Bosch Thermotechnology September 2014 Inside this issue Welcome 3 DDC Controls 4 Tech Talk 6 Technical Bulletin 8 Product Spotlight: LM 10 Case Studies 12 Deliveries by Ship and by Sled 18 A magazine dedicated to engineers who specify boilers, DHW tanks, tankless water heaters, solar, geothermal and water source heat pump systems from Bosch, FHP and Buderus. Middle Creek Wildlife Management Area, Page 12 Photo by: Cheryl Trewella, Pennsylvania Game Commission
2 The Engineer s Choice September 2014 3 Updates & Upgrades to the LV Model by Robert Schwarzkopf Welcome to the fourth edition of The Engineer s Choice This month we will be completing a series of updates and upgrades to the LV Model of heat pumps. In addition to the split version of the LV Model that was recently released for production, we have upgraded the performance of the base LV Models to meet or exceed the latest ASHRAE 90.1 performance guidelines and to conform to Department of Energy requirements for the foreseeable future. Most of these improvements were accomplished through refinements in heat transfer surface and refrigerant management, with the exception of LV015 and LV041, there will be no affect to the unit electrical ratings or other technical data. However, in the case of the LV015 and LV041, upgrading the fan motors was necessary to improve the efficiency and by doing this slightly changes the electrical characteristics of the units. Below is a table showing both the new capacity and efficiency data. All of the revised LV Models will be denoted with a B revision digit in the code string for the model. For more information, please contact your Regional Sales Manager. Category Model # LV Model AHRI Ratings with PSC Motors Water Loop Heat Pump Ground Loop Heat Pump Cooling 86 F Heating 68 F Cooling 77 F Heating 32 F Cap BTU/h EER BTU/ W-h Cap BTU/h COP Cap BTU/h EER BTU/ W-h Cap BTU/h COP Welcome to the fourth edition of Engineer s Choice, where we highlight exciting new happenings at Bosch Thermotechnology. In this issue we highlight the newest product in our FHP Bosch family, the LV Split System. It provides ASHRAE 90.1 efficiencies in a water-cooled heat pump, split into two sections the condensing section and the air handler. It s the perfect solution for the designer needing to place a heat pump in a space where a packaged unit won t fit, or a sound-sensitive area. Like its brother, the LV packaged unit, the LV Split System is filled with many standard features, can be fully optioned, and is available in commercial voltages. Chilton Stewart National Sales Manager Bosch Thermotechnology Geothermal case studies include Middle Creek Wildlife Management Area in Kleinfeltersville, PA and the Vermeer Yellow Iron Academy Early Learning Center in Pella, IA. We are also highlighting a large tankless water heater retrofit at the prestigious Caroline residential apartment in the Flatiron district of New York City. Finally, read about our most traveled boiler s trek to the Antarctic! We are looking forward to seeing you at IGSHPA in Baltimore on October 15-16 and you should already have us penciled in your calendar to join us at our annual customer appreciation hospitality event on January 25, 2015 at The Godfrey Hotel in Chicago during ASHRAE. LV 007 6,100 12.20 7,800 5.30 6,800 15.10 4,900 3.40 009 8,200 12.40 9,900 4.70 8,700 14.60 5,740 3.20 012 10,900 12.20 13,000 4.30 11,800 14.10 8,700 3.20 015 14,200 12.80 16,100 4.40 14,200 14.60 11,300 3.30 018 19,400 13.40 22,200 4.60 21,200 15.80 14,300 3.50 024 23,400 13.40 26,600 4.40 25,000 15.50 17,000 3.40 030 29,200 13.20 33,400 4.30 31,000 14.70 20,900 3.30 036 37,900 14.70 41,800 4.60 39,900 16.90 26,900 3.50 041 39,500 13.10 44,600 4.30 41,200 14.30 29,400 3.20 042 40,000 13.70 46,300 4.30 42,600 14.80 31,000 3.30 048 45,900 13.00 56,400 4.30 48,800 14.90 35,400 3.40 060 57,900 13.00 67,200 4.30 60,100 14.10 46,900 3.20 070 64,000 13.30 72,800 4.40 66,400 15.00 50,800 3.40 On the technical side, Ryan Todaro, P.E., discusses which direct-drive fan motor you should utilize for your heat pump project, providing you with the advantages, disadvantages, and considerations for each technology. Roger Boydstun and Jerry Huson, Bosch Controls Engineers, provide DDC solutions to sensor location and programming issues at the historic Comeau Building in West Palm Beach, FL. Robert Schwarzkopf, Senior Technical Expert, provides exciting news about updates and upgrades to our LV packaged units, which now fully meet ASHRAE 90.1-2013 energy efficiency requirements. Thank you for your interest in FHP Bosch. We thank you for your business and the trust you place in our reps, our people and our products. National Sales Manager Bosch Thermotechnology Have a story or a before and after you would like to share? Send it to frances.bruderer@us.bosch.com
4 The Engineer s Choice September 2014 5 DDC Comeau Building Achieving better indoor air quality through improved design: Part 1 Information provided from site visit report by Roger Boydstun and Jerry Huson T he Comeau Building located on 319 Clematis Street in West Palm Beach, FL, is a 10-story historic office tower boasting 78,000 square feet of professional office space and 8,300 square feet of ground floor retail space. The building was designed by the famous architectural design firm, Harvey and Clarke, and is strategically positioned in the heart of downtown West Palm Beach. A recent renovation required that the Air Conditioning equipment for the 4th, 6th and 8th floors be retrofitted with two (2) 10-Ton FHP EC120 s, equipped with Direct Digital Control (DDC) boards running the standard 7.03.06 software version. The controllers were not incorporated into a Building Management System (BMS) and therefore the units operated independently based upon the temperature sensed from RS wall-mounted sensors. Each of the West EC120 units was configured with a 3rd party field installed CO 2 sensor. The office areas primarily had an East and West exposure. The primary reason for the visit was to address complaints from the building occupants of indoor air discomfort related to higher than desired temperature and humidity levels. Situation: The wall RS-Sensors for both units were located midway in the primary hallway of the offices with the most complaints in the building. The unit for the west office spaces was controlled by the RS-Sensor mounted on the west hallway, and likewise the east hallway sensor was used to control the unit for the East office spaces (see Figure 1) Figure 1 In this particular scenario, due to the temperature sensors being located in the hallway away from the primary sensible heat loads, once the hallway temperature was satisfied the units would cease operation. However, the occupants of the office spaces, all with closed doors to the hallway, were still subject to temperature swings due to the accumulated heat load of the space (sun exposure, people, lights, computers, etc.); in essence, the office spaces were only receiving heating or cooling when the hallway sensors were not satisfied. Furthermore, the office tenants are not allowed to adjust temperature set-points from the sensor. This was leading to the numerous complaints of discomfort reported in the building. Solution: The temperature set-point was reduced using a BACview terminal, and the temperature sensors were made accessible to the occupants of the offices. A setting in the software further allowed a restriction to be placed on the set-point adjustment range (limited to ±3 F for heating and cooling). This implied that the user could only manually manipulate the temporary set-point from the sensor by 3 degrees in either direction with 1 increments / decrements. For example, if the cooling set-point is 74 F the minimum cooling set-point would be 71 F with the range limit of ±3 F. Since the units were not connected to a BMS, each unit had to be adjusted manually to the new range limits. All BACview changes were made via the RS-Sensor access port since access to the actual units proved difficult*. It was further suggested that the wall sensors be moved to an accessible office space if possible to provide more accurate temperature readings. *Tip: The BACview module is a diagnostic and commissioning tool used to configure a unit with DDC. If connection to a controller is required on a unit that is hard to reach or otherwise inaccessible, the BACview module may be connected via an RS Wall-Mounted Sensor connected to that particular unit (see Figure 2). Figure 2 To avoid having this complication to begin with, the ideal solution would have been to install multiple sensors in the office spaces exposed to the outside, and run the unit based on the average temperature of these offices. Each DDC can support up to five (5) daisy-chained room sensors for temperature averaging, as long as one of those sensors in an RS-Pro or RS-Plus. In the next edition of The Engineer s Choice, we will discuss RS-Sensor Setpoint Manipulation Behavior.
6 The Engineer s Choice September 2014 7 Tech Talk: Direct Drive Motor What motor is right for my project? Constant Airflow ECM Option Constant Torque ECM Option PSC versus Constant Torque versus Constant CFM Many times, a project does not specify the type of direct drive motors to be used and you are left with the question: How do I know what motor is right for this project? We will begin by analyzing what different technologies exist in these three motors. PSC and ECM PSC The permanent split capacitor (PSC motor), single speed motor has been the HVAC industry standard for blower motors for many years. The motor is simple to build, operates on simple principles, making it a very affordable motor to manufacture and purchase. The PSC motor utilizes alternating current (AC) and is commonly referred to as induction motor. PSC motors have single speed operation, meaning that they do not contain any programming or micro-controllers to adjust speed or power in order to accommodate changes within the duct system. This is the reason why the delivered air produced by the PSC is drastically reduced as external static pressure (ESP) within the duct system increases. Although the PSC usually has 3 speeds to choose from, the motor is constrained to the fixed rated HP of the motor and, therefore, is limited to the air flow at various ESP. Advantages: 1. Low costs; 2. Readily available; 3. Universal application between manufacturers and OEM, i.e. no specific programming; 4. Simple design and few components. Disadvantages: 1. Lower efficiency compared to ECM. PSC generally are around 60% electrically efficient; 2. Very limited ESP range when requiring a specific CFM. The delivered air is reduced dramatically as ESP is increased; 3. Cannot vary the speed for two stage operation or humidity control; 4. Least quiet when compared to ECM; 5. Does not qualify for federal tax credit program due to its low efficiency; 6. Draws about 90% of FLA for continuous fan operation. This results in high energy consumption for commercial buildings that require constant ventilation. ECM The electronically commutated motor (ECM) has variable speed capability and can be controlled very precisely. ECM utilizes DC power as opposed to the PSC utilizing AC power. The DC motor is inherently more efficient and runs cooler than AC motors. Today s current ECM differs from the traditional DC motor in that the positions of the magnet and windings are switched. The magnet is placed on the rotor and the windings are placed on the stator. This switching allows the motor to work without the use of brushes; hence, a brushless motor. Removing the brushes not only eliminates the failures due the wear down of the brushes, but also the inherent inefficiencies introduced by the brushes. The motors run cooler and more efficiently. Another major addition that the ECM brings is that the motor can be programmed. The type of ECM determines the extent of the programming that can be done; the two types of ECM that are widely used in HVAC are the constant CFM and the constant torque motor. Constant CFM The constant CFM motor is a very sophisticated ECM. The motor itself is as described above. What sets the constant CFM apart from other ECMs is that the outer module of the motor houses a microprocessor. This microprocessor varies the torque delivered by the motor as the external static pressure (ESP) changes to maintain a constant CFM. When the motor is developed in the lab, the blower curve for the specific motor/blower combination is empirically determined and programmed. As the ESP changes in the system, the torque is varied and the system point rides this constant CFM curve to maintain the same CFM throughout the torque range of the motor. There are many reasons as to why the external static pressure (ESP) can change in the duct system. Dampers or registers may be opened or closed, filters can load up, and evaporator coils can become obstructed by buildup. Sometimes duct systems are not built as designed or may have leakage. The constant CFM can compensate and can potentially overcome these deficiencies to provide the intended air flow. This makes what would normally be a legitimate field issue into a non-issue. Advantages: 1. Very quiet operation when compared to PSC motor; 2. The module containing the micro processor can be separated from the motor. If one of the sections goes bad, the entire assembly does not have to be replaced;
8 The Engineer s Choice September 2014 9 3. Large range of available ESP at a specified CFM. Delivers relatively constant CFM from 0.1 WC to 1.0 WC; 4. Draws only about 30% of FLA for continuous fan operation. This lends to very efficient method of maintaining proper air flow for ventilation in commercial applications. It is very practical in maintaining better IAQ; 5. Programmable ramp up and ramp down feature. This leads to quite start up and shut down; avoiding the banging sound that is experienced when a motor is energized; 6. Dehumidification mode available. If the thermostat has a cool-to-dehumidify feature, then the unit will continue running even if the set point has been satisfied, but the motor will slow down to 70% of the full speed to provide further and better dehumidification; 7. Qualifies the unit for federal tax credit program; 8. Adds around 1 EER to the unit when compared to the PSC motor. Disadvantages: 1. Higher costs. The constant CFM motor can reach 4 times the cost of the PSC and 2 times the cost of a constant torque ECM; 2. Adjustments to CFM range is restrictive once factory-programmed. Field adjustments will have to be made if the motor delivers 100 CFM too much or too little. The factory blower performance table must be reviewed carefully to ensure that the CFM will work for the specific application. This is commonly overlooked. Constant Torque The constant torque ECM slightly differs from the constant CFM motor. The DC motor is exactly the same, and therefore has the same efficiency. The difference comes from how the motor is programmed and controlled. The constant torque ECM does not have a microprocessor; instead, the torque values are programmed with fixed speed taps. The actual torque value or the percentage of available torque can be programmed. These values are determined through testing and development with the specific motor/blower combination. For example: Tap 1 could be programmed either as 60 in-oz of torque or as 45% of the maximum torque output of the motor. For field flexibility, the constant torque motor has 5 available speed taps to choose from to closely match the desired air flow with the system pressure drop. When determining if the motor can be applied, reference the blower performance table in the catalog. A constant torque ECM is a good compromise between PSC and a constant CFM ECM. They have a significantly lower cost than the constant CFM, but maintain a much larger ESP range over the PSC, all with the same efficiency as the constant CFM ( 80%). Although they do not maintain a constant CFM, the motor is capable of delivering air at higher ESP than PSC motors are. This lends to better flexibility and ranges of applications. Advantages: 1. Quiet operation when compared to PSC; 2. Less expensive when compared to a constant CFM motor, while delivering the same motor efficiency; 3. Up to 5 different speeds (torque values) can be programmed, lending to greater field flexibility on air flow delivery; 4. Larger range of available ESP when compared to a PSC motor; 5. Draws only about 30% of FLA for continuous fan operation. This is conducive to a very efficient method of maintaining proper air flow for ventilation in commercial applications. It is very practical in maintaining better IAQ; 6. Qualifies the unit for federal tax credit program; 7. Adds around 1 EER to the unit when compared to the PSC motor. Disadvantages: 1. Limited range of ESP at given CFM. Although the range is significantly larger when compared to the PSC, it does not offer the same range as the constant CFM at a given CFM; 2. On/off delays are not available. This feature will have to be available with external controls (i.e. thermostats or DDC); 3. More expensive than a PSC on the scale of twice as much. Considerations When Choosing Now that you know the differences between the motor types, how do you apply that knowledge when selecting the correct motor? To understand the affects of the different technologies when it comes to air flow delivery, refer to the chart: CFM 1000 900 800 700 600 LV024 EP024 LM024 500 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 ESP (IN WC) The three motors are being used on a 2 ton unit. The LV024 (represented by the blue line) utilizes a PSC motor, the EP024 (represented by the red line) utilizes a constant torque motor, and the LM024 (represented by the green line) utilizes an optional constant CFM motor. PSC: The PSC (blue line) has a very limited ESP range and the CFM drops dramatically as ESP increases. The CFM has been reduced so much @ 0.5 in.wc, that the motor is almost unusable and the next larger motor or blower needs to be used. Constant Torque: The constant torque motor (red line) has a much larger ESP range than that of the PSC, however, the CFM is still reduced with increasing ESP, but not as drastically. Although less air flow is produced, the ability to use this motor at higher ESP does bring a big advantage over the PSC, especially when using air filters with higher filtration ratings. Constant CFM: The constant CFM (green line) has the largest ESP range and will maintain relatively constant CFM up to about 0.8 in wc. Even beyond that up to 1 in wc (which is usually the limitation of the blowers), the CFM is only reduced by less than 10%. This motor gives the biggest field flexibility when ensuring a specific CFM is a priority. Knowing the application in which the motor is to be installed and what the budget will allow, will lead you to the correct decision when selecting a direct drive motor. Written by Ryan Todaro, P.E., Project Manager/Mechanical Designer at FAE Consulting in Florida; Ryan is a former Bosch Applications Engineer.
10 The Engineer s Choice September 2014 11 Product Spotlight FHP LV Split System UP TO 15.9 EER (GLHP) UP TO 4.4 COP (WSHP) The option-rich LV Split System was created to provide maximum flexibility. Available in vertical or horizontal configurations (air handling section) from 1½ through 6 tons, this system is designed to meet your every need. Consisting of two sections, these units can be placed remotely to allow for installation in locations where space is limited or sound is an issue. Key Features 2-Position Water Valve Phase Protection (3-phase only) Unit Mounted/Wired Disconnect Switch Meets ASHRAE 90.1 performance data Pump & Compressor Monitor Relays Energy Management Switch (on/off) 75VA & 100VA Transformer Disconnects available on both sections Options Designed for Any Application DuoGuard Air Coil Protection The LV Split System is available with this state-of-the-art coil protection option that features two layers of corrosion protection. All active copper heat transfer surface on the air coil is coated with a tin plating to resist all common forms of formicary coil corrosion. Additionally, the aluminum fins are pre-coated in a state-of-the-art gold enamel protective layer to provide a long service life in the harshest of environments, including salt water. DuoGuard protected coils exceed 1000 hours of ASTM B117 salt spray testing. Quiet Comfort ECM - Provides constant torque (standard) or constant airflow (option) to meet the space temperature & humidity requirements Floating Compressor Base - Reduces vibration and noise transmission from the compressor to the structure Closed-cell Foam Insulation (air handler option) - Helps to provide cleaner, fiberfree air and reduces sound transmission Service Friendly Blower Inlet Ring - Allows quick servicing of blower fan motor without dissassembly of blower housing External LED Status Light (CS option) - Reduces troubleshooting time without removal of service panels Schrader Charging Valves - Facilitates service diagnosis by allowing the connection of refrigerant hoses quickly and securely Robust and Durable Construction G90 Galvanized Steel Cabinet - Provides strength and corrosion protection Stainless Steel Drain Pan - Resists cracking and corrosion which provides long-lasting reliability for condensate collection Cupro-nickel Coaxial Heat Exchanger (option) - Protects against corrosion when water conditions are of low quality Quality Design & Efficiency LEED Friendly Design - Helps qualify for the most credits possible with a water source HVAC system Boilerless Control (option) - Disables the compressor and/or activates remote, fieldsupplied electric heater should the water temperature drop below set point Water Flow Regulator (option) - Provides fixed 3 GPM/ton water flow rate Safety Flow Proving Switch (option) - Prevents the continued operation of the compressor should the water supply fail Unit Protection Module - Controls the operation and monitors the safety protection of the unit Dual Refrigerant Freeze Sensors - Monitors if refrigerant temperatures reach freeze limitations and disables unit compressor operation ECM Constant Airflow Fan Motors Available in 1/3hp to 1hp, provides constant airflow in a wide static pressure range up to 1 in.w.g. Available in unit sizes of 015 and up, this motor is a great choice in high filtration applications, such as with the optional 2 MERV-13 pleated filter. The motor has a soft start/stop feature, keeping noise to a minimum. Passive dehumidification can be achieved with the constant airflow ECM by reducing nominal airflow by 15%. This control feature lowers air coil temperature and prevents over-cooling of the space when in dehumidification mode. The constant airflow ECM requires a neutral wire in a 460V application. MERV-8 and MERV-13 Filters The MERV-8 or -13 filter is the optimal air filtration choice on commercial HVAC projects. These filters are a cost efficient way of upgrading air quality while maintaining low pressure drop and sustaining long service life. The MERV-13 filter effectively removes up to 98% of airborne matter, such as fine particulates, bacteria, smoke, gases, and allergens including dust mites, pollen, mold spores, dust and smog. MERV filtration is an excellent choice to obtain Environmental Quality LEED credits when seeking compliance on a LEED project. Long Refrigerant Line Sets Up to 75 (equivalent) of refrigerant copper tubing between CS & A/H sections to provide flexibility in installation locations. Fiber Free Insulation (Air Handler section only) LV Split units can be provided with non-fibrous closed cell insulation. This insulation provides the ultimate for indoor air quality while attenuating noise. Closed cell foam insulation is cleanable and meets the most stringent requirements for reducing airborne fibers and particles.
12 The Engineer s Choice September 2014 13 Middle Creek Wildlife Management Area Case Study #1 Bosch FHP EC Series 8 & 10 ton heat pumps installed in the ceiling of the auditorium, connect into existing ductwork system to provide year-round comfort Geothermal Retrofit in Central Pennsylvania at the Middle Creek Wildlife Management Area Background Wildlife has always been an important part of Pennsylvania s cultural heritage. For over a century, the Pennsylvania Game Commission has managed the Commonwealth s wildlife resources. With more than 700 full-time employees and thousands of part-timers and volunteers, the agency provides a host of benefits to wildlife, state residents and visitors. Tourists flock to the Middle Creek Wildlife Management Area in Kleinfeltersville to view snow geese, as well as other waterfowl, birds and wildlife. Tundra swans are attracted to Middle Creek annually because it provides a secure resting and water-roosting area from late February and early March. The large birds converge on Middle Creek as a migratory stopover before continuing north to the arctic for breeding. Their stay ranges from a few days to a few weeks. The Game Commission installed a new Bosch FHP geothermal HVAC system at the Middle Creek Wildlife Management Area to replace two aging rooftop units and provide a more comfortable, energy-efficient environment for visitors and staff. According to Chief of the Game Commission Engineering Division Foster Chip Schaffer, P.E., The Visitors Center is an observation and education building located within 4,000 acres of game land including a 350-acre lake. It was built in the 1970s and the existing air to air rooftop units were aging and it was increasingly difficult finding replacement parts. We had some previous experience using geothermal systems with a couple of other state facilities, so we decided to upgrade to geothermal here at Middle Creek. larger units mounted on the ceiling, tie into the building s existing ductwork. A fresh air intake with a 22-kW electric heater tempers incoming outside air. Electric baseboard heaters provide warmth to several small vestibules; otherwise the geothermal system is designed to meet demand for heating and cooling year-round. Twenty geothermal wells, each 300 ft deep in a closed loop system are tied into a header routed to the equipment room which houses two 5-hp circulating pumps. The two aging rooftop units were removed, geothermal wells drilled and the system piped and commissioned by Leibold, who purchased the geothermal equipment from FHP Representative Energy Transfer Solutions in Kennett Square, PA. The Game Commission opted to replace the old roof and increased the new roof thickness to improve the R-value, which in turn enhances the performance & efficiency of the new HVAC system. Summary and Conclusion The renovation project began in early 2014 and completed in spring. The Visitors Center remained open as usual during the renovation project, and no public programs were disrupted. Leibold has done a good job for us; we re pleased with the new geothermal HVAC system and anticipate high performance with lower energy bills, reported Chip Schaffer. Project: Middle Creek Wildlife Management Area, Kleinfeltersville, PA Geothermal Representative: Energy Transfer Solutions, Kennett Square, PA Twenty wells each 300 ft deep provide a closed-loop geothermal field routed to the mechanical room Installation Summary The Visitor Center requires 40 tons of cooling, so with the assistance of Leibold Mechanical, a family-owned HVAC installer, they selected eight Bosch FHP EC and LV Series water-to-air units ranging from one to 10 tons capacity. According to Clayton Leibold, the one-ton units are spaced throughout the building and, along with the Equipment: Conversion to Bosch FHP EC and LV Series geothermal heat pumps Property Owner: Pennsylvania Game Commission Engineers: H&H Sales As sociates, Mechanicsburg, PA Installing Contractor: Leibold Mechnanical, Inc., Pottsville, PA Project Completion: Spring 2014 Project Goals: Lower energy bills No disruption during visitor hours
14 The Engineer s Choice September 2014 15 Vermeer Yellow Iron Academy Early Learning Center Case Study #2 Geothermal HVAC in Child Care Center Yellow Iron Academy, Pella, Iowa Background The Yellow Iron Academy Early Learning Center (named after the bright yellow color of Vermeer machines) built by the company for its employees children. is operated by the independent Bright Horizons Child Care (headquartered in Watertown, Massachusetts with regional office in Chicago). The learning center accepts children from 6 weeks to 12 years, including summer camp and after school care for the older age groups. The program is based on a curriculum for all ages, with focus on hands-on learning and STEM opportunities (Science, Technology, Engineering, Math). Installation Summary Ed Beller, Vermeer s HVAC and Electrical Manager, explained the HVAC system consists of 21 Bosch FHP ES two-stage and EP single-stage geothermal heat pumps. The heat pumps were selected because Vermeer had already integrated geothermal in their data center, one of nine buildings on the Vermeer campus. Vermeer-built FX horizontal drilling machines provided 40 bore holes at varying depths to a maximum of 30 feet adjacent to the new building. According to Jon Oosterhuis, lead architect with SVPA, Vermeer wanted a green building and it was built to LEED standards, although it is not LEED certified. Jon continued, It incorporates efficient LED and fluorescent lighting, rigid insulation exterior to the wall frame to reduce thermal bridging, double pane Pella windows, occupancy sensors with setback controls, and an Energy Recovery Ventilator on the roof. Tim Grossman, Vice President of Mechanical Sales, the FHP representative in Des Moines, supplied the units and Wolin Mechanical installed the HVAC system. Dave Inghram is the mechanical designer with KJWW Engineering and Consulting firm (Des Moines) specializing in educational and industrial buildings. We designed 60 tons of total cooling using 21 water-to-air geothermal units from ½ to 5 tons installed in mechanical closets throughout the building. No backup heat source is required the geothermal heat pumps provide sufficient heating and cooling performance, incorporating hot gas reheat to control humidity, said Dave. Benefits and Conclusion The Early Learning Center is scheduled to open in August for the school year beginning in September 2014. Vermeer incorporates a simple corporate philosophy focusing on People, Product, Profit and ethical Principles, remarked Mindi Vanden Bosch, Vermeer s HR Manager and granddaughter of founder Gary Vermeer. The Yellow Iron Academy embodies our support for our employees families, and is designed and built to a high stand ard of energy-efficiency and sustainability for the education and safety of their children. Project: Yellow Iron Academy, Pella, IA Equipment: Bosch FHP geothermal heat pumps: 21 EP and ES Series totalling 60 tons Building Owner: Vermeer Charitable Foundation Geothermal Representative: Mechanical Sales, Des Moines, IA Architectural Design: SVPA Architects, Des Moines, IA Mechanical Consultant: KJWW, Des Moines, IA Installer: Wolin Mechanical, Des Moines, IA A-One Gerthermal, Earlham, IA Project Completion: August 2014 Project Goals: Comfortable environment for child care center Energy savings and sustainability Resiliency in severe weather Use of Vermeer geothermal drilling equipment
16 The Engineer s Choice September 2014 17 function with the lower gas pressure available in the building. Therm Gas Condensing Tankless Water Heaters Case Study #3 Energy Saving Therm Tankless Water Heaters in Multi-Family Residential Application Background The Caroline is one of the most prestigious residential apartment buildings in New York City, located in The Flatiron district on 23rd Street, between 5th and 6th Avenues. The 20-story building features 433 apartments with premium kitchen and bath amenities, 50-foot sky-lit swimming pool, on-site laundry, fitness center and central climate control. Built in 2000, the building used a central hot water delivery system using four commercial direct fired water heaters. After 12 years, one of the water heaters failed and the existing DHW system was not meeting the demands of the tenants and needed replacement. Installation Summary The building owners were looking to upgrade their DHW system but were challenged with space constraints for new equipment and variable loading due to changing occupancy. Adding additional storage capacity was not an option as the mechanical room was already filled to the maximum. They opted to install 17 Bosch C 1210 ESC condensing gas tankless water heaters cascaded in parallel for a tank loading application. Two zones were required for DHW lower zone with eleven C 1210 ESC units and five storage tanks and upper zone with six C 1210 ESC units and three storage tanks (each storage tank has 240 gallon capacity). This commercial series tankless unit is the only one that can operate at over 140 F outlet water temperature and still be vented with PVC. Tankless water heaters are commonly used in residential on-demand applications. However tankless water heaters can be applied in a commercial tank loading application providing comfort even with variable demand. An advantage of using the Bosch tankless units was that they fit through a standard 30-inch doorway, and they Up to 24 Bosch C 1210 ESC gas tankless water heaters can be linked together to achieve higher flow rates than with single units up to 290 gallons per minute. The 17-unit cascade used in The Caroline can deliver 205 gallons per minute. Commercial tank loading design allows for complete isolation of the system for maintenance and gives the ability to bypass certain system components in case of failure. Some design consideration for tank loading include: Ensure flow through each water heater is between 3.5-5.0 gpm Isolation valves or boiler drains should be installed to facilitate descaling in applications with hard water Whenever possible, plumb the system or configure the tank to draw cold supply water into the water heater during hot water use Summary and Conclusion Unlike conventional water heaters, these condensing units capture latent heat from condensation of the exhaust gas and use it to preheat the incoming cold water, making Bosch condensing tankless water heaters 10% more efficient than traditional tankless water heaters. The building owners are very pleased with the performance, energy savings and flexibility of the THERM C 1210 ESC condensing tankless water heaters, and not a single day of hot water supply was lost during installation. Project: The Caroline residential building, New York, NY www.thecarolineny.com Equipment: 17 Therm C 1210 ESC cascaded in parallel Building Owner: PanAm Equities LLC, New York City Application: Gas condensing tankless water heaters Installing Contractor: Paramount Plumbing, The Bronx, New York Manufacturer s Representative: Marplat, Westbury, NY Project Completion: August 2012 Project Goals: Energy Savings Space-saving Technology Reliable Retrofit
18 The Engineer s Choice September 2014 19 Antarctic: Buderus to the other end of the world By ship and sled: Buderus delivers boiler to the Antarctic Dronning Maud Land, Antarctic No other Buderus boiler has ever travelled so far: 14,400 kilometres (8,948 miles)from Bremerhaven, Germany via Cape Town in South Africa to the Antarctic; most of it by ship. The last part of the adventurous trip, no less than 760 kilometres (473 miles), involved crossing snow and ice on a sled pulled by a PistenBully tracked vehicle. This journey took a total of twelve days at a maximum speed of twelve kilometres per hour (7.5 miles per hour). The oil-fired boiler s destination was the Kohnen Station. This German polar research station serves as the logistics base for ice coring in Queen Maud Land, a European deep-ice project for documenting the climate record in the Antarctic. Since, for understandable reasons, the on-site installation of the boiler could not be performed as would normally be the case by professional installers, the research station s own technical staff had to step in and roll their own sleeves up. With that in mind, they were given comprehensive training in advance in the regional Buderus training center in Berlin, and the installation was carried out without any problems. Extreme conditions for humans and boilers With outside temperatures down to minus 50 Celsius (-58 F), the demands on the heating technology system in the Antarctic are extremely high. The Logano is a replacement for the system s previous reserve boiler in the station. The heating system not only supplies heat but also provides the necessary drinking water. This involves shovelling snow from the surrounding area into a tank where it is then melted by the boiler, after which the resulting water is heated in a storage water heater. Under such extreme climatic conditions it is important for people to be self-reliant. Final destination: The polar researchers at the Kohnen Station are happy to receive their new boiler
20 The Engineer s Choice LM Model Water Source Heat Pump The fully featured LM with two capacity scroll compressor & ECM provides best-in-class efficiency, comfort and peace of mind for years to come. LM Model commercial heat pumps feature: Best-in-class 2-stage efficiency Robust and durable construction with industry leading low sound levels Service friendly features for easy repair and installation Extensive options to meet virtually any jobsite design requirement LEED compliant to help qualify for the greatest potential of credits with a water source HVAC system Part Load UP TO 32.0 EER (GLHP) Full Load UP TO 22.0 EER (GLHP) Contact your rep offices for your next building project TODAY! fhp-mfg.com or 1-866-642-3198