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SECOND EDITION
M ANUAL
OF
M ODERN H YDRONICS
This manual is published in good faith and is believed to be reliable. Data presented is the result of laboratory tests and field experience. IPEX maintains a policy of ongoing product improvement. This may result in a modification of features or specifications without notice. www.warmrite.com www.ipexinc.com
2004 by IPEX. All rights reserved. No part of this book may be used or reproduced in any manner whatsoever without prior written permission. For information, address IPEX, Marketing, 2441 Royal Windsor Drive, Mississauga, Ontario L5J 4C7.
INTRODUCTION
M ODERN H YDRONICS
Each year, construction begins on tens of thousands of new buildings all across North America. Thousands more undergo renovation. Whether new or remodeled, most of these buildings will require the installation or alteration of a comfort heating system. Along with hundreds of other decisions, the owners of these buildings must eventually select a heating system. Unfortunatelyand in most cases unintentionallythe choice is often based on factors that in the end, dont provide the comfort the owner or the occupants are expecting. In many cases the heating system, which is often thought of as a necessary but uninspiring part of the building, is selected solely on the basis of installation cost. In other cases, the selection is based strictly on what the builder offers or recommends. Still other times, the choice is based on whats customary for the type of building being constructed or its location. Such decisions often lead to years of discomfort in thermally-challenged buildings. In retrospect, many people who have made such decisionsand lived with the consequenceswould quickly change their mind if given the opportunity. Most would gladly spend more (if necessary) for a heating system that meets their expectations.
and airborne pollutants through the building. Properly designed hydronic systems are often significantly less expensive to operate than other forms of heating. A wide variety of hydronic heating options exist for everything from a single room addition to huge industrial and commercial buildings. Knowledgeable designers can configure systems to the exact needs of each building and its occupants. The systems can then be installed without compromising the structure or aesthetics of the building. In short, hydronic heating is for discriminating people who expect buildings to be as comfortable to live and work in as they are elegant to look at. Hydronic heating sets the standard of comfort, versatility and efficiency against which other forms of heating should be measured.
The outer PEX layer protects the integrity of the aluminum core, shielding it from abrasion or chemical reactions when embedded in materials such as concrete. The inner PEX layer provides a smooth surface for excellent flow characteristics as well as chemical resistance. The unique construction of Kitec tubing also provides excellent flexibility for easy installation, especially in tight situations where rigid pipe is simply out of the question. Unlike most plastic tubing, Kitec retains the desired shape when bent. It can also be easily straightened for a neat and professional appearance in exposed locations. Kitec pipe is truly a universal product suitable for all types of service in hydronic heating systems. From heated floor slabs, to heated walls and ceilings or snowmelting systems to baseboard circuits, youll find the qualities Kitec possesses will soon make it the tubing of choice for all your hydronic heating needs.
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 Consider the Possibilities! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Heat Source Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Water Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Radiant Floor Heating Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Radiant Walls and Ceilings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Manifold Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Pre-Assembled Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Distribution systems for Hydronic Heating . . . . . . . . . . . . . . . . . . . . . . . .87 Designing Multiple-Load Hydronic Systems . . . . . . . . . . . . . . . . . . . . . . .99 Radiant Pipe and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Hydronic Snow and Ice Melting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 IPEX Radiant Design Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
TM
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.
The days when hydronic systems consisted solely of cast-iron radiators, copper or black iron pipe and fintube baseboard are gone. New hardware such as Kitec pipe and WarmRite Control Panels now make it possible to install quality systems that serve a multitude of heating loads. Modern systems can incorporate a variety of heat emitters. Each are selected to match the exact thermal, aesthetic and budget constraints of a project. Today, hydronic heating contractors are being asked to furnish heating systems for everything from small apartments to large custom-built houses, as well as a variety of commercial buildings. Each job brings its own particular set of requirements. Many modern systems contain several types of heat emitters operating at different water temperatures and divided up into a dozen or more independently controlled zones. Some contractors hesitate to take on such challenging systems. Others recognize that with the right materials and design methods, these systems are not only possible, but also offer excellent profit potential as well as the likelihood of future referrals. Contractors who recognize what modern hydronics technology has to offer, and who take the time to learn how to apply new design techniques and hardware, are enjoying unprecedented business growth. Discriminating clients seek out these hydronic specialists because they offer what their competition cannotthe ability to pull together modern materials and design methods to create heating systems specifically tailored to their clients needs. To take advantage of such opportunities, you need to know how to use these modern piping and control techniques. Thats what this manual is all about. It will show you how to use Kitec pipe, WarmRite Control Panels, and other hardware to assemble state-of-theart hydronic systems that deliver comfort, economical and reliable operation and most importantly, satisfied customers. Armed with this knowledge youll find modern hydronic heating to be among the most satisfying and profitable niches in the HVAC industry. IPEX Incorporated is ready, willing, and able to help you achieve the many benefits offered to those who know how to apply modern hydronics technology.
Many projects may have several of these loads, each requiring heat in different amounts, at different times and at different temperatures. For example, the space heating loads of a given building might best be served by a combination of hydronic heat emitters. Some areas might be perfect for radiant floor heating while others are better suited to radiant ceiling heating. Still other areas might be ideal for baseboard or even ducted forced-air through an air handler equipped with a hot water coil. Almost every house and commercial building also needs domestic hot water. In some cases, this load can be as large or larger than the space heating load. Many facilities are also perfect candidates for hydronic snow melting - if those in charge are aware of the benefits it offers compared to traditional methods of snow removal. Some designers approach situations like these by proposing a separate, isolated hydronic system for each load. One boiler to heat the building, another to melt the snow in the driveway, and perhaps still another to heat the pool. The same building might also use one or more direct-fired domestic water heaters. Although such an approach is possible, it seldom takes advantage of the unique ability of hydronics to connect all the loads to a single heat source. The latter approach often reduces the size and cost of the overall system. It also makes for easier servicing and reduces fuel consumption. Such a synergistic system is made possible through modern hydronics technology.
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
Although the installer could purchase components (such as the manifolds, a bronze circulator, expansion tank) and all the valving separately, using a WarmRite control panel can save much time and labor. All the needed components are preassembled into a compact
Figure 1-3
supplies space heating through a radiant floor subsystem as well as domestic hot water via an indirect water heater. Two WarmRite control panels are used to provide the water and electrical control functions for the space heating portion of the system. In this case, electric valve actuators have been included in the WarmRite control panels to allow individual temperature control of several rooms. An external injection mixing system has been installed between the WarmRite control panels and the primary loop, to vary the water temperature supplied to the floor circuits based on outside temperature (e.g. outdoor reset control). This mixing system also protects the boiler from flue gas condensation that can be caused by low return water temperatures.
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
hydronics can really come through. It is a situation where you can provide an efficient customized system thats exactly right for your customers needs. Figure 1-5 depicts one way such a system could be assembled. Think of this system as a collection of subassemblies plugged into a common source of heated water: the primary loop. The floor heating subassembly appears the same as in figure 1-4 except now there are two of them. Its simply plugged into larger primary loop. Likewise, the manifold supplying the baseboard zones is plugged into the primary loop the same as in figure 1-4. Whats new are the subassemblies that supply the heat exchanger for the snow melting and pool heating systems. Think of the heat exchangers as the separating point between the hot water in the primary loop and the fluids that carry heat to the snow melting circuits and the pool. The heat gets passed from one fluid to the other, but the fluids themselves never mix. The power plant for this sophisticated system is a
pair of boilers controlled by a staging control. This conceptcalled a multiple boiler systemis now common in larger residential as well as commercial systems. The multiple boiler system is sized to deliver the proper amount of heat when all the loads that are capable of running simultaneously are doing so. Such an approach yields higher seasonal efficiency compared to a single large boiler. It also adds to the systems reliability since one boiler can still operate should the other be down for service. The system shown in figure 1-5 uses state-of-the art piping and control techniques to serve all the heating loads of a large house with many amenities. It also makes use of Kitec and WarmRite hardware to speed installation and ensure top quality. The sections to follow discuss many of the key concepts and available options for assembling both simple and sophisticated hydronic systems. Learn them, apply them, and then take pride in providing your customers with the comfort and efficiency that only modern hydronics technology can deliver.
Figure 1-5
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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
distribution system that is designed to operate at higher water temperaturesfin-tube baseboard for examplesuch flue gas condensation is short-lived. It rapidly evaporates as the boiler warms above the dew point of the exhaust gases. However, when a conventional boiler serves as the heat source for a low temperature distribution system it is imperative to keep the inlet temperature to the boiler above the dew point of the exhaust gases. For gas-fired boilers, the inlet water temperature during sustained operation should not be less than 130 deg. F. For oilfired boilers, it should not be less than 150 deg. F. Failure to provide such boiler inlet temperature protection will cause the water vapor (and other compounds present in the exhaust gases) to continually condense on the internal heat exchanger surfaces. The acidic nature of such condensate can cause swift and severe corrosion along with scale formation inside the boiler. It can also rapidly corrode galvanized vent piping, as well as the deterioration of masonry chimneys Hydronic distribution systems with high thermal mass can also cause prolonged flue gas condensation as the system warms up to normal operating temperature. A cool concrete slab with embedded tubing circuits is a good example. As the slab begins to warm, its thermal mass can extract heat from the circulating water stream 3 to 4 times faster than normal. Since the rate of heat release from the water is much higher than the rate of heat production, the water temperature (in an unprotected boiler) will quickly drop well below the dew point temperature of the exhaust gases. The boiler can operate for hours with sustained flue gas condensation. Such a situation must be avoided. The key to avoiding low boiler inlet water temperature is preventing the distribution systemwhatever type it happens to befrom extracting heat from the water faster than the boiler can produce heat. Modern mixing devices can automatically monitor and
adjust boiler return temperature by limiting the rate of heat transfer allowed to pass through a mixing device and into the distribution system. The piping concept is shown in figure 2-1. The details involved in providing boiler return temperature protection will be discussed in section 3.
Figure 2-1
Figure 2-2
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SECTION 2
system. This helps offset a portion of the boilers higher cost. Most condensing boilers can also be side wall vented through a 2 CPVC pipe. This too lowers installation cost relative to boilers vented through a chimney. Figure 2-2 shows how a condensing boiler would be piped in a typical floor heating system.
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. The preferred approach to such dual use systems is to separate the space heating portions of the system from those containing domestic water using a small stainless steel heat exchanger as shown in figure 2-4. Because the heat exchanger isolates the space heating components the distribution system must have an expansion tank, pressure relief valve and air separator.
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
from short cycling under low load conditions. As with condensing boilers, geothermal heat pumps attain their highest efficiency when matched to lowtemperature distribution systems. Slab type radiant floor heating systems operating at water temperatures in the range of 100 to 115 deg. F. at design conditions are ideal. The lower the water temperature, the higher the heat pump efficiency the system can operate at. Avoid geothermal heat pumps in systems requiring design water temperatures above 130 deg. F. In addition to heating, geothermal heat pumps can also supply chilled water for hydronic cooling applications. The most common approach uses an air handler equipped with a chilled water coil. Other terminal units such as radiant ceiling panels can be used for chilled water cooling, but such systems require accurate and reliable dew point control to avoid condensation on the chilled surfaces. A separate air handler is usually required to control humidity.
Figure 2-5
16
SECTION 2
building during the charging cycle, some of the tank water is routed out through the distribution system the same as any other time of day. By the end of the charging cycle the water temperature in the tank may be as high as 200 deg. F. When the switch contact in the meter opens, the electrical elements are turned off. The hot water in the tank contains the heat needed for most if not all of the on-peak hours to follow. Low temperature distribution systems such as radiant floor heating are ideally suited to such a heat source. Their low operating temperature allows the tank to be deeply discharged and thus maximizes its heat storage capability. The heat stored in a heated floor slab also allows the system to coast through the last 2 to 4 hours of the on-peak period should the energy in the tank be depleted. A mixing device installed between the storage tank and the distribution system automatically reduces the water temperature supplied to the distribution system as necessary.
Figure 2-6
17
water volume may be contained in the wood-fired boiler itself or in a separate insulated thermal storage tank. Such a tank must be well insulated so that it can store heat for several hours with minimal losses. The concept is also shown in figure 2-7. Some wood-fired boilers are not pressure rated. The water chambers inside the boiler are vented directly to the atmosphere. Although opinions vary on how best to connect such open system boilers to hydronic distribution systems the conservative approach is to install a stainless steel heat exchanger to isolate the boiler water from that in the pressurized distribution system. Not only does this allow the distribution system to be pressurized for quiet, air-free operation, but it also protects the cast iron and steel components in the distribution system from the possibility of corrosion through contact with boiler water that has a higher concentration of dissolved oxygen.
Figure 2-7
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SECTION 2
common basis. The formulas in figure 2-8 allow the cost of heating energy from each of several fuels to be expressed on the common basis of dollars per million Btus of delivered heat. This is abbreviated as $/MMBtu. These formulas take into account the cost, purchase units, as well as efficiency of the heat source in converting the fuel into useful heat.
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
source off at 185 deg. F. and close them when the sensed temperature drops to 175 deg. F. Figure 3-1 compares these two types of setpoint control. Some setpoint controls have fixed (non-adjustable) differentials, while others provide an adjustable differential. The narrower the differential, the closer the water temperature stays to the desired setpoint. However if the differential is too narrow, the heat source or other equipment in the system could experience excessively short operating cycles that reduce their efficiency and shorten their life. Heat source operating differentials in the range of 10 deg. F. are common in hydronic systems. Systems using setpoint controls provide the same average water temperature to the loads whenever there is a call for heat, regardless of the rate of heat input required by the load. For example, a boiler operated by a setpoint control supplying a circuit of fin-tube baseboard would deliver hot water (perhaps averaging around 175 deg. F.) whether the outdoor temperature was -10 deg. F. on a cold January night, or 50 deg. F. on a mild October afternoon. To prevent overheating under all but design load conditions, flow must be periodically interrupted by turning off the circulator or closing the zone valves. To keep room temperature variations to a minimum, its important to have a thermostat with a narrow differential of perhaps 1 or 2 deg. F. If the thermostat has an anticipator it should be carefully set for the electrical current flow through it during its on-cycle.
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.
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.
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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. The mixing assembly provides the proper supply water temperature to the distribution system. When necessary, it also acts as a clutch to prevent the cold thermal mass of a distribution system from extracting heat faster than the boiler can produce it. This latter function, commonly called boiler protection, is crucially important when a conventional boiler provides heat to a slab-type floor heating system. Mixing reset control allows deep reduction in the water temperature supplied to the distribution system while simultaneously protecting the boiler from low inlet water temperatures. Boiler reset can be used in combination with mixing reset in the same system. The concept is shown in figure 3-4. The boiler reset control monitors and adjusts the water temperature in the primary loop by varying the firing cycles of the boiler(s). The primary loop temperature is often partially reset to prevent the boiler(s) from operating below dew point temperature. The mixing reset control operates the mixing device to reduce the primary loop water temperature as appropriate for the loads they serve. Some systems may have two or more independent mixing devices supplied from a common primary loop.
Figure 3-4
23
An example of the reset lines for a system using both boiler reset and mixing reset is given in figure 3-5. Notice that the primary loop has a minimum supply temperature of 140 to protect the boiler from sustained flue gas condensation. However, the mixing reset control can reduce the temperature of the water to the distribution system all the way down to room air temperature.
gas- and oil-fired boilers fall into this category. Failure to provide this protection can result in severe corrosion and scaling within the boiler. This not only shortens boiler life, but it can also lead to failure of vent piping and spillage of combustion products into the building. Unfortunately, the need to protect the boiler inlet temperature is often viewed as secondary to providing the proper supply temperature to the distribution system. This is an oversight with potentially deadly consequences. It is generally recognized that maintaining return temperatures of 130 deg. F. or higher for gas-fired boilers, and 150 deg. F. or higher for oil-fired boilers will eliminate the damaging effects of flue-gas condensation. There are exceptions, and boiler manufacturers should be consulted regarding the minimum operating temperature of their equipment. Condensing boilers, discussed in section 5, are specifically designed to withstand sustained flue gas condensation and dont need return temperature protection. The cooler the return water temperature the higher their efficiency. In most cases a mixing device is not needed when a condensing boiler is used to supply heat to a low temperature hydronic distribution system as long as the supply temperature matches the design criteria.
Figure 3-5
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SECTION 3
Hydronic heat sources that dont produce flue gases dont need to be protected against flue gas condensation. These include electric boilers, hydronic heat pumps, thermal storage tanks, and heat exchangers.
bellows actuator rather than an internal wax-filled actuator. Their sensing bulb contains a fluid that increases in pressure when heated. This increased pressure causes the valve to partially close the hot water port as it opens the cold water port. A knob on the valve is used to set the desired mixed water temperature. The preferred location of the temperature-sensing bulb is downstream of the distribution loop circulator. This ensures thorough mixing by the time the flow passes by the sensing bulb. Improper placement of the sensing bulb can cause erratic operation. The most accurate temperature sensing takes place with the sensing bulb is immersed in the flowing water. If this is not possible the bulb should be tightly strapped to the pipe and covered with pipe insulation. The piping schematics in figure 3-6 show one piping arrangement for a 3-way valve. This piping arrangement is appropriate if (and only if) low inlet water temperatures or reduced flow rates under low load conditions do not adversely effect the heat source. Reduced boiler flow rate is seldom a problem for high mass boilers or storage tanks. However, low mass boilers, heat pumps or electric boilers may require a minimum flow rate whenever they operate. In such
Figure 3-6
25
cases, the heat source should be equipped with its own pumped bypass circuit as shown in figure 3-7. With this arrangement, flow through the heat source does
will overheat the building unless flow through the heat emitters is interrupted when the desired room temperature is attained. A single 3-way thermostatic mixing valve that controls water temperature to the distribution system does NOT protect a conventional boiler from flue gas condensation. Figure 3-7 shows that a portion of water returning from the distribution system goes directly back to the boiler. When the distribution system operates at low temperatures, this return water will cause sustained flue gas condensation in the boiler. This must be avoided. One way to protect a conventional boiler from sustained flue gas condensation is to install a second 3-way thermostatic mixing valve as shown in figure 38. The additional valve monitors return temperature, and if necessary, mixes hot water from the boiler with cool return water from the return side of the primary loop to boost water temperature entering the boiler. Some manufacturers even build this thermostatic valve into their boilers.
Figure 3-7
not change regardless of the flow proportions through the 3-way valve. Connections from the bypass circuit to the remaining piping system are made using primary secondary tees to prevent interference between the two circulators. 3-way thermostatic valves supply the distribution system with a fixed water temperature regardless of the heating load. Under partial load conditions, the system
Figure 3-8
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SECTION 3
enter the mix and vice versa. Since the sensor is downstream of the valves outlet port, it provides constant feedback to the controller allowing it to fine tune water temperature. The piping for a 3-way motorized valve is shown in figure 3-9. Note the use of a boiler loop with a pair of closelyspaced tees to interface to the distribution system. This accomplishes two important functions. First, it prevents the boiler loop circulator from interfering within the flow through the 3-way valve. Second, it provides another mixing point (shown as point B) allowing hot water in the boiler loop to mix with cool water returning from the distribution system before entering the boiler. The controller operating the valve motor senses both system supply and boiler return temperature. When necessary, the controller can partially close the hot port of the 3-way valve to prevent the distribution system from extracting heat faster than the boiler can produce it. This allows a single 3-way motorized valve to control both the supply temperature, and protect the boiler form low inlet temperature. Most controllers used for mixing valves are able to provide either setpoint or outdoor reset control. The latter cannot be accomplished (automatically) with 3way thermostatic valves. A single 3-way motorized valve piped and controlled as described provides more versatility than does a pair of 3-way thermostatic valves.
Figure 3-9
27
Hot water from the boiler is mixed with cool return water from the distribution system at two locations inside a 4-way valve. In the upper mixing chamber, the hot and cool water streams mix to form the stream supplied to the distribution system. At the same time, mixing also occurs in the lower valve chamber. Here the objective is to boost the temperature of the water returning to the boiler. As with motorized 3-way valve systems, a temperature sensor mounted on the supply pipe to the distribution system provides feedback to the valve controller. Another temperature sensor mounted near the boiler return allows the controller to monitor boiler inlet temperature. When necessary, the controller would partially close the hot inlet port to the valve to prevent the distribution system from extracting heat faster than the boiler can produce it. The recommended piping for a 4-way mixing valve is shown in figure 3-11. Closely- spaced tees are used to connect the valve to the boiler loop. This prevents flow interference between the boiler circulator and distribution circulator. The valve draws hot water from the boiler loop using the momentum of the flow returning from the distribution system. The boiler loop also ensures adequate flow through the boiler under all conditions. Its important to understand that merely using a 4-way mixing valve body in a system does NOT guarantee that the distribution system will receive the proper supply temperature. Neither does it guarantee the boiler is protected from low inlet water temperatures. For proper control, the valve must react to both the supply and boiler return temperatures. To do so, it must be
Figure 3-10
Figure 3-11
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SECTION 3
directed by a controller that senses both supply and return temperature. Its pointless to install a 4-way valve body while omitting the actuator / controller it needs for proper operation.
Hot water from the boiler loop is pushed through a pipe called an injection riser. It enters the side port of a tee at point (A) where it mixes with cool water returning from the distribution system. The blending of these two streams determines the supply temperature to the secondary circuit. The greater the flow rate of hot water entering the tee, the warmer the distribution system gets and the greater its heat output. Injection mixing is ideal for systems pairing a conventional boiler to a low temperature distribution system. The large temperature difference (T) between the incoming hot water and the outgoing return water allows a high rate of heat transfer using a minimal injection flow rate.
Figure 3-12
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. It is important to select the injection control valve based on its Cv rating, NOT the size of the injection riser piping. Oversized injection valves will not produce smooth heat input control under low load conditions. Undersized injection valves will cause excessive head loss and may not be able to deliver design load heat transfer rates. Before selecting the injection control valve, calculate the necessary injection flow rate under design load conditions using the following formula:
Formula 3-1
fi =
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.
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SECTION 3
Once the system is operational, set the flow restrictor valve so the injection control valve remains fully open at design load conditions. This allows the valve to operate over its full range of stem travel as heat input to the distribution system varies from zero to full design load.
The injection mixing control also protects the boiler by monitoring the inlet temperature and reducing the speed of the injection pump when necessary to prevent the distribution system from absorbing heat faster than the boiler can produce it. When using variable speed injection mixing, be sure the tees at points A and B in figure 3-15 are as close together as possible. Also be sure there is a vertical drop of at least 18 inches between the (return) injection riser connection to the primary circuit and its connection to the secondary circuit. This drop forms a thermal trap to reduce heat migration into the distribution system when no heat input is needed. In a properly balanced system, the injection pump should run at full speed when the system is operating at design load conditions. Achieving this balance requires adjustment of the balancing valve located in the return injection riser. There are several ways to set this valve. One of the easier ways is to use a valve that has built-in measuring capability. Many circuit-setter type valves are available for this purpose. To properly set the circuit setter valve, its necessary to calculate the required injection flow rate under design load conditions using formula 3-1. With the injection pump running at full speed, partially close the circuit setter valve until it indicates a flow equal to the value calculated.
Figure 3-15
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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.
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The radiant energy emitted by the relatively low temperature heat emitters used in hydronic heating is technically described as infrared electromagnetic radiation. Its simply light that the human eye cant see. However, other than the fact that its invisible, infrared light behaves just like visible light. It travels in straight lines at the speed of light (186,000 miles per second), and can be partially reflected by polished metallic surfaces. Unlike warm air, radiant energy travels equally well in any direction. Up, down or sideways, direction simply doesnt matter. This characteristic allows a heated ceiling to deliver radiant heat to the room below. The radiant energy emitted by a warm floor, wall or ceiling is a completely natural phenomenon thats literally as old as the universe itself. A surface warmed by sunlight gives off infrared radiation just like one warmed by embedded tubing. The latter simply uses a different heat source and transport system to deliver heat to the surface. Most low temperature radiant panels emit less than 1/10 the radiant flux of bright sunlight, and all of it is infrared as opposed to ultraviolet light. Even the human body gives off infrared radiation to cooler surrounding surfaces.
ceiling insulation and hence lower heating costs. A system thats out of sight: Most people realize that just about every occupied building in North America needs a heating system. However, few enjoy looking at the heat emitters that are a necessary part of that system. The fact that such heat emitters often restrict furniture placement further adds to their invasiveness. With hydronic radiant floor heating, the floor surface is the heat emitter. Theres no need to compromise the aesthetics of the space or restrict furniture placement. Its a system that gives your clients a building interior thats as thermally luxurious as it is aesthetically elegant. A quiet system: One of the strengths of hydronic heating is its ability to deliver heat without delivering noise. A properly designed radiant floor heating system is the epitome of silence. The gas or oil burner on the boiler is often the only component that makes any detectable noise, and its usually located in the mechanical room away from the occupied spaces. A clean system: One of the biggest complaints associated with forced air heating is its tendency to distribute dust, odors and germs throughout a house. In contrast to whole house air movement, hydronic flooring heating creates very gentle (imperceptible) room air circulation. Many people who suffer from allergies have found that radiant floor heating doesnt aggravate the symptoms the way a forced air system often does. A durable system: A slab type floor heating system is nearly as indestructible as the slab itself. Its the ideal way to heat garage facilities, industrial buildings, recreation rooms or other buildings with high interior traffic. A system that reduces fuel usage: Hydronic floor heating systems have a proven record of reduced energy usage relative to other forms of heating, both in residential and commercial / industrial buildings. The savings result from several factors such as the ability to sustain comfort at lower indoor air temperatures, reduced air temperature stratification, non-pressurization of rooms (which leads to higher rates of air leakage), and the ability to operate with lower water temperatures. Savings vary from one building to the next. Although some projects have shown savings in excess of 50%, a more conservative estimate is 10 to 20% in savings. As energy costs continue to escalate, the ability to
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reduce fuel consumption will play an increasingly important role in how heating systems are selected. Hydronic radiant floor heating can keep energy costs to a minimum while also delivering exceptional comfort. Its truly the benchmark system against which all other methods of heating will be compared.
material was cross-linked polyethylene (or PEX). It would soon prove to be the single biggest factor underlying the reemergence of hydronic floor heating in North America. Europeans had amassed considerable experience with PEX and PEX-AL-PEX tubing in floor heating applications by the time these products made their first appearances on the North American market in the early 1980s. Slowly but surely these modern piping materials demonstrated they could deliver comfort, easy installation and long life. The restas they say is history. Today consumers are learning about new methods for installation of hydronic floor heating as never before. They are seeking qualified professional installers and quality products. Kitec pipe and WarmRite accessories let you give these discriminating consumers exactly what theyre looking for. Read on to see all the different ways these systems can be installed.
concrete slab
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Installation Procedure: Figure 4-1 shows a cut-away view of a modern heated slab-on-grade floor.
The installation of a heated floor slab begins by verifying the subgrade has been properly leveled and compacted. Although the heating system installer is probably not responsible for this aspect of
Figure 4-1
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SECTION 4
construction, failing to check for proper subgrade preparation could eventually compromise the embedded tubing circuits. It could also leave the installer having to defend why the floor heating system isnt at least partly responsible for cracks in the slab or other defects. After the subgrade has been prepared, the soil vapor barrier and underslab insulation should be installed. Some building specifications may not call for an underslab vapor barrier. However, its ability to resist moisture migration from the underlying soils can be indispensable, especially when wood products are used as the finish flooring. Heat loss from the edge and underside of a heated slab on grade can be substantial, especially in areas with high water tables or where the slab rests on bedrock. Edge and underslab insulation are essential in reducing these losses. They are a necessary part of any quality floor heating system. Not taking steps to mitigate such heat loss is like leaving the windows open throughout the winter. Realistically theres only one opportunity to install underslab insulationbefore the slab is poured. Discovering high downward heat loss after the system is in operation is a situation thats virtually impossible to correct. It makes little sense to attempt the installation of a high quality heating system while omitting crucial and relatively low cost details. Do it right the first time. The most commonly used material for slab edge and underside insulation is extruded polystyrene. Its sold in 2 by 8 foot and 4 by 8 foot sheets in several thicknesses. Its also available in several densities to handle different floor loading. Extruded polystyrene panels are highly resistant to moisture absorption, and have a well-established record in ground contact insulation applications. New insulating materials are developed to promote the use of under slab insulation. One of them is called radiant barrier foil. It is a composite of plastic and aluminum layers. The concrete Barrier Foils consists of an aluminum layer sandwiched between two layers of bubble insulation. The insulating effect of this new product is comparable with the rigid foam products, but its handling and resistance to mechanical damage is far superior. The amount of underside insulation depends on several factors. Among them are: The severity of the climate: colder climates justify edge- and underside insulation of greater R-value. The cost of energy: higher energy costs justify
edge- and underside insulation of greater R-value. The thermal resistance (R-value) of the floor covering(s): high thermal resistance coverings justify edge- and underside insulation of greater R-value. The shape of the slab: slabs with high ratios of edge length to floor area justify edge- and underside insulation of greater R-value. In most buildings the underslab insulation should have a minimum R-value of 5. In colder climates, it is often recommended that the outer 4 feet of the slab (referred to as the outer band) have R-10 underside insulation. The insulation is generally omitted under structural bearing points such as beneath interior columns or bearing walls. The edge of the slab is especially vulnerable to heat loss. It should be insulated to a minimum of R-5 in mild climates and R-10 in colder climates. The next step on most installations is to locate and temporarily mount the manifold station(s). If one or more of the manifold stations will be located within a stud cavity, its imperative to make accurate measurements when fixing the manifolds location. The manifolds can be temporarily bracketed to a plywood panel supported on wooden or steel stakes driven into the subgrade (as shown in figure 4-2)
Figure 4-2
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Once the insulation is in place, the steel reinforcement for the slab is installed. Most concrete slab on grade floors use welded wire fabric (WWF) for reinforcement and crack control. WWF comes in sheets or rolls. It should be placed directly on top of the underslab insulation. Edges should be overlapped approximately 6 and tied together. Tubing installation takes place one circuit at a time. Begin by securing one end of the circuit to the supply manifold. Roll out the coil like rolling a tire following the layout pattern. The composite pipe, because of the metal content, allows laying the pipe roughly without tying down immediately. This allows it to run the full loop and get the end out to the manifold. Make sure the end reaches the manifold and then tie the piping to the wire mesh. The main difference to laying PEX tubing is that the pipe stays in place and does not want to go back to the coil shape. This is why there is no need to use an uncoiler. If the uncoiler is available, it is also possible to lay the pipe using it. In this case place the tubing coil on an uncoiler and pull the tubing from the coil as needed. Keep plenty of slack ahead of you as the tubing is fastened in place. Kitec tubing should be secured to the WWF using either twisted wire ties or nylon pull ties. The tubing should be tied to the WWF reinforcing every 60 to 72 on straight runs, and two ties at the bend on each side. When all circuits have been installed, prepare the manifold(s) for pressure testing. Install a pressure gauge in one end of either the supply or return manifold and a schrader air valve in the other end. Plug the unused manifold ends. Use an air compressor to increase the pressure in the circuits to about 100 psi. Use a soap bubble solution to check for leaks at the manifold connections. Leave the circuits pressurized for at least 24 hours. If the air pressure drops double check all manifold connections for possible leaks before inspecting the tubing. Aside from the possibility of extreme damage from other construction activity, its very unlikely that the tubing is the source of the air leak. Still, a pressure test is mandatory on any radiant tubing installation. If the WWF has to be positioned in the slab, be sure the concrete placement crew knows to lift the tubing and WWF prior to starting the pour. If the WWF has to be positioned within the slab, it has to be lifted or chaired up to the final position before the concrete is poured. The WWF and attached tubing should be lifted up so the pipe center is 2 below the slab surface. This allows the slab to respond faster when warm water circulates through the tubing. From the heat output point of view, the position of the
piping in the slab is not so critical if full slab insulation is used. Appropriate thermal break will direct the heat flow towards the surface. If insulation is not used the pipe position is critical and in this case the piping has to be lifted to 2 below the surface. As long as the pipe is kept 2 below the surface saw cut control joints will not affect the pipe. If deeper than 3/4 saw cuts are planned the pipe position has to be adjusted accordingly. Anywhere where full cut control joints are used (slabs are separated) a protective sleeve has to be used on the pipe passing through. The sleeve has to be 12 long centered on the joint and approximately 1 diameter. The sleeve reduces stress on the tubing should the slab move slightly at the control joint.
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SECTION 4
Figure 4-3
subfloor
floor joist
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Figure 4-3A
floor joist
underside insulation
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SECTION 4
mix and place the materials. Installation Procedure Installation begins by stapling the tubing to the subfloor. A pneumatic stapler with a special attachment allows the staples to be quickly placed without damage to the tubing. Its the preferred attachment method for all but very small thin-slab areas. Once all tubing circuits have been installed they should be pressure tested as described earlier. Next the floor is sprayed with a combination sealant/bond enhancement coating. This minimizes water absorption into the subfloor as well as strengthening the bond between the slab and subfloor. The poured gypsum underlayment consists of gypsum cement, masonry sand, admixtures and water. The product is prepared is a special mixer usually placed outside the building, and is then pumped in through a hose. As the product is poured, it self-levels with minimum floating. Some installers prefer to install the gypsum slab in two layers (or lifts). This minimizes any differential shrinkage in the slab, resulting is a very flat finish surface. When poured gypsum underlayment cures, it resembles plaster and is almost as hard as standard concrete. However, unlike concrete it is NOT intended to serve as a permanent wearing surface. With the proper preparation, a poured gypsum slab can be covered with almost any finish flooring including carpet, sheet vinyl, ceramic tile and glue-down wood flooring. Always follow the gypsum underlayment manufacturers procedures to verify that the slab is adequately cured that and the surface is properly prepared before installing finish flooring. 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.
Figure 4-4
Unlike with gypsum underlayments, its crucial to prevent the bottom of the slab from bonding to either the subfloor or any wall framing it may contact. The goal is to allow the wood floor deck and concrete thinslab to move independently of each other during curing or seasonal moisture changes. This reduces tensile stresses that can crack the slab. Its also important to divide large floor areas into a grid of smaller areas using plastic control joint strips. As the concrete cures, cracks will develop directly above these strips. These controlled cracks preempt random cracking of the slab. The slab should be cured for a minimum of 3 weeks prior to being heated. This allows time for the concrete to develop strength before being exposed to thermal stresses. To drive off any residual moisture, the slab should also be operated (heated) for several days prior to installation of the finish floor. With either type of thin-slab its imperative to install underside insulation. When the space below the heated floor is also heated, use a minimum of R-11 underside insulation. If the space below the floor is partially heated, install a minimum of R-19 insulation. If the space below the heated floor is an unheated crawl space, install a minimum of R-30 underside insulation. Although these suggested underside R-values are conservative, the installer should verify they meet or exceed local energy code requirements.
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The concept of thin slab installation can be used retrofitting radiant floor heating to existing concrete surfaces. A thin over pour or topping pour is created on the existing surface. Figure 4-4a shows the layers of the installation. Ideally the new layer is separated with a thin layer of insulation. This will drive the heat upwards where we need it and provide quick reaction time. Generally
to 1 rigid foam is used. Using a vapor barrier ensures that no moisture gets into the heated layer. A new type of insulation is also now available. Two layers of bubble insulation with aluminum foil in between has a comparable insulating effect to the rigid foam. It also acts as a vapor barrier. The most difficult part when laying pipe on existing concrete is how to fasten the pipe. Individual clips can be used, though it is very
Figure 4-4a
existing concrete
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time and labor consuming. Special plastic staples or clips can be used when 1 foam is used as insulation. Another effective way is to use pipe track, sometimes called rail fix, to hold the pipe in place. This 6.5 feet long plastic channel is mounted to the floor at 3 points. The pipe clips into the side cutouts perpendicular to the track. 1-1 thickness of smooth regular concrete is poured to cover the pipe and create a very effective thermal mass. There are no structural or strength issuesthe original slab takes care of that. The doors have to be adjusted accordingly to accommodate the level increase.
situations where slab installation is not an option. In such cases the heat dispersion can be provided by highly conductive aluminum plates. Kitec PEX-AL-PEX pipe is ideal for tube and plate applications. Its rate of thermal expansion is very close to that of the aluminum heat dispersion plates. This greatly reduces the potential for expansion sounds as the system warms and cools. Figure 4-5 shows the general concept of a tube and plate system. Notice how the aluminum plates are shaped to fit the perimeter of the tubing. Heat transferred from the tubing to the trough portion of the plate conducts out along the wings of the plate. Because aluminum is an excellent heat conductor, these relatively thin plates can disperse across the floor almost as well as a slab yet at a tiny fraction of the weight and only about 1/2 the added floor height of a thin-slab. They are a versatile component both for floor heating systems as well as radiant walls and ceilings.
The heat is conducted to the plate from the pipe and spreads along the flat "wings". The large contact surface evenly conducts the heat to the floor.
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Above Floor Tube & Plate Systems Figure 4-6 shows the installation of an above floor tube and plate system.
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
SLEEPER SYSTEM ON WOOD FRAMED FLOOR above floor tube and plate
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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
should be glued as well as nailed (or screwed) to the subflooring. Grooves for the return bends, as well as other curved tubing paths can be formed by routering out the 3/4 plywood or OSB. Another way is to place triangular shaped spacers to support the secondary floor layer at
finished flooring
spacer (sleeper)
pipe
subfloor
floor joist
underside insulation
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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. Then tubing is laid out and pushed into the grooves in the plates. Stepping on the tube as it aligns with the grooves ensures it is pushed all the way into the groove. It is NOT necessary to install silicone caulking into the troughs of the plates when installing Kitec PEX-AL-PEX pipe. Above floor tube and plate systems are ideal when nailed-down wood flooring will be installed. The flooring can be placed directly over the tube and plates without needing an additional cover sheet. The flooring should be installed with its long dimension perpendicular to the tubing. Nails can be driven through the heat transfer plates, through the sleepers and into the subfloor. Be careful not to drive nails through the tubing on return bends or other areas when the tubing is not visible as the flooring is laid. If the tubing needs to run parallel to the flooring at times, it is best to drill a shallow hole through the subfloor and route the tubing through the floor framing where it is protected against nail punctures. The tubing can also be plunged beneath the subfloor and then routed up through the bottom plate of a partition to connect to the manifolds. For other types of flooring, it is necessary to install a thin 1/4 or 3/8 cover sheet over the tube and plates to serve as a smooth stable substrate. Plywood is often used as the cover sheet under vinyl flooring or carpet. Cement board has also been used under ceramic tile. All tubing circuits should be pressure tested prior to installing the cover sheet. The tubing should remain pressurized as the cover sheet is installed. Be careful not to drive fasteners through the tubing when securing the cover sheet. The same concept of the sleeper system can be used in low heat load installations, but without the heat transfer platesmostly for floor warming systems. The wood structure is a poor conductor of heat so there is limited heat transfer sideways. The relatively thin layer directly above the pipe will allow a lot more heat through than sideways. This results in large local temperature differences depending on the position of the pipe. This effect limits the amount of heat that can be transferred without creating high temperature lines on the floor surface. The spacing used should be 6-8 and again only a
limited amount of heat output can be provided. To overcome this limitation, some manufacturers produce pre-routed plywood sheets with aluminum layer attached to it to improve sideways transfer. Below floor tube & plate systems Its also possible to fasten the tubing and aluminum heat dispersion plates against the bottom of the subfloor. Below floor tube and plate systems work well when raising the floor level is not an option. The concept is shown in figure 4-7. The plate cradles the tubing against the subfloor as well as disperses the heat across the floor to avoid objectionable variations in floor surface temperatures. The ideal installation conditions for this system would be completely unobstructed floor joist cavities. However this is often not what the installer has to deal with. In some cases, plumbing, electrical, ducting or other utilities may already be routed through the joist cavities. This could make access to the underside of the subfloor difficult or even impossible. Always inspect the underside of the floor deck before committing to a below floor tube & plate installation method.
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Figure 4-7
floor joist
underside insulation
47
With a below floor installation, the tubing is pulled into one joist cavity at a time and fastened up along with the heat dispersion plates. The suggested installation sequence is depicted in figure 4-8. The holes in the floor framing must be large enough for the tubing to be easily pulled through. As with thin-slab systems, its imperative to install underside insulation. When the space below the heated
floor is also heated, use a minimum of R-11 underside insulation. If the space below the floor is partially heated, install a minimum of R-19 insulation. If the space below the heated floor is an unheated crawl space, install a minimum of R-30 underside insulation. Although these suggested underside R-values are conservative, the installer should verify they meet or exceed local energy code requirements.
THREADING pipe
Preparation:
IN
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.
This sketch shows the completed installation from below. The following figures lead us through a step by step process.
Figure 4-8
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Pull pipe from the uncoiler and thread it through the pipe holes making a loop in each bay. The loops neednt be too long, leave just enough hanging from the joist that allows you to handle the pipe. Leave the pipe end hanging free in the last bay.
Return to the first bay. Pull enough pipe from the uncoiler to create a large loop.
Move the slack from the first bay over to the second bay, then over to the third, fourth, etc., until the last bay has enough pipe to run back to the manifold and complete the pipe loop inside the bay itself.
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Use the pipe from the last bay and run it back to the manifold in the same joist holes as the loops. If the slack in the last bay is not sufficient to run back to the manifold, feed more pipe from the uncoiler through the bays until the desired length is achieved. Attach the pipe to the manifold.
Ideally, you should leave enough pipe hanging from the last bay to form the first finished section of the floor. Lift the pipe loop up into the joist space and begin fastening the pipe to the subfloor. Always start fastening the pipe on the side of the loop that runs back to the manifold. If more pipe is needed to complete the loop, it can be fed from the neighboring joist space.
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.
The installation is nearly complete! Once all bays are finished, measure the distance from the first bay to the manifold. Cut the correct length of pipe from the uncoiler making certain to leave enough pipe to connect to the manifold.
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.
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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.
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points associated with installation of hardwood flooring. Kitec PEX-AL-PEX piping is ideal for suspended tube systems. Its aluminum core provides the structure that prevents the tubing from sagging between supports when operated with high water temperatures. As with all floor heating systems, its imperative to install underside insulation. This must be a reflective insulation system meaning that there is a shining reflective metal surface facing the pipe. There has to be an air gap between the pipe and the reflective layer minimum 2 or more. Foil faced batting insulation or the aforementioned bubble insulation can be used. The bubble insulation is different from the one used with concrete. The aluminum layer is exposed on one side minimum and is always facing the piping. The insulating layer can be one or two layers of plastic bubble depending on the amount of insulation required.
Figure 4-9
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When the space below the heated floor is also heated, use a minimum of R-11 underside insulation. If the space below the floor is partially heated, install a minimum of R-19 insulation. If the space below the heated floor is an unheated crawl space, install a minimum of R-30 underside insulation. Although these suggested underside R-values are conservative, the installer should verify they meet or exceed local energy code requirements. Threading the pipe into the joist space is identical to the method explained under the section discussing joist space heating with heat transfer plates. The fastening of the pipe is different in this case. There are three main ways to secure the pipe; stapling to the underside of the subfloor; using a pipe hanger to suspend the pipe in the joist cavity; or use a nail clip to nail the pipe directly to the side of the joist. Stapling to the floor is very simple, however the pipe is close to the surface and can be punctured easily from above. The other two overcome this problem, but an
finished flooring subfloor pipe
extra item pipe hanger or nail clip is used. In high heat load installations, the direct stapling to the underside can result in high and low temperature lines on the floor. The fastest and easiest to install is the nail clip method. They all have their advantages and disadvantages. Its possible to staple Kitec pipe directly against the underside of the subflooring without using heat dispersion plates. As discussed above this approach is only suggested for low heating load situations such as rooms that have minimal if any exterior exposure. Without either a slab or aluminum heat dispersion plates, the floors ability to spread the heat laterally away form the tubing is more limited. Still, when the design heat load of the space doesnt exceed 15 Btu/hr/sqft, this installation method can deliver adequate heat output at reasonable water temperatures.
underside insulation
pipe hanger
floor joist
underside insulation
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reflective layer
Reflective foil insulation (aluminum-bubble) JOIST SPACE HEATING below floor tube suspended
Reflective foil insulation (aluminum-bubble) JOIST SPACE HEATING below floor tube suspended
reflective layer pipe mounted with nail clip floor joist underside insulation
min. 2" air gap
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In this chapter, we pointed out the effects of the floor construction method on the radiant floor heating system. As a summary, it is probably fair to say that piping can be fitted into any floor surface and there are numerous variations to fit the project circumstances. It should also be clear that there are important differences between these methods and some are better suited than the other for effective heat transfer.
The following image (figure 4-10) illustrates the heat transfer process during joist space installation using heat transfer plates or direct staple up. The image speaks for itself and gives very good reasons to consider using the heat transfer plates wherever it is possible.
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
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R ADIANT WALLS AND C EILINGS
Although the majority of hydronic radiant heating systems are installed in floors, the walls and ceiling of a room can also make excellent radiant panels. This is possible because radiant energy travels equally well in any direction. Just as visible light travels downward and sideways from a ceiling fixture to illuminate the surfaces below, infrared light (e.g. radiant heat) will travel to warm the objects in the room below. Experience with hydronic ceiling heating in North America dates back to the 1940s. Many systems were installed using both copper and iron tubing embedded in plaster on lathe ceilings. These systems demonstrated that radiant ceiling heating is not only feasible, but also able to create excellent comfort conditions. Some of these systems are still functioning today.
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and tub surfaces below. In rooms where prolonged foot contact with the floor is likely, the maximum floor surface temperature should not exceed 85 deg. F. This limits the heat output from a heated floor to 35 to 40 Btu/hr/sq. ft. However, this temperature limit does not apply to heated walls and ceilings. A heated ceiling 8 feet above can be operated at temperatures as high as 100 deg. F. A 9 ft. tall ceiling can be operated as high as 110 deg. F. At these surface temperatures, heat outputs in excess of 70 Btu/hr/sqft are possible from either a heated wall or ceiling. Because of the higher outputs, the area of the radiant panel can often be reduced. This in turn reduces installation cost. Heated walls and ceilings typically have very low thermal mass and can respond quickly to changing load conditions. This is especially advantageous in rooms with significant solar gains or other sources of internal heat. This fast response is also beneficial for spaces that need to be quickly restored to normal comfort after prolonged setback periods. Heated walls and ceilings typically add very little weight to the structure and thus dont require structural alterations. Heated ceilings usually require less vertical space than most types of floor heating instalations. This may be a significant advantage in retrofit situations, especially in basements with limited head room. Heated ceilings create very little air distubance in the room below. Approximately 95% of the output from a heated ceiling is in the form of radiant energy. Very little convection is created. The reduced air movement is especially desirable in rooms where dust movement and drafts need to be avoided. A radiant wall is an excellent addition to a walk-in shower. The warmed surface greatly improves the comfort over that of cold tile surfaces, especially if one or more walls are exposed to outdoor ambient conditions. The heated wall can be used to supplement the output of a heated floor. It also helps dry the shower walls quickly after a bath. Radiant walls make an excellent supplement to floor heating for indoor pool enclosures. In many cases, the amount of floor area available is limited due to the size of the pool. A low profile radiant wall will not only supplement the heat output, but will also significantly
improve the comfort and help dry water splashed on the wall.
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Figure 5-1
Where the tubing needs to form a return bend, hold the strapping short of the end of the wall by a distance approximately equal to the radius of the tube bend. A 1.5 x 3/4 plywood strip should be installed at the ends of the wall as a solid surface to which the wall finish can eventually be fastened. Be sure to plan where the tubing will enter and exit the wall. Figure 52 shows these details. After the strapping is installed, the aluminum heat dispersion plates can be set in place and tacked using 2 or 3 staples through one wing of the plate. Be sure to pull the trough portion of the plate to one side of the strapping before stapling it. This creates a slight gap on the other side of the trough allowing the plate to expand slightly as the tube is pressed in place. Leave
a gap of approximately 1 inch between ends of adjacent plates. Uncoil the Kitec pipe and press it into the plates. Be sure to leave enough slack at the beginning and end of the serpentine pattern to connect the circuit to a manifold. A rubber-faced masons float makes an excellent tool for tapping the tubing into the plates without denting them. After the circuits have been pressure tested, the wall can be covered with drywall or other panels. If the wall is to be finished with ceramic tile, the tubing and plates can be covered with a layer of cement board. The tile would then be bonded to the cement board with thin set mortar. Be sure not to drive fasteners through the tubing when installing the wall covering.
59
vapour barrier
Figure 5-1A
60
SECTION 5
Figure 5-2
adjacent plates. Uncoil the Kitec pipe and press it into the plates. A rubber-faced masons float makes an excellent tool for tapping the tubing into place without denting the plates. The slightly overbent shape of the heat dispersion plates will hold the tubing up after it is pushed tightly into place. After the circuits have been pressure tested the ceiling can be drywalled. Leave some air pressure in the tubing as the drywall is installed. Because of the plywood strapping, additional screws and nails can be used if necessary to ensure the drywall is pulled tightly against the tubing and plates. Snap a chalk line halfway between the rows of piping and install the drywall fasteners along it. Be especially careful not to drive fasteners through the tubing near the return bends.
61
Figure 5-3
Figure 5-3A
62
SECTION 6
M ANIFOLD S YSTEMS
6-1 Introduction
The vast majority of new hydronic radiant heating systems use one or more manifold stations as the connecting points for the tubing circuits. All manifold stations consist of a supply manifold and a return manifold. The manifold station might be equipped with trims such as valve actuators, circuit flow meters, isolation valves and venting/draining components. The necessary trim is determined by how the system is intended to operate. For example, its possible (although not always necessary) to operate each radiant panel circuit on the manifold station as an independent zone. A tubing circuit that heats the floor of the master bathroom could operate while the circuit(s) serving the bedroom adjacent to it remain off. This section discusses the various manifold systems available from IPEX and suggests where each is appropriate.
63
If temperature setback is used, all rooms will operate on the same setback schedule. There is relatively good air flow between rooms. The doors between individual rooms and interconnecting spaces are left open most of the time. If these conditions are met, the entire building could be controlled as a single zone using a single thermostat (or other type of interior air temperature sensor). Since the control hardware is minimized, this approach will reduce installation cost. When the conditions described above are not met, its appropriate to plan the system for multiple zones. When planning for multiple zones consider the following: What group of areas (if any) tend to have similar temperature requirements at the same time of day. For example, a home may have two or more bedrooms that are unoccupied during the daytime and thus could be kept at a reduced temperature to reduce fuel usage. What areas have similar internal heat gain patterns. For example on sunny days some rooms may receive enough direct solar heat gain to offset most of their heating load, even when its very cold outside. A properly zoned system should allow the heat input from the hydronic system to these rooms to stop under such conditions. At the same time, other rooms that dont experience these heat gains should receive the necessary heat input to maintain their set temperatures. What areas have heat emitters with similar thermal mass. A room with a higher thermal mass system such as a heated concrete slab will not warm nor cool as fast as an otherwise identical room heated by fin-tube baseboard. If these two rooms were on the same zone, and that zone was operated with a temperature setback strategy, or experienced significant solar heat gain, the two rooms cannot respond comparably. The room heated by fin-tube baseboard could quickly interrupt heat input when solar heat gains occur, while the room with the heated slab would likely overheat due to the significant amount of heat stored in the slab. A common misconception about zoning: Some heating system designers feel that every room that may, at some point, need to be at a temperature different from that of other rooms, must be operated as an independent zone with its own thermostat. This is
not true. Its possible under the right circumstances to maintain rooms at different air temperatures even though they are grouped together as a single zone and operated by a single thermostat. One way to accomplish this is through the heat output capacity of the heat emitters. Imagine two identical rooms that have the same heating load. One has 10 feet of baseboard; the other contains 12 feet of the same baseboard. Water at the same temperature is supplied to both baseboards at the same time. Obviously there will be greater heat output into the room with the longer baseboard and thus it will attain a higher air temperature under all load conditions. In the case of radiant panel heating, the output of the panel at a given water supply temperature can be altered by changing the amount of pipe used in the floor. The easiest way to achieve this is to vary the tube spacing. Again, imagine two identical rooms with a heated slab floor. In one room the tubing is spaced 9 inches on center. In the other the tubing is spaced 12 inches on center. Assuming both rooms are supplied with the same water temperature at the same time, the room with the closer tube spacing will receive more heat input and thus attain a higher air temperature. Another method of controlling heat output, one that can be adjusted once the heat emitters are installed, is by varying the flow rate through individual heat emitters. Once again imagine two identical rooms with identical heating load, and identical heat emitters. Both rooms are controlled from a single thermostat, and have the same supply water temperature while operating. If the flow rate through one baseboard is reduced using a balancing valve, the average water temperature in that heat emitter will decrease as will its heat output. Thus the room operated at the lower flow rate will stabilize at a lower air temperature. Understanding the above concepts and applying them when appropriate can reduce system costs. It also doesnt mandate the installation of individual room thermostats when they are not necessary.
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M ANIFOLD SYSTEMS
circuit is desired a valveless manifold is installed as the supply manifold where each tubing circuit begins, and a valved manifold is installed as the return manifold where each circuit ends. This allows the optimal flow direction through the manifold valves. Figure 6-1 shows a 4-circuit valved as well as valveless manifold.
A valveless manifold can also be combined with a zone valve as shown in figure 6-2 when several circuits are to be controlled from a single thermostat. This option is less expensive than installing several valve actuators on individual circuits and controlling them as a group.
Figure 6-1
Figure 6-2
65
in figure 6-3. As its screwed onto the manifold valve, the actuator pushes the valves stem to its fully closed position. When low voltage (24VAC) is applied to the actuator it retracts its stem allowing the spring inside the valve body to open the valves plug. The valve opens to its full position. The flow balancing is set on the balancing valve on the other manifold. There are manifold types where the travel of the valve stem can be adjusted. The manifold valve only opens to its set balancing position when the actuator is powered up. This allows the valve to provide the proper balancing for the circuit when its open as well as a means of on / off flow control when an actuator is attached. In summary, the following manifold variations are used in hydronic systems; Plain manifold Manifold with plain shut off valves Manifold with provision for electrical valve actuator
Manifold with flow rate indicator Manifold with balancing valve Manifold with balancing valve and flow rate indicator built-in
Figure 6-3
66
SECTION 6
M ANIFOLD SYSTEMS
between the manifold station and the room where the circuit will release most of its heat. Such lengths should be kept to a minimum. Is the diameter of the manifolds sufficient to handle the entire system flow? To avoid noise and possible erosion due to high flow velocities, a 1" manifold should generally be limited to 11 circuits, and a 1.25" manifold limited to 15 circuits. Projects with a high number of circuits are usually better served by designing for multiple manifold stations. What locations are available for manifold stations? Manifold stations can be mounted both horizontally and vertically. In either case it is imperative to provide access to the manifold station. Try to avoid locations where furniture or other heavy or difficult to move objects would block such access. Try to find locations where the manifold access panel does not detract from the interior aesthetics of the building. In buildings with public access, the manifold stations are generally provided with lockable enclosures, or are located in areas where only authorized personnel have access.
How many floor levels does the building have? Its often convenient to provide at least one manifold station on each floor level of a building. The reason is to minimize leader length in tubing circuits. Will some circuits be filled with an anti-freeze solution while others operate with water? Circuits operating with anti-freeze solutions must be supplied through different manifolds than those operating on water. Whenever possible, manifold stations should be located so that circuits can be routed away from them in several directions. This typically reduces the length of circuit leaders. In buildings with wide, spreadout floor plans, it is usually better to install two or more manifold stations (each with circuits clustered around it) rather than attempting to route all circuits back to a single location. The latter approach tends to create situations where tubing is closely packed along hallways that have very low heating requirements. Figure 6-4 shows an example of what can happen when the manifold station(s) are poorly placed. Note the concentration of tubing down the hallway.
Figure 6-4
67
Manifold Mounting
Manifold stations are often mounted within the hollow cavity between wall studs. The lower manifold should be mounted 1.5 2 feet. The top manifold should be 2.5 3 feet above the floor to allow some flexibility in the tubing from where it penetrates the floor surface to where it connects to the manifold. Its important that tubing penetrates the floor surface within the stud cavity. In the case of slab systems, the stud cavity doesnt exist at the time the manifold station is placed. Accurate measurements are essential to making sure the tubing penetrations remain inside where the wall will eventually be located. For slab type floor heating systems, some installers make a wooden tubing template block that aligns the tubing where it penetrates the slab surface with the manifold connections above. The template block is
supported on two driven stakes. The top of the block should be set at the same elevation at the top of the slab. The template block is typically the same width as the wall framing and remains in place after the slab is poured. Other installers erect a temporary support for the manifold stations as shown in figure 6-5. This allows the tubing circuits to be connected to the manifold stations for pressure testing prior to the pour. After the walls are framed, the plywood backer can be removed and the manifold brackets secured to permanent framing. All tubing should be sleeved where it enters and exits a slab surface. The sleeving protects the tubing from trowel edges when the slab is finished, as well as from other physical damage over the life of the system. When the manifold station is to be mounted within a
Figure 6-5
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SECTION 6
M ANIFOLD SYSTEMS
wall framing cavity, that cavity must be sufficiently deep. A 2x4-framed wall with a stud thickness of 3.5 inches is a bare minimum. A 2x6-stud cavity 5.5 inches deep provides an easier installation. The installer might also look for the opportunity to fur out the interior wall of a closet to provide a deeper mounting cavity. The manifold mounting brackets should be secured to a solid wall, or a plywood panel that itself is secured directly to framing. Be sure to make the access opening large enough to install valve actuators if they are planned at the present or may be added in the future. Manifold stations can also be mounted horizontally. A good example is a manifold station secured to the underside of a framed floor deck as shown in figure 6-6. Tubing circuits from a thin-slab or tube & plate floor heating system can drop down through the sub floor and connect to the manifold station. Mounting one or more manifold stations to the underside of a framed floor with access from the basement eliminates the need for access panel in the finished space above.
topping pour
floor joist
plywood panel
supply
Figure 6-6
return
manifold station
Figure 6-7
69
nents from the balance of the system should they require service. Installing a pair of full port ball valves on the supply and return side of each manifold station to provide such isolation is considered good practice. IPEX offers such valves that thread directly to the manifolds. IPEX manifolds can be configured with adapters allowing them to be supplied using either copper tubing or large diameter Kitec pipe. Distribution piping for multiple manifold systems can be set up several ways depending on the flow requirements and routing requirement. These methods include:
Trunkline piping Homerun distribution piping Parallel primary / secondary piping The concept of trunkline piping is shown in figure 6-8. Each manifold station taps into a common supply (trunk) pipe as well as a common return (trunk) pipe. Because this is a form of parallel piping, each manifold station receives the same water temperature (assuming minimal heat loss along the trunk piping). Trunkline distribution piping can be constructed of
Figure 6-8
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SECTION 6
M ANIFOLD SYSTEMS
either rigid metal pipe or larger diameter Kitec pipe. It can be routed through the framing cavities of the building, in a mechanical chase above the ceiling, or even under the floor slab. In the latter case, flexible Kitec PEX-AL-PEX or PEX tubing is recommended. Portions of the trunkline piping may need to be insulated to minimize heat transmission to floor areas en route to the farther manifold stations. The size of the supply trunkline pipe can generally be reduced as flow is removed at each manifold station. Likewise, the piping size of the return trunkline is usually increased as return flow is added at each trunkline. The flow velocity at any point in the trunkline piping should not
exceed than 4 feet per second to minimize flow noise. Another option is to pipe each manifold as a homerun circuit as depicted in figure 6-9. A header is the mechanical room handling the supply and return flow to each manifold station. Homerun systems generally use small tubing than trunkline systems. Smaller diameter Kitec PEX-AL-PEX or PEX tubing is easier to route through confined building cavities smaller tubing, especially in retrofit applications. Homerun systems are another form of parallel piping and thus deliver the same water temperature to each manifold station.
Figure 6-9
71
Another method of supplying multiple manifold systems with the same water temperature is primary/secondary piping. Figure 6-10 depicts the concept. Note that each manifold station now has its own circulator. This circulator can be smaller than a single circulator that provides flow to the entire distribution system and all manifold stations. It can also be independently controlled if necessary. A pair of closely spaced tees connects the manifold
riser piping to a crossover bridge in the primary loop. This detail allows any of the manifold circulators to operate without interference with the circulator in the primary loop. The use of primary/secondary piping to supply multiple manifold stations is generally not necessary in residential and light commercial systems. However, it does provide an option to a large central pump and numerous control valves in larger industrial systems. See more details of piping systems in chapters 8 and 9.
Figure 6-10
accommodate the loop valve actuator. Manifold stations can also be equipped with air venting options as well as fill/drain valves. A float type air vent on the top manifold assists with air removal when the system is filled. When fill / drain valves are installed each manifold station can be individually purged. These accessories are shown in figures along this chapter.
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SECTION 7
P RE -A SSEMBLED C ONTROL PANELS
7-1.1 General
There is an endless variety of design options for hydronic systems. Every installation is designed as a specific project using a combination of pipe, manifolds and individual components to construct a heating system. Depending on the project specifications and features and factoring in individual preferences, even similar projects can show major variations in design and components. Despite this, it is possible to find similarities and create "standard" assemblies that are versatile enough to cover these variations while using basic common principles. This is the fundamental goal of the IPEX Pre-assembled Control Panel concept.
73
The IPEX WarmRite Control Panel product line was developed using this process, in combination with valuable feedback from the North American market place. The result is the following eleven different Control Panels (CP)
tempering valve to set the supply temperature. These three panels control the floor supply temperature so no external supply water temperature control is needed. All other panels rely on receiving the calculated design water temperature.
Each control panel is described in this section. However, because the panels have numerous common elements, a review of their similarities is in order. For detailed information, application notes and installation / operation manuals are available for each panel.
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SECTION 7
is for a consistent temperature pattern which is not often altered. The temperature difference between the areas will remain the same unless the balancing valves are readjusted. Naturally there are applications when the temperature setting has to be changed more frequently - such as a motel where guests change every day, and with them so do individual comfort requirements. Perhaps in our own home there is a guest bedroom that is only used sporadically. In these cases, separate thermostats are required. The pipe loops serving these spaces will have valve actuators connected to the appropriate room thermostat. When the room is occupied and that thermostat calls for heat, valves open on those loops until the appropriate setting is satisfied. The provision for individual loop valves is available on all WarmRite Floor control panels designed for residential or office environments. Industrial and Secondary Injection Mixing Control Panels differ from the others in that the environments they are designed for rarely require loop by loop control. In large areas, the flow adjustment in a single loop has virtually no effect on the overall heat output. There are no sophisticated balancing or actuated valves in these panels because they are not required. All of the other control panels have been designed to accommodate individual loop by loop control when required. Every panel designed for closed loop systems has an automatic air vent on the supply manifold and a fill/drain valve on both manifolds. Each is equipped with a pressure gauge on the return manifold and two
temperature gauges: one for supply and one for return water temperature. The temperature drop in the system characterizes best how the unit is operating.
75
supply manifold
When the control is in the outdoor reset mode, the speed of the injection circulator is varied to maintain a target fluid temperature in the supply return manifold manifold based on outdoor air temperature. The control can alternately be used as a set point fill/drain control. In this mode, the speed of the injection valve isolating valves INJECTION MIXING CP circulator is varied to maintain a user adjustable supply fluid temperature. A room thermostat monitors the desired room temperature and turns the mixing control off when the zone(s) is satisfied. The panel is operated as a single zone system by using the thermostat to activate the control. The secondary circulator operates continuously providing even heat distribution during the heat up and cool down cycles. The panel can be operated with subzones set up on a single zone panel. The system thermostat is operating the main heat input while the subzone thermostats operate the loops fitted with valve actuators. The sub zoning should not exceed more than 50% of the loops. The panel can be operated as a multiple zone system. The on/off valves located on the supply manifold are fitted with optional electrical valve actuators to control individual loops in the system. In this application, every actuator is connected to a thermostat located in the area served by the loop. When the thermostat calls for heat, the actuator opens the loop allowing flow. When all loops are satisfied, the secondary circulator is shut down and the injection control is disabled. The panel operation is controlled by closure of a dry contact. An example of devices that can provide this are: two and three wire room thermostats, programmable thermostats, set point controls, integrated building controls, etc. Balancing valves with flow indicators on the return manifold allow the user to adjust and visually monitor the flow rates of each loop. A circulator control module contains a 24V transformer, a circulator relay, a dry contact enable, and an adjustable high limit which prevents the supply fluid from exceeding the desired temperature. Valves on the supply and return manifolds allow each loop to be isolated when necessary. The optional actuators and thermostats must be ordered separately according to the project specifications. The panel operation is controlled by closure of a dry contact. An example of devices that can provide this are: two and three wire room thermostats, programmable thermostats, set point controls, integrated building controls, etc.
SUPPLY
RETURN
76
SECTION 7
SUPPLY
RETURN
77
expansion tank
supply manifold limit sensor fill/drain valve circulator diverting valve return manifold
isolating valves
SUPPLY
RETURN
78
SECTION 7
Balancing valves with flow indicators on the return manifold allow the user to adjust and visually monitor the flow rate of each loop. The circulator control module contains a 24V transformer, a circulator relay, a dry contact enable, and an adjustable high limit which prevents the supply fluid from exceeding the desired temperature. Valves on the supply and return manifolds allow each loop to be isolated when necessary. The optional actuators and thermostats must be ordered separately according to project specifications. The panel operation is controlled by closure of a 24V dry contact. An example of devices that can provide this are: two and three wire room thermostats, programmable thermostats, set point controls, indoor/outdoor reset controls, integrated building controls, etc.
SUPPLY
RETURN
79
supply manifold
limit sensor
circulator
tempering valve
return manifold
purge valve
FLOOR WARMING CP
isolating valves
The panel is operated as a single zone system by using the thermostat to activate the circulator. The panel can be operated as a multiple zone system. The on/off valves located on the supply manifold can be fitted with optional electrical valve actuators to control individual loops in the system. In this application every actuator is connected to a thermostat located in the area served by the loop. If periodic circulation to avoid stagnation is required, all thermostats on the system must be programmable thermostats with timer capabilities. Balancing valves with flow indicators on the return manifold allow the user to adjust and visually monitor the flow rate of each loop. The circulator control module contains a 24V transformer, a circulator relay, a dry contact enable, and an adjustable high limit that prevents the supply water from exceeding the desired temperature. Valves on both the supply and return manifolds allow for isolation of the loop when necessary. The panel operation is controlled by closure of a 24V dry contact. The panel comes complete with a programmable thermostat, but also may be controlled by devices such as: two and three wire room thermostats, set point controls, indoor/outdoor reset controls, integrated building controls, etc.
RETURN
SUPPLY
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SECTION 7
actuator actuator actuator actuator module module module module (x3) (x3) (x3) (x3)
limit sensor
fill/drain valve
return manifold
pressure balancing bypass
fill/drain valve
isolating valves
SUPPLY
RETURN
81
supply manifold
fill/drain valve
Balancing valves with flow indicators on the return manifold allow the user to adjust and visually monitor the flow rates of each loop. A circulator control module contains a 24V transreturn manifold former, a circulator relay, a dry contact enable, and an adjustable high limit which prevents the supply fluid from exceeding the desired temperfill/drain valve ature. Valves on the supply and return manifolds MANIFOLD STATION with CIRCULATOR allow each loop to be isolated when necessary. The optional actuators and thermostats must be ordered separately according to the project specifications.
isolating valves
The panel operation is controlled by closure of a 24V dry contact. An example of devices that can provide this are: two and three wire room thermostats, programmable thermostats, set point controls, indoor/outdoor reset controls, integrated building controls, etc.
RETURN
SUPPLY
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SECTION 7
Manifold Station
Operation: This panel is designed as a basic manifold station. The panel is operated as a single zone system by using a thermostat to activate the external zone valve or a circulator. The panel can also be used with limited number of subzones. The on/off valves located on the supply manifold can be fitted with optional electrical valve actuators to control individual loops in the system. In this application, every actuator is connected to a thermostat located in the area served by the loop. When the thermostat calls for heat, the actuator opens the loop allowing flow.
supply manifold
fill/drain valve
limit sensor
Balancing valves with flow indicators on the return manifold allow the user to adjust and visually monitor the flow rates of each loop. The unit has no integral zone control device. When a return manifold zone valve or circulator is attached to the isolating valves manifold station a Circulator Control Module has to be fitted in the system. This controls the zone fill/drain valve MANIFOLD STATION valve or circulator and the loop valve actuators for the subzones. The circulator control module contains a 24V transformer, a circulator relay, a dry contact enable, and an adjustable high limit which prevents the supply fluid from exceeding the desired temperature. Valves on the supply and return manifolds allow each loop to be isolated when necessary. The optional actuators and thermostats must be ordered separately according to the project specifications.
SUPPLY
RETURN
83
return manifold
fill/drain valve isolating valves
SNOWMELT / INDUSTRIAL CP
SUPPLY RETURN
84
SECTION 12
supply manifold
limit sensor
circulator secondary mixing tees
return manifold
fill/drain valve
isolating valves
RETURN SUPPLY
85
Isolation Module
Operation: This module is designed to isolate the liquid used in the heating loop from the liquid used in the heat source. For example, a snowmelt system operating with water-glycol mixture is connected to a heat source operating with water or separating a heating system from a domestic water heat source. The primary side of the heat exchanger is connected to the heat source. The primary circulator and the isolating valves are included in the panel. The secondary side contains an expansion tank, pressure relief valve, and isolating valves. Each circuit is monitored with a pressure / temperature gauge. A circulator control module contains a 24V transformer, a circulator relay, a dry contact enable, and an adjustable high limit that prevents the supply fluid from exceeding the desired temperature. The panel operation is controlled by closure of a 24V dry contact. An example of devices that can provide this are: two and three wire room thermostats, programmable thermostats, set point controls, indoor/outdoor reset controls, integrated building controls, etc.
pressure / temperature gauges exp. tank limit sensor primary circulator pressure relief valve heat exchanger
circulator control module
supply
return
return
supply
secondary
primary
SUPPLY
S RETURN P RETURN
P SUPPLY
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SECTION 8
D ISTRIBUTION S YSTEMS FOR H YDRONIC H EATING
There are several methods of transporting water from a hydronic heat source to one or more heat emitters. The method used depends on: How much water has to be moved? Can the heat emitters operate properly at different water temperatures? Do some portions of the piping system need to operate as different zones? Are there several circulators that must operate simultaneously? What type of pipe will be used to convey heated water to the heat emitters? This section examines several classic hydronic distribution system configurations. It also discusses several unique ways to use PEX-AL-PEX pipe to create distribution systems that are easy and fast to install, as well as efficient to operate.
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Figure 8-1
If the water temperature supplied to a series loop is changed to increase or decrease the heat output of one heat emitter, the output of all other heat emitters on the loop will be effected. This also holds true if one attempts to adjust heat output by changing the flow rate through the loop. Another potential limitation of series loop is excessive head loss (e.g. pressure drop). In a series loop the head losses (pressure drops) of each heat emitter and interconnecting piping add together. Too many heat emitters in series could lead to high pressure drops and low flow rates. This often shows up as under heated rooms near the end of the loop. Series loops containing several heat emitters should be designed to accommodate the drop in water temperature from one heat emitter to the next. If the flow rate in the circuit is known, the temperature drop across each heat emitter can be determined using formula 8-1:
Where: T = Temperature drop across the heat emitter (deg. F) Q = Rate of heat output by the heat emitter (Btu/hr) f = Flow rate in the circuit (in gpm) 500 a constant for water (use 479 for 30% and 450 for 50% glycol) For example: Assume water enters a length of fin-tube baseboard at 170 deg. F. and 2 gpm. The baseboard releases heat at a rate of 10,000 Btu/hr. What is the outlet temperature from the baseboard?
T=
Formula 8-1
Solution:
T =
Q 500 x f
Therefor the water exits at 170-10 = 160 deg. F. Formula 8-1 can be used sequentially to determine the
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SECTION 8
temperature drop from one heat emitter to the next. Remember that as the water temperature drops in the downstream direction the size (or length) of the heat emitter needed for a given heat output increases.
selected may be reduced. Homerun systems also allow each circuit to be controlled as an independent zone. When each room is served by its own homerun circuit the temperature of each room can be adjusted as desired. Unoccupied rooms can be set at low temperatures to conserve fuel. Heat output to a room that experience solar heat gains can be interrupted when necessary without compromising comfort in other rooms. The temperature in bedrooms can be reduced during sleeping hours if desired, while bathrooms can remain warm for showers and baths. One way of providing room-by-room zone control is by adding low voltage electric valve actuators to the valves on the manifold. These actuators are controlled by the thermostats in each room. When the room thermostat calls for heat it sends a 24 volt AC signal to the associated actuator. The actuator then opens the manifold valve to which it is attached. An isolated end switch with the valve actuator provides a contact that is used to turn on the circulator and heat source. Non-electric thermostatic radiator valves (TRVs) can also be used in conjunction with a homerun distribution system to provide individual temperature control in each room. TRVs adjust the flow rate of heated water through the heat emitters to regulate heat output. They do not have the ability to signal for circulator or boiler operation. In this type of distribution system the circu-
Figure 8-2
89
lator runs continuously throughout the heating season. The water temperature supplied to the heat emitters is often regulated by an outdoor reset control. The colder it is outside the warmer the water temperature. Still another benefit of homerun distribution systems is the reduced pressure drops they create in comparison to a series piping loop. Lower pressure drops often allow a smaller, less power consuming circulator to be used. This saves not only on installation cost, but also on operating cost over the long life of the system. When designing a homerun distribution system keep in mind that some hydronic heat emitters such as panel radiators and lengths of fin-tube baseboard can be sized to operate with temperature drops as high as 40 deg. F. under design load conditions. Such high temperature drops allow significant reductions in the flow rate supplied to the heat emitters. This in turn can allows the use of small tubing such as 3/8 Kitec PEXAL-PEX for the homerun circuits. For example, a panel radiator delivering 10,000 Btu/hr with 180 deg. F inlet, and 140 deg. F. outlet water temperature only needs about 0.5 gpm of flow. This could easily be handled by 3/8 tubing. Such small diameter tubing is easily routed through framing cavities, even cavities that are closed off. In general, if a piece of electrical cable can be pulled through the building from one location to another, so can a length of small diameter composite tubing. This
makes the homerun approach ideal for retrofit jobs where framing cavities may have limited access. When individual circuit control is used, a differential bypass valve should be installed across the manifold as shown in figure 8-2. It provides a flow bypass that prevents the circulator from dead heading when all the manifold valves are closed. Adjust the knob on the differential pressure bypass valve so it just begins bypassing flow when all the zone circuits are on, then increase the pressure setting slightly. As the individual homerun circuits close off the bypass valve will take an increasing percentage of the manifold flow and prevent the circulator from imposing a high pressure differential on the circuits that remain active.
Figure 8-3
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SECTION 8
Figure 8-4
Notice that the crossover bridge closest to the supply side of the heat source and circulator is also the closest to the return end of the system. The farther out the other crossover bridges are the longer the flow path of the circulating water. To obtain the proper flow rate through each heat emitter a flow balancing valve must be installed in each crossover bridge. The amount each balancing valve is closed depends on the intended flow rate through each heat emitter as well as its position on the mains. Although it is possible to calculate the necessary Cv setting of each balancing valve this is seldom done. Instead, the valves are set through a trial and error process until the heat outputs of all heat emitters are acceptable. Parallel direct-return distribution systems can be constructed of Kitec PEX-AL-PEX pipe. Larger diameter composite piping can be used to create the mains, while small pipe sizes can be used to create the rungs. Notice how the pipe size of the mains decreases as the distribution system expands away from the mechanical room.
called a reverse return system. An example is shown in figure 8-4. In a reverse return system the first crossover bridge attached to the supply main is, in effect, the last to be attached to the return main. This arrangement helps equalize the piping path length through each heat emitter. This in turn help naturally balance flow through the system, especially with the attached heat emitters have similar flow resistance. Because of its ability to be self balancing reverse return systems are often preferred over direct return systems. The optimal arrangement of a parallel reverse return circuit within a building is shown in figure 8-5. Notice that the distribution system makes a loop around the building rather than a dead end at the farthest point out.
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Figure 8-5
tions prompted designers to look for a piping method more flexible and forgiving than the standard 2-pipe system. They soon rediscovered the elegant simplicity of primary / secondary piping, and were able to successfully integrated with modern controls. Today method of piping is rapidly becoming the standard setter as the backbone upon which to build modern multi-load / multi-temperature hydronic systems. The fundamental concept of a P/S system is to uncouple the pressure differential established by any given circulator, from that established by other circulators in the same system. P/S piping allows each circulator in the system to operate with virtually no tendency to induce flow, or even disturb flow, in circuits other than its own. In effect each circulator thinks its circuit is the only circuit in the system. This allows a number of circulators with different head and flow rate characteristics to operate simultaneously without interfering with each other. circuit is shown in figure 8-6. The function of the primary circuit is to deliver hot water to each of the secondary circuit attached to it.
Figure 8-6
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SECTION 8
Figure 8-7
The primary circulator produces flow in the primary loop only, and is NOT intended to create or even assist with flow in any of the secondary circuits. Each secondary circuit is attached to the primary circuit using a pair of closely spaced tees as shown in figure 8-7. Since the pressure drop between the closely spaced tees is almost zero, theres virtually no tendency for flow in the primary circuit to create flow in the secondary circuit. When a secondary circulator is turned on, it establishes its own pressure differential in its secondary circuit. This in turn draws flow from the upstream tee in the primary loop, sends the flow through the secondary circuit, and returns it to the downstream tee in the primary loop. The primary loop functions as the source of hot water as well as a return path, instead of direct piping connections to the heat source itself. The primary loop also becomes the pressure reference point for the secondary circuits. It acts as the point of connection to an expansion tank for each of the secondary circuits. Because of this, its important that each secondary circulator pumps into its associated secondary circuit, (e.g. away from the expansion tank reference point). This allows the pressure in the secondary circuit to increase when the secondary circulator operates.
Formula 8-1
T =
Where:
Q 500 x f
T = Temperature drop in the primary loop across the tees of an operating secondary circuit (deg. F) Q = Rate of heat delivery to the secondary circuit (Btu/hr) f = Flow rate in the primary circuit (in gpm) 500 a constant for water (use 479 for 30% and 450 for 50% glycol)
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Figure 8-8
The heat emitters in the various secondary circuits need to be sized for the water temperature available to them based on where they connect to the primary circuit. The farther downstream a given secondary circuit connects to the primary loop, the lower the water temperature it has available (assuming the upstream secondary circuits are operating). Its usually best to place secondary circuits with higher temperature requirements near the beginning of the primary circuit, and those that can work with lower water temperatures near the end. If a conventional boiler is used as the heat source always check that the water temperature at the end of the primary loop (when all loads are operating) is above the dew point of the boilers exhaust gases. Minimum return temperatures of 130 deg. F. for gas-fired boilers, and 150 deg. F. for oil-fired boilers are often suggested. hot water into a secondary circuit when its circulator is off). This migration is causes by two factors. First theres the natural tendency of hot water to thermosiphon through an unblocked piping loop located above the heat source. Hot water is lighter than cool water. Given an unblocked piping path that rises above the heat source this difference in buoyancy will maintain a weak, but persistent flow. Under such conditions the piping loop and any heat emitter it contains serves as a heat dissipater that could easily overheat spaces that simply dont need any heat input at the time. Another factor that causes heat migration is the fact that the pressure drop between the closely-spaced tees where the secondary circuit connects to the primary loop is not quite zero. The slightly higher pressure at the upstream tee will try to push some hot water into the secondary circuit. Every secondary circuit in a P/S system must include detailing to prevent heat migration when its circulator is off. One method is to install a flow-check valve (which has a weighted plug) on both supply and return
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SECTION 8
risers of the secondary circuit. The opening pressure of these valves is about 1/4 psi. This is sufficient to prevent buoyancy forces from setting up a thermosiphon flow pattern when the secondary circulator is off. A spring-loaded check valve is an acceptable alternative to a flow-check in these locations. These details are shown in figure 8-9. Two other options exist for the return riser of a secondary circuit. One is the under slung thermal trap shown in figure 8-9. Another is a swing check. Neither of these can stop forward flow caused by buoyancy forces and therefore should only be used on the return side of a secondary circuit.
secondary circuits by forcing water around the primary loop. The solution is to install separate purging valves on the return side of each secondary circuit as shown in figure 8-9. During purging the ball valve is closed forcing pressurized make-up water in the desired direction through the secondary circuit as air is blown out through the open hose bib.
Purging:
The closely spaced tees connecting a secondary circuit to the primary circuit make it difficult to purge the
Figure 8-9
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heat source using a selected temperature drop can be found using formula 8-2:
Formula 8-2
fprimary =
Where:
Q 500 x T
Figure 8-10
Each crossover bridge should have a flow-balancing valve so flow rates can be proportioned to the loads being supplied. See figure 8-11. For example, if one crossover bridge serves a load that has twice the heating requirement of a load on another crossover bridge, that bridge should have about twice the flow rate of the other. The pipe sizes of the crossover bridges can even be different if necessary depending on the flows needed. The split primary loop approach is especially helpful when several of the secondary circuits need to operate within a narrow water temperature range.
fprimary =
The designer now chooses a piping size and estimates the head loss of the primary loop based on this flow rate. A circulator capable of providing the necessary head at the calculated flow rate is then selected. Notice there was no need to examine the specifics of the secondary circuits when selecting the primary loop circulator. Selecting a high temperature drop (T) for the primary circuit results in lower flow rates, and often reduces primary loop pipe size. It may also reduce the size of the primary loop circulator. However, selecting a large temperature drop also implies lower supply water temperature to secondary circuits located farther downstream along the primary loop. This is fine for systems using both high temperature and lower temperature heat emitters provided the higher temperature secondary circuits are located near the beginning of the primary loop, while those with lower water temperature requirements are located near the end.
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SECTION 8
Figure 8-11
Figure 8-12
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When a mixing device is used to reduce the supply temperature in the secondary circuit the primary loop creates a second mix point that boosts water temperature returning to the heat source. With the proper controls, this configuration can reliably protect a conventional boiler against sustained flue gas condensation.
The possibilities of what can be constructed using the piping techniques discussed in this section are nearly endless. The next section will show you how to apply these piping techniques when necessary to create sophisticated multi-load / multi-temperature systems.
Figure 8-13
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SECTION 9
D ESIGNING M ULTIPLE -L OAD H YDRONIC S YSTEMS
9-1 Introduction
There was a time when residential hydronic heating consisted of 1 to 3 zones of baseboard piped from a single boiler. Space heating was always considered the main load. Domestic hot water was sometimes provided using a tankless coil suspended in a boiler that had to remain hot 24 hours a day, 365 days a year. Today, residential and light commercial hydronic systems are often more sophisticated than those used in larger buildings. In addition to multiple methods of space heating, these systems almost always provided domestic hot water heating. Many go further to provide snow-melting, intermittent garage heating and perhaps even warm the backyard swimming pool. This section shows how an integrated multi-load hydronic system can be assembled. It will look at ways to configure the heat source, pipe the system and even select control strategies that allow all the loads to operate in an optimal manner.
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is reduced. Should such spillage occur, there is a better chance of detecting it prior to its spread through the building. The heat plant used in most integrated multi-load hydronic systems is one or more gas- or oil-fired boiler(s). Water in the temperature range of 180 to 200 degrees F. is produced for loads such as fin-tube convectors and domestic water heating. Medium and low temperature water for other loads is achieved by blending hot water with cooler return water using one or more of the mixing strategies discussed in section 6. Integrated multi-load hydronic systems can also take advantage of load diversity. Its the concept that all loads in a multiple load system almost never demand full heat input at the same time. Thus, its almost never necessary to size the heat plant equal to the total of all loads operating simultaneously at maximum output. In the unlikely event all loads did call for maximum heating at the same time the systems controls can invoke prioritized load shedding. Heat input to lower priority loads like garage floor heating and pool heating can be temporarily interrupted so heat can be redirected to higher priority loads like domestic hot water production and space heating. When the high priority loads are satisfied, heat output is directed to
making up the heat deficits of the low priority loads. The large thermal mass of slab-type floor heating and swimming pools make boiler sizing more a matter of how much energy can be delivered over a period of several hours, rather than how much instantaneous capacity is available.
Figure 9-1
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SECTION 9
include: The ability to provide partial heat delivery if one boiler is down for servicing. The use of smaller/lighter boilers that are easier to install, especially in retrofit situations. The ability to place all the heat generation in one location and thus eliminate several other dedicated heat sources distributed through the building. To achieve maximum efficiency, the multiple boiler system should be designed so heated water is NOT circulated through unfired boilers. Doing so uses the unfired boiler(s) as heat dissipaters. Although there are several possible ways to achieve this, the piping shown in figure 9-1 is considered by many to be the simplest and most efficient approach. In this configuration, each boilers circulator operates only when that boiler is firing. The flow check valves prevents gravity circulation or reverse flow at all other times. This arrangement also supplies each boiler with the
same (lowest possible) return temperature. The cooler each boiler operates, the higher its efficiency. System controls are configured to prevent any of the boilers from operating at temperatures low enough to cause sustained flue gas condensation. Multiple-boiler systems are usually operated by a staging control. Such controls have the ability to determine the appropriate water temperature for the load(s) that are active at any given time, and then steer the water temperature supplied to the distribution system toward this target temperature. For space heating loads the water temperature is often reset based on outdoor temperature as discussed in section 6. When the load is supplied through a heat exchanger (such as with snow melting, pool heating, or domestic water heating), the control is usually configured to deliver a high (but fixed) water temperature regardless of the outdoor temperature. Figure 9-2 shows how a 3-boiler system can be piped to provide heat to both domestic water heating and space heating loads. Notice the closely-spaced tees that connect the boiler
Figure 9-2
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manifold piping to the distribution system. This piping arrangement allows the boiler system to hand off heat to the distribution system without interference between the various circulators. Also notice the placement of the supply temperature sensor for the boiler staging control. This placement is necessary because the boiler circulators will only operate when the boilers are being called for by the boiler staging control. Do not place the supply sensor on the boiler manifold piping since there will be times when the boiler circulators will be off, yet a load still exists in the distribution system. Without flow through the boiler, manifold piping heat cannot be delivered to the distribution system.
exchanger for fast recovery. Always install a flow-check valve in the supply line leading to the tanks heat exchanger. This prevents the possibility of heat migration due to buoyancy forces and/or slight pressure differentials between the closelyspaced tees connecting the tanks heat exchanger to the primary loop. It also prevents hot water in the tank from establishing a convective cooling loop when the circulators are off. Piping the DHW tank as a secondary circuit requires hot water to flow around the entire primary loop whenever theres a call for domestic water heating. To minimize piping heat loss, this piping arrangement should only be used for short primary loops that run within the mechanical room. Preferably, the primary loop and DHW secondary loop piping will be insulated to further reduce piping heat loss. The system designer should also take note that if the DHW tank is not operated as a priority load, all downstream secondary circuits will receive reduced water temperature while the DHW load is operating. The heat emitters in the downstream secondary circuits should be sized to accommodate this reduced water temperature if extended demand for domestic water heating is likely to occur simultaneously with maximum space heating demand. Another piping option for connecting an indirect water
Figure 9-3A
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SECTION 9
Figure 9-3B
heater into the system is shown in figure 9-3B. The indirect water heater is now connected as a parallel circuit to the primary loop. It can operate independently of the primary loop. If the water heater is located close to the boiler and the piping circuit between the two is short, piping heat loss during the DHW cycle is minimal. Furthermore, this arrangement doesnt reduce the water temperature supplied to the primary loop should that loop be operating simultaneously with domestic water heating. Because of these advantages, the parallel piping arrangement is often preferred over piping the indirect water heaters as a secondary circuit. system. The details and options available for primary/secondary piping were discussed in section 8. The backbone of the system is the primary loop. It conveys hot water to one or more secondary circuits that, in turn, convey that water to the heat emitters. Each secondary circuit can be thought of as a subassembly that is plugged into the primary loop. When the system serves several loads that operate over a wide range of water temperatures, the loads requiring the high water temperatures should be piped in near the beginning of a series-type primary loop, while those requiring lower temperatures are connected near the end. This allows the loads to accommodate the decreasing water temperature around the primary loop. Designers should investigate the possibility of operating primary loops with temperature drops of 30 to 40 degrees F. under design load conditions, (instead
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of the typical 20 degrees F.). The greater the temperature drop, the lower the primary loop flow rate can be to deliver all the output of the heat source. In many cases the size of the primary loop piping as well as the primary circulator can be reduced when the loop is designed around a higher temperature drop. A smaller circulator could significantly reduce the electrical energy used by the system over its lifetime. When designing a series primary loop, its necessary to account for the temperature drop associated with each operating secondary circuit. Formula 8-1, repeated below, can be used for this purpose.
The heat emitters in the various secondary circuits need to be sized for the water temperature available to them based on where they connect to the primary loop. The farther downstream a given secondary circuit connects to the primary loop, the lower the water temperature available to it (assuming the upstream secondary circuits are operating). If a conventional boiler is used as the heat source, the designer should also verify that the water temperature at the end of the primary loop (when all loads are operating) is high enough to prevent sustained flue gas condensation within the boiler or its vent piping. Refer to section 5 for a more detailed discussion of this topic. Figure 9-4 depicts a system using a single boiler to supply radiant floor heating as well as an indirect water heater. The floor heating system consists of three manifold stations piped in parallel. This arrangement supplies the same water temperature to each manifold station (as discussed in section 8). The supply water temperature to the floor circuits is controlled by a variable speed injection mixing system. Note that the DHW tank is connected as a parallel
Formula 8-1
T =
Where:
Q 500 x f
T = Temperature drop in the primary loop across the tees of an operating secondary circuit (deg. F) Q = Rate of heat delivery to the secondary circuit (Btu/hr) f = Flow rate in the primary circuit (in gpm) 500 a constant for water (use 479 for 30% , and 450 for 50% glycol)
Figure 9-4
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SECTION 9
Figure 9-5
circuit to the primary circuit. Also note the locations of the temperature sensors providing feedback to the injection controller. Figure 9-5 expands the system of figure 9-4 by adding a series of secondary circuits supplying finned-tube baseboard. Since the baseboards need to operate at a higher water temperature than the floor heating circuits, the secondary circuit supplying them is connected to the primary loop upstream of the injection mixing system. The distribution system is further expanded in figure 96 by adding a heat exchanger to supply heat to a garage floor heating subsystem that will be filled with a glycol solution allowing it to be completely turned off when desired. The temperature of the glycol solution is controlled by a variable speed injection pump that regulates the hot water flow through the hot side of the heat exchanger. The controller operating the injection pump monitors its own return temperature sensor located near the inlet of the boiler. When necessary, this controller reduces the hot water flow through the garage heat exchanger to prevent the cold garage floor slab from removing heat from the system faster than the heat plant can produce it. The heat exchanger, like the DHW tank, is connected as a parallel (rather than secondary) circuit. In the event the heat exchanger and the DHW tank are allowed by the controls to operate at the same time, this arrangement makes the highest water temperature in the system available to both loads. When the DHW tank or garage floor heat exchanger call for heat, (as evidenced by a contact closure of either a thermostat or aquastat) the boiler staging control receives a setpoint demand. In this mode, the target water temperature leaving the boiler manifold piping is typically in the range of 200 deg. F. When either of the space heating loads calls for heat, the boiler controller receives a heating demand. In this mode, the target water temperature is calculated by the boiler control based on the current outdoor temperature (e.g. outdoor reset control).
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Figure 9-6
Figure 9-7 adds one more subassembly to the system. Its a secondary circuit consisting of a small circulator and homerun manifold station supplying several small heat emitters. Some of these heat emitters may be towel warmers in the building. Others may supplement the output of a heated floor in certain high load areas of the building. The home run approach as described in section 6 allows small diameter Kitec or PEX tubing to be routed through the building structure much like electrical cable. It also allows for individual circuit control and supplies the same water temperature to each circuit. Another modification shown in figure 9-7 is using an external stainless steel heat exchanger between the system water and a conventional hot water storage tank. A stainless steel or bronze circulator must be used between the storage tank and the heat exchanger. This arrangement can be used in situations where the heat transfer capacity of an indirect water heater (with its own internal heat exchanger) is not sufficient to transfer the full heat output of the heat plant to the domestic hot water load. When heat transfer between the heat plant and domestic hot water load is bottlenecked, the boiler will climb to its high limit temperature before the DHW load is satisfied and shut off during part of the cycle. As such, the heat plant is not delivering its full potential heat output rate to the load. Ensuring that this doesnt happen is important in systems that supply domestic hot water to homes with multiple bathrooms, especially those equipped with high water usage fixtures.
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SECTION 9
Figure 9-7
the loads over a period of several hours. Use prioritized load shedding (when necessary) to handle unusually high load requirements. Use a multiple boiler system rather than a single large boiler when the system has a wide range of load requirements (such as a high intermittent demand for domestic water heating). When using multiple boilers, configure the piping and controls so heated water is not circulated through unfired boilers. When using multiple boilers, connect the boiler manifold to the distribution system with a pair of closely-spaced tees to prevent interference between the boiler circulators and those in the distribution system. Use a series primary loop when the water supply temperatures of the secondary loads vary over a wide range. Connect high temperature secondary circuits near the beginning of a series primary loop, and lower temperature loads near the end. Use a parallel primary secondary piping when the water supply temperatures of the secondary circuits are all similar. To minimize piping heat loss connect the indirect DHW tank as a parallel (rather than secondary) circuit. To reduce pipe size, pump size and operating cost, consider designing series-type primary loops for a temperature drop of 30 to 40 degree F. under full load. For maximum recovery rate, ensure that the full output of the heat plant can be delivered to the water heater without the boilers reaching their high limit temperature settings. Use an external heat exchanger if necessary to ensure full heat transfer to the domestic hot water storage tank.
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SECTION 10
R ADIANT P IPE AND T UBING
IPEX is a leading supplier of thermoplastic piping systems, providing customers with one of the worlds largest and most comprehensive product lines. Included in this offering are the two leading products for hydronic radiant heating Kitec XPA pipe and oxygen barrier PEX tubing. Kitec XPA and PEX tubing have each played an important role in the impressive growth of hydronic radiant system popularity in North America. Used in radiant floor heating for residential, industrial and institutional projects, radiator and baseboard hook-up, snowmelt systems and more, XPA and PEX transport liquid from heat source, to heat zone and back again. But why choose PEX tubing for a given radiant heating installation instead of XPA pipe? The answer is really based on personal preference. Some contractors prefer PEX tubing for staple-up applications between floor joists stating that PEX tube is more flexible and less prone to kinking than XPA pipe. Others find smaller 3/8 diameter PEX tube ideally suited for topping pour installations where floor to ceiling height is limited or were changing the floor elevation is restricted. Some say there is no discernable difference between the two and the matter is cost. Still, others feel that XPA pipe is by far the superior pipe for hydronics. The facts show that both PEX tubing and XPA pipe are viable products with decades of proven performance in all manner of hydronic applications. As the worlds leading supplier of thermoplastic piping systems, IPEX offers industry the two leading options for hydronic pipe and tubing. In time, the debate over which is better XPA or PEX will sort itself out.
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longevity of plastic and it brings some unique benefits to the hydronic radiant heating market. XPAs aluminum core is what sets it above all other heating pipes. In combination with x-linked polyethylene and specialized adhesive layers that bond the components together, this aluminum core is responsible for most of XPA pipes unique features and benefits. Thanks to its aluminum core, XPA pipe is stronger than typical heating PEX tubing. XPA pipe exhibits greater long term pressure ratings (25% higher operating pressure than PEX tube), greater burst pressure resistance, greater hoop strength for resistance to crushing, greater beam strength for less sagging.
PEX Tubing
Dimensions in inches
Nominal Size 3/8 1/2 5/8 3/4 1 Average I.D. 0.346 0.485 0.584 0.681 0.875 Average O.D. 0.500 0.625 0.750 0.875 1.125 Weight Volume U.S. lb / 100 ft gal / ft 4.1 5.4 8.1 10.2 16.9 0.005 0.009 0.014 0.019 0.030
Dimensions in mm
Nominal Size 9 12 16 20 25 Average I.D. 8.8 12.5 16.0 20.5 26.0 Average O.D. 12.2 16.0 20.0 25.0 32.0 Weight g/m 69 101 150 203 341 Volume l/m 0.063 0.113 0.201 0.314 0.500
Dimensions in mm
Nominal Size 9 12 16 20 25 Average I.D. 8.8 12.3 14.8 17.3 22.2 Average O.D. 12.7 15.9 19.0 22.2 28.6 Weight g/m 61 81 121 152 252 Volume l/m 1.063 0.111 0.174 0.236 0.372
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SECTION 10
XPA pipe limits oxygen permeation to 0.006g/m3/C/day, 25 times better than the acceptable standard. PEX tubing has its EVOH oxygen barrier located on the outside of the tubing. This layer limits oxygen permeation to minimum acceptable amount of 0.10 g/m3/C/day.
Oxygen permeation
Unlike barrier PEX tubing with its externally applied oxygen barrier XPA pipe houses an aluminum oxygen barrier permanently in between layers of plastic. This means that damage due to installation and construction is avoided making the oxygen barrier a permanent and reliable component of your heating system.
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XPA Pipe Pressure Loss per 100 feet - psi Flow Rate GPM
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.4 1.6 1.8 2.0 2.5 3.0 3.5 4.0
3/8"
0.11 0.45 0.92 1.52 2.24 3.08 3.61 4.58 5.66 6.84 9.48 12.50 15.90 19.60 23.70 35.50 49.20 -
1/2"
0.02 0.05 0.16 0.26 0.39 0.54 0.70 0.89 0.97 1.17 1.62 2.14 2.72 3.36 4.06 6.06 8.41 11.10 14.10
5/8"
0.01 0.02 0.03 0.09 0.13 0.17 0.23 0.29 1.36 0.43 0.52 0.69 0.88 1.08 1.31 1.96 2.71 3.58 4.55
3/4"
0.00 0.01 0.01 0.01 0.04 0.06 0.07 0.09 0.11 0.14 0.19 0.24 0.28 0.34 0.41 0.61 0.85 1.12 1.43
3/8"
0.11 0.45 0.92 1.52 2.24 3.08 3.61 4.58 5.66 6.84 9.48 12.50 15.90 19.60 23.70 35.50 49.20 -
1/2"
0.03 0.06 0.18 0.30 0.45 0.62 0.81 1.03 1.15 1.39 1.92 2.54 3.22 3.98 4.81 7.18 9.96 13.10 16.70
5/8"
0.01 0.03 0.04 0.13 0.19 0.26 0.34 0.42 0.52 0.63 0.77 1.02 1.29 1.60 1.93 2.88 3.99 5.27 6.70
3/4"
0.01 0.01 0.02 0.06 0.09 0.12 0.16 0.20 0.25 0.30 0.42 0.49 0.62 0.76 0.92 1.38 1.91 2.52 3.20
1"
0.00 0.01 0.01 0.01 0.03 0.04 0.05 0.06 0.08 0.09 0.13 0.17 0.19 0.23 0.28 0.41 0.57 0.76 0.96
XPA Pipe Pressure Loss per 100 meters - kPa Flow Rate L / min
0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.67 5.45 6.22 7.00 7.78 9.73 11.70 13.60 15.60
9mm
2.41 10.2 20.7 34.3 50.7 69.7 81.7 104 128 155 215 283 360 44 537 802 1110 -
12mm
0.55 1.11 3.61 5.97 8.82 12.1 15.9 20.1 21.9 26.5 36.7 48.4 61.5 76.0 91.8 137 190 251 319
16mm
0.22 0.43 0.65 1.95 2.88 3.96 5.18 6.55 8.05 9.68 11.9 15.6 19.9 24.5 29.6 44.2 61.4 81.0 103
20mm
0.08 0.16 0.25 0.33 0.91 1.26 1.65 2.08 2.55 3.07 4.22 5.53 6.24 7.71 9.31 13.90 19.30 25.40 32.30
25mm
0.03 0.06 0.09 0.12 0.15 0.39 0.51 0.64 0.79 0.95 1.31 1.71 2.16 2.66 3.19 4.25 5.89 7.77 9.87
12mm
0.97 1.93 2.90 7.74 11.4 15.7 20.6 26.0 32.0 38.5 52.9 63.3 80.4 99.2 120 179 248 327 416
16mm
0.30 0.59 0.89 2.85 4.22 5.8 7.6 9.6 11.8 14.2 17.5 23.0 29.2 36.1 43.6 65.1 90.3 119 151
20mm
0.16 0.32 0.48 1.38 2.03 2.80 3.66 4.63 5.69 6.84 9.41 11.0 14.0 17.3 20.9 31.2 43.2 57.0 72.5
25mm
0.06 0.12 0.18 0.24 0.62 0.85 1.11 1.41 1.73 2.08 2.86 3.75 4.21 5.20 6.28 9.37 13.0 17.1 21.8
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SECTION 10
Electrical Properties
Although XPA pipe contains an aluminum core, its joining systems are not designed to conduct stray current. In consideration of electrical grounding XPA pipe is considered to be a thermoplastic piping system and should never be used to ground. PEX tubing too should be treated as other thermoplastic piping systems are in that it must not be used to ground electrical systems.
Quick Burst 1160 psi 1015 psi 1005 psi 825 psi 790 psi 73F (8004kPa) (7003kPa) (6935kPa) (5693kPa) (5451kPa) (23C) Quick Burst 750 psi 685 psi 655 psi 550 psi 535 psi 180F (5175kPa) (4724kPa) (4520kPa) (3795kPa) (3692kPa) (82C)
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ANSI / NSF 14 Plastics Piping System Components and Related Materials Product Certification Listing IPEX holds NSF certification on its PEX tubing for potable water applications and radiant floor heating in residential and commercial construction, including manufactured housing.
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SECTION 11
H YDRONIC S NOW AND I CE M ELTING
11-1 Introduction:
IPEX hydronic heating products can be used to provide snow and ice melting on all types of exterior areas including: Driveways Walkways Parking areas Steps Wheelchair access ramps Patios Decks Roofs On specialized commercial and industrial properties, hydronic snow melting has been used for the following applications: Car washes Hospital emergency entrances Toll booth areas Loading docks Helicopter landing pads Security gate areas Other areas that must be kept free of snow and ice
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an insulator between the heated pavement surface and the outside air reducing both evaporation and convective losses. Evaporation of the melt water requires much higher heat input.
Class 2 systems:
Generally accepted as sufficient for most retail and commercial paved areas that must be kept clear of accumulating snow during a heavy snow fall, although the pavement will often remain wet. The rate of heat delivery to the surface in typically in the range of 125 to 250 Btu/hr/square foot, depending on location.
Class 3 systems:
Used for high priority areas such as helicopter pads, toll plazas, sloped pavements in parking areas, pavements adjacent to hospital emergency rooms. Class 3 systems are designed with the ability to melt all snow as fast as it falls and quickly evaporate the melt water from the surface. They generally require heat delivery rates of 250 to as high as 450 Btu/hr/square foot.
Class 1 systems:
This class of system is generally accepted as sufficient for most residential walkway and driveway areas. The rate of heat delivery to the surface in generally in the range of 80 to 125 Btu/hr/square foot depending on location. Class 1 systems often allow a layer of snow to accumulate during a heavy snowfall, especially if the system is manually controlled and starts from cold. This snow layer is actually beneficial because it acts as
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SECTION 11
The major distinction between these classes is in the rate of heat delivery to the area being melted. The following table gives suggested heat delivery rates for all three class of snow melting systems in several locations.
Pavements must be sloped to drains capable of routing the melt water to a drywell, storm sewer, or other discharge (check local codes) without it freezing in the process. Drainage piping should not run through the heated thermal mass because the cold water will rob heat from the system. Instead, drainage piping should be routed beneath the underside insulation where it is protected from freezing. Keep in mind that a shallow drainpipe running through unheated soil can quickly fill with ice and be very difficult to thaw. One method of ensuring the drainage system does not freeze is to install a dedicated drain heating circuit of Kitec tubing alongside the drainage trench, receptor and piping. Trench drain systems are often used at the lower elevations in melted pavements. If the pavement slopes toward a building, be sure the melt water can be collected before it can flow into the building. Likewise, be sure melt water running down a pavement toward a street will be collected by a drain before it contacts the unheated pavement. Figure 11-2 shows some examples of pavement drainage concepts. Be sure to discuss drainage provisions with those responsible for its installation as soon as possible in the planning stages of the system.
Drainage considerations
It is crucially important that all melted pavement areas be detailed for proper drainage of melt water. The heat delivery rates used with Class 1 and 2 systems assume that most of the melt water will be drained from the surface (as a liquid) rather than evaporated. The latter method of moisture removal requires considerably more heat input. Failure to provide proper drainage can allow melt water to accumulate at low points in the pavement, or where the melted pavement adjoins non-melted areas. When the system turns off, this standing water can quickly turn to dangerous ice.
overhead door
to drywell
melted pavement
trench drain
underside insulation
to drywell
Figure 11-2
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In cold climates or projects where the pavement will be held at an idling temperature near freezing, it is cost effective to install a layer of extruded polystyrene insulation over the compacted gravel base. This insulation greatly reduces downward heat loss from the pavement. It also shortens the response time of the system when melting is required, especially in cold climates where the system doesnt idle the slab. A thickness of 1 inch (R-5) is usually adequate. Be sure the rigid board insulation lies flat against the compacted gravel base at all locations so the pavement is fully supported when loaded. The compressive stress rating of the insulation should be selected to match loads that may be imposed on the pavement. A 25 psi rated insulation board is the minimum rating for pavements subject to light vehicular traffic. If heavier (truck) traffic is anticipated insulation with a compressive load rating of 40 to 60 psi should be considered. Insulation manufacturers can provide guidance on the proper compressive stress rating for a given pavement application. Welded wire fabric (WWF), or a grid of rebar is now installed over the insulation. Be sure to overlap all sheets of WWF by at least 6 and tie them together with wire twist ties. The Kitec tubing can now be secured to the steel reinforcing using wire twist ties spaced 48 to 60 inches apart. Tube spacing should never exceed 12 inches. Wider spacing can result in uneven melting patterns that may not completely clear the pavement of snow before the melting operation is shut off. Nine inch tube spacing is recommended in most cases. In areas with high snow fall rates, high average wind speeds or situations where a cold (non-idled) slab needs to be brought up to temperature quickly, 6 in. spacing should be used. Section 11-6 discusses tube spacing issues in more detail. Tubing circuits should be planned so as not to exceed the maximum lengths given in section 11-6. The warmest portion of the circuit should generally be routed in the areas with the highest melting priority. For example, the tire track area of a typical driveway would usually have a higher melting priority than the edges of the driveway. Dont install tubing closer than 6 inches to the edge of the pavement.
118
SECTION 11
Figure 11-3
concrete paving
pipe wire mesh insulation heavy duty extruded polystyrene compacted base
Figure 11-3A
119
Figure 11-4 shows a typical tubing layout for a residential driveway based on use of 5/8 Kitec pipe. It is highly recommend that the designer make an accurate tubing layout drawing for each project before installation begins. CAD generated tubing layouts allow the designer to check circuit lengths, determine the total amount of tubing needed and provide the installer with an easy to follow plan. Once installed, all tubing circuits should be pressure tested using compressed air at 75 psi for a minimum of 24 hours prior to placing the concrete. Be sure to cap all circuit ends until they are connected to the manifold to prevent construction dust and moisture from contaminating the system. The tubing and reinforcing steel should be supported or lifted during the pour so the top of the tubing is 1.5 to 2 inches below the finish surface of the slab. Tubing
depth is more critical in a snow melting applications than in radiant floor heating. Leaving the tubing at the bottom of a typical 6 exterior slab significantly increases the response time of the system when melting is initiated. It also increases the required fluid temperature and downward heat loss. The tubing should be protected with sleeving wherever it crosses a full control joint location in the slab. The tubing depth should be sufficient to ensure that sawn control joints will not harm the tubing, no sleeving necessary. In locations where the tubing passes from the paved area through a foundation wall, the installation must be detailed to prevent damage to the tubing should the pavement shift up or down. Air entrained concrete with a minimal 28 day compressive stress rating of 4000 psi is often specified for exterior slabs.
Figure 11-4
120
SESECTION 11
The subgrade and insulation under an asphalt driveway or walkway is prepared the same as for a concrete pavement. A mat of welded wire fabric (WWF) is then laid out over the insulation. All sheets of the WWF
Figure 11-5
asphalt paving
compacted sand
compacted base
Figure 11-5A
121
should be overlapped 6 inches at their edges and tied together with wire twist ties. The tubing is unrolled and secured to the WWF with wire twist ties spaced 48 to 60 inches apart. After pressure testing the circuits a 3 to 4 inch deep layer of sand or stone dust is placed over them. The sand/stone dust layer protects the tubing from the hot asphalt (250-350 degrees F.). After the WWF and tubing have been placed, the sand/stone dust should be uniformly and thoroughly soaked with water to settle the particles around the tubing and provide a stable base for the asphalt. Kitec (PEX-AL-PEX) pipe is especially well suited to this application because its low coefficient of expansion minimizes dimensional changes of long tubing runs as the system cycles between warm and cold. When placed, asphalt paving can be as hot as 350 degrees F. It should never be placed directly on Kitec or PEX tubing. However, when the tubing is embedded in the layer of sand/stone dust as described, the hot asphalt can be placed without damaging to the tubing.
Figure 11-6
122
SECTION 11
paving bricks
compacted sand
compacted base
Figure 11-6A
discharge area. The crushed stone layer should also be tamped flat before the rigid insulation is placed over it. Drainage detailing is still recommended since the rate of melt water (or rainwater) accumulation may at times exceed the rate at which water can weep downward between the pavers. Extruded polystyrene insulation is impermeable to water. To allow water drainage, nominal 1/2 gaps should be left between adjacent sheets of insulation. Alternatively, several sheets of rigid insulation can be stacked and drilled to form a grid of 1 inch diameter holes space 12 inches apart. In either case, the holes or slots must be covered with strips of water permeable filter fabric. This allows water to drain through without carrying the fine particles of sand or stone dust with it. Avoid creating drainage situations where flowing water could form channels through the sand/stone dust layer beneath the pavers. Such channels could lead to voids that may eventually cause some pavers to sink. A mat of welded wire fabric (WWF) is laid out over the insulation. All sheets of the WWF should be overlapped 6 inches at their edges and tied together with wire twist ties. The tubing is then unrolled and secured to the WWF with wire twist ties spaced 48 to 60 inches apart. After the tubing circuits have been pressure tested, the tubing and WWF should be covered with 3 to 4 inches of sand or stone dust. After the WWF and tubing have been layered the sand layer should be uniformly and thoroughly soaked with water to settle the sand or stone dust around the tubing and provide a stable base for the pavers. melting is required, as well as how they control the pavement temperature before, during and after melting operation. They also differ considerably in cost. The approach selected must be based on the expectation of the owner, the degree of unattended operation expected, the size of the area being melted and the class of system being designed. Regardless of the control method used, some fundamental issues must be understood before a snowmelt system can be properly designed:
Antifreeze Issues
Some snow melting systems use a dedicated boiler as their heat source. The boiler and distribution piping is usually filled with an antifreeze solution (typically a 30 to 50% mixture of propylene glycol and water). In other systems snow melting as one of several loads served by the same boiler(s). The boiler(s) and piping thats are not part of the snow melting system are filled with water. In this case, a heat exchanger must be installed to isolate the antifreeze solution in the snow melting distribution system from the remainder of the system. A stainless steel plate type heat exchanger is often used for such applications. The freezing point of the mixture is a function of the % and type of glycol used. The following table helps select the correct mixture based on the outdoor temperature.
Glycol % 10% 20% 25% 30% 35% 40% 45% 50% 55% Propylene 27F 19F 15F 8F Ethylene 27F 18F 10F 5F 0F -3F -15F -28F -40F -2F -10F -20F -33F -50F
When the system starts with a cold boiler it may be possible for very cold antifreeze returning from the exterior circuits to flow through the heat exchanger
123
before much heat is delivered from the boiler to the heat exchanger. This, combined with the fact that plate heat exchangers are very efficient and have little thermal mass, presents the possibility of freezing the water in the hot side of the exchanger before heat can be delivered from the boiler. To avoid this possibility, use a temperature control to sense that hot water is flowing through the heat exchanger before allowing the circulator in the snow melting distribution system from operating. Some snow melting system controllers may have this capability built into them.
Boiler Issues
Section 3 described the necessity of maintaining the inlet temperature to a conventional boiler high enough to prevent sustained flue gas condensation. This is of utmost important when a conventional boiler is used as the heat source for a snow-melting system. The system must use a control that measures the inlet temperature to the boiler and reduces the rate of heat transfer through the mixing device supplying to the snowmelt system, when necessary, to prevent sustained flue gas condensation. The mixing device
Figure 11-7
124
SECTION 11
can be a 2-way, 3-way, or 4-way mixing valve or variable speed injection pump as discussed in section 3 and shown in figure 11-8. Condensing boilers are well suited to the low operating temperatures of hydronic snow melting systems. In most cases there is no need to install a mixing device between a condensing boiler and the snow melt distribution system. If the condensing boiler is operated with the same antifreeze solution as the snow melt circuits, there is no need to install a heat exchanger. This minimizes the operating temperature of a condensing boiler and increases its efficiency.
an idling temperature just above or below freezing. If the pavement temperature is idled just above freezing, it will generally be free of frost and black ice, and be an important advantage in terms of safety. Idling the pavement just below freezing reduces standby heat loss, but still allows for rapid warm-up to melting temperature. Most controls let the installer adjust the pavement idling temperature. Control systems with idling capability typically initiate the idling mode when the outside air temperature drops within a few degrees of freezing (35 to 40 degrees F.). Such air temperatures represent the possibility of frozen precipitation. Idling the system above these air temperatures is largely a waste of fuel. To idle the pavement, the controller must sense pavement temperature. Typically, a small thermistor sensor is located within a well in the slab. This well is usually made of capped copper tubing thats cast
Figure 11-8
125
into the pavement. The position of the slab temperature sensor is crucial to the proper performance of the control system. The slab sensor is typically located 1 below the top of the pavement, and halfway between adjacent tube circuits. The open end of the well should lead to an accessible location so the sensor can be replaced if it ever fails. Be sure to follow the control manufacturers recommendations regarding installation of the pavement temperature sensor.
electrical contact closure whenever precipitation is occurring AND the outside air temperature is below a given temperature. Both types of sensors have a small heated cell at the top of their housing. Precipitation is detected by the electrical conductivity of the water on this cell. This, in combination with an air temperature just above freezing, provides the start-up criteria for the system. Control systems that monitor pavement temperature tend to reduce fuel usage by allowing the system to maintain the pavement surface just a few degrees above freezing. The cooler the pavement surface, the lower the heat losses. Many snow melting controls can also prevent or terminate melting if the outside air temperature rises above a preset value. In non-critical applications (class 1 systems), melting can also be prevented or terminated during very cold weather when heat loss would be excessive.
Flow requirements
The flow rate required for a snow melting circuit to deliver a given amount of heat to the pavement can be determined using formula 11-1.
Formula 11-1
f=
where:
q k x T
k=500
K=477
K=465
K=449
For example: the flow rate required to deliver 22,000 Btu/hr using a 40% solution of propylene glycol in a circuit operating with a 20 degree F. temperature drop is:
126
SECTION 11
f=
1/2" Kitec 5/8" Kitec 3/4" Kitec 180 ft. 250 ft. 400 ft.
The rate of heat delivery required for many snow melting applications is considerably higher than that required for a typical floor heating system. To deliver more heat without excessive temperature drop, the flow rate in the embedded circuits must be increased. The use of glycol-based antifreeze solution (instead of 100% water) reduces the heat carrying ability of the heat transfer fluid, and further increases the flow requirement. For example: the flow rate in a 250 foot long floor heating circuit, with tubing spaced 12" apart, delivering 25 Btu/hr/sqft with a 20 degree F. drop in water temperature is:
Note the allowable length of 1/2" tubing circuit is approximately 50% that of 3/4" tubing. Likewise, the allowable length of a 5/8" Kitec tubing circuit is approximately 65% that of 3/4" tubing.
f=
This flow is easily handled by a 3/8" or 1/2" tube. However, the required flow rate in a circuit using tubing spaced 12" apart, Btu/hr/sqft with a temperature drop of and using a 50% solution of propylene 250 foot long delivering 150 20 degrees F., glycol is:
Formula 11-2
127
pavement, and arguably could allow the system to use higher steady state temperature drops. The larger temperature drops would reduce flow rates and required pumping power. The concept is shown in figure 11-9.
Figure 11-9
128
SECTION 11
snow melting installation. Formula 11-3 is an empirically derived relationship that can be used to approximate the heat output of a snowmelt slab using tubing spaced 12 inches apart, and covered with snow in the process of melting.
Q = 2 x (MFT - 33)
where:
Q = heat output (Btu/hr/sq. ft.) MFT = mean fluid temperature in the circuit (degree F.) For example: assume a tube circuit installed at 12 inch spacing is supplied with 120 degree F. fluid and operates with a 20 degree F. temperature drop. The mean fluid temperature in the circuit is 110 degrees F. When the slab is covered with a film of water (from the melting snow), its rate of heat output is approximately:
Formula 11-3
Figure 11-10
129
SECTION 12
IPEX R ADIANT D ESIGN S OFTWARE
The heating system is an integral part of building design and requires a specific and detailed design process. Heating engineers must analyze building location, function, occupancy and control requirements in order to select and design the proper system and specify the appropriate components. IPEX offers the state-of-the-art IPEX RadiantTM Design software program to assist designers in calculating a number of the key design features of hydronic radiant heating systems. IPEX RadiantTM greatly assists designers by performing the following tasks: Building heat loss calculations Floor output sizing to compensate for heat loss Floor piping details and specifications Control Panel and Manifold Selection Supply and Return Piping Design Temperature Control Selection Suited to the Project Project Material List and Report Generation
TM
Project calculations are summarized in reports of varying details depending on your needs. Summary reports provide overall project design information while detailed reports present every aspect of your calculations. IPEX Radiant comes complete with a WarmRite Floor component data base and prices. It lets you add non IPEX components to your own data base of heating items regularly specified and it creates customer and project data bases to assist in managing on-going designs and for future follow-up. All of these features are compiled inside an interactive, user friendly software that gives designers the flexibility to create and specify the best possible hydronic radiant heating system.
131
Insert the disk and loading starts automatically. If the Auto Run does not start choose Start / Run, type D:SETUP then choose OK. The setup wizard will install the software onto your hard drive. Follow the screen prompts during this process. When the installation is finished an icon will appear on your desktop, giving you access to IPEX Radiant at the click of your mouse. The IPEX RadiantTM Design Software is supported with a Help Wizard and full program tutorial. To obtain your personal copy of the IPEX RadiantTM Design Software, please copy, complete and fax through the required form on the following page.
132
SECTION 12
REQUEST FORM IPEX RADIANT DESIGN SOFTWARE AND/OR MANUAL OF MODERN HYDRONICS
TM
Fax this completed form to 905-403-1124 to request your copy of the IPEX RadiantTM Design Software and/or IPEX Manual of Modern Hydronics.
Name Company Address City Postal Code/Zip Fax Province/State Phone E-mail
Title Dept.
Company classification Architect/Designer Distributor Home Builder Contractor Engineer Inspector Government
Other _______________________________
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air separator
D
spring loaded check valve diverting 3 way valve
T
isolating valve thermostatic 3 way valve
M
gate valve motorized 3 way valve
globe valve
T
thermostatic valve
M
motorized 4 way valve
M
motorized valve
P
pressure gauge
A1
T
pressure reducing valve temperature gauge
T/P
thermo-pressure gauge
circulator
drain valve
expansion tank
A2
heat exchanger
radiator
base board
fan coil
supply
B
return
boiler
hot out
WH
cold in
hot out
indirect WH
cold in
A3
supply manifold
plain manifold
A4
thermostat
sensor
transformer
MIXING CONTROL
controller
single switch
A5
manifold station
isolation module
A6
APPENDIX B HEAD LOSS CALCULATIONS FOR XPA PIPE AND PEX TUBING
The following Appendix provides head loss information for XPA pipe and PEX tubing over a range of flow rates and liquid temperatures. Tables have been developed for 100% water as well as for a range of glycol/water mixtures typically used in hydronic systems. For operating conditions not covered by the following tables contact IPEX for further information. IPEX follows ASHRAE principles for head loss calculation. In particular, the Friction Factor formula used is a function of the Reynolds Number - see below.
friction factor f = 64 / Re# f = 0.3164 / Re#^0.25 f = 0.0032 + 0.221 / Re#^0.237 Reynolds # Re# = v d D / u v = velocity d = inside diameter D = density u = viscosity velocity (ft/sec) v=y/A y = flowrate A = cross section area if if if Re# < 3,000 3,000 < Re# < 10,000 Re# > 10,000 head loss (m) H = f (L/D) (v^2 / 2g) v = velocity L = length D = diameter f = friction factor g = 9.81
B1
APPENDIX B
HEAD LOSS - 3/8" XPA PIPE 100% Water
3/8" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.16 0.33 1.03 1.70 2.51 3.46 4.53 5.72 7.03 7.54 8.94 10.5 12.1 13.8 15.6 17.5 19.5 21.6 23.8 26.1 Velocity ft/s 0.34 0.68 1.02 1.36 1.71 2.05 2.39 2.73 3.07 3.41 3.75 4.09 4.44 4.78 5.12 5.46 5.80 6.14 6.48 6.82 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 3.73 7.45 23.3 38.5 56.9 78.3 102 129 159 171 202 236 273 312 353 396 441 489 539 591 Velocity m/s 0.10 0.21 0.31 0.42 0.52 0.62 0.73 0.83 0.94 1.04 1.14 1.25 1.35 1.46 1.56 1.66 1.77 1.87 1.98 2.08 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B2
APPENDIX B
HEAD LOSS - 1/2" XPA PIPE 100% Water
1/2" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.04 0.08 0.11 0.30 0.44 0.60 0.79 1.00 1.22 1.47 1.74 2.02 2.33 2.36 2.67 3.00 3.34 3.70 4.08 4.47 Velocity ft/s 0.16 0.33 0.49 0.65 0.82 0.98 1.14 1.31 1.47 1.63 1.80 1.96 2.12 2.29 2.45 2.61 2.78 2.94 3.10 3.27 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.85 1.71 2.56 6.70 9.90 13.6 17.8 22.5 27.7 33.3 39.3 45.8 52.7 53.4 60.4 67.8 75.6 83.8 92.3 101 Velocity m/s 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B3
APPENDIX B
HEAD LOSS - 5/8" XPA PIPE 100% Water
5/8" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.01 0.03 0.04 0.06 0.07 0.20 0.26 0.32 0.40 0.48 0.57 0.66 0.76 0.86 0.98 1.09 1.21 1.20 1.32 1.44 Velocity ft/s 0.10 0.20 0.31 0.41 0.51 0.61 0.71 0.82 0.92 1.02 1.12 1.22 1.33 1.43 1.53 1.63 1.73 1.84 1.94 2.04 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.33 0.67 1.00 1.33 1.66 4.44 5.82 7.35 9.03 10.9 12.8 14.9 17.2 19.6 22.1 24.7 27.5 27.1 29.8 32.7 Velocity m/s 0.03 0.06 0.09 0.12 0.16 0.19 0.22 0.25 0.28 0.31 0.34 0.37 0.40 0.44 0.47 0.50 0.53 0.56 0.59 0.62 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B4
APPENDIX B
HEAD LOSS - 3/4" XPA PIPE 100% Water
3/4" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.01 0.01 0.02 0.02 0.03 0.03 0.08 0.10 0.13 0.15 0.18 0.21 0.24 0.27 0.31 0.35 0.39 0.43 0.47 0.51 Velocity ft/s 0.06 0.13 0.19 0.25 0.31 0.38 0.44 0.50 0.57 0.63 0.69 0.75 0.82 0.88 0.94 1.01 1.07 1.13 1.19 1.26 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.13 0.25 0.38 0.51 0.63 0.76 1.85 2.33 2.87 3.45 4.07 4.74 5.45 6.21 7.01 7.84 8.72 9.64 10.6 11.6 Velocity m/s 0.02 0.04 0.06 0.08 0.10 0.12 0.13 0.15 0.17 0.19 0.21 0.23 0.25 0.27 0.29 0.31 0.33 0.35 0.36 0.38 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B5
APPENDIX B
HEAD LOSS - 3/4" XPA SUPPLY PIPE 100% Water
3/4" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 Loss per 100ft PSI 0.15 0.51 0.94 1.57 2.35 3.25 4.29 5.46 6.74 8.15 9.68 11.3 13.1 14.9 16.9 19.0 21.2 23.5 25.9 28.4 Velocity ft/s 0.63 1.26 1.89 2.52 3.14 3.77 4.40 5.03 5.66 6.29 6.92 7.55 8.17 8.80 9.43 10.1 10.7 11.3 11.9 12.6 Flowrate L / min 3.89 7.78 11.7 15.6 19.5 23.3 27.2 31.1 35.0 38.9 42.8 46.7 50.6 54.5 58.4 62.2 66.1 70.0 73.9 77.8 Loss per 100m kPa 3.45 11.6 21.2 35.5 53.1 73.6 97.1 123 153 184 219 256 296 338 383 430 480 532 586 643 Velocity m/s 0.19 0.38 0.58 0.77 0.96 1.15 1.34 1.53 1.73 1.92 2.11 2.30 2.49 2.68 2.88 3.07 3.26 3.45 3.64 3.83 Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0
B6
APPENDIX B
HEAD LOSS - 1" XPA PIPE 100% Water
1" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.02 0.04 0.05 0.06 0.06 0.07 0.08 0.10 0.11 0.12 0.13 0.14 0.16 Velocity ft/s 0.04 0.08 0.12 0.15 0.19 0.23 0.27 0.31 0.35 0.38 0.42 0.46 0.50 0.54 0.58 0.61 0.65 0.69 0.73 0.77 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.05 0.09 0.14 0.19 0.24 0.28 0.33 0.38 0.89 1.07 1.26 1.47 1.69 1.92 2.17 2.42 2.70 2.98 3.28 3.58 Velocity m/s 0.01 0.02 0.04 0.05 0.06 0.07 0.08 0.09 0.11 0.12 0.13 0.14 0.15 0.16 0.18 0.19 0.20 0.21 0.22 0.23 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B7
APPENDIX B
HEAD LOSS - 1" XPA SUPPLY PIPE 100% Water
1" XPA Pipe / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 Loss per 100ft PSI 0.05 0.16 0.29 0.48 0.72 0.99 1.31 1.67 2.06 2.49 2.95 3.46 3.99 4.56 5.16 5.80 6.47 7.17 7.91 8.67 Velocity ft/s 0.38 0.77 1.15 1.53 1.92 2.30 2.68 3.07 3.45 3.84 4.22 4.60 4.99 5.37 5.75 6.14 6.52 6.90 7.29 7.67 Flowrate L / min 3.89 7.78 11.7 15.6 19.5 23.3 27.2 31.1 35.0 38.9 42.8 46.7 50.6 54.5 58.4 62.2 66.1 70.0 73.9 77.8 Loss per 100m kPa 1.07 3.58 6.49 10.9 16.2 22.5 29.7 37.7 46.6 56.3 66.8 78.2 90.3 103 117 131 146 162 179 196 Velocity m/s 0.12 0.23 0.35 0.47 0.58 0.70 0.82 0.94 1.05 1.17 1.29 1.40 1.52 1.64 1.75 1.87 1.99 2.10 2.22 2.34 Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0
B8
APPENDIX B
HEAD LOSS - 3/8" PEX TUBING 100% Water
3/8" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.16 0.33 1.03 1.70 2.51 3.46 4.53 5.72 7.03 7.54 8.94 10.5 12.1 13.8 15.6 17.5 19.5 21.6 23.8 26.1 Velocity ft/s 0.34 0.68 1.02 1.36 1.71 2.05 2.39 2.73 3.07 3.41 3.75 4.09 4.44 4.78 5.12 5.46 5.80 6.14 6.48 6.82 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 3.73 7.45 23.3 38.5 56.9 78.3 102 129 159 171 202 236 273 312 353 396 441 489 539 591 Velocity m/s 0.10 0.21 0.31 0.42 0.52 0.62 0.73 0.83 0.94 1.04 1.14 1.25 1.35 1.46 1.56 1.66 1.77 1.87 1.98 2.08 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B9
APPENDIX B
HEAD LOSS - 1/2" PEX TUBING 100% Water
1/2" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.04 0.09 0.13 0.34 0.51 0.70 0.91 1.15 1.41 1.70 2.01 2.34 2.69 2.80 3.16 3.55 3.96 4.39 4.83 5.30 Velocity ft/s 0.17 0.35 0.52 0.69 0.87 1.04 1.22 1.39 1.56 1.74 1.91 2.08 2.26 2.43 2.60 2.78 2.95 3.13 3.30 3.47 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.97 1.93 2.90 7.74 11.4 15.7 20.6 26.0 32.0 38.5 45.5 52.9 60.9 63.3 71.6 80.4 89.6 99.2 109 120 Velocity m/s 0.05 0.11 0.16 0.21 0.26 0.32 0.37 0.42 0.48 0.53 0.58 0.64 0.69 0.74 0.79 0.85 0.90 0.95 1.01 1.06 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B10
APPENDIX B
HEAD LOSS - 5/8" PEX TUBING 100% Water
5/8" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.02 0.04 0.06 0.08 0.21 0.29 0.38 0.48 0.59 0.70 0.83 0.97 1.11 1.27 1.43 1.60 1.59 1.76 1.94 2.12 Velocity ft/s 0.12 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 1.32 1.44 1.56 1.68 1.80 1.92 2.04 2.16 2.28 2.40 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.46 0.92 1.38 1.84 4.73 6.51 8.53 10.8 13.2 15.9 18.8 21.9 25.2 28.7 32.4 36.2 35.9 39.8 43.8 48.1 Velocity m/s 0.04 0.07 0.11 0.15 0.18 0.22 0.26 0.29 0.33 0.37 0.40 0.44 0.47 0.51 0.55 0.58 0.62 0.66 0.69 0.73 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B11
APPENDIX B
HEAD LOSS - 3/4" PEX TUBING 100% Water
3/4" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.01 0.02 0.03 0.04 0.05 0.14 0.18 0.23 0.28 0.34 0.40 0.47 0.54 0.61 0.69 0.77 0.86 0.95 0.93 1.02 Velocity ft/s 0.09 0.18 0.26 0.35 0.44 0.53 0.62 0.70 0.79 0.88 0.97 1.06 1.15 1.23 1.32 1.41 1.50 1.59 1.67 1.76 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.25 0.50 0.75 0.99 1.24 3.14 4.11 5.19 6.38 7.67 9.06 10.6 12.1 13.8 15.6 17.5 19.4 21.5 21.0 23.0 Velocity m/s 0.03 0.05 0.08 0.11 0.13 0.16 0.19 0.21 0.24 0.27 0.30 0.32 0.35 0.38 0.40 0.43 0.46 0.48 0.51 0.54 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B12
APPENDIX B
HEAD LOSS - 1" PEX TUBING 100% Water
1" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.00 0.01 0.01 0.02 0.02 0.02 0.03 0.07 0.09 0.10 0.12 0.14 0.16 0.19 0.21 0.23 0.26 0.29 0.32 0.35 Velocity ft/s 0.05 0.11 0.16 0.21 0.27 0.32 0.37 0.43 0.48 0.53 0.59 0.64 0.69 0.75 0.80 0.85 0.91 0.96 1.01 1.07 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.09 0.18 0.27 0.36 0.46 0.55 0.64 1.58 1.94 2.33 2.76 3.21 3.69 4.20 4.74 5.31 5.90 6.52 7.17 7.85 Velocity m/s 0.02 0.03 0.05 0.07 0.08 0.10 0.11 0.13 0.15 0.16 0.18 0.20 0.21 0.23 0.24 0.26 0.28 0.29 0.31 0.33 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B13
APPENDIX B
HEAD LOSS - 1" PEX SUPPLY TUBING 100% Water
1" PEX Tubing / 100% Water / 80 Deg F (27 Deg C)
Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 Loss per 100ft PSI 0.10 0.35 0.63 1.06 1.58 2.19 2.89 3.68 4.55 5.50 6.52 7.63 8.81 10.1 11.4 12.8 14.3 15.8 17.5 19.2 Velocity ft/s 0.53 1.07 1.60 2.13 2.67 3.20 3.73 4.27 4.80 5.34 5.87 6.40 6.94 7.47 8.00 8.54 9.07 9.60 10.1 10.7 Flowrate L / min 3.89 7.78 11.7 15.6 19.5 23.3 27.2 31.1 35.0 38.9 42.8 46.7 50.6 54.5 58.4 62.2 66.1 70.0 73.9 77.8 Loss per 100m kPa 2.33 7.85 14.3 24.0 35.8 49.6 65.5 83.2 103 124 148 173 199 228 258 290 323 358 395 433 Velocity m/s 0.16 0.33 0.49 0.65 0.81 0.98 1.14 1.30 1.46 1.63 1.79 1.95 2.11 2.28 2.44 2.60 2.77 2.93 3.09 3.25 Flowrate GPM 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0
B14
APPENDIX B
HEAD LOSS - 1/2" XPA PIPE 30% Glycol
1/2" XPA Pipe / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.11 0.21 0.32 0.42 0.53 0.64 0.74 0.85 0.96 1.06 1.29 2.29 3.07 3.50 3.95 4.42 4.91 5.43 5.97 6.53 Velocity ft/s 0.16 0.33 0.49 0.65 0.82 0.98 1.14 1.31 1.47 1.63 1.80 1.96 2.12 2.29 2.45 2.61 2.78 2.94 3.10 3.27 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 2.40 4.80 7.20 9.60 12.0 14.4 16.8 19.2 21.6 24.0 26.4 60.4 69.5 79.1 89.3 100 111 123 135 148 Velocity m/s 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B15
APPENDIX B
HEAD LOSS - 1/2" XPA PIPE 50% Glycol
1/2" XPA Pipe / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.22 0.44 0.66 0.88 1.10 1.32 1.54 1.76 1.98 2.20 2.42 2.64 2.86 3.08 3.30 3.52 3.74 3.96 4.18 4.40 Velocity ft/s 0.16 0.33 0.49 0.65 0.82 0.98 1.14 1.31 1.47 1.63 1.80 1.96 2.12 2.29 2.45 2.61 2.78 2.94 3.10 3.27 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 4.98 10.0 14.9 19.9 24.9 29.9 34.9 39.8 44.8 49.8 54.8 59.8 64.7 69.7 74.7 79.7 84.7 89.6 94.6 100 Velocity m/s 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B16
APPENDIX B
HEAD LOSS - 5/8" XPA PIPE 30% Glycol
5/8" XPA Pipe / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.04 0.08 0.12 0.17 0.21 0.25 0.29 0.33 0.37 0.41 0.45 0.50 0.54 0.58 1.29 1.44 1.60 1.77 1.95 2.13 Velocity ft/s 0.10 0.20 0.31 0.41 0.51 0.61 0.71 0.82 0.92 1.02 1.12 1.22 1.33 1.43 1.53 1.63 1.73 1.84 1.94 2.04 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.93 1.87 2.80 3.74 4.67 5.61 6.54 7.48 8.41 9.35 10.3 11.2 12.2 13.1 29.1 32.6 36.3 40.1 44.0 48.2 Velocity m/s 0.03 0.06 0.09 0.12 0.16 0.19 0.22 0.25 0.28 0.31 0.34 0.37 0.40 0.44 0.47 0.50 0.53 0.56 0.59 0.62 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B17
APPENDIX B
HEAD LOSS - 5/8" XPA PIPE 50% Glycol
5/8" XPA Pipe / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.09 0.17 0.26 0.34 0.43 0.51 0.60 0.69 0.77 0.86 0.94 1.03 1.11 1.20 1.29 1.37 1.46 1.54 1.63 1.71 Velocity ft/s 0.10 0.20 0.31 0.41 0.51 0.61 0.71 0.82 0.92 1.02 1.12 1.22 1.33 1.43 1.53 1.63 1.73 1.84 1.94 2.04 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 1.94 3.88 5.82 7.75 9.69 11.6 13.6 15.5 17.4 19.4 21.3 23.3 25.2 27.1 29.1 31.0 33.0 34.9 36.8 38.8 Velocity m/s 0.03 0.06 0.09 0.12 0.16 0.19 0.22 0.25 0.28 0.31 0.34 0.37 0.40 0.44 0.47 0.50 0.53 0.56 0.59 0.62 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B18
APPENDIX B
HEAD LOSS - 3/4" XPA PIPE 30% Glycol
3/4" XPA Pipe / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.02 0.03 0.05 0.06 0.08 0.09 0.11 0.13 0.14 0.16 0.17 0.19 0.20 0.22 0.24 0.25 0.27 0.28 0.62 0.68 Velocity ft/s 0.06 0.13 0.19 0.25 0.31 0.38 0.44 0.50 0.57 0.63 0.69 0.75 0.82 0.88 0.94 1.01 1.07 1.13 1.19 1.26 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.36 0.71 1.07 1.42 1.78 2.13 2.49 2.84 3.20 3.56 3.91 4.27 4.62 4.98 5.33 5.69 6.05 6.40 14.0 15.3 Velocity m/s 0.02 0.04 0.06 0.08 0.10 0.12 0.13 0.15 0.17 0.19 0.21 0.23 0.25 0.27 0.29 0.31 0.33 0.35 0.36 0.38 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B19
APPENDIX B
HEAD LOSS - 3/4" XPA PIPE 50% Glycol
3/4" XPA Pipe / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.03 0.07 0.10 0.13 0.16 0.20 0.23 0.26 0.29 0.33 0.36 0.39 0.42 0.46 0.49 0.52 0.55 0.59 0.62 0.65 Velocity ft/s 0.06 0.13 0.19 0.25 0.31 0.38 0.44 0.50 0.57 0.63 0.69 0.75 0.82 0.88 0.94 1.01 1.07 1.13 1.19 1.26 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.74 1.48 2.21 2.95 3.69 4.43 5.16 5.90 6.64 7.38 8.11 8.85 9.59 10.3 11.1 11.8 12.5 13.3 14.0 14.8 Velocity m/s 0.02 0.04 0.06 0.08 0.10 0.12 0.13 0.15 0.17 0.19 0.21 0.23 0.25 0.27 0.29 0.31 0.33 0.35 0.36 0.38 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B20
APPENDIX B
HEAD LOSS - 1/2" PEX TUBING 30% Glycol
1/2" PEX Tubing / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.12 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 2.65 3.09 3.55 4.04 4.56 5.11 5.68 6.28 6.90 7.55 Velocity ft/s 0.17 0.35 0.52 0.69 0.87 1.04 1.22 1.39 1.56 1.74 1.91 2.08 2.26 2.43 2.60 2.78 2.95 3.13 3.30 3.47 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 2.71 5.42 8.14 10.8 13.6 16.3 19.0 21.7 24.4 27.1 60.0 69.8 80.3 91.4 103 116 128 142 156 171 Velocity m/s 0.05 0.11 0.16 0.21 0.26 0.32 0.37 0.42 0.48 0.53 0.58 0.64 0.69 0.74 0.79 0.85 0.90 0.95 1.01 1.06 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B21
APPENDIX B
HEAD LOSS - 1/2" PEX TUBING 50% Glycol
1/2" PEX Tubing / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.25 0.50 0.75 0.99 1.24 1.49 1.74 1.99 2.24 2.49 2.74 2.98 3.23 3.48 3.73 3.98 4.23 4.48 4.72 4.97 Velocity ft/s 0.17 0.35 0.52 0.69 0.87 1.04 1.22 1.39 1.56 1.74 1.91 2.08 2.26 2.43 2.60 2.78 2.95 3.13 3.30 3.47 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 5.63 11.3 16.9 22.5 28.1 33.8 39.4 45.0 50.6 56.3 61.9 67.5 73.1 78.8 84.4 90.0 95.6 101 107 113 Velocity m/s 0.05 0.11 0.16 0.21 0.26 0.32 0.37 0.42 0.48 0.53 0.58 0.64 0.69 0.74 0.79 0.85 0.90 0.95 1.01 1.06 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B22
APPENDIX B
HEAD LOSS - 5/8" PEX TUBING 30% Glycol
5/8" PEX Tubing / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.06 0.11 0.17 0.23 0.29 0.34 0.40 0.46 0.51 0.57 0.63 0.68 0.74 1.67 1.89 2.11 2.35 2.60 2.85 3.12 Velocity ft/s 0.12 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 1.32 1.44 1.56 1.68 1.80 1.92 2.04 2.16 2.28 2.40 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.3 11.6 12.9 14.2 15.5 16.8 37.8 42.7 47.8 53.2 58.7 64.6 70.6 Velocity m/s 0.04 0.07 0.11 0.15 0.18 0.22 0.26 0.29 0.33 0.37 0.40 0.44 0.47 0.51 0.55 0.58 0.62 0.66 0.69 0.73 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B23
APPENDIX B
HEAD LOSS - 5/8" PEX TUBING 50% Glycol
5/8" PEX Tubing / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.12 0.24 0.35 0.47 0.59 0.71 0.83 0.95 1.06 1.18 1.30 1.42 1.54 1.66 1.77 1.89 2.01 2.13 2.25 2.37 Velocity ft/s 0.12 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 1.32 1.44 1.56 1.68 1.80 1.92 2.04 2.16 2.28 2.40 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 2.68 5.35 8.03 10.7 13.4 16.1 18.7 21.4 24.1 26.8 29.4 32.1 34.8 37.5 40.1 42.8 45.5 48.2 50.8 53.5 Velocity m/s 0.04 0.07 0.11 0.15 0.18 0.22 0.26 0.29 0.33 0.37 0.40 0.44 0.47 0.51 0.55 0.58 0.62 0.66 0.69 0.73 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B24
APPENDIX B
HEAD LOSS - 3/4" PEX TUBING 30% Glycol
3/4" PEX Tubing / 30% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.03 0.06 0.09 0.12 0.15 0.19 0.22 0.25 0.28 0.31 0.34 0.37 0.40 0.43 0.46 1.02 1.13 1.25 1.38 1.51 Velocity ft/s 0.09 0.18 0.26 0.35 0.44 0.53 0.62 0.70 0.79 0.88 0.97 1.06 1.15 1.23 1.32 1.41 1.50 1.59 1.67 1.76 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 0.70 1.40 2.09 2.79 3.49 4.19 4.88 5.58 6.28 6.98 7.68 8.37 9.07 9.77 10.5 23.0 25.6 28.3 31.1 34.0 Velocity m/s 0.03 0.05 0.08 0.11 0.13 0.16 0.19 0.21 0.24 0.27 0.30 0.32 0.35 0.38 0.40 0.43 0.46 0.48 0.51 0.54 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B25
APPENDIX B
HEAD LOSS - 3/4" PEX TUBING 50% Glycol
3/4" PEX Tubing / 50% Glycol / 80 Deg F (27 Deg C)
Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Loss per 100ft PSI 0.06 0.13 0.19 0.26 0.32 0.38 0.45 0.51 0.58 0.64 0.70 0.77 0.83 0.90 0.96 1.02 1.09 1.15 1.22 1.28 Velocity ft/s 0.09 0.18 0.26 0.35 0.44 0.53 0.62 0.70 0.79 0.88 0.97 1.06 1.15 1.23 1.32 1.41 1.50 1.59 1.67 1.76 Flowrate L / min 0.39 0.78 1.17 1.56 1.95 2.33 2.72 3.11 3.50 3.89 4.28 4.67 5.06 5.45 5.84 6.22 6.61 7.00 7.39 7.78 Loss per 100m kPa 1.45 2.89 4.34 5.79 7.24 8.68 10.1 11.6 13.0 14.5 15.9 17.4 18.8 20.3 21.7 23.2 24.6 26.1 27.5 28.9 Velocity m/s 0.03 0.05 0.08 0.11 0.13 0.16 0.19 0.21 0.24 0.27 0.30 0.32 0.35 0.38 0.40 0.43 0.46 0.48 0.51 0.54 Flowrate GPM 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
B26
ABOUT IPEX
IPEX, a leading supplier of hydronic radiant heating solutions, offers an innovative and comprehensive range of heating products throughout the North American marketplace. These products form the WarmRite Floor IPEX Radiant System and include Kitec XPA pipe, PEX tubing, pre-assembled control panels, fittings, accessories and heating controls. With state-of-the-art manufacturing facilities and distributions centers located across North America, IPEX delivers heating solutions for a broad range of markets and applications including: Primary residential heating Supplemental floor warming systems Residential snow and ice melt systems driveways, entrances Industrial heating for factories and warehouses Commercial heating systems stores, offices Institutional heating for schools, hospitals, seniors complexes Industrial snow and ice melt systems parking ramps, loading docks, sidewalks Established more than 50 years ago, IPEXs leading position in the industry is largely due to the IPEX mission to provide its customers with the highest quality products, service and support and to make continuous improvement a core objective of its business. Our marketing strategy in both Canada and the United States is to supply complete systems of pipe, fittings, accessories and all the components required for your heating project. We provide our customers with all the materials they need to ensure the integrity and high performance of their entire systemall designed, manufactured and backed by one company. IPEX publishes technical design manuals, state-of-the-art IPEX Radiant design software, product catalogues and supporting literature. We host comprehensive training and education programs tailored to the needs of our distributor, installer, builder and design partners. For more information contact the IPEX office nearest you.
About IPEX
IPEX is a leading supplier of thermoplastic piping systems. We provide our customers with one of the worlds largest and most comprehensive product lines. All IPEX products are backed by over 50 years of experience. With state-of-the-art manufacturing facilities and distribution centers across North America, the IPEX name is synonymous with quality and performance. Our products and systems have been designed for a broad range of customers and markets. Contact us for information on: Radiant heating systems PVC, CPVC, PP, FR-PVDF, ABS, PEX and PE pipe and fittings (" to 48") Industrial process piping systems Municipal pressure and gravity piping systems Plumbing and mechanical pipe systems Electrical systems Telecommunications and utility piping systems Irrigation systems
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This manual is published in good faith and is believed to be reliable. Data presented is the result of laboratory tests and field experience. IPEX maintains a policy of ongoing product improvement. This may result in modification of features or specifications without notice.