1. Sean Kalman – Hays Fluid Controls
Hydronic Balancing
Using Automatic Balancing Valves to Dynamically Balance Hydronic Systems
Hello, Thank you for having me today.
My name is Sean Kalman and I am the Western Regional Sales Manager for Hays Fluid Controls.
Today, I am going to speak with you about automatic flow control valves.
Sean Kalman – Hays Fluid Controls

2. Automatic Balancing Valves
Agenda
Methods of Hydronic Balancing
How Automatic Flow Control Works
Automatic Flow Control Saves Money
Where to Apply Automatic Flow Control Valves
Selecting an Automatic Flow Control Valve
In looking at Automatic Flow Control Valves, these topics come to mind.
If anybody has any questions along the way, please feel free to speak up.
Automatic Balancing Valves

3. Methods of Hydronic Balancing
Balancing Valve Type
Information
Ball Valve
Inexpensive & Inaccurate
Circuit Setter
Moderately Priced & Somewhat Accurate
Venturi
Higher Priced with Improved Accuracy
Automatic
First Cost eqivalent to Venturi, Lower TAB Cost
Ball valves always seem to be the choice of contractors because they have a very low first cost, but the cost to balance them is immeasurable. Balancing with ball valves is an inexact operation with little accuracy.
Circuit Setters would be the next logical step, but again has accuracy issues.
Venturi flow control is the best option of all of the manual valve options. However, you still are not afforded the flexibility you can have with automatic valves.
While the automatic valves have the highest first cost, the installation, balancing and operation make up for the first cost and then some as we will see.
Automatic Balancing Valves

4. How Automatic Flow Control Works
When the Differential Pressure increases, the diaphragm presses up to and flexes against the orifice plate. This limits the area for the water to flow through.
When Differential Pressure decreases, the diaphragm relaxes, and increases the area for the water to flow through.
This is just one design for the internal make up of an automatic flow control valve. There are several on the market today. All of them use the same principle for controlling the flow of water however.
Flow
Automatic Balancing Valves

5. Automatic Flow Control Valves Save Money
Less Valves Required in System
Higher Accuracy
Lower Installation Cost
Lower Test, Adjust & Balance Cost
Lower Long Term Maintenance Cost
Lower Pumping Capacity Requirement
Can Be used in Variable Flow Systems
Automatic Balancing Valves

6. Typical Manual Balancing System
Circuit Balance Valves required at all terminal units as well as riser.
System to be rebalanced when new terminal unit brought on line.
Notice here when you add a terminal unit to the mix, you will have to go back and rebalance all of the terminal units as well as the riser.
This is because the original settings on the circuit balance valves are no longer at the right Delta P.
Automatic Balancing Valves

7. Automatic Flow Control System
Automatic Flow Control Valves only required at terminal units.
No system rebalance needed when new terminal unit brought on line. AFCV dynamically adjust to maintain flow.
In this system, no rebalance is necessary when the new terminal unit is added. This is because the AFCV dynamically change in order to maintain system and unit balance.
Also note that there is no need for the AFCV on the riser since the other valves can handle a broad range of Delta P.
No AFCV required on riser.
AFCV offers unmatched flexibility for your design.
Automatic Balancing Valves

8. Automatic Balancing Valves
Automatic Is Accurate
Most manual valves give somewhere between ±15% to ±25%
Automatic valves increase your accuracy to ±10% as a general rule
Automatic Balancing Valves

9. Lower Installation Cost
5 Components 1 Package 4 Connections
Most contractors who pipe all of these fittings together in the field are spending way too much.
All automatic flow control manufacturers offer pre-assembled kits that will help the contractor avoid costly field assembly of piping kits. This also cuts down on the number of joints which are places where leaks can occur.
17 Components 21 Connections
Automatic Balancing Valves

10. Less Valves Required with AFCV
There are less valves used since the AFCV are pressure independent and can accommodate changes in the Delta P and still maintain the constant rate of flow they were designed for.
In this manual system, 26 manually adjusted flow control valves are required. In the same system using automatic valves, only 18 valves are required.
Automatic Balancing Valves

11. Less Valves Required With AFCV
In an automatic 3 way system, there is no need for an additional balancing valve in the bypass line.
These were originally installed to throttle the bypass to nearly the same pressure drop as created by the coil.
Pressure independent AFCV can handle this additional Delta P and therefore save in installation cost in 3 way configurations.
No balancing valve required in bypass with AFCV
Automatic Balancing Valves

12. Automatic Balancing Valves
Lower TAB Cost
Because AFCV are pressure independent, they are balanced from the time the pump is turned on. Thus, only flow verification is needed, saving as much as 60% over outdated manually adjusted valves.
1.5 Hrs to manually balance 1 coil.
$50 / Hour Labor X 1.5 Hrs $75 Per Coil X 100 Coils $7500 Balancing Cost
.5 Hrs to verify flow on AFCV.
$50 / Hour Labor X .5 Hrs $25 Per Coil X 100 Coils $2500 Balancing Cost
These manual TAB numbers are conservative. Most TAB engineers will say that to get the best balance, you will need to test and adjust each coil 3 and sometimes 4 times.
Automatic Balancing Valves

13. Less Energy Consumed With AFCV
When your building load changes, AFCV can dynamically change to maintain your flow requirements.
When the ΔP decreases, the valves open to maintain a constant flow rate.
When the ΔP increases, the valves close slightly to maintain a constant flow rate.
Manually adjusted valves cannot adjust to the changing ΔP to maintain a constant flow rate. If ΔP increases, so does the flow, if ΔP decreases, so does the flow.
Automatic Balancing Valves

14. Less Energy Consumed With AFCV
Application:
In an office building on a Spring day, the building may not be calling for less chilled water than what it was designed for. Except for a cafeteria which is at 100% capacity. By using AFCV, you can reduce your pump speed to meet only the chilled water need you have. With manually adjusted valves you do not have that luxury. In turn, reducing your pumping cost and saving money.
Automatic Balancing Valves

15. Less Energy Consumed With AFCV
Notice that the pump is not having to work as hard with the AFCV system, and therefore is working at a more efficient level conserving energy.
Automatic Balancing Valves

16. Less Energy Consumed With AFCV
Automatic Balancing Valves

17. AFCV With Variable Speed Pumps
Automatic Can accommodate changes in system.
Only AFCV can change to maintain exact flow rate.
For use with 2 position valves is excellent application.
Automatic Balancing Valves

18. AFCV With Variable Flow Systems
Many engineers have suggested that AFCV is not suited for variable flow systems. Here are some reasons they are perfect for the job:
Control Valve has complete authority except when fully open and flow is beyond design.
Prevents “Overflow” of coil.
Aids in preventing valve cavitation.
Aids in preventing premature erosion of control valve body.
WSHP W/ ON-OFF Valve and VFD
2 Position VAV or FCU Systems
Automatic Balancing Valves

19. Cost Savings With AFCV
Use $50 per hour for labor
Use ½ hour for installation time
Use 1.5 hours for TAB on manual valves
Use .5 hours for TAB on automatic valves
Use price of $27 on ½” CBV
Use price of $53 on ½” AFCV
27 Circuit Setters = $729 Installation Labor = $675 TAB Labor = $2,025 Total Installed Cost = $3,429
18 AFCV = $954 Installation Labor = $450 TAB Labor = $450 Total Installed Cost = $1,854
In this example, we saved $1575 first cost alone.
Automatic Balancing Valves

20. Where to use Automatic Flow Control Valves
Water Source Heat Pumps
Fan Coils
VAV Box with Reheat Coils
Air Handlers
Unit Ventilators
Cabinet Heaters
Radiant Floor Heating Systems
Hydronic Baseboard Heaters
Cooling Towers
Chillers
There are many applications for all of these devises. Automatic Flow Control Valves often enhance the performance of all of them.
Chiller- Multiple cooling towers ensures proper flow of condenser water
Cooling Tower Filtration ensures filter media is not too disturbed.
Automatic Balancing Valves

21. Automatic Flow Control Placement
In most applications, it is best to place the AFCV on the return side of a coil. This ensures that your water tube is full and providing maximum heat transfer.
Supply side will work, but is not ideal as too much air or turbulence may occur.
Automatic Balancing Valves

22. Automatic Flow Control Placement
In an closed loop system, the AFCV can be on the return side or the supply side of the coils. The best practice is still to have your AFCV on the return side.
In an open system, the AFCV must be on the return side of the coils to ensure that the tubes are flooded and ensure maximum heat transfer.
Automatic Balancing Valves

23. AFCV For All Applications
A small inline valve will work in tight spaces
A multipurpose valve provides unlimited options.
Larger valves accommodate high flow rates.
Automatic Balancing Valves

24. Choosing The Right AFCV
Choosing the right AFCV is very important. Here are some items to consider when choosing an AFCV:
Operating Range: AFCV have a PSID range that they will operate within. Make sure the one you choose meets your needs.
Flow Rates Available: Most AFCV manufacturers provide several flow rates to choose from. Some have a better selection than others. Make sure you are getting the flow rate you need.
Hassle Free Operation: Ask the manufacturer if there are maintainance isssues with their valves. Will you have clogging problems or noise problems?
Automatic Balancing Valves

25. Automatic Flow Control Valves
SATISFIED CUSTOMER
Installation
Valve Selection
No Callbacks
Comfort
Balance
Automatic Balancing Valves

26. Automatic Balancing Valves
Conclusion
AFCV are a good application in all types of systems.
AFCV saves money on both installation and operation of system
AFCV are best option for balancing of Hydronic HVAC systems.
Automatic Balancing Valves