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Vapco Professional Glycol Calculator

Use the Vapco Glycol Calculator to determine total pipe volume and fluid requirements for chillers, hydronic heating loops, and geothermal systems. Designed for HVAC technicians and engineers, this tool helps you easily calculate the gallons of Arctic Protection (Standard Propylene), Arctic Protection HT-1 (NSF Food Safe), or Ethylene Glycol needed to reach your exact freeze protection target.

Project Information
1. System Volume Calculator
TOTAL ESTIMATED SYSTEM VOLUME
0 gal
2. Concentration Adjustment
Existing System
New Fill (Empty)
PRO TIP: Before filling a new system, it is highly recommended to clean with Vapco Hydronic System Cleaner to remove factory oils and installation debris that can reduce efficiency.
*Check glycol percentage to ensure accuracy
RECOMMENDED DOSAGE
Enter Target %
INHIBITOR NOTICE: Vapco utilizes a proprietary inhibitor package formulated in-house. All Vapco Glycol ships with this standard protection unless otherwise requested. Vapco Products assumes no liability for systems where inhibitors are requested to be omitted or where system monitoring and maintenance are not performed in accordance with industry best practices.
Vapco Products: Custom Glycol Solutions
Arctic Protection HT-1 NSF Food Safe Propylene
Ex: APHT-55-95
Arctic Protection Standard Propylene
Ex: AP-55-95
Ethylene Glycol Industrial Grade
Ex: EG-55-95
BULK TANKER DELIVERY AVAILABLE (4,000+ GAL)
Stock Items (95% & 70% AP): Ships in 24-48 Hours
Custom Blends: Ships 48-96 Hours after PO
Bulk Tankers: 21-Day Lead Time Required
FOR AN ACCURATE QUOTE, PLEASE PROVIDE:
  • Ship-to Zip Code
  • Total Volume (Gallons)
  • Type of Glycol (HT-1, AP, EG)
  • Desired Percentage (%)
  • Container Size (5, 55, 275, or Tanker)
  • Color Preference (Optional)
Glycol Protection Chart
Propylene
Ethylene
% Conc. Freeze
(°F/°C)		 Burst
(°F/°C)		 Boiling
(°F/°C)
• Freeze Protection: Crystals form, solution remains pumpable.
• Burst Protection: Expansion occurs; risk of pipe damage.
Showing data for Propylene Glycol.
Glycol Technical Resources
Compliance & Cost How to choose between NSF Food-Safe vs. Industrial Propylene Glycol for specific HVACR environments. Why Inhibitors Matter Critical protection tips for winter prep and why untreated glycol can be more corrosive than water. System Cleaning Guide Step-by-step instructions for flushing and cleaning hydronic loops before adding new glycol. Optimizing HVAC Systems Exploring how the right glycol blend protects components and optimizes heat transfer efficiency. Glycol for Pros: Top 5 FAQs The most common questions on concentration levels, refractometer testing, and using pre-mixed solutions vs. concentrates.
Essential Glycol Support Products
DI Water
DILUTION FLUID Deionized Water (DI) High-purity water essential for diluting glycol concentrates without introducing scale-causing minerals.
System Cleaner
PRE-FILL FLUSH Hydronic System Cleaner Removes oils, grease, and installation debris from new or retrofitted loops before filling.
Glycol Inhibitor
MAINTENANCE Glycol Inhibitor Recharges the corrosion protection package in aging glycol systems to extend fluid life.

How to Calculate Glycol System Volume

Determining the correct fluid volume is critical for maintaining proper freeze and corrosion protection. Follow these steps to use the professional calculator:

  1. Input Pipe Data: Select your specific pipe diameter and enter the total linear footage of the piping network.
  2. Calculate Base Volume: The tool determines the gallon capacity of the piping, including a 10% safety factor for expansion tanks and heat exchangers.
  3. Determine Freeze Point: Consult standard freeze protection tables to find your target percentage for the local climate.
  4. Calculate Fill Amount: Enter your current and desired concentration in Section 2 to determine exact gallon requirements for a drain-and-fill correction.

Glycol Calculation & System Maintenance FAQ

Is this calculator compatible with all glycol brands?

Yes. This calculator utilizes standard industry specific gravity and volume formulas compatible with most inhibited Propylene and Ethylene glycol fluids. However, always verify specific requirements with your manufacturer's technical data sheet (TDS).

Can I run my system at a low concentration (e.g., 20%)?

Vapco strongly advises against concentrations below 25%. While glycol can provide freeze protection at lower levels, concentrations below 25-30% lose their bacteriostatic properties. This allows biological growth (bacteria, algae, and slime) to flourish, which can clog pumps and foul heat exchangers. If a system must run at 20%, a professional biocide monitoring and injection system is mandatory. For standard maintenance-free operation, keep concentrations above 25%.

What is the difference between Freeze Protection and Burst Protection?

Freeze Protection ensures the fluid remains completely liquid at the lowest expected temperature, allowing pumps to operate. Burst Protection involves a lower concentration that allows the fluid to turn into a "slush" but prevents it from expanding and damaging pipes or components.

Should I use Ethylene or Propylene Glycol?

Use Propylene Glycol for systems with potential potable water contact, food processing (NSF HT-1), or residential applications where low toxicity is required. Use Ethylene Glycol for industrial efficiency and heavy-duty cooling where toxicity is not a concern, as it offers superior heat transfer.

How do I correct concentration in an existing loop?

Utilize the Concentration Adjustment section of this tool. By entering your Total System Volume, your Current Test Percentage (via refractometer), and your Desired Target Percentage, the tool will provide the exact amount of fluid to drain and replace with either water or glycol concentrate.

Key Industry Terms:

• NSF HT-1: A food-grade certification for heat transfer fluids where incidental food contact is possible.
• Burst Protection: Prevents pipe failure in dormant systems by allowing slush formation without expansion.
• Freeze Protection: Ensures fluid remains pumpable and liquid at design temperatures.
• Inhibitor Package: Chemical additives in Vapco glycol that protect system metals like copper, steel, and aluminum from corrosion.
• Bacteriostatic: The ability of a fluid (at sufficient concentration) to stop bacteria from reproducing.

Vapco Products Technical Resource - Developed by Elliot Garner. Verified for HVACR industry standards.