System treats heating water in apartment building

Gas-condensing boilers replace aging system in commercial plaza

Problem: Climate-Tech, a third-generation family-owned business serving western Cuyahoga and parts of Ohio, managed the HVAC systems in five commercial buildings operated by Flair Management in Middleburg, Ohio. In fall 2015, two 30-year-old 650,000 Btuh flex-tube boilers in building No. 1 required replacement.

Solution: Climate-Tech recommended Buderus GB162 gas-fired condensing boilers from Bosch Thermotechnology in a four-unit cascade configuration with total input of 1,332 MBH. “We replaced two 650,000 Btuh flex-tube boilers and a 40-gallon hot-water tank with the Buderus GB162 TR-400 cascade package with a Buderus SST150-40 indirect tank,” says Josh Dubecky, field operations manager of Climate-Tech. The system is controlled by an open-source building control system that sends a low-voltage staging signal to the Buderus MCM-10, which rotates firing of the boilers to meet building heating and domestic hot-water demand to save fuel. In order to minimize disruption to building tenants, Climate-Tech prepped and protected the flooring, disassembled and removed the old boilers on a Saturday, and assembled piping on the roof before transporting it into the fourth-floor mechanical room.

Result: Overall, the installation required just one week. The building is comfortable and the two restrooms enjoy adequate hot water provided from the single Buderus 40-gallon tank. There are hopes to upgrade another one of the buildings with the same system. “According to our January, February and April 2015 and 2016 results, the gas usage, on average, generated 46 percent savings at the baseline temperature of 55 degrees F when the boilers are activated. This 46 percent savings is based off cubic feet of natural gas per heating degree day,” says Dubecky. 800/283-3787; www.boschheatingandcooling.com.

System treats heating water in apartment building

Problem: Water used for heating purposes in an apartment building in Iceland was infested with bacteria, causing corrosion, fouling and slime, resulting in frequent maintenance and increased costs. Furthermore, the water needed to be treated with chemicals to reduce these problems.

Solution: Technicians from LubeCorp Manufacturing installed the Heating/Cooling System Water Treatment H/CS. It contains no toxic chemicals and completely eliminates microbial activity, scaling and fouling, prevents corrosion, is biodegradable and is environmentally safe to flush into municipal sewage systems. It is blended at a 25-1 ratio and extends water life up to 10 years with proper maintenance. Microbiological activity is eliminated by biodegradation of bacterial food supply, i.e. calcium, magnesium, phosphates, sulphates and iron oxides, hence requiring no biocides.

Result: Scaling and fouling was eliminated, as tests showed improved utilization of hot water, reducing energy costs. This is because heating/cooling transfer contact between water and the piping is optimized through reduced surface tension. Corrosion was eliminated with H/CS built-in inhibitors. 800/661-6100; www.lubecorp.com.

Control system simplifies LEED school HVAC

Problem: The extreme remoteness of Creede, Colorado, required an HVAC control system for the town’s new LEED Gold K-12 school that could be monitored remotely by the installer. Also, the system needed to be capable of harnessing numerous heating and ventilation components without the need for a controls specialist or ongoing maintenance costs associated with the control platform.

Solution: Rogers & Sons Inc. traveled 260 miles from Denver to install miles of radiant tubing, multiple boilers, an HRV system and condensing duct furnaces at the new 37,000-square-foot school. All equipment is tied to a Taco iWorX control system. “There’s no code to write,” says Shawn Metzler, controls superintendent at Rogers & Sons. “You don’t need special tools or software. Compared to a DDC system, you eliminate a lot of hours typically spent programing and commissioning.” Preprogrammed modules are used on equipment, zone valves and dampers throughout the building. All components report back to a touch-screen local control interface in the boiler room. Each module self-identifies on the network when first turned on.  

Result: While under construction, the project required Rogers technicians to find lodging in Creede, but now effortless operation and monitoring can be done on site or from Denver. There are no continuing fees associated with it and software upgrades are free. Proprietary systems, including LON, BACnet and Modbus, interface easily with iWorX. “The advantage of an iWorX system quickly hits home for the building owner,” says Metzler. “When they realize they don’t need a separate controls contractor — at the time of installation or going forward — they see value.” 401/942-8000; www.taco-hvac.com.

Historic church saves money with high-efficiency condensing boilers

Problem: With failing boilers and an inefficient heating system, historic Zion Episcopal Church in Oconomowoc, Wisconsin, needed guidance and help. “Our heating system consisted of four nearly 12-year-old 199 MBH boilers,” says Linda Georgeson, senior warden with Zion Episcopal Church. “Two of the four boilers were no longer functioning, and we were convinced the other two would fail because one was leaking.”

Solution: Schulte Heating replaced the four failing boilers with two Evergreen boilers, a 299 MBH and a 399 MBH from Weil-McLain. They were installed as a multiple-boiler system using the Modbus communication feature. “Evergreen is the only boiler I proposed to Zion because I really like the technology of the fire tube heat exchanger in those boilers,” says Rich Schulte Jr. “In addition, they are easy to set up through the setup wizard provided on initial startup and also easily maintained. The units don’t require a separate, external control panel or boiler panel, which was ideal because the church did not currently have a separate interface to view the status of the systems.” The installation took less than a week.

Result: The units are configured to handle the five separate church thermostats/zones. Each thermostat is programmed for usage depending on the day and whether the area is occupied. “We’ve noticed significant savings on our energy bills when comparing this year’s monthly bills to last year,” says Georgeson. 219/879-6561; www.weil-mclain.com.


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