Manual of Modern Hydronics: - Residential - Industrial - Commercial - Snow and Ice Melt
Manual of Modern Hydronics: - Residential - Industrial - Commercial - Snow and Ice Melt
Manual of Modern Hydronics: - Residential - Industrial - Commercial - Snow and Ice Melt
Modern
Hydronics
SECOND EDITION
Residential
Industrial
Commercial
S n ow a n d I c e M e l t
Professional Radiant Heating Solutions
TABLE OF C ONTENTS
Section 1:
Section 2:
Section 3:
Section 4:
Section 5:
Section 6:
Section 7:
Section 8:
Section 9:
Section 10:
Section 11:
Section 12:
Appendix
SECTION
1
C ONSIDER T HE P OSSIBILITIES !
Question:
What kinds of heating loads can be handled using modern hydronics technology?
Answer:
Almost any load you can think of!
For years the concept of hydronic heating evoked thoughts of cast-iron radiators or fin-tube baseboards in homes
and commercial buildingsand not much else.
Early hydronic systems were usually classified as being residential or commercial in nature. Residential
systems were the domain of plumbing / heating contractors. Rule of thumb design was usually good enough given
the limited variety of systems installed. The piping and control methods used in these systems remained essentially unchanged between the 1950s and the 1980s in North America.
Commercial hydronic systems were a world apart from their residential counterparts. Techniques such as primary
/ secondary piping, multiple water temperature distribution systems, and outdoor reset control were successfully
deployed in commercial systems, but almost never considered for residential applications.
SECTION 1
Figure 1-2
the WarmRite control panel to the water heater,
connect the floor circuits, and then route power to it.
Although this system is very simple in concept and
construction its also capable of delivering comfort far
superior to its alternatives, several of which may cost
more to install as well as to operate.
Figure 1-1
Figure 1-3
Another part of the building may be heated with fintube baseboard that needs 180 deg. F. water at the
same time. Providing these multiple water temperatures is relatively straightforward using the
piping/control scheme depicted in figure 1-4.
Notice that the manifold supplying the baseboard
circuits is piped directly into the primary loop and thus
receives hot (180 deg. F.) water. The floor heating
circuits are supplied with reduced water temperature
through use of an injection mixing system and the
WarmRite control panel. Note that all components
related to run the floor heating circuits are integrated
into one preassembled WarmRite control panel. The
boiler also supplies hot (180 deg. F.) water to the heat
exchanger of the indirect water heater for fast recovery.
This system now serves three different heating loads
using two water temperatures. But thats far from
pushing the limits of modern hydronics technology.
A Sophisticated System
Suppose that after discussing the above system, your
customer asks if you can also provide snow melting,
occasional garage heating or pool heating. Maybe even
all three at the same time. This is an opportunity where
Figure 1-4
10
SECTION 1
Figure 1-5
11
SECTION
2
H EAT S OURCE O PTIONS
A wide variety of heat sources can be used with hydronic heating systems. They include gas- and oil-fired boilers,
hydronic heat pumps and domestic water heaters to name a few. Some are better suited to higher temperature
systems, while others are ideal for low temperature systems.
This section briefly describes the characteristics of several heat sources suitable for hydronic systems. More
detailed information pertaining to their selection and installation is best found in manufacturers literature and
manuals. Relevant building / mechanical codes should also be consulted for specific installation requirement.
The information at the end of this section allows designers to compare the cost of energy provided by several
common fuels based on their local cost and the efficiency at which they are converted to heat.
13
Figure 2-1
Figure 2-2
14
SECTION 2
bution system. The tank is directly piped to the distribution system as shown in figure 2-3. The tanks
thermostat is set for the desired supply water temperature.
In some systems a water heater is expected to supply
both domestic hot water and space heating. Although
possible under some circumstances, the designer must
ensure that the heating capacity of the water heater
can handle both the space heating and domestic water
heating loads. If these loads occur simultaneously, it is
usually necessary to make the domestic water heating
load a priority over the space heating load. Temperature
controls can be used to temporarily suspend heat
output to the space heating system until the domestic
water heating load subsides and the tank temperature
recovers.
Opinions vary on the suitability of circulating potable
water through the space heating circuits. Under some
circumstances, the potable water can remain stagnant
in the space heating circuits for several months
allowing for the possibility of microbe growth. Because
potable water is used in the space heating circuits, all
metal components must be bronze or stainless steel to
resist corrosion from the oxygen-rich water. There is
also the possibility of scale or sediment in the space
heating system due to contaminants in the potable
water.
Figure 2-3
Because tank-type water heaters are designed to
operate at lower water temperatures, mixing devices
are not usually used between the tank and the distri-
Figure 2-4
15
Figure 2-5
16
SECTION 2
Figure 2-6
17
Figure 2-7
18
SECTION 2
common basis.
Figure 2-8
19
SECTION
3
WATER T EMPERATURE C ONTROL
All hydronic heating systems must control the water temperature supplied to their heat emitters. A simple system
may only need to supply one water temperature to all the loads it serves. A more sophisticated system containing
several types of heat emitters may need to simultaneously supply two or more water temperatures.
This section discusses several methods of water temperature control and the hardware necessary to accomplish it.
Figure 3-1
21
They are:
1. boiler reset control
2. mixing reset control
A boiler reset control takes over operation of the burner
from the standard (fixed) high limit control supplied
with most boilers. As the outside air temperature
changes, the reset control continually recalculates how
high the boiler water temperature will be allowed to
climb and operates the burner accordingly.
Boiler reset is well suited for systems using relatively
high temperature hydronic heat emitters, like
baseboard or panel radiators. However, because
conventional boilers should not operated for prolonged
periods at temperatures below the dew point of their
exhaust gases, boiler reset is limited when used in
conjunction with low temperature heat emitters. In
such cases, boiler water temperature can only
partially reset down to a user-selected minimum
temperature setting as shown in figure 3-2.
22
Figure 3-2
For the case shown, the boiler outlet temperature
would not be reduced below 140 deg. F. This water
temperature happens to correspond to an outside air
temperature of 25 deg. F. Air temperatures of 25 deg.
F. and higher represent a large percentage of the
heating season in many parts of North America. This
implies the 140 deg. F. water temperature supplied to
the heat emitters will be higher than necessary during
much of the heating season. The room thermostat must
turn the circulator (or zone valve) on and off to prevent
overheating under these conditions.
SECTION 3
Figure 3-3
Mixing reset control requires a mixing assembly
between the boiler loop and a separate distribution
circuit. This assembly could contain a modulating 2way, 3-way, or 4-way valve, or a variable speed injection
pump as depicted in figure 3-3. These options are
discussed in more detail later in this section.
Figure 3-4
23
Figure 3-5
24
SECTION 3
Figure 3-6
25
Figure 3-7
Figure 3-8
26
SECTION 3
Figure 3-9
27
Figure 3-10
Figure 3-11
28
SECTION 3
Figure 3-12
Hot water from the boiler loop is drawn into the supply
injection riser at point B. It passes through the
injection control valve and enters the side port of a tee
at point C where it mixes with cool return water from
the distribution system. The flow rate through the
injection risers depends on the stem position of the
injection control valve, as well as the flow restrictor
valves setting. The greater the injection flow rate, the
Figure 3-13
29
Figure 3-14
higher the water temperature supplied to the distribution system and the greater its heat output. In a
typical low temperature floor heating system supplied
by a conventional boiler, the flow rate through the
injection control valve is about 15 to 20% of the flow
rate in the distribution system. This allows a relatively
small modulating injection valve to regulate a large rate
of heat transfer.
When a motorized valve operated by an electronic
controller is used, boiler protection is accomplished by
monitoring the boiler inlet temperature and partially
closing the injection valve when necessary to prevent
the distribution system from absorbing heat faster than
the boiler can produce it.
Unlike a motorized valve with a smart controller, a
single thermostatic 2-way modulating valve cannot
control both the supply temperature to the distribution
system and the inlet temperature to the boiler. To
protect the boiler, it is necessary to use another mixing
device that can monitor and adjust the boiler inlet
temperature when necessary. Figure 3-14 shows the
use of a 3 way thermostatic valve for this purpose.
When using a 2-way valve for injection mixing, be sure
the tees at points A and B in figure 3-13 are as close
as possible. Also be sure theres a vertical drop of at
least 18 inches between where the return injection
riser connects to the boiler loop and where it connects
to the distribution system. This drop forms a thermal
trap to reduce heat migration into the distribution
system when no heat input is needed.
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Formula 3-1
fi =
Q
500 x (T1 _T2)
Where:
fi = required design injection flow rate at design
load (in gpm)
Q = Heat input to distribution at design load
conditions (in Btu/hr)
T1 = water temperature being injected
(in deg. F.)
T2 = water temperature returning form
distribution system (in deg. F.)
500 = a constant for water
(use 479 for 30% glycol, 450 for 50% glycol)
Select an injection control valve with a Cv factor
approximately equal to the injection flow rate just
calculated.
SECTION 3
Figure 3-15
31
SECTION
4
R ADIANT F LOOR H EATING M ETHODS
The availability of modern materials such as Kitec pipe has allowed the market for hydronic radiant floor heating
to increase approximately ten fold over the last decade. Installation methods have been developed for many
types of floor constructions in residential, commercial and industrial buildings. Each year these installation
techniques allow thousands of buildings to be equipped with what many consider to be the ultimate comfort
heating system.
33
34
SECTION 4
finished flooring
adhesive
concrete slab
pipe
wire mesh
insulation
vapor barrier
foundation
compacted fill
35
finished flooring
adhesive
pipe
wire mesh
"chair"
concrete slab
vapor barrier
foundation
compacted fill
Installation Procedure:
Figure 4-1 shows a cut-away view of a modern heated
slab-on-grade floor.
Figure 4-1
36
SECTION 4
Figure 4-2
37
38
SECTION 4
Figure 4-3
finished flooring
adhesive
gypsum slab
pipe
sealant
subfloor
floor
joist
39
Figure 4-3A
finished flooring
adhesive
concrete slab
pipe
polyethylene sheet
subfloor
floor
joist
underside insulation
40
SECTION 4
Figure 4-4
Poured gypsum slabs are water-resistant not waterproof. The slab will eventually soften if exposed to
water for prolonged periods. They should not be
installed under conditions where rain or other sources
of moisture can accumulate. They should also not be
installed in areas that are likely to experience flooding.
Concrete Thin-Slab Systems
A specially formulated concrete mix can also be used
to create a heated thin-slab floor. The mix proportions
are given in figure 4-4
The installation of a concrete thin-slab differs considerably from that of a poured gypsum slab. Concrete is
not self-leveling. It must be screeded flat when placed.
To simplify screeding, the concrete thin-slab is best
poured before walls are constructed.
41
Figure 4-4a
finished flooring
adhesive
concrete slab
pipe
insulation
existing concrete
42
SECTION 4
pipe
finished flooring
spacer (sleeper)
subfloor
43
Here the tubing and plates are located on the top side
of the floor deck. The tubing can be run in virtually any
direction. The system can be adapted to several types
of finish flooring, and is particularly well suited for
nailed down wood floor installations.
Figure 4-6
finished flooring
spacer
(sleeper)
pipe
subfloor
floor
joist
underside insulation
44
SECTION 4
Installation Procedure:
Begin by fastening 5/8 - 3/4 plywood or oriented
strand board (OSB) sleepers to the floor. The
sleepers are placed to create 3/4 wide grooves into
which the tubing and trough portion of the plates are
recessed. To minimize any squeaks, the sleepers
finished flooring
spacer
(sleeper)
pipe
subfloor
floor
joist
underside insulation
45
curved areas.
The plates are set into the grooves with ends spaced
about 1 apart. Pull each plate against one edge of the
sleeper and tack it in place with two or three light
gauge staples on the same side (and only on this side).
This allows the plate to expand as the tubing is pushed
into it as well as when the plate heats and cools.
46
SECTION 4
Figure 4-7
floor
joist
underside insulation
47
THREADING pipe
IN
Preparation:
Make a sketch of the floor surface and joists through which piping will be threaded and installed. Identify the
manifold location and route to the manifold for each pipe loop.
Measure the length of the floor joist and multiply the joist length by two. This defines the footage of pipe per
joist cavity when floor joists are installed on 10" through 18" centers. When floor joists are on 10" through 18"
centers, two runs of pipe are installed in each joist space. Three runs of pipe are installed in a joist space
when joists are spaced greater than 18" apart.
Calculate the number of joist spaces you can cover with the pipe coil length you are using. For example, if the
joist is installed on 18" centers and it is 20 feet long, multiply 20 x 2 to get 40 feet of pipe per cavity.
Assuming a 300 foot coil length, 7 joists cavities could be covered. BUT, remember that you need to allow for
the length of pipe running from the manifold and back again. In this example and depending on the manifold
location perhaps only 6 cavities can be filled.
Pre-drill holes in the floor joists through which pipes will run. Two 1/2" pipes require a 1-1/2" diameter hole,
while four 1/2" pipes require a 2" diameter hole. Holes should always be straight and aligned. Holes must be
drilled in the center of the floor joist and at least one foot away from the end of the joist support point.
Figure 4-8
48
SECTION 4
49
The slack in the last bay has disappeared and the pipe is now attached
to the subfloor. Move back to the first
bay and pull more pipe from the
uncoiler until a large amount of slack
exists. Transfer this slack through
adjacent bays until it arrives in the
second to last bay. Lift the slack up
and fasten the pipe in this joist space
as before. Continue this process until
all joist spaces are complete.
This process involves a good deal of pipe threading, but it eliminates pipe kinks and reduces stress on the
pipe. Two people can work very effectively together with this installation method - one feeding pipe while the
other fastens pipe in the joist space.
50
SECTION 4
For joists installed on greater than 18" centers, three runs of pipe are required in each joist space. The pipe
handling and installation technique is similar in concept to that described in steps 1 through 8. Create pipe
slack and transfer the slack to adjacent bays as before. Note in the following sketch however, that pipe enters
the bay at one end of the joist and exists at the opposite end in order to accommodate three runs of pipe.
51
Figure 4-9
52
SECTION 4
finished flooring
subfloor
pipe
reflective layer
floor
joist
underside insulation
finished flooring
subfloor
pipe in pipe hanger
pipe hanger
reflective layer
min. 2" air gap
floor
joist
underside insulation
53
finished flooring
subfloor
pipe in pipe hanger
pipe hanger
reflective layer
floor
joist
underside insulation stapled
inside the joist cavity
finished flooring
subfloor
pipe in pipe hanger
pipe hanger
floor
joist
reflective layer
finished flooring
subfloor
1"- 2" distance from floor
reflective layer
pipe mounted with nail clip
floor
joist
underside insulation
54
SECTION 4
Comparison of floor surface temperatures with and without heat transfer plates for 1/2" tubing
8" o.c., operated at 100F and 140F water temperatures
Figure 4-10
55