Www.hrai.ca Welcome to the AC Installation Optimization Training Program

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Welcome to the AC Installation Optimization

Training Program

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About the Workbook

• Your Participant Workbook:o Introduces the course purpose and objectives.o Lists key points for future reference.o Provides area to write down notes.o Presents activities.o Contains a pocket with copies of course reference materials and

resources.

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About the Group

1. Break into pairs with someone new.

2. Take turns interviewing each other:o Who are you and where do you work?o How many years of HVAC experience do you have?o What part of the business are you involved in: Sales? Design?

Installation?

3. Take turns presenting each other back to the group.

5 Minutes

7

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Scenario: What Went Wrong?

1. Break into small groups.

2. Review the scenario in your workbook.

3. Brainstorm what could be causing:o No real energy savingso No noticeable improvement to comfort

4. Present discussion points back to the group.

10 Minutes

8

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Scenario Debrief

• Many players: sales rep, designer, installer, customer.• Many factors affect the efficiency of an AC system.• Many factors affect the comfort that an AC system provides.• Different stakeholders influence the final solution at different stages.• An effective air conditioning system provides both comfort and

energy efficiency.

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Optimizing AC Installations – Who Wins?

Consumers

• Comfort• Energy savings

The Province

• Greater energy conservation

HVAC Companies

• Rights to use saveONenergy collateral materials provided

• Possibility to increase revenues

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Enhancing Market Capability…

• This training is one in a series of initiatives sponsored by the OPA to enhance the market’s capability to deliver conservation by optimizing AC installations.

• The training will be mandatory effective 2014 to participate in HEATING AND COOLING Incentive Initiative.

• The goal is market transformation.

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Market Transformation

“Long-lasting sustainable changes in the structure or functioning of the market achieved by reducing barriers to the adoption of energy-efficiency measures to the point where further publicly funded intervention is no longer appropriate in that specific market.”

How does “recycling” illustrate market transformation?

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Overview of Training Development

1. HRAI conducted a review and analysis of current market research into factors affecting energy efficiency.

2. The results were reviewed and discussed in a workshop with representatives from the HVAC industry.

3. Based on the outcome of the workshop, HRAI developed a Market Research Report for the OPA highlighting a number of critical areas, including:o Incentiveso Verificationo Training

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Key Opportunities

• There is a growing opportunity to expand the market of consumers willing to pay for energy efficiency by:o Expanding consumer knowledge and awareness around the

requirements of an energy efficient installation.o Demonstrating to contactors the benefits they can attain by

selling energy efficient installations.

What could account for this growing opportunity?

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Technical Requirements

• Main technical requirements covered in this training are from CSA standard CAN/CSA-C273.5-11 - Installation of air source heat pumps and air conditioners.

• Note:o Today’s session refers to a 2-page summary of the standard in

the pocket of your Workbook.o You will be able to download a copy of the standard from CSA’s

website.

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Target Audience

• Contractors who participate in the HEATING AND COOLING INCENTIVE Initiative and their employees, including:

a) Designers/estimators and sales personnel• This group influences equipment choice, sizing and

other specifications that affect comfort and efficiency of the system.

• Also responsible for communicating the benefits of energy efficient solutions to consumers.

a) Installers• This group will indicate on the online form how the

installation meets CAN/CSA-C273.5-11.• This group influences equipment choice, sizing and

other specifications that affect comfort and efficiency of the system.

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Course Objectives

1. List the main installation factors that affect the comfort and energy efficiency of central air conditioning systems.

2. Describe CAN/CSA-C273.5-11 requirements for each key installation factor.

3. Explain how each stakeholder can influence the comfort and energy efficiency before, during and after installation.

4. Identify common barriers to ensuring the comfort and energy efficiency of central air conditioning installations.

5. Develop strategies to overcome these barriers within your own business.

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Course Agenda

Introduction

Overview of Key Factors

Break

Before Installation

Lunch

During Installation

Break

After Installation

Course Wrap Up

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Overview of Key Factors

In this section we examine:• SEER Ratings• Overview of Industry Research

Results• Overview of HRAI Survey

Results• Group Survey• At What Stage Can We

Influence Each Key Factor?

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SEER Ratings

• SEER ratings refer only to the performance of the condenser and evaporator equipment under standard conditions.

• However, HVAC contractors use many independent components to construct the complete air-conditioning system.

• Every system is uniquely constructed for the customer’s home.

• Manufacturers of condensers and evaporators usually specify the system conditions that should be met in order for their equipment to achieve the best performance results.

• But field experience often shows that these conditions are not being realized, and the equipment performs lower than its rated SEER.

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Six Key Factors

• Research results have determined that the following factors have an impact on the comfort and efficiency of air conditioning systems:

1. Proper duct design and sealing

2. Size of system

3. Correct coil matched with condensing unit

4. Correct air flow over the indoor coil

5. Correct refrigerant charge

6. Complete commissioning

How do these findings compare to your list from the first scenario?

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Survey: Impact of Factors

1. Review the survey in your workbook.

2. Rank each factor’s impact (1 = greatest, 5 = least).

3. Present your top three factors back to the group.

Factors Energy Efficiency ComfortSize of systemCorrect air flow over the indoor coilCorrect refrigerant chargeProper duct design and sealingComplete commissioning

5 Minutes

10

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HRAI Survey Results

11

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HRAI Survey Results

11

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Rated SEER

Fie

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ted

SE

ER

12 13 14 156

7

8

9

10

11

12

13

14

15Proper Charge

Correct Flow

Typical Installation

Airtight Ducts

Sized Right

1.5

0.5

2.0

0.75

Research Results

Based on US data from Advanced Energy Corp., 2009

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Controlling the Factors that Affect Comfort and Efficiency

Before Installation During Installation After Installation

At what stage can you control the impact of each key factor on energy efficiency and comfort?

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Overview of Each Stage

Before Installation

• Proper duct design and sealing

• Size of system• Correct coil

matched with condensing unit

During Installation

• Correct air flow over the indoor coil

• Correct refrigerant charge

After Installation

• Complete commissioning

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Before the Installation

• Scenario – Selling the Energy Efficient System (Part 1)

• Proper duct design and sealing

• Proper sizing

• Matching correct oil with condenser

• Scenario – Selling the Energy Efficient System (Part 2)

1. Pre-Installation

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Scenario: Selling the EE System (Part 1)

1. In small groups, review the scenario in your workbook.

2. Analyze how each of the three sales scenarios will impact the customer’s comfort and energy savings.

3. Together, decide:o Which company provides the better solution? Why?o Which do you think the customer will actually opt for? Why?o If different, what are potential reasons for not choosing the better

solution?


5 Minutes

14

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Proper Duct Design and Sealing

• Leaks in the supply ducts cause a direct loss in the system’s total capacity.

• Leaks in the return ducts can bring unconditioned and unfiltered air into the house from the attic or crawlspace.

• The difference in supply leakage and return leakage causes an additional negative effect on energy use from the infiltration it causes.

Illustration courtesy of Advanced Energy Corp.

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Effects of Duct Leaks

• Field studies based on air distribution ducts in existing homes show that about 35% of a system’s cooling capacity is lost from duct leakage and from thermal losses due to poorly insulated ducts.

• Proper sealing and insulation of ducts is estimated to cut those losses in half.

*US data from Advanced Energy Corp., 2009

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Effect of Duct Leakageon 12 SEER Rated Equipment

Impacts of Duct leakage on Rated SEER

Duct Leakage

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ted

SE

ER

8

9

10

11

12

None Good Typical


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Survey – Inspecting Duct Work

17

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Survey – Sealing Leaks

17

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Proper Sizing

• According to ASHRAE recommendations, a system should be designed so that it runs full time for 2.5% of the summer season

• A properly sized system quickly reaches its “cruising speed,” where it operates most efficiently


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Impact of Incorrect Sizing

• Field studies show that central air conditioners are on average being oversized from 24% to 100%.

• Over sizing by 50% has been shown to increase seasonal energy use by 9%.


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Percent Equipment Oversize

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ted

SE

ER

8

9

10

11

12

20 40 60 80 100 120


Effect of Oversizingon 12 SEER Rated Equipment

Impacts of Incorrect Equipment Size on Rated SEER

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Problems from Oversizing

• Oversizing can lead to:– Higher equipment cost– Excessive loading/unloading– Frequent cycling– High conditioned-space

humidity– Large conditioned-space

temperature swings

– Low efficiency and high operating costs

– Short equipment life– Occupant discomfort– Nuisance service calls

What are common mistakes that can lead to incorrect sizing?

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Common Sizing Mistakes

• Research has shown that the most common sizing mistakes are:

o Miscalculation of the square footage and orientation of glazing

o Miscalculation of Air Changes per Hour (ACH)

o Exaggeration of outdoor design temperature (too warm for cooling equipment sizing)

o Sizing by capacity of existing equipment

o Sizing by rules of thumb.

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Survey – Sizing Systems

19

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Survey – Correct Coil

20

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CAN/CSA-C273.5-11 Pre-Installation Requirements

1. Refer to the Summary of CAN/CSA-C273.5-11to review the requirements under:o Equipment requirements o System design

2. Consider each of the requirements that pertain to AC systems:o Which ones do you currently meet?o Which requirements are you not meeting? Why?

3. Be prepared to share your responses with the group.

5 Minutes

20

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CAN/CSA-C273.5-11Equipment Requirements

• Certification should be provided that the air conditioning system meets the requirements of CSA C656 Performance Standard for split-system air conditioners.

• All evaporators, condensing units, furnaces and air handlers should be properly matched and performance-rated by AHRI as a system.

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CAN/CSA-C273.5-11System Design

• The system (if new) shall require a heat loss and heat gain calculation in accordance will CAN/CSA F280 (e.g. the HRAI Residential Heat Loss and Heat Gain Calculation Manual).

• A single stage central air conditioner shall be selected with a cooling capacity between 0.95 to 1.15 of the total heat gain of the house as calculated according to CAN/CSA- F280

• The system shall be capable of handling the pressure drop produced by the air filtration system being used.

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CAN/CSA-C273.5-11System Design (cont’d)

• All equipment shall be located in accordance with manufacturer’s instructions with due consideration to the following:o Keep outdoor unit away from fences, walls, other surfaces that

could reduce flow or cause recirculation;o Keep refrigerant line lengths to the minimum; o Minimize the length of refrigerant lines outside the conditioned

space;o Minimize sound problems (7.6 bels maximum for unit sound

rating is considered good industry practice);o Ensure good service access;o Ensure no shifting due to frost.

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CAN/CSA-C273.5-11System Design (cont’d)

• All new supply and return ducts shall be sealed with suitable long-life material to minimize air leakage. All duct sealing materials should be rated to UL181A or UL181B specifications and used in accordance with manufacturer instructions.

• Any ducts installed in unconditioned spaces shall have RSI 3.5(R20) insulation with vapour barrier specified.

• The refrigerant lines shall be insulated in accordance with the manufacturer’s recommendations.

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Scenario: Selling the EE System (Part 2)

1. The customers in the first part of this scenario ended up by choosing the quote from Sales Rep B.

2. In your groups, discuss:o Why might this have been the outcome?o What are typical barriers for companies to properly design an

energy efficient AC system?o What are typical barriers for customers to invest in the energy

efficiency of their AC system?


5 Minutes

21

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Research – Pre-Installation Barriers

• Barriers to proper duct work and sealing:o Time required for proper load calculations.o Costs for consumers to modify and/or install new duct work.

• Barriers to correct sizing: o Time required for proper calculations.o Costs involved.

• Barriers to correct coil matching:o Cost cutting – using cheaper coils.o Physical constraints – using a coil that fits more easily into the

space.

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Survey – Barriers

22

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Educating Customers

Benefits Challenges

Informed customers can make informed choices.

Customers can look at the long term value (comfort and cost savings) of their investment.

Customers can better understand the environmental impact of their decision.

Customers are busy and may not have the time.

Not all customers are interested in learning more.

To understand HVAC systems requires a certain level of technical knowledge.

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Marketing Energy Efficiency

1. As a group, review the see the HRAI and OPA Consumer Pamphlet.

2. In small groups, discuss the following:o How could you use this pamphlet to help educate

potential customers on the importance of investing in a quality installation?

o Does your company have similar educational resources for consumers?

o What other educational strategies do you use or have heard of?

3. Be prepared to share your answers with the group.

5 Minutes

23

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Using Customer Surveys

1. In small groups, review the sample questions and activities to include in a customer survey:o Which ones do you currently perform? Why?o Which ones do you not perform? Why?

2. Be prepared to share your answers with the group.

5 Minutes

24

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Quality in the Sales Process

• ‘Quality’ in the sales process helps to ensure ‘quality’ in the installation process since:o The AC system will be sized correctly.o Proper consideration will have been given to duct work issues.o The correct coil will have been chosen.

• The documented customer survey results feed into the work order.

• The focus is then on completing the tasks on the work order to the standard.

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During the Installation

• Scenario – Installing the Energy Efficient AC System

• Checking correct air flow over the indoor coil

• Checking correct refrigerant charge

2. Installation

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Scenario: Installing the EE System

1. In small groups, review the scenario in your workbook:o Each piece of equipment comes from a different

company (AC, coil, furnace, and thermostat).o The distance from the outdoor unit to the indoor coil is 23 feet.

2. Brainstorm potential technical problems you could experience installing such a system (even though in theory the equipment should work together).

3. For each problem, discuss the kinds of actions you might have to take to ensure that the system is installed and works properly.


26

5 Minutes

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Correct Air Flow Over Coil

• Without proper air flow, the desired temperature change across the evaporator will not occur.

• Low air flow is often caused by:– Ducts that are too small.– Duct layout that restricts

airflow.– Poorly selected or restricted

grilles.– Mismatch of air handler with

the other equipment.


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Effects of Low Air Flow

Field studies show that:• 70% of installed residential cooling systems have inadequate air

flow over coil.• Airflow through evaporator is often lower than 400 cfm/ton.• Improving system air flow to recommended values could reduce

energy use by 10%.• A system using fixed orifice

flow control is more seriously affected by low air flow than a system using a thermal expansion valve (TXV)


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Percent Low Airflow

Fie

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djus

ted

SE

ER

11.0

11.5

12.0

12.5

10% 20% 30% 40% 50%

Effect of AirflowEffects of Incorrect Airflow on Rated SEER

*Based on US data from Advanced Energy Corp., 2009

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Problems with Incorrect Air Flow

If airflow and static pressure are too high…

• duct leakage increases;• latent cooling capacity

decreases; and• air handler blower energy

use increases.

If airflow is too low…• distribution efficiency drops and

accelerated compressor wear can lead to failure, often resulting from slugging;

• Units must have at least the manufacturer’s rated CFM per ton at the coil to ensure that only gas refrigerant is leaving the evaporator coil and that liquid refrigerant is not evaporating in the line.

• Additional problems include coil freezing, too much latent cooling and lower capacity.

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Survey – Measuring Air Flow

28

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28

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29

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Proper Charge

• Getting the right refrigerant charge is a critical field adjustment factor that is often overlooked.

• The effect of improper charge depends on the type of refrigerant flow control device being used in the system.

• A system using fixed orifice flow control is more seriously affected by improper charge than a system using a thermal expansion valve.


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Effects of Improper Charge

Field studies show that:• 7 out of 10 systems have an improper charge.• Most are undercharged but some are 100% overcharged.• Systems with longer line sets are more undercharged than shorter

line sets.• Incorrect measurement of line set length is a common cause of

improper charge in pre-charged systems


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Deviation From Recommended Charge

Fie

ld A

djus

ted

SE

ER

9

10

11

12

10% 20% 30%

Undercharged TXV

Overcharged TXV

Undercharged FO

Overcharged FO

Effect of Improper Chargeon 12 SEER Rated Equipment

Impacts of Incorrect Charge on Rated SEER

*Based on US data from Advanced Energy Corp., 2009

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Indications of Incorrect Charge

• Indications of low refrigerant charge include:– Inadequate cooling

capacity.– An overheated compressor

motor resulting from low suction pressure.

– If the system has a sight glass, bubbles might indicate a low charge (a clamp-on “sight glass” may be used to electronically “listen” for bubbles).

• Indications of refrigerant overcharge include:– Excessive condensation on

compressor housing as a result of refrigerant flood back.

– In severe cases, compressor failure.

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Survey – Charging System

31

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Survey – Charging System

31

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CAN/CSA-C273.5-11 Installation Requirements

1. Refer to the Summary of CAN/CSA-C273.5-11 to review the requirements to meet during the installation stage for AC systems under:o System Installationo Refrigerant Piping and Ductworko Start Up

2. Consider each of the requirements:o Which ones do you currently meet?o Which requirements are you not meeting? Why?


5 Minutes

32

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CAN/CSA-C273.5-11Refrigerant Piping & Ductwork

• Qualified sheet metal workers, except as otherwise permitted by local codes, shall install all ductwork.

• Supply and return ductwork seams shall be sealed.

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CAN/CSA-C273.5-11 System Installation

• The installing contractor shall adhere to applicable local by-laws, specifications of the manufacturer of the equipment, and the following codes:o CSA Standard C22.1 Canadian Electrical Code Part 1o CAN/CSA B149.1 Natural Gas and Propane Installation Codeo CSA B139 Installation Code for Oil Burning Equipmento CSA B52 Mechanical Refrigeration Code

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CAN/CSA-C273.5-11Start Up

• On start-up, the following operational checks and measurements are to be made:

o Refrigerant charge check: Contractor shall use the method approved and specifically stated by manufacturer that will ensure proper refrigerant charge.

o Ensure that airflow across indoor coil is to manufacturer’s specification.

o Check that circulating fan motor and compressor motor power inputs are to specification.

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Research – Installation Barriers

• Barriers to checking air flowo Time required to test air flowo Cost of equipment required to test air flowo Customers unwilling to pay for added time to test air flow

• Barriers to checking system charge: o The cost of a return trip to measure the refrigerant charge if the

outdoor temperature was not over 20o C during the time of installation

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Survey – Barriers

33

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Overcoming Barriers

• Educating customers:o Customers who are more engaged in the design and sales stage

of the process are more invested in the successful installation of their AC system – see the HRAI and OPA Consumer Pamphlet.

• Leveling the playing field. o Contractors must complete a new step on the HEATING AND

COOLING INCENTIVE form to indicate how the installation meets CAN/CSA-C273.5-11 .

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Building Quality Processes…

• All the ‘quality’ measures taken before and during an installation help to ensure ‘quality’ in your discussion with customers after the installation since:o The AC will be sized correctly.o Proper consideration will have been given to duct work issues.o The correct coil will have been chosen.o The installed system will provide the intended energy efficiency

and comfort.o The customer will have been kept informed at each stage in the

process.

• This is a time of opportunity – for both the customer and your business!

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After the Installation

• Examining Customer Needs

• Commissioning – Engaging the Customer

• Completing the Installation section on the HEATING & COOLING INCENTIVE Initiative online form

• Auditing Installations3. Post-Installation

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What Do Your Customers Need?

1. Put yourselves in the shoes of your customers:o What kind of information and resources would

you need to get the most energy efficiency andcomfort out of your system?

2. Compare your answers with the rest of your group:o Which ones are similar?o Which ones are different?o What are the reasons for your differences?

3. Present discussion points back to the whole group.

5 Minutes

36

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Survey – Complete Commissioning

37

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Survey – Complete Commissioning

37

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CAN/CSA-C273.5-11 Post-Installation Requirements

1. Refer to the Summary of CAN/CSA-C273.5-11 to review the requirements under:o System Documentationo Owner Education

2. Consider each of the requirements:o Which ones you currently meet?o Which requirements are you not meeting? Why?


5 Minutes

38

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CAN/CSA-C273.5-11System Documentation

• The following information shall be provided to the purchaser:

o OEM equipment performance information;

o Maintenance and operating instructions;

o Equipment and contractor warranties;

o Model and serial numbers of all equipment;

o Copy of the Completion Certificate.

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CAN/CSA-C273.5-11Owner Education

• The installer shall provide and explain as necessary the following to the purchaser:

o Proper operation of the system including operation and programming of the indoor temperature controller;

o Proper service and maintenance requirements;

o Warranty procedures and responsibilities;

o A contact for warranty maintenance and service.

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Research – Post-Installation Barriers

• Barriers to complete commissioning:

o The time required to educate consumers.

o The consumer’s unwillingness to learn about the system.

o Smaller contractors may not have the tools required such as installation checklists and information to leave behind with the consumer.

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Overcoming Barriers

• Educating customers:o Engaging customers in the design and sales stage of the

process – see the HRAI and OPA Consumer Pamphlet.

• Leveling the playing field. o Requiring contractors to indicate whether or not the installation

meets the CAN/CSA-C273.5-11.

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Confirming against CAN/CSA-C273.5-11

• Contractor must complete a new step on the HEATING AND COOLING INCENTIVE initiative form to indicate whether or not the installation meets the CAN/CSA-C273.5-11.

• This is a new requirement on the online form designed to reinforce the need to follow due diligence in the installation start-up checks and problem solving of a central AC system to ensure that it is operating efficiently.

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Completing the Installation Step

• The programming logic built into this new step in the form reveals only the fields that you need to complete based on what you have inputted in the previous fields.

Click on image to enlarge the flow chart.

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Using the EE Installation Checklist

• The Energy Efficient (EE) Installation Checklist is an optional tool.

• Use this checklist to record the information required to complete the new step on the online form.

Click on image to enlarge the checklist.

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Scenario: Completing the EE Checklist

1. Refer to the Energy Efficient Checklist you can use to document the information needed to complete the new step to the online form.

2. Review the scenario in your workbook.

3. Based on the information provided, complete the checklist.


2 Minutes

39

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Course Wrap up

• Summary – Who Wants to Be A Millionaire?

• Taking Action

• Other Energy Conservation Programs

• Course Evaluation

• Course Assessment

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Test Your Knowledge

Click on image to play the game.

Who Wants To Be A Millionaire?

Phone a Friend% 50-50

Ask the Audience

C) Comfort D) Conservation

B) Customer satisfaction

$ 500

A) Higher SEER equipment

Capacity building for the OPA involves enhancing the market capacity to deliver:

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Taking Action!

1. Consider the key actions and behaviours covered

in this course that help to ensure an energy

efficient AC system.

2. Using the Personal Action Plan in your workbook:o Assess how well you and/or your company ensure the energy

efficiency of residential AC systems before, during and after the installation.

o Identity one or more strategies from this training that you will implement to improve the energy efficiency of the installation.


5 Minutes

42

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Other Energy Conservation Programs

• Enhance the service you provide your customers by directing them to other energy conservation initiatives sponsored by the OPA!

o peaksaver PLUSTM lowers your customers’ energy bills by remotely managing electricity consumption when demand is high through small adjustments to their appliance(s) (including central air conditioner, electric water heater and/or in-ground pool pump) for short periods of time.

o COUPONS offers your customers a wide selection of coupons on energy efficient products for their home at www.saveONenergy.ca.

http://www.saveonenergy.ca/

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Your Feedback is Important!

• Before writing the final course assessment, please complete and hand in the anonymous course evaluation form.

• Your feedback helps us continuously improve our training programs!

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Course Assessment

To complete the course assessment:• Fill in the required information

on the cover page.• Read the questions carefully.• Circle the correct answer.

o There is only one correct answer per question.

Documents

Www.hrai.ca Welcome to the AC Installation Optimization Training Program