Cool Just in Time for the Season Opener

Located in the heart of Pennsylvania’s Amish Country, the Ephrata Playhouse in the Park is the remodeled historic barn (circa. 1915) of the Daniel Eicher family who settled there in 1734. Blessed with a rich history, the 300-seat Playhouse is home to the Ephrata Performing Arts Center (EPAC), formed in the 1950s by renowned Broadway Producer John Cameron. With sold-out performances from May to December, EPAC produces seven plays and musical productions per year for the community of south central Pennsylvania.

Superior Entertainment, Inferior Indoor Comfort
Known for “star-studded” entertainment (Cameron brought in big names like Veronica Lake, Eva Gabor and Chico Marx), the historic pavilion had an unfortunate reputation for inadequate indoor comfort levels. A successful “Raise the Roof” Capital Campaign enabled EPAC to contract with Chris Harmes, HVAC project manager, Ames Construction, Ephrata, Pa. Improvements were made to the original structure, including expansion of the lobby, concession area, and existing dressing rooms, improved seating, more rehearsal rooms, costume storage and restrooms. For cooling the stage and auditorium on the main level, Harmes installed a 33-ton, high-velocity, forced-air system.

Basement Rooms Demand a Different Solution
This ducted system was fine for the conventional, constant cooling needs of the stage and auditorium—about 9,000-square-feet on the main level. But for the lobby and 5,000-square-foot lower level of the barn, Harmes needed a much more flexible, ductless zoning solution for cooling and climate control. The basement area was divided into small rooms housing set and costume storage, rehearsal and dressing rooms, offices and restrooms. The lobby and concession area presented a further challenge.

Flexibility and Variable Loads Mandatory
To find the best solution for cooling and heating these rooms, Harmes turned to a trusted colleague, Bob Stroh, Stroh Sales Associates, Phoenixville, Pa. “We met at the Playhouse before Thanksgiving 2003,” Stroh said. “Chris told me that his clients wanted the theater to be a totally comfortable place in time for the first production in early May 2004. When we toured the small rooms on the lower level, it was apparent that the different requirements of each room demanded variable loads; running ductwork was totally impractical because of the old barn support beams; that quiet operation was essential; and that flexibility was paramount to making this installation a success. I knew that there is only one system that could do all this, and suggested we design a VRF zoning system for the balance of the Playhouse.”

Efficiency and Extraordinary Versatility
Stroh specified a Variable Refrigerant Flow (VRF) zoning system from Mitsubishi Electric Cooling and Heating Solutions, Suwanee, Ga., for the lower level, lobby and concession area. He chose the Mitsubishi Electric R2-Series because of its ability to simultaneously cool and heat independent spaces, quiet operation and individualized climate control capabilities. Additionally, the configuration of the Playhouse to the lower level did not allow for ductwork.

Through efficient design, the linesets connecting outdoor units to the individual air handlers were reduced from Harmes’ original estimate by 400 linear feet. “One of Mitsubishi Electric’s big advantages comes from the extraordinary versatility made available by the Branch Circuit (BC) Controller units,” Stroh said. “These well-designed BC Controller units must be within 230 feet of the outdoor units, but they allow total flexibility in an HVAC design plan and help reduce the length of a run to the air handlers.”

From Resourceful Plan to Installation
Stroh’s plan called for two PURY-100TMU-A outdoor units, a G-50A centralized controller, two BC Controllers, six PLFY-20NAMU-A indoor ceiling-recessed cassettes, a variety of eight PKFY (08, 12, 20 and 32) indoor wall-mounted units, and a single PDFY-16NMU-A indoor ceiling-concealed ducted unit.

Chosen for the function of their particular rooms, the ceiling cassette and wall-mounted units were installed inconspicuously in the basement offices, rehearsal rooms, dressing rooms, costume storage rooms and restrooms. The piping and electrical work was neatly concealed in the ceilings of these rooms. The indoor ducted unit was installed in the lobby and concession area because there was ample ceiling space to accommodate the ductwork.

The BC Controllers and G-50A centralized controller were installed in the basement to allow for easy access and service. The two outdoor units were neatly tucked onto a concrete pad behind the Playhouse – the only visible exterior evidence of the Mitsubishi Electric system.

Flawless Performance Delivers a Standing Ovation
The VRF zoning system was installed in plenty of time for the April rehearsals of “1776,” EPAC’s first musical of 2004. Harmes said, “There were two major factors guiding this project: the historic nature of the original structure and the level of comfort needed from the system. Without question, the Mitsubishi Electric system turned both of these goals into reality. Ideally suited for maintaining the integrity of old buildings, it is a masterful employment of 21st century advanced technology that quietly delivers a high degree of comfort. Over the past two summers, the system has performed flawlessly which has brought nothing less than a standing ovation (and appreciation) from very happy clients.”

Further Demonstration of Versatility
Stroh said that after the first year of operation, Harmes discovered some of the basement rooms were not being used as expected. He wondered if it was possible to take an air-handling unit out of one space and move it to another. This was no problem due to the genius of the BC Controllers. “There is no other system in the world capable of such total flexibility,” Stroh said.