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A low loss header is a crucial component in modern heating systems, designed to improve efficiency and performance. This guide will explore the intricacies of low loss headers, their benefits, and how they function within a heating system.
Low Loss Header, flanged 435kW, 4" insulated
Low Loss Header 420kW Low Loss Header with 4 flanged tapings DN16, insulated.
The whole technical info and sizes are available in the attached pictures.
Availability: Low stock
Dispatched within: 5 days
Low Loss Header, flanged 420kW, 3" insulated
ELTERM products are made of high-quality mild steel, manufactured in accordance with the highest testing and certification standards. All products are designed and welded to meet the strictest quality requirements.
.Our factory has over 30 years of experience in the heating industry. Throughout these years, we have developed and invented numerous products that have become widely used. We distribute these solutions across Europe and other continents, ensuring quality and innovation in every application.
Please note: We (Culm Stores Distribution Elterm Ltd) do not offer any products made of so-called "galvanized stainless steel." Our products are made from genuine materials that meet rigorous EU & BS safety and quality standards.
Low-Loss Header, also known as a Hydraulic Balancer, is designed to separate the boiler’s circulation from the heating system, suitable for medium to high-power systems (25 kW and above, ideal for an average house). It is used in setups with one or more boilers and various heating circuits, such as floor heating, radiators, or hot utility water. The LLH automatically manages flow separation, eliminating the need for manual balancing of pump flows. Its construction includes a desilter and air vent, offering additional benefits of system cleaning and air removal while protecting the boiler from low-temperature corrosion of the return water.
Operational Modes:
- When the heat requirement equals the boiler’s power, the system operates in balance.
- If the requirement is less than the boiler’s capacity (e.g., thermostatic valves are closed), some heat returns from the LLH, signaling the boiler to decrease output or switch off.
- If the requirement exceeds the boiler’s capacity, increased pump suction signals the boiler to produce more heat.
Features of the Low Loss Header SHE 3”:
- Max flow: 24 m³/h
- Max power: 420 kW
- Connectors: 4 x 3" DN80 Flanges
- Nominal pressure: 6 bar
- Max temperature: 110°C
- Capacity: 27.5 l.
- Vent and drain valves included
Advantages for investors:
- Up to 30% longer boiler service life through protection from low return water temperatures
- Enhanced operational comfort via system desiltering and aeration
- Up to 30% longer pump service life due to smooth, undisturbed operation
- Faster boiler reactions to changing demands
- Cost savings of up to 50% compared to traditional 3- or 4-way valves
Advantages for installers:
- No need for complex system regulation, thanks to automatic flow management
- Reduced claims caused by air locking or improper operation
Variants Available:
- SHE – LLH: Power range from 40 to 420 kW
- SHE-OC: Insulated with polyprene shell, power from 40 to 156 kW (up to 420 kW can be insulated with ROCKWOOL upon request)
Customer satisfaction benefits from reliable, efficient heating operation with less maintenance and fewer issues.
Availability: Low stock
Dispatched within: 5 days
Set of the low loss header 156W, 2" insulated + 2 way manifold 2" + 3 way manifold 2" (5 circuits)
2" 156kW Coated Low Loss Header + 3 Way insulated connecting manifold 2" with female threaded tapings + 2 way connecting manifold 2" (5 circuits).
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header, flanged 225kW, 2.5" insulated
ELTERM products are made of high-quality mild steel, manufactured in accordance with the highest testing and certification standards. All products are designed and welded to meet the strictest quality requirements.
Our factory has over 30 years of experience in the heating industry. Throughout these years, we have developed and invented numerous products that have become widely used. We distribute these solutions across Europe and other continents, ensuring quality and innovation in every application.
Please note: We (Culm Stores Distribution Elterm Ltd) do not offer any products made of so-called "galvanized stainless steel." Our products are made from genuine materials that meet rigorous EU & BS safety and quality standards.
Low-Loss Header, also called a Hydraulic Balancer, is designed to separate the boiler’s circulation from the heating system, suitable for medium- to high-power setups (from 25 kW up to 420 kW). It’s used with one or more boilers and supports various heating circuits like floor heating, radiators, and hot utility water.
Key Functions and Benefits:
- Flow Separation: Automatically divides flow, allowing boiler and system to operate independently without manual balancing.
- Additional Features: Equipped with a desilter and air vent, which aid in system cleaning and removing air, enhancing efficiency.
- Protection: Prevents low-temperature corrosion by maintaining appropriate return water temperatures.
Operational Modes:
- Heat demand = boiler output: System operates normally.
- Heat demand < boiler output (e.g., thermostatic valves closed): Part of the heat returns, signaling the boiler to decrease or switch off.
- Heat demand > boiler output: Pump suction increases, prompting the boiler to produce more heat.
Equipment Details:
Low Loss Header SHE 2.5" Flanges
- Max flow: 24 m³/h
- Max power: 420 kW
- Connectors: 4 x 2.5" flanges
- Nominal pressure: 10 bar
- Max temperature: 110°C
- Capacity: 19.7 liters
Advantages for Investors:
- Up to 30% longer boiler lifespan due to protection from low return water temperatures
- Increased comfort through system desiltering and aeration
- Up to 30% longer pump operation life
- Faster boiler response
- Up to 50% cost savings versus 3- or 4-way valves
- No system regulation needed
- Fewer system claims caused by air locking or improper operation
Variants Available:
- SHE – LLH: Power range from 40 to 750 kW
- SHE-OC: Insulated with PUR foam and leatherette; power from 40 to 156 kW (larger units up to 750 kW can be insulated with ROCKWOOL if requested)
- Summary:
This hydraulic balancer ensures efficient, reliable operation of heating systems, reduces maintenance, and prolongs equipment lifespan—offering long-term savings and peace of mind for system owners.
Availability: Low stock
Dispatched within: 48 hours
Set of the low loss header 115W, 2" insulated + 2 way manifold 2" + 3 way manifold 2" (5 circuits)
2" 115kW Coated Low Loss Header + 3 Way insulated connecting manifold 2" with female threaded tapings + 2 way connecting manifold 2" (5 circuits).
Availability: Low stock
Dispatched within: 48 hours
Set of the low loss header 100W, 1 1/2" insulated + 2 way manifold 1 1/2" + 3 way manifold 1 1/2" (5 circuits)
1 1/2" 70kW Coated Low Loss Header + 3 Way insulated connecting manifold 1 1/2" with female threaded tapings + 2 way connecting manifold 1 1/2" (5 circuits).
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 70kW, 1 1/4" PRO + 3 way, compact, insulated manifold 1 1/4" (no pump groups included in this set).
- Insulated, Low Loss Header up to 70kW with 4 x 1 1/4" tapings (can be used in systems with heating sources up to 70kW + 3 way compact, polyprene insulated compact manifold, ready to be connected to any other: 2 or three way, compact PRO manifolds. This set may be combined in many ways to create up to 8 circuits.
- All circuit distances (125mm between tapings) are ready to fix our pump groups.
- The whole set can be mounted horizontally only.
- Distances between 1" circuit tapings -125 mm
- Total length of the insulated manifold -770 mm
- Distance between main connecting tapings 1 1/4" -150 mm
- Distance form the bottom of the manifold to the top of the 1", circuit taping -315 mm
- The whole set consists of: Low Loss Header up to 70kW PRO, dedicated to 3 way compact manifold KRE 3D+
Connecting couplings 1 1/4"
Thermometer
Brackets
Polyprene insulation
Air vent & Drain valve
NO PUMP GROUPS AVAILABLE WITH THIS PARTICULAR SET
PLEASE NOTE: All pump groups that are shown in the picture are only meant to visualize possible uses with the set and do not necessarily represent the actual configuration or models you will be working with.
These visualisations simply showcase potential setups where the set my be applied.
Availability: Low stock
Dispatched within: 48 hours
Set of the low loss header 70W, 1 1/4"" insulated + 2 way manifold 1 1/4" + 3 way manifold 1 1/4" (5 circuits)
1 1/4"" 70kW Coated Low Loss Header + 3 Way insulated connecting manifold 1 1/4" with female threaded tapings (865 mm) length + 2 way connecting manifold 1 1/4" (605mm) length
- 2 way insulated manifold length (F) - 605mm
- 3 way insulated manifold length (F) - 865mm
- 1 1/4 couplings for the low loss header and manifolds - 100mm each.
- distance between ciruit tapings (1 zone) 125mm
- distance between zone 135mm
Availability: Low stock
Dispatched within: 48 hours
Set of the low loss header 40kW, 1" insulated + 2 way manifold + 3 way manifold 1"
1" 40kW Coated Low Loss Header + 3 Way insulated connecting manifold 1" with female threaded tapings + 2 way connecting manifold 1"
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 156kW, 2" + 3 way insulation manifold 2" -set
2" 156kW Coated Low Loss Header + 3 way, + 2 way insulated, connecting manifold with female threaded tapings.
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 70kW, 1 1/4" PRO + 2 way, compact, insulated manifold 1 1/4" (no pump groups included in this set).
The core of the set is the 70kW PRO Low Loss Header (4 x 1 1/4" tapings), paired with a 2-way compact, polyprene insulated manifold.
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 115kW, 2" + 3 way insulation manifold 2" -set
2" 115kW Coated Low Loss Header + 3 way + 2 way insulated, connecting manifold with female threaded tapings.
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 100kW, 1 1/2" + 3 way insulated manifold 1 1/2" -set
1 1/2" 100kW Coated Low Loss Header + 3 way insulated, connecting manifold with female threaded tapings.
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 156kW, 2" + 2 way insulation manifold 2" set
2" 156kW Coated Low Loss Header + 2 way insulated, connecting manifold with female threaded tapings 2"
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 115kW, 2" + 2 way insulation manifold 2"
2" 115kW Coated Low Loss Header + 2 way insulated, connecting manifold with female threaded tapings 2"
Availability: Low stock
Dispatched within: 48 hours
Low Loss Header 70kW, 1 1/4" + 3 way insulation manifold 1 1/4" -set
1 1/4" 70kW Coated Low Loss Header + 3 way insulated, connecting manifold with female threaded tapings.
Availability: Low stock
Dispatched within: 48 hours
What is a Low Loss Header?
A low loss header, also known as a hydraulic separator or low loss manifold, is a device used in heating systems to separate the primary and secondary circuits hydraulically. This separation allows for optimal flow rates in both circuits, ensuring efficient heat transfer and system performance.
The primary function of a low loss header is to create a point of hydraulic separation between the primary circuit (typically containing the boiler or heat source) and the secondary circuit (which distributes heat to various zones or appliances). This separation helps maintain constant flow rates in both circuits, regardless of variations in demand from the secondary circuit.
How Does a Low Loss Header Work?
The operation of a low loss header is based on the principle of low flow velocity within the header itself. As water flow enters the header from the primary circuit, it slows down significantly due to the increased cross-sectional area. This reduction in velocity allows for efficient mixing of hot water from different sources and helps prevent interference between the primary and secondary circuits.
The low loss header typically has four connections:
- Primary flow (from the heat source)
- Primary return (back to the heat source)
- Secondary flow (to the heating system)
- Secondary return (from the heating system)
Water flows through these connections in a way that maintains hydraulic separation between the circuits. The low flow velocity within the header ensures that there is minimal pressure loss across the device, hence the name "low loss header".
Benefits of Using a Low Loss Header
- Improved System Efficiency
By separating the primary and secondary circuits, a low loss header allows each circuit to operate at its optimal flow rate. This separation can lead to improved overall system efficiency, as the commercial boiler system or heat source can operate more effectively without being affected by fluctuations in the secondary circuit.
- Enhanced System Flexibility
Low loss headers enable the integration of multiple heat sources and secondary circuits into a single system. This flexibility is particularly useful in complex heating systems or those with varying heat demands, such as those incorporating underfloor heating alongside traditional radiators.
- Simplified System Design
The use of a low loss header can simplify the design and installation of heating systems, especially in cases where multiple boilers or heat sources are involved. It eliminates the need for complex balancing valves and allows for easier system expansion in the future.
- Improved Air and Dirt Separation
Many low loss headers incorporate features for air and dirt separation, which can help maintain system cleanliness and efficiency over time. This added functionality can reduce maintenance requirements and extend the lifespan of system components.
- Constant Flow Rate
By maintaining constant flow rates in both circuits, a low loss header helps ensure stable and predictable system performance. This stability can lead to improved comfort for building occupants and reduced wear on system components.
When to Use a Low Loss Header
Low loss headers are particularly beneficial in the following scenarios:
- Systems with Multiple Heat Sources
When integrating multiple boilers or different types of heat sources (e.g., boilers and heat pumps), a low loss header can help manage the varying flow rates and temperatures effectively.
- Systems with Variable Secondary Demands
In heating systems with multiple zones or varying heat demands, a low loss header can help maintain stable primary circuit operation while accommodating fluctuations in the secondary circuit.
- High-Capacity Systems
Large-scale heating systems, such as those found in commercial or industrial buildings, often benefit from the use of low loss headers due to their ability to manage high flow rates and complex distribution networks.
- Systems Requiring Future Expansion
If there's a possibility of future system expansion or modification, incorporating a low loss header can make these changes easier to implement without significant disruption to the existing system.
Sizing and Installation Considerations
Proper sizing and installation of a low loss header are crucial for optimal performance. The header should be sized based on the maximum flow rate of the primary circuit, ensuring that the flow velocity within the header remains low enough to maintain hydraulic separation.
When installing a low loss header, consider the following:
- Positioning: The header should be installed vertically, with the primary flow connection at the top and the primary return at the bottom.
- Insulation: Proper insulation of the header and connecting pipework is essential to minimize heat loss and maintain system efficiency.
- Air Venting: Ensure that an automatic air vent is installed at the top of the header to remove any trapped air from the system.
- Dirt Separation: If the low loss header doesn't include built-in dirt separation, consider installing a separate dirt separator to maintain system cleanliness.
- Flow Direction: Pay close attention to the flow direction indicators on the header to ensure correct installation and optimal performance.
- Accessibility: Install the low loss header in a location that allows for easy access for maintenance and future modifications.
FAQ
How to calculate low loss header size?
Calculating the size of a low loss header involves considering the maximum flow rate of the primary circuit. The general rule is to size the header so that the flow velocity within it remains below 0.2 m/s. To calculate:
- Determine the maximum flow rate of the primary circuit in m³/h.
- Use the formula: Area = Flow Rate / (Velocity × 3600)
- Calculate the diameter using the area.
For example, if the maximum flow rate is 5 m³/h: Area = 5 / (0.2 × 3600) = 0.00694 m² Diameter = 2 × √(Area / π) = 0.094 m or 94 mm
Always round up to the nearest standard size and consult manufacturer guidelines for specific recommendations.
Is a buffer tank better than a low loss header?
Both buffer tanks and low loss headers serve important functions in heating systems, but they are not directly interchangeable. The choice between the two depends on the specific requirements of your system:
Low Loss Header:
- Provides hydraulic separation between both circuits
- Maintains constant flow rates
- Ideal for systems with multiple heat sources or variable secondary demands
- Takes up less space than a buffer tank
Buffer Tank:
- Stores thermal energy to reduce boiler cycling
- Provides a larger volume of water for system stability
- Can help manage heat pump systems more effectively
- Useful in systems with low water content or high temperature fluctuations
In some cases, using both a low loss header and a buffer tank can provide optimal system performance.
Is a hydraulic separator the same as a low loss header?
Yes, a hydraulic separator is essentially the same as a low loss header. These terms are often used interchangeably in the heating industry. Both devices serve the same primary function of providing hydraulic separation between the both circuits in a heating system.
Other terms that may be used to describe this component include:
- Low loss manifold
- Hydraulic break
- Hydraulic switch
- Decoupler
Regardless of the term used, the fundamental principle and function remain the same: to create a point of low flow velocity that allows for efficient hydraulic separation and optimal system performance.