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You're a busy little bee, plumbing wise, aren't you?
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Yup...I am remodeling our entire basement, and so, have most of the walls and some of the ceiling ripped out. I figure this would be the time to do any and all upgrades I want while I have access.
My house is pretty much just a long box, with the main living area upstairs, and the garage underneath the front half. The other half is basement that was finished by previous owners, years ago. The kitchen plumbing is directly above one of the garage doors, so access to the plumbing there is easy. The water heater is a straight shot to the aft of the house, so running the return line will require going through the half of the lower section I am currently remodeling.
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But isn't that what you're trying to get away from? The long wait for hot water to the sink?
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I've decided that if I do this I will most likely go ahead and run the 1/2" return. If for no other reason it would just bother me too much not to do it correctly. But for arguments sake, and I hope you won't mind me making this argument, I agree that having the smaller return line would take longer for the heated water to arrive at the pump, but it's not like I would be standing there waiting for it. It would already be there because that's what the pumps job is for...to have the heated water ready at the faucet when you turn it on. The delay in the time that it would take the heated water to arrive at the pump would happen when the faucet is off and not being used, so what difference would it make, other than the extra work load that it would place on the pump. I agree with you on that point, which is another reason why I've decided not to do it.
But, the user, standing at the faucet, would not notice anything different, other than the water would be immediately hot when they turned on the faucet, because the pump had already pumped the heated water to that point. Yep, it took the pump twice as long to get it there using the 1/4" return line, but nobody noticed that because it happened while they weren't looking, so to speak.
Ok, I know a bit about volume and preessures from my occupation and training, but I'm not a plumber, so maybe I'm all wrong here, but this is just my take on it from what I know. I don't know what kind of pressures these pumps work at so maybe the back pressure that the 1/4" line would create would cause other complications rendering the system inoperative. Theoretically, it seems it should work. But I don't believe I'll waste the money to find out.
Cheers...Randy