HPAC Modern Hydronics Spring 2019

MODERN HYDRONICS 2019 SPRING

THE BENEFITS OF INTERNALLY CLEAN SYSTEMS THERMAL ENERGY METERS: AN UPDATE

THE CASE FOR SYNCHRONIZED LOOPS PRODUCT SHOWCASE SMALL SCALE HYDRONIC COOLING

PROPOSED EFFICIENCY REGS PROMPT INDUSTRY REACTION MASTERING THE ART OF ZONING

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CONTENTS

Modern Hydronics

MH4 COOLING

MH12 REGULATORY NEWS

Small scale hydronic cooling

Industry reacts to NRCan proposed equipment efficiency regulations

A market sector with growth potential. BY JOHN SIEGENTHALER

MH16

PRODUCT SHOWCASE

MH8 SYSTEM DESIGN

The case for synchronized loops

MH22 ZONING

Mastering the art and science behind ideal environments

A system composed of synergistic components enhances the efficiency of the entire loop.

There are solutions to the thermal problems often associated with bad buildings.

BY JOHN SHEFF

BY ROBERT BEAN

MH10 METERING

In-service accuracy is key to uptake Measurement Canada to approve thermal energy meters within the year.

MH28 CORROSION Clean your pipes

Establish physically and chemically “clean” surfaces inside piping and other components.

BY JOHN SIEGENTHALER

MODERN HYDRONICS

a supplement of Heating Plumbing Air Conditioning Magazine

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

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Kerry Turner (416) 510-5218 KTurner@hpacmag.com

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Manufacturers’ printed instructions, datasheets and notices always take precedence to published editorial statements.

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MODERN HYDRONICS

SPRING 2019

MH3

COOLING

SMALL SCALE HYDRONIC COOLING A market sector with serious growth potential.

BY JOHN SIEGENTHALER

MH4

SPRING 2019

MODERN HYDRONICS

All piping and components conveying chilled water mus be insulated and vapor seale

COOLING MODE entire system filled with propylene glycol antifreeze solution

INSIDE

nology. Geothermal water-to-water heat pumps, as well as air-to-water heat pumps, stand ready, willing and able to supply warm water for low temperature radiant panel heat systems in all areas of North America.

In many areas of North America, geothermal heat pumps currently enjoy generous subsidies that cover their higher installation cost. Air-to-water heat pumps, although currently not subsidized in most markets, can still hold their own on the basis of cost competitive performance, even in cold climates.

The icing on the cake: In addition to their ability to serve as high performance hydronic heat sources, nearly all currently available geothermal water-towater heat pumps, and air-to-water heat pumps, come with refrigerant reversing valves and associated control logic that allows them to function as chillers.

That’s a game changer when the question “but what do I do about cooling” comes up with prospective clients.

A typical hydronic heat pump (waterto-water or air-to-water) can produce chilled fluids with temperature down to about 40F. Those temperatures are very sufficient for both sensible and latent cooling. All that’s needed is a way to interface this chilled fluid with interior space in a way that produces comfortable air temperatures and humidity levels. That interface should also take advantage of the benefits offered by hydronic delivery system, such as zoning, high distribution efficiency, and minimal invasiveness.

OUTSIDE

H

ydronic heating has long been known for providing superior cold weather comfort.

Even so, the question that often comes from potential clients who are already convinced about of the benefits of hydronic heating, is: “What do I do about cooling?”

In the days when nearly all hydronic heating systems were supplied by boilers, the answer to this question was to install a separate cooling system. It might be a standard ducted system where an outdoor condenser unit supplied a single air handler in the building. The cooled and dehumidified air was then routed through a ducted forced air system.

The potential customer’s argument was typically: Why should I pay to install a hydronic heating system and then pay several thousand dollars more for a fully ducted cooling system, when the ducted system could also be used for distributing heated air? In some cases the allure of superior comfort, especially that provided by a hydronic radiant panel heating system, was sufficient justification for this “two separate systems” approach. However, when the construction budget was the controlling factor, the “ducts can do both” option typically doomed the hydronic heating system in favour of a furnace topped with an A-coil for cooling.

Today, there are many indicators that point to heat pumps gaining a greater share of the hydronic heat source market. There is also a significant overlap between heat pumps and hydronic tech-

spr che val

(P1) air-to-water heat pump (HP)

flexible connectors

There are several possibilities. Let’s take a look.

One approach is to set up a zoned distribution system serving multiple fancoil units, such as depicted in Figure 1.

This system, shown in cooling mode operation, uses an air-to-water heat pump to supply two zones of radiant panel heating, or two zones of cooling.

To ensure freeze protection of the outdoor heat pump, the entire system operates with a 30 per cent solution of inhibited propylene glycol antifreeze.

Some manufacturers also offer “split system” air-to-water heat pumps that only contain refrigerant in the outdoor unit. This eliminates any concern for WWW.HPACMAG.COM

Modern Hydronics

(FC1)

high wall air handler

OFF (ZVH1) (ZVC1)

(FC2)

s st ed

high wall air handler

(ZVC2)

(P2)

ring eck lve

(ORC)

(S2)

(S1) (S3) temperature sensors

(SPC)

buffer tank

Figure 2 High wall unit

from migrating into the radiant panel zones by a combination of a closed zone valve on the supply pipe and a check valve on the return side piping.

A variable speed circulator provides flow to the radiant panel manifold stations, or the air handlers, depending on operating mode. Zone valves determine which manifold or air handler receives flow. The circulator automatically adjusts speed as zone valves open or close.

The buffer tank prevents the heat pump from short cycling when only one zone is operating.

TERMINAL VARIATIONS Figure 1 Zoned distribution system

freezing in the outdoor unit. All piping carrying chilled fluid must be insulated and vapour sealed to prevent condensation. Although this is a simple concept, it remains a challenge in practice, especially for installers not used to insulating piping in hydronic heating systems.

When piping insulation is not properly done condensation on piping, valves, and circulators is sure to occur. That condensate can drip onto drywall surfaces and produce stains in short order.

If you are not willing and able to do the insulation system right, do not get involved with any chilled fluid cooling system.

In Figure 1, chilled water is prevented WWW.HPACMAG.COM

The fan-coils depicted in Figure 1 are called “high wall” units. Figure 2 shows an example of such a unit installed about six inches below ceiling level.

High wall hydronic fan-coils are virtually identical to the air handlers used on many mini-split heat pump systems. The only significant difference is that the hydronic air handler has a water coil, rather than a direct expansion (refrigerant) coil.

Hydronic high wall air handlers are currently available from several North American suppliers. They are typically turned or or off using a remote, and sport features such as vertically oscillating air diffusers, variable speed blowers, and different control modes for cooling, heating, and dehumidification.

MODERN HYDRONICS

PHOTO COURTESY JAGA

(ZVH2) OFF

Figure 3 Console fan-coil

These air handlers come with condensate drainage tubes that can either be routed through an exterior wall, or connected to 3⁄4 inch plastic drainage piping routed through partitions.

It is also possible to use “console” fan-coil units such as the unit shown in Figure 1.

Console fan coils can be surface mounted or recessed into wall cavities.

The later arguably looks better, but requires coordination with wall framing to ensure the recessed cavity is located and sized correctly.

Yet another possibility is one or more ducted air handlers. These are widely available with both vertical or horizontal cabinet configurations. An example of the latter is shown in Figure 4.

Some ducted air handlers are designed Continued on MH6 SPRING 2019

MH5

COOLING

Figure 4 Ducted horizontal air handler

to connect to standard ducting systems. Others are designed as “high velocity” units with blowers that generate high static pressure. the latter are typically configured with a single trunk duct that supplies several flexible two-inch diameter branch ducts.

These small branch ducts can be snaked through partitions or along framing cavities. They terminate in a small orifice mounted on a ceiling or wall. Typically there needs to be six or seven branch ducts per ton (12,000 Btuh) of cooling capacity.

The branch ducts are typically limited to runs of 25 feet from where they connect to the trunk duct.

Figure 5 shows an example of a horizontal air handler mounted within a conditioned attic space. The small two-inch flex ducts supplied from the single trunk are seen fastened to the insulated roof surface. If you look closely you will also see a secondary drain pan under the air handler. It is there in case the drain pan within the air handler develops a leak, or the piping from that drip pan somehow gets plugged. A secondary drain pan is cheap insurance against the possibility of a condensate leak that could damage expensive interior surfaces under the air handler.

PAY ATTENTION Whenever a fan-coil or air handler is used for chilled fluid cooling it is important to understand, respect, and implement several details: 1. Always be sure that the air handler or fan coil is equipped with a condensate drip pan and drain tube.

2. Be sure to plan for how electrical power, an insulated supply and return pipe, and a condensate drain tube will be routed to each air handler or fan coil.

3. When a recessed fan coil is used be sure to provide framers or other construction contractors with information on the size and exact location of the wall cavity.

4. Be sure to pitch the condensate drainage tube to allow gravity drainage.

5. If the condensate drain is connected to the building’s DWV plumbing system be sure to install traps that prevent MH6

SPRING 2019

Figure 5 Air handler in conditioned space

sewer gas from reaching the air handler or fan coil. Follow applicable code requirements for the trap details.

6. Place air handlers or fan coils so that air discharge is not directly aimed at areas where occupants are seated.

Drafts create discomfort.

7. Always get a wiring diagram for the specific air handler or fan coil being used so that it functionality can be coordinated with other control functions such as turning on the distribution circulator and heat pump.

COOL SURFACES Another option is radiant panel cooling. This technology enjoys a more developed market in Europe, but is currently in its infancy within North America. It involves circulating a chilled fluid (water or an antifreeze solution) thorough radiant panel tubing circuits embedded in ceilings, walls, or floors. Of these, radiant ceilings are ideal for cooling.

A key concept is to regulate the chilled fluid temperature to the radiant panel so that it remains just above the dewpoint temperature of the space being cooled. This is critically important in avoiding condensation on the panel.

The May 2014 HPAC article “I Need This Controller” covers the details and possible piping/control designs for radiant cooling. Check it out in the HPAC archives for more information. <> John Siegenthaler, P.E., is a mechanical engineering graduate of Rensselaer Polytechnic Institute and a licensed professional engineer.

He has over 34 years experience in designing modern hydronic heating systems.

Siegenthaler’s latest book is Heating with Renewable Energy (see www.hydronicpros.com for more information).

SEE JOHN AT THE MODERN HYDRONICS SUMMIT 2019.

CHECK MODERNHYDRONICSSUMMIT.COM FOR UPDATES.

MODERN HYDRONICS

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SYSTEM DESIGN

THE CASE FOR SYNCHRONIZED LOOPS

A system composed of synergistic components enhances the efficiency of the entire loop.

BY JOHN SHEFF

A

building’s hydronic HVAC system is rarely just the sum of its parts. The system is comprised of chillers, boilers, pumps, variable frequency drives (VFDs), air handling units (AHUs) and valves that create a loop through which water is circulated to control the building’s temperature and its occupants’ comfort. In this loop, each component is a node that has an effect not just on the one next to it but on every other one, regardless of how far they are from each other.

In fact, the nodes furthest from each other may impact each other the most.

Variable speed pumps, for example, surrender much of their part-load efficiency if the wrong balancing valves are installed at the terminal units. Too often systems are designed and components specified as though this loop is made of discrete nodes. Consequently, building owners continue to install inefficient systems and then struggle to find lasting solutions to chronic problems like hot spots, high utility bills and constant maintenance calls.

A system composed of synergistic components, on the other hand, enhances the efficiency of the entire loop.

Pressure independent control versus manual balancing.

Pressure independent control valves (PICVs) installed at the AHUs tightly control the water temperature entering and exiting the unit’s coils, allowing the chiller’s oil-free variable speed compressor to work as efficiently as possible. VFDs on the pumps supply only as much water as is demanded to take advantage of part load conditions to save energy. All the while, each component collects valuable data on energy usage, flow, pressure and temperature for the building management system to aggregate and use to make decisions about predictive maintenance, fault detection and comfort.

Investing in a synchronized hydronic loop made of synergistic components ultimately offers solutions to the following common problems associated with conventional hydronic HVAC systems: • Occupant comfort • Design efficiency versus installed efficiency • Degradation of efficiency over time These problems are often symptoms of an unbalanced system but are frequently misdiagnosed as issues with individual components. Those disconnected components, however, are operating as best they can in a system not at equilibrium.

A system composed of synergistic components.

MH8

SPRING 2019

MODERN HYDRONICS

WWW.HPACMAG.COM

Modern Hydronics

pumps and oil-free variable speed compressors to match the system’s energy consumption to that demand, allowing the system to achieve design efficiency in all load conditions.

SUSTAINED EFFICIENCY OVER TIME

Hydronic pumping strategies.

Left, how much oil is common? Right, how oil impacts performance.

PRECISE COMFORT CONTROL A traditional HVAC system is designed using manual balancing valves to provide proper flow to all coils during the hottest and coldest days of the year, which typically occur just two per cent of the time. These balancing valves, however, possess a fixed orifice that remains in the same open position the other 98 per cent of the time, allowing the system’s differential pressure to change, and thus flow to the coils to shift even as loads remain constant.

Ideally, flow should vary only in response to changes in load.

This improper flow at constant load creates a situation known as “hunting,” which causes inefficient heat transfer, spikes in chiller and pump energy consumption, dramatic swings in discharge temperatures and, ultimately, chronic hot and cold spots in the occupied space.

The pressure independent control valves (PICVs) in a synchronized hydronic loop, on the other hand, continuously adjust their differential pressure orifice poWWW.HPACMAG.COM

sition in response to dynamic load conditions, maintaining consistent differential pressure across the valve. This means the flow into the coils only varies in response to changing loads, allowing for efficient heat transfer and precise comfort control in the occupied space.

DESIGN EFFICIENCY IN ALL LOAD CONDITIONS It is easy to assume that achieving maximum efficiency in an HVAC system means sacrificing comfort. After all, conserving energy at home usually means adjusting the thermostat past the point of comfort. When it comes to hydronic HVAC systems, however, comfort and efficiency are two sides of the same coin.

As the PICVs at the air handlers continuously adjust to current load conditions to optimize heat transfer and comfort, they’re also minimizing flow into the coils.

This means the system is only heating, cooling and pumping as much water as is necessary to meet demand. A synchronized hydronic loop utilizes variable speed MODERN HYDRONICS

Regardless of where a system starts out, its efficiency will decline with time.

Chillers with traditional compressors degrade at a faster rate, as oil from the chiller mixes with the refrigerant and contaminates the system. That could lead to an immediate efficiency decrease of seven per cent, eventually climbing to a peak of around 20 to 30 per cent efficiency loss. However, a synchronized hydronic loop utilizes oil-free chillers, completely avoiding these issues. Instead of oil, these chillers use magnetic rotors to eliminate friction.

This technology is designed to not only allow the system to maintain a high level of efficiency, but to also significantly reduce maintenance costs.

The synchronized hydronic loop offers solutions to many of the problems associated with conventional hydronic systems. It also proves that a systems-based approach, as opposed to selecting components individually, is necessary to maximize efficiency, decrease downtime and, ultimately, improve occupant comfort and the bottom line.

The efficiency of each component in the synchronized hydronic loop is superior to the efficiency of that same component in a system without the other components. In this way, the synchronized hydronic loop is truly greater than the sum of its parts. <> John Sheff is a business development manager focused on utility programs and end user strategy at Danfoss. Previously, he worked as an energy and sustainability policy analyst in the office of Maryland’s governor.

SPRING 2019

MH9

METERING

IN SERVICE ACCURACY IS KEY TO UPTAKE

Measurement Canada to approve thermal energy meters within the year.

T

WHAT ARE THERMAL ENERGY METERS? Thermal energy meters measure the amount of heat energy given up or absorbed by a liquid in a heat exchange circuit such as a radiator. These meters are used to measure the amount of heat energy used by a customer for the purpose of billing.

Thermal energy meters can be used with:

Thermal energy meters consist of three main parts:

• Gas-fired boilers • District heating systems • Sub-metering configurations • Other systems

• A flow sensor • A temperature sensor pair • A calculator

MH10

SPRING 2019

Thermal energy meter installed.

“in service” accuracy (to protect consumers from erroneous billing) are what is needed to advance this technology.”

In 2017 with the intention of developing technical requirements, input was sought from owners of thermal energy meters in use used within Canada; industry members and associated organizations; and consumers who were billed for heating or cooling on the basis of the measurements provided by a thermal energy meter.Following those consultations, Innovation, Science and Economic Development Canada tells HPAC that technical requirements have been formalized and MC will continue to expand its knowledge in this field by visiting partner laboratories across the world to learn best practices. It is expected that MC will issue its first approvals of thermal energy meters before the end of 2019.

Devices installed prior to the requirement to use an approved meter (tentatively, 2021) will be allowed to remain in service until 2026. After that date, MC will begin requiring their removal and replacement with an approved meter.

In the interim period from 2021 to 2026, MC reserves the right to perform inspections of all installed thermal energy meters, whether or not approved. If an unapproved meter is inspected, it will be allowed to remain in service until 2026, provided that its performance is satisfactory.

For background and more information on this topic see "A Shot in the Arm" by Evans in HPAC August 2015 (digital archives at www.hpacmag.com). <>

MODERN HYDRONICS

WWW.HPACMAG.COM

PHOTO COURTESY ONICON

hermal energy meters, also known as Btu meters and heat meters, are moving from the realm of simple measurement into use as billing devices, which raises some regulatory questions on the municipal, provincial and federal levels. The issue is analogous to a gas pump that is measured and calibrated in accordance with the prescriptive requirements governed by Industry Canada–Measurement Canada (MC) under the mandate of the Weights and Measures Act. Previously, there was no specific legislation or guideline in place from MC to govern the suitability or certification of Btu meters in Canada, meaning the devices were not regulated under the Weights and Measures Act. This is unlike electricity, water and gas, which have regulated measurement (metering) practices in place to ensure fair measurement for both suppliers and consumers.

Without accurate measurement systems installed, thermal energy systems will not be able to allocate costs effectively.

This could potentially result in lower returns on investments for suppliers, increased end-user consumption (waste), or unfair bills to end consumers.

As HPAC columnist Mark Evans noted in a 2015 article, “We have a long way to go before Btu metering becomes ubiquitous and hydronic heating/cooling are mainstream. A fully-vetted, consensus Standard, along with guidelines requiring manufacturers meet a single stated accuracy level to ensure ongoing

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REGULATORY NEWS

Limited product offerings for replacement applications is expected to be just one result of proposed increased NRCan efficiency requirements that are not in harmony with U.S. regulations.

INDUSTRY REACTS TO NRCAN PROPOSED EQUIPMENT EFFICIENCY REGULATIONS

I

n October 2018 Natural Resources Canada (NRCan) published new proposed energy efficiency regulations for heating equipment in the Canada Gazette Part 1. These proposed regulations are part of Amendment 15 to the Energy Efficiency Act and introduce new or increased efficiency requirements to a range of products including commercial water heaters, household and commercial boilers, mobile home furnaces and gas fireplaces.

Publication in the Canada Gazette Part 1 is the last step the government takes prior to passing these new requirements into law. After publication of the proposed regulations, NRCan provided for a final comment period, which ended on December 29, 2018, that allowed all stakeholders to provide feedback.

The proposed regulations are controversial, with several of them being opposed by heating industry associations. The Canadian Institute of Plumbing and Heating (CIPH), the Heating, Refrigeration and Air Conditioning Institute (HRAI) and the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) represent manufacturers and distributors in the plumbMH12

SPRING 2019

ing and heating industry. These three associations presented a joint submission to NRCan outlining their concerns regarding the proposed regulations. The submissions by CIPH-HRAIAHRI covered two separate product categories: water heaters and boilers.

The water heater regulations being proposed by NRCan cover commercial electric, gas and oil-fired storage water heaters, and residential and commercial tankless water heaters. For electric and oil-fired storage water heaters, NRCan is harmonizing energy efficiency requirements with those already in place in the U.S. For gas-fired storage water heaters NRCan is taking a new approach with two different efficiency requirements, which cover new installations and retrofit installations. New installations will require condensing level efficiency equipment, while retrofit applications can still use non-condensing equipment. The industry associations endorse most of the proposed water heater regulations and are very supportive of the concept of separate requirements for new construction and existing construction for

MODERN HYDRONICS

WWW.HPACMAG.COM

REGULATORY NEWS commercial gas fired storage water heaters. The associations have however raised objections to the proposed regulations for non-condensing gas-fired storage water heaters that are more stringent than current United States Department of Energy (DOE) regulations.

“The industry objects to the increase in the efficiency requirements being proposed for non-condensing equipment that can be used for retrofit applications. NRCan is raising the thermal efficiency requirement for this category from 80 per cent (current DOE requirements) to 82 per cent for this category and this is extremely problematic for the industry,” explained Robert Waters, technical consultant for codes and standards for CIPH. The industry associations claim this increased efficiency requirement will not be in harmony with U.S. regulations and will result in the elimination of the majority of the models currently utilized for replacement applications in Canada.

The result will be a very limited product offering for consumers, as most models currently available would not meet the new efficiency requirements. There are also some technical and safety concerns with possible flue gas condensation in existing venting systems with the proposed higher efficiency equipment.

CIPH-HRAI-AHRI do not object to the proposed new water heater efficiency regulations for the new construction category, but have recommended the requirement for non-condensing equipment be harmonized with the current U.S. DOE regulations for those products, ensuring availability of a wide range of products and a smooth transition in the market. They have also asked NRCan to push back the proposed implementation date to allow more time for industry to react to the changes.

The boiler regulations being proposed

by NRCan cover residential and commercial, gas and oil-fired boilers. For oilfired boilers, NRCan is harmonizing MH14

SPRING 2019

“The proposed regulations are controversial, with several of them being opposed by heating industry associations.” efficiency regulations with current DOE regulations. For gas-fired boilers, NRCan is deviating from current DOE regulations and proposing only condensing level efficiency equipment can be used for all applications.

These proposed gas-fired boiler regulations are much more contentious.

“The majority of our members are not in support of the new gas fired boiler regulations being proposed by NRCan,” stated Waters. “Members are very disappointed dual level efficiency requirements for replacement and new construction applications are not being proposed for gas-fired hot water boilers.

“NRCan has proposed this approach for commercial water heaters, but have not applied this same approach to boilers, even though similar technical and other issues apply to both categories of products,” added Waters.

NRCan commissioned a Cost-Benefit Analysis (CBA) study to look at the economic impact for consumers of the proposed new regulations. NRCan’s CBA report has been used to justify its proposal to increase efficiency levels to condensing technology for all gas hot water boilers. CIPH-HRAI-AHRI believe there are many issues with the CBA study and feel that it contains errors and inconsistencies as well as incomplete and/or incorrect data.

The industry associations state the market for household and commercial condensing boilers has grown significantly over the last 15 years without having any minimum efficiency regulations in place. CIPH-HRAI-AHRI believe that condensing boilers are being utilized extensively where they are economically justified, but feel there will be MODERN HYDRONICS

significant financial and technical burdens for consumers by forcing condensing boilers into all existing installations.

The associations have also stated there continues to be many retrofit applications where condensing boilers cannot be justified and non-condensing boilers are still the best option for consumers.

“There are many existing buildings that will have to incur huge costs to install new venting and mechanical room repiping to accommodate a condensing boiler,” said Waters. “There are also many applications that only use high system water temperatures, resulting in minimal condensing in the boiler. These applications will see minimal if any fuel savings from a condensing boiler, but may have to spend huge amounts to install the boiler.”

CIPH-HRAI-AHRI have recommended that NRCan implement dual level standards for household and commercial gas-fired water boilers for new installations and retrofit installations, similar in concept to the proposed efficiency regulations for commercial storage water heaters.

None of the new proposed equipment efficiency regulations are finalized yet, as NRCan is currently reviewing all of the final comments received. Once they finalize their review NRCan will then have to decide the final version for the new regulations. This is expected to be published sometime in the next few months in the Canada Gazette, Part 2, at which point the regulations will become law.

Waters noted that these regulations will have a big impact on what type of equipment Canadian mechanical contractors will be allowed to be installed in the future. <> WWW.HPACMAG.COM

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magnet motor, leading-edge hydraulic

model code developed by IAPMO to

efficiencies, a series of advanced

govern the installation and inspec-

control modes, and multi-pump func-

tion of solar hydronic, and geother-

tionality. A Flow Limiting Function

mal energy systems as a means of

eliminates the need for a pump bal-

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ancing valve. The pump also has a

ty and welfare. Published previously

built-in heat energy meter that can

as the Uniform Solar Energy Code,

monitor heat energy distribution and

the 2018 edition adds provisions

consumption. A built-in sensor and

concerning hydronic and geothermal

an external sensor connected directly to the TPE3 allow the pump to

systems. Key provisions of the 2018 USHGC and changes from the

take charge of the systemâ&#x20AC;&#x2122;s need for flow based on differential tem-

2015 edition include new: insulation and fasteners provisions for radi-

perature. Wireless technology enables the TPE3 to connect with up to

ant and heating/cooling systems; snow and ice melt system controls;

four single TPE3 pumpsâ&#x20AC;&#x201C;they can be controlled jointly in either cascade

slab penetration tube and joint protection used in hydronic systems;

mode, alternating mode or duty/standby without the need for any other

listing requirements for ground coupled and water source heat pumps;

pump controller unit. www.grundfos.com

Continued on MH18

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SpacePak’s Solstice Extreme low ambient

create hydraulic separation between the boiler

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loop and emitter heating loop. Panels are

ing pressure is 145 PSI. Maximum operating

commercial primary heating and cooling ap-

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Master models include powder coating, quick

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Solstice Extreme provides up to 48,000 Btuh

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Bacharach’s PCA 400 may be used for spot-

EC Power micro CHP systems can operate as

checking and tuning boilers. It has a high-

one single stand-alone engine, or in a larger

KN-Series Plus cast iron condensing boilers

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tioner. Features include a 4.3 in. colour touch

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drophobic coated finned stainless steel heat

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gy allows for live streaming of data to PCs and

cent (thermal and electrical) when operating

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variable flow water-side condensing boiler, al-

emissions testing are optional. The dilution

heating redundancy. Popular sizes in Canada

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boiler systems. It is certified for use with PVC

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battery-operated

paired

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ZONING

Inconsistency in space and surface temperatures can occur where multiple elevations exist off a single floor plate.

MASTERING THE ART AND SCIENCE BEHIND IDEAL ENVIRONMENTS There are solutions to the thermal problems often associated with bad buildings.

BY ROBERT BEAN

T

his continues to shock many readers but as I have said repeatedly the construction industry does not exist to employing building professionals. The industry exists to create spaces for humans because without shelter for protection we would not be able to populate many parts of the world. When it comes to buildings it all comes down to MH22

SPRING 2019

Maslow’s hierarchy of needs where food and shelter are basic essentials and the final stage manifested through self-actualization. In architecture, self-actualization is expressed through creative forms and interior finishes.

But here’s the thing, creative forms and interior finishes are not sufficient for creating ideal environments–supplementary solutions are most always necessary to condition indoor spaces. This explains the existence of lighting and HVAC systems. These take on many forms from meeting mandatory minimum requirements established by building codes, to voluntary compliance to higher requirements identified by proMODERN HYDRONICS

grams such as Well, Living Building Challenge or Active House.i In the former neither comfort nor energy are the priority, being trumped by basic needs of safety and reducing risk of illness. In the latter it is assumed the former is a prerequisite to support much higher aspects of human factor design (self-actualization) and earth stewardship.

When it comes to zoning, most design practitioners carrying out HVAC load calculations to minimum code compliance often follow a single or minimal approach ignoring many of the factors which contribute to occupant discomfort and system inefficiencies. As I have discussed before, HVAC load calculaWWW.HPACMAG.COM

Modern Hydronics

tions are not comfort calculations and should never be represented as such.ii Alternatively the designer could lead the client to a multi-zone system, which based on good practice, considers the space dynamics due to wind, precipitation, solar loads and enclosure performance; and occupant’s metabolic rate and clothing and tactics which promote adaptive strategies.iii If compliance to comfort standard ASHRAE 55 is desired (and why wouldn’t it be) then separate calculations according to the Standard are necessary. To precede with comfort calculations two approaches are considered. Use a multizone systems approach or design and construct a building of such high performance that single or minimal zoning is sufficient.

Zoning is both an art and science, which strategically must consider the

representative occupant, competing representative occupants, their individual and collective authority over controllability, system operation, and economics.

Tactically it considers the following as good practices:

ARCHITECTURAL ELEMENTS How a building is orientated on a parcel of land will affect precipitation, wind and solar loads on exposed above grade surfaces or unexposed below grade surfaces. These mass and energy loads are then transmitted to the interior spaces through differentials in moisture, pressure, and temperatures. Surfaces and spaces that receive extraordinary loads ought to have their own comfort controls.

Examples of these are southern facing rooms with large window to wall ratios and finished with interior blinds and

without exterior shading. These southern surfaces will receive relatively large amounts of shortwave radiation which depending on solar heat gain coefficients could influence the space conditions differently than other spaces. If the southern space had the only thermostat and was combined with (for example) northern facing rooms it is possible that under heating could occur in the north spaces during some periods. This is due to the thermostat shutting down the heating system due to a rise in temperature from the solar load.

Likewise, if the north space had the thermostat it is highly likely that the southern spaces will overheat. This is due to the thermostat remaining on to satisfy the setpoint but can’t pick up the temperature rise in the south facing rooms. It is important for designers to develop this, Continued on MH24

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MODERN HYDRONICS

SPRING 2019

MH23

ZONING TABLE 1: ZONING STRATEGIES BASED ON ROOM FUNCTION, TYPES, MOISTURE LOADS, TEMPERATURE SETPOINT, CLOTHING (CLO) AND METABOLIC (MET) RATE Space function

Typical room types

Moisture load

Temperature setpoint

Typical clo values

Typical met rates

Socializing, entertaining

Living, family, kitchens, break rooms, lounges, solariums, atriums

Steady state

Normal

Low to medium

Low

Food preparation and consumption

Kitchen, dining, pantries, break rooms, lounges

Variable

Normal to low

Low to medium

Low to high

Hygiene

Bathrooms, powder rooms, change rooms, laundry

Variable

Above normal

Low to medium

Low

Rest, sleeping

Bedrooms, dens

Steady state

Below normal

Low to medium

Low

Study, work

Offices, study, libraries, reception, meeting, copy/print

Steady state

Normal

Low to medium

Low to medium

Personal

Hobbies, music gyms, greenhouses, solariums

Variable, steady state

Varies

Low to high

Low to high

Media

Theatre, music

Steady state

Normal

Low to medium

Low

Pool/wet rooms

Swimming, hot tubs, steam, sauna

Med to high

Above normal

Low

Low to high

Cellars

Wine, food

Steady state

Below normal

na

na

Storage

Household goods, office supplies, janitorial

Steady state

Below normal

na

na

Any space with an extraordinary source of heat such as fireplace, stoves, theatre equipment, kilns, solar loading etc. Should be on separate controls.

Any spaces with extraordinary low heating or cooling loads with similar function, moisture loads, temperature set points and where occupants are doing similar activities and wearing similar clothing should be combined for simplifying systems and reducing capital costs.

Mixed spaces should permit adaptive strategies (clothing, shading) and accommodate personal devices such as desk fans and heaters.

â&#x20AC;&#x153;if/thenâ&#x20AC;? understanding and herein (in part) lays the art of zoning.

CHANGES IN ELEVATION OR GEOMETRY Any time there is changes in elevation such as in a multi floor building there could be thermal consequences due to stack effect. This will result in stratification where warmer air temperatures accumulate in the higher floors and colder temperatures at lower floors due to convective flows. There can also be inconsistency in space and surface temperatures where multiple elevations exist off a single floor plate (ex. vaulted ceilings mixed with flat ceilings) or where floor plates change direction (L-shaped rooms exposed to different solar loads) or are sepMH24

SPRING 2019

arated (for example) by stairwells or elevator shafts. For these reasons floor plates of different geometry, separation or with different elevations should not be combined, as a single thermostat cannot accurately represent the different conditions that may exists.

SPACE FUNCTION/PURPOSE AND CONTROL There is frequent control conflict when rooms of different use and purpose are assigned to a single control point.

Consider the metabolic rate, clothing and pattern of an occupant in a specific space relative to occupants in other spaces; and consider what heat and/or moisture sources might be present in one room but not in another. Also conMODERN HYDRONICS

sider the location and types of control employed in one space but not others this includes shading, fans, heaters and building management systems. In addition, there could be any number of mixtures of spaces, people, lights and equipment operating at any time. Any combination of the above could cause conflicts if the entire building is treated as a single zone. Good practice suggests rooms of unique characteristics and use each be considered for separate controls as described in Table 1.

INTERIOR DESIGN AND FINISHES The importance of interior systems on indoor environmental quality and energy use cannot be overemphasized. This Continued on MH26 WWW.HPACMAG.COM

ZONING includes effects of short wave radiation and moisture on finishes (outgassing) and effect of surface treatments on heat transfer.iv The latter has significant consequences for designers of radiant floor systems. For this reason zones of similar flooring conductivities with similar fluxes should be grouped together.

Another way of stating this is zones with different floor conductivities and fluxes should not be controlled with the same control system. In practice the radiant system (tube spacing) along with the flooring conductivities (U values) and enclosure design (ACH and U values) should be manipulated to harmonize the necessary fluid temperatures to the least number of required profiles.

GOOD BUILDINGS There is in practice a conflict between zoning, controllability and economics. Consider the entry level, two-storey home with a single furnace and thermostat. In a “built to code” house it is almost impossible to comply with ASHRAE Standard 55 due to the thermal dynamics in the home.

The same applies to poorly designed and constructed commercial spaces with single roof top units. Even multi-zoned balanced air systems will have noncompliance issues such as

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MH26

SPRING 2019

HPAC_Aug_Roth.indd 1

cold floors, radiant asymmetry, drafts and stratification simply because of climate inappropriate architecture, poor choices in finishes and inadequate enclosure designs.

Solving the non-compliance issues by zoning and enclosure improvements often makes the building uncompetitive relative to the market for entry level structures. Until the benchmark for entry level products changes, industry will always have non-compliance complaints. Simply put if the industry wants to reduce the complaints stop doing bad buildings.

Good buildings with flexible policies around adaptive strategies can have simple single or simpler multi-zone systems because the occupants, building and finishes solve many of the thermal problems often associated with bad buildings.

Zoning in and of itself is not a single solution to comfort problems. Anyone making this suggestion does not fully understand the relationships between people and buildings.

Understanding how spaces respond to exterior and interior stimuli and how these relate to occupant needs and preferences for space conditions helps develop the designer’s art of zoning but the art first must be based upon the sciences of physiology, psychology and buildings.v <> REFERENCES

i Bean, R. 2018. Human factors and their influence on building perfor-

Radiant, Snowmelt, Oil Storage and Solar

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

“Zoning in and of itself is not a single solution to comfort problems.”

mance and comfort. HPAC Magazine Canada ii Bean, R. 2012. Built to code: What does it mean for consumer thermal comfort? < http://www.healthyheating.com/Built-to-code.htm> iii Bean, R. 2016. It is time HVAC system design grew up. HPAC Magazine Canada iv Bean, R. 2012. Together Forever. HPAC Magazine Canada v Bean, R. 2014. Integrating Elements to Improve Comfort Design.

HPAC Magazine Canada

Robert Bean is a Registered Engineering Technologist in building construction (ASET) and a Professional Licensee (Engineering) in HVAC (APEGA). He is president of Indoor Climate Consultants Inc. and director of www.healthyheating.com; a past ASHRAE Distinguished Lecturer; recipient of ASHRAE’s Lou Flagg Award and ASHRAE Distinguished Service Award; and a member of ASHRAE technical committees 2.1 (Physiology & Human Environment) 6.1 (hydronics), 6.5 (radiant), 7.04 (eXergy) and SSPC 55 (thermal comfort).

Bean is also the author of numerous industry courses and seminars covering the building sciences, indoor environmental quality, energy, and radiant-based HVAC systems.

MODERN HYDRONICS 2018-07-17 3:06 PM

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CORROSION

CLEAN YOUR PIPES Establish physically and chemically “clean” surfaces inside piping and other components.

BY JOHN SIEGENTHALER

W

ater is the “life-blood” of hydronic systems. Its chemical characteristics can make the difference between a system that lasts for decades, versus one that develops expensive corrosion issues within months of commissioning.

We discussed the advantages of establishing and maintaining good water quality in hydronic heating and cooling systems in the March 2016 issue of HPAC. Part of that discussion focused on removing dissolved ions created by calcium and magnesium salts, which are commonly found in groundwater.

The resulting “demineralized” water would ideally have a total dissolved solids (TDS) reading between 10 and 30 parts per million (PPM). This gives the water just enough electrical conductivity to allow low water cutoff safety devices to function properly, but not enough to support galvanic corrosion. It also high enough to prevent the water from scavenging ions from piping materials, which can happen when the water’s TDS number approaches zero.

Although demineralization is the primary method for improving water quality in hydronic systems, its effectiveness is dependent, in part, on establishing physically and chemically “clean” surfaces inside the piping and other components of a closed loop system.

Although it is easy to think of a new crafted hydronic piping system as being internally clean since it was built with all new materials, this is seldom the case. To begin with, think about how copper or steel tubing makes its way from the mill to a newly assembled system. Those materials are typically handled, transported, and stored multiple times and at different locations before they make it to your job site. During that time they can be exposed to dust, rain, wind, pollen, road salt, insects, birds, mice and more.

It is inevitable that contaminants from some of these sources will get into piping that is not capped at both ends.

These contaminants aside, there is also likely to be some residual of lubricants used during manufacturing. When copper MH28

SPRING 2019

Figure 1. Recommended setup

piping is soldered together there is going to be residual flux inside the piping. Threaded steel piping is also going to contain some cutting oil.

Cast iron components, especially those that are not internally painted, or that have been stored in high humidity conditions, are going to have internal surface oxidation. There is also likely to be small pieces of metal inside the pipe from sawing, deburring, reaming, grooving, or other metal cutting operations.

These contaminants should be physically removed, to the extent possible, as the system is assembled. In some cases, this is as simple as wiping down components with a clean rag before they are joined together. I know one experienced hydronics pro who pushes and pulls a small wad of clean cloth through every piece of copper tubing that is four feet or less in length, before joining them into the system.

After physical cleaning has done all it can, the next step is chemical cleaning–giving systems a healthy and thorough internal bath before filling it with demineralized water.

Internal washing is done by filling the system with water, adding a “hydronic detergent” formulation (now available from several suppliers) and circulating this blend through the entire system, with the heat source operating at normal temperature, for at least one hour.

Suppliers of these hydronic detergents typically avoid giving out their proprietary formulations, which break down oils and greases within the system and suspend them in the circulating fluid. At the end of the wash cycle the wash water is completely drained from the system and disposed of based on the detergent supplier’s directions. Most of the currently available hydronic detergents are biodegradable and can be disposed

MODERN HYDRONICS

Continued on MH30 WWW.HPACMAG.COM

February 2019

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CORROSION

MH30

SPRING 2019

ON

partially closed open

inlet purging valve

water sample valve open outlet purging valve

demineralizer

of in sewer drains. The piping should get a final rinsing flush and drain to remove as much of the wash water as possible.

I recommend use of a double-ported purging valve, along with a sump pump and a clean five gallon pail for getting the mixture of water and hydronic detergent into smaller systems. The setup is shown in Figure 1.

The inline ball within the double-ported purging valve is closed during this process. A hose from the sump pump carries the mix of water and hydronic detergent into the system, the other hose returns it to the pail after it has passed through the system. A clean white pail lets you see what gets flushed out. Keep the fluid level in the pail high enough and the end of the return hose far enough away from the sump pump to reduce entrained air bubble entry into the system.

After the system has been internally washed it can be filled with demineralized water–assuming a source of that water is available. Alternatively, it can be filled with clean on-site or trucked in water and then demineralized using a “sidearm” assembly as shown in Figure 2.

Demineralizing cartridges or carts are now available from several North American suppliers. Each time some of the system water passes through the demineralizer ions are removed. Water leaving the cartridge gets mixed back into the remaining system water. Thus, with this method of demineralizing it is necessary to draw small periodic samples of the system water to check its TDS reading. Maintain the demineralizing process until a TDS reading between 10 and 30 PPM is reached.

After demineralizing, best practices call for adding a film-forming hydronic system stabilizing formulation. Again, several such products, with proprietary chemical combinations, are available in North America. These products form extremely thin protective films on the inside of the piping and components that help isolate the water from the raw metal sur-

TDS testing

Figure 2. Sidearm assembly

face. They also stabilize the pH of the water, and help protect the system against the slow but unavoidable oxygen entry that occurs over the system’s life.

To keep the system clean you should include high performance air and dirt separation devices in every system.

These functions can be achieved with separate devices, or a single device. If the system contains any ferrous metals such as cast-iron or steel, as most systems do, the dirt separating device should include a magnet to capture ferrous oxide particles. I also highly recommend dirt separation for systems containing high efficiency circulators with permanent magnet motors.

Internally clean hydronic systems help maintain peak component efficiency and lengthen service life. You wouldn’t take a bath in dirty water. You would not MODERN HYDRONICS

(knowingly) put contaminated fuel in your vehicle and you probably would not eat with a rusty fork. Treat your hydronic systems with the same respect and enjoy their benefits for decades. <> John Siegenthaler, P.E., is a mechanical engineering graduate of Rensselaer Polytechnic Institute and a licensed professional engineer. He has over 35 years experience in designing modern hydronic heating systems. Siegenthaler’s latest book is Heating with Renewable Energy (see www.hydronicpros.com for more information).

SEE JOHN AT THE MODERN HYDRONICS SUMMIT 2019. CHECK MODERNHYDRONICSSUMMIT.COM FOR UPDATES. WWW.HPACMAG.COM

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VITOTRANS 300 Commercial high-output DHW heating station The new Vitotrans 300 is a compact, pre-assembled and self-contained DHW heating station, designed to provide large volumes of on-demand hot water to commercial applications, such as hotels, resorts and recreation complexes, hospitals and industrial facilities.

Powerful. Cost Effective. No Downtime.

Works seamlessly with any new or existing hydronic heat source to provide a reliable and consistent supply of endless hot water at flow rates of up to 180 GPM. Eliminates the need for dedicated DHW heating boilers, batteries of direct or indirect-fired DHW tanks, or cascades of tankless water heaters for maximum cost savings.

Multi-heat exchanger design provides built-in redundancy and eliminates costly downtime during service and maintenance.