Free cooling guide

C O O L I N G I N T E G R AT I O N I N LO W -
ENERGY HOUSES

01 | 2013
 Table of contents

1. Introduction to the concept of free cooling ...3
The need for cooling in low-energy houses.............4
Comfort and energy efciency the best t
for low-energy houses ............................................4
Investing for the future the design of a
low-energy house ...................................................5
2. Cooling loads in residential buildings .............6
Factors inuencing the sensible cooling load ..........6
Factors inuencing the latent cooling load .............7
The effect of shading ..............................................7
Room variation .......................................................8
Duration of the cooling load ..................................8
Required cooling capacity .......................................9
6. Free cooling in combination with
different heat sources ....................................19
7. Choosing and dimensioning the radiant
emitter system ................................................20
Capacity of different radiant emitter systems ........20
Radiant oor constructions and capacity ..............22
Radiant ceiling constructions and capacity ...........24
Capacity diagrams .................................................24
Regulation and control..........................................26
The self-regulating effect in underoor heating ..27
Functional description of Uponor Control
System .................................................................27
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 ux density...................................................13
Dew point management parameters and
Thermal transfer coefcient ..................................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 prole...................................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
temperatures are used for cooling purposes in buildings.
This guide presents a free cooling concept based on
a ground coupled heat exchanger combined with a
radiant heating and cooling system. A ground coupled
heat exchanger can for example be horizontal collectors,
vertical boreholes or energy cages. A radiant system
means that the oors, ceilings or walls have embedded
pipes in which water is circulated for heating and
cooling of the building. Under oor heating and cooling
is the most well know example of a radiant system.
A radiant system combined with a ground coupled heat
exchanger is highly energy efcient and has several
advantages. In the summer period, the ground coupled
heat exchanger provides cooling temperatures that are
UPONOR FREE COOLING GUIDE
lower compared to the outside air. The radiant system
operates with large surfaces, which means it can utilize
the temperatures from the ground directly for cooling
purposes. The result is that free cooling can be provided
with only cost being the electricity required for running
the circulation pumps in the brine and water systems.
No heat pump is required.
In the heating season the system is operated using a
heat pump. As the ground temperature during winter
is higher compared to the outside air temperature,
the result is improved heat pump efciency (COP)
compared to an air based heat pump. In addition, the
radiant emitter a system (under oor heating) operates
at moderate water temperatures in large surfaces which
further improves the heat pump COP.
3

The need for cooling in low-
energy houses
Today, there is a high focus on saving energy and
utilising renewable energy sources in buildings.
The energy demand for space heating is reduced by
increased insulation and tightness of buildings.
However, increased insulation and tightness also
increase the cooling demand. The building becomes
more sensitive to solar radiation through windows and
becomes less able to remove heat in the summer. More
extreme weather conditions further contributes to the
cooling needs and together with an even more increased
consumer awareness of having the right indoor climate,
the need for cooling also in residential buildings will
become a requirement. Optimal architectural design
and shading will help to reduce the cooling need, but
Comfort and energy efciency
the best t for low-energy
houses
Using shading will help to reduce the cooling demand.
However, this forces occupants to actively pull down the
shades e.g. when leaving the house. Also, shading will
block daylight which increases electricity consumption
on articial light, and shading will block the view which
may not be in the interest of the home occupant.
In fact many architects state that energy efciency
and comfort may conict when dening comfort in a
broader sense, such as the freedom to design window
sizes, spaciousness with increased ceiling height,
daylight requirements and the occupants tendency to
utilise open doors and windows. All such requirements
put increased demands on the HVAC applications.
Ground heat exchangers combined with radiant systems
is the only all-in-one solution, with the ability to
provide both heating and cooling. Such systems are
more cost efcient and simpler to install than having
to deal with a separate heating and cooling systems.
4 UPONOR FREE COOLING GUIDE
simulations and practical experience show that such
measures alone will not eliminate the cooling need.
Space cooling is needed, not only in the summer, but
also in prolonged periods during spring and autumn
when the low angel of the sun gives high solar radiation
through windows. In order to meet the energy frame
requirements of the building regulations, space cooling
can be provided by utilising renewable energy sources
such as ground heat exchangers for cooling purposes in
conjunction with a radiant system with embedded pipes
in the oor, wall or ceiling.
Cooling needs will differ between rooms and are highly
inuenced by direct solar radiation. Rooms with larger
window areas and facing the south will generally have
higher cooling requirements. In periods with high
cooling loads, active cooling is normally required during
both day and night time.
Furthermore, radiant systems are able to heat at a
low supply temperature and cool at a high supply
temperature. This ts perfectly to the typical operating
temperatures of a ground coupled heat exchanger.
Furthermore, the connected heat pump will be able
to run more efciently and thereby consume less
electricity. In addition, a radiant system provides no
draught problems and provides an optimal temperature
distribution inside a room. Last but not least, radiant
systems provide complete freedom in terms of interior
design, as no physical space is occupied inside the room.
Even more important when looking at the lifetime and
property value of a house, such systems have very low
maintenance need and a lifetime that almost follows
the lifetime of the building itself. In todays uncertain
environment of future energy prices, free cooling and
ground coupled heat pumps provides a high stability
on the future energy costs of the building in question.
It will most certainly meet todays and future building
regulations even in a scenario where future property
taxation would be linked to energy efciency. Hence, it
is an investment that helps to maintain and differentiate
the future property value.
 Investing for the future the
design of a low-energy house
A radiant system, e.g. underoor heating and cooling,
coupled to a ground source heat pump, provides
optimal comfort with high energy efciency 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 efcient, 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 efcient 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 efciency 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 gure above shows the correlation between

5
property prices and the energy efciency 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 efciency ratio (ESEER) for different cooling
systems. ESEER is dened by the Eurovent Certication 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 inuencing 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 gure above, heat gains can come from Direct and indirect sunshine through windows,
external sources, e.g. solar radiation and inltration 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 inltration 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 inuencing 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: efcient 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 inltration through cracks in the building, doors,
shading. The gures 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
inltration through the building envelope/ventilation.
The gure 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 gures above, even with the

most efcient shading factor, the cooling load still
Heat from air ows 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
oors (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 gures 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 signicant 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 oor 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 gures 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 oor surface temperatures. These factors can
inuence 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 dissatised (PPD)
and predicted mean vote (PMV). PMV/PPD basically
The PPD predics the number of thermally dissatised
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

Dissatised [%]

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 dissatised. The reason
PMV for the different target temperatures is because that the
two seasons apply different clothing conditions as can
be seen in below gure:
PMV Predicted mean vote
PPD Predicted percentage dissatised [%]
Metabolic rate:
Predicted Percentage of

+3 Hot 1.2
Dissatised [%]

+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 gure below, the radiant asymmetry
differs depending on the location of the emitter system,
and whether its 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).
Dissatised

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

t (wall-room)
0.2
3.0 K 7.0 K Local discomfort caused by warm and cool oors
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 underoor heating
2,5
systems as the preferred emitter system, because of the B

perceived comfort of walking on a warm oor. Similarly, 2

the question is if the occupants complaint about discom-

1,5
fort when utilising the oor to remove heat (cooling). A

0 9 18 27 36 45 54 63 [F] 0,5
80
60 0
40 Warm ceiling Cool wall 2 4 6 8 10
Dissatised [%]

20 T oor surface room

Cool ceiling Warm wall
10
Correlation between the temperature difference oor surface to room
8 and the vertical air temperature difference (Deli, 1995).
6

The study concludes that up to a T 8K, the comfort

2
1
0 5 10 15
Radiant temperature asymmetry [C]
According to ISO 7730, the lowest PPD (6%) is found
at a oor temperature of 24 C. A typical oor cooling
system will have to operate with a minimum oor
temperature of 20 C, where the expected PPD would
still be under 10%. As will be seen later, such oor
temperatures still provide a signicant cooling effect,
due to the large surface area being emitted.
Vertical air temperature
category is still A. This would equal a oor temperature
20 25 30 35
of 20 C and a dimensioned room temperature of
[C]
28 C. The dimensioned room temperature must be
below 26 C and similarly above a oor temperature
of 20 C in order to reach comfort class B. Hence, the
vertical air temperature difference will in practice not
cause a indoor climate below category A.
As the pictures below show, different emitter systems
provide different temperature gradients in a room.
Clearly, a radiant heating system in the oor provides
a temperature gradient closest to the ideal. Similarly,
a radiant cooling system in the ceiling provides a
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 oor level and at a height equivalent to
a seated person. As can be seen below, the temperature
difference must be under 2C in order to reach
category A.
18 20 22 24 26
Vertical air temperature difference a [C]
Category C Ideal heating Underoor heating
Radiant ceiling heating External wall radiator heating
A <2
B <3 Vertical temperature prole with different emitter systems

C <4
a) 1,1 and 0,1 m above oor

A study done by Deli in 1995 shows the correlation

between the T oor surface/room (difference between
the oor surface temperature and the dimensioned
room temperature) and the vertical air temperature
difference.
18 20 22 24 26
[C]

Radiant oor Radiant ceiling Radiant wall

cooling cooling cooling

Temperature prole radiant cooling

12 UPONOR FREE COOLING GUIDE

4. Capacity and limitations of radiant emitter
systems

All emitter systems, whether it is pure air-based, Thermal transfer coefcient

radiators or pure radiant systems, are bounded by their
ability to transfer energy. The capacity of any radiant
emitter systems is limited by the heat ux density, which
differs depending on the location of the emitter, i.e.
oor, wall or ceiling. The heat ux density can be used
to calculate the capacity of the emitter, also known as
the thermal transfer coefcient. Specically regarding
cooling, any radiant emitter will need to work within the
dew point limitations in order to avoid moisture on the
surface and within the construction.
The thermal transfer coefcient is an expression of how
large an effect per m2 the surface is able to transfer to
the room, per degree of the temperature difference
between the surface and the room. The gure below
shows the thermal transfer coefcient for different
surfaces for heating and cooling respectively.
[W/m2K] Surface heating and cooling
15

Thermal transfer coefcient

Heating

Heat ux 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 ux density. According to EN 1264/EN 15377,
the values below can be used to express the heat ux
0
density. Ceiling
Floor Wall

Due to natural convection, the oor provides the

Floor heating, ceiling cooling: q = 8.92 (s,m - i)1.1 best thermal transfer coefcient for heating while the
Wall heating, wall cooling: q = 8 (| s,m - i |) ceiling provides the best thermal transfer coefcient for
Ceiling heating: q = 6 (| s,m - i |) cooling.
Floor cooling: q = 7 (| s,m - i |)
Dew point limitations
Where In order to secure that there is no condensation on the
q is the heat ux density in W/m 2 surface of the emitter in the room the supply water
temperature should be controlled so that the surface
s,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
i 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 specied embedded radiant cooling
according to the dew point. The dew point is dened 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 dened 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 oor 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 gure
room temperature recommendation is that it should not below.
exceed more than 14 K. For standard conditions (26 C,
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 signicantly reduced. Hence, the
The capacity and mean water temperature for radiant
biggest capacity can be achieved by heating from the
oor cooling depends on the oor construction, pipe
oor, and cooling from the ceiling. In practice, either
pitch and surface material. To have the highest possible
a oor system or a ceiling system is installed and used
capacity of the system you should design your oor
for both heating and cooling. A oor 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, specic 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 dene the capacity of a ground heat
better performing ground heat exchanger than sand or
exchanger. The dimensioning has a signicant impact
clay.
on the energy efciency 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 grounds 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
between horisontal and vertical collectors. These can be
further classied as follows:
Horisontal:
Horisontal or surface collectors
Energy cages
Vertical:
Boreholes
Energy piles and walls
Horisontal collectors
Collectors installed horisontally or diagonally in the
upper ve meters of the ground (surface collector).
These are individual pipe circuits or parallel pipe
registers which are usually installed next to the building
and in more rare cases under the building foundation.
Boreholes
Collectors installed vertically or diagonally in the
ground. Here one (single U-probe) or two (double
U-probe) pipe runs are inserted in a borehole in
U-shape or concentrically as inner and outer tubes.
16
The suitability of the different collectors depends on the
environment (soil properties and climatic conditions),
the performance data, the operating mode, building
type (commercial or private), the space available and
the legal regulations.
Energy cages
Collectors installed vertically in the ground. Here, the
collector is arranged in a spiral or a screw shape. Energy
cages are a special form of horisontal collectors.
Energy piles
Collectors build into the pile foundations that are
used in construction projects with insufcient load
capacity in the ground. Individual or several pipe runs
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 lled with concrete. Most often energy
piles are used for larger commercial buildings.
UPONOR FREE COOLING GUIDE
Ground temperature prole
The gure below shows a generic temperature prole in
the ground for each season during the year.
Temperature (earths surface) [C]
0 5 10
0
5 summer period. A combined use for heating and cooling
Depth in soil [m]
10
15
20
0 5 10
Temperature (depth) [C]
The closer to the ground surface, the higher the
inuence from the outside temperature and solar
radiation. Hence not surprisingly, the highest
temperatures are found in late summer and the
lowest temperatures in late winter. The reason for the
temperatures being higher in late autumn than late
spring, has to do with the grounds ability to store
energy. After a warm summer period, the ground
remains relatively warm during the autumn. Ground
temperatures stabilize below 10-15 m. It is clear from
these ground temperature proles that the cooling
capacity is higher below 15 m. Hence vertical collector
systems provides a better cooling capacity than
horisontal collector systems.
Primary supply temperatures
The temperatures mentioned in the previous section
are often referred to as the undisturbed ground
temperature. Depending on the thermal resistance
between the collector and the surrounding ground, the
temperature of the uid in the collector will be higher
than the surrounding ground.
UPONOR FREE COOLING GUIDE
Dimensioning of ground heat
exchangers for free cooling
The rst thing to decide is whether the ground heat
exchanger shall be used for heating only or for both
15 20
heating and cooling. As demonstrated in this guide,
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
also balances of the ground temperature during the
year and leaves the ground environment undisturbed.
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
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.
Dimensioning for the heat load should be done based
15 20
on the peak load for space heating plus the domestic
hot water need. As a heat pump is used for covering
the heat load, the COP of the heat pump on the
coldest day (design day) should be applied in the
design calculation. In addition to this, the specic
characteristic of the chosen heat exchanger and the
thermal conditions in the ground must be taken into
account.
Dimensioning for the cooling load should be done
based on valid information of the maximum cooling
load in the building. Free cooling operates without a
heat pump. It is therefore vital that the thermal capacity
of the ground heat exchanger is able to fully cover the
max cooling load (no COP is included). In residential
buildings in Northern Europe the cooling need will
normally be covered with the capacity derived from
the heating requirements. But a design check is always
recommended.
In special cases in residential buildings and typically in
ofce buildings, the cooling need will be dominant and
thus the design driver. In such case vertical collectors
are normally recommended as the deeper ground
temperatures are sufciently stable and independent of
surface temperature and solar radiation. If a horizontal
system is chosen, the space requirements can be a
capacity limitation. Designing for inadequate cooling
capacity on the warmest summer days may then
be necessary compromise, but should be evaluated
carefully.
17
 Dimensioning examples
In order to dimension ground heat exchangers cer-
tain information has to be considered. First of all an
estimation of the physical properties of the ground is
needed. Normally its possible to obtain local ground
data (thermal conductivity etc.) from local databases
or authorities. The gures below show the capacity for
different collectors.

*) 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 dened, the ow can be different from the physical properties of pure water.
calculated. When using ground collectors, the water The table below shows the required ow of often used
used has to be mixed with anti-frost liquid. Hence, brines for providing different cooling capacity.
the specic 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
ow 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 inuence. 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 ow 0.38 l/s, 1.37 m3/h

0
0 0.5 1 1.5 2 2.5 3
Diameter of collector 32 mm
Rate of ow [m3/h]

18 UPONOR FREE COOLING GUIDE

6. Free cooling in combination with dierent heat
sources
The illustrations below shows a ground heat exchanger
combined with a radiant system in heating mode and
cooling mode. In this example a ground sourced heat
pump is providing heating to domestic hot water
(DHW), space heating, and for heating up the incoming
ventilation air. This could of course be utilized with
other heat sources such as boilers or district heating.
Free cooling is provided through a special pump and
exchanger group (see chapter 8) that supplies cold
water/brine from the ground heat exchanger directly to
the radiant emitter system and possibly the incoming
ventilation air. In cooling mode, the heat pump will only
be active for domestic hot water generation.
Heating mode, the free cooling is deactivated
UPONOR FREE COOLING GUIDE
As one can see from the grey connection lines the pump
and exchanger group is not active in heating mode.
Similarly, the connection lines from the heat pump (or
any other heat source) to the emitter systems are in-
active in cooling mode.
If a boiler or district heating system is used as heating
source, the ground heat exchanger will only work during
cooling (also known as a bivalent system). If a ground
source heat pump is used as heat source, the ground
ground heat exchanger will work both during heating
and during cooling (also known as a monovalent
system).
Cooling mode, the free cooling is activated
19
 7. Choosing and dimensioning the radiant emitter
system

Embedded emitters are the key to any radiant system. the oor has the highest heating efciency, but with a
In order to have an energy efcient and comfortable lower cooling efciency.
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 oor, 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 efciently than others. The most
cooling. This secures a heating/cooling system with
efcient cooling system is placed in the ceiling, but the
high energy efciency and optimal conditions for the
heating efciency 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 inuence 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 oor
construction, the performance of the radiant system can
be optimised by choosing the right construction, pipe
Example: oor construction
layout and surface material.

20 UPONOR FREE COOLING GUIDE

 Y = Specic thermal output qc [W/m2]
Thermal resistance in the surface X = Temperature difference between
construction room and cooling medium [c K]

The thermal resistance in the surface construction has a

RB = 0
big inuence on the performance of the emitter. In the
qCN (RB = 0)
diagram, an example of a cooling curve where different RB = 0.05
thermal resistance values from 0.00 to 0.15 m2K/W are RB = 0.10
shown. The curve shows that higher resistance gives a
lower capacity. All constructions with embedded radiant
qCN (RB = 0.15) RB = 0.15
emitter systems will have a surface resistance that has to
be considered. In order to get the highest efciency, the
resistance value has to be as low as possible.

CN

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 inuence 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 oor

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 m 15.5 C, m 18.5 C,
14 mm parquet 14 mm parquet
to utilise free cooling and maintain an even surface
temperature. m 15.5 C, m 18.5 C,
7 mm parquet 7 mm parquet

m 15.5 C, m 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
effect on the systems ability to distribute heating and
cooling in the thermal mass. A construction with a low
thermal conductivity requires a smaller pipe pitch, in
order to obtain an equal surface temperature variation.
For dry constructions, high performance material like
heat distribution plates in aluminium or similar are used
to ensure optimal heating and cooling distribution.

UPONOR FREE COOLING GUIDE 21

 Radiant oor constructions and
capacity
Radiant oor systems are far more common than
ceiling or wall systems, and can be used for cooling and
heating. A radiant oor system can be installed in wet
constructions using concrete and screed, and in dry
constructions with heat emissions plates.
A radiant oor has a cooling capacity of up to 42 W/m2
limited by a surface temperature of 20 C. The most
efcient installation is in a wet construction with con-
crete or screed, because of its high heat conductivity,
using a relatively short distance between the pipes, and
a surface material with a low thermal resistance.
In the gure below, an overview of the capacity in
the most common oor installations is shown with
mean water temperatures of 15.5 C and 18.5 C
corresponding to supply temperatures of 14 C and
17 C with a T of 3 K over the emitter loops. Figures
are based on a room temperature of 26 C and a surface
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
m 15.5 C m 18.5 C m 15.5 C m 18.5 C

Wet oor
42 40 33 24
installation

Installation
integrated in 42 40 33 24
construction

Installation on the
28 20 27 19
joists

Dry oor
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 oor 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 gure below, an overview of the capacity of the
dimensioning the oor 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 m 15.5 C m 18.5 C m 15.5 C m 18.5 C m 15.5 C m 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 efcient systems
for cooling, but can also be used for heating. Ceiling
systems have originally been developed for ofce
environments, but are also available for residential
constructions using wet plaster or dry gypsum panels.
Radiant ceiling systems have a cooling capacity of up
to 97 W/m2. It is important to note that especially for
ceiling cooling, the surface temperature of the system
is in peak often very close to the dew point. Special
attention has to be taken for adequate dew point
control.
In the gure below, an overview of the capacity in
the most common ceiling systems is shown, with
mean water temperatures of 15.5 C and 18.5 C
corresponding to supply temperatures of 14 C and
17 C with a T of 3 K over the emitter system. Figures
are based on a room temperature of 26 C and a surface
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
m 15.5 C m 18.5 C m 15.5 C m 18.5 C m 15.5 C m 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 oor, 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 c. = i - c [K]
order to make the planning of the capacity. The diagram
and example on next page shows a oor 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 v - r, 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

Thermal output heating qH [W/m2]

=
80 T 30 H
80

Thermal output cooling qc [W/ m2]

H

60 60
10 K

8K
40 40

6K

20 =4K 20
=
C
i C

0 0
30 5 20 T 15 T 10
T T2 T T qH 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
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 V, Ausl. Calculated: r, m = i - 4.3 K
Given: qc = 29 W/m r, m = 21.7 C
i = 26 C (O.K., as this is above the recommended
RB = 0.05 m K/W minimum surface temperature (20 C)
Chosen pipe pitch = Vz 15 V, calc. = i - c - (v- R)/2
T: v - H = 2 K V, calc. = 26 - 9 - 2/2
V, calc. = 16 C
Read from the diagram: c = 12 K
r, m - i = 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
or more climate parameters within specied limits
without a manual interference. Heating and cooling
systems require a control system in order to regulate
room temperatures during shifting internal loads and
outdoor temperatures. Good control systems adapt
to the desired comfort temperatures while minimising
unnecessary energy use.
In residential buildings two different types of controls
principles are common; zone control and individual
room control.
In a zone control system, the temperature is
controlled in a common zone consisting of several
rooms and heating and cooling is supplied evenly to
the full zone. Not all national building codes allow
zone control systems as they have major shortfalls with
comfort as well as energy consumption.
In low-energy buildings there will in particular be high
variations in the individual room heating and cooling
loads (see gure 5.2). This means that lack of individual
Living room Kitchen
21C 21C
Bedroom Bath 1 Room 3
21C 22C 21C
Typical desired temperature (set points) in a single family house.
26
room control causes the room with the highest demand
to determine the heating or cooling supply to a full
zone, resulting in over temperatures and unnecessary
high energy consumption.
An individual room control system is much
preferable in order to meet room specic load variations
and individual comfort requirements. Due to high
variations in the individual room loads in low-energy
buildings, an individual room control system is also
required to minimise the energy consumption.
The basic principle in an individual room control system
is that a sensor measures the room temperature and
regulates the heating or cooling supplied to the space
controlled in order to meet a user dened temperature
set point. The most well-know examples are radiators
with thermostatic valves and underoor heating systems
with room thermostats.
In addition, room by room regulation provides the
possibility to shut down cooling in a specic room, such
as a bathroom or a room without cooling loads.
Room 1
18C
Room 2
Entrance Bath 2
18C
20C 22C
Typical variation between individual room heat demands in a
low-energy house.
UPONOR FREE COOLING GUIDE
The self-regulating effect in
underoor heating
Radiant oor heating and cooling benets from a
signicant effect called self control or self regulating
effect. The self regulating effect occurs because the
heat exchange from the emitting oor is proportional
to the temperature difference between the oor and
the room. This means that when room temperature
drifts away from the set point, the heat exchange will
automatically increase.
The self regulating effect depends partly on the
temperature difference between room and oor surface
and partly on the difference between room and the
average temperature in the layer, where the pipes are
embedded. It means that a fast change of the operative
temperature will equally change the heat exchange.
Due to the high impact the fast varying heat gains
(sunshine through windows) may have on the room
temperature, it is necessary that the heating system can
compensate for that, i.e. reduce or increase the heat
output.
Low-energy houses will largely benet from the self
regulating effect, because the temperature difference
between oor and room will be very small. A typical
low-energy house has on average for the heating
season a heat load of 10 to 20 W/m and for this size of
heat load, the self regulating effect will be in the range
of 30 - 90%.
C ensures an adequate and very accurate supply of
27
= Floor surface temperature
26
= Room temperature
c cooling = -10.5 W/m2
25
c
24
23
22
b Uponor DEM
21
a Lower
b heating = 13.9 W/m2
20
a heating = 19.1 W/m2
19
Time
Self-regulating effect. UFH/C outputs for different temperatures
between room and oor surface.
UPONOR FREE COOLING GUIDE
Functional description of
Uponor Control System
Individual room control with traditional
on/off functionality
For a radiant oor heating and cooling system, the
control is normally split up in a central control and
individual room controls. The central control unit is
placed at the heat source. It controls the supply water
temperature according to the outside temperature
based on an adjustable heat curve. The individual room
control units (room thermostats) are placed in each
room and controls the water ow in the individual
underoor heating circuit by ON/OFF control with a
variable duty cycle. Its done according to the set-point
by opening and closing an actuator placed at the central
manifold.
Individual room control with DEM
technology
Uponors Dynamic Energy Management control
principle is an advanced individual room system based
on innovative technology and an advanced self learning
algorithm. Instead of a simple ON/OFF control, the
actuators on the manifold supplies the energy to each
room in short pulses determined based on feedback
from the individual room thermostats.
Uponor Control System DEM is self learning and will
remember the thermal behavior of each room. This
energy, which means better temperature control and
energy savings.
Saved energy when
Higher using Uponor DEM technology Actuator on/off
temperature
+
Thermostat set
point 20 C
Lost energy when
technology
using Uponor DEM technology
temperature -
Time
Typical behaviour in a heavy oor construction, where Uponor
DEM technology ensures that a minimum of energy is lost to the
construction. Compared with traditional on/off regulation, saving
gures between 3-8% can be obtained.
27
 Zone control
When using zone control for a radiant oor heating
and cooling system, the central controller is normally
placed at the heat source. It controls the supply water
temperature according to the outside temperature
based on an adjustable heat curve. The manifold system
has no actuators and normally the system works at a
constant ow with temperature regulation based on
a reference thermostat is placed in one of the main
rooms.

I-76

C-46

C-46

C-56
C-56
230 V AC C-56

230 V AC

H-56 T-54 T-55

M
T-75
24 V DC
M

230 V AC M

Simple zone control, the central controller provides a regulated supply Individual room control, the central controller provides a regulated
temperature based on the outdoor/indoor temperature. supply water temperature based on the outdoor/indoor temperature and
the room thermostat controls the room temperature by using actuators.

28 UPONOR FREE COOLING GUIDE

8. Uponor Pump and exchanger group (EPG6) for
ground sourced free cooling

The Uponor Pump and exchanger group, EPG6,
is designed for a separate cooling supply and
temperature control for ground source free
cooling. The EPG6 is pre-mounted and ready
to install in the installations. Together with
the Uponor ground collectors it is ready
to provide free cooling for radiant emitter
systems.
The EPG6 can be integrated in HVAC
installations for applications a separate supply
of cooling needs to be provided through a
heat exchanger (e.g. from a ground collector).
The EPG 6 is controlled by Uponor Climate
Controller C-46, which is able to adjust the
secondary temperature supplied to the emitter
system and interact with the Uponor Control
System used to control the emitter system.
Uponor Climate Controller C-46 is also able to
control the temperature according to the dew
point, in order to prevent condensation.
The primary side of the system is driven by
a circulation pump, to circulate the uid
in the brine circuit and a 3-way mixing
valve for controlling the primary ow, in
order to maintain the correct temperature
on the secondary side. The exchanger that
exchanges the brine from the ground circuit
with the water in the emitter system is
designed for a capacity up to 6 kW.

Secondary circlet,
to emitter system

5
7

8
Component overview

3 Primary side
4
The primary side of the system (ground collector) is
connected to the EPG6 and will work as the heat sink.
2 The mixing valve (1) will adjust the ow of the primary
10
9 side and is controlled by the Uponor Climate Controller
C-46 (10), which opens and closes the valve to the
adjusted supply temperature on the secondary side
1 measured by the supply sensor (7). The primary pump
(2) will circulate the uid in the brine circuit through
11 the exchanger (4) and will shut down when there is no
request from the secondary control system. The lling
Primary side, ground collector and air valve (3) is used to ll up the primary system
or other cooling supply
with brine. Connection to an expansion tank and safety
valves can be done on the connection valve (9).
1 3 way mixing valve Kvs 7 m3/h
2 Primary circulation pump Grundfos Alpha 2L 26-60
3 Filling and air valve G
Secondary side
4 Heat exchanger 6 kW SWEP ESTH x 40/1P-SC-S 4 x The secondary ball valves (5 and 6) are shutting down
5 Ball valve with integrated check valve and thermometer Rp 1
the secondary side of the system, and have a ball
6 Ball valve with integrated thermometer Rp 1
valve (5) including a check valve to prevent backow
7 Sensor pocket (supply)
8 Blind piece 180 mm G 1 for secondary circulation pump in the system. The blind piece (8) can be replaced
9 Filling valve G by a circulation pump, if no other pump is used for
10 Uponor Climate Controller C-46 the secondary side. The secondary pump has to be
11 Primary connection Rp 1 connected to the Uponor Climate Controller C-46 (10).

UPONOR FREE COOLING GUIDE 29

 Dimensions
360 230
Rp 1 Rp 1 80

580

Rp 1 Rp 1
125

Pump diagram
Available pressure for the primary circuit

50

40
Pressure loss [kPa]

30
CP2

20
CP1

10

0
0 0.5 1 1.5 2 2.5 3
3
Flow rate [m /h]

30 UPONOR FREE COOLING GUIDE

Control principle Primary control cooling
The primary control of the cooling system is provided by
Controls is required for the primary system as well as the the EPG6 which includes the Uponor Climate Controller
secondary system. C-46 that manages:
Since the primary control of the heating mode is the supply temperature of the system
separated from the primary control of the cooling mode,
the change-over between heating and cooling must pump management of primary and secondary
be dened. This can be done either automatically if a pumps
communication interface can be setup between the change-over between heating and cooling
Uponor Climate Controller C-46 and the heat source or
through a manual switch if it is not possible to setup a dew point management with up to six wireless dew
communication interface. point sensors (Uponor Relative Humidity Sensor
H-56)
Because a radiant emitter system can act for both
heating and cooling, the secondary system can be In order to eliminate the
controlled by one system as described below. risk of condensation on the
emitter surface, dew point
Secondary control heating and cooling management is an essential
part of the cooling system.
For the secondary control of the emitter system, The relative humidity sensors
Uponor recommends to apply individual room control, measure the relative humidity
in order to provide energy efciency and comfort. The and the temperature in the
individual control system also secures that cooling can room, and Uponor Climate
be deactivated in single rooms/zones, e.g. in bathrooms Controller C-46 uses the data
where cooling might not be required. The Uponor to calculate the dew point.
Control System offers a long range of benets for the Thereby, it is able to secure
user and can be integrated with the primary controller that the supply water temperature never gets too low,
for cooling, Uponor Climate Controller C-46. and that no condensation will occur on the emitter
surface.

H-56 T-54 T-55 T-75

C-56 I-76

UPONOR FREE COOLING GUIDE 31

 Hydraulic change-over between heating
and cooling
Uponor recommends using a diverting valve in the
secondary heating/cooling distribution system, which
opens and closes when changing between heating and
cooling. The diverting valve is controlled by the Uponor
Heating mode
In heating mode, the free cooling system is deactivated.
Hence, no pumps are running and the diverting valve is
closed (the ow goes straight through).
32
Climate Controller C-46 either directly through a 24 V
actuator or through a relay for a 230 V actuator. The
diverting valve is activated by the change-over signal
between the heating and cooling modes.
Cooling mode
In cooling mode, the free cooling system is activated.
Hence, pumps are running and the diverting valve is
open. An internal circuit is secured for the heat source
for producing domestic hot water.
UPONOR FREE COOLING GUIDE
Installation examples

Brine to water heat pump with Uponor EPG6

The system diagram illustrates a Uponor free cooling
installation using a ground collector and Uponor EPG6
in combination with a brine to water heat pump for
space heating and domestic hot water.
The EPG6 (3) is connected to a Uponor ground collector
(1) on the primary side of the free cooling installation. If
more than one ground loop is installed, a manifold can
be used to connect the ground loops.
The secondary side of the EPG6 is connected to the
heating pipe system before the manifold of the radiant
system (4).
A diverting valve (7) is used to switch the ow direction
in the hydraulic system between heating and cooling
(diverting valve to open when cooling is activated).
When switching between heating and cooling, the heat
pump must be in a position where it only produces
domestic hot water (typically summer mode can be
used).
The Uponor Climate Controller C-46 can send an
external signal to the heat pump when switching
between heating and cooling or it can be done
manually with a relay switch. Contact the heat pump
manufacturer in order to check the possibilities.

6
TW

7 3

1 Ground collector 6 Domestic hot water tank

2 Brine to water heat pump 7 Diverting valve

3 Uponor EPG6 with Uponor Climate Controller C-46 8 Non return valve

4 Radiant emitter system 9 Secondary circulation pump

5 Buffer tank

UPONOR FREE COOLING GUIDE 33

 Condensing boiler with Uponor EPG6
The system diagram illustrates a Uponor free cooling
installation using a ground collector and Uponor EPG6
in combination with a gas/oil boiler for space heating
and domestic hot water.
The EPG6 (3) is connected to a Uponor ground
collector (1) on the primary side of the free cooling
installation. If more than one ground loop is installed, a
manifold can be used to connect the ground loops.
The secondary side of the EPG6 is connected to the
heating pipe system before the manifold of the radiant
system (4).
A diverting valve (7) is used to switch the ow direction
in the hydraulic system between heating and cooling
(diverting valve to open when cooling is activated).
2
5
1 Ground collector
2 Condensing boiler
3 Uponor EPG6 with Uponor Climate Controller C-46
4 Radiant emitter system
34
When switching between heating and cooling, the boiler
must be in a position where it only produces domestic
hot water (typically summer mode can be used).
The Uponor Climate Controller C-46 can send an
external signal to the boiler when switching between
heating and cooling or it can be done manually with a
relay switch. Contact the boiler manufacturer in order to
check the possibilities.
In the example below, a solar collector is supporting the
boiler for space heating and domestic hot water but is
not interacting with the cooling system.
8
M
5 Solar tank
6 Solar panel
7 Diverting valve
8 Secondary circulation pump
UPONOR FREE COOLING GUIDE
Free cooling with Uponor EPG6

The system diagram illustrates a Uponor free cooling
installation using a ground collector and Uponor EPG6
as a stand-alone system.
The EPG6 (3) is connected to a Uponor ground
collector (1) on the primary side of the free cooling
installation using the same supply line as to the heat
pump. If more than one ground loop is installed, a
manifold can be used to connect the ground loops.
The secondary side of the EPG6 is connected to the
heating pipe system before the manifold of the radiant
system (4).
Please note that a circulation pump (180 mm) has to be
added to the EPG6 in order to circulate the secondary
circuit. There is a blind piece on the EPG6 that can be
replaced with a pump.
The activation of the EPG6 cooling module can be
done automatically through the Uponor Climate
Controller C-46 included in the EPG6 or through
another external signal through the climate controller.

1 Ground collector (or bore hole)

2 Uponor EPG6 with Uponor Climate Controller C-46
3 Radiant emitter system

UPONOR FREE COOLING GUIDE 35

 Operation of Uponor Climate
Controller C-46
Uponor EPG6 is delivered integrated with Uponor
Climate Controller C-46. It is important that the settings
and parameters are programmed to t the designed
system. A detailed user manual describes all settings
and parameters.
Wizard great installation guide
When Uponor Climate Controller C-46 is started for
the very rst time, it guides the installer to make the
necessary primary settings of the system. Wizard helps
you step by step through the installation process. On
the display, the installer can read all about the set-up
and what to do next. The installation wizard is also
started after changing or resetting the operation mode.
Quick menu gives easy access to basic settings
Made for end-users: The quick menu consists of a series
of screens easily accessible from the Uponor screen.
These screens display readings for daily use. If the
Uponor Climate Controller C-46 is set to installer access
level, it is also possible to modify some parameters.
Main menu all informations and settings on the
whole
The main menu and all its sub-menus are used for
displaying any accessible information, parameter
settings, and selecting operating modes that are
accessible in the system.
36
Operation mode of Uponor
Climate Controller C-46
Two possible operation modes for cooling are described
below. The most typical operation mode of Uponor
Climate Controller C-46 is heating and cooling mode
when the controlled radiant system is used for both
heating and cooling emitter. In the case where a radiant
ceiling or wall system is installed purely for cooling
purposes, the operation mode is set to cooling mode.
This could apply to an example where cooling is needed
in an energy renovated house with radiators.
Operation mode heating and cooling of
Uponor Climate Controller C-46
When having a combined heating and cooling system
where you change between heating and cooling, the
climate controller always have to be in heating and
cooling mode, even though the climate controller is not
used as the primary controller for heating.
Operating mode
Heating
Heating and cooling
Cooling
Uponor > Main menu > Control settings > Advanced control > Operation
mode. Note that the startup wizard will start when changing mode.
Heating min./max. supply Uponor
Climate Controller C-46
In the case of combined heating and cooling system,
where you can change between heating and cooling,
the climate controller C-46 must always be set to
Heating and cooling mode, even when the climate
controller is not used as primary controller for heating.
In this case the heating setting in the climate controller
must be neutralized as follows:
Min./max supply
Min Max
5.0 C 8.0 C
Uponor > Main menu > Control settings > Heating > Min./max supply
OK, also covered in startup wizard.
UPONOR FREE COOLING GUIDE
Cooling mode only
Dew point margin
If the system works as a stand alone cooling system
without any change over between heating and cooling,
cooling mode is chosen: 1

Operating mode Uponor > Main menu > Control settings > Cooling > Dew point

Heating The functions require Uponor Relative Humidity

Heating and cooling Sensor H-56 and can handle up to six sensors, placed
Cooling in different rooms/zones. The sensor mode function
allows to decide which value to use in the dew point
Uponor > Main menu > Control settings > Advanced control > Operation calculation. It can be set as an average or maximum
mode. Note that the startup wizard will start when changing mode. value of the sensor. For cooling application, it is always
recommended to use the maximum sensor mode.
Dew point management
parameters and settings
Sensor mode
In the operation mode cooling, indoor compensated
supply with dew point control will help you to prevent Average
condensation problems if the actual condition in the Maximum
room/zone is different from the design criteria.
The supply water set point is referring to the design
Uponor > Main menu > Control settings > Cooling > Sensor mode
supply temperature of the system, and is the absolute
minimum temperature that the Uponor Climate
Controller C-46 will provide. The supply temperature
Resulting supply water temperatures
should be set according to the design of the emitter The dew point control is activated if the cooling supply
system, taking into account the limitations factors, such setpoint is below the calculated dew point. The function
as surface temperature and dew point. overrules the cooling supply setpoint, and automatically
adapts the temperature according to calculated dew
point based on the measured room temperature and
Supply setpoint humidity of the room/zone. The resulting supply water
temperature is the calculated dew point + the dew point
margin.
14.0 C
Uponor Climate Controller C-46 calculates the dew
point using data from Uponor Relative Humidity Sensor
H-56, i.e. relative humidity and temperature. It is
Uponor > Main menu > Control settings > Cooling
displayed in the quick menu.
The function also allows using a dew point margin as
an extra safety to compensate for having the variation
in room conditions, occupation of the room, etc. The Calculated dew point
dew point margin can be adapted to the installation.
A smaller margin will improve the cooling power, while
18.3 C
a larger margin will reduce the risk of condensation.
The installation needs to be checked after startup and
re-conguration. If condensation occurs, the dew point
margin must be increased.

UPONOR FREE COOLING GUIDE 37

 Heating and cooling change-
Bus master
over: external signal
Indoor and outdoor
When having a combined emitter system for heating Supply water temp.
and cooling, the change-over between heating and General purpose input
cooling system can be managed by Uponor Climate
Controller C-46 or through it. The climate controller Uponor > Main menu > Control settings > H/C switchover > Bus master
has several options for how to switch between heating
and cooling. The most common is to use the general
purpose input (5 and 6) in the climate controller, to
General purpose output
control that the system should switch from heating to
cooling. The general propose input is a contact sensing Inactive
input that can be connected to a relay in the heat H+C commands
source or a manual switch. The heating and cooling Fault signalling
change-over behavior needs to be congured in Uponor
Climate Controller C-46. The hydraulic change-over with Uponor > Main menu > General settings > General purpose output >
the diverting valve is managed by the general purpose Mode
output (11 and 12) that sends out a free signal using a
dry contact output. Heating and cooling change-
over: Uponor Climate Controller
Reset
C-46
1 2 3 4 5 6 7 8 9 10 11 12

1
2A
24VAC/DC
G H I J K L
Change-over between heating and cooling can also
C-56

230 V 5 6 be handled by Uponor Climate Controller C-46, either

V ~ 50 Hz

0-10V
+ - N L
230 V ~
automatically using the indoor-outdoor temperature
24 V 2A
L
N
50 Hz
controlled switch-over, or a manual command. When
230 V ~

the change over from the climate controller is activated,

5
the hydraulic change-over with the diverting valve is
managed by the general purpose output (11 and 12)
4 that sends out a potential free signal. At the same time,
3 2
the same signal can be used through a relay to send a
1 Heat pump signal to the heat source. The automatic change-over
2 Pump indoor, outdoor and trigger parameters have to be
3 Diverting valve
4 Actuator 24 V
selected in the climate controller, as well as the function
5 Relay (e.g. Uponor 1000517) of the general purpose output.

Contact closing output from the best source or from manual switch. The
supplier of the heat source will be able to give guidelines of which signal
is available.
Reset
1 2 3 4 5 6 7 8 9 10 11 12

Activating the general purpose output needs to be 2A

24VAC/DC
1 G H I J K L
C-56

congured in Uponor Climate Controller C-46. 230 V 5 6

V ~ 50 Hz

+ - N L
0-10V 230 V ~
24 V 2A
L
N
50 Hz

H/C switchover 230 V ~

Bus master
Bus slave
No bus 2

230 V
Uponor > Main menu > Control settings > H/C switchover 1 Heat pump 4
3
2 Pump
3 Diverting valve
4 Actuator 24 V
5 Relay (e.g. Uponor 1000517)

The heat source must be able to receive potential free signal, i e sense a
dry contact closure. The supplier of the heat source will be able to give
guidelines of which signal is available

38 UPONOR FREE COOLING GUIDE

 The secondary pump can also be connected through
H/C switchover the Uponor Climate Controller C-46, but the pump relay
has a limit of 100 W for the primary and the secondary
Bus master
pump. The primary pump has a maximum consumption
Bus slave of 45 W. Hence, 55 W is left for the secondary pump.
No bus An alternative is to connect the secondary pump to the
secondary controller, i.e. Uponor Controller C-56.
Uponor > Main menu > Control settings > H/C switchover

Bus master
Indoor and outdoor 1 2 3 4 5 6
Reset
7 8 9 10 11 12
Supply water temp.
General purpose input 2A
24VAC/DC

C-56
Uponor > Main menu > Control settings > H/C switchover > Bus master 230 V 5 6

General purpose output DEM

Inactive
H+C commands
Fault signalling

Uponor > Main menu > General settings > General purpose output >
Mode

Pump management EPG6

The EPG6 is equipped with a Grundfoss circulation Pump management
pump Alpha 2L 25-60 for circulation of the primary
Internal control
brine circuit. The pump is powered up through the
Uponor Climate Controller C-46 and prepared for pump Bus control
management. The actuator for the three-way mixing Always on
valve is also powered by the climate controller and
connected to the control signal. The signal adjusts the Uponor > Main menu > Control settings > Advanced control > Pump
management
valve and secures the correct supply temperature using
the supply sensor which is also pre-installed in the
EPG 6.
In order to get the correct operation of the mixing
valve, motorised valves have to be selected in Uponor
Climate Controller C-46. The pump management also
has to be selected in the climate controller and in order
to get optimal control, bus control is selected. The bus
control will react on the secondary control system and
the pump will stop if there is no demand to the zones.

UPONOR FREE COOLING GUIDE 39

2012-12-18_UK Production: Uponor AB, IC/EL, Virsbo; Sweden

Uponor Corporation
www.uponor.com

Uponor reserves the right to make changes, without prior notication, to the specication of
incorporated components in line with its policy of continuous improvement and development.