Are there other THERMAL-XR® benefits?

Perform also has excellent corrosion prevention exceeding 10,000 hours of salt spray (ASTM B117) and can extend the life of equipment to delay capital expenditure of new equipment in a corrosive environment. Improved efficiency with better heat dissipation of the coil in hot weather conditions aids in a potentially lower condensing pressure along with high-pressure trip-outs resulting in cost savings with expensive technician callouts.

The graphene used in THERMAL-XR® is also water resistant, which can aid defrost time in specific applications as well as keeping the coil easier to maintain with mild cleaners.

Can I use THERMAL-XR® for any condenser coil?

For use with air-cooled refrigeration or air conditioning condenser, either round tube plate fin (RTPF) or microchannel heat exchanger (MCHE) designs.

Can I use THERMAL-XR® on a coated coil?

Yes, the current coating will need to be treated for THERMAL-XR® for best adhesion.

Can it be removed at all? Will there even be any coating on the tube (the fins have collars)? As it’s only 12-15 microns, will it make a difference?

The burnt-off coating section should undergo the initial coating installation process.

Can you repair the coil after it’s been coated?

A coil can be repaired after the coating is applied.

Does it affect the equipment’s warranty?

Equipment manufacturer’s have varying warranty coverage that addresses the entire piece of equipment and various more components in the system. Always follow OEM guidelines to ensure warranty coverage. Condenser coils, depending on how they are treated at the factory or other applicator can have more limited coverage due to potential corrosive microclimates in the field. THERMAL-XR® aids in addressing ongoing oxidation/degradation of the aluminum coil from date it was installed. THERMAL-XR® provides corrosion resistance to the coil as well as reinstates some heat transfer capability that was lost due to metal degradation after it was installed.

Electric defrost is often used, with heaters (Calrods) in very close proximity to the fins, and in some cases touching them. Temps reach nearly 350°F, will the coating survive and not flake off?

Curently, only BronzeGlo is approved as a coating for evap coils needing electric defrost.

The Operational Tolerance (PDS) upper limit is 1500C. Hence in these circumstances the current THERMAL-XR® won’t be able to be used on these evaporators.

The only time THERMAL-XR® might possibly be used is for a coil that has tubes in which the elements (Calrods) are placed into so there is no direct contact.

For CO2 systems, can THERMAL-XR® reduce the trans critical time?

The difference between subcritical CO2 systems and Transcritical CO2 systems is subcritical condenses the refrigerant at the condenser as the compressor discharge pressure is lower than the critical pressure. As for the trans critical system, the compressor discharge pressure is higher than the critical pressure therefore it cannot be condensed, they use a gas cooler instead of a condenser to dissipate the heat. We believe THERAMAL-XR® will work in both CO2 processes.

Has the technology in THERMAL-XR® been independently tested?

THERMAL-XR® has been independently tested so that we are confident it will provide the best outcomes possible for our customers.

Independent testing has shown an average 15% pull down rate reduction and a 5% reduction in energy usage over a 48hr continuous cycle testing on a new HVACR system.

Another independent study of the coating has been undertaken with 11 systems being applied in the field, and resulted in an energy reduction in the tested systems between 5 to 20% or an average 12%.

Have we tested with variable speed condenser fans? The thought is the savings might even be greater.

GMG haven’t lab tested a condensing unit with the variable speed fans, though the testing has displayed the ability to turn 1 fan off to regulate the discharge temperature.

High temp applications for heat exchangers (the gas fired HXers for heating in winter), can we get a formula that can help with corrosion and extend the lives?

The current formulation has existing tolerances for certain market segments. To create a new formulation for higher temperature tolerances would be new product that would require insights and collaborations from both parties to make an assessment. We can add this to regular distributor discussion points.

How are energy saving results calculated?

THERMAL-XR® results thus far have been estimated using an internationally known model for energy savings called International Performance Measurement and Verification Protocol (IPMVP). This is an accredited model for calculating and reporting energy savings for use in carbon credit schemes, CaaS, and energy performance contracts. The comparison of before and after energy consumption is made using the following general Measurement and Verification equation:

Savings = Baseline Period Energy less Reporting Period Energy +/- Adjustments

How deep can THERMAL-XR® penetrate with various fin spacings?

Penetration of the coating will vary depending on spray application used, how many rows deep the coil is and yes fin spacing, though generally on a 10-12 FPI coil you will see penetration of roughly 2-3 inches give or take.

How do you prove to customers it works?

The best approach is to find an application/system where variables can be best isolated so there is a consistent compare of before and after application of THERMAL-XR®. This includes a consistent cooling load and reasonably consistent weather pattern since these variables will affect how the system performs. It is imperative to gather energy data before and after application of Perform plus other system vitals. It is also imperative to know that it will take several days or more for the coating to cure before performance is best realized. For specific questions, contact GMG.

How does it respond to brazing?

Brazing is a very high-temperature operation (>4500C). The Operational Tolerance (PDS) upper limit is 1500C.

How does the curing time change with temperature?

The hotter the ambient conditions, the quicker the drying time and vice versus for cooler ambient conditions. A potential option to decrease dry time in cooler ambient situations would be to use a UV lamp.

How does the viscosity change with temperature?

The hotter the paint is, the lower the viscosity becomes. The cooler the paint is, the higher the viscosity becomes.

How does THERMAL-XR® provide energy savings?

Inside a very thin layer of THERMAL-XR®, graphene increases the heat transfer process allowing more efficient operation of the system with less energy and potentially leading to lower CO2 emissions.

With new systems or systems in the field, the unique properties of graphene within THERMAL-XR® transfers heat at a much faster rate, creating more efficient system operation and faster time to reach cooling set points. Faster cooling with less fan and compressor operating times results in energy savings.

The coating restores lost efficiency caused by corrosion of the existing coil.

How hard can the coating be blasted with a pressure washer? What can it withstand?

Do not blast a coil with a pressure washer as it will damage the fins and decrease the equipment’s performance. If there is no other choice then the pressure needs to be on the lowest setting possible and stand far back from the coil as possible otherwise you risk the fins being bent over and yes the coating will more than likely come of in areas.

How involved is the THERMAL-XR® application process?

The THERMAL-XR® process is a two or three step process depending on the specifics of the condenser at the jobsite. For bare metal RTPF or microchannel coils, it requires a three-step process of cleaning with a coil cleaner, metal preparation with THERMAL-XR® Bare Aluminum Prep, followed applying for THERMAL-XR®. For previously coated coils, it requires a two-step process of cleaning with an aggressive cleaner for best surface preparation followed by applying THERMAL-XR®.

How much coverage should I expect THERMAL-XR®?

The practical coverage is approximately 200 sq/quart (flat surface). For coil application we recommend three light coats at three different angles (straight, 45° left, 45° right) for best coverage of the tube, aluminum fin or microchannel surface area. For planning purposes, estimate 20 sq. feet of coil surface area per quart when applying three light coats at different angles to the coil. Ultimately, how the applicator applies the coating dictates coverage area.

How much time should I plan for the application process?

3-6 hours, depending on complexity of coil access, equipment size and conditions. Some applications may be a little quicker or longer depending on its own uniqueness.

Depending on how this is planned, this can be a one or two-day process. For a two-day process, the coil is cleaned and THERMAL-XR® Bare Aluminum Prep, a metal primer, is applied (for non-coated condenser). THERMAL-XR® is applied the following day, this process ensures the coil is completely dried before coating application. The process can be easily completed in a single day, however the use of a power blower is strongly recommended between the cleaning/primer step and THERMAL-XR® application to speed up drying process to ensure it is dry

IMPORTANT: The coil surface must be completely dry before the application of THERMAL-XR® so it adheres properly to coil.

If THERMAL-XR® is exposed to freezing temperatures or is frozen, is it still good?

The short answer is yes, we have performed cyclical testing to where paint has been exposed to three separate freeze cycles, allowed to thaw and tested successfully. However, it is possible THERMAL-XR® is exposed to extreme storage conditions well beyond what we recommend for extended period of times that could alter its properties. If the coating looks suspicious when the container is opened, contact GMG.

Is THERMAL-XR® only for air condenser coils?

Perform also has excellent corrosion prevention exceeding 10,000 hours of salt spray (ASTM B117) and can extend the life of equipment to delay capital expenditure of new equipment in a corrosive environment. Improved efficiency with better heat dissipation of the coil in hot weather conditions aids in a potentially lower condensing pressure along with high-pressure trip-outs resulting in cost savings with expensive technician callouts.

The graphene used in THERMAL-XR® is also water resistant, which can aid defrost time in specific applications as well as keeping the coil easier to maintain with mild cleaners.

What added advantage does THERMAL-XR® have on heat pump systems?

This advantage is still being explored but it is believe the thermally conductive coating on the outdoor coil, now the evaporator for cooler climates. The coating is also water resistant. Tests have shown a reduction in defrost time for these systems or if applied to refrigeration evaporators.

What are the most important considerations with THERMAL-XR®?

Determine if the application is the right fit for THERMAL-XR® by reviewing system size, run time, condition of the equipment, local kW cost so it provides the required ROI to the end-user.

In evaluating THERMAL-XR®, GMG has a payback estimator and has test set-up suggestions to ensure reasonably consistent cooling loads and outdoor conditions to have best comparative results to highlight the benefit of the coating.

Once THERMAL-XR® is applied to the coil, more aggressive coil cleaners in the market can no longer be used. Before applying, ensure using mild cleaners. Like any paint system, surface preparation is everything. If the coil is too severely corroded to the point where the fins are brittle, this is not an application for THERMAL-XR®. Clean coils with the right cleaner, the use of THERMAL-XR® Bare Aluminum Prep where appropriate is important prep work and a dry surface before painting.

IMPORTANT: The coil must be dry before applying THERMAL-XR®. A wet coil surface will inhibit good adhesion and must be avoided. Clean the coil the day before and apply the next day or if done on the same day, use a power blower to accelerate good drying before applying Perform.

Use a mild cleaner (ph 7 to 9) for long term maintenance of coil efficiency with removing materials from the coil after THERMAL-XR® application. Aggressive acidic or sodium/potassium hydroxide water-based or solvent-based cleaners will damage the coating to where it will require a recoat.

What average energy savings should I expect with THERMAL-XR®?

Independent testing has shown 15% improvement of pull-down rate and 5% reduction in compressor wattage. Depending on degradation of the coil in the field, systems in service saw improved wattage reduction where an independent study showed an average of 12%, the results were specific to each situation in the study. Field tests have shown a range of 8 to 30+% depending on the condition of the coil where slightly degraded coil saw most improvement.

The actual savings will depends on factors including variable operating conditions, climate, system loads, change in temperature set points, system design and age. As a result, the product may perform differently from how it is described. Testing is recommended where these variables can be best isolated to properly and fairly evaluate properties of THERMAL-XR® to determine if the product provides the necessary benefit for a particular application.

What chemical environments can THERMAL-XR® be exposed to?

Perform is formulated to help with heat transfer of coils in industry environments. Contact GMG with detailed requirements to see if THERMAL-XR® is suitable for a specific corrosive environment.

What cleaner is recommended to clean the condenser coil after THERMAL-XR® is applied?

Allow two weeks for THERMAL-XR® to fully cure on the coil before applying any coil cleaner. Only use mild, near pH neutral cleaners (pH between 7-9) for cleaning the condenser coil with the coating.

THERMAL-XR®when fully cured has hydrophobic properties that make subsequent cleaning much easier with a milder cleaner such as Cal-Green.

What if I have trouble fully accessing the coil to apply THERMAL-XR®?

Applying THERMAL-XR® in the field with existing equipment requires application specific planning, understanding how to best access as much coil surface area on both sides of the coil as possible for best corrosion protection and energy savings potential. There may be circumstances where coil depth, coil geometries/access where limited coil exposure to where applying Perform may not make sense.  Each circumstance needs to be reviewed on its own merit.  

The good news with current findings is that worthy energy gains have been seen with only a good coating (three thin coats from different sprayer angles) on the air intake side of the condenser coil. Third party and field testing have all been done with coating condensers in field assembled condensing units.  Coil coverage in these circumstances is never perfect, it is about what can be reasonably available for best coverage to optimize the benefit of THERMAL-XR®. Independent findings have shown field applications of assembled systems have shown 15% pull down rate reduction and 5% energy savings on a new coil, with coils in service about 12% energy savings; some applications dramatically more because of system circumstances. As the system ages in service, where the coil has seen some ongoing specific microclimate degradation, field testing routinely has shown higher realized energy cost savings when compared to testing on a new coil.

What is graphene?

Graphene is a two-dimensional allotrope of carbon that is one atom thick that exhibits an extraordinary ability to conduct heat with its ability to superconduct via vibrational mechanical energy (phonon heat transfer) by its lattice of carbon atoms.

What is return on investment or payback?

THERMAL-XR® has excellent payback models in comparison to other capital energy savings options. Perform is an operating or maintenance expense (OPEX). It’s payback will based on the size of the equipment, run-time, equipment condition (coil) condition, local kilowatt cost. Each of these variables need to be considered in determining its specific return on investment for an application, but payback is generally expected less than 1 to 3 years in many commercial and industrial applications. Since the coating makes the system more efficient, this can only aid with its service longevity.

What is the dry time for THERMAL-XR®?

This depends on outdoor temperature and humidity. At 70°F and less than 80% relative humidity, expect THERMAL-XR® to touch dry in five minutes, can recoat in 10 minutes, handled in one hour, complete cure in 24 hours. In climates that have ongoing long periods of time at high humidity (coastal environments), full cure may take a week or longer.

What is the purpose of THERMAL-XR® Bare Aluminum Prep?

THERMAL-XR® Prep is a concentrate chromium-free conversion coating (primer) for aluminum constructed fin/microchannel coil that forms a colorless conversion layer to enhance the adhesion of THERMAL-XR®.

Pour entire contents of 6 fl oz. bottle into two gallons of water in a standard pump-up sprayer. The primer is to be applied to coil directly after cleaning the coil. The primer needs to dwell for at least five minutes on the coil before solution is rinsed off coil. Do not use the primer on a previously coated coil since it will leave a film and prevent good adhesion of THERMAL-XR® to previous coating.

What is the recommended storage conditions of THERMAL-XR®?

Store in cool (60°F to 75°F) conditioned environment, away from direct sunlight in it’s original, unopened packaging. Do not expose Perform to freezing (below 32°F) conditions with outside storage or elevated temperatures – this could affect the shelf life of the product.

What is THERMAL-XR® storage life?

Five years in its original unopened bottle when stored in a conditioned environment away from direct sunlight. With an opened or partly used bottle of THERMAL-XR®, its nominal shelf life is 12 months.

What is THERMAL-XR®?

THERMAL-XR® is a unique air-dry water-based acrylic HVAC/R coil coating. THERMAL-XR® is powered by GMG Graphene to provide a novel way of increasing heat transfer of air-cooled coils used in HVAC/R equipment. The coating provides coil corrosion resistance as well. The coating is specifically developed for air cooled round tube plate fin (RTPF) and microchannel heat exchangers made of copper/aluminum or all aluminum construction. THERMAL-XR®is not suitable water cooled condensers.

What makes THERMAL-XR® different than other coil coatings in the market?

Other coil coatings in the market provide corrosion resistance to the coil, and they nominally affect heat transfer rate. THERMAL-XR® is a two-in-one product which provides corrosion resistance but also makes the condenser coil more conductive with its application vs. not applying a coating or a using a competing coating.

What metals can THERMAL-XR® adhere to?

THERMAL-XR® will adhere to most metals used in heat exchangers

  • Aluminium
  • Copper
  • Stainless Steel
  • Steel

What supplies are needed for THERMAL-XR®?

Protective eyewear, gloves, paint respirator, coil cleaner depending on the specific coil situation, Coil Gun sprayer/hose, THERMAL-XR® Bare Aluminum Prep for previous non-coated coils, two gallon pump sprayer, exterior painter’s tape, plastic sheeting, electric or pneumatic HVLP sprayer, THERMAL-XR®, power blower (optional), tools to remove equipment panels to best access all sides of outdoor coil.

What temperature range can we apply the coating?

Application temperatures are stated on the PDS. Apply at above 5°C and below 40°C and +30C above dew point.

What type of customers will benefit?

THERMAL-XR® can be used on any sized air conditioning and refrigeration air-cooled heat exchange coils. End users that most benefit with quicker ROI will be high energy costs commensurate to their overall operating costs, and/or those who are looking to protect the outdoor coil to extend the life of their equipment.

Small to medium businesses generally don’t have a lot of levers to pull to offset savings weighing in inventory, staffing and rent costs. The ability to reduce energy cost with the Perform coating is ability to save operational costs, achievable year on year – especially if utility company has a program available to offset the application cost.

Some notable examples of high use/energy applications including air conditioning/refrigeration systems in commercial buildings such as stores, offices, schools, gymnasiums, libraries, hospitals, clinics and others including supermarkets, plus data centers and industrial applications.

What type of equipment can THERMAL-XR® be applied on?

THERMAL-XR® is formulated for use on air cooled HVAC/R condenser (outdoor) evaporator coils. The product can be applied on any size equipment, typically the larger size equipment with longer run times operating in areas with higher kilowatt cost see the quickest return on investment.

What’s the recommended conditions for applying THERMAL-XR®?

Apply when the outdoor temperature is between 50°F and 100°F with a relative humidity less than 80%. Do not apply coating if there is a high probability of rain within the next 24 hours.

Why is GMG Graphene unique?

GMG Graphene is produced from a proprietary process from natural gas not mined graphite. This process produces high quality, low input costs, scalable, tunable and low contaminant Graphene suitable for use in clean-technology applications.

Will I see the benefits of THERMAL-XR®on a coated coil vs. bare metal coil surface?

Yes, independent testing on a new OEM coated coil, first cleaned/prepped with an alkaline cleaner, followed by THERMAL-XR® application showed 15% pull-down rate improvement with a 5% energy benefit on a constant load study. Systems and applications do vary as well as the final benefit of using THERMAL-XR®.