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2011

Recirculation system

How a water heater recirculation system works
Hot water recirculation system
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Hot water re-circulation system with timer turned off

Cold water available immediately, but wait for hot water.

Water- savings estimate of 15,000 gallon per year is promotional foolery: this amount equals 41 gallons per day or 2 full bathtubs of water per day.

Test your home: put empty gallon can under tub spout and see how much water is wasted waiting for hot water. Use water for plants.
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Re-circulation system
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Re-circulation system with timer turned on.

Hot water available, but wait for cold water.

Timer saves energy compared with recirculation system that runs full time.
Autocirc uses timer, but also turns off when temperature reaches 95, and turns on when water drops to 85.
For product info:
1) Search 'AutoCirc'
2) Search 'Recirculation system'
3) Call local plumbing supply
4) Auto circ at Amazon
Choose between 'Timed' operation or 'Thermostatic' operation using slide switch located below timer dial.
For Thermostat operation, slide switch to ON.
For Timed operation, slide switch to Timer.
To turn off the system, slide switch to OFF
General guide for setting timer
Timer or thermostat?
The timer will save money.
While thermostat operation runs throughout the day.

 See larger
Direct return connects to water heater drain port.
Add valve so water heater can be drained/flushed periodically
Read how to remove drain valve
Add air vent to keep air out of line will prolong life of pump



Re-circulation install/ maintenance tips
Troubleshoot recirculation pump
How much does it cost to operate recirculation pump?
Using the timer and running Autocirc 1 hour a day costs between $11 and $17 per year to operate.
Run autocirc 2 hours a day is $22-34 per year.
Run 12 hours a day costs $11-17 per month, or $132-204 per year.
This includes pump operation and additional time that water heater operates. See calculations

Grundfos circulation timerLarger image
Grundfos installation manual
General guide for setting timer


Autocirc timer dial
Larger Autocirc image
Auto circ installation manual
Keep Water Heater Temperature Below 140ºF (60ºC): Higher temperatures can cause calcium and magnesium
elements to come out of solution and create solids which could not only cause damage to the pump but also reduce water heater efficiency and premature failure of the water heater.
How to adjust temp of water heater
Taco 265-3
Larger
Taco 265 DIGI timer
DIGI cross reference w/ FM1D
DIGI 240V manual
Grasslin DIGI series product sheet

At Plumbersurplus

Recirculation in tank
See entire Auto-circ system
Grundfos website
Grundfos assorted manuals

Grundfos service and repair information
Terminal strip and capacitor replacement/ pdf
Sample manuals below:
UP-018
UP-043 installation photos
UP-042
UP-053
UP-035
UP-092
Choose pump size sheet

Laing AutoCirc Pump residental selection guide
Laing ACT install operation manual
Laing E1 E3 E10 series installation
Laing E1 Replacement Parts


Taco recirculation pumps manual
Taco.com
Taco timer sell sheet
Taco analog/digital timer install/program manual
Taco timer image

Troubleshoot recirculation pump
Grundfos product list
Grundfos 24 hour programmable clock
Grundfos clip-on thermostat control

Grundfos contact us
Will recirculation pump work on Tankless heater?
Yes if you select correct recirculation pump.
   Tankless water heaters require minimum flow rate to activate burner, so more powerful recirculation pump is needed.
Laing UCT-909 Tankless AutoCirc is used for Tankless At Amazon  Product Sell Sheet and specs
Grundfros RCP-96 Recirculation pump for Tankless 145 psi.; 0-25 GPM At Faucet Depot

   Read tankless manual thoroughly for minimum flow rate since flow rate appears in every tankless troubleshooting section.
   Flow rate and performance figures apply only when Tankless unit is new.
   Tankless cannot be exposed to hard water or parts will fail.
   As tankless ages, expect problems that are difficult to diagnose and expensive to repair.
   Re-circulation pumps are also susceptible to hard water and affects of age.

Read Bradford White side-by-side tankless vs tankless test results: "Tankless falls short of payback and cannot be exposed to hard water.'
Read ConsumerReports.org side-by-side test results
Read Common problems with tankless water heaters
Pro-n-con tankless heater
Read research pdf on Tankless/Tank efficiencies and softened water: Tankless cannot be exposed to hard water or parts fail 2 years.
Hot water slow to arrive at faucet
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Typical faucet has 2 gpm (gallon per minute)
Typical tub spout has 2-1/2 gpm

Faucet can fill one gallon container in 30 seconds.

2gpm water flow, in 30 seconds hot water will travel a distance of 83' along 1/2 pipe.

If single handle faucet is lifted in center, then equal amounts of hot and cold water will flow, so distance is 41' along each 1/2 pipe.

Low hot water pressure
Hot water options > for localized sink
hot water dispenser Pot heater
Immersion heater
Objective: now guests can stay in the barn
Put 120V electric heater in bucket of water > makes 150° hot water



Insinkerator Hot Water Dispenser
Objective: save water, save energy
Point of use hot water
Kohler, Sunbeam, Franke, KitchenAidPanasonic Others
Pot heater
Objective: Fill pot for hot water at any sink
12" tall heater heats plugs into 115V outlet
Dispenses 2-3 liters hot water into cup or sink
Use switch or timer
Hubbell point of use
Objective: save water and money 
115 Volt, 2-1/2 Gallon point of use heaters available at most home centers
Connect heater to cold water line
Use switch or timer
Chilipepper
How to install gas water heater

How to clean water heater

Troubleshoot electric water heater


Programmable water heater timer on wall
Demand pump: D'MAND
Taco.com
Objective: Water circulates to faucet quickly when activated
Demand pump: Chilipepper
Objective: Water circulates to faucet quickly when activated 
Check if Demand Pump gets hot. I have not checked this. Advertised as 1/3 HP implying 230Watts ... which is same as having 2-100 Watt light bulbs under sink near flammable materials. Also advertised as 60 psi, question if supply tubes will hold up long-term. Read comparison
Anode rods

How much does it cost to operate Autocirc?
Using the timer and running Autocirc 1 hour a day costs between $11 and $17 per year to operate.
Run autocirc 2 hours a day is $22-34 per year.
Run 12 hours a day costs $11-17 per month, or $132-204 per year.
This includes pump operation and additional time that water heater operates.
Calculate cost of running recirculation system
Autocirc is 33 watts each time motor operates
Timer runs 2 half-hour periods per day > yearly cost for re-circulation is $11-17 at Today's Rates

Two factors affect cost:
1) Pump cost: Pump uses approx 30 Watts = .030 Kw
Pump runs 1 hour per day = .030 Kwh per day
365 days x .030 Kwh = 10.95 Kwh per year
10.95 Kwh x Todays Rate 10¢ per Kwh (expect 30¢ tomorrow)= $1.95 per year

2) Water heater cost from re-heating water:
Amount of water: 1.2 gallons per 100 ft 1/2'" pipe (see calculation to right)

Amount of wasted heat:
Hot water travels to faucet anyway, so waste equals return length of pipe
Exact calculation would factor insulation, temperature of water, effect of home HVAC, efficiency of water heater, water heater thermostat setting, cost of energy.

Additional water heater Cost: Reheating 1-2 gallons uses .2 Kwh of electricity per event See chart
2 events per day x .2 Kwh  x 365 days per year = 146 Kwh per year
146 Kwh x 10¢ per Kwh = $15 per year for electric heater, $9 for gas

So $9-15 per year for reheating + $2 to run pump = $11-17 per year for re-circulation system that runs 1 hour per day assuming new equipment and optimal conditions, and today's low energy prices.

Read more
Calculate gallons inside 100' pipe:
1 gallon = 231 cu inches
Inner diameter of 1/2 pipe .54" so r radius = .27"
Area = πr²

A = 3.14 x .27 x .27 = .229 sq in
100 ft = 1200 in
1200 in x .229 sq in = 274 cu in
274 cu in
÷ 231 cu in per gallon = 1.2 gal

3/4" pipe: r radius .37"
A = 3.14 x .37 x .37 = .429 sq in
100 ft = 1200 in
1200 in x .429 sq in = 514 cu in
514
cu in ÷ 231 cu in per gallon = 2.2 gal
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