What is a Low Loss Header? In this guide we'll reveal their pros and cons, how to use one, alternatives & more.
Are you wondering what a low loss header is?
Or do you just need to know where you can buy one? Or perhaps you simply want to know how it works.
Whatever the case, we’ve got you covered with our low loss headers guide.
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What is a Low Loss Header?
For this section, we’ll define a low loss header and discuss how exactly it works.
Defining a Low Loss Header
A low loss header is essentially a large box/tube with water that can be fitted outside a boiler.
It is a means of hydraulically separating a boiler primary circuit from secondary system circuits.
As a result, it can improve the boiler’s efficiency and performance while also regulating the flow rate and pressure.
How Low Loss Headers Work
Looking a bit more at its functioning, the chamber within a low loss header establishes a shortcut from the flow to return pipework.
Should a boiler featuring an internal pump make use of a low loss header, nearly all the water being pumped through will make its way back to the boiler.
This will minimize water flowing into the system. As a result, the boiler’s system pump may be installed on the opposite end of the header.
The system pump can operate in a similar way with very limited disruption occurring to the boiler side of the low loss header.
Not only can low loss headers be used for multiple pumps, but they may also be used to connect various boilers and heat sources to just one system.
Some low loss headers with a slightly more complex design can be used to enable differing flow and return temperatures of a range of heat sources.
This is possible thanks to what are called baffle plates. These plates divert the lowest returns to the ideal heat sources as a way of maximizing energy efficiency and the effectiveness of the boiler.
As you can see different low loss headers work in somewhat different ways. Always read the manufacturer’s guidance for a specific low loss header to understand aspects such as how it works and how it’s installed.
Pricing of Low Loss Headers
You may be more concerned with the cost of a low loss header or/and where you can buy one.
In this section, we’ll explore these two topics. Please note that only a qualified professional should install a low loss header.
How Much Does One Cost?
The average standalone cost of purchasing a low loss header is around £150 to £500. However, some can cost closer to £1,000.
The exact price will depend on the quality and brand of the product as well as the type and perhaps complexity of the design.
With the installation process likely taking an hour or two, you can expect to pay somewhere between £60 and £120 in labour costs.
This would cover the fees necessary for a certified heating engineer to install a low loss header, bringing the total cost between labour and supplies to around £200 to £600.
Where to Buy a Low Loss Header
Thankfully some boiler brands such as Viessmann sell their own brand low loss headers. Otherwise, you should consider a boiler/heating product supplier such as Mr Central Heating and Culm Stores.
If you can’t find the right low loss header for your boiler or you don’t know what one you even need to buy, it’s best to get in touch with your boiler manufacturer for guidance.
You may also want to consider asking a qualified professional to source the low loss header for you as well as install it. This could save you plenty of hassle and if you have any doubts, it can provide assurance that the correct product will be purchased.
Benefits of Low Loss Headers
You may still be wondering whether a low loss header is actually worth the cash. Why spend a few hundred pounds on one?
Well, as discussed, low loss headers can improve performance, efficiency and the regulation of pressure and the flow rate.
Beyond that, a low loss header lets suspended particles of dirt fall to the bottom of the unit. In addition, small air bubbles will separate from the water flow, rising to the top of the low loss header.
The larger a low loss header is (and therefore the slower the flow process is), the more effective it will be at separating air and dirt from the water flow.
But that’s not all. A low-velocity filter can even collect non-magnetic dirt such as brass, tin, copper and lead.
This would even apply potentially to particles of steel and iron since these elements can see a loss in magnetism over a prolonged duration due to traditional system corrosion. This would only apply, however, if the header is vertical rather than horizontal.
Downsides of Low Loss Headers
Since we’ve laid out the advantages of low loss headers, it’s only fair that we also discuss the disadvantages.
First and foremost, it’s important that a low loss header is properly insulated. If it isn’t then it poses a risk of being a large undesired radiator. However, if it is insulated correctly, the main con of low loss headers is certainly their cost.
Another issue that might arise from the process of hydraulic separation is distortion.
This is when higher temperatures are needed at the boiler as a means of getting the emitters (e.g., radiators or/and underfloor heating) to an appropriate temperature should the flow rates differ on either end of the low loss header. And the thing is, they almost always do differ.
Higher temperatures can, in turn, result in a loss of a small percentage of energy efficiency. Distortion risk may be reduced with the correct low loss header and the right sort of installation.
Aside from the legalities involved, reducing the risk of distortion is another key reason for a competent and qualified engineer to install a low loss header.
If not installed by such professional, other issues that can arise are slow cylinder loading times and insufficient emitter temperatures and as a result insufficient room temperatures.
Distribution Headers and Why You Might Want to Use One
A fluid distribution header features a drain on one end with an inlet on the other. It also features multiple outlets along its sides. These headers are generally made from a section of a pipe/bar that comprises threaded or welded end connections.
Having a distribution header installed is an easier way of connecting lots of circuits to a low loss header without the use of non-return valves or zone valves (both of which have more potential to fail).
It will also allow individual pumps to perform the same in any system scenario without allowing for reverse circulation.
In addition, a distribution header may be the same size as the low loss header. This would practically make the entire fitting into a large sideways H shape header.
This can further increase performance and simultaneously reduce the number of moving parts. Obviously, the key disadvantages of adding a distribution header are that it will use up more space and increase your installation bill.
Ultimately, this may not be the best option for most properties but if you have extra cash to spend you may want to consider it.
If you run a sizeable commercial premise, it may be worth the money either way. A distribution header, as with a low loss header must be installed by a competent and qualified professional.
How to Avoid Using a Low Loss Header
You may decide that a low loss header is right for you. However, if you’d rather not spend the time and money on having one installed, there are ways of improving your boiler such that having a low loss header wouldn’t be necessary to meet your heating goals.
First and foremost, you want to get the right calculations. One common issue is homeowners having a CHS installed that significantly exceeds their heating requirements.
Overestimating your heating and hot water needs can leave you with unrealistic flow rate estimates. This can substantially increase your calculated system loss.
If you get your calculations right, however, then you can have a much more accurate idea as to whether a low loss header would be worth the money.
The issues to consider would be a high flow rate requirement, that there are multiple heat sources in your property, or if the high resistance across the boiler bump/system is not sufficient enough.
If you are doubtful as to how much of a benefit a low loss header would bring (and therefore what its value for money is), it’s worth consulting with a professional.
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