App Piping Strategies Webinar

Applications and Piping Strategies for
Condensing Boilers - Introduction

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
Foil 2, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies
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

Control Objectives for Hydronic Systems
1. Maximize Occupant Comfort:

 Maintain a constant room air temperature
 Vary temperatures as occupants desire.
2. Minimize Energy Consumption:

 Maximize boiler condensing efficiency
 Minimize boiler on/off cycling
 Minimize electrical consumption

3. Protect Equipment:

 Prevent boiler short cycling
 Prevent excessive temperature from
damaging flooring, tubing, etc.
The Control Challenge
1. Maintain a constant room temperature, with constantly changing conditions.
Outdoor air
temperature
Heat loss changes
through
building
envelope
Heat loss
Solar
Gain
Objective:
Constant temperature
Heat loss
Heat input

Infiltration and
wind losses
Internal gain:
People, equipment lights
The Control Challenge
2. Control a multiple function, multiple temperature system.
Snowmelting High-temp RFH

Pool or spa wood sub-floor
Fan coil heating
Heat
Heat Exchanger
Exchanger
DHW

Low-temp RFH
concrete slab
70oF-110oF
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

Understanding Hydronic Fundamentals
The Universal Hydronics Formula
GPM = BTU/hr ÷ (T x 500)

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


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)


9 GPM
180oF GPM = BTU/hr ÷ (20 x 500)
Typical hydronic GPM = BTU/hr ÷ 10,000

system: 20oF

temperature drop

90,000
BTU/hr
160oF

Controlling the Rate of Heat Output:
 Control the flow
 Control the water temperature Room
thermostat

Rate
of M

heat
output

Flow Controls:
 On-off (zone valves/pumps) Outside
air
 Balancing sensor
Room
Water temperature controls thermostat
 Boiler outdoor reset
 Mixing valves
 Thermostatic

Rate
 Motorized
of M

heat
output
Outdoor Reset Control
Why use it?
1. Comfort
 Consistent, even space temperatures
 Constant heat output to match the load
 Keep up vs Catch up
2. Efficiency
 Eliminate overheating

 Increases condensing in boiler
 Longer boiler run times

 Lower standby losses
How does it work? Heating curves
 Heat loss changes continuously
Boiler / supply water temperature

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
20-60oC / 70-140oF
Temp Range

95 35

68 20
20 15
68 59
Outdoor temperature
Heating curve selection
High temp heating

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

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

system, eg Radiant floor

heating

Controls
Foil 15
03/05
Webinar Objectives:

hydronic systems
2. Review of hydronic fundaments
principals
condensing boilers
Piping strategies for condensing boilers

Application Guide

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
1. Typical hydronic emitters water temperature requirements
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
Medium temperature emitters:

 Cast iron radiators 100 - 140 oF
 Low mass radiant floor
ie: wood joist floors 100 -150 oF

Low temperature emitters:

 High mass radiant floor
ie: concrete floors 80 - 120 oF
 Snowmelting systems 80 - 120 oF
2. Boiler requirements – Temperature
How do you maximize the efficiency of condensing boiler?
98
130oF Dew Point
96 of Natural Gas
Boiler efficiency %
94
92
90
88
140oF
Condensing

86 mode
120oF
84

82 Non-Condensing
mode
80
80 100 120 140 160
Boiler return water temp oF
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)
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
2. Boiler requirements – Piping
Primary-Secondary
piping

Piping directly to
system
2. Boiler requirements – Hydraulic separation with Primary-Secondary Piping
Option 1: Option 2:
Closely spaced Tees Low Loss Header

2. Boiler requirements – Hydraulic separation with Primary-Secondary Piping
Happy boiler:
 Always gets the flow it needs
 Less likely to short cycle
This pump only has to  Not affected by on/off zones
over come the friction loss
of the heat emitters and
secondary loop piping

This pump only has to
Secondary over come the friction
loss of the boiler and

Loop Primary
primary loop piping
Loop
2. Boiler requirements – Low Loss Header operation
Mixing occurs within the hydraulic separator.
Secondary Primary Secondary Primary

Primary flow higher Secondary flow higher
than secondary flow than primary flow
3. Zoning requirements
Multiple zone pumps Thermostatically controlled zone pumps
 Higher electrical consumption

 Flow balance with speed control
Multizone
control

Single pump, multiple zone valves Thermostatically controlled zone valves
 Lower electrical consumption

 Individual loop control for RFH
 With single speed pump use pressure
bypass valve to balance flow
M M M
Multizone
control

Single speed
pump
Pressure bypass
valve
Single pump, multiple zone valves Thermostatically controlled zone valves
 Lower electrical consumption

 Individual loop control for RFH
 Variable speed pump to balance flow
M M M
Multizone
control

Variable speed
pump
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
Webinar Objectives:

hydronic systems
2. Review of hydronic fundaments
principals
condensing boilers
4. Introduction to NEW Vitodens 100
Application Guide

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

Application Guide – Boiler Nomenclature

Application Guide – Recommended Product Application

Application Guide – Component Index

Application Guide – Piping Layouts

Application Guide – Wiring Layouts

Application Guide – Set-up and Programming

Application Guide – Application # 1






Application Guide Phase 2 – Vitodens 200 piping
Motorized

mixing
valve


Motorized
mixing
valves

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.

Applications and Piping Strategies for
Condensing Boilers - Introduction

App Piping Strategies Webinar

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Applications and Piping Strategies for

Condensing Boilers - Introduction

1. Control objectives for hydronic systems

Foil 2, 10/2015 © Viessmann Manufacturing

1. Control objectives for hydronic systems

Foil 3, 10/2015 © Viessmann Manufacturing

1. Maximize Occupant Comfort:

2. Minimize Energy Consumption:

Foil 4, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

Foil 5, 10/2015 © Viessmann Manufacturing

Snowmelting High-temp RFH

Foil 6, 10/2015 © Viessmann Manufacturing

1. Overview of control objectives for

Foil 7, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

GPM = BTU/hr ÷ (T x 500)

Foil 8, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

GPM = BTU/hr ÷ (T x 500)

Foil 9, 10/2015 © Viessmann Manufacturing

GPM = BTU/hr ÷ (T x 500)

180oF GPM = BTU/hr ÷ (20 x 500)

Typical hydronic GPM = BTU/hr ÷ 10,000

Foil 10, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

GPM = BTU/hr ÷ (T x 500)

Foil 11, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

GPM = BTU/hr ÷ (T x 500)

Foil 12, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

Foil 13, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

 Heat loss changes continuously

Boiler / supply water temperature

Foil 14, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

High temp heating

Medium temp heating

Low temp heating

Foil 15, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

1. Overview of control objectives for

Foil 16, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

1. What are the system water temperature requirements?

2. What are the boilers requirements

Foil 17, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

High temperature emitters:

Medium temperature emitters:

Foil 18, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

How do you maximize the efficiency of condensing boiler?

Foil 19, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

Vitodens 100 / 200 series:

Vitocrossal 300, CU3A series:

Foil 20, 10/2015 © Viessmann Manufacturing

Applications and Piping Stratigies

Vitodens 100 / 200 series:

Vitocrossal 300, CU3A series:

Foil 21, 10/2015 © Viessmann Manufacturing