Headers play a crucial role in hydronic HVAC systems by distributing flow between circuits. Learn how header design affects stability, temperature control and overall energy performance.
Headers are more than simple connection points — they determine how flow, pressure and temperature are shared between multiple branches. Poorly designed headers can create unintended shortcuts, cause uneven distribution or distort temperature regimes.
A well-structured header ensures circuits operate independently, stabilises flow behaviour and prevents pumps or valves from compensating for hydraulic problems created upstream.
In heating applications, the header influences how hot water is divided across different zones or branches. Configurations such as those shown in header configuration heating illustrate how the arrangement of supply and return lines shapes the temperature regime and pressure distribution.
If the header geometry is incorrect, the system can experience:
Proper placement and sizing ensure each branch receives stable flow without forcing the pump into inefficient operating regions.
Cooling systems face similar hydraulic challenges but are more sensitive to temperature mixing and unintended recirculation. The layouts in header configuration cooling show how header structure affects return temperature and chiller efficiency.
Because cooling ΔT is typically narrower than heating ΔT, even minor mixing at the header can degrade performance. Stable flow separation is therefore critical to ensure coils receive water at the correct temperature and that chiller lift is not increased unnecessarily.
Effective header design aims to separate circuits hydronically while maintaining predictable pressure relationships. Key considerations include:
When integrated correctly into the hydraulic network, headers simplify control, maintain stable temperatures and support more efficient operation of pumps, boilers and chillers.
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