Free cooling guide COOLING INTEGRATION IN LOW-ENERGY HOUSES
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Table of contents 1. Introduction to the concept of free cooling ...3 6. Free cooling in combination with The need for cooling in low-energy houses.............4 different heat sources ....................................19 Comfort and energy efficiency – the best fit 7. Choosing and dimensioning the radiant for low-energy houses ............................................4 emitter system ................................................20 Investing for the future – the design of a Capacity of different radiant emitter systems ........20 low-energy house ...................................................5 Radiant floor constructions and capacity ..............22 2. Cooling loads in residential buildings .............6 Radiant ceiling constructions and capacity ...........24 Factors influencing the sensible cooling load ..........6 Capacity diagrams .................................................24 Factors influencing the latent cooling load .............7 Regulation and control..........................................26 The effect of shading ..............................................7 The self-regulating effect in underfloor heating ..27 Room variation .......................................................8 Functional description of Uponor Control Duration of the cooling load ..................................8 System .................................................................27 Required cooling capacity .......................................9 Component overview ............................................29 3. The ISO 7730 guidelines .................................10 8. Uponor Pump and exchanger group (EPG6) Optimal temperature conditions............................10 for ground sourced free cooling.....................29 Draught rate .........................................................11 Dimensions ...........................................................30 Radiant asymmetry ...............................................11 Pump diagram.......................................................30 Surface temperatures ............................................12 Control principle ...................................................31 Vertical air temperature difference ........................12 Installation examples.............................................33 Operation of Uponor Climate Controller C-46 .......36 4. Capacity and limitations of radiant Operation mode of Uponor Climate emitter systems ..............................................13 Controller C-46 .....................................................36 Heat flux density...................................................13 Dew point management parameters and Thermal transfer coefficient ..................................13 settings .................................................................37 Dew point limitations ............................................13 Heating and cooling change-over: Theoretical capacities of embedded external signal .......................................................38 radiant cooling ......................................................14 Heating and cooling change-over: 5. Ground heat exchangers .................................15 Uponor Climate Controller C-46 ............................38 Ground conditions ................................................15 Ground heat exchangers .......................................16 Ground temperature profile...................................17 Primary supply temperatures.................................17 Dimensioning of ground heat exchangers for free cooling .....................................................17 2 UPONOR · FREE COOLING GUIDE
1. Introduction to the concept of free cooling Free cooling is a term generally used when low external lower compared to the outside air. The radiant system temperatures are used for cooling purposes in buildings. operates with large surfaces, which means it can utilize This guide presents a free cooling concept based on the temperatures from the ground directly for cooling a ground coupled heat exchanger combined with a purposes. The result is that free cooling can be provided radiant heating and cooling system. A ground coupled with only cost being the electricity required for running heat exchanger can for example be horizontal collectors, the circulation pumps in the brine and water systems. vertical boreholes or energy cages. A radiant system No heat pump is required. means that the floors, ceilings or walls have embedded In the heating season the system is operated using a pipes in which water is circulated for heating and heat pump. As the ground temperature during winter cooling of the building. Under floor heating and cooling is higher compared to the outside air temperature, is the most well know example of a radiant system. the result is improved heat pump efficiency (COP) A radiant system combined with a ground coupled heat compared to an air based heat pump. In addition, the exchanger is highly energy efficient and has several radiant emitter a system (under floor heating) operates advantages. In the summer period, the ground coupled at moderate water temperatures in large surfaces which heat exchanger provides cooling temperatures that are further improves the heat pump COP. UPONOR · FREE COOLING GUIDE 3
simulations and practical experience show that such The need for cooling in low- measures alone will not eliminate the cooling need. energy houses Space cooling is needed, not only in the summer, but also in prolonged periods during spring and autumn Today, there is a high focus on saving energy and when the low angel of the sun gives high solar radiation utilising renewable energy sources in buildings. through windows. In order to meet the energy frame The energy demand for space heating is reduced by requirements of the building regulations, space cooling increased insulation and tightness of buildings. can be provided by utilising renewable energy sources However, increased insulation and tightness also such as ground heat exchangers for cooling purposes in increase the cooling demand. The building becomes conjunction with a radiant system with embedded pipes more sensitive to solar radiation through windows and in the floor, wall or ceiling. becomes less able to remove heat in the summer. More Cooling needs will differ between rooms and are highly extreme weather conditions further contributes to the influenced by direct solar radiation. Rooms with larger cooling needs and together with an even more increased window areas and facing the south will generally have consumer awareness of having the right indoor climate, higher cooling requirements. In periods with high the need for cooling also in residential buildings will cooling loads, active cooling is normally required during become a requirement. Optimal architectural design both day and night time. and shading will help to reduce the cooling need, but Comfort and energy efficiency Furthermore, radiant systems are able to heat at a low supply temperature and cool at a high supply – the best fit for low-energy temperature. This fits perfectly to the typical operating houses temperatures of a ground coupled heat exchanger. Furthermore, the connected heat pump will be able Using shading will help to reduce the cooling demand. to run more efficiently and thereby consume less However, this forces occupants to actively pull down the electricity. In addition, a radiant system provides no shades e.g. when leaving the house. Also, shading will draught problems and provides an optimal temperature block daylight which increases electricity consumption distribution inside a room. Last but not least, radiant on artificial light, and shading will block the view which systems provide complete freedom in terms of interior may not be in the interest of the home occupant. design, as no physical space is occupied inside the room. In fact many architects state that energy efficiency and comfort may conflict when defining comfort in a Even more important when looking at the lifetime and broader sense, such as the freedom to design window property value of a house, such systems have very low sizes, spaciousness with increased ceiling height, maintenance need and a lifetime that almost follows daylight requirements and the occupant’s tendency to the lifetime of the building itself. In today’s uncertain utilise open doors and windows. All such requirements environment of future energy prices, free cooling and put increased demands on the HVAC applications. ground coupled heat pumps provides a high stability on the future energy costs of the building in question. Ground heat exchangers combined with radiant systems It will most certainly meet today’s and future building is the only “all-in-one” solution, with the ability to regulations even in a scenario where future property provide both heating and cooling. Such systems are taxation would be linked to energy efficiency. Hence, it more cost efficient and simpler to install than having is an investment that helps to maintain and differentiate to deal with a separate heating and cooling systems. the future property value. 4 UPONOR · FREE COOLING GUIDE
Investing for the future – the design of a low-energy house A radiant system, e.g. underfloor heating and cooling, coupled to a ground source heat pump, provides optimal comfort with high energy efficiency both summer and winter. In addition, due to the increased tightness requirements in low-energy houses, a ventilation system is necessary to maintain an acceptable indoor air quality. In order to keep the ventilation system energy efficient, it should be coupled to a heat recovery ventilation (HRV) unit to minimise heat losses through the air exchange. Energy sources for cooling DKK/m2 There are several alternative HVAC applications available for cooling purposes. A district heating connection is an energy efficient option for space heating, but cannot be used for cooling purposes. Alternative means of cooling could be an air-to-water heat pump, but no “free cooling” can be extracted from such a system, hence cooling can only be provided with the heat pump running causing a higher electricity consumption. Purely air-based systems like split units can also act as a cooling system but as can be seen from the picture below, the efficiency is considerably lower than for water-based cooling systems. 25 20 Energy class 15 Correlation between average property m2 prices and energy class 10 The figure above shows the correlation between 5 property prices and the energy efficiency level of the property in Denmark. Properties with energy class A or 0 Air to air Air to water Brine to water Free B are on average 6% more expensive than energy class heat pump heat pump heat pump cooling C and 17% more expensive than energy class D. European seasonal energy efficiency ratio (ESEER) for different cooling systems. ESEER is defined by the Eurovent Certification Company and calculated by combining full and part load operating conditions. UPONOR · FREE COOLING GUIDE 5
2. Cooling loads in residential buildings The design cooling load (or heat gain) is the amount Factors influencing the sensible of energy to be removed from a house by the HVAC equipment, to maintain the house at indoor cooling load design temperature when worst case outdoor design temperature is being experienced. As can be seen • Windows or doors from the figure above, heat gains can come from • Direct and indirect sunshine through windows, external sources, e.g. solar radiation and infiltration skylights or glass doors heating up the room and from internal sources, e.g. occupants and electrical equipment. • Exterior walls Two important factors when calculating the cooling load • Partitions (that separate spaces of different of a house are: temperatures) • sensible cooling load • Ceilings under an attic • latent cooling load • Roofs The sensible cooling load refers to the air temperature • Floors over an open crawl space of the building, and the latent cooling load refers to the humidity in the building. • Air infiltration through cracks in the building, doors, and windows • People in the building • Equipment and appliances operated in the summer • Lights 6 UPONOR · FREE COOLING GUIDE
Factors influencing the latent The effect of shading cooling load To reduce the cooling load from solar gains, the most Moisture is introduced into a room through: efficient and sustainable way is to use passive measures. From an architectural point of view, shading can be • People created by building components and by using blinds. • Equipment and appliances Depending on the type of blinds used, the solar gain can typically be reduced with up to 85% with external • Air infiltration through cracks in the building, doors, shading. The figures below show a building simulation and windows example conducted on a low-energy single family house, where using different shading factors have been Transmission (Sensible) applied. External heat gain Solar Radiation (Sensible) (Sensible) Total Air sensible CONDITIONED Ventilation (Latent) S PA C E Cooling Lighting (Sensible) Load Total Internal heat gain (Sensible) latent Equipment (Latent) (Sensible) People (Latent) Internal gains in residential buildings are limited to the Without shading; cooling loads up to 60 W/m2. people normally occupying the space and household equipment. In national building regulations, the load for internal gains in ordinary residential buildings is often mentioned (3-5 W/m2). In residential buildings, the cooling load primarily comes from external heat gains, and mostly from solar gains through windows and doors, transmission through wall and roof, and infiltration through the building envelope/ventilation. The figure below shows that about 2/3 of the cooling load comes from the solar radiation. Shading factor 50%; cooling loads up to 40 W/m2. 2% 5% 3% 10% 52% 13% 15% Shading factor 85%; cooling loads up to 25 W/m2. As can be seen from the figures above, even with the most efficient shading factor, the cooling load still Heat from air flows Heat from lighting amounts to 25 W/m2. Heat from occupants Heat from daylight (incl. latent) (direct solar) Heat from equipment Heat from windows (including absorbed solar) Heat from walls and and openings floors (structure) UPONOR · FREE COOLING GUIDE 7
Room variation There is a big variation in the cooling load from room to room, caused by the architectural design of the building. Large window areas facing the south and west are needed for daylight requirements and winter heat gains, but they also incudes high summer cooling loads. As a result of large south facing window areas, the cooling demand in south facing rooms are higher than in the north facing rooms. In addition, the desired temperature levels of each room may differ ranging from the highest temperature requirements in the bathroom, to the lowest temperature requirements in the bedroom. Duration of the cooling load 37 36 No window opening, no HRV by-pass 35 Open windows, no HRV by-pass 34 33 Open windows, with HRV by-pass The figures below show the duration of over-tempera- Temperature [°C] 32 31 UFH, no opening window ture with different shading and ventilation strategies. 30 29 The data originates from a full year building simulation 28 27 of a low-energy single family house in Northern 26 25 European climatic conditions (Denmark). 24 23 22 21 20 19 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 Time [h] Without shading; over-temperature up to 2 300 hours per year. 37 37 36 No window opening, no HRV by-pass 36 No window opening, no HRV by-pass 35 Open windows, no HRV by-pass 35 Open windows, no HRV by-pass 34 34 33 Open windows, with HRV by-pass 33 Open windows, with HRV by-pass Temperature [°C] Temperature [°C] 32 UFH, no opening window 32 31 31 UFH, no opening window 30 30 29 29 28 28 27 27 26 26 25 25 24 24 23 23 22 22 21 21 20 20 19 19 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 Time [h] Time [h] Shading factor 50%; over-temperature up to 1 100 hours per year. Shading factor 85%; over-temperature up to 800 hours per year. The simulations show that without active cooling building regulations across Europe have already started there will be a significant amount of time with over- to implement maximum duration periods of over- temperature (assuming that the maximum temperature temperature. In Denmark, the requirement in the 2015 allowed is 26 °C). All the cases also show that standard is that a temperature above 26 °C is only with radiant floor cooling, it is possible to keep the allowed for maximum 100 h during the year and above temperature below 26 °C all year round. National 27 °C for maximum 25 h during the year. 8 UPONOR · FREE COOLING GUIDE
Required cooling capacity Based on the peak load calculations of the building, the As can be seen, the cooling capacity peaks are actually heating and cooling system can be designed. The HVAC higher (up to 4 kW), than the heating capacity peaks system should be designed to cover the worst case (up to 3.5 kW) under any shading conditions (excluding (peak load). The figures below show an example of the domestic hot water). Although, the heating period variation of the needed capacity to cover the heating still remain longer than the total cooling period, it is and cooling loads. interesting to note that the cooling period extends into early spring and late autumn. Required heating and cooling capacity 5000 5000 Cooling Cooling 4500 4500 Heating Heating 4000 4000 3500 Capacity [W] 3500 Capacity [W] 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 500 500 0 0 January February March April May June July August September October November December January February March April May June July August September October November December Low energy building, no shading. Low energy building, shading in-between windows. Window opening and HRV by-pass are used during cooling season Window opening and HRV by-pass are used during cooling season 5000 4500 Cooling Heating 4000 3500 Capacity [W] 3000 2500 2000 1500 1000 500 0 January February March April May June July August September October November December Low energy building, external shading. Window opening and HRV by-pass are used during cooling season UPONOR · FREE COOLING GUIDE 9
3. The ISO 7730 guidelines In order to provide thermal comfort, it is necessary to take into account local thermal discomfort caused by temperature deviations, draught, vertical air temperature difference, radiant temperature asymmetry, and floor surface temperatures. These factors can influence on the required capacity of the HVAC system. Optimal temperature conditions EN ISO 7730 is an international standard that can be used as a guideline to meet an acceptable indoor and thermal environment. These are typically measured in terms of predicted percentage of dissatisfied (PPD) and predicted mean vote (PMV). PMV/PPD basically The PPD predics the number of thermally dissatisfied predicts the percentage of a large group of people persons among a large group of people. The rest of that are likely to feel “too warm” or “too cold” (the the group will feel thermally neutral, slightly warm or EN ISO 7730 is not replacing national standards and slightly cool. requirements, which always must be followed). The table below shows the desired operative tempera- PMV and PPD ture range during summer and winter, taking into con- sideration normal clothing and activity level in order to The PMV is an index that predicts the mean value of achieve different comfort classes. the votes of a large group pf persons on a seven-point thermal sensation scale (see table below), based on the Comfort requirements Temperature range heat balance of the human body. Thermal balance is Winter Summer obtained when the internal heat production in the body 1.0 clo 0.5 clo is equal to the loss of heat to the environment. PPD PMV 1.2 met 1.2 met Class [%] [/] [°C] [°C] PPD A < 6 - 0.2 < PMV < + 0.2 21-23 23.5-25.5 B < 10 - 0.5 < PMV < + 0.5 20-24 23.0-26.0 Dissatisfied [%] C < 15 - 0.7 < PMV < + 0.7 19-25 22.0-27.0 ISO 7730 basically recommends a target temperature of 22 °C in the winter, and 24.5 °C in the summer. The higher the deviation around these target temperatures, the higher the percentage of dissatisfied. The reason PMV for the different target temperatures is because that the two seasons apply different clothing conditions as can be seen in below figure: PMV Predicted mean vote PPD Predicted percentage dissatisfied [%] Metabolic rate: Predicted Percentage of +3 Hot 1.2 Dissatisfied [%] +2 Warm +1 Slightly warm Basic clothing Basic clothing 0 Neutral insulation: 1.0 insulation: 0.5 -1 Slightly cold -2 Cool Operative temperature [°C] -3 Cold Seven-point thermal sensation scale Operative temperature for winter and summer clothing 10 UPONOR · FREE COOLING GUIDE
Radiant asymmetry When designing a radiant ceiling or wall system, make sure to stay within the limits of radiant asymmetry. As can be seen in the figure below, the radiant asymmetry differs depending on the location of the emitter system, and whether it’s used for heating or cooling. With the insulation levels typically used today, radiant asymmetry does normally not cause any problems due to the moderate heating and cooling load the Draught rate emitter has to perform. However, especially when using ceiling heating, a calculation must be made for a given Radiant systems are low convective systems and will reference room. not create any problems with draught. However, down draught from a cold wall can put a limitation to the system. A cold wall can create draught as we know from windows. When designing wall cooling, the velocity on the air need to be within the recommendation (Class A is 0.18 m/s). Dissatisfied 0.4 Maximum air velocity, 0.5 m from wall [m/s] Recommended comfort limit for 0.35 sedentary persons 0.3 0.25 0.2 0.15 Floor temperature Δt (wall-room) 0.2 3.0 K 7.0 K Local discomfort caused by warm and cool floors 4.0 K 8.0 K 0.05 5.0 K 9.0 K 6.0 K 10.0 K When designing radiant cooling systems, the dew point 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 is normally reached before radiant asymmetry problems Height of cool wall [m] occur. Can be calculated according to ISO 7726. UPONOR · FREE COOLING GUIDE 11
Surface temperatures 0,1 - 1,1 m 3 Vertical air temperature difference [K] For many years, people have chosen underfloor heating 2,5 systems as the preferred emitter system, because of the B perceived comfort of walking on a warm floor. Similarly, 2 the question is if the occupants complaint about discom- 1,5 fort when utilising the floor to remove heat (cooling). A 1 0 9 18 27 36 45 54 63 [°F] 0,5 80 60 0 40 Warm ceiling Cool wall 2 4 6 8 10 Dissatisfied [%] 20 ΔT floor surface room Cool ceiling Warm wall 10 Correlation between the temperature difference floor surface to room 8 and the vertical air temperature difference (Deli, 1995). 6 4 The study concludes that up to a ΔT 8K, the comfort 2 category is still A. This would equal a floor temperature 1 0 5 10 15 20 25 30 35 of 20 °C and a dimensioned room temperature of [°C] Radiant temperature asymmetry [°C] 28 °C. The dimensioned room temperature must be below 26 °C and similarly above a floor temperature of 20 °C in order to reach comfort class B. Hence, the According to ISO 7730, the lowest PPD (6%) is found vertical air temperature difference will in practice not at a floor temperature of 24 °C. A typical floor cooling cause a indoor climate below category A. system will have to operate with a minimum floor temperature of 20 °C, where the expected PPD would As the pictures below show, different emitter systems still be under 10%. As will be seen later, such floor provide different temperature gradients in a room. temperatures still provide a significant cooling effect, Clearly, a radiant heating system in the floor provides due to the large surface area being emitted. a temperature gradient closest to the ideal. Similarly, a radiant cooling system in the ceiling provides a Vertical air temperature temperature gradient closest to the ideal. difference The comfort categories are divided into A, B and C depending upon the difference between the air temperature at floor level and at a height equivalent to a seated person. As can be seen below, the temperature difference must be under 2°C in order to reach category A. 18 20 22 24 26 Vertical air temperature difference a [°C] Category °C Ideal heating Underfloor heating Radiant ceiling heating External wall radiator heating A
4. Capacity and limitations of radiant emitter systems All emitter systems, whether it is pure air-based, Thermal transfer coefficient radiators or pure radiant systems, are bounded by their ability to transfer energy. The capacity of any radiant The thermal transfer coefficient is an expression of how emitter systems is limited by the heat flux density, which large an effect per m2 the surface is able to transfer to differs depending on the location of the emitter, i.e. the room, per degree of the temperature difference floor, wall or ceiling. The heat flux density can be used between the surface and the room. The figure below to calculate the capacity of the emitter, also known as shows the thermal transfer coefficient for different the thermal transfer coefficient. Specifically regarding surfaces for heating and cooling respectively. cooling, any radiant emitter will need to work within the dew point limitations in order to avoid moisture on the [W/m2K] Surface heating and cooling surface and within the construction. 15 Thermal transfer coefficient Heating Heat flux density 10 Cooling The ability of a surface to transfer heating or cooling between the surface and the room, is expressed by the 5 heat flux density. According to EN 1264/EN 15377, the values below can be used to express the heat flux 0 density. Ceiling Floor Wall Due to natural convection, the floor provides the Floor heating, ceiling cooling: q = 8.92 (θs,m - θi)1.1 best thermal transfer coefficient for heating while the Wall heating, wall cooling: q = 8 (| θs,m - θi |) ceiling provides the best thermal transfer coefficient for Ceiling heating: q = 6 (| θs,m - θi |) cooling. Floor cooling: q = 7 (| θs,m - θi |) Dew point limitations Where In order to secure that there is no condensation on the q is the heat flux density in W/m 2 surface of the emitter in the room the supply water temperature should be controlled so that the surface θs,m is the average surface temperature (always limited temperatures of the emitter always is above dew point. by dew point) In the diagram below, the dew point temperatures can θi is the room design temperature (operative) be found under different levels of relative humidity (RH): 24 23 Room temp. 26 °C 22 Dew point temperature [°C] 21 Room temp. 25 °C 20 Room temp. 24 °C 19 Room temp. 23 °C 18 17 16 15 14 13 12 11 10 9 8 40 45 50 55 60 65 70 75 80 Relative humidity RH [%] UPONOR · FREE COOLING GUIDE 13
Emitter surface and humidity Theoretical capacities of Design temperatures for cooling systems are specified embedded radiant cooling according to the dew point. The dew point is defined by the absolute humidity in the room and can be estimated Taking both ISO 7730 (surface temperatures, radiant from the relative humidity RH and the air temperature. asymmetry, and down draught) and the dew point The cooling capacity of the system is defined by the limitations into account, the following surface difference between the room temperature and the mean temperature limitations exist. water temperature. 45 Often standard design parameters for cooling systems 40 Heating are an indoor temperature of 26 °C and a relative Temperature [°C] 35 Cooling humidity of 50%. At the dew point, condensation will occur on the emitter surface. In order to avoid 30 condensation, the emitter surface temperature has to be 25 above the dew point temperature. 20 For radiant floor cooling a minimum surface temperature 15 Floor Parimeter Ceiling Wall of 20 °C is required, which means that only when the relative humidity exceeds 70% in the room, the risk Surface temperature limitations of condensation occurs, because that corresponds to a relative humidity of 100% at the emitter surface. With these surface temperature limitations in mind, the Radiant cooling from the ceiling is limited by the radiant maximum capacities of different radiant emitter systems asymmetry between the surface of the emitter and the can be calculated. The results are shown in the figure room temperature recommendation is that it should not below. exceed more than 14 K. For standard conditions (26 ºC, 50% RH) the surface of the emitter usually reaches the 200 dew point before the radiant asymmetry limit. 180 Heating Heating and Cooling Capacity [W/m2] Cooling 160 Distribution pipes and manifolds 140 In any cooling system where you have distribution pipes 120 or manifolds you have to be aware of that these parts 100 of the system also have a risk of condensation because they sometime operates below the dew point. Insulation 80 of distribution system is often necessary in order to 60 avoid condensation. 40 20 Design temperature 0 Floor Parimeter Ceiling Wall The design supply water temperature of the system depends on the type of surface used, the design indoor Maximum heating a cooling capacities conditions (temperature and relative humidity) and the cooling loads to be removed. It should be calculated to In theory, the highest heating capacity can be achieved obtain the maximum cooling effect possible from the from the wall. Since space is limited due to windows system. and other things hanging on the wall, the real heating capacity from walls is significantly reduced. Hence, the The capacity and mean water temperature for radiant biggest capacity can be achieved by heating from the floor cooling depends on the floor construction, pipe floor, and cooling from the ceiling. In practice, either pitch and surface material. To have the highest possible a floor system or a ceiling system is installed and used capacity of the system you should design your floor for both heating and cooling. A floor system should construction so the surface temperature is equal to the be chosen if the heating demand is dominant and a minimum temperature of 20 °C. ceiling system should be chosen if the cooling demand The capacity and mean water temperature for radiant is dominant. cooling from the ceiling is calculated, or can be read directly, in the capacity diagram of the cooling panels. To have the highest possible capacity of the system you should design as close to the dew point as possible. 14 UPONOR · FREE COOLING GUIDE
5. Ground heat exchangers Ground conditions When planning the use of ground heat exchangers, on being in contact with ground water. Hence the depth the ground conditions are of fundamental importance. of ground water levels has an important impact on the Determining the ground properties, with respect to performance of a vertical ground heat exchanger. the water content, the soil characteristics (i.e. thermal In addition to the water concentration, different ground conductivity), density, specific and latent thermal types have different thermal conductivity. For example capacity as well as evaluating the different heat and rock has a higher thermal conductivity than soil, so substance transport processes, are basic pre-requisites ground conditions with granite or limestone will give a to determine and define the capacity of a ground heat better performing ground heat exchanger than sand or exchanger. The dimensioning has a significant impact clay. on the energy efficiency of the heat pump system. Heat pumps with a high capacity have unnecessary Thermal conductivity high power consumption when combined with a poorly Soil type (W/m K) dimensioned heat source. Clay/silt, dry 0.5 With a higher water concentration in the ground, you Clay/silt, waterlogged 1.8 get a better system capacity. Horisontal collectors are Sand, dry 0.4 hence depending on the ground’s ability to prevent rain water from mitigating downwards due to gravitation. Sand, moist 1.4 The smaller the corn size in the soil, the better the Sand, waterlogged 2.4 ground can prevent rain water from gravitation. Hence Limestone 2.7 clay will provide a better performing ground heat Granite 3.2 exchanger than sand. Vertical collectors are depending Source: VDI 4640 UPONOR · FREE COOLING GUIDE 15
Ground heat exchangers With ground heat exchangers, a distinction is made The suitability of the different collectors depends on the between horisontal and vertical collectors. These can be environment (soil properties and climatic conditions), further classified as follows: the performance data, the operating mode, building type (commercial or private), the space available and Horisontal: the legal regulations. • Horisontal or surface collectors • Energy cages Vertical: • Boreholes • Energy piles and walls Horisontal collectors Energy cages Collectors installed horisontally or diagonally in the Collectors installed vertically in the ground. Here, the upper five meters of the ground (surface collector). collector is arranged in a spiral or a screw shape. Energy These are individual pipe circuits or parallel pipe cages are a special form of horisontal collectors. registers which are usually installed next to the building and in more rare cases under the building foundation. Boreholes Energy piles Collectors installed vertically or diagonally in the Collectors build into the pile foundations that are ground. Here one (single U-probe) or two (double used in construction projects with insufficient load U-probe) pipe runs are inserted in a borehole in capacity in the ground. Individual or several pipe runs U-shape or concentrically as inner and outer tubes. are installed in foundation piles in a U-shape, spiral or meander shape. This can be done with pre-fabricated foundation piles or directly on the construction site, where the pipe runs are placed in prepared boreholes that are then filled with concrete. Most often energy piles are used for larger commercial buildings. 16 UPONOR · FREE COOLING GUIDE
Ground temperature profile Dimensioning of ground heat The figure below shows a generic temperature profile in exchangers for free cooling the ground for each season during the year. The first thing to decide is whether the ground heat exchanger shall be used for heating only or for both Temperature (earth’s surface) [°C] 0 5 10 15 20 heating and cooling. As demonstrated in this guide, 0 new built low energy houses will often have substantial cooling loads. It is therefore highly recommendable to use the ground heat exchanger for free cooling in the 5 summer period. A combined use for heating and cooling also balances of the ground temperature during the Depth in soil [m] year and leaves the ground environment undisturbed. 10 Existing guidelines for dimensioning ground heat exchangers are typically based on the peak load for the heating demand. But in order to ensure that adequate 15 1. February cooling capacity is available in the summer season, it 1. May is recommend doing a design check for the maximum 1. November 1. August cooling load as well. 20 Dimensioning for the heat load should be done based 0 5 10 15 20 on the peak load for space heating plus the domestic Temperature (depth) [°C] hot water need. As a heat pump is used for covering the heat load, the COP of the heat pump on the The closer to the ground surface, the higher the coldest day (design day) should be applied in the influence from the outside temperature and solar design calculation. In addition to this, the specific radiation. Hence not surprisingly, the highest characteristic of the chosen heat exchanger and the temperatures are found in late summer and the thermal conditions in the ground must be taken into lowest temperatures in late winter. The reason for the account. temperatures being higher in late autumn than late Dimensioning for the cooling load should be done spring, has to do with the ground’s ability to store based on valid information of the maximum cooling energy. After a warm summer period, the ground load in the building. Free cooling operates without a remains relatively warm during the autumn. Ground heat pump. It is therefore vital that the thermal capacity temperatures stabilize below 10-15 m. It is clear from of the ground heat exchanger is able to fully cover the these ground temperature profiles that the cooling max cooling load (no COP is included). In residential capacity is higher below 15 m. Hence vertical collector buildings in Northern Europe the cooling need will systems provides a better cooling capacity than normally be covered with the capacity derived from horisontal collector systems. the heating requirements. But a design check is always recommended. Primary supply temperatures In special cases in residential buildings and typically in office buildings, the cooling need will be dominant and The temperatures mentioned in the previous section thus the design driver. In such case vertical collectors are often referred to as the undisturbed ground are normally recommended as the deeper ground temperature. Depending on the thermal resistance temperatures are sufficiently stable and independent of between the collector and the surrounding ground, the surface temperature and solar radiation. If a horizontal temperature of the fluid in the collector will be higher system is chosen, the space requirements can be a than the surrounding ground. capacity limitation. Designing for inadequate cooling capacity on the warmest summer days may then be necessary compromise, but should be evaluated carefully. UPONOR · FREE COOLING GUIDE 17
Dimensioning examples In order to dimension ground heat exchangers cer- data (thermal conductivity etc.) from local databases tain information has to be considered. First of all an or authorities. The figures below show the capacity for estimation of the physical properties of the ground is different collectors. needed. Normally its possible to obtain local ground *) Energy cage; normal height is 2.0 m, and Horisontal collectors Energy cage Vertical collectors XL height 2.6. Required depth is 4 m. Pipe size 25, 32 and 40 mm Normal 32 mm XL 32 mm 40 mm Capacity cooling 7-28 W/m2 800-1120 W 1000-1500 W 30-70 W/m Dimensioning temperature, 17-20 °C 14-17 °C 10-13 °C 10-13 °C supply/return Flow and pressure drop in the collector When the cooling need is defined, the flow can be different from the physical properties of pure water. calculated. When using ground collectors, the water The table below shows the required flow of often used used has to be mixed with anti-frost liquid. Hence, brines for providing different cooling capacity. the specific heat capacity and density in the brine is Cooling need Ethanol Monoethylenglyciol Propylenglycol [kW] Flow [kg/s] Flow [l/s] Flow [kg/s] Flow [l/s] Flow [kg/s] Flow [l/s] 2 0.16 0.15 0.18 0.19 0.17 0.18 3 0.24 0.23 0.27 0.28 0.26 0.27 4 0.32 0.31 0.36 0.38 0.34 0.36 5 0.40 0.38 0.45 0.47 0.43 0.45 6 0.48 0.46 0.54 0.56 0.51 0.54 When calculation the pressure loss in the collector the In the diagram below, the pressure loss in the flow is divided equally up in the number of loops. For ground collector should be maximum 34 kPa at the vertical collectors the total pressure loss is normally dimensioning conditions, and the ground collector very low hence the pressure is equalized and it is only should be dimensioned so that the pressure loss in each the pressure loss in the feeding pipe has an influence. loop is less than 34 kPa. For horisontal collectors and partly energy cages Pump diagram the pressure loss has to be calculated in order to be Available pressure for the primary circuit. sure that the pump will be able to circulate the water through the collector and the cooling exchanger Pressure loss [kPa] including manifolds and valves. 50 Example: 4 kW installations 40 Horisontal collector extraction 15 W/m2 30 CP2 power CP1 20 Liquid Monoethylenglycol 10 Total flow 0.38 l/s, 1.37 m3/h 0 0 0.5 1 1.5 2 2.5 3 Diameter of collector Ø 32 mm Rate of flow [m3/h] 18 UPONOR · FREE COOLING GUIDE
6. Free cooling in combination with different heat sources The illustrations below shows a ground heat exchanger As one can see from the grey connection lines the pump combined with a radiant system in heating mode and and exchanger group is not active in heating mode. cooling mode. In this example a ground sourced heat Similarly, the connection lines from the heat pump (or pump is providing heating to domestic hot water any other heat source) to the emitter systems are in- (DHW), space heating, and for heating up the incoming active in cooling mode. ventilation air. This could of course be utilized with If a boiler or district heating system is used as heating other heat sources such as boilers or district heating. source, the ground heat exchanger will only work during Free cooling is provided through a special pump and cooling (also known as a bivalent system). If a ground exchanger group (see chapter 8) that supplies cold source heat pump is used as heat source, the ground water/brine from the ground heat exchanger directly to ground heat exchanger will work both during heating the radiant emitter system and possibly the incoming and during cooling (also known as a monovalent ventilation air. In cooling mode, the heat pump will only system). be active for domestic hot water generation. Heating mode, the free cooling is deactivated Cooling mode, the free cooling is activated UPONOR · FREE COOLING GUIDE 19
7. Choosing and dimensioning the radiant emitter system Embedded emitters are the key to any radiant system. the floor has the highest heating efficiency, but with a In order to have an energy efficient and comfortable lower cooling efficiency. solution, the emitter system has to be designed to Another important factor is the supply water the construction but also to the task it has to solve. temperature. Radiant emitter systems operate on a There are many types of constructions for floor, wall relatively low temperature for heating, and a relatively and ceilings. Uponor offers emitters that can meet the high temperature for cooling. A radiant system should requirements of all types of installations. All emitters be designed for the lowest possible temperature for are able to provide heating and cooling. However, some heating and the highest possible temperature for emitters are more efficiently than others. The most cooling. This secures a heating/cooling system with efficient cooling system is placed in the ceiling, but the high energy efficiency and optimal conditions for the heating efficiency is lower whereas an emitter system in heating and cooling supply. Floor installation Wall installation Ceiling installation Capacity of different radiant emitter systems In order to calculate the capacity of the radiant emitter, it is important to know the construction in which the embedded emitter is integrated, including the surface material on top of the construction. In general, there are three factors that influence on the capacity of a radiant emitter system: • Thermal resistance in the surface construction RB • Pipe pitch, i.e. the distance between the pipes T • Thermal conductivity in the construction material In practice, this means that when designing the floor construction, the performance of the radiant system can be optimised by choosing the right construction, pipe Example: floor construction layout and surface material. 20 UPONOR · FREE COOLING GUIDE
Y = Specific thermal output qc [W/m2] Thermal resistance in the surface X = Temperature difference between construction room and cooling medium [θc K] The thermal resistance in the surface construction has a RλB = 0 big influence on the performance of the emitter. In the qCN (RλB = 0) diagram, an example of a cooling curve where different RλB = 0.05 thermal resistance values from 0.00 to 0.15 m2K/W are RλB = 0.10 shown. The curve shows that higher resistance gives a lower capacity. All constructions with embedded radiant qCN (RλB = 0.15) RλB = 0.15 emitter systems will have a surface resistance that has to be considered. In order to get the highest efficiency, the resistance value has to be as low as possible. ΔθCN Field of characteristic curves of a cooling system Pipe pitch, i.e. distance between the 45 pipes 40 The pipe pitch, i.e. the distance between the pipes in the embedded construction, not only has an influence 35 Thermal output q [W/m2] on the capacity, but also on how equal the surface 30 temperature is. This is especially important from a comfort perspective. 25 The diagram shows the capacity of a concrete floor 20 construction with =1.8 W/(mK), and with different kinds of surface material. The diagram illustrates the 15 variation of the capacity depending on the pipe pitch. A short distance between the pipes, gives a higher 10 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 capacity and vice versa. For a combined heating and Pipe spacing T [m] cooling system, it is recommended to use a relatively small distance 300 mm between the pipes, in order θm 15.5 °C, θm 18.5 °C, 14 mm parquet 14 mm parquet to utilise free cooling and maintain an even surface temperature. θm 15.5 °C, θm 18.5 °C, 7 mm parquet 7 mm parquet θm 15.5 °C, θm 18.5 °C, 10 mm tiles 10 mm tiles Floor surface temperature limit 20 °C Thermal conductivity in the construction The thermal conductivity in the construction has an For dry constructions, high performance material like effect on the system’s ability to distribute heating and heat distribution plates in aluminium or similar are used cooling in the thermal mass. A construction with a low to ensure optimal heating and cooling distribution. thermal conductivity requires a smaller pipe pitch, in order to obtain an equal surface temperature variation. UPONOR · FREE COOLING GUIDE 21
Radiant floor constructions and capacity Radiant floor systems are far more common than using a relatively short distance between the pipes, and ceiling or wall systems, and can be used for cooling and a surface material with a low thermal resistance. heating. A radiant floor system can be installed in wet In the figure below, an overview of the capacity in constructions using concrete and screed, and in dry the most common floor installations is shown with constructions with heat emissions plates. mean water temperatures of 15.5 °C and 18.5 °C A radiant floor has a cooling capacity of up to 42 W/m2 corresponding to supply temperatures of 14 °C and limited by a surface temperature of 20 °C. The most 17 °C with a T of 3 K over the emitter loops. Figures efficient installation is in a wet construction with con- are based on a room temperature of 26 °C and a surface crete or screed, because of its high heat conductivity, temperature of 20 °C. Surface material Surface material Tiles 10 mm, = 1.0 W/mK Wood 14 mm parquet, = 0.014 W/mK Cooling effect Cooling effect Cooling effect Cooling effect Floor Installation q [W/m2] q [W/m2] q [W/m2] q [W/m2] installation principle θm 15.5 °C θm 18.5 °C θm 15.5 °C θm 18.5 °C Wet floor 42 40 33 24 installation Installation integrated in 42 40 33 24 construction Installation on the 28 20 27 19 joists Dry floor 28 20 27 19 installation Installation 24 17 18 14 between the joists 22 UPONOR · FREE COOLING GUIDE
Radiant wall constructions and capacity Radiant wall systems are typically used as a supplement by a surface temperature of 17 °C, in order to be within to floor and ceiling emitter systems for rooms the limits of radiant asymmetry and to prevent draught. with a higher need for cooling/heating. Instead of In the figure below, an overview of the capacity of the dimensioning the floor or ceiling system according to most common wall systems is shown with mean water the room with the highest peak load, it can be designed temperatures of 15.5 °C and 18.5 °C corresponding according to the average and the peak room(s) can be to supply temperatures of 14 °C and 17 °C with a T supplemented with a wall emitter. of 3 K over the emitter system. Figures are based on a A radiant wall system will be limited by the architecture room temperature of 26 °C and a surface temperature and by the furnishing. Radiant wall systems have a of 20 °C . cooling capacity of up to 60 W/m2 (active area) limited Surface material Surface material Surface material Plaster 10 mm, = 0.7 W/mK Plaster 11 mm, = 0.24 W/mK Plaster 11 mm, = 0.23 W/mK Cooling effect Cooling effect Cooling effect Cooling effect Cooling effect Cooling effect Wall Installation q [W/m2] q [W/m2] q [W/m2] q [W/m2] q [W/m2] q [W/m2] installation principle θm 15.5 °C θm 18.5 °C θm 15.5 °C θm 18.5 °C θm 15.5 °C θm 18.5 °C Dry wall 45 32 installation Wet wall 60 45 installation Stud wall 42 34 installation UPONOR · FREE COOLING GUIDE 23
Radiant ceiling constructions and capacity Radiant ceiling systems are the most efficient systems attention has to be taken for adequate dew point for cooling, but can also be used for heating. Ceiling control. systems have originally been developed for office In the figure below, an overview of the capacity in environments, but are also available for residential the most common ceiling systems is shown, with constructions using wet plaster or dry gypsum panels. mean water temperatures of 15.5 °C and 18.5 °C Radiant ceiling systems have a cooling capacity of up corresponding to supply temperatures of 14 °C and to 97 W/m2. It is important to note that especially for 17 °C with a T of 3 K over the emitter system. Figures ceiling cooling, the surface temperature of the system are based on a room temperature of 26 °C and a surface is in peak often very close to the dew point. Special temperature of 16 °C. Surface material Surface material Surface material Plaster 10 mm, = 0.7 W/mK Plaster 11 mm, = 0.24 W/mK Plaster 11 mm, = 0.23 W/mK Ceiling Cooling effect Cooling effect Cooling effect Cooling effect Cooling effect Cooling effect Installation installation q [W/m2] q [W/m2] q [W/m2] q [W/m2] q [W/m2] q [W/m2] principle θm 15.5 °C θm 18.5 °C θm 15.5 °C θm 18.5 °C θm 15.5 °C θm 18.5 °C Wet ceiling 75 55 installation Dry ceiling 59 42 installation Suspended ceiling 97 67 installation Capacity diagrams Uponor offers a wide range of embedded emitter 3. Pipe pitch, i.e. centre distance between the pipes T systems adapted to different kinds of constructions in [cm] the floor, wall or ceiling. Whenever the choice of system 4. Difference between room temperature and mean has been selected, detailed diagrams can be used in water temperature θc. = θi - θc [K] order to make the planning of the capacity. The diagram and example on next page shows a floor construction 5. Recommended minimum surface temperature with the cooling and heating output of the emitter (20 °C) system. 6. Difference between room temperature and surface temperature θv - θr, m [K] Dimensioning diagram for cooling If three of the parameters above are known, the Analogue to dimensioning for heating, the following remaining parameters can be calculated using the parameters must be considered: diagram to the right. 1. Cooling effect of the radiant area qc [W/m2] 2. Thermal resistance in the surface construction RB [m2 K/W] 24 UPONOR · FREE COOLING GUIDE
100 T 15 T 20 T 25 K = 15 Ðθ Thermal output heating qH [W/m2] i =θ 80 T 30 H 80 Δθ Thermal output cooling qc [W/ m2] H 60 60 10 K 8K 40 40 6K 20 =4K 20 Δθ = θ Ðθ C i C 0 0 30 5 20 T 15 T 10 T T2 T T qH Δθ H,N Thermal resistance RB [m2 K/W] 0,05 cm W/m2 K 0,10 Heating 10 15 20 98,6 96,3 93,0 15,9 18,1 20,3 25 87,3 22,0 30 81,3 23,6 0,15 0 20 15 T 10 25 T T T 0,05 Δθ C,N Cooling T cm 10 qC W/m2 34,8 K 8 0,10 15 39,8 8 20 27,5 8 25 24,5 8 0,15 Dimensioning example for cooling Estimating the dimensioned supply water temperature θV, Ausl. Calculated: θr, m = i - 4.3 K Given: qc = 29 W/m² θr, m = 21.7 °C θi = 26 °C (O.K., as this is above the recommended RB = 0.05 m² K/W minimum surface temperature (20 °C) Chosen pipe pitch = Vz 15 θV, calc. = θi - θc - (θv- θR)/2 T: θv - θH = 2 K θV, calc. = 26 - 9 - 2/2 θV, calc. = 16 °C Read from the diagram: θc = 12 K θr, m - θi = 3.9 K Note: The required cooling effect can only be achieved to avoid condensation, a supply water controller such as if the median surface temperature and the dimensioned Uponor Climate Controller C-46 is needed. supply temperature are above the dew-point. In order UPONOR · FREE COOLING GUIDE 25
Regulation and control The purpose of a control systems is to keep one room control causes the room with the highest demand or more climate parameters within specified limits to determine the heating or cooling supply to a full without a manual interference. Heating and cooling zone, resulting in over temperatures and unnecessary systems require a control system in order to regulate high energy consumption. room temperatures during shifting internal loads and An individual room control system is much outdoor temperatures. Good control systems adapt preferable in order to meet room specific load variations to the desired comfort temperatures while minimising and individual comfort requirements. Due to high unnecessary energy use. variations in the individual room loads in low-energy In residential buildings two different types of controls buildings, an individual room control system is also principles are common; zone control and individual required to minimise the energy consumption. room control. The basic principle in an individual room control system In a zone control system, the temperature is is that a sensor measures the room temperature and controlled in a common zone consisting of several regulates the heating or cooling supplied to the space rooms and heating and cooling is supplied evenly to controlled in order to meet a user defined temperature the full zone. Not all national building codes allow set point. The most well-know examples are radiators zone control systems as they have major shortfalls with with thermostatic valves and underfloor heating systems comfort as well as energy consumption. with room thermostats. In low-energy buildings there will in particular be high In addition, room by room regulation provides the variations in the individual room heating and cooling possibility to shut down cooling in a specific room, such loads (see figure 5.2). This means that lack of individual as a bathroom or a room without cooling loads. Room 1 Living room Kitchen 18°C 21°C 21°C Room 2 Bedroom Bath 1 Room 3 Entrance Bath 2 18°C 21°C 22°C 21°C 20°C 22°C Typical desired temperature (set points) in a single family house. Typical variation between individual room heat demands in a low-energy house. 26 UPONOR · FREE COOLING GUIDE
The self-regulating effect in Functional description of underfloor heating Uponor Control System Radiant floor heating and cooling benefits from a Individual room control with traditional significant effect called ”self control” or “self regulating on/off functionality effect”. The self regulating effect occurs because the heat exchange from the emitting floor is proportional For a radiant floor heating and cooling system, the to the temperature difference between the floor and control is normally split up in a central control and the room. This means that when room temperature individual room controls. The central control unit is drifts away from the set point, the heat exchange will placed at the heat source. It controls the supply water automatically increase. temperature according to the outside temperature based on an adjustable heat curve. The individual room The self regulating effect depends partly on the control units (room thermostats) are placed in each temperature difference between room and floor surface room and controls the water flow in the individual and partly on the difference between room and the underfloor heating circuit by ON/OFF control with a average temperature in the layer, where the pipes are variable duty cycle. Its done according to the set-point embedded. It means that a fast change of the operative by opening and closing an actuator placed at the central temperature will equally change the heat exchange. manifold. Due to the high impact the fast varying heat gains (sunshine through windows) may have on the room Individual room control with DEM temperature, it is necessary that the heating system can technology compensate for that, i.e. reduce or increase the heat Uponor’s Dynamic Energy Management control output. principle is an advanced individual room system based Low-energy houses will largely benefit from the self on innovative technology and an advanced self learning regulating effect, because the temperature difference algorithm. Instead of a simple ON/OFF control, the between floor and room will be very small. A typical actuators on the manifold supplies the energy to each low-energy house has on average for the heating room in short pulses determined based on feedback season a heat load of 10 to 20 W/m² and for this size of from the individual room thermostats. heat load, the self regulating effect will be in the range Uponor Control System DEM is self learning and will of 30 - 90%. remember the thermal behavior of each room. This °C ensures an adequate and very accurate supply of 27 energy, which means better temperature control and = Floor surface temperature energy savings. 26 = Room temperature c cooling = -10.5 W/m2 Saved energy when 25 Higher using Uponor DEM technology Actuator on/off temperature + c 24 23 Thermostat set point 20 °C 22 b Uponor DEM Lost energy when technology 21 using Uponor DEM technology a Lower b heating = 13.9 W/m2 temperature - Time 20 a heating = 19.1 W/m2 19 Typical behaviour in a heavy floor construction, where Uponor Time DEM technology ensures that a minimum of energy is lost to the construction. Compared with traditional on/off regulation, saving Self-regulating effect. UFH/C outputs for different temperatures figures between 3-8% can be obtained. between room and floor surface. UPONOR · FREE COOLING GUIDE 27
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