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Below is a graph that shows us this rule of thumb equation and the required air-side pressure based on the height of the system piping.

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The bulk of the discussion centers around surge protection technology and its critical importance in protecting HVAC systems and other electronic equipment. Mike provides an excellent analogy, comparing surge protectors to pressure relief valves for electrical systems. He explains how Metal Oxide Varistors (MOVs) work as semiconductors that create low impedance paths to ground when voltage exceeds certain thresholds. The conversation delves into the evolution of MOV technology, particularly the development of thermally protected MOVs that provide enhanced safety features.

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Michael Housh from Housh Home Energy in Ohio wrote this tip to help techs determine the air-side charge on a pressure tank. Thanks, Michael!

If you need to adjust your pressure relief valve, the process is very simple. Tools Needed: ¼" allen wrench. Adjusting the PRV.

Substituting ‘Dc’ into the original equation would give us a slightly less complicated equation that can be used as a rule of thumb to solve for the air-side pressure.

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A lot of the “rule of thumb” equations for hydronic systems are based on the density of water @60°F is 62.37, so we could simplify the above equation into a rule of thumb equation by first solving for the density (Dc). (Note: the formulas that we use in hydronic system GPM calculation also use the 60°F baseline. We have published an article about hydronic system GPM calculations, which you can read HERE.)

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In this enlightening episode, we sit down with Mike, a 20-year veteran from DITEK, a leading American manufacturer of surge protection devices based in Largo, Florida. The conversation begins with a brief discussion about recent hurricane impacts in the Tampa Bay area, where DITEK maintains its 65,000-square-foot manufacturing facility. Mike shares how the company, despite facing challenging weather conditions, continued its operations and maintained its commitment to American manufacturing.

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The formula for calculating the air-side pressure is relatively easy and directly related to the highest point in the system from the inlet of the expansion tank.

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The episode also addresses common misconceptions about surge protection, particularly the belief that surge protectors are primarily for lightning protection. Mike explains that while lightning strikes are a concern, especially in areas like Florida, approximately 65% of surges actually originate from within facilities themselves, often from equipment cycling on and off or other power quality issues. He emphasizes the importance of proper installation, particularly regarding ground connections and lead lengths, noting that every six inches of wire length can add about 100 volts to the clamping voltage of the device.

The proper air-side charge is equal to the static pressure of the fluid at the inlet of the tank, plus an additional 5.0 PSI allowance for the pressure at the top of the system. The air side of the tank should be checked and adjusted before adding water to the system. If the tank is already installed and the system has pressure in it, the pressure should be drained at the tank to 0 PSI before testing the pressure on the tank.

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Determining the air-side charge of an expansion tank in a hydronic heating system is a relatively easy task.  A properly sized and charged tank is designed to keep the system pressure about 5.0 PSI lower than the pressure relief while the system is at maximum operating temperature.

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