ZoomLock vs Brazed Fittings

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vrfwizard

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October 31, 2017

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ZoomLock or RLS Fittings vs Brazed Fittings

ZoomLock vs Brazed Fittings.

Which piping joint method is best for your project? There are several things to consider.

What materials are the structure constructed of, and what is the occupancy of the building? If it is a wood structure then creates a greater risk of using a flame when brazing piping joints. If the occupancy is a senior facility or some other occupancy type that would create additional risk due to the occupant’s non-ambulatory ability or employees sensitivity to the byproducts of the brazing process.

Once you have considered the risk analysis based on occupancy and material structure type, then you can look at a cost analysis. The material for ZoomLock™ or other mechanical piping joints cost considerably more than the standard wrot copper brazed fitting.

ZoomLock™ is to be used only on copper to copper applications using either hard or soft copper. ZoomLock™ is a trademark of Parker Hannifin Corporation, the Sporlan Division. The technology is owned by RLS (a Berkshire Hathaway Company) and is licensed to Parker Hannifin.

HVAC Commercial vs Residential

The advantage may lean more towards the HVAC commercial and Industrial markets than that of residential. The HVAC commercial application provides more opportunities due to longer lengths of piping and the need for more fittings. With residential you might have 6 connections, two at the condenser, and two at the evaporator and another two if you’re installing a drier or site glass. There are additional advantages to using the RLS or ZoomLock™ in both market sectors as discussed later.

Pressure Rating of ZoomLock™ Fittings

Are you concerned that the fittings won’t standup to the increased pressures in a R410A system as compared to R22?

Rated at 700 psi / 48 bar
Minimum burst pressure of 2,100 psi / 145 bar
Maximum burst pressure of 3,000 psi / 207 bar

ZoomLock™ O-Rings

There is concern over the durability of the internal O-ring of the RLS or ZoomLock™ fitting. How many years will it last? Will it leak? What happens in a fire? Can you braze a failed ZoomLock™ fitting?

Temperature Rated -40 F to +300 F (-40 C to +149 C)
Material HNBR – Hydrogenated Nitrile Butadiene Rubber
Life of O-Ring – 30 years when used with the temperature & pressure ratings according to ZoomLock
Don’t braze a fitting as this could cause the O-Ring to contaminate the system.

Just remember they use O-rings on the space shuttle and just about any type of military aircraft. If it’s good enough for NASA, may be its good enough for a refrigerant fitting.

MEP Academy Online Courses — HVAC Sheet Metal Courses Online

Smoke, Smell, Fire Watch & Burn Permits

When brazing in an enclosed area within a building you will need to be aware of the location of smoke detectors or deactivate them in some way to avoid setting off the annoying little screamers. In some commercial facilities the smell caused by brazing could raise concerns amongst the occupants, such as those with chemical sensitivities or within a senior living facility.

Also, if you have a flammable storage area or other rooms that contain materials easily ignited, a flameless application will work best. With the RLS or ZoomLock™ fittings you won’t get any customer or employee complaints about smell.

Most jurisdiction and facilities require you to have a fire watch. This is an extra worker that must be trained on how to respond to a fire and understand the procedures and protocol in case of an emergency. This person is required to have a fire extinguisher on hand.

Agency Approvals

If you have a concern over whether or not theses fittings are accepted in your jurisdiction, then you should know that there is a good chance they are. The following certifications and agency approvals are usually adopted into most local codes in some form.

2015 IMC (International Mechanical Code)
2015 UMC (Uniform Mechanical Code)
2015 IRC (International Residential Code)
ASHRAE 15
UL 207, SA#33958, SDTW(7)(Except where noted)
CRN (Approved for couplings & 90 Degree Elbows)

Fitting Warranty

We’re always concerned about the warranty, which is a good indication of the manufactures belief in their own manufacturing process and fitting. Currently ZoomLock™ offers a 5-year warranty with a full page of terms and conditions, read page 28 of their K-1 Catalog dated June 2017.

Vibration Concerns

What happens in an earthquake or when equipment vibrates? Can the fitting hold under such conditions? See UL109

Here is ZoomLocks response to the use of their fitting in a transportation application where the vibration level is high. “ZoomLock™ has gone through extensive vibration testing and results are actually better than that of a braze joint. Please review the vibration testing procedure and conclusion for more information.”

Available Sizes of ZoomLock™ Fittings

Available ZoomLock™ Fittings

Couplings
90 Degree Long Radius Elbows
Tees
Reducers
Caps
SAE Flare
Y-Joints (Coming Soon)
45 Degree Elbows (Coming Soon)
P-Traps (Coming Soon)
Reducing Bushings (Coming Soon)

Crimp Tools

According to ZoomLock™ the tool has a red LED on the back of the tool that will blink for 20 seconds after a crimp. When this occurs, take the tool back to an authorized dealer to have the tool analyzed. They will be able to verify if the tool needs to be sent in for service.

Life of Jaws – 10,000 to 12,000 Crimps
Battery – 100 to 150 Crimps* (15 Minute Charging Time)(2.0 Ah)
Warranty – 24 Months from date of purchase (Verify with supplier)
Klauke 19 kN required for 1-3/8” size fittings

*According to ZoomLock™ you can get 100 to 150 Crimps depending on the sizes used. The system comes with two batteries, so this extends your capabilities up to between 200 to 300 crimps. Make sure you go to the jobsite with your batteries fully charged. The equivalent with brazing is that you will need to replenish your gases when depleted.

Crimp Tool Manufactures & Models

Klauke 15 kN MAP2LCER (J Series Jaw)
Klauke 19 kN MAP2L19 (KJ Series Jaw)
Ridgid RP 100-B (RJ Series Jaw)
Ridgid RP 200-B (RJ Series Jaw)
Ridgid RP 210-B (RJ Series Jaw)

What do you do if your HVAC unit ships with flared ends at the connection points? ZoomLock suggest that if you have at least two inches and room to fit the crimp tool, then cut off the flare and use their fitting.

ZoomLock™ Cost Analysis

ZoomLock claims on their site that the fitting only requires 10 seconds and can save up to 60% of your labor cost. See our post about ZoomLock Cost Analysis (Brazed versus Zoomlock).

You Can’t Teach an Old Dog New Tricks

For those of you who are a little older and are stuck in your ways, changing to a new way of doing things is usually met with resistance. Maybe you still have VHS tapes or don’t market your company on the internet. Using ZoomLock™ is changing the way the industry installs refrigerant piping, it’s just a matter of time before it becomes more prevalent. Also checkout the SmartLock Fitting as it claims a 90% savings over brazed fittings.

Manufactures will keep investing in ways to reduce labor and make installations simpler in hopes of earning your money for doing so. When installed correctly you should have a satisfied customer, at least for 30 years, and by then there will be some other labor saving fitting or system that you can sell to replace the old one.

Resources

ZoomLock vs Brazed Fittings Breakeven Calculator

Checkout ASHRAE’s Study on Mechanical Piping Joints

Happy Crimping!

Check out our article on ZoomLock Cost Analysis or our review of the ZoomLock Value Calculator. and our ZoomLock Klauke 19 kn Tool Review

Also checkout our article on the Lokring Pressfit fitting , SmartLock Fitting and the Reftekk Bendable Piping.

Important Notice for ZoomLock Users

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VRF System Control Wiring

By

vrfwizard

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October 14, 2017

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VRF System Control Wiring

This VRF System control wiring is for a VRF VRV Heat Recovery System with single port branch selector boxes. The control wiring is very simple, it’s basically two 18 gauge wires that go from the thermostat to the fan coils (Wire #1), so that each zone will have a wire from the thermostat to the fan coil. One controller (Thermostat) can control more than one indoor fan coil if desired.

VRF VRV System Control Wiring - Branch Selector Box — VRF VRV System Control Wiring – Thermostat and Branch Selector Box

And then from the Indoor VRF Fan Coil to the single-port branch selector box (Wire #2), that will be a separate wire. Then the branch selector boxes are daisy chained together. So, you can just run one continuous wire jumping from box to box (Wire #3). You don’t have to run a homerun from each box separately to the outdoor unit. They daisy chain from each other in one long chain to the outdoor unit (Wire #4). And then from the VRF VRV outdoor unit to the control panel (Wire #5).

VRF VRV Control Wiring - Heat Recovery System — VRF VRV Control Wiring – Heat Recovery System

So, if you had multiple VRF VRV outdoor units you could daisy chain (Wire #6) them together and then go to the control panel (Wire #5). So, with a VRF VRV heat recovery system the VRF control wiring is very simple and if you are going to have a BACnet you can tie-in from the control panel, most of them have the capability, you’ll need to bring in an IP address and then your customer can remote access into the control panel and then from this control panel you can basically see and control each one of these fan coils you can lock out the capabilities of the thermostat if you wanted too. System status and alarms will show up on the main control panel.

VRF VRV Control Wiring - Multiple VRF VRV Outdoor Units — VRF VRV Control Wiring – Multiple VRF VRV Outdoor Units

Each VRF VRV manufacture may have slightly different VRF System Control wiring layouts but they all have maximum Outdoor Units and Indoor Units that a control panel can be connected to without the addition of an expansion module or adapter (Wire #7). Daikin allows 64 maximum fan coils that you can put on one control panel. In order to expand the control panel capacity, you use adapters (Wire #7).

VRF VRV Control Wiring with Expansion Adapters

Each adapter allows you to connect another 10 Outdoor Units (Wire #8), with 64 addresses or 128 raw fan coils. Use adapters to add additional fan coils for large facilities or use multiple control panels. You daisy chain the adapters (Wire #7) together and then you go to the control panel. Check the VRF VRV manufacture that you’re using for their control wiring requirements, this one is from Daikin.

You can also watch the video of the VRF System Controls Wiring on Youtube.

Leave us a comment. What VRF System Control Wiring do you normally install and how does the wiring differ from this?

How to Calculate Cooling Loads.

VRF System Cost

By

vrfwizard

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October 11, 2017

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VRF System Cost

We know that VRF system cost varies based on many factors which must be considered when budgeting or bidding on a commercial HVAC project. Of course, it’s not the best option to provide a GMP (Guaranteed Maximum Price) based on a parameter such as cost per square foot or cost per ton.

Using cost parameters is beneficial when called upon to provide a budget or to double check a current bid for alignment with your historical project cost data. Whether you are an Engineer providing a budget to the Architect or owner, or an HVAC Contractor, the following consideration of cost apply.

Project Historical Cost Data

Maintaining historical cost data is in your best interest if you plan on being in the HVAC industry for a career. Having cost data is useful whether you’re an engineer or an HVAC contractor.

Knowing how much a VRF System cost or any HVAC system is important to your business. Having a spreadsheet that records all the pertinent cost data of completed projects or bids will allow you to use that cost data to compare against a proposed buildings square footage or installed tons.

VRF System Cost - Cost per Square Foot - Cost per Ton — VRF System Cost – Cost per Square Foot – Cost per Ton

Historical data is great for saving time and money when an owner or a General contractor request a quick budget. Having a cost database of previous projects is a smart approach to being responsive to your customers’ needs for quick cost values. Or are you one of the fortunate ones that never get a request for a budget that is due with very little notice or time to complete?

VRF System Cost per Square Foot

When comparing the VRF System cost or other HVAC Systems from one building to another, it’s important that the buildings share the same characteristics or you make adjustments for the differences.

Just like a real estate appraiser makes adjustments for differences between homes, such as differing amenities and finishes, the HVAC budget between buildings needs to be adjusted for differences.

There are parameters that you want to save in your cost database that are related to building characteristics. For example, building use (Office, School, Hotel, etc.), the quantity of floors, type of structure (wood, concrete), height of building, new construction or retrofit, floor to floor height, etc.

VRF System Cost Project Info – VRF Wizard Project Cost Database

In addition to building characteristics there are job conditions that have an impact on project cost such as: Project access, stacking of trades, security clearances, working height, dust or sound control measures, project meeting & safety requirements. Each project is unique at least in the commercial HVAC sector.

VRF System Cost per Ton

Similar to the VRF System Cost per Square Foot, using tonnage as a parameter for comparison has several things to be considered in addition to the ones discussed above. In addition to the characteristics of the building, you’ll need to evaluate the differences between VRF Systems types and components.

VRF System Cost - Cost per Square Foot — VRF System Cost – Cost per Square Foot – VRF Wizard Project Cost Database

Are you comparing a VRF Heat Pump system or a VRF Heat Recovery System? Is this a three-pipe system or a two-pipe VRF system? Are there single port branch selector boxes or all multi-port boxes? How many fan coils? How many Main Controllers? If you are installing another type of HVAC system, then the pertinent data for that system type needs to be recorded in your historical database.

VRF System Cost - VRF Parameters - VRF Wizard Project Cost Database — VRF System Cost – VRF Parameters – VRF Wizard Project Cost Database

VRF System Cost per HVAC Contractor

There are many factors that can impact the cost of an HVAC system between contractors. Each HVAC contractor has a different business model and cost structure that impacts their HVAC installed cost.

If you are an engineer doing a budget for an owner or Architect it is imperative that you understand who the targeted HVAC contractors will be for the project.

Will there be Union or Non-Union HVAC contractors bidding on the project?
Is the project for a municipality where prevailing wages are required?
Is the project located in a Union dominated city like San Francisco or New York?

Impact of Labor Rates on VRF System Cost

HVAC systems and VRF System Cost are impacted by the HVAC contractors cost for skilled labor. If the HVAC contractor is a Union affiliated company then these labor rates are dictated by the union located near the project site.

If the project is located in the city of San Francisco or New York there is a good chance that you will be dealing with a Union contractor. Was the project executed on overtime or straight time or a combination? Unions usually have scheduled labor rate increases that occur semi-annually or annually.

VRF System Cost - Project Conditions — VRF System Cost – Project Conditions

Impact of Material Cost on VRF System Cost

Another factor to consider is the current state of the economy and the cost of commodities. Is the cost of copper going up or down? VRF projects are heavy users of ACR Copper. When will the project be built, this year or next year?

Material escalation can be accounted for if you know when the project will be built. You can review the PPI (Producers Price Index for Copper) year over year as a percentage and add that value to your material cost as state as such in your proposal. What does your material or equipment cost per square feet for the various projects?

Impact of Time on VRF System Cost

Each year the cost of labor and material mostly goes up due to inflation. Is the HVAC project you are considering being built this year or next year? What is the duration of the project? It’s important to know when the project is being built and the duration.

If you are an engineer putting together a budget for the Architect or owner it’s imperative that you qualify your budget based on time, as time has a value. In large projects that will be built over several years or that won’t start for another year or even latter as owners are often looking for the right economic and strategic time to expend cost for a project.

It’s important to qualify your proposal, whether an Engineer or HVAC contractor, bringing awareness to the cost impact due to time. This is often accomplished by HVAC contractors by putting an expiration date on the proposal, but that date often gets forgotten during negotiations with the General contractor or owner, and the HVAC contractors desire to close a sale.

In the interest of all parties it’s a good idea to bring the cost factor of time into the proposal by highlighting the cost impact due to escalation of labor and material cost for projects delayed until a later time period.

Due to the unpredictability of the material and labor markets this budget is subject to increase due to the economic climate at the time of contract, which may differ substantially from the current environment.

Impact of Delivery Method on VRF System Cost

Is the project based on a set of plans and specifications designed by an engineer or is this a design/build project? The delivery method can have an impact on the project timeline, cost and quality of work.

Tracking your projects based on the type of delivery method will let you know which projects produce the best results based on profit margins.

My historical data shows that greater project margins are made with design/build projects, but you may find a different result. You won’t know unless you track your projects. This goes for any HVAC project, irrespective of the type of system.

Engineering Parameter

Another useful piece of information is how many Ft2/Ton was engineered for each project. When given an architectural background or just the total square feet of a proposed project you can use this data to come up with the total tons required and then use your other cost parameters to arrive at the total cost.

VRF System Cost Summary

No matter which parameter you use the VRF System cost per square foot or cost per ton, you will need to use historical data that relates to your current project and make an educated adjustment as needed. You will also need to consider escalation for any duration beyond the immediate construction of the project.

As you can see there are many variables to pricing a VRF or HVAC project, and anyone that tells you it cost a certain amount per square foot or ton, you should be specious of, as no one value can possibly cover all project variables of the installed cost of an HVAC system.

Each project has characteristics that change the installed cost and having a database from which to compare is a valuable asset for any Engineer or HVAC contractor. Using a Project Cost Database that contains all the pertinent parameters of a project including engineering and cost data will save you time and money while giving you the best opportunity to provide the most accurate budget for your customer.

You can spend hundreds of hours building a project cost database or you can get one the VRFWizard Project Cost Database. This database can be used for all HVAC system types, not just for VRF System Cost. Get the VRF Wizard Project Cost Database for just $99 See the NEW Updated Version of the VRF Cost Tracking Spreadsheet here.

VRF Refrigerant Leak Detection

By

vrfwizard

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October 10, 2017

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Refrigerant Monitoring Code Requirements

ASHRAE 15 requires the monitoring of refrigerant leaks under certain conditions within a mechanical room, but what about an occupied space where refrigerant is circulated through VRF/VRV (Variable Refrigerant Flow) Indoor Fan Coils? When is a VRF Refrigerant Leak Detection system required in an occupied space?

The possibility of a leak is always present and its migration into the occupied space is sure to happen if this occurs. In some parts of Europe a refrigerant monitor is required for occupied spaces that have the capability of being diluted with a refrigerant leak. Although in the United States for the most part this requirement is met by applying the ASHRAE 15 & 34 calculation for the acceptable minimum room size based on the volume of refrigerant in the system.

Refrigerant Leak Detector Locations

The refrigerant monitor system is small enough to fit into an electrical outlet box, which makes for a quick installation and provides for an aesthetically pleasing appearance as it is flush mounted. The refrigerant leak detector should be mounted between 12” to 18” of the floor, as refrigerant is heavier than air and will accumulate along the floor. The refrigerant monitoring system can also be located in attic spaces where pipe manifolds, fittings or equipment connections may leak. Avoid putting refrigerant leak detection devices in areas that lack air movement, such as in corners or behind doors.

VRF Refrigerant Leak Detector to be located 12″ to 18″ Above floor

Refrigerant Monitoring System Alarms

The ability to have an audible alarm (Buzzer) and a visible display (LED) to indicate a leak is available to alert the occupants and the BMS or VRF Main Controller.

The sensor will shut down your HVAC or VRF/VRV system; notify your BMS or Main VRF/VRV Controller upon sensing a refrigerant leak in the occupied space. These refrigerant monitors can be used in any occupied space for an additional level of safety above the refrigerant volume limitations set by ASHRAE 15 & 34.

Highly recommended in spaces where individuals are non-ambulatory, disabled or advanced in age, such as senior facilities, hospitals, apartments, or for any living space such as hotels, dormitories, condos, townhouses, etc.

When is Refrigerant Leak Detection Required

ASHRAE 15 & 34 is the primary designed safety precaution used in the United States for protecting occupants of spaces using refrigerant capable of leaking into that space. The refrigerant monitor can be used as a secondary device for early notification of a leak, but shouldn’t be used as the only means of protecting the occupants.

The designing of the system in compliance with ASHRAE 15 & 34 is the first line of defense in safety. R-410A displaces the oxygen in the room which leads to an unsafe condition.

The use of a refrigerant monitor can provide early notification to the occupants of the space before the level of the refrigerant leak (Refrigerant Concentration Level) reaches that of the maximum set by ASHARE 15 & 34 for the spaces volume.

Refrigerant Leak Detection Manufactures

Here are two manufactures of these refrigerant alarms for use in occupied spaces, the Bacharach MVR-300 and the MSA Chillgard VRF Refrigerant Leak Detector for Variable Refrigerant Flow Systems.

Leave us a comment on how you have used leak detection?

VRF Piping Connections

By

vrfwizard

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October 4, 2017

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VRF Piping Connection Methods Zoomlock LokRing Refnet

VRF Piping Connections

There are several methods for joining refrigerant piping to VRF System components and fittings. The following mechanical VRF Piping connections can save labor but will cost extra in material.

ZoomLock™ by Parker

This is a mechanical joint that can be done quickly and without a flame. This is good when you have a lot of fittings in a wood structure or when labor rates are high. The fittings cost more than the standard wrot copper fitting, but you save on labor. Check out this video on how quick this joint is made.

https://youtu.be/enZ9YUL5uUw

Using ZoomLock™ allows you to make ACR refrigerant piping connections without brazing. This means less labor and no special permits or fire watch. ZoomLock™ claims that their HVAC contractors are stating a 40% to 60% savings on labor by eliminating the requirement to braze fittings and, that it only takes 10 seconds to make a pipe connection. Check out our two other articles on ZoomLock™

ZoomLock Rigid Pzk-Rj4 Pressing Jaw 1/4″ Size
ZoomLock Rigid Pzk-Rj6 Pressing Jaw 3/8″ Size
ZoomLock Rigid Pzk-Rj8 Pressing Jaw 1/2″ Size
ZoomLock Rigid Pzk-Rj12 Pressing Jaw 3/4″ Size
ZoomLock Rigid Pzk-Rj14 Pressing Jaw 7/8″ Size

ZoomLock™ is available in the following sizes: 1/4”, 5/16”, 3/8”, 1/2”, 5/8”, 3/4”, 7/8”, 1-1/8”
Temperature Range: -40˚F to 300˚F (-40˚C to 148.9˚C)
Maximum Operating Pressure: 700 psi (48 bar)

ZoomLock Fittings 7/8″ to 5/8″ Reducers

Installation Instructions Manual: ZOOMLOCK Installation Instructions
Website: ZoomLock Website
ZOOMLOCK™ is a Trademark of Parker Hannifin Corporation

LOKRING by Vulkan

Another mechanical joint is the LokRing by Vulkan. This is a solder-free joint that saves on labor, but like the ZoomLock™, the fittings cost more than the standard wrot copper ones.

Using LokRing by Vulkan is another mechanical method of connecting ACR pipe and fittings in a refrigeration system.

Website: LokRing Website
Installation Instructions (English): LokRing Installation Manual

LOKRING™ is a Trademark of Vulkan

Refrigerant Piping Flares by Yellow Jacket

Flares are made with special tools that ensure you get the proper amount of the pipe flared so as to avoid leaks at the connections.

VRF Manufactured “Y” Fittings

Check to see if the VRF manufacture requires that you use a special fitting for the proper operation of their systems. Daikin has a Refnet fitting that is required for the system to perform as designed, so don’t substitute a standard copper tee for their “Y” branch fitting.

Yellow Jacket 60278 Flaring Tool

Yellow Jacket 60295 Flaring Tool with Eccentric Cone for 3/16″ to 3/4″ O.D.

For those who are installing or have installed a VRF heat recovery system or other types of systems using the Refnet type fitting, there are some guidelines around how they get installed.

As with other system components, each manufacture has a different name for the same functional item. Just like the VRF branch selector boxes, the “Y” branch fitting has a different name based on the manufacture.

IWISS Copper Tube fittings Crimping tool with 1/2″,3/4″ and 1″ Jaw suits Viega ,MrPex, Apollo, Nibco, Propress, REMS, Elkhart, Conex copper pipe fittings

Leave us a comment below. What VRF piping connections do you use and prefer?

VRF Heat Recovery System

By

vrfwizard

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September 29, 2017

0

VRF Heat Recovery - Single Port Branch Selector Box

VRF Heat Recovery System

Using a VRF Heat Recovery system allows you to provide simultaneous cooling and heating. This means that one zone can be in cooling mode while another is in heating. This is not possible with a VRF heat pump system. This is accomplished with the addition of a Branch Selector Box, which is the traffic cop of the refrigerant. The Branch Selector Box is located between the outdoor unit and the indoor unit.

VRF Manufactures Selector Box Names

Each VRF manufacture uses a different name to describe this box. Daikin calls theirs the
Branch Selector Box which is the name we have chosen to use through this presentation, the other VRF manufacture names for the branch selector box, include;

Mitsubishi’s BC Controller (Branch Circuit Controller)
Toshiba FS Unit (Flow Selector Unit)
Fujitsu RB (Refrigerant Branch Unit)
Hitachi COB (Change Over Box)
Daikin BS (Branch Selector Box)

VRF Single-Port and Multi-Port Branch Selector Box

The VRF branch selector box can be a single-port box or a multi-port box. The easiest way to think of a branch port is that each port is a zone or area that has a similar heating and cooling load profiles. If you’re familiar with a VAV system, then each port is similar to a VAV Zone box, except that we are using refrigerant at the zone level instead of cooled air from an air handler.

VRF Heat Recovery System - Single Port Branch Selector Box — VRF Heat Recovery – Single Port Branch Selector Box

A VRF single port branch selector box gives you one zone where you can attach multiple indoor units, much like an air diffuser on a VAV system.

The VRF multi-port branch selector box allows multiple zones where each zone can decide whether to be in the cooling or heating mode in a VRF Heat Recovery System.

VRF Heat Recovery System - Multi-Port Branch Selector Box — VRF Heat Recovery – Multi-Port Branch Selector Box

Each manufacture provides differing quantities of ports on their multi-port branch selector boxes, anywhere from 2 ports to 12 ports, with the ability to tie several boxes together to expand the capabilities.

Each port can serve a manufacture defined quantity of indoor units that will all share the same mode of operation, that’s either heating or cooling. Each port can deliver either heating or cooling, so put all of the same type of thermal profile rooms on the same port if so desired.

VRF Branch Selector Box Capacity (MBH)

Each port in a VRF Heat Recovery System Branch Selector Box is also rated for a maximum amount of BTU’s. So, let’s say that the manufacture states that each port can deliver a maximum of 54,000 btu’s. If you have a zone that is larger than that, then you can combine more than one port together to achieve the total BTU’s you are trying to achieve, or you can provide multiple Indoor Units using separate ports for each to feed the same zone. The Branch Selector Box also has a maximum amount of BTU’s that it’s capable of delivering. See VRF Manufacture Comparison.

VRF 2-Pipe versus 3-Pipe Systems

The other item of interest is the controversy over 2-pipe versus 3-pipe systems. Each VRF manufacture will say that their system is better than the competitions system. A VRF two-pipe system uses only 2 pipes that run between the outdoor unit and the indoor unit, while other manufactures use 3 pipes.

Although it would seem that the VRF 2-pipe system would save you material and labor cost, the other fact not mentioned when manufactures tout their 2-pipe system is that there Branch Selector Box needs a condensate drain line where as the 3-pipe system doesn’t, hence their 2-pipe VRF system has a third pipe, it’s just not a refrigerant pipe, but a condensate one, so in effect a VRF two-pipe system is a VRF three-pipe system of a different type.

The advantage of the VRF Heat Recovery System is that it allows simultaneous heating and cooling where as a Heat pump system doesn’t.

For a comparison of VRF Heat Recovery Systems between VRF Manufacturers, including maximum quantity of ports, capacity per port, and who has a VRF two-pipe system versus a VRF three-pipe system, and much more see our article on VRF Manufacture Comparison.

Watch the VRF VRV Heat Recovery System Video.

What experience have you had with VRF Heat Recovery systems and either single-port or multi-port branch selector boxes? Leave us a comment below.

VRF Manufacture Comparison

By

vrfwizard

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September 24, 2017

0

VRF Manufacture Comparison

With so many VRF manufactures to compare, it’s hard to decipher all the variations between systems. Below you’ll find a comparison of VRF manufactures such as, Daikin, Mitsubishi, LG, Carrier, Toshiba (Carrier), Fujitsu, Panasonic, Hitachi (York) and others to follow. We will be adding additional VRF Manufacture Comparison charts in the following weeks.

VRF Maximum Cooling Capacity

The following chart indicates the maximum cooling capacity in tons and 1,000’s of BTU for both VRF Heat Recovery Systems and VRF Heat Pump Systems.These values are based on multiple outdoor unit modules being attached to makeup the maximum, often three ODU.

Maximum Cooling Capacity – (Tons)

System	Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi	York
Heat Recovery	38	24	42	28	38	24	30	36	36
Heat Pump	34	30	42	36	38	24	30	36	36

Maximum Cooling Capacity MBH – (1,000’s of BTU’s)

System	Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi	York
Heat Recovery	456	288	504	336	456	288	360	432	432
Heat Pump	408	360	504	432	456	288	360	432	432

VRF Maximum Piping Lengths

The following chart indicates the maximum piping lengths that is approved by the various VRF manufactures in order that the system perform as designed. Confirm with manufacturers literature as there are often limiting factors effecting these lengths. Some manufacturers show equivalent length which means the actual distance is less, but that a fitting is added in as an equivalent length of pipe.

Total Maximum Piping Length – Between ODU & IDU (Feet)

Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi
TBD	541′	656′	541′	656′	541′	TBD	TBD

Maximum VRF Indoor Units Attached to ODU’s

The following chart indicates the maximum quantity of VRF Indoor Units that can be attached to a set of VRF Outdoor Units. VRF Manufacturers connect several Outdoor Units together using various module sizes (tons) to comprise the maximum tons, often composed of three to four modules. This chart shows the maximum number of Indoor Units that can be connected to those connected Outdoor Modules.

System	Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi	York
Heat Recovery	64	50	64	64	64	45	52	TBD	64
Heat Pump	64	50	64	62	64	45	64	TBD	64

VRF Single-Port vs Multi-Port Branch Selector Box*

The following chart indicates if the VRF manufacture has a single-port branch selector box, as all VRF manufactures carry the Multi-port Branch Selector Box for their Heat Recovery systems.

System	Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi	York
Single Port	Yes	No	No	No	Yes	Yes	Yes	TBD	Yes
Multi Port	Yes	Yes	Yes	Yes	Yes	Yes	Yes	Yes	Yes

* Fujitsu uses (RB) Refrigerant Branch Unit as the name for their Branch Selector box, Mitsubishi use “BC Controller”, Branch Circuit Controller, Toshiba calls their boxes “Flow Selector Unit”, Hitachi (COB) Change-over Box,

VRF Heat Recovery Branch Selector Box

The following chart is a comparison of HVAC VRF manufactures options and capacities for their VRF Heat Recovery Branch Selector Boxes.

System	Daikin	Mitsubishi	LG	Carrier	Toshiba	Fujitsu	Panasonic	Hitachi	York
Max Capacity	290	120	192	TBD	96	96*	TBD	272	TBD
Max 1-Port	54	TBD	54	TBD	TBD	96	TBD	TBD	TBD
Max Ports	12	TBD	4	TBD	6	4	8	12	12

Max Capacity = The maximum capacity in MBH (1,000’s of BTU’s) for the VRF manufacturers largest box.
Max 1-Port = The maximum capacity out of one port on the multi-port box.
Max Ports = The maximum number of ports on one box.

* Some HVAC VRF Manufactures allow you to connect several branch selector boxes in series to increase capacity. Fujitsu allows two RB Units to be attached to increase the maximum capacity to 191 MBH. Mitsubishi allows the connection of Sub BC Controllers to increase capacity.

*TBD – To Be Determined at a Latter date

Leave us any comments related to the enclosed charts or any other HVAC VRF manufacture comparisons you would like to see.

VRF Cost per Ton

By

vrfwizard

-

September 19, 2017

0

VRF Cost per Ton or Cost per Ft2 to Install?

How do you determine the cost per ton or cost per square foot for the installation of a VRF system?

What factors play a role in the VRF cost per ton of a VRF system from one contractor to another?

Why do you care what it cost per ton to install a VRF system?

VRF Cost per Ton

You can make a simple calculation of taking your sales price divided by the total installed tons of the VRF system.

Sales Price $240,000 / 40 Tons = $6,000 / Ton
Sales Price $200,000 / 40 Tons = $5,000 / Ton
Sales Price $160,000 / 40 Tons = $4,000 / Ton

VRF System Cost Per Square foot — VRF System Cost Historical Database

VRF Cost per Ft2

You can make a simple calculation of taking your sales price divided by the total square footage served by the VRF system.

Sales Price $240,000 / 16,000 Ft2 = $15.00 / Ft2
Sales Price $200,000 / 16,000 Ft2 = $12.50 / Ft2
Sales Price $160,000 / 16,000 Ft2 = $10.00 / Ft2

What Factors Play a Role in the Cost per Ton or Cost per Ft2?

Your company’s legal structure, size and overhead requirements are a big factor in your cost.

Are you a union or non-union company?
Do you pay your workers the prevailing wage rate?
Are you a sole proprietor or a state registered corporation?
Do you have buying power when you purchase equipment and materials from your suppliers?
How much is your markup to cover the cost of overhead and profit?
How fast or productive are your field installers?

A company’s cost structure varies between one company and another.

Why do you care what it Cost/Ton or Cost/Ft2 to install a VRF system?

Keeping track of your cost for the installation of various VRF systems is beneficial when called upon to provide a quick budget or to check a current estimate. Keeping track of the projects you install or bid is useful for your estimators, saving them time and money.
Using a simple spreadsheet to track all your projects will allow you to retrieve the required information quickly. Using a spreadsheet will also help automate parametric data calculations. Your competition can calculate budgets for their customers quickly and accurately, saving time and money while providing a great service.

If you bid similar VRF systems at $4,000/Ton and your current estimate is only totaling $3,000/Ton, is there an error in your estimate?

Did you forget something, or is the job different in enough aspects to justify the lower price?

Get a set of Refrigerant Gauges.
Maintaining historical data helps spot problems or errors in your estimates by allowing you to look back at other projects that have been completed or bid. Check out the VRF Wizard Historical Database.

The Historical database tracks many other parameters, such as;

Piping Cost/Linear Feet
Piping Linear Feet/Man Day
Sheet Metal Cost $/Ft2
Equipment Cost $/Ft2
Controls Cost $/Ft2
Electrical Cost $/Ft2
Engineering Cost $/Ft2
Start & Test Cost $/Ft2
Air & Water Balance Cost $/Ft2
Insulation Cost $/Ft2
Rentals Cost $/Ft2
Plumbing Cost $/Ft2
General Construction Cost $/Ft2
Guest Rooms (Bedrooms, Apt’s, Etc) Cost $/Room

Checkout the Historical Database which can be used for all project types, Commercial, Residential and all system types from VRF, Air Conditioning Packaged Units, Chilled Water Systems, Boiler Systems, etc ..

How do you budget VRF or HVAC projects quickly so as to save time and money? How do you save this data?

VRF Refrigerant Piping Thermal Expansion

By

vrfwizard

-

September 13, 2017

0

VRF Refrigerant Piping Expansion Loops - Pipe Leaks

VRF Piping Hangers and Expansion Loops

When hanging or fastening VRF copper refrigerant piping that involves long runs, then some form of considerations needs to be made for expansion due to temperature differences.

If no allowances are made for expansion in the ACR copper piping then leaks are possibly to occur at some point because of the stress exerted on “Y”-Branches, joints, equipment connections or 90 degree elbows.

Thermal Expansion

The thermal expansion of piping or materials of various composition expand and contract with a change in temperature. Therefore, we find expansion joints in concrete, or we use bi-metals in thermostats. The ability of metals and materials to expand and contract has been used to accomplish great inventions, but it can also cause havoc if not designed into your VRF system.

When running long lengths of ACR copper refrigerant piping you want to allow for the pipe to grow as the temperature increases. Your copper piping can expand up to 4” in length depending on the temperature and length of run. it’s more likely that you’ll experience from 1/2” to 2” of expansion in refrigerant piping systems. Allowing the copper piping to move is critical when you have long runs.

VRF Refrigerant Copper Piping Hangers

It’s like a pool cue when playing billiards, you allow the cue to slide through your fingers without a firm grip so you can move it back and forth to hit the pool ball. The same needs to happen with your VRF refrigerant piping, it needs to move through the hanger holding it to compensate for the expansion. The hanger should hold the refrigerant piping firmly, but should allow for it to move slightly to avoid rupture of a joint. You can use some form of expansion loop.

VRF Refrigerant System Piping Expansion Loop — VRF Refrigerant Piping Expansion Loop

Expansion Loops and U Bends

You can also use some sort of thermal expansion device to compensate for the growth in length. You can accomplish the required thermal expansion compensation by fabricating a small shaped “U” bend or “Loop” in your long run of VRF Refrigerant piping.

VRF Refrigerant System Piping Expansion U-Bend — VRF ACR Copper Refrigerant Expansion U-Bend

How have you corrected for thermal expansion or have you ever experienced a pipe leak due to the lack of an expansion loop or “U” bend?

Got Refrigerant R410A?

Leave the VRF Wizard community your thoughts below.

Estimate VRF Projects

By

vrfwizard

-

September 7, 2017

0

How to Estimate VRF Projects

HVAC Estimating is the foundation upon which all construction company profits are built. If you don’t get the estimates correct, your company won’t be in business very long. If you don’t understand your cost and what is in your estimate, how will you know if you made or loss money between jobs? How will you know what part of the project lost money? Did you lose money by spending too much on materials or did you take longer than expected to complete the project? Learning how to estimate VRF projects while aggregating the data for budgeting will save you time and money in the future.

VRF Equipment & Project Parameters

Do you track the cost of one project compared to another? What did you sell the last project for as measured by cost per ton? How many liner feet of piping did you put in compared to other projects? Can your piping crew install 50 feet a man day or 100 feet/MD of small hard copper? Knowing what parameters to measure and maintain is important when called upon by a customer to throw together a quick budget or to provide a sanity check with a current estimate. Having a VRF System Installation Cost Budgeting Database of historical values will save you time and money.

HVAC Piping and Sheet Metal Estimating

How do you estimate HVAC Piping and Sheet Metal materials and labor? Can you look at a drawing and tell how many men you’ll need and for how long? What if there are multiple drawings with lots of work on each page, are you confident about your guess based on looking at the drawings without knowing quantifiable counts? Do you take off the material with a scale and send it out for supplier pricing?

There are many ways to approach an estimate, and having been in charge of over twenty estimators working for a company doing half a billion dollars a year, I have seen it all. No matter how good you think you are, there is no way you’re that good without an accurate material takeoff from which to make informed decisions on labor and materials when the project is of any substantial size.

Computer Estimating Software

If you are bidding large HVAC plan and specification projects with lots of materials to add up, then using computer mechanical estimating software is a must. I remember one project where we had close to forty-thousand lines of take-off for just the sheet metal trade. The cost of the estimating software and the time for implementation needs to be considered, along with the annual maintenance fees. These programs have many features that make updating of prices, importing drawings for takeoffs and reporting worth their cost.

VRF and HVAC Estimating Spreadsheets

Having a clear and understandable VRF or HVAC Estimating Spreadsheet is the first step in getting to understand your cost and project parameters. Maintaining an organized file naming structure for easy retrieval of previous estimates will make life a lot better for those responsible for estimating.

Your HVAC estimating spreadsheet is the bedrock of your estimating department and should be versatile enough to handle any size project. Some companies prefer several HVAC estimating spreadsheets, based on project size.

Some companies use a simple single page form for very small projects and a multi-page spreadsheet for anything larger. I prefer one estimate spreadsheet for all my project estimates as it keeps maintenance of the form easier to make changes, such as when labor rates, material multipliers or tax rates change.

Summary – How to Estimate VRF Projects

Maintaining a VRF Installation Cost Historical Database on past projects can add value to your future estimating needs; saving you time and money, while allowing you to spot check current estimates against past projects.
Using parameters can assist you in developing budgets and identifying cost and engineering ranges to compare current projects against past projects.
Using Estimating software can save you time and money while allowing for informed decisions based on quantifiable takeoff data.
Learn how to Estimate VRF Projects using historical data that you have aggregated from past bids or completed projects.

We will cover mechanical estimating in more depth in other articles. Be sure to checkout our time and money saving spreadsheets;

Please leave us a comment and let the other VRF Wizards know how your company bids VRF projects; what estimating software you use, and what type of project or equipment historical data or parameters do you collect or measure.

ZoomLock vs Brazed Fittings.

HVAC Commercial vs Residential

Pressure Rating of ZoomLock™ Fittings

ZoomLock™ O-Rings

Smoke, Smell, Fire Watch & Burn Permits

Agency Approvals

Fitting Warranty

Vibration Concerns

Available Sizes of ZoomLock™ Fittings

Available ZoomLock™ Fittings

Crimp Tools

Crimp Tool Manufactures & Models

ZoomLock™ Cost Analysis

You Can’t Teach an Old Dog New Tricks

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VRF System Control Wiring

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VRF System Cost

Project Historical Cost Data

VRF System Cost per Square Foot

VRF System Cost per Ton

VRF System Cost per HVAC Contractor

Impact of Labor Rates on VRF System Cost

Impact of Material Cost on VRF System Cost

Impact of Time on VRF System Cost

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Engineering Parameter

VRF System Cost Summary

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Refrigerant Monitoring Code Requirements

Refrigerant Leak Detector Locations

Refrigerant Monitoring System Alarms

When is Refrigerant Leak Detection Required

Refrigerant Leak Detection Manufactures

Bacharach Refrigerant Leak Detector

MSA Chillgard Refrigerant Leak Detector

SensAC – Unlimited Controls

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VRF Piping Connections

ZoomLock™ by Parker

LOKRING by Vulkan

Refrigerant Piping Flares by Yellow Jacket

VRF Manufactured “Y” Fittings

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VRF Heat Recovery System

VRF Manufactures Selector Box Names

VRF Single-Port and Multi-Port Branch Selector Box

VRF Branch Selector Box Capacity (MBH)

VRF 2-Pipe versus 3-Pipe Systems

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VRF Manufacture Comparison

VRF Maximum Cooling Capacity

Maximum Cooling Capacity – (Tons)

Maximum Cooling Capacity MBH – (1,000’s of BTU’s)

VRF Maximum Piping Lengths

Total Maximum Piping Length – Between ODU & IDU (Feet)

Maximum VRF Indoor Units Attached to ODU’s

VRF Single-Port vs Multi-Port Branch Selector Box*

VRF Heat Recovery Branch Selector Box

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VRF Cost per Ton or Cost per Ft2 to Install?

VRF Cost per Ton

VRF Cost per Ft2

Why do you care what it Cost/Ton or Cost/Ft2 to install a VRF system?

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VRF Piping Hangers and Expansion Loops

Thermal Expansion

VRF Refrigerant Copper Piping Hangers

Expansion Loops and U Bends

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How to Estimate VRF Projects

VRF Equipment & Project Parameters

HVAC Piping and Sheet Metal Estimating

Computer Estimating Software

VRF and HVAC Estimating Spreadsheets

Summary – How to Estimate VRF Projects

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