P/N WFS272 05/03

Application
Manual
R

Residential and Light Commercial

Hydronics Application Manual
Water-to-Water
Heat Pumps

Table of Chapter 1 Introduction to Geothermal Chapter 5 Hydronics Applications/Piping/

Hydronics systems ...................... 3 Schematics/Pump Sizing ................ 21
Contents Section I Overview ........................................ 3 Section I System Type ........................... 21-36
Section II Hydronics Basics ........................ 3-4 Section II Piping System Design
Section III Delivery Systems ........................ 4-7 Requirements ............................... 37
Section IV Design Efficiencies ......................... 7 Section III Piping System Installation ....... 37-38
Section V Controls Systems ........................ 7-8 Section IV Safety ........................................... 38
Section VI Conclusions ................................... 8 Section V System Components ............... 38-39
Chapter 2 Heat Loss/Heat Gain Calculations .... 9 Section VI Source and Load Pump Sizing .... 40
Section I Heat Loss Calculations for Chapter 6 Control Strategies ............................ 41
Radiant Floor or Zoned Chapter 7 Hydronic Heating/Cooling
Baseboard Systems .................. 9-10 Distribution Design .......................... 47
Section II Heat Gain Calculations ................ 10 Section I Baseboard Radiation ................... 47
Section III Equipment Sizing ......................... 10 Section II Cast Iron Radiation ...................... 48
Chapter 3 Sizing Water-to-Water Equipment/ Section III Radiant Floor Heating .................. 48
Buffer Tanks ............................... 11 Section IV Fan Coil Units .............................. 49
Section I Heating Requirements ............ 11-15 Chapter 8 Snow Melting Applications .............. 51
Section II Cooling Requirements ............ 15-16 Section I Snow Melt System Design ........... 51
Section III Buffer Tank Sizing/Application ..... 17 Section II Snow Melt Control Systems ......... 52
Chapter 4 Sizing The Geothermal Closed Chapter 9 Equipment Suppliers ....................... 53
Loop System .............................. 19
 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Note:
This document includes references to WaterFurnace products.
Most of the references apply to WaterFurnace Versatec water-to
water units. However, in general, the Premier line of water-to-
water units can also be applied in the same manner.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Introduction to Geothermal Hydronics Systems CHAPTER 1

Geothermal systems have been in use for many years, with the vast majority of applications featuring water-to- Section I:
air heat pumps using forced air duct systems. The use of hydronics has been popular for even a longer period Overview
of time. Traditionally, hydronics systems have used oil or gas boilers to produce hot water and chillers to
produce chilled water. Combining a water-to-water heat pump with a hydronics application allows the designer
greater application flexibility and unmatched performance when designed properly.

The combination of geothermal and hydronics applications results in a system which not only has the benefits
of both technologies independently, but also has some distinct advantages as a result of the combination.

Benefits of geothermal systems: Benefits of hydronic systems when coupled

with geothermal heating:

• Highest efficiency of any system • Can also provide domestic hot water
• No outdoor equipment • Less drafts and cold spots
• All electric (no flue, fumes, combustion) • Energy savings over forced air
• 19+ years average life expectancy • No filters to change
• Low maintenance costs • No air movement (with less dust)
• Quiet operation • Flexibility of zoning
• Clean operation • Reduces heat loss
• Environmentally responsible • Occupies less space
• Can also provide cooling

In addition to the above mentioned benefits, savings experienced with geothermal heating compared to
traditional systems is in the 20% to 60% range, depending upon electricity and fuel rates. It is an accepted fact
in the industry that hydronics systems typically operate for 20% less than forced air systems. Therefore, the
combination can result in substantial savings.

Geothermal hydronics applications offer a wide variety of space, water, air and process conditioning. Examples
of typical applications are listed below:

• Radiant floor heating • Chilled water cooling

• Radiant wall or ceiling heating • Pool heating
• Industrial process water heating/cooling • Snow melt
• Domestic hot water generation • Make-up air preheating/cooling
• Baseboard radiation*
*Requires back-up heat source in most instances.

Section II:
Hydronics
Hydronics is known as the science of heating and cooling with a liquid. Heating with hot water is versatile. Basics
There are many ways of distributing the heat through the building. The options range from heavy cast iron
radiators seen in older buildings to modern, baseboard style convection radiation, to invisible radiant floor
heating and forced air systems using fan coil units. The central heating plant (water-to-water heat pump or
boiler) is often used to heat homes or buildings, domestic hot water, swimming pools and hot tubs, or water
for piping systems in snow melting applications.

The various distribution systems have all been used successfully in conjunction with a geothermal heat pump.
When designing or retrofitting an existing hydronic heating system, however, the water temperature produced
by the heat pump is a major design consideration.

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Chapter 1 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 1-1 As the TD increases, the Coefficient Heat pumps using R-22 refrigerant are not designed to
of Performance (COP) decreases. When the produce water above 130° F (54° C). The system efficiency
system produces 130° F (54° C) water from a 30° decreases as the temperature difference (TD) between the
F (-1° C) earth loop, the TD is 100° F (55°C), and
heat source (generally the earth loop) and the supply water
the COP is approximately 2.5. If the system is
(the distribution system) increases. Figure 1-1 illustrates the
producing water at 90° F (32° C), the TD is 60° F
(33° C) and the COP rises to about 3.8, an effect of source and load temperatures on the system. The
increase of over 50%. heating capacity of the heat pump also decreases as the
temperature difference increases.

When using the various types of hydronic heat distribution

systems, the temperature limits of the geothermal system
10
must be a major consideration. In new construction, the
8
distribution system can easily be designed with the
temperature limits in mind. In retrofits, care must be
6 taken to address the operating temperature limits of the
COP

existing distribution system.

4

0 20°F 40°F 60°F 80°F 100°F

(11°C) (22°C) (33°C) (44°C) (56°C)
Temperature Difference
(Source Temperature vs Load Temperature)

Section III:
Delivery The next few pages describe some of the common hydronic heating distribution systems.
Systems
Baseboard Radiation: In existing systems, baseboard radiation is typically designed to operate with
160-240° F (71-116° C) water or steam. Baseboard units are typically copper pipe with aluminum fins the
length of the pipe, as shown in Figure 1-2. A decorative cover is normally fitted over the fin tube.

Figure 1-2 Baseboard radiators are typically

Aluminum Fins
constructed of copper tube with closely spaced
aluminum fins attached to provide more surface area
to dissipate heat. Some of the factors affecting the
amount of heat given off by fin tube radiators are the
water temperature, water flow, air temperature, pipe
size and fin size/spacing.

Enclosure
Copper Tube

Fin Tube

Cast Iron Radiation: Retrofit applications for hydronic/geothermal heat pump systems are often required to
work with existing cast iron radiators. Typically, cast iron radiator systems operate with water temperatures of
125-160° F (52-71° C).

Radiant Floor Heating: Radiant floor heating has been the system of choice in many parts of Europe for some
time. Manufacturers have developed tubing designed for installation in concrete floors and built-up wood floors.
Floor heating systems have several benefits in residential, commercial and industrial heating applications. In a
building with a radiant floor heating system, the entire floor acts as a heat source for the room.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 1

In residential applications, occupants in a space feel comfortable with lower air temperatures if their feet are
warm. Typically the space will feel comfortable with air temperatures as low as 65° F (18° C). Since the heat
loss of a building is directly related to the temperature difference between the inside and outside, a lower
temperature difference means the heat loss is lower.

Air temperatures in a room with a forced air heating system tend to be warmer near the ceiling than the floor.
The hot air rises and creates a greater pressure imbalance between the inside and outside. The building's
infiltration increases, resulting in a higher heat loss. Air temperatures in a room with floor heating tend to be
warmer at the floor than the ceiling, helping cut down on infiltration in the building. The energy savings in a
building with floor heating can range from 20-40% over traditional forced air systems.

Figure 1-3 (below) shows that temperatures in a forced air system tend to be more uneven than in a radiant
floor heating system. The air temperatures in a forced air system tend to be much higher than with radiant
floor heating, making the temperature difference between inside and outside higher, which results in a higher
BTU requirement. Industrial buildings, especially those with high ceilings and large overhead doors, have an
advantage with a radiant floor heating system– heat is stored in the concrete floor. When a door is opened,
the stored heat is released to the space immediately. The larger the TD between the air in the space and the
floor, the quicker the floor releases its heat to the space.

High ceilings are often a problem in industrial buildings. Temperatures near the ceiling often reach 90-100° F
(32-38° C), which can be 20-30° F (11-17° C) higher than the temperature at the floor. Radiant floor heating
can cut the temperature difference to as little as 2-4° F (1-2.5° C). Again, because the TD between the ceiling
and the outside is lower, the BTU requirement is lower. This can have a dramatic effect on the cost of heating a
building with high ceilings.

Figure 1-3 Radiant floor heating systems tend

to have more consistency in temperatures
throughout the room compared to forced air 10° 10°
systems. 95° 60°
90° 60°
60°
85° 79°
74° 65° 65° 65°
95° 68°
100° 63° 59° 81° 81° 81°

Forced Air System Radiant Floor Heat

Maintenance garages benefit from radiant floor heating systems. Cold vehicles brought into the garage are
warmed from underneath. The snow melts off the vehicle and dries much more quickly than when heated from
above. In addition, mechanics who work on the vehicles will be more comfortable, especially when their work
requires them to lie on the floor.

Health care centers and child care centers can also benefit greatly from radiant heating. Eliminating air
circulation (with the exception of ventilation air) will help keep airborne contaminants from being spread
throughout the facility.

Fan Coil Units & Air Handlers: Fan coil units, air handlers, force flow units, etc. are all basically a hot water
radiator, or coil, (usually copper piping with aluminum fins) with a fan or blower to move the air over the coil.

The term “fan coil units” typically applies to smaller units, which are installed in the zone or area the heat (or
cooling) is needed. They are available in many different configurations, sizes and capacities, from a number of
manufacturers. Some are designed to be connected to a ductwork system and can be used to replace a forced
air furnace. Others are designed for use without ductwork, and are mounted in a suspended ceiling space with
only a grill showing in place of a ceiling tile. Some can be mounted on a wall under a window, projecting 8-10"

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Chapter 1 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

(20-25 cm) into the room, or even flush to the wall surface, mounted between wall studs. Some are available
with or without finished, decorative cabinets. For industrial applications, inexpensive “unit heaters” are
available, with only a coil and an axial fan. Fan coil units and unit heaters are normally available with air
handling capacities of 200-2,000 cfm (94-944 L/s).

The term “air handler” normally applies to larger units, mounted in mechanical rooms, mechanical crawlspaces
or rooftops. They typically have an air handling capacity of over 2,000 cfm (944 L/s), and are available for
capacities of up to 50,000 cfm (23,595 L/s). Air handlers are typically built for a specific installation, and are
available with many different types of heating and cooling coils, and can include additional coils for heating
make-up air, dehumidification and exhaust air heat recovery.

Figure 1-4 Fan coils and air handlers typically

have one or two coils and a blower. Air is Blower
heated by hot water circulated through a hot
water coil. Chilled water is circulated through
the coil if air conditioning is needed. Blowers
can be provided to fit various applications, with
or without ductwork. Unit heaters typically use
axial fans in applications where ductwork is
not needed.
Chilled Water Coil Hot Water Coil

Fan coil units and air handlers are used in many different applications. They have been used to heat buildings
using water temperatures as low as 90-100° F (32-38° C). New systems can be designed to operate very
efficiently with a geothermal system.

Cooling Systems: Cooling an existing building with a radiant hydronic heating system can be a challenge. If
baseboard or cast iron radiators, or a radiant floor heating system is cooled lower than the dew point, conden-
sation will form on the floor or drip off the radiators.

There is generally minimal ductwork for ventilation, or no ductwork in existing buildings with radiant hydronic
heat. Typically, cooling is provided with separate units where it is needed. This is often done using through-the-
wall or window air conditioners, ductless split air conditioning units or rooftop units.

A water-to-water heat pump system can provide chilled water to ducted or unducted fan coil units. The system
can provide chilled water to cool the building, as well as hot water for the heating system when needed.

A limited amount of cooling can be done by circulating chilled water through the piping in the floor. This can
be effective in buildings with high solar loads or lighting loads, where much of the heat gain is radiant heat being
absorbed by the floor. Cooling fresh air used for ventilation as it is brought into the building (using a chilled
water coil) can sometimes provide the additional cooling needed. Care must be taken to avoid cooling the floor
below the dew point, when condensation begins to form on the floor.

Buildings with fan coil units and air handlers can generally be retrofitted for cooling quite easily. Often it is
simply a matter of adding a cooling coil to the existing air handlers and fan coil units. The coils can use either
chilled water or refrigerant as the cooling medium. Water-to-water heat pumps can provide hot water for the
heating coils as well as chilled water for air conditioning.

Integrated Systems: In large buildings, there are often simultaneous heating and cooling demands. Internal
gains from the occupants, the lighting or large solar gains will require cooling when outdoor temperatures are
below freezing. At the same time, the perimeter areas may need heat.

Geothermal systems, using individual heat pumps operating on an internal building loop, are often used in this
type of application. A heat pump operating in the cooling mode will reject heat into the building loop, while a
second heat pump will take heat from the loop to heat another area. When the cooling loads of the building

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 1

match the heating loads, heat is transferred from one part of the building to another by using a heat pump in the
cooling mode and a second heat pump in the heating mode. In some cases (retrofits, hybrid systems), a boiler
is used to add heat to the loop. In the same respect, a cooling tower may be used to reject the excess heat from
the building loop. These are known as “boiler/cooling tower heat pump systems.”

Section IV:
The efficiency, life expectancy and reliability of a system depends upon how well the different components work Design
together. A hydronic/geothermal system combines heat pump(s), an earth loop (and/or boiler-tower), Efficiencies
circulating pumps, supply and return piping, a distribution system and a control system. The heat pumps are
sized for the building loads. The earth loop must be sized to match the equipment, ground conditions and
climate. The circulating pumps must be sized for the equipment, piping and ground loop. The distribution
system must be designed to heat and cool the building comfortably. The components must then all be
controlled efficiently.

Building Heat Loss & Heat Gain: The design must begin with an accurate heating and cooling load for the
building. This is the most important step in the design process. The sizing of the circulation pumps, the
distribution system and the earth loop are all derived directly from the sizing of the equipment. Overestimating
the heat loss or heat gain means oversizing the system. The extra cost of the oversized system is unnecessary.
It may result in a different type of system being installed. If an oversized system is installed, it will be
inefficient and uncomfortable. If the system is undersized it will not do an adequate job of heating and
cooling the building.

Loop Design & Installation: Several factors determine the loop design for a specific installation. The energy
balance of the building determines how much heat is taken from and rejected to the earth over a year. The
climate determines the ambient earth temperatures and is a major factor in the energy needs of the building.
The earth itself (the conductivity of the soil or rock and the moisture content) is a major factor in calculating
the size of the loop. The earth can only take (heat rejected) or give up (heat extracted/absorbed) a fixed
amount of Btu/hr (Watts) in a given area. The heat exchanger must have sufficient surface area.

The design of the loop itself (the size and type of pipe, the velocity of the liquid circulating in the pipe and the
spacing and layout of the pipe) has a major effect on the heat absorption and rejection capabilities of the loop.
The depth (vertical) or trench length (horizontal) of the loop must be calculated using International Ground
Source Heat Pump Association (IGSHPA) methods or approved software. In addition, the type and percentage
of antifreeze can have a significant effect on loop performance.

The workmanship of the installation also plays a large role in the effectiveness of the loop. Fusion joints must
be done properly. Vertical loops must be grouted properly for good contact with the earth. Horizontal loops
must be backfilled with material that will not cut the pipe, and the soil should be compacted around the pipe
for good contact.

These are some of the factors that affect loop performance. WaterFurnace offers training on loop design and
installation, and will assist in the design of loops for specific applications.

Section V:
The control of a mechanical system determines how it functions. For the system to work efficiently and Controls
comfortably, the building owner or manager must understand what the system is doing and how to control it. Systems
As Figure 1-1 (page 4) shows, the efficiency of a heat pump is a factor of the difference in temperature between
the source and the load. The heat loss or heat gain of a building varies with the weather and the use of the
building. As the outdoor temperature decreases, the heat loss of the building increases. When the ventilation
system is started up, the heating or cooling loads increase. As the occupancy increases, more lighting is used,
or the solar gain increases, the cooling load increases. At other times the building may require virtually no
heating or cooling.

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Chapter 1 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

With hydronic heating and cooling distribution equipment, whether it is baseboard radiation, fan coil units or
radiant floor heating, the output of the equipment is directly related to the temperature and amount of the water
flowing through it. Baseboard radiation puts out approximately 50% less heat with 110° F (43° C) water than
with 130° F (54° C) water. The same is true with fan coil units and radiant floor heating.

If a system is designed to meet the maximum heat loss of a building with 130° F (54° C) water, it follows that if
the heat loss is 50% lower, when the outdoor temperature is higher and the building has high internal gains
(because of lighting and occupancy), the lower heat loss can be met with 110° F (43° C) water. This greatly
increases the COP of the heat pump(s).

The same control strategy is equally effective in cooling. During peak loads, water chilled to 40° F (4° C) may
be needed; at other times 55° F (13° C) water will provide adequate cooling. Significant increases in the EER
(COP) can be achieved.

A significant portion of the operating cost of a heating system is the energy to get the heat where it is needed
(the cost of operating pumps and fans). As an example, the operating cost of circulation pumps for the earth
loop side of a heat pump system can be 15-25% of the total system operating cost. Therefore, pump controls
and sizing are crucial in determining operating costs and system performance.

Section VI:
Conclusions Hydronic/geothermal systems can be used very effectively in new installations, as well as in many retrofit
applications. Efficient systems can be built for residential, commercial and industrial applications.

To make a system as efficient as possible, it is important to follow good design criteria. Some of the factors to
consider are listed below:

• An accurate heat loss and heat gain calculation must be done to size the system to operate efficiently.
• The system must meet the application requirements. In other words, the design of the system must take
into consideration the type of distribution system and the needs of the customer. For example, baseboard
radiation designed for 180° F (82° C) water should not be used with 130° F (54° C) water without careful
consideration and design analysis.
• The components of the system must be designed to work together. The loop must be designed to work with
the heat pumps, the pumping system must work efficiently with the earth loop and the heat distribution, and
the distribution system must be chosen to work efficiently with the water temperatures available from the
equipment.
• The system must be controlled to operate as efficiently as possible. It is important to operate the system to
take variations in the building loads into account. For example, the heat loss of the building is reduced when
the outdoor temperature climbs, and the temperature of the water circulated through the distribution system
can be lowered, allowing the heat pumps to operate more efficiently. It is possible to integrate the functions of
the mechanical systems in a building. Using the system to provide heating and cooling simultaneously can
effectively double the efficiency of the system.
• Modulating the various components of a system to meet the varying requirements of a building can
significantly improve the efficiency of a system. Variable-speed pumps, for example, can greatly increase
the overall efficiency of a system.
• The cost-effectiveness of the system must be considered. Regardless of the application, the design must take
into account operating costs, installation costs and future repair/maintenance.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Heat Loss/Heat Gain Calculations CHAPTER 2

Heat Loss/Heat Gain Calculations

Heat loss/gain calculations for any residential HVAC design should be performed using standard industry
practices. WaterFurnace accepted calculations include methods developed by Air Conditioning Contractors of
America (ACCA) used in Manual J, Heating/Refrigeration and Air Conditioning Institute of Canada (HRAI) and
American Society of Heating Refrigeration and Air Conditioning Engineers (ASHRAE). Light commercial load
calculations should be performed using ACCA Manual N or the ASHRAE method.

Section I:
A room-by-room calculation must be performed for all radiant floor or fan coil systems in order to determine Heat Loss
the design of the radiation system. Once the heat loss has been calculated and the decision on flooring Calculations for
material has been made for each room, the amount of radiant floor tubing, pipe spacing, water temperature Radiant Floor
and layout can be determined, based upon the Btuh/sq. ft. (Watts/sq. meter) requirements. Similarly, the or Fan Coil
amount of heat loss will allow the designer to determine the length of baseboard convector required based Systems
upon the design water temperature.

Outdoor design temperatures should be obtained from the appropriate ACCA, ASHRAE or HRAI manual at the
2.5% condition or local requirements, whichever is most severe. Indoor design temperatures vary, based upon
the type of system and customer preference. Following are some minimum design guidelines:

System Type Indoor Design Range Minimum Indoor Design

100% radiant floor* 65-70° F (18-21° C) 65° F (18° C)
Mixed radiant/forced air 68-72° F (20-22° C) 68° F (20° C)
Baseboard 68-72° F (20-22° C) 68° F (20° C)

*The nature of radiant floor heating tends to allow occupants to feel the same comfort level at 65° F (18° C) as
forced air system at 70° F (21° C).

It is important to remember that radiant floor heating heats objects, not the air. In turn, these objects radiate
heat, which heats people and furnishings to a comfortable temperature. Air temperature remains near 65° F
(18° C), and is approximately equal from ceiling to floor. Forced air heating, by comparison, heats the air,
which heats the people and objects. Therefore, a higher air temperature is required in order to bring people
and objects up to the same temperature as in a radiant heating system. For example, 70° F (21° C) air may be
required to heat an object to 65° F (18° C).

When calculating the heat loss of a structure, the nature of radiant heating should be considered to allow for a
more appropriately sized system. As alluded to above, a thermostat setting of 65° F (18° C) for a radiant floor
system is comparable to a forced air system with a thermostat setting of 70° F (21° C). This principle affects
the heat loss in two ways: 1) the lower temperature difference causes the heat loss to be lower. 2) the lack
of air movement (especially systems not designed for neutral pressure) lowers the infiltration rate of the
structure. Following is an example of the differences in load calculations for radiant floor systems and forced
air systems.

System A: Forced Air System

Outside design temperature = 0° F (-18° C); indoor design temperature = 70° F (21° C)
Temperature difference = 70° F (39° C)
Air changes per hour = 0.60 AC/H
Heat loss = 45,954 Btu/hr (13,469 Watts)

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Chapter 2 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

System B: Radiant Floor System

Outside design temperature = 0° F (-18° C); indoor design temperature = 65° F (18° C)
Temperature difference = 65° F (36° C)
Air changes per hour = 0.50 AC/H
Heat loss = 40,760 Btu/hr (11,947 Watts)

When the characteristics of a radiant floor system are considered, equipment sizing can be significantly
impacted. In the example above, the heat loss for the structure decreases by 5,194 Btu/hr (1,522 Watts) or
11%. Industry estimates are as high as 20%. However, WaterFurnace encourages the use of load calculations
at actual temperature differences and infiltration rates for equipment sizing, rather than "rules of thumb".

Section II:
Heat Gain Most space cooling is accomplished through the use of forced air. Heat gain calculations must be performed
Calculations on a room-by-room or zoned basis. Although load calculations for single zone systems may consider the whole
house or building as one zone, a room-by-room calculation will facilitate air duct sizing.

Outdoor design temperatures should be obtained from the appropriate ACCA, ASHRAE or HRAI manual at the
2.5% condition or local requirements, whichever is most severe. Indoor design temperatures for cooling
typically range from 70-78° F (21-25° C), with most designed at 75° F (24° C).

Section III:
Equipment Once heat loss/gain calculations have been completed, the water-to-water equipment, delivery system and
Sizing buffer tank can be determined. See Chapter three (page 11) for detailed procedures.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Sizing Water-to-Water Equipment/Buffer Tanks CHAPTER 3

Water-to-water equipment sizing is dependent upon the type of hydronic system application and the type of
loop system (open or closed) chosen. Since the capacity and efficiency of the water-to-water unit is directly
related to the entering source temperature, care must be taken to ensure that the unit will provide adequate
capacity at design conditions.

Regardless of the application, there are several design steps which must be followed to ensure proper sizing.
The following steps outline the design procedure once the heat loss/gain has been determined:

Section I:
1) Determine the heating correction factor. Although ACCA, HRAI and ASHRAE heat loss calculations Heating
are adequate at determining the peak block heating load at design conditions, they do not take into account
the lag associated with the thermal mass of the structure (especially in radiant floor applications), solar Requirements
gains or internal gains. Therefore, a heating correction factor can be calculated to more closely match the
heating equipment to the structure being conditioned. This calculation can also help predict the heating
balance point (i.e. the outdoor temperature at which the structure needs heating). Typical heating
correction factors range between 0.65 and 0.90. Based upon this number, the heating balance point can
be calculated if desired. Most homes require heating when the outdoor temperature falls below 50-65° F
(10-18° C), depending upon internal gains, solar gains and infiltration. Note: If computer software is
used to size the water-to-water equipment, this step may not be necessary, depending upon if the
software calculates a heating correction factor. Consult your software manual.

Calculations for English Units:

a) Heat loss: _______________ (Btu/hr)

b) Heating degree days: ______________ (°F-Days)

Rate the following items:

c) Solar gain: ________ 1 to 3 (1 = low amt. of glass; 3 = high amt. of glass)

d) People gain: ________ 1 to 3 (1 = few people per sq. ft.; 3 = high concentration)

e) Base load: ________ 2 to 6 (2 = low base electric use; 6 = high base electric use)

NOTE: Base load = electric use not including heating or cooling.

f) Subtotal (c + d + e) = _________________ (Gains factor)

Rate the following item:

g) Construction quality: ________ 4 to 8 (4 = high infiltration or poor quality, 8 = low infiltration or

high quality)

h) Gains factor = fxg= _________

i) Heating correction factor = _______________ (Use Table 3-1, page 12)

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Chapter 3 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Table 3-1 Heating Correction Factor Chart (English Units)

G Annual Degree-Days (°F-Days)
a 0 1000 2000 3000 4000 5000 6000 7000 8000
i 100 0.63 0.59 0.55 0.51 0.47 0.43 0.45 0.47 0.49
n 90 0.67 0.63 0.60 0.56 0.52 0.48 0.50 0.52 0.54
s 80 0.71 0.68 0.64 0.61 0.57 0.53 0.55 0.57 0.59
70 0.75 0.72 0.69 0.65 0.62 0.57 0.59 0.61 0.63
F 60 0.79 0.76 0.73 0.70 0.67 0.62 0.64 0.66 0.68
a 50 0.84 0.81 0.78 0.75 0.72 0.67 0.69 0.71 0.73
c 40 0.88 0.85 0.82 0.80 0.77 0.72 0.74 0.76 0.78
t 30 0.92 0.89 0.87 0.84 0.82 0.76 0.78 0.80 0.82
o 20 0.96 0.94 0.91 0.89 0.87 0.81 0.83 0.85 0.87
r 10 1.00 0.98 0.96 0.94 0.92 0.86 0.88 0.90 0.92

Calculations for S.I./Metric Units:

a) Heat loss: _______________ (kW)

b) Heating degree days: ______________ (K-Days)

Rate the following items:

c) Solar gain: ________ 1 to 3 (1 = low amt. of glass; 3 = high amt. of glass)

d) People gain: ________ 1 to 3 (1 = few people per sq. ft.; 3 = high concentration)

e) Base load: ________ 2 to 6 (2 = low base electric use; 6 = high base electric use)

NOTE: Base load = electric use not including heating or cooling.

f) Subtotal (c + d + e) = _________________ (Gains factor)

Rate the following item:

g) Construction quality: ________ 4 to 8 (4 = high infiltration or poor quality, 8 = low infiltration or

high quality)

h) Gains factor = fxg = ________

i) Heating correction factor = ________ (Use Table 3-2)

Table 3-2 Heating Correction Factor Chart (S.I./Metric Units)

G Annual Degree-Days (K-Days)
a 0 556 1111 1667 2222 2778 3333 3889 4444
i 100 0.63 0.59 0.55 0.51 0.47 0.43 0.45 0.47 0.49
n 90 0.67 0.63 0.60 0.56 0.52 0.48 0.50 0.52 0.54
s 80 0.71 0.68 0.64 0.61 0.57 0.53 0.55 0.57 0.59
70 0.75 0.72 0.69 0.65 0.62 0.57 0.59 0.61 0.63
F 60 0.79 0.76 0.73 0.70 0.67 0.62 0.64 0.66 0.68
a 50 0.84 0.81 0.78 0.75 0.72 0.67 0.69 0.71 0.73
c 40 0.88 0.85 0.82 0.80 0.77 0.72 0.74 0.76 0.78
t 30 0.92 0.89 0.87 0.84 0.82 0.76 0.78 0.80 0.82
o 20 0.96 0.94 0.91 0.89 0.87 0.81 0.83 0.85 0.87
r 10 1.00 0.98 0.96 0.94 0.92 0.86 0.88 0.90 0.92

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 3

2) Multiply the heating correction factor by the heating load.

Adjusted heating load = heating load X heating correction factor = ________

3) Determine the minimum entering source water temperature at design conditions to be used
in selecting the capacity of water-to-water equipment needed. For open loop applications, the
minimum source temperature would be the average ground water temperature, usually 45 to 70° F
(7 to 21° C), depending upon geographical location. For closed loop systems, the minimum source
temperature would be minimum water temperature used in sizing the ground loop piping, usually 30
to 50° F (-1 to 10° C), depending upon geographical location.
Minimum source temperature: ________

4) Determine the maximum entering load water temperature at design conditions to be used
in selecting the capacity of water-to-water equipment needed. All water-to-water units used in
heating applications require a buffer tank to prevent equipment short cycling and to allow different flow
rates through the water-to-water unit than through the hydronic heating delivery system. Therefore, the
maximum load temperature would be the maximum temperature maintained in the buffer tank, typically
120° F (49° C) or less. Maximum load temperature: ________

5) Determine the percentage of heating load the water-to-water unit(s) will be handling. In other
words, will the water-to-water unit(s) be providing 100% of the heating to the structure/zone or will there
be back up heat installed with the system? Typically, if a backup system is desired, the water-to-water unit
should be sized to handle 80% to 90% of the heating load unless the application is designed around the
cooling load in the case of some retrofit hydronic applications (see section II, pages 15 - 16).
Unit sizing load = adjusted heating load X percentage of heating load (as a decimal)

6) Using the specifications catalog for the water-to-water unit desired, match up the unit sizing
load with the source and load water temperatures and flow rates required for the application
to determine the water-to-water unit(s) needed.
Unit size/capacity: __________________________________

7) Determine the amount of backup (auxiliary) heat required. If result is a negative number or zero,
no backup is required.
Backup heat = Adjusted heating load unit capacity
Note: If using English units, divide the backup heat required by 3,413 to get kW.

Heating requirements example #1 (English Units):

System characteristics: Closed loop system with radiant floor heating (no backup)
Heat Loss = 50,000 Btu/hr

SOLUTION:

1) Determine the heating correction factor.

Calculations for I.P./English Units:

a) Heat loss: 50,000 (Btu/hr)

b) Heating degree days: 6,000 (°F-Days)

Rate the following items:

c) Solar gain: 2 1 to 3 (1 = low amt. of glass; 3 = high amt. of glass)

d) People gain: 2 1 to 3 (1 = few people per sq. ft.; 3 = high concentration)

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Chapter 3 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

e) Base load: 4 2 to 6 (2 = low base electric use; 6 = high base electric use)
NOTE: Base load = electric use not including heating or cooling.

f) Subtotal (c + d + e) = 8 (Gains factor)

Rate the following item:

g) Construction quality: 6 4 to 8 (4 = high infiltration or poor quality, 8 = low infiltration or

high quality)

h) Gains factor = f x g = 48

i) Heating correction factor = 0.69 (Use Table 3-3)

Table 3-3 Heating Correction Factor Chart (English Units)

G Annual Degree-Days (°F-Days)
a 0 1000 2000 3000 4000 5000 6000 7000 8000
i 100 0.63 0.59 0.55 0.51 0.47 0.43 0.45 0.47 0.49
n 90 0.67 0.63 0.60 0.56 0.52 0.48 0.50 0.52 0.54
s 80 0.71 0.68 0.64 0.61 0.57 0.53 0.55 0.57 0.59
70 0.75 0.72 0.69 0.65 0.62 0.57 0.59 0.61 0.63
F 60 0.79 0.76 0.73 0.70 0.67 0.62 0.64 0.66 0.68
a 50 0.84 0.81 0.78 0.75 0.72 0.67 0.69 0.71 0.73
c 40 0.88 0.85 0.82 0.80 0.77 0.72 0.74 0.76 0.78
t 30 0.92 0.89 0.87 0.84 0.82 0.76 0.78 0.80 0.82
o 20 0.96 0.94 0.91 0.89 0.87 0.81 0.83 0.85 0.87
r 10 1.00 0.98 0.96 0.94 0.92 0.86 0.88 0.90 0.92

2) Multiply the heating correction factor by the heating load.

Adjusted heating load = heating load X heating correction factor
= 50,000 X 0.69
= 34,500 Btu/hr

3) Determine the minimum entering source water temperature at design conditions to be used
in selecting the capacity of water-to-water equipment needed.
Minimum source temperature: 30° F

4) Determine the maximum entering load water temperature at design conditions to be used in
selecting the capacity of water-to-water equipment needed.
Maximum load temperature: 120° F

5) Determine the percentage of heating load the water-to-water unit(s) will be handling.
Unit sizing load = adjusted heating load X percentage of heating load (as a decimal)
= 34,500 X 1.00
= 34,500 Btu/hr

6) Using the specifications catalog for the water-to-water unit desired, match up the unit sizing
load with the source and load water temperatures and flow rates required for the application
to determine the water-to-water unit(s) needed.

The Versatec V060 unit at 30° F EST/120° F ELT/14.0 gpm (both sides) has a heating
capacity of 41,500 Btu/hr, which will satisfy the heating requirements.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 3

7) Determine the amount of backup (auxiliary) heat required. If result is a negative number or zero,
no backup is required.
Backup heat = adjusted heating load unit capacity
= 34,500 - 41,500
= -7,000 Btu/hr (no backup required)
Note: If using I.P./English units, divide the backup heat required by 3,413 to get kW.

Heating requirements example #2 (English Units):

System characteristics: Closed loop system with radiant floor heating (with backup)
Heat Loss = 80,000 Btu/hr

SOLUTION:
Steps 1 through 4 are identical to the above example. Following are steps 5 through 7,
which differ:

5) Determine the percentage of heating load the water-to-water unit(s) will be handling.
Unit sizing load = adjusted heating load X percentage of heating load (as a decimal)
= 55,200 X 0.80 (80%)
= 44,160 Btu/hr

6) Using the specifications catalog for the water-to-water unit desired, match up the unit sizing
load with the source and load water temperatures and flow rates required for the application to
determine the water-to-water unit(s) needed.

The Versatec V060W unit at 30° F EST/120° F ELT/14.0 gpm (both sides) has a heating capacity
of 41,500 Btu/hr, which will satisfy the heating requirements. The Versatec V036 unit at 30° F
EST /120° F ELT/9.0 gpm (both sides) has a heating capacity of 23,600 Btu/hr, which will NOT
satisfy the heating requirements.

7) Determine the amount of backup (auxiliary) heat required. If result is a negative number or zero,
no backup is required.
Backup heat = adjusted heating load unit capacity
= 44,160 - 41,500
= 2,660 Btu/hr
Note: If using English units, divide the backup heat required by 3,413 to get kW.
Backup kW = 2,660 ÷ 3,413
= .78 kW (an electric water heater has a capacity of 4.5kW)

Section II:
Cooling is not always desired with radiant heating systems. Skip this section for heating only systems or systems Cooling
with separate equipment for cooling. Below are the necessary steps for sizing a water-to-water unit which will Requirements
supply chilled water to fan coil units.

1) Determine the maximum entering source water temperature at design conditions to be used in
selecting the capacity of water-to-water equipment needed. For open loop applications, the
maximum source temperature would be the average ground water temperature, typically 45 to 70° F (7 to
21° C), depending upon geographical location. For closed loop systems, the maximum source temperature
would be maximum water temperature used in sizing the ground loop piping, usually 90 to 100° F (32 to
38° C), depending upon geographical location.
Maximum source temperature: ________

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Chapter 3 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

2) Determine the minimum entering load water temperature at design conditions to be used in
selecting the capacity of water-to-water equipment needed. Some water-to-water units used in
cooling applications require a buffer tank; others do not (see Section III, page 17). Therefore, the minimum
load temperature would be the minimum temperature needed for fan coil unit operation or the minimum
temperature maintained in the buffer tank, typically 40 to 55° F (5 to 13° C).
Minimum load temperature: ________

3) Using the specifications catalog for the water-to-water unit desired, match up the cooling load
with the source and load water temperatures and flow rates required for the application to
determine the water-to-water unit(s) needed.

4) Determine which space conditioning mode will take precedence for equipment sizing.
For applications where the water-to-water unit(s) will handle more than 80% of the heating load, size the
unit(s) to meet the greatest need (heating or cooling). A buffer tank will be required if the unit(s) is more
than 20% larger than the cooling load and/or multiple fan coil units will be used. For retrofit applications
where cooling and add-on heating is required (i.e. an existing boiler will be used for the remainder of
the heating load) or applications with larger cooling than heating needs, size the unit(s) to meet the
cooling requirements.

Cooling requirements example (English Units):

System characteristics: Closed loop system with radiant floor heating (no backup) and fan coil units
for cooling.
Heat Loss = 50,000 Btu/hr; Heat Gain (total) = 22,000 Btu/hr.

SOLUTION:

1) Determine the maximum entering source water temperature at design conditions to be used
in selecting the capacity of water-to-water equipment needed.
Maximum source temperature: 90° F

2) Determine the minimum entering load water temperature at design conditions to be used in
selecting the capacity of water-to-water equipment needed.
Minimum load temperature: 50° F

3) Using the specifications catalog for the water-to-water unit desired, match up the cooling load
with the source and load water temperatures and flow rates required for the application to
determine the water-to-water unit(s) needed.

The Versatec V036W unit at 90° F EST/50° F ELT/9.0 gpm (both sides) has a cooling capacity
of 23,800 Btu/hr, which will satisfy the cooling requirements.

4) Determine which space conditioning mode will take precedence for equipment sizing. Since
this example requires a system without backup heating, the V036W will not meet the
requirements. As determined in the first heating example (above), an V060W will be
required. Regarding cooling capacity, the Versatec V060W unit at 90° F EST/50° F ELT/
14.0 gpm (both sides) has a cooling capacity of 42,400 Btu/hr, which will satisfy the
cooling requirements.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 3

Section III
Buffer Tank
All water-to-water units used in heating applications require a buffer tank to prevent equipment short cycling
and to allow different flow rates through the water-to-water unit than through the hydronic heating delivery
Sizing/
system. A buffer tank is also required for cooling applications if the water-to-water unit(s) is more than 20% Application
larger than the cooling load and/or multiple fan coil units will be used. Water-to-water units sized for the
cooling load in applications with only ONE fan coil unit may be able to operate without a buffer tank.

The size of the buffer tank should be determined based upon the predominant use of the equipment (heating or
cooling). For heating, buffer tanks should be sized at one U.S. gallon per 1,000 Btuh (13 Liters per kW) of
heating capacity at the maximum entering source water temperature and the minimum entering load water
temperature, the point at which the water-to-water unit has the highest heating capacity, usually 50-70° F
(10-21° C) EST and 80-90° F (26-32° C) ELT. For cooling, buffer tanks should be sized at one U.S. gallon per
1,000 Btuh (13 Liters per kW) of cooling capacity at the minimum entering source water temperature and the
maximum entering load water temperature, the point at which the water-to-water unit has the highest cooling
capacity, usually 50-70° F (10-21° C) EST and 50-60° F (10-16° C) ELT. Select the size of the tank based upon
the larger of the heating or cooling calculations. The minimum buffer tank size is 40 U.S. gallons (36 Liters) for
any system.

Electric water heaters typically make good buffer tanks because of the availability and relatively low cost.
Attention should be paid to insulation values of the tank, especially when a buffer tank is used to store chilled
water due to the potential for condensation. A minimum insulation value of R-12 (2.11 K-m2/W) is recom-
mended for storage tanks. Care must be taken when using the fittings where the elements are threaded into the
water heater for piping connections. Typically, these fittings have very few threads, and use a flange to seal
against the water heater.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Sizing The Geothermal Closed Loop System CHAPTER 4

Sizing the geothermal closed loop system for a water-to-water unit is very similar to loop sizing for a water-to-
air system. Once the size of the equipment is known (Chapter 3, pages 11-17), loop sizing software should be
used to obtain the proper amount of closed loop to match the loads of the structure and the heat of extraction/
absorbtion or rejection of the equipment chosen.

Currently, WaterFurnace software does not include water-to-water equipment. However, accurate loop lengths
may be obtained using the water-to-air calculations, as long as the steps below are followed.

1) Determine the type of system to be used. Choices are "all water" (hydronic heating and chilled water
with fan coil units) or "hydronic heating with separate cooling system."

2) "All water" systems:

a) Enter the heating and cooling loads into the software.
b) Select a water-to-air unit that is comparable in size to the water-to-water unit sized in Chapter 3,
pages 11-17.
For example, if an V036W unit was selected, a Versatec 036W forced air unit can be used for the
purpose of loop sizing.
c) Enter the loop type and minimum/maximum loop temperatures.
d) Calculate the amount of loop needed for heating and print out the data for future reference.

3) Hydronic heating with separate cooling system:

a) Enter the heating load and a very small cooling load into the software, so that the loop
will not be sized for cooling.
b) Select a water-to-air unit that is comparable in size to the water-to-water unit sized in Chapter 3,
pages 11-17. For example, if an V036W unit was selected, a V036 forced air unit can be used for the
purpose of loop sizing.
c) Enter the loop type and minimum/maximum loop temperatures.
d) Calculate the amount of loop needed for heating and print out the data for future reference.
e) Enter the cooling load and a very small heating load into the software, so that the equipment/loop
will not be sized for heating.
f) Choose the appropriate water-to-air unit to meet the cooling requirements.
g) Enter the loop type and minimum/maximum loop temperatures.
h) If the water-to-water and the water-to-air equipment will share the same loop, install the amount of
loop required by the larger of the two calculations. If each piece of equipment will have its own loop,
install the appropriate amount for each unit.

4) Determine inside piping and pump sizing, based upon application of equipment. Note that one
flow center may be used for two units in some situations. For example, suppose a V060W water-to-water
unit is used for radiant floor heating and a Premier unit is used for cooling. As long as both units will not
be running at the same time, one two-pump flow center can be used to supply both units, piped in parallel.
A pressure drop calculation must always be performed to assure proper water flow.

5) If using more than one piece of equipment, verify that all heating and cooling equipment can control the
loop pumps.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Hydronics Applications/Piping Schematics/Pump Sizing CHAPTER 5

As mentioned in Chapter 1, pages 3-8, hydronic applications offer a wide range of application flexibility, so
much in fact, that it is necessary to narrow down the choices in order to start designing the system. As with any
heating and cooling design, there is never a perfect solution, but rather a compromise between installation
costs, operating costs, desired features and comfort.

Section I:
This section will address the design and application of twelve different types of hydronics and combination
System Type
systems. Table 5-1 below shows the twelve different system types, and a matrix of information to assist in
determining the correct application for the job to be designed. Local codes supersede any recommenda-
tions in this manual.

Table 5-1 System Type

System Characteristics Figure(s) Equipment* Advantages** Disadvantages**
1 Hydronic htg. only--no backup 5.1, — 5.3 w-w 1,4 7,9
2 Hydronic htg. only w/boiler backup 5.10 — 5.13 w-w & blr. 1,2,3,4 9
3 Hydronic htg. only w/elect. wtr. htr. backup 5.8 — 5.9 w-w & w.h. 1,2,3,4 9
4 Hydronic htg.--no backup w/sep. forced air clg. 5.1 w-w & w-a 1,4,5,8 7
5 Hydronic htg.--no backup w/mult. fan coil units 5.4 — 5.5 w-w & f.c.2 1,4,5,8 7
6 Hydronic htg.--no backup w/one fan coil unit 5.6 — 5.7 w-w & f.c.1 1,3,4 6
7 Hydronic htg. w/boiler backup & sep. forced air clg. 5.10 w-w, blr. & w-a 1,2,4,5,8 7
8 Hydronic htg. w/boiler backup & mult. fan coil units 5.4 — 5.5 w-w, blr. & f.c.2 1,4,5,8 7
9 Hydronic htg. w/boiler backup & one fan coil unit 5.6 — 5.7, w-w, blr. & f.c.1 1,2,3,4 6
5.10 — 5.13
10 Hydronic htg. w/elect. wtr. htr. backup & sep. f.a. clg. 5.8 — 5.9 w-w, w.h. & w-a 1,2,4,5,8 7
11 Hydronic htg. w/elect. wtr. htr. backup & mult. fan coil units 5.8 — 5.9 w-w, w.h. & f.c.2 1,4,5,8 7
12 Hydronic htg. w/elect. wtr. htr. backup & one fan coil unit 5.8 — 5.9 w-w, w.h. & f.c.1 1,2,3,4 6
* Definitions are as follows:
w-w = water-to-water heat pump w-a = water-to-air heat pump f.a = forced air
blr. = boiler f.c.2 = multiple fan coil units
w.h. = water heater f.c.1 = single fan coil unit
** Advantages/Disadvantages:
1 = No air movement in heating 6 = Only allows one zone of cooling per water-to-water unit
2 = Good for retrofit 7 = Expensive to install
3 = Less expensive to install 8 = Best comfort of any system
4 = Allows multiple zones of heating 9 = No air conditioning
5 = Allows multiple zones of cooling

The systems listed in Table 5-1, as well as the drawings in Figures 5-1 through 5-13 give the designer an idea of
system characteristics, as well as the advantages and disadvantages of each type of system. Following is a
discussion of each system, including basic operation modes:

System #1– Hydronic heating only (no backup): System #1 uses one or more water-to-water units
and a buffer tank for each unit. Figure 5-1 shows a typical piping arrangement for this system. An aqua-stat
controls the buffer tank temperature, causing the water-to-water unit compressor, load pump and source pump
to engage when the tank temperature drops below the set point, typically 120° F (49° C) or less. The radiant
floor (or baseboard, radiator, fan coil, etc.) system, therefore, is completely isolated from the water-to-water
unit. The hydronic distribution system controls engage pumps and/or zone valves to allow heated water in the
buffer tank to flow through the heating distribution system.

System #2 – Hydronic heating only with boiler backup: System #2 can be used for two different types
of applications. A boiler backup may be required because the water-to-water unit lacks sufficient capacity at
design conditions, or because the hydronic heating distribution system requires hotter water than the
water-to-water unit can produce.

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Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

a) Water-to-water unit lacks capacity: This type of system would be used when the water-to-water
unit has been sized to handle less than 100% of the heating load. It is common practice to size
geothermal heat pump systems to handle approximately 80% of the load in order to lower equipment
and loop requirements, especially when the cooling load is less than the heating load. In this case, the
boiler mixing valve should be set at the same temperature as the buffer tank aqua-stat (refer to Figure
5-10, page 33). When the buffer tank begins to drop in temperature, the boiler comes on to make up
the difference. This type of system is excellent for retrofit installations, where an existing boiler is in
good operating condition.

b) Distribution system requires hotter water: This type of system would be used when baseboard
convectors, cast iron radiators or fan coil units are already installed in a retrofit application. As
mentioned in option "a," a boiler in good operating condition contributes to the cost-effectiveness of
this approach. Since the water-to-water unit is only capable of producing up to 130° F (54° C) water,
and the existing distribution system may require up to 180° F (82° C) at design conditions, the water-
to-water system should be sized to handle the heating load up to the point where hotter water is
required (i.e. at the outdoor temperature balance point). Typically, a properly sized water-to-water
unit can handle the load until the outdoor temperature drops to 20 to 30° F (-7 to -1° C). At that
point, the water-to-water unit compressor must be disengaged (through the use of an outdoor
thermostat or other control means), and the boiler should be started. The water delivered to the
hydronic system now increases in temperature to help satisfy the increased load.

System #3 – Hydronic heating only with electric water heater backup: System #3 is the most cost
effective heating only system if an existing boiler is not already in place. Like system 2a (above), this type of
system would be used when the water-to-water unit has been sized to handle less than 100% of the heating
load. The water heater thermostat should be set at the same temperature as the buffer tank aqua-stat (refer to
Figure 5-4, page 27). When the buffer tank begins to drop in temperature, the water heater comes on to make
up the difference. This type of system should not be used when hotter water is required (as in system 2b), since
the water heater capacity is limited to approximately 4.5 kW. An electric water heater will not have the recovery
rate or capacity to maintain a continuous supply of hotter water to the distribution system.

System #4 – Hydronic heating (no backup) with a separate forced air cooling system: Heating
requirements and operation for system #4 are identical to those in system #1, since the cooling system is
separate. In this case, the conditioned space would have separate thermostats for heating and cooling. The
cooling system would be designed to operate independently of the heating system. There are several advantages
to a system such as this one. Few will argue that a hydronic heating system with a separate forced air cooling
system is the most comfortable heating and cooling system available if designed properly. In addition, water-to-
air equipment can share the same geothermal loop as the water-to-water equipment in most cases. Lastly,
controls are much easier for separate systems, as compared to integrated ones.

System #5 – Hydronic heating (no backup) with multiple fan coil units for cooling: System #5
shares all of the advantages of system #4 with the exception of controls (refer to Figure 5-2, page 25).
However, system #5 uses one unit (or multiple water-to-water units) for both heating and cooling. The heating
system will be identical to system #1. Cooling is accomplished by circulating chilled water through one or more
fan coil units. Note that if multiple fan coil units are used, a buffer tank is required to prevent equipment short-
cycling. For example, suppose one V060W unit is required for heating and three 12,000 Btu/hr (3.5 kW) fan
coil units are used for cooling in three zones. When only one zone is calling for cooling, the water-to-water unit
is approximately five times larger than necessary; short-cycling could easily occur. Also note that when a buffer
tank is used, there is a time lag associated with switch-over between the heating and cooling modes. In other
words, some time is required to switch from a heated buffer tank to a chilled buffer tank. If quick switch-over
is desired, system #4 or #6 should be designed.

System #6 – Hydronic heating (no backup) with one fan coil unit for cooling: System #6 is a
compromise between system #'s 4 and 5 (refer to Figure 5-3, page 26). This application has the advantage of
using only one piece of equipment to produce both heating and cooling, but lacks the flexibility of having

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

multiple zones for cooling. By limiting this application to one fan coil unit per water-to-water unit (providing
the water-to-water unit is not more than 20% larger than the fan coil unit), a buffer tank is not required for
cooling. A buffer tank is always required for heating. The elimination of the buffer tank allows quick switch-
over from heating to cooling.

System #7 – Hydronic heating with boiler backup and separate forced air cooling: System #7 is a
combination of system #2 and system #4.

System #8 – Hydronic heating with boiler backup and multiple fan coil units for cooling: System #8
is a combination of system #2 and system #5.

System #9 – Hydronic heating with boiler backup and one fan coil unit for cooling: System #9 is a
combination of system #2 and system #6. This system is the most cost-effective hydronic heating and cooling
system if an existing boiler is in good working order.

System #10 – Hydronic heating with electric water heater backup and separate forced air cooling:
System #10 is a combination of system #3 and system #4.

System #11 – Hydronic heating with electric water heater backup and multiple fan coil units for
cooling: System #11 is a combination of system #3 and system #5.

System #12 – Hydronic heating with electric water heater backup and one fan coil unit for
cooling: System #12 is a combination of system #3 and system #6. This system is the most cost-effective
hydronic heating and cooling system if an existing boiler is not available.

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Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-1 Piping schematic for hydronic heating with buffer tank (heating only or heating with separate forced air
cooling system)

Return from
Hydronics
System

Make-up
Water
Supply to Supply
Hydronics
System
H C Pressure Gauge
Dip P Backflow
Tube Air Preventor
Factory
Installed Vent WaterFurnace
Relief
Unit
Buffer Tank

Exp
Aqua- Tank
Terminate stat Remove elements Air Pad
6” (15 cm) T to use fittings for
connections to Inlet & Outlet
above Floor Label Direction of Flow
hydronic system. P/T Port

1) Expansion tank not needed on “floor side,” since tank has

Insulation
been added to water-to-water side.
2) Minimum buffer tank up to V036W = 52 U.S. Gal. (197 L);
minimum buffer tank up to V060W = 80 U.S. Gal. (303 L).
3) Minimum insulation for buffer tank = R-12 (2.11 K=m2/W).
Well- 4) Use only copper type “M” straight tubing for piping.
Buffer
Type 3/4” (19 mm) piping is permissible up to V036W;
Tank Aqua-
Stat
1” (25 mm) piping is permissible up to V060W.
Brass “T” 5) Above piping sizes assume a maximum length of 25 ft.
(7.6 meters) one way and a maximum of 8 elbows.
6) If tank has internal thermal siphoning trap, remove check
Connection to valve ball to lessen pressure drop.
Water-to-Water
Unit
7) If tank is self-cleaning, dip tube may need to be replaced
with straight copper (original causes additional restriction).
Dip tube should also be replaced if using antifreeze.
Local codes supersede 8) Remove anode rod and replace with brass plug.
any recommendations 9) Avoid tanks with 1-3/8” (35 mm) fittings used for elements.
in this manual. 10) All above recommendations can be applied when using
a (Grundfos UP2699) or equal.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

24
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-2 Heat pump with outdoor reset tekmar®-application

- Application A 1126
07/98
Heat Pump with Outdoor Reset.

Mechanical
253
Outdoor
Class II Sensor (S2) 070
Transformer
120 V (ac) 24 V (ac)

R1

M M M

S1
P1

Heat Pump
Buffer Tank

Electrical 5A 253
No Power

1 2 3 4 5 6 7 8
Com Boil Out Power
Sen Sen Sen Boiler T R+ C-

S1

S2 Heat
Pump

R1
Zone Valve Motor
7 6
End Switches
8 5
T1 Z1
1 4
M 2 3
T2 Z2
M
T3 Z3
Class II P1
Transformer M
24 V (ac) C
R
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

25
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-3 Heat pump with outdoor reset and indoor feedback, tekmar®-application

- Application A 1127
07/98
Heat Pump with Outdoor Reset and Indoor Feedback.

Mechanical RTUs
054 370
Outdoor
Sensor (S2) 070

120 V (ac)

S1

Heat Pump
Buffer Tank

Electrical 5A
2.4A 370 5A 5A 5A 5A
Do not apply power here

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Sys Power Var. Com RTU RTU Com RTU RTU Com Uno Zo Com Boil Sup Out DHW DHW Com Com
Pmp N L Pmp Sen 1 2 Sen 3 4 Sen Sw In Sen Sen Sen Sen Boiler Pmp / Vlv DemDem 1-2 1 2 3-4 3 4

H H
S1
H H
S2 Heat
Pump

Thermal Motor DHW during UnOcc.

Optimum Start Boiler Return DHW Priority
Occ/UnOcc Mixing DHW Valve
Zone 1 Cooling
Zone 1 Heating
Zone 1 2 3 4 Boiler DHW Pump
Occ. only Off Boiler Supply Off

120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

26
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-4 Piping schematic for hydronic heating and chilled water/fan coil unit(s) cooling
with buffer tank

From Coil Unit(s)

NOTE: If more than fan coil unit is installed,
To Coil a bypass valve must be installed on each
Return from Unit(s) unit to bypass coil when thermostat is not calling.
Hydronics System N.C.

C N.O.

Make-up
M
Supply to Water
Hydronics Supply
H C
System
Aqua- Pressure Gauge
stat Dip P Backflow
(clg) Tube
Air Preventor
T Vent WaterFurnace
Factory Unit
Buffer Tank

Installed
Relief
Aqua- Exp
stat
Tank
(htg) Remove elements Air Pad
Terminate to use fittings for
T
6” (15 cm) connections to P/T Port
above Floor hydronic system.

1) Expansion tank needed on “floor side,” since tank has

Insulation been added to water-to-water side.
2) Minimum buffer tank up to V036W = 52 U.S. Gal. (197 L);
minimum buffer tank up to V060W = 80 U.S. Gal. (303 L).
3) Minimum insulation for buffer tank = R-12 (2.11 K=m2/W).
Buffer Well- 4) Use only copper type “M” straight tubing for piping.
Type 3/4” (19 mm) piping is permissible up to V036W;
Tank Aqua-
Stat 1” (25 mm) piping is permissible up to V060W.
Brass “T” 5) Above piping sizes assume a maximum length of 25 ft.
(7.6 meters) one way and a maximum of 8 elbows.
6) If tank has internal thermal siphoning trap, remove check
Connection to
Water-to-Water Unit
valve ball to lessen pressure drop.
7) If tank is self-cleaning, dip tube may need to be replaced
with straight copper (original causes additional restriction).
Local codes supersede Dip tube should also be replaced if using antifreeze.
any recommendations 8) Remove anode rod and replace with brass plug.
in this manual. 9) Avoid tanks with 1-3/8” (35 mm) fittings.
10) All above recommendations can be applied when using
a (Grundfos UP2699) or equal.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

27
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-5 Heat pump with outdoor reset indoor feedback and multiple cooling, tekmar®-application

- Application A 1130
08/98
Heat Pump with Outdoor Reset, Indoor Feedback and Multiple Cooling.

Mechanical RTUs
054 370
Outdoor
Sensor (S2) 070

Class II
Transformer
120 V (ac)
24 V (ac)

R1

M M M M M M

S1
P1

Heat Pump
Buffer Tank

Electrical 5A
2.4A 370 5A 5A 5A 5A
Do not apply power here

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Sys Power Var. Com RTU RTU Com RTU RTU Com Uno Zo Com Boil Sup Out DHW DHW Com Com
Pmp N L Pmp Sen 1 2 Sen 3 4 Sen Sw In Sen Sen Sen Sen Boiler Pmp / Vlv DemDem 1-2 1 2 3-4 3 4

H
S1
H H
S2 Heat
Pump

Thermal Motor DHW during UnOcc. Cooling

Optimum Start Boiler Return DHW Priority
Cooling Valve Motor Enable
Occ/UnOcc Mixing DHW Valve
Zone 1 Cooling End Switches
Zone 1 Heating
T1 Z1
M M
7 6
Zone 1 2 3 4 Boiler DHW Pump
Occ. only Off Boiler Supply Off P1 M 8 5

T2 Z2
1 4 M
2 3
M R1
T3 Z3
Class II
Transformer M
24 V (ac) C
R
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

28
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-6 Piping schematic for hydronic heating with buffer tank and chilled water with ONE fan coil unit for
cooling (no buffer tank)

Additional 30 psi (207 KPa)

pressure relief valve required
Return from when buffer tank relief valve
Hydronics Fan Coil
is bypassed in cooling.
System Unit
Aqua-
P stat P/TPort
(clg) Only one fan coil unit may be used in Make-up
this arrangement. Multiple fan coil Water
Supply to units require the use of a buffer tank. Supply
Hydronic H C
System
Aqua- Pressure Gauge
stat Dip P Backflow
(clg) Tube
Factory Air Preventor
Installed T
N.C.
Vent WaterFurnace
Relief Unit
Buffer Tank

M C
Aqua- Exp
stat
Tank
Terminate (htg) Air Pad
6” (15 cm) T
P/T Port
above Floor

N.O. M C Remove elements to use

fittings for connections to
hydronic system.
Insulation
1) Expansion tank not needed on “floor side,”since tank has
been added to water-to-water side.
2) Minimum buffer tank up to V036W = 52 U.S. Gal. (197 L);
minimum buffer tank up to V060W = 80 U.S. Gal. (303 L).
Buffer Well-
Type 3) Minimum insulation for buffer tank = R-12 (2.11 K=m2/W).
Tank Aqua- 4) Use only copper type “M” straight tubing for piping.
Stat 3/4” (19 mm) piping is permissible up to V036W;
Brass “T”
1” (25 mm) piping is permissible up to V060W.
5) Above piping sizes assume a maximum length of 25 ft.
Connection to (7.6 meters) one way and a maximum of 8 elbows.
Water-to-Water Unit 6) If tank has internal thermal siphoning trap, remove check
valve ball to lessen pressure drop.
7) If tank is self-cleaning, dip tube may need to be replaced
Local codes supersede with straight copper (original causes additional restriction).
any recommendations Dip tube should also be replaced if using antifreeze.
in this manual. 8) Remove anode rod and replace with brass plug.
9) Avoid tanks with 1-3/8” (35 mm) fittings.
10) All above recommendations can be applied when using
a (Grundfos UP2699) or equal.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

29
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-7 Heat pump with outdoor reset indoor feedback and central cooling, tekmar®-application

- Application A 1129
07/98
Heat Pump with Outdoor Reset, Indoor Feedback and Central Cooling.

Mechanical RTUs
054 370
Outdoor
Sensor (S2) 070

Class II
Transformer
120 V (ac)
24 V (ac)

R1

M M M M

S1
P1

Heat Pump
Buffer Tank

Electrical 5A
2.4A 370 5A 5A 5A 5A
Do not apply power here

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Sys Power Var. Com RTU RTU Com RTU RTU Com Uno Zo Com Boil Sup Out DHW DHW Com Com
Pmp N L Pmp Sen 1 2 Sen 3 4 Sen Sw In Sen Sen Sen Sen Boiler Pmp / Vlv DemDem 1-2 1 2 3-4 3 4

Cooling
C H Enable
S1 R1
H H
S2 Heat 7 6
Pump 8 5
1 4
2 3
Thermal Motor DHW during UnOcc.
Optimum Start Boiler Return DHW Priority
Occ/UnOcc Mixing DHW Valve
Zone 1 Cooling
Zone 1 Heating M M
Zone 1 2 3 4 Boiler DHW Pump
Occ. only Off Boiler Supply Off P1
M N
C

Cooling
Class II Diverting
Transformer Valve

24 V (ac) C
R
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

30
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-8 Piping schematic for hydronic heating with 4.5 kW backup electric heat

Return from
Hydronics
System

Supply to
Hydronics
System
H C H C Pressure Gauge
Dip Dip P
Tube Air
Tube
Electric Water Heater

Factory Vent
w/Elements Wired

Installed
Relief
From Unit
Buffer Tank

Exp
Aqua-
stat Remove elements Tank
Terminate
T to use fittings for
6” (15 cm)
connections to
above Floor
hydronic system.
To Unit

Insulation Insulation

Local codes supersede any recommendations

in this manual.

1) Use this piping schematic ONLY when the capacity of the unit is insufficient by less
than 4.5 kW (15,400 Btuh)—not for when hotter water is required.
2) Elements in the electric water heater must be set at the same temperature as the heating
aqua-stat. Otherwise, power consumption could be more than expected.
3) See System #3 on page 22 for additional notes.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

31
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-9 Heat pump with outdoor reset and electric water heater backup, tekmar®-application

- Application A 1128
07/98
Heat Pump with Outdoor Reset and Electric Water Heater Backup.

Mechanical
255
Outdoor
Class II Sensor (S2) 070
Transformer
120 V (ac) 24 V (ac)

R1

M M M

S1
P1

Heat Pump
Water Buffer Tank
Heater
Nº of boilers

Electrical 10A 10A 255

No Power
1 2 3 4 5 6 7 8 9
2
Power Pump / Com Sup Out
—
1 C- R+ Boiler 1 Boiler 2 Sen Sen Sen

S1

Heat Water S2
Pump Heater

R1
Zone Valve Motor
End Switches 7 6
8 5
T1 Z1
1 4
M 2 3
T2 Z2
M
T3 Z3
Class II
Transformer M P1

24 V (ac) C
R
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

32
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-10 Piping schematic for hydronic heating with boiler backup for capacity (not temperature)

Return from
Hydronics System

Supply to
Hydronics System

Mixing valve required on

non-condensing boilers. H C Pressure Gauge
Dip P
Tube Air
OUT Vent

Boiler Factory
Buffer Tank
From Unit
Installed
IN Relief Exp
Aqua-
Remove elements Tank
Terminate stat
6” (15 cm) to use fittings for
T connections to
above Floor
hydronic system.
To Unit

Local codes supersede

any recommendations Insulation
in this manual.
1) Consult boiler manufacturer documentation for installation, design, application and
safety considerations.
2) Use this piping schematic ONLY when the capacity of the unit is insufficient–not for when
hotter water is required. Boiler mixing valve must be set at same temperature as buffer
tank heating aqua-stat.
3) See system 2a, on pages 21-22 for additional notes.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

33
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-11 Heat pump with outdoor reset and backup, tekmar®-application

- Application A 1131
07/98
Heat Pump with Outdoor Reset and Boiler Backup.

Mechanical
255
Outdoor
Class II Sensor (S2) 070
Transformer
120 V (ac) 24 V (ac)

R1

Boiler

M M M

S1
P1

Heat Pump
Buffer Tank
Nº of boilers

Electrical 10A 10A 255

No Power
1 2 3 4 5 6 7 8 9
2
Power Pump / Com Sup Out
—
1 C- R+ Boiler 1 Boiler 2 Sen Sen Sen

S1

Heat Boiler S2
Pump

Zone Valve Motor

End Switches 7 6
8 5
T1 Z1
1 4
M 2 3
T2 Z2
M
T3 Z3
Class II
Transformer M
24 V (ac) C
R
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

34
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Figure 5-12 Piping schematic for hydronic heating with boiler backup when hotter temperatures are required.

Return from
Hydronics System

Supply to M
Hydronics System

Mixing valve required on

H C Pressure Gauge
non-condensing boilers.
Dip P
Tube
OUT Air
Vent
Boiler
Buffer Tank
Factory From Unit
Installed
IN
Relief Exp
Aqua-
Remove elements Tank
Terminate stat
6” (15 cm) to use fittings for
T connections to
above Floor
hydronic system.
IN To Unit

Insulation

Local codes supersede any recommendations

in this manual.
1) Consult boiler manufacturer documentation for installation, design, application and
safety considerations.
2) Use this piping schematic when hotter water is required for second stage, such as in
baseboard radiant heating applications.
3) See system 2b on page 22 for additional notes.

30 PSI Relief Valve

ASME Rated Exp
Bladder-Type Expansion Tank
Tank
Factory Installed Relief Valve

Check Valve Automatic Air Vent

Ball Valve Union Fitting

Gate Valve Pump

Pressure Reducing Valve Pressure/Temperature (P/T) Port

N.C.

3-Way Motorized Valve P Pressure Gauge

N.O. M C

3-Way Mixing Valve T Well-Type Thermometer (Aqua-Stat)

4-Way Mixing Valve N.C. Normally Closed (Valve Outlet)

N.O. Normally Open (Valve Outlet) C Common (Valve Feed)

35
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 5-13 Heat pump with outdoor reset and boiler change over tekmar®-application

- Application A 1132
07/98
Heat Pump with Outdoor Reset and Boiler Change Over.

Mechanical 150
253 Outdoor Outdoor
Sensor (S2) 070 Sensor (S3) 070

Class II
Transformer
120 V (ac) 24 V (ac)

R2

R1

Boiler

M M M
M

S1
P1

Heat Pump
Buffer Tank
PWM

Electrical 5A 253 8A 8A 150

No Power No Power

1 2 3 4 5 6 7 8 On 1 2 3 4 5 6 7
Com Boil Out Power — Power
Sen Sen Sen Boiler T R+ C- Off C- R+ Com N/O N/C Sensor

S1 S3

S2
Boiler Heat
Pump
7 6
Zone Valve Motor 8 5
7 6 1 4
End Switches
8 5 2 3
T1 Z1
1 4
M R2
2 3
T2 Z2 R1
M
T3 Z3 N
Class II C
P1
Transformer M
24 V (ac) C Diverting
R Valve
120 V (ac) L
N

Note: This is only a concept drawing. The designer must determine whether this application will work in his system and must ensure compliance with
code requirements. Necessary auxiliary equipment, isolation relays (for loads greater than the specified tekmar internal relay ratings), and other safety
and limit devices must be added.

36
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Section II:
As with any heating and cooling application, proper design of the delivery system is crucial to system perfor-
Piping System
mance, reliability and life expectancy. This section will address some basic guidelines for piping between the Design
water-to-water unit and the buffer tank. Refer to ASTM 388 for detailed information. Local codes supersede Requirements
any recommendations in this manual.

Table 5-2 gives specifications for 3/4" (19 mm) and 1"(25 mm) copper piping. WaterFurnace recommends
only type "M" straight length copper tubing for connection between the water-to-water unit and the buffer tank.
In addition, all piping must be rated for 760 psi @ 200° F (5.2 Pa @ 93° C). All piping must be insulated. The
smaller 3/4"(19 mm) tubing requires 7/8" ID (25 mm) diameter insulation with a minimum 1/2" (13 mm)
wall thickness. The larger 1" (25 mm) tubing requires 1-1/8" ID (35 mm) diameter insulation with a
minimum 1/2" (13 mm) wall thickness.

The smaller 3/4" (19 mm) tubing may be used on water-to-water units up to the SXW036 with a maximum of
25 ft. (7.6 m) one way and 8 elbows. The larger 1" (25 mm) tubing may be used on water-to-water units up
to the SXW060 with a maximum of 25 ft. (7.6 m) one way and 8 elbows.

Table 5-2 Copper type "M" piping specifications

Pipe Size* Flow Rate** Pres. Drop*** Volume**** Pipe Size* Flow Rate** Pres. Drop*** Volume****

3/4" (19 mm) 2 (126) 1.5 (185) 2.7 (23) 1" (25 mm) 10 (631) 7.0 (700) 4.1 (35.5)

4 (252) 5.0 (600) 12 (757) 9.0 (900)

6 (379) 10.0 (1200) 14 (883) 13.0 (1200)

8 (505) 17.0 (2000) 16 (1010) 16.0 (1500)

10 (631) 25.0 (2750)

* Nominal inside diameter water pipe -- e.g. 3/4" (19 mm) type "M" has an inside diameter of
0.811" (20 mm) & an outside diameter of 0.875" (22 mm)
** In U.S. gallons per minute (mL/sec.)
*** In ft. per 100' (Pa/meter)
**** U.S. gallons per 100' (mL/meter)

Once the piping system has been designed, proper installation techniques must be used to ensure a problem-
free installation. When piping is hung, 3/4"(19 mm) tubing must be supported every 5' (1.5 m); 1" (25 mm) Section III:
tubing must be supported every 6' (1.8 m). Always support the pipe where a transition from horizontal to Piping System
vertical is made. Plastic coated or copper hangers should be used, allowing enough space for the pipe Installation
insulation. Stand-off type supports are good for rigid support, wall runs or short runs less than 10'. (3 m).
Clevis hangers (held by threaded rod) are good for piping at different heights. Finally, rail type hangers are
good for different types of pipe (e.g. water, conduit, etc.). Polyethylene clips are best for small pipes. Always
run piping at 90° or 45° angles. Local codes supersede any recommendations in this manual.

Two types of soldering material may be used for hydronic installations, 50/50 (50% tin, 50% lead) and 95/5
(95% tin, 5% antimony). However, 50/50 may not be used for domestic water piping. Table 5-3 below shows
the properties of both types.

Table 5-3 Pressure ratings for solder types

Max. Water Press. Max. Water Press.
Surface Temp. 50/50 Solder 95/5 Solder
100°F (38°C) 200 psi (1.38 MPa) 500 psi (3.45 MPa)
150°F (66°C) 150 psi (1.03 MPa) 400 psi (3.70 MPa)
200°F (93°C) 100 psi (689 MPa) 300 psi (2.07 MPa)
250°F (121°C) 85 psi (85 MPa) 200 psi (1.38 MPa)

37
Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

50/50 - 1/8" (3 mm) diameter solder has melting point of approximately 361-421° F (183-216° C), and is
typically applied using a propane torch. Proper flux is required. An actylene torch may be used, but care must
be taken not to overheat the piping, which can cause the material to become brittle.

95/5 - 1/8" (3 mm) diameter solder has melting point of approximately 452-464° F (233-240° C), and is
typically applied using a MAPP2 gas torch (propane will work). Proper flux is required. An actylene torch may
be used, but care must be taken not to overheat the piping, which can cause the material to become brittle.

When preparing copper joints for soldering, tubing should be cut square, and all burrs must be removed. Do
not use dented or pitted copper. Clean the inside of the fitting with a brush; clean the outside of the tubing with
emery cloth approximately 1/2"(13 mm) from the end of the tubing. Debris in the system can cause pump
failure or corrosion. Do not put the fitting in a bind before soldering. Flux should be applied as a thin film to
both pipe ends and inside fittings. Excess flux will end up in the circulating fluid. Rotate fitting before
soldering to spread flux over entire fitting.

Once the fitting has been prepared, take care not to use too much solder. Look for a silver ring to appear on
fitting. When solder drips, the joint has excess solder. Excess solder can get into the system circulating fluid.
Note that approximately 0.9" (2 cm) of 1/8" (3 mm) diameter solder is all that is needed for 3/4"
(19 mm) copper, 1.3" (3 cm) is needed for 1" (25 mm) copper, and 1.7" (4 cm) is needed for 1-1/4"
(32 mm) copper.

Let the joint cool naturally. Cooling with water can cause high stress at the joint area, and potentially premature
failure (this is especially important when heavy objects are soldered in place, such as pumps). Once the joint is
cool, wipe excess flux and wipe joint with an oily rag to lessen potential surface oxidation.

Keep piping open to the atmosphere. Pressure can cause blow-out of material when heated, causing pin hole
leaks. When a thread by sweat (soldered) transition fitting is used, always make the soldered connection first
and then make the threaded fitting (with proper sealants). Adequate ventilation must be present when
soldering. Flux fumes can be dangerous.

When soldering valves and unions, take care not to overheat the non-metalic components. Remove synthetic
gasket material from dielectric unions before soldering. Likewise, use small strips of damp, clean rags to keep
the valve body cool when soldering.

Section IV:
Safety WaterFurnace is always concerned about the safety of installation technicians. Exercise caution when soldering
around combustible materials, wood, plastic or paper. Cleaning fluids, pressurized containers and other
hazardous materials should be removed before beginning any solder joints.

Always wear eye protection, long sleeve shirts and gloves when installing WaterFurnace equipment and related
systems/components. Use shields on safety glasses. Always have the proper fire extinguisher and/or water near
the work area.

Local codes supersede any recommendations in this manual.

Section V:
System Section V gives general guidelines for component selection and design/installation criteria for the piping system.
Components Below is a list of components with some information on each item. Local codes supersede any recommen-
dations in this manual.

Shut off/flow regulation valves: Use full port ball valves or gate valves for component isolation. If valves are
going to be used frequently, ball valves are recommended. Globe valves are designed for flow regulation.
Always install globe valves in the correct direction (fluid should enter through the lower body chamber).

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 5

Check valves: Swing check valves must be installed in the horizontal position with the bonnet of the valve
upright. Spring check valves can be mounted in any position. A flow check valve is required to prevent
thermosiphoning (or gravity flow) when the circulator pump is off or when there are two circulators on the
same system.

Mixing valves: Three and four port thermostatic mixing valves are common in hydronics applications,
especially when boilers are used. Most oil and gas-fired boilers cannot accept cool return water without flue
gas condensation problems. Three way mixing valves are limited to systems where the coolest return water
from the distribution system is always above the dewpoint temperature of the exhaust gases.

Buffer tanks: A buffer tank is required for all hydronic heating systems using water-to-water heat pumps and
some chilled water systems. Figure 5-1 on page 24, shows capacity requirements. Also refer to Chapter 3,
pages 11-18, for buffer tank sizing. See note below regarding pressure relief valves.

Pressure relief valves: Most codes require the use of a pressure relief valve if a closed loop heat source can
be isolated by valves. Even if local code does not require this device, WaterFurnace recommends its installation.
If the pressure relief valve in the buffer tank is not already rated at 30 psi (207 kPa) maximum pressure, one
must be installed. The pressure relief valve should be tested at start up for operation. This valve can also be
used during initial filling of the system to purge air. Note that the waste pipe must be at least the same diameter
as the valve outlet (never reduce), and valves may not be added to this pipe. The bottom of the pipe must
terminate at least 6" (15 cm) above the floor. If the piping is connected to a drain, there must be an air gap.

Backflow prevention check valves: Most codes require backflow prevention check valves. Note that a
single check valve is not equal to a backflow prevention check valve. Even if local code does not require
this device, WaterFurnace recommends its installation. This is particularly important if the system will
use antifreeze.

Pressure reducing valves or feed water valves: This valve lowers the pressure from the make-up water
line to the system. Most are adjustable and directional. A "fast fill" valve is required for initial filling of the
system. Some have screens, which must be cleaned after the initial filling. If there is a restriction in the screen,
the system could go to 0 psi (0 kPa), potentially causing pump(s) failure. A valve on each side of the pressure
reducing valve should be installed for servicing. Both valves should have tags reading, "Do not shut this valve
under normal operation – service valve only".

Expansion tanks: Expansion tanks are required on hydronics systems to help absorb the pressure swings as
the temperature in the system fluctuates. If the piping system will be used for chilled water, the tank must be
insulated. A non-metallic (plastic, fiberglass) tank is recommended for chilled water systems to lengthen the
life expectancy of the expansion tank.

Elbows/T's: Long radius elbows or two 45's will lower pressure drop. Standard T's have a greater restriction
on the "T" portion than T's designed with angled outlet ports.

Antifreeze: Antifreeze is required if any of the piping system is located in areas subject to freezing. In
addition, antifreeze should be used for snow melt systems and fan coil unit installations where design water
temperatures drop below 38° F (3° C). Consult the antifreeze manufacturer's specifications catalog for
concentration amounts and recommendations.

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Chapter 5 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Section VI:
Source and Consult the WaterFurnace piping design manual (Part # WFS72) and the pressure drop calculation manual
Load Pump (Part # WF310) for source side (loop) pump sizing. This section provides a guideline for load pump sizing
Sizing with maximum piping lengths and typical valving configurations. Consult the 1997 ASHRAE Fundamentals
Handbook, Chapter 33, for pressure drop calculations not meeting the guidelines in this section.

For units up through the 060W, one 1/6 hp (124 W) circulator pump (Grundfos UP2699 or equivalent) will be
sufficient for the load side piping, providing the following guidelines are not exceeded:

• Maximum one-way distance from the water-to-water unit to the buffer tank of 25 ft. (7.6 meters).

• Minimum copper tubing size for units up through the 036W of 3/4"(19 mm) I.D.; minimum size for
units up through the 060W of 1" (25 mm) I.D.

• Maximum of 8 elbows.

• Maximum components limited to those shown in Figures 5-1 through 5-6 in this chapter.

• Only one water-to-water unit is piped to each buffer tank.

• Maximum one-way distance from fan coil unit to water-to-water unit (system without buffer tank) is 5 ft.
(1.5 meters). A second circulator pump will be necessary in most cases.

• Fan coil unit pressure drop is less than 3 ft. of head (9.0 kPa).

40
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Control Strategies CHAPTER 6

The first step in deciding which control strategy is appropriate for the application is to decide how many heating
and cooling zones are desired. Once the total number of zones has been determined, it is important to decide if
there will be an equal number of heating and cooling zones.

Systems with an equal number of heating and cooling zones may be able to share the same thermostats for
both modes. Generally, when the number of zones is unequal, a separate heating thermostat and cooling
thermostat must be used. In many cases, there may be multiple heating zones, but only one cooling zone
(refer to Chapter 5, Figure 5-3, page 26). In this case, separate thermostats must be used. An alternative to
the separate thermostats would include a microprocessor-based controller, such as the tekmar® 371, which
can handle up to five zones of heating and one zone of cooling.

The next decision regarding controls involves buffer tank temperatures. A fixed temperature, controlled by an
aqua-stat is the most simple and least expensive type of control strategy to install. However, outdoor reset
(changing the temperature of the water in the buffer tank based upon outside temperature) is the most cost-
effective strategy when controlled by a microprocessor-based controller. This decision can include a whole-
house controller like the tekmar® 371 or a separate outdoor reset controller simply used for tank temperature
control (i.e. not affecting the zone thermostat controls).

The next several pages show the various controls drawings outlined by Table 6-1 below. No one strategy is best
for all hydronics applications. Individual customer preferences and budgets will help determine which system
is best for that application.

Table 6-1 System Types

System Characteristics W-W Unit Figure(s)

1 Hydronic htg. only--no backup 6.1, 6.2, 6.3
2 Hydronic htg. only w/boiler backup (1 & 2) or (2 & 6)
3 Hydronic htg. only w/elect. wtr. htr. backup (1 & 2) or (2 & 6)
4 Hydronic htg.--no backup w/sep. forced air clg. (1 & 2) or (2 & 6)
5 Hydronic htg.--no backup w/mult. fan coil units 2 & 3
6 Hydronic htg.--no backup w/one fan coil unit 2 & 3
7 Hydronic htg. w/boiler backup & sep. forced air clg. (1 & 2) or (2 & 6)
8 Hydronic htg. w/boiler backup & mult. fan coil units 2 & 3
9 Hydronic htg. w/boiler backup & one fan coil unit 2 & 3
10 Hydronic htg. w/elect. wtr. htr. backup & sep. f.a. clg. (1 & 2) or (2 & 6)
11 Hydronic htg. w/elect. wtr. htr. backup & mult. fan coil units 2 & 3
12 Hydronic htg. w/elect. wtr. htr. backup & one fan coil unit 2 & 3

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Chapter 6 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 6-1 Water-to-water unit low voltage connections (hydronic heating only or
heating w/separate forced air cooling system).

Factory-installed
jumper

WaterFurnace unit
Outdoor
reset* 2 4 6 7 11
R C COMP

Warm weather
shut down

Heating aqua-stat
(“make” on temp. fall)

*Outdoor reset is not necessary for systems with

backup for capacity reasons (Chapter 5, Figures 5-8
and 5-10). However, for systems requiring hotter
water during second stage (Chapter 5, Figure 5-12),
an outdoor reset must be installed to prevent water
hotter than 120° F (49° C) from returning to the
water-to-water unit.

Figure 6-2 Water-to-water unit high voltage load and source pump
connections.
Compressor

L1 L2
Contactor

T1 T2

All wiring must

conform to local Fuses
codes.

Connect to 230V
load pump
and source pump(s)

42
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 6

Figure 6-3 Water-to-water unit low voltage connections (hydronic heating and chilled water cooling system).

factory-
WaterFurnace unit
installed
2 4 6 7 11 jumper

RV COMP R

DPDT Relay
Heating aqua-
stat (“make”
on temp. fall)

N.C.
Cooling aqua-
SPST Relay N.C. stat (“make”
on temp. rise)

Mode Switch Signal to energize bypass

(open for htg; valve, allowing chilled
All wiring must closed for clg) water to flow through coil.
conform to local
codes.
C R G S Fan coil unit
(separate transformer)

R G Y Thermostat

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Chapter 6 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Figure 6-4 Thermostat connections to water-to-air unit and hydronic heating system

To zone valve
(controller
2 stg htg; 2 stg clg t-stat supplied
by others)

L G R C W2 Y2 Y1 W1

Optional forced air auxiliary backup

SPST Relay
To “R”
(controller
supplied
by others)

L G R C O W Y Y

Premier Unit
All wiring must To zone valve
conform to local (controller
codes. 1 stg htg; 1 stg clg t -stat
supplied
by others)
L G R C Y W

SPST Relay
To “R” (or
controller
supplied
L G R C O Y by others)
Premier or Versatec Unit

1) Use this drawing only when one thermostat will control both heating and cooling, AND
when the number of heating zones equals the number of cooling zones (i.e. for each
hydronic heating zone, there is one water-to-air unit).
2) Thermostat must have DIP switch for “Fan with Plenum” position to keep fan from being
energized during heating. Continuous fan can still be selected.
3) Premier DIP switch #SW2-8 must be in the 24VAC position.
4) Heat pump thermostats cannot be used with this application.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 6

Figure 6-5 Thermostat connections to fan coil units and hydronic heating system
(equal number of heating and cooling zones).

To zone valve
1 stg htg; 1 stg clg t-stat (or controller
supplied
by others)
G R C Y W

SPST Relay
Thermostat must have DIP switch
for “Fan with Plenum” position to
keep fan from being energized
during heating. Continuous fan
can still be selected.

To “R” (or
G R C S controller
Fan coil unit supplied
by others)
Signal to energize
bypass valve, allowing
chilled water to flow
through coil.

All wiring must conform to local codes.

Figure 6-6 Thermostat connections to fan coil units and hydronic heating system
(unequal number of heating and cooling zones).

Cooling Thermostat:
1 stg htg; 1 stg clg t-stat
G R C Y W

Heating Thermostat:

1 stg htg t-stat

Signal to energize
R W bypass valve, allowing
chilled water to flow
To “R” T (or To zone valve through coil.
controller (or controller G R C S
supplied supplied by others) Fan coil unit
by others)
All wiring must conform to local codes.

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 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Hydronic Heating/Cooling Distribution Design CHAPTER 7

Chapter 1 included an overview of hydronic distribution systems. This chapter looks at the design parameters
associated with each of the delivery systems, particularly when retrofitting an existing hydronic heating
system. Radiant Floor heating and fan coil units, baseboard radiation, cast iron radiators, will be addressed
in this chapter.

Section I:
The heating capacity of a baseboard system is a factor of the area of copper tube and fins exposed to the air, Baseboard
and the temperature difference between the air and the fin tube. The velocity and volume of water flowing Radiation
through the baseboard affects the temperature of the copper and fins. Baseboard units are normally rated in
heat output/length of baseboard at a standard water temperature and flow rate. Manufacturers can provide
charts which will give the capacities at temperatures and flow rates below the standard. Table 7-1 shows
approximate heating capacities for fin tube radiation using water from 110-200° F (43-93° C).

Table 7-1 Heating capacities for fin tube radiation.

Average Ent. Air Temp.
Water Temp. 55°F (13°C)* 65°F (18°C)* 70°F (21°C)*
110°F (43°C) 190-380 (184-364) 160-320 (154-308) 150-300 (144-289)
120°F (49°C) 240-480 (230-463) 205-410 (197-394) 195-390 (187-374)
130°F (54°C) 295-590 (282-568) 265-532 (255-512) 245-490 (236-472)
140°F (60°C) 350-700 (338-673) 315-630 (302-607) 295-590 (282-568)
200°F (93°C) 700-1400 (673-1345)
*Table values are in Btuh/ft. (W/m)

Table 7-1: The heating capacity in Btuh/foot (Watts/meter) of baseboard radiators drops as the water tempera-
ture is reduced. The heating capacity of most baseboard radiators is rated using 200° F (93° C) water and
65° F (18° C) air temperature. Listed is the range of heating capacities of baseboard radiators at the standard
temperatures and the capacities when the temperatures are reduced to the operating range of a heat pump
system. Some of the factors that affect the capacity of a radiator are:
• Size of the fins - range from 2.75" x 3" (7 x 8 cm) to 4" x 4"(10 x 10 cm)
• Fin spacing - 24 to 48 per foot (79 to 157 per meter)
• Size of copper tube - range from 3/4"(19 mm) to 2" (50 mm)
• Fin material - aluminum or steel
• Configuration and height of the enclosure
• Height unit is mounted from the floor
• Water flow through the radiator
Generally, smaller fins with less fins per foot (meter) will have lower heating capacity. Larger copper tube
diameter and aluminum fins will have a higher capacity. Higher water flow will increase capacity. Adding a
second fin tube to the same enclosure will increase the capacity by 50 - 60%. Adding two fin tubes will increase
the capacity by 75 - 80%.

Baseboards are available using two or three fin tubes tiered above one another in the same cabinet. The air can
be heated enough with the additional surface area to set up a convection current with water temperatures as low
as 110-130° F (43-54° C). Table 7-1 above shows the correction factors.

The operation of a baseboard radiation system depends on the ability to set up a convection current in the room
(i.e. air is warmed by the fin tube, rises and is displaced by cool air). It is important to ensure the heat output
of the system is adequate to meet the heat loss of the room or building at the temperatures the geothermal
system is capable of producing. Baseboard radiation is limited to space heating. Cooling is typically provided
by a separate, forced air distribution system.

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Chapter 7 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Section II:
Cast Iron
Cast Iron Radiation: Retrofit applications for hydronic/geothermal heat pump systems are often required to
Radiation work with existing cast iron radiators. Typically, cast iron radiator systems operate with water temperatures of
125-160° F (52-71° C).

Operating temperatures for cast iron radiation are typically higher than geothermal water-to-water heat pumps
are capable of providing. However, if enough surface area is present, cast iron radiators can work well with
geothermal systems, provided the heat output of the radiators will meet the maximum heat loss of the building
at the lower temperatures.

Steel
Figure 7-1 Many different configurations of radiators
Radiator are available for replacement of old cast iron radiators to
fit many different applications. Radiators are available
for special applications such as towel drying racks. As
with baseboard radiators, the heating capacity varies with
water temperatures and flow rates, air temperatures, and
Hot surface area.
Water

Radiators in various
configurations & sizes

Note: If the insulation of the building has been upgraded since the original installation, it is possible that the
lower temperatures provided by water-to-water heat pumps will be able to meet the reduced heat loss of the
building.

Section III:
Radiant Floor Radiant floor heating works well with geothermal heat pump systems. For efficient operation, the system must
be designed with the lowest possible water temperatures. A floor heating system is virtually silent and invisible.
Heating
In residential applications occupants in a space feel comfortable with lower air temperatures if their feet are
warm. Typically the space will feel comfortable with air temperatures as low as 65° F (18° C). Since the heat
loss of a building is directly related to the temperature difference between inside and outside, a lower tempera-
ture difference also means the heat loss is lower.

Some of the factors affecting the heating capacity of a floor heating system are:
• Spacing of the pipe
• Water flow through the pipe
• Temperature of the supply water
• Sub-floor material (wood, concrete or light-weight poured concrete)
• Floor covering (ceramic tile, carpet, wood, etc.)
• Insulation value under the floor
• Piping layout

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL Chapter 7

Section IV:
Fan coil units and air handlers are used in many different applications. They have been used to heat buildings Fan Coil Units
using water temperatures as low as 90-100° F (32-38° C). New systems can be designed to operate very
efficiently with a geothermal system.

In a retrofit situation when replacing a conventional boiler, care must be taken to ensure that any air
handlers or fan coil units in the building will heat the building with water temperatures below 130° F
(54° C), and will be able to handle the increased flow rates if necessary. If the insulation levels of the
building are being upgraded, the existing coils may meet the lower heat loss of an upgraded building with
lower water temperatures.

Consult the fan coil manufacturer's specifications catalog and application manuals for design of fan coil units
for heated or chilled water. Chapter 9, page 53, lists suppliers.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Snow Melting Applications CHAPTER 8

As shown in Figure 8-1 below, piping design and component selection for a snow melt system are identical to
the system used for hydronic heating. The difference is simply the load on the system. In other words, the size
of the water-to-water unit and the related components is calculated based upon the amount of heat needed for a
sidewalk (for snow melting) instead of the amount of heat needed to condition a structure.

Figure 8-1 Piping schematic for snow melting system with buffer tank

Return from
Hydronics
System

Make-up
Water
Supply to Supply
Hydronics
System
H C Pressure Gauge
Dip P
Tube Backflow
Factory Preventor
Air WaterFurnace
Installed
Vent
Relief unit
Buffer Tank

Aqua-
Exp
Terminate
6” (15 cm) stat Tank
Remove elements
Air Pad
above Floor
T to use fittings for
connections to P/T Port
hydronic system.

1) Minimum buffer tank up to V036W = 52 U.S. Gal. (197 L);

minimum buffer tank up to V060W = 80 U.S. Gal. (303 L).
Insulation 2) Minimum insulation for buffer tank = R-12 (2.11 K=m2/W).
3) Use only copper type “M” straight tubing for piping
Local codes supersede 3/4” (19 mm) piping is permissible up to V036W;
any recommendations 1” (25 mm) piping is permissible up to V060W.
in this manual. 4) Above piping sizes assume a maximum length of 25 ft.
(7.6 meters) one way and a maximum of 8 elbows.
5) If tank has internal thermal siphoning trap, remove check
valve ball to lessen pressure drop.
6) If tank is self-cleaning, dip tube may need to be replaced
with straight copper (original causes additional restriction).
Dip should also be replaced if using antifreeze.
7) Remove anode rod and replace with brass plug.
8) Avoid tanks with 1-3/8” (35 mm) fittings.
.

Section I:
As with any hydronic heating systems, the load calculation is the first and most important step in designing a Snow Melt
reliable and cost-effective snow melt system. Consult the 1995 ASHRAE HVAC Applications Handbook, Chapter System Design
46, for slab piping design and temperature requirements. This will determine the Btu/hr (kW) requirement of
the water-to-water equipment. Follow procedures in Chapter 3 for sizing the equipment and buffer tank. One
change should be noted, however, when using Chapter 3 for equipment sizing. A heating correction factor
SHOULD NOT BE USED for snow melt applications.

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Chapter 8 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Section II:
Snow Melt The simplest system for controlling a snow melt system is an aqua-stat located in the buffer tank, and an
Control ON-OFF toggle switch to engage the slab piping circulator pump. The hot water in the piping system will heat
Systems the slab, melting the snow. However, this is a manual system, which may not allow the user to heat the slab
quick enough to begin melting the snow. More sophisticated control systems exist that actually sense when
conditions are right for snowfall.

Snow/ice melt detection is used to automatically start and stop a snow melt system. When there is snow on the
sensor, the sensor melts the snow/ice, detects the moisture and allows the control to start the melting process.
This prevents accumulation of snow on the slab and provides a faster response. Automatic snow/ice detection is
safer, more convenient and consumes less energy than manual systems.

In systems where snow and ice removal is critical, such as hospital ramps, the log time for a snow melting slab
can be reduced by maintaining the slab at an idling temperature. The idling temperature may be just below the
freezing point. When snow melting is required, the slab temperature is increased.

When the slab and outdoor temperatures are warm enough, the snow melting system should automatically turn
off. The warm weather cut off feature of controls like the tekmar® 661 automatically shut off the system when
snow melting is not required in order to save energy.

Another important aspect of choosing a good controller is slab protection. Snow melt systems deal with
extreme temperature differences. Slab protection is provided by limiting the rate of heat transfer into the slab.
This is done by slowly ramping up the temperature difference across the slab and limiting the maximum
temperature difference. This function prevents cracking of the slab due to thermal expansion caused by high
heat output.

Several microprocessor-based snow melt control systems, manufactured by tekmar® Controls Systems, allow a
variety of design options. To contact tekmar® write to 4611 23rd Street, Vernon, British Columbia (Canada)
V1T 4K7 or call (250) 545-7749.

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RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Equipment Suppliers CHAPTER 9

Baseboard Radiation & Convectors Radiant Floor Piping

Dunham-Bush Maxxon Corporation

101 Burgess Road Infloor Heating Systems
Harrisonburg, VA 22801 920 Hamel Road
Phone: (703) 434-0711 Hamel, MN 55340
Fax: (703) 434-4010 Phone: (612) 478-9600
Fax: (612) 478-2431
Runtal North America, Inc.
187 Neck Road Wirsbo Company
Ward Hill, MA 01835 5925 148th Street
Phone: (800) 526-2621 Apple Valley, MN 55124
Phone: (612) 891-2000
Fan Coils & Air Handlers Fax: (612) 891-2008

Dunham-Bush Controls
101 Burgess Road
Harrisonburg, VA 22801 Tekmar Control Systems Ltd.
Phone: (703) 434-0711 4611 23rd Street
Fax: (703) 434-4010 Vernon, BC V1T 4K7 (Canada)
Phone: (250) 545-774
Systems Components (expansion Fax: (250) 545-0650
tanks, pressure reducing valves, air
vents, 3-way valves, etc.) Aqua-stats

ITT Bell & Gossett Honeywell

8200 N. Austin Avenue (Available at local wholesalers)
Morton Grove, IL 60053
Phone: (708) 966-3700
Fax: (708) 966-9052

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 RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Notes:

54
RESIDENTIAL AND LIGHT COMMERCIAL HYDRONICS APPLICATION MANUAL

Notes:

55
9000 Conservation Way
Fort Wayne, IN 46809-9794

Phone: 1-260-478-5667 or
1-800-222-5667
FAX: 1-800-783-5667
http://www.waterfurnace.com

In Canada Call: 1-800-463-8108

Residential and Light Commercial

Hydronics Application Manual

P/N WFS272 05/03

WaterFurnace has a policy of continuous product research

and development and reserves the right to change design
and specifications without notice. WaterFurnace is a
registered trademark of WaterFurnace International, Inc.
©2003WaterFurnace International, Inc.