Applications and Piping Strategies for Condensing Boilers ... · Applications and Piping Strategies for Condensing Boilers Webinar Objectives: 1. Overview of control objectives for

Applications and Piping Strategies for

Condensing Boilers - Introduction

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Applications and Piping Strategies for Condensing Boilers

Webinar Objectives:

1. Control objectives for hydronic systems

2. Review of hydronic fundamental

principals

3. System control and piping strategy for

condensing boilers

4. Introduction to NEW Vitodens 100

Application Guide

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Webinar Objectives:

1. Control objectives for hydronic systems

Review of hydronic fundamental principals

System control and piping strategy for

condensing boilers

Introduction to NEW Vitodens 100

Application Guide

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Control Objectives for Hydronic Systems

2. Minimize Energy Consumption:

Maximize boiler condensing efficiency

Minimize boiler on/off cycling

Minimize electrical consumption

1. Maximize Occupant Comfort:

Maintain a constant room air temperature

Vary temperatures as occupants desire.

3. Protect Equipment:

Prevent boiler short cycling

Prevent excessive temperature from damaging flooring, tubing, etc.

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The Control Challenge

SolarGain

Internal gain:People, equipment lights

Infiltration and wind losses

1. Maintain a constant room temperature, with constantly changing conditions.

Objective:Constant temperature

Heat loss through building envelope

He

at in

put

He

at lo

ss

Heat loss

Outdoor airtemperaturechanges

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The Control Challenge

2. Control a multiple function, multiple temperature system.

HeatExchanger

Pool or spaheating

HeatExchanger

Snowmelting High-temp RFHwood sub-floor

Fan coil

DHW

Low-temp RFHconcrete slab

70oF-110oF

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Webinar Objectives:

1. Overview of control objectives for

hydronic systems

2. Review of hydronic fundamental

principals

System control strategy and component

selection

Piping strategies for condensing boilers


Application Guide

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Understanding Hydronic Fundamentals

The Universal Hydronics Formula

Why is this formula important to understand?

Sizing pipes

Sizing pumps

Sizing Low loss headers, zone valve, air scoops, etc

Trouble shooting systems

Controlling heat transfer rates

GPM = BTU/hr ÷ (T x 500)

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WHERE:

GPM = Fluid flow rate in gallons per minute

BTU/hr = Heat Loss at design temperature of area being heated

T = Temperature drop across the piping circuit (Typically 10 - 20oF)

500 = 8.33 lb/gal x 60 min/hr x 1 (Specific heat or water - Btu/lb./oF)


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Typical hydronic

system: 20oF

temperature drop

180oF

160oF

GPM = BTU/hr ÷ (20 x 500)

GPM = BTU/hr ÷ 10,000

90,000

BTU/hr

9 GPM

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Controlling the Rate of Heat Output:

Control the flow

Control the water temperature

Rate

of

heat

output

Room thermostat

M


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Rate

of

heat

output

Flow Controls:

On-off (zone valves/pumps)

Balancing

Water temperature controls

Boiler outdoor reset

Mixing valves

Thermostatic

Motorized

Room thermostat

M


Outside air sensor

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Outdoor Reset Control

Why use it?

2. Efficiency Eliminate overheating

Increases condensing in boiler

Longer boiler run times

Lower standby losses

1. Comfort Consistent, even space temperatures

Constant heat output to match the load

Keep up vs Catch up

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How does it work?

Heat loss changes continuously

with outdoor temperature

Water temperature is varied based

on outside air temperature

Heat output of boiler (or mixing

device) now matches heat loss of

building

15

59

20

68

Outdoor temperatureBoiler

/ supply

wate

r te

mpera

ture

68 20

95 35Tem

p R

ange

20-6

0oC

/ 7

0-1

40

oF

Heating curves

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Controls

03/05Foil 15

Low temp heating system, eg Radiant floor heating

Heating curve selection

Medium temp heating system, eg Cast iron radiation, Staple-up RFH

High temp heating system, eg Fin tube radiation, fan coils

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Webinar Objectives:


hydronic systems

2. Review of hydronic fundaments

principals


condensing boilers

Piping strategies for condensing boilers


Application Guide

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Control Strategy And Component Selection

Where do you start?

1. What are the system water temperature requirements?

Low, medium or high temp emitters

Multiple function, multiple temp systems

DHW heating requirements

2. What are the boilers requirements

High mass / Low mass construction

Minimum / Maximum flow rates

Maximizing condensing efficiency

3. What are the zoning requirements?

Areas experiencing solar gain or internal heat gains

Areas with different use patterns

Night or weekend temperature setback

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1. Typical hydronic emitters water temperature requirements

Low temperature emitters:

High mass radiant floor

ie: concrete floors 80 - 120 oF

Snowmelting systems 80 - 120 oF

Medium temperature emitters:

Cast iron radiators 100 - 140 oF

Low mass radiant floor

ie: wood joist floors 100 -150 oF

High temperature emitters:

Finned tube baseboard 140 - 190 oF

Air heat fancoils 140 - 180 oF

Pool/spa heat exchangers 160 - 180 oF

DHW production 150 - 190 oF

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2. Boiler requirements – Temperature

How do you maximize the efficiency of condensing boiler?

140oF

120oF

80

82

84

86

88

90

92

94

96

16014012010080

130oF Dew Point of Natural Gas

Condensingmode

Non-Condensingmode

Bo

iler

effic

ien

cy %

Boiler return water temp oF

98

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2. Boiler requirements – Construction

Vitodens 100 / 200 series:

Low mass HX construction

Low water content

Minimum and Maximum flow rate requirements

Higher friction loss through heat exchanger

Maximum boiler temperature limitations (= 167oF or 176oF)

Vitocrossal 300, CU3A series:

High mass HX construction

High water content

No Minimum flow rate requirements

Lower friction loss through heat exchanger

Maximum boiler temperature limitations (= 194oF)

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2. Boiler requirements – Piping

Vitodens 100 / 200 series:

To avoid short cycling, flow must be maintained

Dedicated boiler pump usually required

Primary-secondary piping usually required

Closely spaced tees or

Low loss header

Vitocrossal 300, CU3A series:

Not flow sensitive

Dedicated boiler pump not required

Primary secondary not required

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2. Boiler requirements – Piping

Primary-Secondary

piping

Piping directly to

system

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2. Boiler requirements – Hydraulic separation with Primary-Secondary Piping

Option 1:

Closely spaced TeesOption 2:

Low Loss Header

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2. Boiler requirements – Hydraulic separation with Primary-Secondary Piping

This pump only has to

over come the friction

loss of the boiler and

primary loop piping

This pump only has to

over come the friction loss

of the heat emitters and

secondary loop piping

Primary

Loop

Secondary

Loop

Happy boiler:

Always gets the flow it needs

Less likely to short cycle

Not affected by on/off zones

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2. Boiler requirements – Low Loss Header operation

PrimarySecondary

Primary flow higher

than secondary flow

PrimarySecondary

Mixing occurs within the hydraulic separator.

Secondary flow higher

than primary flow

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3. Zoning requirements

Multiple zone pumps

Higher electrical consumption

Flow balance with speed control

Thermostatically controlled zone pumps

Multizonecontrol

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Single pump, multiple zone valves

Lower electrical consumption

Individual loop control for RFH

With single speed pump use pressure

bypass valve to balance flow

Pressure bypass valve

Thermostatically controlled zone valves

M M M

Multizonecontrol

Single speed pump

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Single pump, multiple zone valves

Lower electrical consumption

Individual loop control for RFH

Variable speed pump to balance flow

Variable speed pump

Thermostatically controlled zone valves

M M M

Multizonecontrol

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Time to start designing!

1. System water temperature requirements

Separate heating circuits by temperature

Use mixing valves to satisfy lower

temperatures

2. Boilers requirements

Size boiler to match heating load

Pick piping strategy to meet boiler

construction

3. What are the zoning requirements?

Add zone controls to meet zoning demands

of building

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Webinar Objectives:


hydronic systems

2. Review of hydronic fundaments

principals


condensing boilers

4. Introduction to NEW Vitodens 100

Application Guide

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Application Guide

First module for Vitodens 100 introduced in

November 2015

Installer / Designer assistance for:

Component selection

Hydronic piping layouts

Wiring diagrams

Control Programing / coding

Design tips

Future modules – Vitodens 200, Vitodens 222-F

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Application Guide – Boiler Nomenclature

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Application Guide – Recommended Product Application

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Application Guide – Component Index

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Application Guide – Piping Layouts

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Application Guide – Wiring Layouts

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Application Guide – Set-up and Programming

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Application Guide – Application # 1

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Application Guide Phase 2 – Vitodens 200 piping

Motorized

mixing

valve

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Motorized

mixing

valves

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For More Information…

1. Contact your local Viessmann Sales Representative

2. Download literature and technical manuals by going to

the ProLogin section of the Viessmann website:

http://www.viessmann.ca/en/Residential/Downloads/Ma

nuals.html

3. Get more training at one of our in-depth 1 or 2-day

Academy seminars. Go to the Academy section of the

Viessmann website for the full schedule of all our in-

house training.

http://www.viessmann.ca/en/Residential/Downloads/Manuals.html

Applications and Piping Strategies for

Condensing Boilers - Introduction

Documents

Applications and Piping Strategies for Condensing Boilers ... · Applications and Piping Strategies for Condensing Boilers Webinar Objectives: 1. Overview of control objectives for