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As The Zone Valve Closes. . .

John Siegenthaler
July 9, 2001

John Siegenthaler, P.E.

Figure 1
A zone valve is arguably one of the most commonly used control components in residential and light
commercial hydronic systems. A rack of several such valves is often installed downstream of the system
circulator as shown in Figure 1.
Figure 2
Under design load conditions all space heating zones should, theoretically, need heat, and thus all zone
valves should be open simultaneously. In this mode the distribution system exhibits its lowest ow
resistance. It's like a multiple lane bridge with all lanes open.
As the zone thermostats reach their setpoint and the associated zone valves close, the distribution system
as a whole develops increasing resistance to ow. The overall system ow rate decreases, but the ow rate
through each open zone circuit increases. Some of the lanes on the bridge are now blocked off, and it's
simply not possible to get the same amount of traf c across, even though traf c moves slightly faster
along each lane.

The system curve of the distribution system steepens each time a zone valve closes. Figure 2 shows this
effect for a system having several identical oor heating circuits each controlled by its own zone valve.

Figure 3
From the standpoint of uid mechanics, all hydronic systems constantly seek equilibrium between the
mechanical energy (head) input from their circulator and the head loss due to uid friction in the piping.
When represented on a graph, the system always operates at the point where the system curve crosses over
the pump curve as shown in Figure 3.
Formula 1
To nd the ow rate through the circulator, drop a line straight down from the intersection of the curves to
the lower axis of the graph. To determine the differential pressure across the circulator, draw a horizontal
line from the operating point to the vertical axis and read the head added to the uid as it passes through
the circulator. Afterward, convert that head gain to a differential pressure using Formula 1.
Where:

DeltaP = pressure differential across pump

H = head added by circulator (in ft. of head)
d = density of uid being pumped (in lb./cubic ft.) (use 61.3 lb. / cubic ft. for 140-degrees F water)

Anything that changes the ow resistance of the distribution system causes the system curve to either
steepen, (for increasing ow resistance), or atten (for decreasing ow resistance). As the system curve
shifts so does the point where it intersects the pump curve.

When a zone valve closes, the system curve steepens forcing the operating point to slide upward along the
pump curve. This increases the pressure differential imposed on the zones that remain open. The
increased pressure differential increases the ow rate through these zones. At some point the increased
ow velocity will probably cause noise in either the zone valve or the piping. And believe me, the sound of
a "singing" zone valve is about as soothing as a fourth-grader learning to play the violin.

In some systems the increased differential pressure generated by several inactive zones can partially open
what are supposed to be closed zone valves. This causes heat input to zones that are supposed to be off.

Imagine, for example, a system having several zoned space heating circuits and a separate circuit
supplying an indirect water heater. Assume all the circuits are controlled by zone valves. The domestic
water heater is likely to be the only zone operating during warm weather. It's possible that a high
differential pressure across the circulator when the DHW load is operating could lead to hot water "oozing"
through the closed zone valves on the space heating circuits. This is especially unappealing when the
home's cooling system is running full tilt. I'd say that warm air rising from baseboards when the outside
temperature is 90+ degrees F is legitimate cause for a complaint, wouldn't you?
Figure 4
Under Pressure
One way to minimize changes in differential pressure as zone valves open and close is to select a circulator
with a relatively " at" pump curve. Figure 4 shows the curve of such a circulator as well as the curve of a
"high head" circulator. Also shown are progressively steeper system curves that represent zone valves
closing off in the system.
Compare the changes in differential pressure as the operating point shifts upward along the " at" pump
curve to those that would occur along the pump curve of the high head circulator. In both cases the zone
circuits that remain on "feel" increased differential pressure as the other zones close, but far less in the
system using the circulator with the at pump curve.

If atter is better, what do you think an "ideal" pump curve would look like? That's right. It would be a
straight horizontal line at some xed value of differential pressure. A circulator with this pump curve
could deliver constant differential pressure regardless of the ow rate passing through it. Unfortunately,
no xed speed centrifugal pump can yield this ideal pump curve. However, several smaller circulators
operating in parallel can produce a decent approximation for systems needing relatively high ow rates.

Using a circulator with a at pump curve in zone valve systems is not a new concept. It's been described in
many references over several decades for those willing to learn how to properly select hydronic circulators.
Still, I wish I had a dollar for every time someone installed a "high head" pump in a system containing
several zone valves, and eventually heard about the problem - literally! In most cases I would bet the
installer didn't know if a standard 1/25 horsepower circulator had enough "humph" for a system with more
than three or four zones. Immediately following that moment of uncertainty they invoked the ever-popular
bigger-is-better selection criteria. Just be glad these guys "design" heating systems rather than airplanes.

Another technique for limiting the differential pressure across the circulator is to install a differential
pressure bypass valve as shown in Figure 5. This valve works like a pressure relief valve that "relieves" ow
back to the intake side of the circulator rather than to a drain.
As zone valves close, the bypass valve shuttles increasing amounts of ow through a piping detour rather
than forcing the pump to operate at higher pressure differentials trying to push ow through a more
restrictive distribution system.
When you adjust a differential pressure bypass valve set the knob so the disc just starts to lift away from its
seat when all zone valves are open, then increase the differential pressure setting just a tad. Some valves
have a small "window" that let's you see as the valve begins to bypass ow. For those that don't, you can
determine the differential pressure across the system when all zones are operating by nding the head at
the operating point and converting it to a differential pressure using Formula 1. You could also install
pressure gauges on the supply and return sides of the distribution system to determine the pressure
differential when all zones are operating.

In my opinion a differential pressure bypass valve should be used in any zone valve system or sub-system
that contains more than four zones or uses a circulator having a rating greater than 1/25 horsepower. They
should also be used to prevent "dead heading" the circulator in systems where several parallel-piped heat
emitters are controlled by thermostatic radiator valves.

Figure 6
The Ultimate Solution
Having just extolled the virtues of differential pressure bypass valves let me now say they represent a
"Band-Aid" solution to the ultimate challenge at hand. True, they do prevent the circulator from operating
at high differential pressures and, hence, eliminate ow noise and valve seat leakage. However, they do so
by throttling away head energy rather than reducing electrical power input to the circulator. It's sort of like
limiting the speed of your car by partially applying the brakes instead of backing off on the gas pedal.
A more elegant solution to controlling differential pressure as zone valves close is to reduce the speed of
the circulator. As the speed decreases, the pump curves shifts to the left and downward on the graph as
shown in Figure 6.

As the zone valves open and close and the system curve changes its "steepness," the pump curve of a
variable speed circulator can be shifted as necessary to maintain the same differential pressure across the
operating zones. The zones that remain on don't sense that other zones have closed. All active zones
operate at the same ow rate and differential pressure regardless of which zones are off. Properly
controlled, the circulator operates as a constant differential pressure device regardless of the ow passing
through it. Just like a circulator with the "ideal" pump curve we discussed earlier.

Variable speed circulators prevent changes in differential pressure and reduce electrical energy use in the
process. Such circulators have been used in Europe for several years, and will soon gain market share in
North America. At least two major pump manufacturers now have small variable speed circulators on the
market. Most vary their speed using a 2-10 volt DC or 4-20 milliamp control signal.

What remains is for manufacturers to develop a simple, low-cost differential pressure sensor that can serve
as the eyes for the circulator, telling it when and by how much to vary its speed.

Another possibility is to vary to circulator's speed based on the temperature differential across the
distribution system. In this scenario, the controller operating the circulator is set to maintain a xed
temperature drop across the distribution system. When a zone valve closes less heat is released by the
distribution system and, hence, the temperature drop from the supply to return header drops. The
temperature sensors associated with the pump controller sense this change as it develops and reduces the
speed of the pump downward to maintain a set temperature drop.

Look for one or more of these strategies to show up in the not too distant future on a hydronic system near
you. In the meantime, use a circulator with a at pump curve and differential pressure bypass valve on
those zone valve systems to keep both your piping and your complaint line quiet.

Recent Articles By John Siegenthaler, P.E.

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Single coil solution John Siegenthaler, P.E., is a consulting engineer and principal
of Appropriate Designs in Holland Patent, N.Y. His latest
John Siegenthaler: Low temperature leverage textbook “Heating With Renewable Energy,” will be released
in January 2016 from Cengage Publishing. It shows how to use
 modern hydronics technology to create systems supplied by
solar thermal, heat pump and biomass heat sources.
Additional information is available at www.hydronicpros.com.

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