expose tanks to any elements where they will get overheated. The Department of Transportation (DOT) has regulations about transport- ing A2L refrigerants. And yes, those regulations are a bit more stringent than those for R-410A. But the rules are no different than those DOT has for transporting oxygen acetylene torches, which most contractors have carried on their service trucks for decades. Acetylene oxygen is 10 times more flammable than A2L refrigerants. Most good contractors and technicians flared connections. There is no rea- son for a technician to use torches on mini-splits with these connections. The problem is that many technicians fear flaring due to minimal experience and practice. I recommend watching this vid- eo to learn about the best practices for making ductless flares. When brazing lines that may have had an A2L refrigerant in them, the technician must ensure they’re braz- ing with nitrogen. This process is something everyone should be doing anyway, no matter what refrigerant may have been in the line. Nitrogen helps reduce the oxide contamination that builds up inside the copper line. Nitrogen brazing has been around for a very long time. The safety aspects have always been there. KNOWLEDGE IS POWER Regarding A2Ls, the objective is not to scare technicians and consumers away because of its light flammability. The aim is to give them knowledge. They need to know whether the A2L they’re working with is a drop-in or re- placement refrigerant. What does it mix with? What oil is compatible and not compatible with it? What service low ambient temperatures. Again, different A2L refrigerants have different properties, so pay at- tention to the charge on the data tag as well as your temperature and pressure readings to be sure you charge the sys- tem correctly. SERVICE CONSIDERATIONS Other questions in the industry re- volve around servicing equipment charged with A2L refrigerant. For ex- ample, I’m often asked how to check this equipment for leaks. What pre- cautions are necessary? If a leak exists in a room, there is lit- tle difference between most A2Ls and R-410A besides the A2Ls being slight- ly more flammable. The key is proper- ly ventilating the space, which you’re supposed to do, no matter what refrig- erant you’re working with. By follow- ing existing service protocols and pro- cedures, you should have no problems. Most HVAC equipment manufac- turers have safety procedures they provide when it comes to charging their equipment. What about when installers do chan- geouts? Again, standard procedures al- ready exist. When changing out a com- pressor on an A2L unit, technicians should ensure they flush the system with nitrogen. Then they must cut the copper connections on compressors in- stead of un-sweating them. The old mentality was to remove a filter dryer or a reversing valve. You’d un-sweat it and then re-sweat it back in. When a technician services the components of an A2L-based mini- split system, removing them using copper or tubing cutters is safer than using a torch to un-sweat it. Many R-32 based mini-splits have Many technicians get scared when they think about A2Ls, and that’s because they have yet to acquire the proper knowledge and experience.JULY 2023 17HVACTODAY.COM TECHNICAL ncilink.com/A2L-Facts zDaikin Atmosphera R-32 Single Zone Heating and Cooling System ncilink.com/Atmosphera z 32 Reasons For R-32 Website ncilink.com/32Reasons zDaikin Training Center ncilink.com/DaikinTraining. certifications for people who work on their products. ESCO’s eLearning net- work has several free and paid courses (some of which provide NATE credits) about A2L refrigerants. Some manufacturers also have we- binars and courses available through ESCO’s eLearning network. You can find a list of resources below. The secret is understanding what you’re working on and knowing what limitations and safety precautions to take. The fact is, A2Ls, including R-32, will be the prominent refrigerants used in HVAC equipment in the Unit- ed States by 2026, so the HVAC service industry really can’t shy away from it. RESOURCES z The facts about R-32 and R-454B don’t hang their torches loosely in the back of the truck. They also don’t al- low acetylene nor oxygen bottles to roll around. Many technicians get scared when they think about A2Ls, and that’s be- cause they have yet to acquire the proper knowledge and experience. Proper education with a good under- standing of these refrigerants’ prop- erties and how to work with them will provide technicians with the same comfort level they have today. EDUCATION IS EVERYTHING Anytime there is a change, fear al- ways follows. The key to alleviating anxiety is education and certification. That’s why most HVAC equipment manufacturers provide training and Roman Baugh is a Direc- tor of Commercial HVAC for Kalos Services . He spent 17 years working in central Florida’s me- chanical and industrial trades as a senior tech- nical support manager, HVAC service manager, project foreman, and service technician. Before his time at Daikin in 2021, he was the first technician in the U.S. to install a complete R-32-based mini-split system. He can be reached at ncilink.com/ ContactMe . Jim Brown, of the Jim Brown Company in Moun- tain Home, AR, is a sec- ond-generation owner who has set the stage for his son to take over the business. “For me,” he says, “our cus- tomer base best describes the shared vision. If we are meeting their needs and are servicing their homes well with sound finan- cial practices, the business has a strong chance of moving forward with the next generation. “This means everyone has to be strong listeners and open communicators.” Brown adds that leadership starts with loy- alty. He says that if a person doesn’t want to be involved in the long haul, they aren’t a qualified candidate for leadership. In his opinion, leaders need to understand the tasks necessary for suc- cess, need to perform those tasks, and need to have a desire to go beyond them. “I am talking about work ethic here,” he adds. “If they don’t have that, they won’t have anything else. Oh, and by the way – none of these attri- butes are academically teachable. They can be learned by example. The saying that there is no external solution for an internal problem is true in all segments of life. You foster leadership by having a friendly environment with people will- ing to help one another.” Rob Basnett, the owner of Basnett Plumbing and Heating, Littleton, MA, says he is just starting to prepare for the next generation of leaders in his company. “We have succession meetings to discuss each other’s goals, L et’s face it – none of us are getting any younger. At least in the HVAC Industry, many owners and managers are either at or beyond retirement age and must pre- pare the next generation of leadership for their HVAC companies. By the way – it’s not just that HVAC contractors are retiring or want to. We can partially blame the leadership gap on the pandemic creating a work-from-home ideology where people leave their companies to start home-based businesses. This “movement” is called The Great Resigna- tion, where older millennials and younger Gen X people in prime positions to step into leadership roles – are leaving the HVAC workforce. So what should you do? We contacted several HVAC company owners to discuss how they are working to develop the next generation of leaders, where they are in that process, and why they think it’s so important. THE IDEA OF SHARED VISION Having a shared vision is something that many consultants say is vital for a family business to continue from one generation to the next. Ac- cording to Steven P. Miller of Family Enterprise Center, UNC Kenan-Flagler Business School, Chapel Hill, NC, “Lack of a shared vision for the family enterprise and weak next-generation lead- ership are often cited as two of the leading rea- sons for the failure of family firms to successfully transition from one generation of family owner- ship to the next.” In an article posted on the Frontiers in Psy- chology website, Miller says that developing next-generation leadership in a family business also requires having the right family climate (open communication and shared values). 18 JULY 2023HIGH-PERFORMANCE HVAC TODAY Develop Your Next-Generation Leadership Team Now By Mike Weil COVER STORYtomorrow’s leaders need to learn to navigate challenges and keep their companies moving forward. He de- fines this forward momentum as “transformational leadership” and says such people help members of their teams, company, and communi- ties reimagine a better future. At GV’s Heating and Cooling, Inc. of Glenview, IL, owner Greg Vick- ers is a strong pro- ponent of re-imag- ining the future. Though they do not have a formalized leadership model, he says he has some younger team members, including his daughter, who are forward thinkers with solid work ethics and positive at- titudes, and want to be his company’s next-generation leadership team. “From the beginning, when my wife and I started our company in 1990, we focused on creating a culture of hon- esty, accountability, and putting oth- er team members first,” he says. “We developed an onboarding process to show prospective team members and staff what the company’s culture is, our expectations, and how we must focus on exceeding all of our custom- er’s expectations.” Then he says by leading by exam- ple and practicing servant leadership; he hopes to get potential leader candi- dates to think outside the box and to visualize a better future. “We are and have been nurturing fu- ture leaders with our vision and their vision for the company and their role in moving the company and them- selves forward. Leadership develop- ment is an ever-evolving process. We also have conversations about how nothing is guaranteed, but positive things happen through hard work, dedication, and giving 100% every day,” he adds. Vickers’ comment ties in with what Meginley says about transitional lead- ership. Meginley writes, “To trans- form your workforce, the next gener- ation of leaders should be authentic, open, compassionate, curious, and inclusive.” THE IMPORTANCE OF A SERVANT LEADER MINDSET Meginley’s transitional leadership segues nicely with what is known as a servant-leader mindset. When Jim Ball owned his own HVAC company, plans, and vision. It is a work in prog- ress that we tweak yearly. We’re work- ing on a vision for the next 5-10 years,” Basnett says. “For me, I want our leaders to treat people with respect. I want them to foster encouragement, always to be positive and confident, and to know how to make decisions no matter the situation.” He says he tries to teach this by lead- ing by example and being present and available. “Not everyone is built to be a lead- er,” he continues. “There are leaders and followers. For those I see with potential, I’ll guide them, encourage them, and point out ways to improve their leadership. “For those who don’t have leader- ship potential, I try to help them see other attributes to strive for. Every- one has strengths; they just may be in a different area. It is our job to fig- ure that out and encourage, guide, and coach.” TRANSFORMATIONAL LEADERSHIP In an article posted on the HRCO Learning Center website, author David Meginley writes about how JULY 2023 19HVACTODAY.COMNext >