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Q&A about heat pump design - CAREL

Author: Emma Ren

Sep. 08, 2025

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Q&A about heat pump design - CAREL

This is my third and last Q&A post about heat pumps. After a general overview of this interesting application in the Q&A and a second post focusing on efficiency, I have collected a few questions on some of the most interesting design aspects
 
Designing heat pumps means analysing their components, such as compressors and expansion valves, selecting the right number and type of sensors and defining the most convenient layout with an eye to carbon footprint and future maintenance, among other matters.

For more information, please visit our website.

 

How to develop a high-efficiency heat pump? 

 

High-efficiency heat pumps currently rely on variable capacity DC inverter compressors, electronic expansion valves, electronic fans and pumps. They all fit permanent magnet motors for improved efficiency compared to asynchronous motors and can modulate capacity to match the load in real time. 

Modulation is the key factor to better energy efficiency compared to fixed capacity devices of any kind, which are just on or off. 

Well-designed heat exchangers are energy-saving components as well. “Well designed” is the key here because the plate heat exchangers for water and finned coils in air sources have been the norm for decades. The R&D for both water and finned coil technologies is now focused on good refrigerant distribution and this has become even more important considering the modulation capabilities of the other components mentioned above. Poor distribution leads to poor performance and a waste of the heat exchange surface. 

Finally, controllers are very important because they are the “brains” of the heat pump. They must optimise the control of all devices together, such as the compressor safety envelope, the fan/pump vs compressor energy consumption balance, and most of the time they manage the energy-saving defrost and hot water production features. 

 

What roles will sensors play in the heat pump market? 

 

Heat pumps, as any other air conditioning and refrigeration application, have always relied on temperature and pressure sensors
In the Far East, especially in Japan, manufacturers produce very few models in very large numbers. In this way, they design heat pumps by mapping them in all conditions, define the control logics, and then remove most of the sensors. Incidentally, they work with a few temperature sensors. 
 
Instead, the market in western countries is fragmented with plenty of customization needs. In the current and future residential market, there will be a lot of players, at least compared to the few operating in Japan, with many different models and layouts. Mapping is not suitable. 
 
Furthermore, there will be a great need for reliability and simplicity of use to compete with the current market reference (gas boilers). Heat pumps are a key application for decarbonization, which also means that governments will need to “certify” their efforts to achieve the goal by measuring the efficiency increase offered by this technology. 
 
As a result, more than just temperature and pressure sensors will be needed. The need for measuring the efficiency of millions of heat pumps on the field will drive the use of cost-effective energy meters and heating capacity meters (water flow meters and precise temperature sensors). Additionally, the growing interest in the use of Artificial Intelligence and IoT technologies based on big data will require connectivity, more temperature and pressure sensors for maximizing heat pump reliability, and information on weather forecasts, which may come from sensors or the Internet. 

 

What about cascading, work in parallel and upgrading existing heat pump units? 

 

Cascade heat pumps are more suitable for the industrial market, where the low and high temperatures of the sources can vary greatly. Multiple refrigerants appropriately chosen according to the temperature range are used in this case. 

I remember having observed the use of cascade heat pumps in the residential Korean market right after the Fukushima disaster. This terrifying event forced all neighbouring countries to massively reduce energy consumption. Korean heating systems were based on electric boilers at that time and there was a great need of short-term conversion to heat pumps. High temperature lift heat pumps were needed to comply with the existing typical water distribution systems and the Korean external temperature profiles and a R-410a / R134a cascade solution was found. Nowadays, I think R-290 heat pumps can work with a good COP down to -25°C of the external temperature and up to 80°C of water delivery temperature so that cascade systems are rarely needed in this market. 

On the other hand, the concept of modular design is not a bad idea. We have years of experience of multiple R-290 circuits in the refrigeration field to reduce the charge per circuit and comply with the safety standards. So, I think a modular design, with multiple circuits in the same unit or multiple units, can match heating capacities above 12-15kW. 

Finally, concerning the upgrade of existing units we have no direct experience beside the modular design mentioned above. I would just like to stress that this approach fits better the industrial market. 

 

What is the carbon footprint of a heat pump/chiller system for AC per nominal kW compared to a direct Air/Air packaged unit?

 

Comparing the carbon footprint of these two systems is hard, at least without precise specs and measurements. 
 
In general, I can say that direct expansion units are always more efficient than air-to-water units simply because they do not need an extra "refrigerant to water" heat exchange. I’m focusing on efficiency because the carbon footprint in HVAC applications is mainly dependent on energy consumption
 
However, air-to-water heat pumps are suitable for various plant layouts, including the most efficient underfloor heating and cooling that requires low compressor ratios to work. For example, direct expansion heating usually works with 40°C air outlet temperature and 45-50°C refrigerant condensing temperature. Underfloor heating, on the other hand, can work at 30°C water temperature, with 35°C refrigerant condensing temperature. 
 
For sure, this comparison is not fair, but it is worth mentioning. 
 
In terms of carbon footprint, refrigerant choice and charge are involved as well. Air-to-air packaged units and air-to-water heat pumps are mostly the same in this regard. We can assume that the shift towards R-290 will be quick in both cases

 

Can you provide a short troubleshooting guide for electronic expansion valves for heat pumps? 

 

The troubleshooting of EEVs does not depend on the application type (cooling, heating, refrigeration, air conditioning). It involves three aspects: mechanical, electrical and control issues. 
 
The most common mechanical issue of EEVs is step loss. A stepper motor, assuming we are talking about this kind of EEVs, can lose steps during movement. With a proper closed loop electronic control, the negative impact of this issue is limited because the valve position is adjusted according to sensor feedback. Furthermore, controllers have many step recovery functions, such as zero/100% position extra steps or resync when regulation stops. 
 
Leakages are more critical issues.  They are diagnosed by checking the evaporator pressure, which can drop slightly or significantly depending on the extents of the leakage, and blockages. A pressure switch alarm is very likely to trigger when an EEV is blocked. Blockages are more frequent in full closing position, and their root causes are dirt, pressure shocks and ice formation due to water/moisture in the circuit, mechanical or electrical failures. 
 
From the electrical point of view, wiring errors are the most common issue. An incorrectly wired EEV will not move or move in the wrong direction (closing instead of opening). Wire or coil failures, sometimes due to water infiltrations, are less frequent. 
 
In any case of presumed de-sync between assumed and real EEV position, manually moving the valve using magnets is a good way to troubleshoot the issue. 
 
Finally, control issues are assumed when the valve regulation is unstable (valve position and sensor values swing up and down around a reference setpoint). Most controllers use PID algorithms to define the valve movement vs sensors measurements (most commonly superheating, temperature or pressure). PID parameter adjustment cannot be explained briefly in a few words. I simply suggest firstly pinpointing whether the instability is caused by the EEV regulation. This can be determined by setting the EEV in manual positioning and stopping it in a defined position (i.e. 50%). If instability is still present, it probably comes from a different source, such as the fan/pump or compressor regulation, for instance. If it is caused by the EEV, most likely the regulation is too “reactive”, and it should be slowed down by reducing the proportional gain (P) and/or increasing the integral time (I) and/or reducing the derivative time (D). 

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Ep. 32: The Heat Pump Business Blueprint: Mike Cappuccio's Guide ...

Building a heat pump business isn't just about technical expertise — it's about understanding the metrics that drive profitability, the systems that enable scale, and the strategic decisions that create long-term value. Mike Cappuccio did exactly that, growing Dominate Ductless to over $15 million with 72 employees before selling to private equity in .

Most HVAC contractors start the same way: they're skilled technicians who see an opportunity to build something of their own. But as Mike Cappuccio learned over two decades, there's a massive difference between being good with your hands and building a scalable, profitable business that someone else wants to buy.

Today, Mike coaches contractors across the country on building heat pump-focused businesses. His perspective is unique because he's walked the entire journey — from being a technician to startup struggles to private equity exit — and he's willing to share the specific metrics and systems that made the difference.

Why Private Equity Was the Right Exit Strategy

For most contractors, getting into business is straightforward. Getting out profitably? That's where things get complicated.

"It's very easy to get into business as a contractor," Mike explains. "It's much harder to get out."

When Mike started exploring exit options, he discovered that not all buyers are created equal. Many acquisition companies wanted him to stay on for years, offering only 30% upfront with the remaining 70% contingent on hitting aggressive targets over the next three years.

"Believe me, you're going to break your hump for the next three years to earn that other 70% of that money, which you're probably never going to see," Mike says, reflecting on conversations with other contractors who took those deals.

Private equity offered something different: 95% of the purchase price upfront, with no extended earnout period. The trade-off? Once you sell, it's their company, their rules. "The house was white, they painted it orange. But it's their house, not mine anymore."

For contractors in their 30s and 40s looking to scale without the cash flow constraints of organic growth, Mike sees private equity as an attractive option. 

But here's the key: private equity firms only want businesses that meet specific criteria. And most contractors have no idea what those criteria are.

The 6 Key Metrics Private Equity Firms Actually Care About

"I don't think most business owners under 25 employees truly even know what those KPIs are," Mike observes. These metrics separate viable acquisition targets from businesses that will never attract serious buyers.

1. Revenue Per Employee: The Make-or-Break Number

If your company generates less than $250,000 per employee annually, you're not even in the conversation. Mike's target range? $250,000 to $350,000 per employee — and that includes everyone: installers, office staff, warehouse workers, everyone.

The math is brutal but clear. A 10-person company doing $1 million in revenue ($100,000 per employee) is "a sinking ship," as Mike puts it. But 20 people generating $5-7 million? Now you're talking.

2. Overhead Costs and Gross Profit Per Work Hour

Private equity buyers want to see that you understand your true operating costs and can maintain consistent profitability. This means knowing exactly what it costs to run your business each day and how much gross profit each work hour generates. These metrics reveal whether your pricing structure can support the overhead required for a larger operation — and whether your business model is fundamentally sound.

3. Revenue Per Salesperson: Beyond the $1 Million Ceiling

A salesperson generating $1 million annually might sound impressive, but Mike calls it "horrible." At an average ticket price of $20,000-25,000, that's less than $100,000 per month — essentially one sale per week.

"That better be at least $300,000 per month," Mike says. "You got a $3 million guy, you're putting some numbers on the board."

4. Revenue Per Service Truck

Service vehicles should generate at least $200,000 annually. This metric reveals how efficiently you're deploying your mobile assets and whether your service operation contributes meaningfully to overall revenue.

5. Installation Revenue Metrics

Understanding the revenue generated by your installation teams helps buyers assess operational efficiency and growth potential.

6. Number of Maintenance Agreements: The Retention Gold Mine

This is where many contractors — including Mike — leave money on the table. Recurring revenue through maintenance agreements creates customer retention and predictable cash flow that private equity firms love.

"A retained customer over ten years will bring you $50,000," Mike explains. "And if that customer does not bring you the exact $50,000, but you know what they'll do? Refer you to other people."

Why Heat Pumps Create Better Business Fundamentals

After spending the first decade of his business focused on commercial work, Mike made a strategic pivot to residential heat pumps — and the business metrics immediately improved.

"Heat pumps make money. Heat pumps require the least amount of labor to install," Mike explains. "The material to labor ratio is sometimes 6 to 1, 5 to 1, 4 to 1. I've seen traditional jobs 2 to 1, 1 to . It's very hard to lose money on a heat pump job."

The operational advantages go beyond margins:

Simplified Inventory: Fewer parts and pieces mean less working capital tied up in stock and fewer logistical headaches.

Easier Training: Teaching technicians to install heat pumps is more straightforward than training them on the dozens of different heating and cooling systems they might encounter in traditional HVAC work.

Higher Average Tickets: Heat pump jobs typically fall into three categories — problem rooms, whole home solutions, and dual fuel systems — all of which command premium pricing.

Better Problem-Solving Positioning: Unlike replacement jobs where you're simply swapping like-for-like equipment, heat pumps let you solve actual comfort problems in homes, creating opportunities for consultative selling and higher margins.

Premium Product Positioning: "It's very easy to sell best with heat pumps because you're already at the highest tier anyway," Mike notes. When you're already selling premium technology, customers expect to pay premium prices.

The business model advantages compound over time. While traditional HVAC contractors often find themselves competing primarily on price, heat pump specialists can differentiate based on expertise, solution design, and long-term value.

The Four Essential Business Systems Every Heat Pump Contractor Needs

After interviewing dozens of successful contractors over the past year and personally coaching hundreds more, Mike identified four core systems that separate thriving heat pump businesses from struggling ones.

System #1: Marketing That Actually Works

"Contracting businesses are like a watch — for a watch to tell time, all the gears need to spin," Mike explains. Marketing is the first gear, but it has to be the right kind of marketing.

Mike built his business around "problem-solution" video marketing. The approach was simple: document real problems in real homes and show how heat pumps solved them. The videos weren't sales pitches — they were educational content that demonstrated expertise and built trust.

The power of this approach became clear years later when Mike ran into a golf course employee who had used Mike's YouTube videos to learn how to operate a Mitsubishi remote control. "That video had about a million hits," Mike recalls. "That's the power of video and marketing."

Today's contractors have even more powerful tools available. Video marketing has become more accessible, and new technologies can help contractors understand what messaging resonates with different types of buyers.

System #2: Speed-to-Lead That Captures Customers

"The speed to lead has to be two minutes in today's world. It's 50 times more likely you'll capture that customer if you respond within two minutes."

This is where many contractors fail despite having good marketing. They spend money driving traffic to their website, generating leads, and creating chat opportunities — then lose prospects because no one responds quickly enough.

Mike's rule is absolute: if you're going to invest in marketing, you better have the customer service infrastructure to capture the leads it generates. That means live people answering phones on weekends, immediate response to online inquiries, and systems that notify multiple team members when leads come in.

"HVAC is 24/7, 365," Mike emphasizes. "Don't do marketing if you have horrible speed-to-lead customer service."

System #3: A Defined Sales Process

Too many contractors hire salespeople and "just let them go out and sell." The million-dollar salespeople Mike sees struggling? "Most times your million-dollar guy has no sales process."

Heat pump sales are fundamentally different from replacement sales. With a furnace replacement, the equipment is broken and needs to be fixed — any technician can handle that conversation. Heat pumps require consultative selling: understanding the customer's goals, evaluating the home's characteristics, explaining different solution options, and designing integrated systems.

Mike's sales process includes a comprehensive "Home Comfort Survey" that takes 30-45 minutes. The goal isn't just to gather technical information — it's to understand what the customer is really trying to accomplish.

"Why am I here today? What type of system are you working with? What are we trying to accomplish?" These aren't casual questions. The answers determine whether you're selling a single-zone system or a $30,000+ whole-home solution.

System #4: Price Books, In-Home Quoting Tools and Margin Management

The final system is about turning expertise into profit. Mike sees contractors who can quote furnace replacements on the spot but struggle to price heat pump systems because the variables are more complex.

"You have to define your price book and your in-home quoting tool. What is that going to be? Whose software are you going to use? How are you going to put it together?"

This is where many contractors fail as they grow. They price based on their overhead when they had 5 employees, but they haven't adjusted as they've grown to 15 or 25 people. The new overhead structure requires different margins, but they're still pricing jobs the old way.

"I see so many guys that don't know the difference between margin and markup," Mike observes. "They don't know what the difference is between the two."

The result? Business owners working 60-70 hours per week, managing 20+ employees, and not paying themselves because the margins don't support the actual cost structure of their business.

Competing Against Low-Price Contractors

With heat pumps becoming more mainstream, competition has intensified. Solar contractors, electricians, and insulation companies are all entering the market, often with lower prices than established HVAC firms.

Mike's response? "Knowledge is power."

The low-price contractors typically fall into one of two categories: new entrants with low overhead (the "low barrier to entry guys") or established companies using heat pumps as a loss leader to support other profitable divisions.

Neither can compete with contractors who truly understand heat pump system design and customer education.

"The cheapest guy, I guarantee you, doesn't have a finance company. Can't finance the job. He might not even be able to get you the rebates either," Mike points out. More importantly, "I'll guarantee you that cheapest guy spent a half hour in the house, if that."

Mike's approach to premium pricing centers on demonstrating expertise through tools and process:

Ask Better Questions: A comprehensive discovery process reveals opportunities for higher-value solutions. "If you want to get the right price, you better ask the right questions."

Educate, Don't Just Quote: "If you want to get the highest price, you better be the most educated guy. You've got to know everything inside out and three times around."

Use Technology to Show Competence: LiDAR scanning, load calculations, and augmented reality system design demonstrate sophistication that builds confidence in your pricing.

Show, Don't Tell: Instead of explaining how a system will work, use visual tools to show customers exactly what they're getting. "You can't just tell them how things are going to get done. You've got to show them how things are going to get done."

The contractors who master this approach find that price becomes less of an issue. "The customer is going to look at you and say, 'We're going with you because you're the most educated. You knew more than this guy knew and we're willing to pay more for it.'"

The Technology Edge: New Tools for Better Sales

Mike is particularly excited about new technologies that can improve the sales process. He mentions LiDAR and Augmented Reality driven tools like Amply and AI-powered conversation analysis tools that help salespeople understand what they did well or poorly during customer interactions.

"I just want to know what type of buyer am I working with? What did I do wrong in the house? What can I do better in the house?" These tools can provide insights that help salespeople improve their approach and better serve customers.

The key is using technology to enhance the customer experience, not to replace human expertise. Load calculation software and augmented reality system design tools all serve the same purpose: demonstrating knowledge and helping customers visualize solutions.

Building Recurring Revenue Through Maintenance

One of Mike's biggest regrets was not focusing more on maintenance agreements during his ownership. "It was probably one of the biggest neglects that I had in my business at the time."

The business case for maintenance agreements is compelling:

  • They create recurring revenue that potential buyers value
  • They build customer loyalty and reduce churn
  • They generate opportunities for additional sales and referrals
  • They provide predictable cash flow for business planning

Mike recommends having dedicated inside sales people focused on selling maintenance agreements, and training customer service representatives to promote these programs during every customer interaction.

The retention value is significant: "A retained customer over ten years will bring you $50,000. That customer might not bring you the exact $50,000, but you know what they'll do? Refer you to other people and you're going to get a replacement system out of that at some point."

The Future of Heat Pump Contracting

Mike sees several trends shaping the industry:

Increased Competition: "There's a lot of guys that have seen that there's money to be made in it, and the ratios were very high."

Technology Integration: From load calculation software to AI-powered sales tools, technology is becoming essential for competitive differentiation.

Customer Education: As more contractors enter the market, customer education becomes increasingly important for premium positioning.

Changing Customer Behavior: "80% of your calls used to come in through the . That's changing. It's now 80/20, with 80% coming in through chat, website leads, e-commerce selling."

The contractors who adapt to these changes — by building deep heat pump-specific expertise, developing strong systems, leveraging technology, and maintaining high service standards — will capture the most valuable opportunities.

Key Takeaways for Building a Scalable Heat Pump Business

Mike's journey to $15+ million offers several critical lessons:

Understand Your Numbers: Revenue per employee, overhead costs, and margin management aren't just important for private equity — they're essential for running a profitable business at any size.

Build Systems Early: Marketing, speed-to-lead, sales process, and quoting systems become more important as you grow, not less important.

Focus on Heat Pumps: The operational and financial advantages of heat pump specialization compound over time.

Invest in Customer Education: Premium pricing requires demonstrating premium expertise.

Plan Your Exit Strategy: Whether you want to sell or not, building a business that could be sold creates options and usually means building a better business overall.

For contractors serious about building scalable, profitable heat pump businesses, Mike's experience provides a roadmap. The opportunity is significant, but it requires disciplined execution of the fundamentals: understanding your metrics, building proper systems, and consistently delivering value that customers are willing to pay for.

The heat pump market will continue growing, but not everyone will profit from that growth. The contractors who build real businesses — with real systems, real metrics, and real value — will be the ones who capture the opportunity.

Want to learn more about Mike's training programs? Visitdominateductless.com for upcoming courses and coaching opportunities.

Timestamps:

[00:00] - Why heat pump businesses are hard to lose money on

[04:15] - Mike’s journey: scaling and selling his HVAC business

[11:49] - Key KPIs Private Equity investors care about.

choig are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

[17:18] - Revenue per employee and sales performance metrics

[20:24] - Importance of maintenance agreements

[23:25] - Heat pumps vs. traditional HVAC from a business lens

[28:00] - Four core systems every contractor must build

[32:47] - Why fast response time (speed-to-lead) matters

[38:54] - How to compete against low-price contractors

[42:53] - Educated selling: show, don’t tell

[49:22] - Final thoughts: don’t give away value


Connect with Mike Cappuccio: 

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