Articles by John Siegenthaler, P.E.

In hydronic systems, the circuit usually passes through the boiler, which adds heat. When using a block heater and the boiler is off, it dissipates heat from the circuit. This heat loss must be considered when measuring the circuit's true "net" heating output.

Figure 1 shows the piping layout for an actual installation. It uses two boilers, fired in stages, to supply three areas of a building. One of those areas is sub-divided into three zones. The other two areas are handled by individual zone circulators. The "primary circulator" operates whenever any load circuit is on. All circulators are fixed speed. There's a partially closed ball valve at the end of the "primary loop."

Modern hydronic systems benefit from wider temperature drops, energy scavenging, and careful integration with domestic hot water.

Measuring the flow rate through a circuit has always been more of a challenge compared to measuring temperatures. Very few circuits are equipped with permanently installed flow meters.

Single-stage non-modulating heat sources in zoned distribution systems often face short cycling, particularly with low thermal mass. When few zones are active, they struggle to dissipate generated heat quickly, causing temperature build-up and potential shutdown of the heat pump based on internal limits, with varied restart behavior depending on controls.

Can you speculate why heat delivery in zone 3 was insufficient before the helper pump? How could the piping system be improved, considering the wasted length of PEX-AL-PEX tubing from the manifolds to the floor panels in figure 2?

Last month, we reviewed the basics injection mixing. It’s a method for controlling water temperatures by regulating the flow of heated water “injected” into a circulating distribution system, while simultaneously removing an equal flow of cooler water from that distribution system. Any method that controls the rate of injection flow also controls the rate of heat transfer into the distribution system.

For boilers operating on natural gas or propane, flue gas condensation begins at inlet water temperatures below about 130 ºF. Boilers operating on low sulfur #2 fuel oil have lower dewpoint temperatures in the range of 110 ºF.

The homerun system is a simple technique for connecting multiple heat emitters using two runs of small flexible tubing (such as PEX) for supply and return. In North America, the standard size is 1/2-inch, but 3/8-inch tubing can be used with proper design and compatible fittings.

An owner, who has never been satisfied with the performance of his heating system, decides that the boiler must be the root cause of all the performance issues. Not wanting to spend any more than necessary, he makes several calls looking for the lowest boiler replacement price.