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Technology Solutions Case Study: Hydronic Systems: Designing for Setback Operation

For years, conventional wisdom surrounding space heating has specified two points: size the mechanical systems to the heating loads, and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. Determining the appropriateness of setback for a particular project is the first step. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step-by-step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

ACCA Manual J↗

Hydronic Systems: Designing for Setback Operation, Ithaca, New York [Fact Sheet]

Conventional wisdom surrounding space heating has told us a couple of things consistently for several years now: size the mechanical systems to the heating loads and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. Determining the appropriateness of setback for a particular project is the first step. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step by step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Measure Guideline: Condensing Boilers - Optimizing Efficiency and Response Time During Setback Operation

Conventional wisdom surrounding space heating has told us a couple of things consistently for several years now: size the mechanical systems to the heating loads and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. Determining the appropriateness of setback for a particular project is the first step. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step by step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Measure Guideline: Condensing Boilers-Optimizing Efficiency and Response Time During Setback Operation

Conventional wisdom surrounding space heating has consistently stated two things: size the mechanical systems to the heating loads, and setting the thermostat back at night will result in energy savings. The problem is these two recommendations oppose each other. A system that is properly sized to the heating load will not have the extra capacity necessary to recover from a thermostat setback, especially at design conditions. The implication of this is that, for setback to be successfully implemented, the heating system must be oversized. This issue is exacerbated further when an outdoor reset control is used with a condensing boiler, because not only is the system matched to the load at design, the outdoor reset control matches the output to the load under varying outdoor temperatures. Under these circumstances, the home may never recover from setback. Special controls to bypass the outdoor reset sensor are then needed. Properly designing a hydronic system for setback operation can be accomplished but depends on several factors. The first step is to determine the appropriateness of setback for a particular project. This is followed by proper sizing of the boiler and baseboard to ensure the needed capacity can be met. Finally, control settings must be chosen that result in the most efficient and responsive performance. This guide provides step-by-step instructions for heating contractors and hydronic designers for selecting the proper control settings to maximize system performance and improve response time when using a thermostat setback.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Optimizing Hydronic System Performance in Residential Applications

Even though new homes constructed with hydronic heat comprise only 3% of the market (US Census Bureau 2009), of the 115 million existing homes in the United States, almost 14 million of those homes (11%) are heated with steam or hot water systems according to 2009 US Census data. Therefore, improvements in hydronic system performance could result in significant energy savings in the US. When operating properly, the combination of a gas-fired condensing boiler with baseboard convectors and an indirect water heater is a viable option for high-efficiency residential space heating in cold climates. Based on previous research efforts, however, it is apparent that these types of systems are typically not designed and installed to achieve maximum efficiency. Furthermore, guidance on proper design and commissioning for heating contractors and energy consultants is hard to find and is not comprehensive. Through modeling and monitoring, CARB sought to determine the optimal combination(s) of components - pumps, high efficiency heat sources, plumbing configurations and controls - that result in the highest overall efficiency for a hydronic system when baseboard convectors are used as the heat emitter. The impact of variable-speed pumps on energy use and system performance was also investigated along with the effects of various control strategies and the introduction of thermal mass.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Optimizing Hydronic System Performance in Residential Applications, Ithaca, New York (Fact Sheet)

Condensing boiler technology has been around for many years and has proven to be a durable, reliable method of heating. Based on previous research efforts, however, it is apparent that these types of systems are not designed and installed to achieve maximum efficiency. For example, in order to protect their equipment in the field, manufacturers of low-mass condensing boilers typically recommend design strategies and components that ensure steady, high flow rates through the heat exchangers, such as primary-secondary piping, which ultimately result in decreased efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Technology Solutions Case Study: Optimizing Hydronic System Performance in Residential Applications, Ithaca, New York

Condensing boiler technology has been around for many years and has proven to be a durable, reliable method of heating. Based on previous research efforts, however, it is apparent that these types of systems are not designed and installed to achieve maximum efficiency. For example, in order to protect their equipment in the field, manufacturers of low-mass condensing boilers typically recommend design strategies and components that ensure steady, high flow rates through the heat exchangers, such as primary-secondary piping, which ultimately result in decreased efficiency. There is also a significant lack of information for contractors on how to configure these systems to optimize overall efficiency. In response to these findings, researchers from Building America team Consortium for Advanced Residential Buildings worked with industry partners to develop hydronic system designs that would address these issues and result in higher overall system efficiencies and improved response times.

AFUE↗

Optimizing Hydronic System Performance in Residential Applications

Even though new homes constructed with hydronic heat comprise only 3% of the market (US Census Bureau 2009), of the 115 million existing homes in the United States, almost 14 million of those homes (11%) are heated with steam or hot water systems according to 2009 US Census data. Therefore, improvements in hydronic system performance could result in significant energy savings in the US.

AFUE↗