HVAC School - For Techs, By Techs

• Learning Hydronics, Boilers and Steam w/ Ray Wohlfarth

  div]:bg-bg-000/50 [&_pre>div]:border-0.5 [&_pre>div]:border-border-400 [&_.ignore-pre-bg>div]:bg-transparent [&_.standard-markdown_:is(p,blockquote,h1,h2,h3,h4,h5,h6)]:pl-2 [&_.standard-markdown_:is(p,blockquote,ul,ol,h1,h2,h3,h4,h5,h6)]:pr-8 [&_.progressive-markdown_:is(p,blockquote,h1,h2,h3,h4,h5,h6)]:pl-2 [&_.progressive-markdown_:is(p,blockquote,ul,ol,h1,h2,h3,h4,h5,h6)]:pr-8"> _*]:min-w-0 standard-markdown"> In this episode of the HVAC School podcast, Bryan sits down with Ray Wohlfarth, a seasoned HVAC contractor and prolific author who has dedicated over 30 years to mastering the art and science of boiler systems. What began as a competitive disadvantage—competitors claiming he knew nothing about boilers—became Ray's driving passion. Through daily reading, countless mistakes, and an unwavering commitment to learning, Ray transformed himself into one of the industry's most respected voices on hydronics and steam systems. Ray shares the personal story of how legendary author Dan Holohan literally "saved his marriage" with his book on one-pipe steam systems. When Ray and his wife moved into their first house with steam heat, mysterious banging sounds threatened domestic harmony until Dan's book provided the answers Ray desperately needed. This experience inspired Ray to pay it forward, eventually authoring 14 technical books himself—all written with the vision of a technician stuck in a boiler room at 9 PM on a Friday night, frantically searching for solutions. The conversation dives deep into practical wisdom earned through experience. Ray emphasizes the critical importance of safety in boiler rooms, recounting a harrowing story of a hospital engineer who bypassed safety controls and manually lit a boiler with a flaming broom—resulting in dangerous explosions. He stresses that technicians should always identify escape routes before beginning work, as a lifting relief valve can quickly fill a room with steam, displacing oxygen and eliminating visibility. Beyond safety, Ray shares diagnostic techniques like listening for dripping, hissing, or the "Rice Krispies" sound that indicates scaling, and visually inspecting for soot streaks that reveal combustion problems and potential carbon monoxide issues. Throughout the episode, Ray's philosophy shines through: humility, continuous learning, and the joy of solving complex problems. Whether discussing the holistic nature of steam system troubleshooting, the importance of water quality treatment, or the surprising efficiency of properly designed steam systems (like the LEED Gold-certified Empire State Building), Ray's expertise and passion are evident. His advice for aspiring boiler techs is simple but profound: read 15 minutes daily about your industry, engage with online communities like HeatingHelp.com, and never stop learning from every service call. Topics Covered Ray's Journey: Transitioning from Carrier air conditioning to boiler expertise over 30+ years The Writing Process: Creating 14 technical books designed specifically for technicians in the field Dan Holohan's Influence: How Dan's books and mentorship shaped Ray's career and literally saved his marriage Boiler Room Safety: Critical importance of identifying escape routes and recognizing dangerous practices Diagnostic Techniques: Using your senses—listening for dripping, hissing, and scaling sounds; looking for soot, leaks, and discoloration Near-Boiler Piping: Why 90% of steam boiler installations have incorrect piping and the importance of proper insulation Steam vs. Hydronic Systems: Key differences in troubleshooting approaches and why steam operates more like air conditioning than hydronic One-Pipe vs. Two-Pipe Steam: Fundamentals of steam system design, traps, and venting behavior Condensing Boilers: The reality of "conditional condensing" and why 95% efficiency requires specific return water temperatures Radiant Heat Comfort: Why hydronic radiant heating provides superior comfort compared to forced air Water Quality Issues: The critical importance of water treatment, the mystery of deteriorating fittings, and potential chlorine impacts Learning Resources: The value of HeatingHelp.com, reading 15 minutes daily, and engaging with online communities Ray's Book Series: Overview of his "Lessons Learned" series and specialized books on brewery boilers and wiring diagrams Common Mistakes: Real-world troubleshooting stories including the mystery of the 2-degree delta T and lessons in humility   Check out some of Ray's boiler books on Amazon HERE. His latest book, Lessons Learned: Understanding Boiler Wiring Diagrams, is available HERE. Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android.

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• How Duct Tape Got Its Name (and Why It Shouldn't Be on Ducts) - Short #264

  In this short podcast episode, Bryan explains how duct tape got its name and why it shouldn't actually be used on ducts. Duct tape is a versatile home DIY-fix tool, but despite its name, it wasn't initially made to seal ducts at all. In 1943, we were in the thick of World War II, and ammo shipments were sealed with wax and paper tape. These were often not durable or difficult to open. Johnson & Johnson developed a tape with rubber adhesive on a cotton duck cloth backing (which was already widely used for military uniforms and tent fabrics). This new tape was nicknamed "duck" tape due to the material and its waterproof abilities (like the waterfowl). A woman named Vesta Stoudt informed President FDR about duct tape, and the War Production Board began using it in wartime supply packaging. After the war, America had a housing boom in the 1950s, which included the demand for forced-air heating and cooling systems. Marketers thought the tape could seal the ducts in those homes, so they changed the color to match sheet metal and rebranded it as "duct tape." In the 1960s, this tape was available in retail outlets with the "duct tape" branding. Unfortunately, in tests by the Lawrence Berkeley National Lab, duct tape failed miserably at sealing the ducts because the rubber adhesive dries out under heat, and dust weakens the adhesive. As a result, many building codes ban duct tape on ducts (spearheaded by California). Instead, UL-listed foil tape and mastic are approved for sealing ducts. However, duct tape still became famous for its versatility as a patching material. It's prevalent in pop culture and has been used in television shows and even in space.   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android.

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• The Art of De-escalation

  In this comprehensive discussion, Bryan and Bert tackle one of the most critical yet underdeveloped skills in the trades: conflict resolution and de-escalation. They argue that poor conflict management is one of the primary reasons technicians lose jobs, damage team dynamics, and limit their career advancement. The conversation explores both customer-facing conflicts and internal team disputes, offering practical strategies grounded in real-world experience. The hosts distinguish between rational and irrational customer anger, noting that both require similar approaches—taking clients seriously, listening fully, and resisting the urge to immediately correct or defend. Bert emphasizes the importance of body language, describing how he physically leans into difficult conversations rather than backing away, making eye contact, and allowing customers to repeat themselves until they feel genuinely heard. Bryan adds that the "slow is smooth, smooth is fast" military principle applies perfectly to people problems—rushing to fix the emotional situation often prolongs the conflict, while patient listening typically resolves issues more quickly. When addressing internal team conflicts, they stress going directly to the person involved rather than gossiping or complaining to management. Both hosts acknowledge that ego, the need to be right, and past trauma can trigger fight-or-flight responses that sabotage productive conversations. They advocate for approaching conflicts with humility and a willingness to be wrong, focusing on the single most important issue rather than bringing up a laundry list of grievances. Bert shares that preventing conflict often means letting minor issues go while addressing patterns before they fester into major problems. The conversation concludes with practical advice about maintaining relationships after difficult conversations, recognizing that drawing back creates rejection while intentionally staying connected demonstrates genuine care. They emphasize that mastering conflict resolution isn't just about keeping your job—it's about becoming invaluable in your career and developing skills that serve you in every area of life. Topics Covered: Common sources of customer anger: feeling dismissed, not taken seriously, fear around property damage, and frustration with time and money The difference between rational emotions (legitimate grievances) and expectation gaps (perceived as "irrational") Body language techniques for de-escalation: leaning in, maintaining eye contact, staying present rather than fleeing Why interrupting customers to prove you're right backfires and escalates conflict Managing fight-or-flight responses and recognizing when fear drives aggressive reactions The importance of letting customers repeat themselves until emotional release occurs Internal team conflict triggers: lack of recognition, perceived unfair workloads, misinterpreted communication Why going directly to the person involved beats gossiping or complaining to management The danger of storytelling and assigning motives to others' actions Practical conflict resolution framework: prepare both parties, choose private settings, listen twice as much as you speak, and be willing to be wrong How mastering conflict resolution makes you invaluable and accelerates career advancement Maintaining relationships after difficult conversations to avoid creating rejection   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

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• Legionnaires' Disease: The Cooling Tower Killer - Halloween Short #263

  In this spooky Halloween short podcast episode, Bryan tells the story of the cooling tower killer: Legionnaires' disease. In the summer of 1976, the nation celebrated its bicentennial anniversary. The American Legion was holding its 58th annual convention at the Bellevue Stratford Hotel in Philadelphia, PA. In the days following the convention, doctors in Philadelphia started noticing dozens of Legionnaires in their hospitals with high fevers, chills, coughs, and difficulty breathing. Their symptoms resembled those of pneumonia, but patients deteriorated quickly, and antibiotics didn't work as expected. People became more ill, and 34 of them died. There were many theories, from food poisoning to novel viruses to bioterrorist attacks. The CDC investigated biological samples from patients and swabs from the hotel alike, but their findings were inconclusive. As news outlets sensationalized speculation over the cause of the illnesses, the disease was named after the unfortunate Legionnaires who suffered from it. However, the speculation would come to a close months later when CDC scientist Joseph McDade reviewed the samples and found a tiny, round-shaped bacterium living in the lung tissue of the victims. The bacteria would be named Legionella pneumophila.  Investigators traced the bacteria back to the hotel's cooling towers. Cooling towers are essentially giant evaporative coolers and can create a mist. Legionella can thrive in the warm water of cooling towers, and the cooling towers dispersed the mist throughout the area, making hundreds ill. When water stagnates, bacteria can fester, but temperature is just as important as movement. As contractors, our maintenance procedures can save lives. In cooling towers, that maintenance entails regular cleaning, chemical treatment, and monitoring water temperature and flow.   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

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• Group Training - What We Have Learned

  In this episode of the HVAC School podcast, Bryan Orr sits down with Bert and Leanna to discuss Kalos's first official cohort apprenticeship program, dubbed the "Launch Program." What started as Bryan's persistent idea—one that the team initially resisted as too expensive and logistically challenging—evolved into a transformative three-month training experience that brought 15 green apprentices through intensive classroom, lab, and field work across HVAC, electrical, and building automation systems. Bert, who graded himself a B for his first attempt at leading the program, shares candid insights about the challenges of planning and execution. While he meticulously mapped out the first two weeks hour-by-hour, the remaining time was far less structured, leading to valuable lessons about the importance of ongoing planning and verification. Leanna, who came to Kalos with both teaching experience and a commercial HVAC background, brought crucial support that Bert initially didn't think he needed. Her contribution proved essential in managing the group of 15 and ensuring hands-on engagement. Of the original cohort, nine graduated, with two additional apprentices added later who showed exceptional promise. The conversation reveals critical insights about what makes training effective in the trades. Both trainers emphasize the importance of hands-on experience over lecture, with Bert noting his biggest mistake was spending an entire day lecturing on refrigerant circuits before showing apprentices actual equipment. The most successful exercises involved real-world scenarios, like Leanna's mock dispatch day where apprentices handled service calls from start to finish, including customer communication. The program also incorporated broader trade skills beyond HVAC—carpentry, ladder safety, and tool confidence—recognizing that many young workers today lack the tactile experience that builds confidence in using tools and solving problems independently. Perhaps most importantly, the discussion highlights the value of verification and confidence-building over knowledge dumping. Bert learned that making diagnostic exercises too complex early on destroyed apprentice confidence, while starting simple and building up created self-motivated learners. The cohort model's unique advantage lies in its competitive yet supportive environment, where apprentices can gauge their progress against peers who started at the same level, creating natural motivation to improve. While expensive and demanding, the program represents a long-term commitment to developing well-rounded tradespeople who can think critically and solve problems—not just perform repetitive tasks. Topics Covered: The origins and initial resistance to implementing a cohort-style apprenticeship program Structuring a 90-day training program with classroom, lab, and field components The critical importance of planning and having adequate instructor support Selecting apprentices: key traits including self-motivation, adaptability, and humility Balancing lecture, hands-on training, and real-world field experience The power of verification and skills checklists over pure knowledge transfer Teaching broader trade skills (carpentry, ladder work) to build overall confidence Creating realistic scenarios like mock service calls for soft skills development Managing group size and the challenges of keeping all apprentices engaged The role of confidence-building in safety and long-term success Starting simple with diagnostic exercises and building complexity gradually Using field feedback and peer comparison as motivational tools The cost and commitment required to run effective cohort training programs   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

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