\u003c/strong>\u003cem >Photo courtesy of Thermal Solutions\u003c/em>\u003c/p>\u003cp >\u003cem >\u003cstrong >Explanation: \u003c/strong>\u003c/em>\u003cem >Eco Propel Cognitive Pump Technology is a variable-speed control for Thermal Solutions Products’ line of Apex condensing boilers. This entails integration of boiler firing rate with pump speed to improve boiler and system efficiency while reducing electric and fuel consumption. A 0- to 10-v signal is communicated to a pump to ensure desired flow and ∆T are returned across all firing ranges.\u003c/em>\u003c/p>","children":[]},"type":"text","cl":"text p-_Js1xJSc"},{"key":"e-PuDjem7OK","content":{"children":[]},"type":"section","children":["eD_l2SzTKcl","eWmqtTVkm0M","eszsqEZ9lS7"],"cl":"section"},{"key":"evJ5OuSm6-z","content":{"text":"\u003cp >Until recently, changing the flow rate through a light commercial boiler to match Btu input has largely been an afterthought. Just five or six years ago, only a few boiler manufacturers offered variable flow to optimize system efficiency as an option. The general consensus seemed to be it simply isn’t economical to pay for the upgraded variable-speed circulator. \u003c/p>\u003ch2 >\u003cstrong >The bigger picture: conserving gas\u003c/strong>\u003c/h2>\u003cp >To a great extent, most references to the use of variable-speed circulators for boilers have focused on electrical efficiency. Based on the inherent efficiency of ECM motors and the ability to run at much lower speeds, electric consumption falls significantly — by as much as 85% to 90%. But in the grand scheme of things, only one circulator is involved.\u003c/p>\u003cp >“The real advantage is fuel savings,” Schnorr said. "Eight years ago, and with the cooperation of Taco, Thermal Solutions developed a variable-speed boiler pump kit called Eco-Propel. The modification they made was simple, and it consistently yielded up to a 3% reduction in gas consumption. \u003c/p>\u003cp >This was accomplished by increasing heat transfer at low- and mid-fire rates where over-pumping limits condensing performance. And, 3% might not sound like much, but when assigning a dollar value to the gas that an 825 MBH boiler uses over the course of a year — or several for that matter — the savings accumulate quickly. This\u003cem > \u003c/em>is the catalyst for using variable-speed pump technology coupled with condensing boilers.\u003c/p>\u003cp >Schorr pointed out that, while testing the Eco-Propel kit, they consistently found a 6° to 10° reduction in return water temperatures over the course of a firing cycle. Each degree is critical in producing as much condensate as possible. More heat stays in the system, while less goes out the stack.\u003c/p>\u003cp >Ultimately, the result was an all-inclusive, plug-and-play boiler pump package that provides a 12-month payback in the Northeast based on heating degree days and fuel prices. A user’s ROI varies, chiefly dependent on what part of the country the boiler’s located in, but is typically in about two years’ time. \u003c/p>\u003ch2 >\u003cstrong >Circulator adaptation\u003c/strong>\u003c/h2>\u003cp >According to Schnorr, Thermal Solutions began to work with Taco experts to select and modify an ECM circulator for the task. \u003c/p>\u003cp >Taco’s engineering department examined the pump requirements and found their ECM-powered VR15 offered the correct performance curves.\u003c/p>\u003cp >The only hurdle was the pump’s ability to receive a 0- to 10-v signal. Taco pumps had that capability for several years, but had not yet implemented it on the 00e line of high-efficiency circulators because the demand didn’t justify it. This was the same challenge Thermal Solutions was finding with other pumps available in the same category.\u003c/p>\u003cp >At the very beginning of the project, engineers from both firms attempted to run the variable-speed pump with a set of temperature sensors on the supply and return pipes. While the sensors work well within a distribution system, there was a slight lag time that they weren’t willing to tolerate for the application. And, there was the possibility of firing rate and pump flow fighting each other. \u003c/p>\u003cp >The solution was to orchestrate all facets of operation — optimizing boiler modulation and system flow — through the Apex boiler’s control. \u003c/p>\u003ch2 >\u003cstrong >Savings trifecta\u003c/strong>\u003c/h2>\u003cp >“There are actually three ways that this solution conserves resources,” Schnorr said. “Annual electrical and gas savings are easy to quantify; $245 and $600, respectively (\u003cem >$245 savings in electrical cost and $600 in fuel costs versus constant/fixed speed full flow pumping practice ) \u003c/em>in the Northeast. The last benefit, boiler longevity, is just as real but more difficult to quantify.” \u003c/p>\u003cp >By reducing the number of boiler cycles and limiting thermal shock to the heat exchanger, the use of a variable-speed boiler circulator extends the service life of the condensing boiler. In addition to boiler longevity, circulator life also is extended. This is due to slower motor operation during the vast majority of runtime hours.\u003c/p>\u003cp >Electrical consumption is also reduced by the water-tube heat exchanger. Its design permits low flow rates and high delta Ts, finely tuning system efficiency, Schnorr stated. \u003c/p>\u003ch2 >\u003cstrong >The future is now\u003c/strong>\u003c/h2>\u003cp >The industry is moving from fixed-speed/variable-speed systems (boiler loop/distribution) to variable-variable-speed. This especially is true on commercial projects. Over the past several years, engineers and installers in the U.S. and Canada have grown comfortable with variable-speed distribution and its benefits. But as buildings become more efficient, flow rates are reduced and supply temperatures fall, there’s a real need for the boiler to respond accordingly.\u003c/p>\u003cp >“This is definitely what the hydronic industry needs to maintain its competitive advantage,” Schnorr said. “And in many places, variable-speed boiler pumps and circulators are incentivized. I believe this is really an evolution in system piping to maximize system efficiency and eliminate wasteful over pumping. The technology is here; the question is, will we embrace it in new designs and the replacement market.”\u003c/p>","children":[]},"type":"text","cl":"text p-_Js1xJSc"},{"key":"etHINk4jABQ","content":{"children":[]},"type":"section","children":["evJ5OuSm6-z"],"cl":"section"},{"key":"ew0bkTVjKrO","content":{"src":{"key":"QCuVvV1K7V","url":"https://cdn.vev.design/cdn-cgi/image/f=auto,q=82,h=1920/private/KaxzywoIf0Rx41JdO6oEbX8EsUI3/image/QCuVvV1K7V.jpg","ratio":0.75}},"type":"image","cl":"image"},{"key":"ezaOvj1vlRQ","content":{"text":"\u003ch3 >Greg Hughes\u003c/h3>\u003ch4 >Greg Hughes is internal sales manager for Thermal Solutions and Burnham Commercial.\u003c/h4>","children":[]},"type":"text","cl":"text 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>Coming up next ...\u003c/h4>\u003ch2 >\u003cstrong >Enhancing IAQ in kitchens: A guide for HVAC professionals\u003c/strong>\u003c/h2>","children":[]},"type":"text","cl":"text pnyIbvpAvt"},{"key":"eaxFPUKDbYw","content":{"children":[],"link":{"mode":0,"page":"p00ApCIdlnk"}},"type":"external-link","cl":"external-link"},{"key":"eTVqGyxVulx","content":{"children":[]},"type":"frame","actions":["eaxFPUKDbYw"],"children":["eUVsV9OIvel","e3B3ucclMMX","ensYo0K3O2B","eekLa4J_KsQ"],"cl":"frame"},{"key":"eiUCEjzavrH","content":{"children":[]},"type":"section","children":["eTVqGyxVulx"],"cl":"section"},{"key":"eDXe0EDOo0y","content":{"children":[],"link":{"mode":0,"page":"pKEO3CF_5i-"}},"type":"external-link","cl":"external-link"},{"key":"e5cm-9aYIfJ","content":{"text":"\u003cdiv>\u003cp >Table Of 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