HPAC Modern Hydronics Fall 2018

MODERN HYDRONICS 2018 FALL

ACHIEVE ENERGY SAVINGS WITH DYNAMIC SYSTEM CONTROL CONCEPT

REALISTIC EXPECTATIONS: HOW TO IMPROVE THE CONSUMER EXPERIENCE

HYDRONIC PRODUCT SHOWCASE BOILER CLEANUP TIPS SOLAR & RADIANT PAIR UP

a publication of

CONTENTS

Modern Hydronics

MH24

MH4

Pennies Per Day

Boiler Maintenance To-Do List

The diminutive cost of operating a well-designed hydronic distribution system. BY JOHN SIEGENTHALER

Fend off fuel waste with regular attention to waterside and fireside. BY TIM KANE

MH10

MH26

Spend the time upfront with customers to review system components and how they will work together.

The advent of condensing boilers, variable speed drives, and modern control platforms calls for a review and rethink of control concepts. BY DAVE CONNORS

How to Align Expectations With Reality

Change of Vision With Differential Temperature Control

BY MIKE MILLER

MH34

MH16

The State of Solar Heating

PRODUCT SHOWCASE

How effectively are contractors integrating solar into hydronic systems?

BY ROBERT WATERS

MODERN HYDRONICS

a supplement of Heating Plumbing Air Conditioning Magazine

111 Gordon Baker Road, Suite 400, Toronto, ON M2H 3R1 TEL: 416.442.5600 FAX: 416.510.5140 www.hpacmag.com EDITOR ASSISTANT EDITOR ASSOCIATE PUBLISHER ACCOUNT MANAGER ACCOUNT COORDINATOR ART DIRECTOR CIRCULATION MANAGER PUBLISHER VICE PRESIDENT PRESIDENT & CEO

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MODERN HYDRONICS

FALL 2018

MH3

EFFICIENCY

PENNIES PER DAY The diminutive cost of operating a well-designed hydronic distribution system.

BY JOHN SIEGENTHALER

M

any hydronic heating professionals like to promote that the modern boilers they install are capable of operating with thermal efficiencies in the range of 95 +/- per cent. Professionals who install geothermal heat pumps often boast that their equipment is capable of coefficients of performance (COPs) in the range of three to perhaps four. Both claims are possible given the right equipment, the right application, and the specific definition for thermal efficiency and COP used when evaluating the equipment.

However, if past practice is any indication, those same professionals may not bother to mention that a well designed and properly installed hydronic heating system has a distribution efficiency much higher than that of either a forced air system or a system that moves heat through a building using refrigerant.

ing load of 30,000 Btu/hr. The building will be heated using eight identical panel radiators measuring 24 in. high by 72 in. long by 4 in. thick. These relatively large panels were chosen so that the building’s design heating load could be met using a supply water temperature to the radiators of 120F, along with a 20F temperature drop. That temperature makes the system compatible with mod/con boilers, heat pumps, and solar thermal collectors.

The piping for the system is shown in Figure 1.

8, 24" x 72" x 4" panel radiators TRV

120 ft x 1/2" pex homerun circuits

distribution efficiency=

rate of heat delivery rate of energy use by distribution equipment

Distribution efficiency has nothing to do with converting any type of fuel into heat. Instead, it describes how many Btu/hr of heat the distribution system can move from the heat source to the heat emitters for each watt of electrical power supplied to operate that distribution system. The more heat the distribution system can deliver, per watt of electrical power input, the higher its distribution efficiency.

To show how wide the gap is between two contemporary systems I will compare a relatively simply hydronic heating distribution system, using currently available off-the-shelf hardware to a forced air system on a state-of-the-art geothermal heat pump.

The hydronic system assumes a building with a design heatMH4

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heat source

For the system to be considered best in class it needs a high efficiency heat source, as well as the ability to move heat (or cooling effect) through a building using minimal amounts of electrical energy. The latter criteria can be quantified using an index called distribution efficiency. That index is defined by Formula 1:

manifold station

pressure regulated variable speed circulator

BEYOND THE HEAT SOURCE

buffer tank

Figure 1

The system is equipped with wireless thermostatic radiator valves, allowing each panel radiator to function as an independent zone. This allows each room to individually respond to internal heat gains, temperature setbacks, and personal comfort preferences.

MODERN HYDRONICS

Continued on MH6 WWW.HPACMAG.COM

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EFFICIENCY Each radiator is connected to a manifold station by 120 feet of ½ in. PEX tubing (60 feet on supply plus 60 feet on return). The result is a simple homerun distribution system. A buffer tank is shown between the heat source and distribution system. Its purpose is to prevent heat source short cycling given the relatively low design load combined with a highly zoned distribution system.

From the standpoint of distribution efficiency the heat source that warms the buffer tank is irrelevant. It’s the hydraulics of the distribution system and those of the variable speed pressure-regulated circulator that count.

The total system flow rate required to deliver 30,000 Btu/hr with a 20F temperature drop is only three gallons per minute. This divides up equally among the panels so each circuit only requires 0.38 gpm.

The combined head load of the 120 feet of PEX tubing and the panel radiator at this small flow Figure 2 rate is only about 4.2 feet of head. I added 10 per cent to this to allow for some head loss in the short 1-in. piping connecting the manifold station to the buffer tank.

The circulator duty point in this system is therefore three gpm at 4.6 feet of head.

LOW POWER The flow / head requirement can be used to estimate the electrical power input to a circulator. To be conservative, I assumed an ECM circulator with a wire-to-water efficiency of 30 per cent at the calculated duty point.

The estimated electrical input to the circulator can be calculated using Formula 2:

we =

0.4344 f ncirculator

P

=

0.4344 3.0 4.6 ( 0.43) = 8.6watt 0.3

If a circulator operated continuously at this power input, and at a location where electricity costs 20 cents per kWh, the total daily operating cost would be a paltry 4.1 cents. If the circulator operated continuously throughout a heat season lasting 3500 hours, the total cost would be about six dollars.

I suspect that most people could work that into their budget.

A few years ago, you would not be able to find a circulator that could operate at such low power. Today there are several circulators on the North American market that can operate in the nominal eight to 10 watt input power range. The European market has even more selections available in this range. One MH6

FALL 2018

such circulator, with a listed input power range of three to 40 watts is shown in Figure 2.

The distribution efficiency of the example hydronic distribution system can be calculated using Formula 1:

distribution efficiency =

Btu hr = 3581 Btu / hr 8.6watt watt

30,800

So how does a distribution efficiency of 3,581 Btu/hr/watt rank relative to that of other systems?

To put this number in perspective, let’s compare it to the distribution efficiency of a modern geothermal water-to-air heat pump with a variable speed ECM blower motor.

One manufacturer lists the wattage of an ECM blower on a nominal four-ton (48,000 Btu/hr) rated water to air heat pump, at full speed, as 746 watts. Assuming that the heat pump delivers 48,000 Btu/hr using 746 watts input to the blower, its distribution efficiency would be:

Btu hr = 64.3 Btu / hr distribution efficiency = 746watts watt 48,000

The two calculated distribution efficiencies can be compared by forming their ratio: 3581/64.3= 55.7. This means that the hydronic system is delivering almost 56 times as

MODERN HYDRONICS

Continued on MH8 WWW.HPACMAG.COM

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EFFICIENCY much heat to the distribution system, per watt of electrical input energy, compared to the heat pump using forced air distribution.

The reciprocal of that ratio, 64.3/3581 = 0.018, or 1.8 per cent, implies that the hydronic system delivers heat to the building using only about 1.8 per cent of the electrical input power required by the forced air system.

Either way you look at it, the hydronic system in this comparison is far more efficient when it comes to delivering heat.

Unfortunately, this profound performance difference goes largely ignored by heating professionals, utilities, energy auditors, and government agencies, all of which tend to focus on high thermal efficiency (that is high AFUE, or high COP) of the heat source.

THIS NEEDS TO CHANGE The concept of high distribution efficiency should be a starting point (rather than an oft-forgotten afterthought) when discussing the advantages of modern hydronic systems. Our industry needs to get this message to trade allies such as architects and engineers involved with low energy or net-zero

buildings, energy auditors, professionals involved in thermally-based renewable energy heat sources, and regulators who determine which HVAC technologies are incentivized through government programs. The superior distribution efficiency of hydronic systems could (and should) play an important role in helping provinces achieve their carbon reduction goals.

At a time when energy efficiency enjoys support from a wide spectrum of society, the hydronics industry should not be leaving its best cards on the table. There are lots of decision makers with eager minds who have never heard about distribution efficiency. Some of them would embrace the concept based on real comparisons. It is time we tell them what is possible.

John Siegenthaler, P.E., is a mechanical engineering graduate of Rensselaer Polytechnic Institute and a licensed professional engineer.

He has over 34 years experience in designing hydronic heating systems. Siegenthaler’s latest book is Heating with Renewable Energy (for more information see www.hydronicpros.com).

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MODERN HYDRONICS

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SYSTEM PERFORMANCE

HOW TO ALIGN EXPECTATIONS WITH REALITY Spend the time upfront with customers to review system components and how they will work together.

By Mike Miller

I

t is not uncommon for contractors, and sometimes consumers, to call me to complain about the performance of a hydronic system. Many of these times, if it is not system settings related, it is because the consumer is expecting different behaviour from the system.

Before dealing with the expectations

issue, I believe that once a control system is properly setup and commissioned, all the kinks should have been worked out and controls should be set to run the HVAC system as required.

Fine tuning of some settings may need to be made, but overall, the system should be set and run its course.

That aside, I believe that in most

cases consumer dissatisfaction is due to unrealized and unreasonable expectations. As trade professionals we often forget that the vast majority of consumers have very little, if any, knowledge of our trade and its associated technologies, and how they should be running together to achieve the premier comfort.

Can we really blame them? Surely, if the

Figure 1 Loop layout for a smaller building

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MODERN HYDRONICS

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Figure 2 Radiant zoning

consumer is not in our field of work, there are more exciting things to pay attention to, at least in their mind. It is ok to be shocked by this revelation, as I was the first time someone made me aware of this.

We can help ourselves by spending the time upfront with customers to go over the various pieces and how they will work together, so that the expectations are closer to the reality the consumers will find themselves living with down the road.

The more common complaints consumers have are, more often than not, about comfort and speed of performance.

COMFORT CONTROL IN RADIANT SYSTEMS The lengthy response time when dealing with hydronic radiant floor heating systems is a case in point, especially if it is the consumer’s first radiant floor heating system. You will need to explain that the temperature of the fluid supplied hydronically is much lower than that of air based systems. The mass of the slab is what needs to respond to fluid temperaMH12

FALL 2018

ture changes and this does take time, particularly when air temperature setback is used during periods of absence.

It is very important to highlight the recovery limitations of the radiant floor heating systems. It is best to recommend a 2F to 3F setback maximum atnight or during the day when everyone is out of the house. Use thermostats or control systems with the ability to learn the rate of setback recovery and to start early in order to be recovered at a desired time to reduce the dissatisfaction due to room comfort at time of recovery.

For prolonged periods of absence, a holiday for example, when consumers tend to crank down the thermostat I would promote limiting the degree of setback to something that allows recovery within four hours.

Some of the more sophisticated control systems available today have a learning algorithm that would be compromised by many rapid and bigger changes to the system. Consumers with hydronic systems need to understand that the temperature setpoints should be changed only when necessary and then only in smaller increments.

MODERN HYDRONICS

Snowmelt systems are another pretty common call where the main complaints are operating costs and the length of time it takes to clear the surface. When digging into higher operating costs, I often find that slab melt temperature setpoints are too high. The consumer needs to understand that the greater the surface temperature is set to, the greater the energy consumption. I typically recommend keeping a snowmelt surface temperature just above freezing (36F is a setpoint I normally run with).

This takes us to the second complaint, which is the amount of time it takes for the snow to melt. With lower melt setpoints, it will take longer to melt the slab. The question the consumer needs to ask is what does he/she have more of? Is it money, or is it patience?

The differences between time versus costs need to be explained at the outset.

Idling is another discussion you would want to have with the consumer. If you are idling a slab, it will reduce the melting time once the snow does land, but it will also cost a lot more to idle a slab while waiting for snow accumulation that may or may not come anytime soon.

I personally do not recommend idling of snowmelt slabs to consumers for residential applications. It makes more sense in commercial applications when the speedy removal of snow is more important than the cost to get it done.

If idling of a snowmelt slab is what the consumer wants, the same principle mentioned above applies. The lower the idling setpoint, the more cost effective it will end up being. I often recommend something in the neighbourhood of 29F for an idling setpoint.

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SYSTEM PERFORMANCE them, with the common complaint being overheating and/or underheating. As soon as you use slab sensors and you set either, or both, slab minimum and maximum limits, it will compromise air setpoint as soon as one of them is reached. For example, if you have a slab minimum limit that is greater than air temperature setpoint, the air temperature may be overshot as the minimum slab setpoint takes precedent over air setpoint.

The same is true for slab maximum limit. This is the greatest temperature a slab can rise to in order to satisfy air setpoint, but it cannot go beyond. Calls regarding performance and the resulting dissatisfaction will be greatly reduced if the consumer clearly understands the purpose and functionality of slab sensors and their associated limits.

MORE ADVANCED SYSTEMS Whatever approach the HVAC designer/ installer takes to a hydronic system consisting of multiple radiant zones serviced by one air zone, thorough training of the consumer is imperative. The end result will be a happier customer and fewer service calls if you spend enough time here.

Figure 1 shows an example of a loop layout for a smaller building. Figure 2 shows the radiant zoning within the same building and Figure 3 shows the air zoning. My recommendation would be to work with a control system capable of integrating radiant and air zones together.

The system would utilize a thermostat in each of the radiant zones with one of the being a “master” that would control radiant and the air zone. They communicate with each other to best harmonize the needs of the radiant system with the air system. Systems such as this allow the radiant to operate independently across all stats, but when it comes to the control of the air zone, the master would take over and control it.

In many of these systems, the conMH14

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Figure 3 Air zoning

sumer is often confused about how the radiant thermostats interact with the thermostat controlling the air zone. An air zone thermostat’s operation could be suspended for cooling if a radiant thermostats needs heat at the same time. Understanding the limitations and strengths of this kind of system will take time, but it is invaluable.

INTERNET OF THINGS (IOT) As more options are available and will be available moving forward, it is even more important to explain to your consumer when and how they should be using the remote connectivity feature of the new devices entering our businesses. Only because we ‘could’ change things remotely, does not mean we ‘should.’ There are times when it makes sense to make changes to comfort settings, but those are usually limited to returns from holidays/longer periods of absence, or, to start certain devices in the building prior to needed use, such as pools and hot tubs.

Suggest to the consumer that the remote connectivity should be mainly used for monitoring of the systems. If at MODERN HYDRONICS

all possible, I would even recommend limiting the adjustment capabilities to the consumer as much as possible. Give them what they need, but whenever possible make sure you eliminate system critical settings that could compromise the system’s functionality. Also, make sure that you understand for yourself and then clearly explain to the consumer, the IT related requirements to have these systems remotely accessible. Many of those needs do not fall into our typical day-to-day expertise either.

As is the case with many things, there are many opportunities to save our future workload by putting in the necessary time at the beginning to educate the consumer. This will only help you by leaving you with less support needs and customers who will recommend your services to others.

Mike Miller is director of sales, commercial building services, Canada with Taco Inc. and a past chair of the Canadian Hydronics Council (CHC). He can be reached at hydronicsmike@tacocomfort.com.

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PRODUCT SHOWCASE The Peerless brand series PBC gasRiello introduces the new 95 per

fired, combination boiler is a 95 per

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cial wall hung boiler. Featuring a

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er utilizes 2 in. or 3 in. piping in a vari-

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ety of materials including PVC, CPVC,

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tures include an isothermic and stainless steel heat exchanger, an easy-tofollow control menu for set-up and service and 10:1 turndown.

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from ½ in. to 24 in. The SDR 9

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model offers a lower wall thickness and weight per foot, 15 per cent higher flow capacity and 20-100 per cent higher pressure-capacity compared to the company’s other SDRs. www.aquatherm.com From Belimo Americas, NPT pressure compensated globe valves for water and steam applications range from ½ in. to 2 in. The two-way (G2) and threeway (G3) globe valves offer ANSI Class VI leakage rating and 100:1 rangeability to provide close-off up to 250-psi

Slant/Fin’s Revital/Line pre-cut covers are designed to replace covers on

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powder-coated for a durable, enamel-like finish. www.slantfin.ca

MH20

FALL 2018

MODERN HYDRONICS

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PRODUCT SHOWCASE REHAU Insulpex preinsulated PEXa piping is designed for the efficient transfer of hot or chilled fluid within a building or in buried applications between buildings with minimal energy lost in transit. Using hydronics for the transfer of energy between buildings on a college campus, between indoor climate control and outdoor geo-exchange, snow melting or turf conditioning systems gives facility managers greater flexibility to meet changing requirements while optimizing overall consumption. The piping consists of flexible REHAU PEXa pipe surrounded by a solid layer of BFIT series boilers from Bryan Boilers provide access to the heat ex-

CFC-free polyurethane foam insulation. The pipe’s flexibility allows it to

changer and burner for cleaning and maintenance. The boilers feature

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Complete solutions for energy production, storage, and distribution

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HEY WETHEADS! DO NOT MISS THE OCTOBER ISSUE OF HPAC In addition to all the latest hydronic products our gurus will be stimulating your thoughts on topics including balancing valves and buffer tanks, and more!

John Siegenthaler

www.Roth-America.com Call 800-969-7684 MH22

FALL 2018

HPAC_Aug_Roth.indd 1

Robert Bean

Mike Miller

Make sure to mark your calendar for Modern Hydronics Summit 2019 in Mississauga, ON. Check www.modernhydronics summit.com for updates and registration details starting in January!

MODERN HYDRONICS HPAC_Filler_Aug18_EJS.indd 1 2018-07-17 3:06 PM

WWW.HPACMAG.COM

2018-08-15 9:19 9:51 AM

BOILERS

MAINTENANCE TO-DO LIST Fend off fuel waste with regular attention to waterside and fireside.

BY TIM KANE Energy Loss Due to Scale Deposits*

Fuel Loss, % of Total Use Scale Thickness, inches

Scale Type “Normal”

High Iron

Iron Plus Silica

1/64

1.0

1.6

3.5

1/32

2.0

3.1

7.0

3/64

3.0

4.7

–

1/16

3.9

6.2

–

Note 1: “Normal” scale is usually encountered in low-pressure applications. The high iron and iron plus silica scale composition results from high-pressure service conditions.

Note 2: These energy losses are for firetube boilers that are not equipped with stack gas heat recovery equipment such as feedwater economizers or combustion air preheaters. *Extracted from National Institute of Standards and Technology, Handbook 115, Supplement 1.

chanical cleaning typically utilizes moving brushes to remove scale from the walls of tubes and pipes, the chemical process uses a chemical solution to flow through the tubes dissolving and flushing out the scale.

TIPS FOR A HEALTHY BOILER • Stick to an Inspection and Maintenance Schedule – At least once a year qualified on-site personnel or a third party should inspect and clean all parts of the boiler. Contractors may create a maintenance plan to be done internally or do the work themselves. It is important to have a solid schedule in place to keep clients on track.

•R eview the Chemical and/or Mechanical Cleaning Solutions – You will notice a significant reduction in operating costs by removing the contaminants on both the waterside (scale formation) and the fireside (soot and scale formation) of boilers. While meMH24

FALL 2018

Condensing boiler heat exchanger cutaway.

MODERN HYDRONICS

• Maintain Daily Logs – Most problems develop slowly, therefore a log is the best way to detect significant changes.

Have the facility manager keep daily logs on the following: type and amount of fuel used; flue gas temperature; makeup water volume; and steam pressure, temperature, and volume.

Ongoing logs will help monitor for any potential issues that might develop or identify problems that could be fixed with proper cleaning.

• Perform Visual Inspections – Look at the boiler tubes and conducting a visual inspection to check for scale accumulation on a more frequent basis to help ensure the boiler tubes are free of scale and buildup.

Tim Kane is president of Goodway Technologies. Editors note: For more information on the effects of scale and corrosion see Modern Hydronics Part I and II 2017 at www.hpacmag.com.

WWW.HPACMAG.COM

U.S. DEPARTMENT OF ENERGY, STEAM TIP SHEET #7

O

ne of the biggest thieves of efficiency in boiler operations is the accumulation of soot and/or scale on heat exchanger surfaces. It does not take long for soot to start causing significant loss of energy efficiency.

In a matter of just a couple of weeks, there could be a potential of 1/8 in. of soot on equipment stemming from regular usage, which means lost efficiency and overspending in utility costs.

Scale can also accumulate quickly and add unnecessary operational expenses.

According to the U.S. Department of Energy, fuel consumption could increase as much as five per cent in firetube boilers as a result of scale.

Routine maintenance and cleaning is the most beneficial way to keep boilers healthy and running efficiently. Performing this maintenance at least once a year is an investment that will pay off.

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SYSTEM CONTROL

CHANGE OF VISION WITH DIFFERENTIAL TEMPERATURE CONTROL The advent of condensing boilers, variable speed drives, and modern control platforms calls for a review and rethink of control concepts.

BY DAVE CONNORS

O

ver time the hydronic industry has changed the approach to system piping designs and temperature control as equipment efficiency and technology has evolved. In the late 1960s and early 1970s out-door air reset was utilized. This allowed for better temperature control in the occupied space at a significant reduction in energy cost with reduced water temperature.

Reducing water temperature as the outdoor air temperature increased caused the control valves operating the space temperature to stay open longer.

This also proved that the terminal units were still sized large enough to satisfy the conditions at lower water temperatures. The unfortunate reality was the standard boiler design only allowed minimum return water temperatures of 140F to prevent them from condensing the flue gases.

Most boiler designs utilized steel and cast iron as the choice in heat transfer media until copper was introduced and perfected in the early 1980s. The modular copper boiler design resolved the thermal shock issues, but 140F was still the lowest acceptable return water temperature.

With the introduction of modulating firing rate and as water mass boilers were being replaced with the new evolution in the modular boiler design, the floodgates opened to new technologies and opportunities.

MH26

FALL 2018

ENERGY CONSERVATION WITHIN REACH As new control technology became very affordable with the introduction of electronics in the late 1990s, the entire industry changed once again and new standards were invoked in the hydronic industry that revolutionized energy conservation. Energy would now be considered a performance-based opportunity rather than just a cost of doing business.

With the ability to monitor the entire building from a central location and to optimize energy efficiency with very precise controllability, a new series of problems was created with the boiler technology and system designs of the past. The requirement to operate at return water temperatures well below the 140F as a norm presented real challenges to the boiler industry.

As energy costs continued to rise and buildings were being monitored by the controls industry, the boiler market was slow to adapt. In the past boilers were protected by three-way valves, as well as unique piping configurations and pumping techniques; all attempting to adapt the modular boilers to existing systems.

The past techniques would ultimately shorten the equipment life by short cycling or corrosion from low water temperatures, which became inherent to the misapplied designs and operating conditions.

The challenge to maintain reset temMODERN HYDRONICS

perature capability as well as protect the heating device from condensing would now be managed by utilizing boilers capable of lower return water temperatures.

FIXED TEMPERATURE SYSTEMS CHALLENGED In most systems designed over the past 50 years in the hydronic industry the temperature differential across the supply and return was approximately 20F with operating temperatures of 180F to 160F. This was the basis for all pipe sizing, pump selections, and terminal unit approach temperatures. It was a very safe design and a steadfast rule until the recent development in condensing boilers and central location control technology.

It is only recently that control valve positions and system flow rates have been easy to monitor and control. This monitoring presented a wealth of information, which surprised the industry and allowed many to capitalize on future designs. If we look at the actual system temperature differential of the standard 20F design; we can show that this differential temperature occurs less than 0.5 per cent of the total system operation time. Systems designed for the maximum heat loss and flow rates across the system are fixed. The 20F applies to design day conditions. The balance of the operating hours in each year run a system differential less than 20F.

Continued on MH28 WWW.HPACMAG.COM

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SYSTEM CONTROL

VFD TECHNOLOGY EMPLOYED System terminal units are traditionally underutilized and water circulation is typically more than the system requires during operations other than design day conditions. This was the beginning of industry standards that utilize VSD (Variable Speed Drive) or VFD (Variable Frequency Drive) for most circulation pumps in the hydronic systems.

THE PROBLEM WITH DELTA P CONTROL STRATEGY The system supply provides a desired water temperature at a specific flow to the system while the control valves react to the space conditions and open or close. Think about the control valves MH28

FALL 2018

and terminal units for a moment: A control valve is reacting to the space conditions. If the valve closes the space is satisfied. This would be an indication that the water temperature is too hot.

If the water temperature was too cold then the valve would stay open because there would not be enough heat to satisfy the space. The terminal units do not know nor do they care what the differential temperature is across the unit. It is the control valve that does all the work.

If the terminal unit has more flow than it needs during operation it passes through the additional flow and temperature to the return line.

As the control valves close the pressure differential across the system will inMODERN HYDRONICS

crease because the same volume of water is attempting to flow through less piping. By monitoring the pressure differential between the supply and return we can typically slow the pump down.

However, it is only a reference as to how many valves are open versus closed because the system can have the same differential pressure at full load (winter) when the pump is running at full speed as it could at partial load (spring/fall) when the pump is running at partial speed with valves closed and higher water temperatures throughout the system.

The differential pressure control has no way of knowing the supply temperature or the differential temperature

Continued on MH30 WWW.HPACMAG.COM

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SYSTEM CONTROL

across the system. There is no way to verify that the original 20F differential temperatures designed into the system would occur, other than during the design day conditions.

For example: as 50 per cent of the valves close the pressure differential would automatically slow down the pumps but the assumed 20F temperature difference across the system may not be present, unless it could be monitored.

THE ADVENT OF DELTA T CONTROL What is the significance of monitoring the temperature differential? We established that the water temperature causes the valves to close, why not lower the water temperature to control the space temperature and leave the valves open longer?

If the valves stay open and the water temperature passing through the terminal units has a chance to dissipate the heat completely rather than pass it on to the return line we could effectively conMH30

FALL 2018

trol the supply and return temperature across the system.

System designs based on outdoor air reset, coupled with temperature controlled variable flow rates to create condensing opportunities, causes the system to maintain a balanced differential temperature between the supply and return. The position of the control valves and the pressure differential in the system would lend itself to the direct correlation between the temperature across the supply and return.

Sending hotter water back to the heating device lowers the overall system efficiency. One must have the opportunity to use all the available heat in the terminal device and have the lowest possible return water temperature to take advantage of the high efficiency condensing capabilities in industry today.

The control valves would close or modulate as the space conditions allow, changing the temperature in the return, slowing the pumps to maintain a desired temperature differential. Nothing MODERN HYDRONICS

in the typical system design changes but the return temperature is monitored and flow is controlled based on temperature differential across the system rather than the temperature differential being a result of the slower pumping and higher temperatures.

The preferred method of temperature control is to tie together (parallel) the firing rate signal with the flow rate VFD signal based on a supply and return water temperature. A specified system differential temperature of approximately 30F when achievable is the preferred operation. The pressure differential control signal could be utilized as a minimum system setpoint, if desired, to protect low-end flow only.

ADDING OUTDOOR AIR RESET TO THE MIX As an added feature to the system operation, outdoor air reset temperature requires a specific setpoint. The boiler water setpoint differential can be shifted or lowered by +/- 5F, which will allow the system control valves to stay in the open position longer.

This will allow a lower boiler discharge (supply) water temperature and operate the boiler at the lowest potential temperature. The individual unit control valves will not have to close prematurely due to excess water temperature in the system. This is very similar to a boiler short cycling because it is oversized for the load.

The control valves should act as a "high limit device" allowing the water

Continued on MH32 WWW.HPACMAG.COM

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1

Previous steps to make when transitioning from copper to PEX piping...

1 ... crimp press valve to copper piping 2 ... solder copper piping to PEX adapter 3 ... connect adapter to PEX piping Current steps with new press transition ball valves...

1 ... connect press transition valve to PEX piping

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SYSTEM CONTROL temperature to control the space temperature utilizing the lowest possible water temperature available for that specific zone always. Several water temperatures set points may be necessary to satisfy the load but always revert to the lowest temperature whenever possible.

NIGHT SET-BACK AND BOILER SEQUENCING The building terminal units/loads should be energized from setback mode on a sequencing schedule. Each load should have a minimum time when energized to allow the boiler to catch the load before a second load is energized and set-point established. Night "Set-back" should be accomplished by reducing water temperature +/- 15F as a shift to a lower water temperature rather than terminal loads shutting down completely. The building temperature will be reduced due to a lower water temperature while not causing morning start-up inefficiencies due to higher than necessary boiler firing rates. This will allow the boilers to operate in a lower fire input matching the building heat loss at lower building temperatures.

The staggering sequence to an occupied setpoint will allow the boiler to operate at low fire input rather than high fire and utilize multiple boilers to match the load. This will increase the overall thermal operating efficiency. This method of sequencing the boilers to satisfy hot water return (HWR) temperature setpoint should occur regardless of the system water flow rate.

FLOW METER INCORPORATION The boiler firing rate should be tied (parallel) to the pump flow rate signal if a flow meter is incorporated into the system design in the main system header piping. With temperature sensors on the supply and return of the system and information on system flow through the flow meter; a simple system Btu/hr calculation can be made in real time as an MH32

FALL 2018

attempt to maximize the boiler firing rate based on actual Btus required to satisfy the load.

BOILER OPERATION Introducing a specific time delay between boiler stages and a slow ramping of the firing rate will give the boilers a chance to react to the system load before driving to high fire. A typical system designed with a 20-degree differential should have a circulation of at least once back to the boiler in less than 10 minutes. If we ramp the boiler firing rate slowly the system control valves should have ample time to react to the load and provide an average return line temperature.

Using the return line for a setpoint location offers a stable place to sense the actual system load with very few radical changes. Incorporating a supply sensor as well gives us two reference points to establish a system delta T. The system delta T should be as wide as possible to take advantage of the condensing opportunities the boilers are now designed for.

The new age of increased Delta T across the system has arrived. We are no longer constrained with high return water temperatures, which enables us to design supply temperatures at 160F with return temperatures as low as 100F as an example. This ability to spread out the Delta T allows us to condense the entire heating season if designed properly.

Many experts will challenge the analogy of total energy savings of shutting the system down at night versus reducing the temperature of the water and leaving the pumps operational. The energy consumed by the pumps running at a substantially reduced flow rate and horsepower would be less power than starting the system at a specific time in the morning warm-up at full capacity.

The control valves will be wide open and the system temperature differential will cause the boilers to operate at a higher firing rate and temperatures to satisfy the load quickly.

MODERN HYDRONICS

What if we could use a sensor in the living space with a similar function to that of the outdoor air sensor to override to the outdoor air sensor. If the space temperature requirement is satisfied the water temperature would not have to increase based strictly on outdoor air temperature alone. If the inside air temperature falls below a given desired temperature, only then would the water temperature be allowed to increase and the pump speed increased.

We could set up an individual indoor air reset curve for the conditioned space temperature changing the water temperature with respect to the outside air temperature. The two temperature reset curves could work to complement each other and attempt to always keep the water temperature as low as possible.

Why raise the water temperature just because the outdoor air temperature curve plotted requires us too when this is the only reference point that has no input feedback from the actual space conditions? This simple concept could take the guesswork out of what water temperature is required to satisfy the space temperature.

The success to any of this thought process is to incorporate a learning period to examine how the building will react to the operating conditions and then customizing the operation. Constantly looking at water temperatures required to satisfy the conditions will be the key to energy savings.

This is not a fix for every system design but an opportunity to think differently than we have for so many years.

Run the system continuously at the lowest possible water temperature in your design. Typically, systems are oversized and will have the capacity available if needed.

David Connors is regional sales manager with Harsco Industrial PattersonKelley. He can be reached at dconnors@ harsco.com.

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RENEWABLE ENERGY

THE STATE OF SOLAR HEATING How effectively are contractors integrating solar into hydronic systems?

BY ROBERT WATERS

T

here is currently a lot of attention being devoted to reducing greenhouse gas (GHG) emissions from buildings. One of the primary methods that governments are using to meet their goals is to tighten up building codes to require super-insulated and super-airtight building construction that require much less energy to heat.

The path forward and timing with building codes changes is not clearly defined in all areas yet, but the ultimate target of most governments seems to be to get to a level of Net Zero Energy Ready standard by about 2030. Net Zero Ready homes will have space heating requirements that are almost 90 per cent less than current building code levels. These newly constructed low energy homes will have dramatically reduced energy consumption and emissions.

Making new homes more efficient is only a part of the solution, as they only make up a small part of the entire building stock. Existing buildings will still account for the bulk of emissions from buildings and the vast majority of homes in Canada are heated with natural gas. So another big focus for GHG emission reductions is to transition away from fossil fuel burning equipment altogether, and start utilizing low carbon heating systems.

There are various “renewable” heating options that can be considered low carbon, such as electric resistance, air and water source heat pumps, biomass and solar thermal. With my background in the solar thermal (ST) and hydronic heating industries, I am often asked about integrating solar thermal into hydronic systems. What kind of integrated systems are possible? Are any of these types of systems being used?

In response to the first question, there are numerous possibilities for integrating ST with hydronics. Unfortunately the answer to the second is there are very few of these systems being installed. Before looking more closely at the types of system possibilities, let’s look at the current state of solar heating.

Solar thermal water heating suffers from several significant market barriers, with the primary issue being the economics.

There is plenty of proven and reliable ST heating equipment available in the market, especially from some European suppliers, but the initial capital cost for equipment and installaMH34

FALL 2018

Design support is available to help you avoid design and installation pitfalls.

tion is quite high. Combine this high cost for ST heating with the low cost of natural gas, and the resulting system paybacks are very long.

The ST industry in Canada also does not currently have any government support incentives to help out. Steve Royce is the solar thermal specialist at Viessmann Manufacturing Company, and he says “There is lots of interest in solar thermal heating, but the cost generally scares people away. This is especially true after they realize that the solar system will only provide supplemental heat, and that you still require a backup heating system.”

Another barrier facing ST water heating is the lack of awareness in the industry about the capabilities of solar systems, and the installation requirements. Royce says that most people have unreal expectations about the winter heat output of a solar system. “I get requests all the time from people who say “I want to heat my home with solar.” I have to explain to them that solar systems do create plenty of heat, but it comes primarily in the spring and fall shoulder seasons.”

There is also an issue with a lack of knowledgeable solar heating contractors. According to Royce, “Even good hydronic guys are often dumbfounded with solar system design and installation.” He tells me “There are very few contractors out

MODERN HYDRONICS

WWW.HPACMAG.COM

Modern Hydronics

there who have the technical knowledge and skills to properly install a solar combi system. We end up dealing with many systems, which have installation or design issues.”

Market pressure from other types of renewables, especially solar photovoltaics and heat pump technologies have also slowed down the use of solar thermal heating systems.

Hydronics expert and HPAC columnist John Siegenthaler devoted an entire section to solar thermal heating systems in his 2016 book Heating with Renewable Energy. This book is one of the best resources available for anyone who wants to know how to properly design and install solar thermal heating.

Siegenthaler, admits however that “solar PV is so dominant now that solar thermal has suffered.” He still sees interest in solar thermal, but says “people are tending to put their money where the best bang for the buck is, and right now that is in grid connected or net-metered solar PV systems.”

FIGURE 1 COURTESY VIESSMANN MANUFACTURING COMPANY INC.

Figure 1 Flat plate solar collector array

Even with these barriers, solar thermal heating still has a lot to offer for those interested in utilizing renewable energy to reduce fossil fuel use.

There are three primary loads that can be very effectively met by ST heating: domestic hot water heating, pool heating, and supplementing radiant heating systems. The most common application for ST is for DHW heating. SDHW systems tend to be small scale with one or two collectors, and a 200 to 300 gallon storage tank. There are several manufacturers offering packaged SDHW systems, which are pre-designed, have all of the components required, and are fairly easy to install.

Solar combi systems are systems that combine solar DHW heating with space heating and/or pool heating. DHW is a year round load, so it is the ideal “base load” for the system.

By adding additional loads, the solar panel array size can be increased and more fossil fuel energy can be displaced.

Solar combisystems tend to be custom systems and the success of these systems is heavily dependent on the designer and installer. There are unique design considerations WWW.HPACMAG.COM

to solar combi systems, with many being related to how cold and how hot things can get in a ST system.

The potential for wintertime freezing in the solar collector loop must be addressed with either the use of freeze proof glycol in the collector loop, or by using a drainback system.

Closed loop glycol systems tend to be more popular, primarily due to the ease with which the supply and return lines can be run from the collector array to the storage tanks. Glycol however must be maintained properly, and can turn nasty if it is exposed to long periods of stagnation.

Drainback systems eliminate the use of glycol, as water is used as the heat transfer medium and it all drains back into the building every time the pump shuts off. To achieve this the challenge of installing the supply and return lines is substantially increased. There is no margin for error in the Canadian climate when using drainback system design.

The inability to shut off the fuel source (sun) can create excessively hot collector loops in the summer months. This often results in collector stagnation, steam formation and glycol damage. These problems often plague many solar combisystems due to the larger size of the collector array.

Even skilled hydronic professionals often make key mistakes related to these two important factors that can dramatically affect system performance and durability. Commonly found issues include: Insufficient solar storage tank volume, undersized expansion tanks, incorrectly located check valves, overly complex control systems, incorrectly piped diverting valves, and systems missing key components.

If you are going to tackle a solar combisystem, here are several key factors that must be addressed to ensure that you have success:

1. Do not try and do too much with solar While it may be tempting to try and get as much solar support as possible, this can often lead to poor economics, summertime overheating problems, and overly complex designs. Most European combi systems are moderately sized, utilizing storage tank sizes of between 450 to 750 liter, and collector arrays of 10 to 15 m2 (four to six flat plate collectors). These systems have proven to be simpler to design, install and maintain.

2. Simplify the design Complicated designs with multiple tanks, multiple pumps and diverting valves feeding numerous loads are certainly possible with solar combi-systems. These systems however require skilled designers and knowledgeable installers, complex controls and must be precisely commissioned and maintained.

Royce agrees the simple approach is often the best way. “I

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find that I primarily recommend simple designs, and often back off on the size of the system. Wherever possible I try and design systems with a single pump, a diverting valve, a dualcoil solar storage tank and simple controls,” he added.

Besides being easier for the contractor to install and commission, these types of systems are also easier for the building owner to understand, and simplify future troubleshooting and maintenance.

3. Match up solar with low return water temperatures Solar panels are similar to condensing boilers, in that they operate more efficiently with low return water temperatures.

Therefore, to keep the solar combi systems operating as efficiently as possible it is important to match them up with loads that require low temperature distribution systems. The two best choices for this are swimming pool heating and radiant floor heating systems.

Pool heating makes for a great solar combi system. The spring and summertime load of the pool occurs at the exact time when the days are long and the most solar energy is available.

DHW/pool combi systems are relatively simple designs that use a single DHW storage tank and a solar pool heat exchanger. A second pump or three-way diverting valve will redirect the solar fluid through the pool heat exchanger when the DHW tank has been heated.

It is also possible to have a simple switch the homeowner can activate when they want the pool to have priority and get all of the solar energy. The biggest challenge is often making the connection between the basement where the solar stor-

Continued on MH38

Figure 2 DHW-pool solar combi system

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age tank is located and the solar pool pump which is often out in the back yard somewhere.

Using solar to supplement a radiant heating system is a good combination due to the low water temperature requirements of radiant systems. This is especially true in the spring and fall shoulder seasons when most of the solar space heating support will be produced.

Do not expect huge solar contributions in the coldest part of winter, as this is the time of year with the shortest days and least amount of solar radiation. To keep summertime stagnation issues to a minimum, avoid installing too large a collector array. One way to increase wintertime output, and lessen summer overheating is to consider vertically wall mounting the solar panels, or keep the panel slope very steep (at least 70 degrees from horizontal).

1/2" air vent w/ isolation valve

ct

or

ar

ra

y

(S1)

outdoor temperature

lle co

antifreeze protected solar subsystem

so

la

r

thermostatically controlled electric tankless water heater

(S7) sensor

outdoor temperature sensor

zone thermostats

(S5)

(MV1) (S3) (S4)

DHW

sensors in well

spring-loaded check valve

(S6) (P4)

manifold valve actuators

(HX2) (P5) (DTC)

(P1)

modulating / condensing boiler

(HX1)

(P2)

fill / purge valves

zoned radiant ceiling panels

(P3)

make up water

sensor in well

3-way motorized mixing valve (provides outdoor reset control)

Several years ago in Europe, ST industry representatives created the “CombiSol Project.” This project resulted in several key documents related to best practices in design and installation of solar combi systems, which can be found at www.combisol. eu. Siegenthaler’s book, which was mentioned earlier, contains detailed schematic layout drawings showing both closed loop design and drainback design solar combi systems.

ST manufacturers also offer an excellent source of design and sizing support for solar combi systems. They should be relied upon to help with system design, selecting the right components and getting them installed correctly. Some will also offer to run a computerized solar analysis using solar simulation software.

Solar combi system performance is very site specific and depends on your location and the solar panel orientation and slope. Simulation programs are great design tools that provide a detailed analysis of the solar system output and performance specific to the parameters of your project. They will also quickly show, with both data and graphs, if a system design is likely to have overheating problems.

A source of free energy, solar combi systems can be a great way to provide a low-carbon heating solution that reduces the reliance on fossil fuel use. They are very effective when paired up with the appropriate system and application. Avoid some of the problems mentioned earlier and get advice from the experts if you are going to tackle one of these systems.

expansion tank

(S2)

Figure 3 DHW-radiant floor slab combi system

Fortunately solar combi systems have been very popular in Europe for many years and there is design support available to help you avoid design and installation pitfalls.

Robert Waters is president of Solar Water Services Inc., which provides training, education and support services to the hydronic industry. He has over 30 years experience in hydronic and solar water heating. He can be reached at solwatservices@gmail.com.

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ADEY........................................................................................ www.adey.com/us...................................................................................................... MH25 AERCO..................................................................................... www.aerco.com.......................................................................................................... MH13 Amvic Building System........................................................ www.amvicsystem.com.............................................................................................. MH17 Aqua-Tech Sales & Marketing............................................ www.aquatech-canada.com........................................................................................ MH8 Bradford White....................................................................... www.bradfordwhite.com............................................................................................ MH27 Caleffi...................................................................................... www.caleffi.com........................................................................................................... MH9 Eco-King.................................................................................. www.ecokingheating.com.......................................................................................... MH37 Granby..................................................................................... www.granbyindustries.com........................................................................................ MH29 Harsco..................................................................................... www.harscopk.com.................................................................................................... MH23 Lochinvar................................................................................ www.Lochinvar.com...................................................................................................... MH2 Master Group......................................................................... www.master.ca........................................................................................................... MH19 Navien...................................................................................... www.TanklessMadeSimple.com.................................................................................. MH7 NEXT Supply........................................................................... www.nextsupply.ca..................................................................................................... MH11 NIBCO...................................................................................... www.nibco.com.......................................................................................................... MH31 Noble....................................................................................... www.noble.ca............................................................................................................. MH33 Roth......................................................................................... www.Roth-America.com............................................................................................. MH22 Taco......................................................................................... www.tacocomfortsolutions.com................................................................................ MH40 Triangle Tube.......................................................................... www.triangletube.com............................................................................................... MH21 Viessmann.............................................................................. www.viessmann.ca..................................................................................................... MH39 Webstone................................................................................ www.webstonevalves.com/TMV.................................................................................. MH5 MH38

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FIGURE 3 COURTESY JOHN SIEGENTHALER, HEATING WITH RENEWABLE ENERGY, CENGAGE PUBLISHING

RENEWABLE ENERGY

Easy start-up and operation

On-demand DHW

Easy to service

Simple installation and space saving design

Quality and reliability Made in Germany

Ideal for apartment units and houses with one DHW draw