E50C Boiler System Piping and Applications Design Manual

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Table of Contents Table of Contents ..................................................... 2 Note to the User ....................................................... 3 General Piping Information ...................................... 4 Frequently Asked Questions .................................... 5

Definitions & Circulating Head Pressure Chart......... 6

Calculating Zone Flow Rates ..................................... 7

Calculation of Resistance of Longest Loop /

Zone in a System ................................................ 8

Example Plumbing Drawings .................................. 10

Apendix A— Piping and System Components ........ 15

Appendix B—Properties of Water .......................... 17

Appendix C—Copper Tube Heat

Transfer Capacities ........................................... 17

Appendix D— Example for Calculating

Equivalent Length ............................................ 18

Appendix E—Diverter Tee Equivalent

Length Calculation ............................................ 21

Total Equivalent Lengths Worksheet ..................... 22 Notes ...................................................................... 23

Tables

Table 1—General Piping Information ..................... 4

Table 2—Copper Finned Tube Base Board Specific Information .................................................... 4

Table 3—Copper Sweat Fittings Head Loss Table .. 15

Table 4—Cv Values for System Parts....................... 16

Table 5—M Type Copper Tubing (Feet of Head

per 100 Linear Feet) ......................................... 16

Table 6—M Type Copper Tubing (Feet of Head

per 1 Linear Foot) ............................................. 16

Table 7—Properties of Water ................................ 17

Table 8—Copper Tubing Heat Transfer Capacity

and Flow Rate .................................................. 17

Drawings

Drawing 1—Example-Calculating Pressure Drop ..... 8

Drawing 2—Single Serial Flow Loop (zone) ............ 10

Drawing 3—Multiple Zone Valves .......................... 11

Drawing 4—Hydronic Air Handler .......................... 11

Drawing 5—One Pipe System using Diverter Tee

(Mono Flow Tee) .............................................. 12

Drawing 6—Multiple Zone Circulators with

Low Loss Header Plumbing Kit ......................... 12

Drawing 7—Single Serial Flow Loop (Zone)

(Low Loss Header Plumbing Kit Required) ....... 13

Drawing 8—Radiant Manifold System .................. 14

Drawing 9—Example-Calculating the

Equivalent Length (Alternate Method) ............ 18

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It is the responsibility of the contractor and/or engineer to ensure the system is correctly designed and installed to

allow for proper boiler operation. The guidelines and drawings in this document are for reference purposes only. This

manual is not intended to replace proper system sizing, installation, and design by your chosen professional. The

tables presented in this document are not representative of all possible fittings and pipes or sizes, designs, and

materials available. If they are fittings or pipe sizes and materials being used that are not covered in this manual please

contact Rinnai for further information. This is not a product installation manual, please refer to the installation/

operation manual that accompanied the product for specific information regarding installation and safety.

The drawings shown in this document are not engineering drawings; they are intended only as a guide and not as a

replacement for professional engineering project drawings. These drawings are not intended to describe a complete

system. It is up to the contractor or engineer to determine the necessary components and configuration of the

particular system to be installed. The drawings herein do not imply compliance with local building code requirements.

It is the responsibility of the engineer or contractor to ensure that the installation is in accordance with all local

building codes. Confer with local building officials before installation. The piping arrangements shown in the drawings

herein are not representative of engineered drawings and are for illustration purposes only and do not represent

calculated loop lengths or pressure drops.

All of the calculations and tables in this manual are for use with water only systems. When antifreeze is added to any

system the properties of viscosity and heat transfer are altered. Please contact your antifreeze manufacturer for

additional information on how to perform system calculations when using antifreeze.

Proper installation in a proper environment with the correct tools and materials is the responsibility of the installer. It

is the responsibility of the consumer and/or installer to verify water quality at the application and to check all local and

national codes. Rinnai America Corporation, its agents, employees, directors, officers, parent and affiliate companies

assume no liability for any damage arising from incorrect usage of or reliance on the information provided in this

manual which is solely for reference or guidance, or for the failure to have adequate water quality, or to comply with

local and/or national codes.

NOTE TO USER

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General Piping Information

Copper Finned Tube Base Board Specific Information

1) Assumes copper finned baseboard with an output of 510 BTU per linear foot @ 2.0 gpm flow rate and 170°F

entering water temperature. 2) Based on the use of type M copper tubing

3) Based on 2.0 gpm flow rate, higher flow rates will reduce the maximum loop length.

4) Refer to example located in Appendix D.

Zone Pipe Size ½” ¾” Single Heating Loop

Minimum Header Pipe sizing 1” 1” ¾”

Maximum system flow (gpm) 4.5

Maximum Available circulator head pressure for heating loop (ft/psi)

4.6 feet of head (2.0 psi)

Table 1

Table 2

Notice The figures in tables 1 & 2 are for use with copper tube aluminum finned baseboard only. If the boiler is installed in a system that utilizes other types of heat emitters or piping such as: cast iron base board cast iron radiators steel panel radiators air handlers black iron piping PEX piping piping, fittings, and emitters other than copper Then the maximum flow rate and available pump head should be used to determine if the boiler is suitable for installation without the addition of a Rinnai low loss header plumbing kit (part number 804000061). It is the responsibility of the contractor or engineer to calculate the pressure drop through the system and the required flow rate for the heat emitters and the entire system to operate correctly.

Zone Pipe Sizing ½” ¾” Single Heating Loop System

Maximum flow per loop @20°F ∆T (gpm)

2.2 2.2 4.5

Maximum BTU output (MBH) 45

Maximum BTU load per zone (MBH) 22.5 22.5 45

Minimum number of zones

2 2 NA

Maximum number of zones

3 3 NA

Maximum feet of finned tube baseboard

43’1 43’1 43’

Maximum loop length (equivalent feet)2

50’3 200’3 92’

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In a multiple temperature system utilizing a thermostatic mixing valve or a third party motorized mixing control, a low loss header plumbing kit (part number 804000061) must be used.

ATTENTION

How to decide if a low loss header plumbing kit is required or not for the E50C boiler? The following instructions will guide you through how to determine if the E50C boiler can be used for your application and then how to correctly pipe your system for use with the E50C boiler. How to confirm your system is suitable for use for the E50C:

1) Is the system a single zone or multiple zone system? Answer: The E50C boiler can be used for both types of systems.

2) If the system has multiple zones; can zone valves and/or circulators be used? Answer: The E50C boiler (as shipped from the factory) should only be utilized in systems with zone

valves. Systems which utilize multiple zone circulators instead of zone valves must be coupled to a Rinnai boiler that has a low loss header as standard equipment or a low loss header plumbing kit part number: 804000061 must be purchased and connected to the E50C boiler. The following models are supplied with a low loss header from the factory: E75C, E110C, Q85S, Q130S, QP85, and QP130. Rinnai strongly recommends the use of full port ball valve type zone valves to allow for the best performance of the boiler and system.

3) What is the pressure drop across the longest loop/zone in the system or what is the total pressure drop in the single zone system?

Answer: See table 1 and/or figure 1 to determine if the boiler circulator has enough feet of head to properly pump the entire system without the addition of a low loss header plumbing kit.

4) What type heat emitters can be utilized?

Answer: The E50C boiler can be utilized with some types of heat emitters without a low loss header plumbing kit as long as the total system flow requirements and pressure drop requirements are observed, which means no more than 4.5 gpm of flow and 4.6 feet of head (2.0psi) of pressure drop through the longest loop in the system.

5) When doing a boiler replacement in a single zone with a system (loop) circulator how do you know if a low loss

header is needed? Answer: The first thing that should be done when installing the E50C boiler is to calculate the pressure

drop through the loop. Do not include the existing pump in the pressure drop calculation. If the pressure drop in the loop is less than 4.6 feet of head, then the existing pump should be removed and the boiler can be piped directly to the system. If the pressure drop is greater than 4.6 feet of head, then a low loss header plumbing kit should be installed in between the boiler and the system pump as shown in drawing number 7.

If the E50C boiler is installed in a system with zone valves and the constant recirculation function is activated, then a differential pressure bypass valve or a low loss header plumbing kit is required to be installed.

Frequently Asked Questions

When installing the E50C boiler in systems with dissimilar metals, Rinnai strongly recommends the use of dielectric unions in between the boiler and the system.

ATTENTION

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Circulator Head Pressure

Figure 1

2 psi =

The difference between the resistance curve of the heat exchanger and the circulator curve is the available pump

head for the system. The maximum available head pressure from the boiler circulator for the system is 2 psi = 4.6

feet of head at 4.5 gpm.

Single Heating Loop System – A single heating loop system can be considered any of the following piping arrangements: series loop, one pipe with diverter tees, or two pipe reverse return. These types of systems will have only a single room thermostat centrally located that controls the boiler.

Zoned System – A zoned system is a heating system that utilizes multiple zones which are individually controlled by room thermostats. The individual zones can be configured in series, with diverter tees, or a two pipe reverse return.

Diverter Tee – A diverter tee is a device that creates a pressure differential through the use of an orifice inside a tee pipe fitting. The pressure differential forces water into the branch off of the main line. A diverter tee is also commonly known as a mono flow tee.

Zone pipe Size – This is the diameter of the zone or branch of piping that comes off of the main or header.

Definitions

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Notice

Zones should be balanced using balancing valves to ensure the correct output (flow rate) of each zone. Use the

hydronic formula to calculate the flow rate for each zone. The constant 500 is based on the use of water as the heat

transfer fluid in the system, where 8.33 pounds/gallon of water x 60 minutes per hour = 500. If glycol is used please

contact the manufacturer to find the correct value for the density of the glycol water mixture.

Calculating Zone Flow Rates

Hydronic Formula

20’ x 510 BTU = 10,2000 BTU 170°F 150°F

A zone has 20 total feet of finned tube base board. The baseboard has a BTU output of 510 BTU per linear foot according to the manufacturer. The design day temperature for the baseboard is 170°F and the zone will be run at a 20°F delta T. What is the correct flow rate for this zone?

Total BTU for the loop = 510 BTU x 20ft = 10,200

Example of the use of the Hydronic Formula

GPM= 10,200 BTU 20 X 500

GPM= 1.02

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In order to correctly calculate resistance first determine the longest equivalent length loop in the system. The length of this loop is calculated starting at the supply connection of the boiler and ending at the return connection to the boil-er. Select this loop for your calculations. The system/longest loop head pressure can be determined by adding up all the fittings in the longest loop and the total length of straight pipe in the longest loop to get an equivalent length. If the pressure drop in the loop/system is greater than the available head pressure from the boiler circulator a Low Loss Header Plumbing kit part number: 804000061 must be used. If the boiler is to be installed in a system that utilizes zone circulators and not zone valves, a low loss header plumbing kit is required to be installed.

Rinnai strongly recommends the use of full port ball valve zone valves; these valves provide a lower pressure drop than

a gate valve type zone valve. The lower pressure drop will allow for longer loop lengths and better flow through the

zones.

ATTENTION

= specific weight of fluid at operating temperature (the specific weight of water is given in appendix B table 7)

Flow rate = flow rate through the device

Cv = value from the device manufacturer

To calculate the resistance for a fitting, reference Appendix A tables 5 and 6 (when using copper tubing).

Example – Calculating the Pressure Drop

Drawing 1

Calculating the Resistance of the Longest Loop/Zone in a System

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The single zone serial flow system in Drawing 1 consists of the following copper fittings and tubing and is designed to operate at 4.0 gpm flow rate at 170°F supply temperature. (Below is a list of each type of component and quantity of the components contained in drawing 1.) a. 6 - 90° elbows ¾” b. 8 - Tees (straight run) ¾” (PRV tee, Tridicator tee, boiler drain tee, purge tee, 2 x bypass tees) c. 3 - Ball valves (standard port) ¾” d. 40 feet of 3/4” copper type M tubing e. 1 – air separator ¾” f. 1 – dirt trap ¾”

1) To calculate the total equivalent length, add up the number of each type of fitting and multiply the number of each type of fitting by its equivalent length. See Appendix A table 3 for equivalent lengths of fittings. The chart below is an example of the

calculation (also a blank worksheet is included on page 22 of this manual) . Add up the equivalent lengths of the fittings using the worksheet for your calculations.

2) Add the total equivalent length of the fittings from step 1 to the length of straight tubing:

3) Convert equivalent feet pipe from step 2 to feet of head. (See Apendix A table 6 for the feet of head per linear foot.)

equivalent feet of pipe x feet of head per liner foot = feet of head 61.8’ x 0.035 = 2.16 feet of head

5) Convert the pressure drop calculated in step 4 from psi to feet of head. (1psi = 2.3 feet of head)

6) Add the feet of head from step 3 with the feet of head of the two fittings calculated in step 5. 2.16 + 0.472 + 0.472 = 3.1 feet of head

4) Calculate the pressure drop of the additional fittings e and f by using the Cv value of fittings from Appendix A table

4 and for the values of from appendix B table 7:

Pressure Drop (psi) = 2.3 X Pressure Drop (psi) from step 2

Pressure Drop (feet of head) = 2.3 X 0.205

Pressure Drop (feet of head) = 0.472

Pressure Drop (psi)

Pressure Drop (psi)

Pressure Drop (psi)

(Abbreviated Sample of Worksheet 1)

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Example Piping Drawings

The drawings in this section represent only a few of the piping options and system concepts the boiler can be connected to and are not intended to serve as engineering or design drawings.

Notice Rinnai recommends that the tee fittings for the pressure relief valve and the boiler drain are placed directly below the boiler as

shown in the drawing above. These fittings then can be utilized as connection points for taking a differential pressure in the

event it is required for finding the pressure drop through the system.

Drawing 2

Single Serial Flow Loop (zone) Less than 4.6 feet of head pressure drop

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If the boiler is installed in a system with zone valves and the constant recirculation function is activated then a differential pressure bypass valve or a low loss header plumbing kit is required to be installed.

Drawing 3

*Rinnai strongly recommends the use of full port ball valve type zone valves to allow for the best performance of the boiler and system. When piped as shown in the drawing above, the air handler cannot have an internal pump.

*

*

*

Drawing 4

Multiple Zone Valves Less than 4.6 feet of head pressure drop

Hydronic Air Handler Less than 4.6 feet of head pressure drop

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Drawing 5

Drawing 6

One Pipe System using Diverter Tee (Mono Flow Tee) Greater than 4.6 feet of head pressure drop

Low loss header plumbing kit required (Low Loss Header Plumbing kit part number: 804000061)

Multiple Zone Circulators with Low Loss Header Plumbing Kit Circulators used for Zoning

Low loss header plumbing kit required (Low Loss Header Plumbing kit part number: 804000061)

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Drawing 7

Single Serial Flow Loop (zone) Greater than 4.6 feet of head pressure drop

Low loss header plumbing kit required (Low Loss Header Plumbing kit part number: 804000061)

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Drawing 8

If the boiler is installed in a system with zone valves and the constant recirculation function is activated then a differential pressure bypass valve or a low loss header plumbing kit is required to be installed.

Drawing 8

Radiant Manifold System Low loss header plumbing kit required

(Low Loss Header Plumbing kit part number: 804000061)

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Piping and System Components

Fitting Size* ½” ¾” 1” 1 ¼” 1 ½”

90° elbow (copper) 1.00 2.00 2.50 3.00 4.00

45° elbow (copper) 0.50 0.75 1.00 1.20 1.50

Tee (straight run) (copper) 0.30 0.40 0.45 0.60 0.80

Tee (side port) (copper) 2.00 3.00 4.50 5.50 7.00

Reducer coupling (copper) 0.40 0.50 0.60 0.80 1.00

Gate valve** 0.20 0.25 0.30 0.40 0.50

Globe valve** 15.00 20.00 25.00 36.00 46.00

Angle valve ball valve (standard port)** 3.10 4.70 5.30 7.80 9.4

Swing check valve** 2.00 3.00 4.50 5.50 6.60

Ball valve** (standard port) 1.90 2.20 4.30 7.00 6.50

Flow check valve** NA 83.00 54.00 74.00 57.00

Butterfly valve** 1.10 2.00 2.70 2.00 2.70

Diverter Tee (B&G) (copper) NA 70.00 23.5 25.00 23.00

*All values in the table are shown as equivalent feet of copper tubing of the size listed in the column **Equivalent lengths are generalizations and not brand specific, for detailed information please see the manufacturer of the fitting that will be used in the actual installation

Appendix A

Table 3 Copper Sweat Fittings Head loss table

(Equivalent feet of copper pipe)

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Notice The tables below are for copper M type tubing only. They are expressed in feet of head at a given flow rate. If the system utilizes PEX tubing (must be PEX barrier tubing with oxygen barrier) then the manufacturer of the PEX tubing should be contacted for information about the tubing and fittings that have been selected for the given system.

Table 4 Cv Values for System Parts1

1) All values for parts used for example in table 4 are current as of this printing but are subject change. For detailed

and current information please consult the specific fitting manufacture that will be used in the installation. 2) Sweat connection 3) NPT connection Table 4 is a small sampling of Cv values for types of system components other than pipes and fittings. For additional component types and models, contact the component manufacturer.

Table 5 M Type Copper Tubing

(Feet of head per 100 linear feet)

Flow (gpm) ½” ¾” 1” 1 ¼” 1 ½”

1 1.6 0.2 0.00 0.00 0.00

2 5.5 0.9 0.7 0.00 0.00

3 11.8 2.1 0.2 0.2 0.00

4 19.8 3.5 0.9 0.5 0.2

5 30.0 5.3 1.4 0.5 0.2

Flow (gpm) ½” ¾” 1” 1 ¼” 1 ½”

1 0.016 0.002 0 0 0

2 0.055 0.009 0.007 0 0

3 0.118 0.021 0.002 0.002 0

4 0.198 0.035 0.009 0.005 0.002

5 0.3 0.053 0.014 0.005 0.002

Component Type and Model ½” ¾” 1” 1 ¼” 1 ½”

Taco 570/571/572/573 zone valve (heat motor) 4.2 6.1 7.0 7.2 NA

Taco Z075T zone valve (zone sentry) 4.9 10.3 8.9 NA NA

Honeywell V4043A Zone valve 3.5 8.02/3.53 8.02/10.03 NA NA

Caleffi Dirtcal (dirt trap) NA 19 33 57 73

Caleffi Discal 551 (air separator) NA 19 32 56 73

Spirotherm Spirovent Jr.(air separator) NA 13 20 35 48

Spirotherm Spirotrap (dirt trap) NA 13 20 35 48

Taco 4900 (air separator) NA 14 24 37 49

Table 6 M Type Copper Tubing

(Feet of head per 1 linear foot)

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Properties of Water

Table 7

Temperature Specific Weight Dynamic viscosity

°C °F lb/ft3 kg/liter lb/ft-s kg/m-s

0 32 62.4167 0.99982 0.00120417 0.001792

5 41 62.4280 1 0.00102139 0.00152

10 50 62.4136 0.99977 0.00087894 0.001308

15 59 62.3774 0.99919 0.00076537 0.001139

20 68 62.3212 0.99829 0.00067398 0.001003

25 77 62.2488 0.99713 0.00059872 0.000891

30 86 62.1601 0.99571 0.00053623 0.000798

35 95 62.0584 0.99408 0.00048382 0.00072

40 104 61.9441 0.99225 0.0004388 0.000653

45 113 61.8174 0.99022 0.00040049 0.000596

50 122 61.6801 0.98802 0.00036757 0.000547

55 131 61.5321 0.98565 0.00033867 0.000504

60 140 61.3748 0.98313 0.00031381 0.000467

65 149 61.2075 0.98045 0.00029163 0.000434

70 158 61.0314 0.97763 0.00027148 0.000404

75 167 60.8473 0.97468 0.000254 0.000378

80 176 60.6550 0.9716 0.00023855 0.000355

85 185 60.4546 0.96839 0.00022444 0.000334

90 194 60.2467 0.96506 0.00021167 0.000315

95 203 60.0320 0.96162 0.00020025 0.000298

100 212 59.8091 0.95805 0.0001895 0.000282

Appendix B

Copper Tube Heat Transfer Capacities

Copper Tubing Heat Transfer Capacity and Flow rate Table Pipe Size Flow rate (gpm) 10°F ∆T (BTU) 20°F ∆T (BTU) 30°F ∆T (BTU)

½” 1.5 7,500 15,000 30,000

¾” 4 20,000 40,000 80,000

1” 8 40,000 80,000 160,000

1 ¼” 14 70,000 140,000 280,000

Appendix C

Table 8

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Appendix D Example – Calculating the Equivalent Length (Alternate Method)

The single zone serial flow system in Drawing 9 consists of the following copper fittings and tubing and is designed to operate at 4.0 gpm flow rate at 170°F supply temperature. (Below is a list of each type of component and quantity of the components contained in drawing 9.) a. 6 - 90° elbows ¾” b. 8 - Tees (straight run) ¾” c. 3 - Ball valves (standard port) ¾” d. 1 – dirt trap ¾” e. 1 – air separator ¾” f. 40 feet of 3/4” copper type M tubing

Drawing 9

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1) Calculate the pressure drop of the additional fittings d and e by using the Cv value of fittings from Table 4 and for the values of from Appendix B table 7. For this case both fittings d and e have the same Cv value so account for this in step 5:

2) Convert the pressure drop calculated in step 1 from psi to feet of head (1psi=2.3 feet of head)

3) Convert the pressure drop calculated in step 3 from feet of head to equivalent feet of pipe. Use Appendix A Table 6 to calculate the equivalent length:

Pressure Drop (psi) = 2.3 X Pressure Drop (psi) from step 1

Pressure Drop (feet of head) = 2.3 X 0.205

Pressure Drop (feet of head) = 0.472

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5) Add the equivalent length of the fittings to the length of straight tubing: 48.76’+40’= 88.76’ 6) Determine if the total equivalent length of the loop is greater than or less than the maximum allowable length for

the BTU output of the boiler at the maximum flow rate. For a single loop, the maximum allowable length is 92’ of ¾” type M copper tubing, so 88.76’<92’ which means the boiler can pump the loop without needing to use a low loss header plumbing kit as an accessory.

4) Add up the number of each type of fitting and multiply the number of each type of fittings by its equivalent length see Appendix A table 3 for equivalent lengths of fittings. Then add up the equivalent lengths of the fittings using Worksheet 1 for you calculation; remember to account for the both the air separator and the dirt trap

(Abbreviated Sample of Worksheet 1)

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Appendix E Diverter Tee Equivalent length Calculation

Calculating the resistance of a diverter tee loop

R1 = radiation equivalent length R2 = vertical rise equivalent length and elbow equivalent length R3 = vertical rise equivalent length and elbow equivalent length R4 = main loop equivalent length and standard Tee fitting equivalent length R5 = Diverter tee

Example R1 = 3 feet ofstraight ¾” tube = 3 equivalent feet R2 = ¾” 90° elbow and 2 feet of ¾” tube = 2 + 1 = 3 equivalent feet R3 = ¾” 90° elbow and 2 feet of ¾” tube = 2 + 1 = 3 equivalent feet R4 = 3 feet ofstraight 1” pipe and one 1” Tee = 3 + 0.45 = 3.45 equivalent feet R5 = 1” x 1” x ¾” diverter tee = 23.5 equivalent feet

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Total Equivalent Lengths Worksheet

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NOTES

Rinnai America Corporation 2013

Rinnai America Corporation • 103 International Drive, Peachtree City, GA 30269 Toll-Free: 1-800-621-9419 • Phone: 678-829-1700 • www.rinnai.us

©2013 Rinnai America Corporation. Rinnai is continually updating and improving products; therefore, specifications are subject to change without prior notice. Local, state, provincial, federal and national fuel gas codes must be adhered to prior to and upon installation.

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