Viega/vanguard Pex Radiant Heat

Transcript

Revised July 2005 INSTALLATION INSTRUCTIONS HYDRONIC RADIANT HEATING SYSTEMS Congratulations on the selection of Vanguard’s Vanex® PEX (cross-linked polyethylene) tubing and components for your Hydronic Radiant Heating System installation. This installation guide is presented to assist installers, designers and code officials in the quality installation and inspection of a Vanguard Radiant Heating System. This installation guide relates specifically to PEX tubing and components supplied by Vanguard Piping Systems, Inc. and is not applicable to tubing or components from other manufacturers. To assure the successful and quality installation of a Vanguard Hydronic Radiant Heating System, it is important that those doing the installation read and understand this guide, fully. Since many hydronic heating systems are literally “cast in concrete”, and must endure a very long service life, it is very important that the PEX tubing is not damaged during installation or by further construction activity after installation. PEX tubing is a durable product; however, nails, staples, shovels and other sharp objects or tools can damage it. Damage that compromises the integrity of the tubing can lead to premature failure and is costly to repair. Exercising a reasonable amount of care during the installation process and making other trades aware of the presence of the tubing will help insure that the PEX tubing will perform without incident for decades to come and will probably outlast the structure. The key to the flawless performance of any radiant floor heating system relies heavily upon proper planning. Each system must be properly designed for the particular structure and the system must be installed in accordance with that design. A radiant floor heating system cannot cure a heating problem in a poorly insulated or uninsulated building. Since radiant floor systems operate at relatively low temperatures, are limited to the available floor area and are difficult to modify after installation, the heating system must be designed to provide the required heat-load of the building or supplemental heat must be a part of the design. This guide contains no significant heat-load design information. However, Vanguard’s Hydronic Radiant Heating Design Software is available to assist system designers. Other, industry accepted methods of calculating heat-load design requirements can also be employed. Do not attempt to install a system without a proper heat-load design as it invites poor system performance and can adversely affect the comfort level attainable by the system. Thank you for choosing the Vanguard System. 2 TABLE OF CONTENTS SYSTEM BASICS....................................................................................................................................................................4 SYSTEM COMPONENTS ...................................................................................................................................................5 DEFINITIONS .........................................................................................................................................................................7 BEFORE YOU BEGIN ..........................................................................................................................................................8 PEX TUBING LOOPS ....................................................................................................................................................... 10 TYPES OF FLOOR CONSTRUCTION SLAB ................................................................................................................................................................................. 11 OVER AN EXISTING SLAB .............................................................................................................................................. 17 POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR ....................................................................... 18 POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR WITH SLEEPERS (OR NAILERS) ................ 20 INSTALLATION BELOW THE SUB-FLOOR ..................................................................................................................... 21 MANIFOLD LOCATION.................................................................................................................................................... 23 MANIFOLD CONNECTIONS ......................................................................................................................................... 24 SYSTEM PRESSURE TESTING ...................................................................................................................................... 27 SYSTEM FILLING AND AIR ELIMINATION ................................................................................................................ 28 SYSTEM CONTROLS ........................................................................................................................................................ 30 PIPING SCHEMATICS ...................................................................................................................................................... 31 APPENDIX MAKING CRIMPSERT CRIMP CONNECTIONS..........................................................................................................A CRIMP TOOL CALIBRATION ............................................................................................................................................B ADJUSTING “HCM” TOOLS ..............................................................................................................................................C ADJUSTING “HAR” TOOLS .............................................................................................................................................. D ADJUSTING “HAR34ST” TOOL ....................................................................................................................................... E VANEX REPAIR INSTRUCTIONS ...................................................................................................................................... F 3 SYSTEM BASICS A hydronic radiant floor heating system is really quite simple. Heated water is circulated through Vanex PEX tubing installed in or under the floor of the building. As the heated water warms the floor, it becomes a huge radiant-heat radiator. Since radiant heat energy passes through air readily and radiates in all directions, it warms the human body and objects in the building without relying on the conduction of heat by air as with forced air systems. The warmth that is felt from the sun easily describes the radiant heat of a floor heating system. Even though the sun is millions of miles away, the radiant (also referred to as infrared) heat waves pass through those millions of miles of space and are readily absorbed by the skin. Radiant heating systems offer increased comfort levels while generally allowing for lower building air temperatures. A RADIANT FLOOR HEATING SYSTEM USES THE HEATED FLOOR PANEL TO RADIATE HEAT INTO THE HOME OR BUILDING To provide the necessary heat output from a radiant floor system, there must be a sufficient amount of tubing installed in or under the floor and the temperature of the heated water must be within a range that will supply the needed output without overheating the floor. A floor that’s too warm will be as much a detriment to system comfort as one that is too cool. A properly designed system will maintain a comfortable floor temperature while supplying the required heat output. A minimum hydronic radiant floor heating system includes: 1. Water heating unit of sufficient size to meet the heat-load of the building or space to be heated CIRCULATOR MANIFOLDS 2. Circulation pump or pumps 3. Manifold or manifolds to distribute the heated water to Vanex PEX tubing loops and return the cooled water from those loops 4. Vanex PEX tubing loops installed in or under the floor 5. Vanex PEX supply and return tubing from the hot-water source to the manifold(s). HEAT SOURCE PANEL LOOPS SIMPLIFIED RADIANT HEATING SYSTEM SCHEMATIC 6. Thermostatic control to turn water circulation on and off as required. Generally, additional components are also needed to assure safe and efficient operation of the system and will be covered in detail throughout this manual. 4 SYSTEM COMPONENTS VANEX PEX TUBING The key to the Vanguard Radiant Heating System is Vanex PEX tubing. The flexibility and durability of Vanex PEX offers ease of installation and extremely long service lifetime expectancy when properly installed and operated. Vanex PEX is also available with an oxygen barrier layer. Oxygen barrier PEX is made available since it has been demonstrated that hydronic heating systems that contain ferrous iron components (steel and cast iron) may be adversely affected by the presence of too much oxygen in the water. Vanex Barrier PEX, having a thin layer of oxygen permeation resistant material permanently applied to the exterior of the tubing, limits the amount of oxygen that can enter the system by permeation through the wall of PEX tubing, substantially reducing the overall aggressiveness of the water towards ferrous iron components. For a more detailed explanation of oxygen ingress into radiant heating systems and its affects, see the Plastics Pipe Institute technical paper TR-4. (PPI phone 888-314-6774 or go to www.plasticpipe.org.) All Vanex PEX and Barrier PEX is manufactured, tested and third-party listed to meet or exceed the requirements of ASTM (American Standards for Testing and Materials) F 876 and F 877, and CSA (Canadian Standards Association) B137.5. Additionally, both Vanex PEX and Barrier PEX are certified for potable water use and Barrier PEX meets the requirements of German DIN Standard 4726 for oxygen permeation resistance. MANUFACTURER TUBE SIZE TEMPERATURE & PRESSURE RATINGS VANGUARD VANEX® Barrier PEX 1/2” CTS-OD OXYGEN BARRIER TUBING 100 PSI@180 F TRADE NAME TUBING TYPE ASTM SPECIFICATIONS [ NSF-pw ASTM F-876/F-877] TUBING CLASS CAN B137.5 POTABLE WATER CERTIFICATION INCREMENTAL FOOTAGE L23707 ICBO ES ER-5287 PEX SDR-9 .070 2/28/02 CB 298 ADDITIONAL THIRD PARTY LISTINGS DATE CODE VANEX HYDRONIC HEATING MANIFOLDS Vanguard offers three separate lines of supply/return manifolds for hydronic heating systems. System size, control features and economics represent the primary differences between the separate offerings. See the Vanguard Piping Systems Product Catalog for a complete listing of the different manifolds and features. Copper Manifolds The size of the system and the desired amount of control for separate zones and/or individual loops will govern the type of manifold and available manifold control options. Very small systems having only one to a few loops may not require a manifold. Comap Manifolds Simplex Manifolds 5 SYSTEM COMPONENTS VANEX PEX AND COMPAX-L® PEX-ALUMINUM-PEX (PAX) TUBING FOR SUPPLY AND RETURN PIPING Larger size Vanex PEX and COMPAX-L PAX tubing (3/4" and 1") is used for the supply and return piping from the water-heating unit to and from the manifolds. For maximum control of oxygen ingress into the system, Vanex tubing is also available as Barrier PEX with an oxygen barrier or the natural properties of the aluminum layer in PAX make COMPAX-L PAX a good choice as well. However, with relatively short supply/return piping runs, the advantage of oxygen barrier tubing for supply/return piping runs is limited. It should be noted however, that some boiler manufacturers, in order to meet warranty requirements, require that all of the tubing in a system be oxygen barrier. Consult with the water heating unit manufacturer for their recommendation. CRIMPSERT® AND FAILSAFE™ PLUS FITTING SYSTEMS The Vanguard CRIMPSERT and Failsafe PLUS fitting systems are used to make transition connections at the water-heating unit and at the manifolds. Vanguard offers an extensive line of fittings to make transition connections to all types of water heating units as well as directional changes when required. Consult the Vanguard Piping Systems Product Catalog for a complete listing of available fittings, crimp rings and crimp tools. SYSTEM CONTROLS Vanguard offers an extensive line of radiant heating system controls. Every radiant floor heating system requires some form of control for comfortable and efficient operation. More complex systems, requiring multiple water temperatures and/or remote on/off control of manifolds or individual loops, will require additional control elements to insure that all heated areas, regardless of heat load demand differences, are properly heated. BOILERS, PUMPS AND OTHER SYSTEM COMPONENTS Vanguard does not supply boilers, circulation pumps and other system components (such as expansion tanks and air eliminators). These components are commonly available at wholesalers that supply the hydronic heating market. It is important in selecting components to choose those that are made specifically for hydronic heating systems and are of the correct size for the particular system. 6 DEFINITIONS These are terms used throughout this manual that are specific to hydronic radiant floor heating systems. Circulator - A pump designed to circulate fluid through a hydronic heating system. These pumps are generally fractional horsepower and low pressure but large-scale systems may require pumps of considerable size and output. Downward Loss - The amount of heat energy transmitted downward from a radiant floor that is not available to heat the living space. Edge Insulation - Insulation covering the thickness of the slab edges that are exposed or nearest the outside wall and extending into the ground and preferably to at least the prevailing frost line. EVOH - ethylene vinyl alcohol - This barrier is used in the outer layer of Vanex barrier PEX to minimize the oxygen transfer into a heating system, reducing the corrosion in boilers and other accessory items. Expansion Tank - A tank having a flexible, internal bladder that can be charged with compressed air to compensate for volumetric changes of the fluid in a radiant heating system due to expansion and contraction caused by temperature fluctuations of the water. Head Loss - The pressure, expressed as feet of head, lost to friction as the result of flowing water (or water/antifreeze mix) through system components. The total head loss for a zone is additive of the losses through each component in the flow stream based on the amount of flow through each component. Multiple loops on a common manifold are not additive. Only the loss through the longest loop is used. Injection Mixing - A method of providing temperature-controlled supply water by injecting hightemperature water from the water-heating unit into the cooled, return water from the heating zones. Loop - A single, continuous loop of tubing in a radiant panel. Oxygen Permeation - The transfer of oxygen into a closed loop heating system PAX - PEX-Aluminum-PEX (COMPAX-L) SDR9 tubing is a multilayer tubing consisting of a layer of aluminum sandwiched between two layers of PEX and is intended for hot and cold potable water distribution systems and hydronic radiant heating systems. The aluminum acts as a barrier for oxygen transfer into a heating system, reducing the corrosion in boilers and other accessory items. PEX - Cross-linked Polyethylene (VANEX) SDR9 tubing intended for hot and cold potable water distribution systems and hydronic radiant heating systems. Perimeter Insulation - Insulation placed under a slab around its perimeter from the edge of the slab 4 feet in towards its center. Radiant Floor Panel - A heated area of floor used as a radiant heat source. Thermostatic Mixing Valve (TMV)- A valve that mixes high-temperature water from the water heating unit with cooled, return water from the heating zones to provide a set supply water temperature. A TMV can be manually set or automatically controlled. Zone - a loop or group of loops controlled by a single thermostat. 7 BEFORE YOU BEGIN BEFORE STARTING INSTALLATION OF A VANGUARD HYDRONIC RADIANT HEATING SYSTEM, READ, UNDERSTAND AND FOLLOW THESE CAUTIONS: ◆ Vanex PEX or Barrier PEX must not be exposed to direct sunlight for long periods of time. If the tubing is to be stored outdoors, it must be covered to protect it from direct sunlight. For cast-in-slab systems where the tubing will not be protected from direct sunlight during installation, PEX or Barrier PEX tubing must be covered with concrete shortly after laying the loops. The tubing must be covered within 2 weeks or it must otherwise be protected from sunlight exposure. Tubing tails left out of the slab for connection to manifolds must also be protected from sunlight exposure. Too much exposure to direct sunlight will cause tubing embrittlement, loss of long-term stabilization and will lead to premature failure. ◆ Pressure test the system before pouring the concrete or other topping material. The PEX tubing loops must be pressure tested before being permanently cast into the floor material. Also, leave a lower pressure on the loops while pouring to expose any leaks that might happen during the pour. (See page 28 for further information on system testing.) ◆ DO NOT use tubing that is damaged. DO NOT connect shorter lengths of tubing together to make longer loops. Unless damaged during topping pour, there should be no joints in the floor loops. It must always be the policy to use only continuous lengths of PEX tubing for floor loops. (See appendix F for repair of loops damaged during the pour.) ◆ Inform the other trades working on the same structure of the floor loops. Common damage to PEX tubing loops is from staples, nails, screws, or other sharp fasteners. Informing the other trades of the presence of the loops may help prevent damage. ◆ Follow the guidelines for attaching the PEX tubing. Fasteners that are too tight or that have sharp edges can cause damage to the tubing over time and can lead to premature failure. 8 BEFORE YOU BEGIN ◆ DO NOT fill the system with water if there is any possibility that freezing conditions might occur. If the system is filled with plain water (no antifreeze), and freezing temperatures are encountered, the tubing will likely burst at expansion joints or at naturally occurring voids in the concrete. While PEX tubing out of the slab is not prone to freeze damage, tubing encased in concrete will likely burst from the expansion of the water as it turns to ice. The resulting pressure increase inside the tubing will seek a point of least resistance and burst the tubing at that point. Substantial slab damage can also result. SYSTEM MUST BE PROTECTED IF 32°F FREEZING (0°C) TEMPERATURES ARE POSSIBLE ADDITIONAL CONSIDERATIONS BEFORE STARTING ◆ Do you have details for loop spacing and lengths for each room or zone? For the system to operate properly, an accurate room-by-room heat-loss must be done to calculate loop spacing, loop lengths and water temperature(s). Installing a system without first performing a heat-loss evaluation of the structure is an invitation to poor and/or inefficient system operation. ◆ All floor coverings must be considered for the system to operate properly. It must be understood that certain changes in the floor covering can adversely affect system function and efficiency. Carpet pad type and thickness, carpet type and pile height, the thickness of coverings such as stone or marble can all affect system output and may require closer loop spacing or higher delivered water temperature. The system designer must be made aware of any changes to floor coverings before placing PEX loop tubing. ◆ Laying of PEX tubing loops and pouring of regular or thin slab should be coordinated with the other trades working in the same structure. Once you start laying out potentially thousands of feet of PEX tubing in a structure it is important that other trades are not walking on and working over the tubes. This is an invitation for damage and may result in leaks if the damage is not found and repaired prior to covering the tubing. The placement and covering of radiant loops must be coordinated with other trades to minimize, to the greatest extent possible, damage to the tubing prior to and after the slab pour. ◆ When considering thin-slab, it is important to locate an applicator. Since thin-slab is a relatively new and specialized application, there are generally only a few, if any, applicators in various regions of the country. Therefore, we recommend you locate an applicator prior to placing PEX loop tubing. ◆ Since radiant systems use a substantial amount of Vanex PEX tubing, it is important to arrange with the wholesaler to have the required amount of tubing on hand when you need it. Wholesalers that don’t generally serve the hydronic heating industry may not have the type, size and quantity of Vanex PEX on hand when you’re ready to starting laying out loops. It is important to plan the number and size of tubing coils as well as manifolds, fittings, ties, and tools and to convey those needs to the wholesaler in advance so that the materials will be available. Vanguard’s Hydronic Heating Software will prepare a list of materials complete with part numbers. 9 PEX TUBING LOOPS LAYOUT BASICS Each radiant floor panel will contain one or more loops of Vanex PEX tubing through which the heated water is circulated. To ensure proper heat output from the panel the loops must be laid out in a specific pattern and attached at specific intervals. Also, the length of individual loops must not be too long. The system design will specify the number, length and spacing of loops. Loops that are too long will experience higher than necessary head-loss and temperature drop and will lead to poor system performance. For panels with more than one loop, the length of individual loops within the panel should be within 10% to prevent inconsistent heat output. Even though individual loops connected to the same manifold can be adjusted at the manifold with built-in balancing valves, it is better to have consistent loop lengths as balancing individual loops can be a tedious trial and error task unless individual flow meters are used on each loop increasing system cost. Maximum loop lengths for the different sizes of PEX tubing are shown in the chart on the right, however, the panel design should dictate the actual lengths used for any particular radiant panel. Typical loop spacing is 4" to 15" and is dependent on the location of the loops within the room and the required heat output of the radiant panel. Loops spaced too far apart will lead to cold spots between the loops and can also require higher supply water temperatures and will lower panel output. 85° 83° 120° 105° 85° 120° 80° 140° RIGHT 105° 140° WRONG LOOPS SPACED TOO FAR APART LEAD TO HOT AND COLD SPOTS AND POOR PERFORMANCE. THE SPACING DICTATED BY THE SYSTEM DESIGN MUST BE FOLLOWED. Each size of Vanex PEX used in radiant floor loops has a minimum bend radius dimension. When the loops are spaced closer together than the minimum bend radius X 2, then 180° turns in the tubing need to be swept out to the minimum dimension as shown below. X Dimension X Tubing Size With the Coil 3 /8" 8" 1 10" 5 12" 3 /4" 14" 1" 18" /2" /8" X FOR LOOP SPACING LESS THAN “X”, SWEEP THE TUBING AS SHOWN 10 PEX TUBING LOOPS To minimize waste, select coil lengths based on the required loop lengths. Vanguard makes Vanex PEX tubing available in numerous coil lengths and, while there may not be a coil length that matches each required loop length, a longer coil can be cut into several loops as needed. A little planning before ordering loop tubing can result in substantially reduced tubing waste. The Vanguard Radiant Heating Design Software automatically selects the best coil lengths for each system layout. Always mark both ends of each tubing loop during placement. The marking must indicate which end is the send and which is return and it should also be marked with some form of loop number or other identifier when numerous loops are connected to the same manifold. A permanent marker (such as Sharpie® or Marks-a-lot®) is usually sufficient or a flag of tape can be attached to the portion that will be trimmed off when connected to the manifold. This is an important step and is critical if the manifolds will not be placed immediately. Alternately, the loops can be connected to the manifold immediately but the loops must still be identified as to manifold position for balancing and other adjustments. Individual Vanex PEX tubing loops must always be run in a continuous length from the manifold, through the layout and back to the manifold. This is especially important for systems where the tubing will be cast into concrete or other material. DO NOT connect shorter lengths of tubing together to make up needed loop lengths. Some connections are allowed in systems where the tubing is not “cast-in”, however, fittings in the loops must be kept to a minimum. If the manifolds have not been placed prior to installation of the loops, the ends of the loops can be connected together temporarily to facilitate pressure testing. The figure to the right shows one method of connection the loops so that they can be pressure tested together. When doing this, ensure that there is sufficient tubing to make manifold connections after the temporary fittings are cut out. ALL PEX TUBING LOOPS MUST BE IDENTIFIED FOR CONNECTION, PURGING AND BALANCING PEX TUBING LOOPS MUST BE PRESSURE TESTED BEFORE POURING SLAB. A LOWER PRESSURE SHOULD BE MAINTAINED ON THE SYSTEM DURING THE POUR. WARNING! Excessive sunlight exposure will damage PEX tubing! If the loop ends protruding from the slab will not be shielded from direct sunlight within 2 weeks of tubing installation they must be protected from sunlight exposure. Wrap the tubing with black plastic or otherwise cover it to completely shield the tubing from sunlight. Failure to do this will result in premature tubing failure. 11 PEX TUBING LOOPS DOUBLE SERPENTINE Outside Wall Outside Wall SINGLE SERPENTINE WITH PERIMETER BANDING TRIPLE SERPENTINE Outside Wall Outside Wall Outside Wall Outside Wall Outside Wall SINGLE SERPENTINE Each radiant panel requires a layout that is specific to the space being heated. The illustrations below show the most common loop layouts but these may need to be modified for some rooms. The rule is that the supply side of each loop (with the hottest water) is installed towards the exterior wall or walls and the cooler part of the loop (as it is returning to the manifold), is installed towards the room’s center or interior walls. The design may also require closer spacing near the outside walls, commonly called perimeter banding, to account for higher heat loss. For rooms with no exterior wall, it is recommended to use the counter-flow spiral pattern to provide the most even heating. At high radiant panel heat-loads, loop lengths, loop spacing and layout become more critical. Please remember that modifying a layout once the floor covering has been placed is nearly impossible without completely destroying the floor and starting over. It is better to plan ahead to prevent potential problems. 12 TYPES OF FLOOR CONSTRUCTION SLAB Slab construction is well suited to radiant floor heating since the warmed concrete becomes a huge thermal mass. For most slab applications, the tubing is tied to the re-mesh or re-bar reinforcement with zip-ties (Vanguard part #HRCT) or re-bar twist ties. When using re-bar twist ties they must not be twisted too tight possibly damaging the PEX tubing. Once the concrete is poured over the tubing, the ties no longer serve an anchoring function so they need not be installed overly tight. Tie the tubing to the re-bar or re-mesh every 3-4 feet along straight runs. At 90° turns, tie the tubing within 12" on each side of the turn. For turns greater than 90°, tie the tubing within 12" on each side of the turn and in the middle of the arc to prevent the tubing from moving or floating to the top during the concrete pour. (See figure at left.) LOOP TUBES ARE ATTACHED TO RE-MESH (SEE TEXT) Keep the PEX tubing at least 6" away from slab penetrations, blockouts or other similar structural embedments. Unless local building code does not allow it, a vapor barrier (such as 6 mil polyethylene sheeting or equivalent) should be installed under the entire slab. Install only continuous loops of tubing into the slab. Starting at the manifold location and leaving sufficient tubing to make the manifold connections, run each loop continuously through the loop layout and back to the manifold location. DO NOT connect several shorter lengths of tubing together the make a complete loop. Vanguard supplies Vanex PEX in numerous coil lengths to minimize waste. To provide for a cost-effective installation, order coil lengths that are either close to the required loop lengths or that can be cut into lengths that will minimize the length of “tails” to be cut off. Run continuous lengths of Vanex pex through the loop layout and back to the manifold location. Use HRSL3 or HRSL4 plastic elbows or HRCSL3 or HRCSL4 corrugated sleeving where the tubing enters the slab. Elbows or sleeving can be tied to re-bar supports as shown. Cut re-bar off flush with concrete when cured. Elbows or sleeving may be tied on alternate sides of support to provide better line-up with manifolds. 13 TYPES OF FLOOR CONSTRUCTION Ideally, the PEX tubing loops should be placed about 2 inches below the top surface of the slab. This is usually accomplished by installing risers that hold the re-bar or re-mesh at a constant height, or during the concrete pour, by hand pulling the reinforcement (with PEX tubing attached) to the desired level. NOTE: All fill material below a radiant slab must be free of sharp objects that can damage the Vanex PEX tubing. If gravel is specified for under-slab fill, it must not have sharp edges. Smooth pea gravel is recommended. CAUTION! DO NOT drill into or drive fasteners into the slab as you can puncture the PEX tubing causing a leak. Make the other construction trades aware of the presence of the tubing to minimize the risk of this type of damage as it is difficult and costly to repair. If the slab must be penetrated, the tubing loops must be accurately located to prevent damage. INSULATION Exposed slab edges must be insulated for efficient system operation. The most common edge insulation is 1 to 2 inch in thick, closed-cell Styrofoam extending down to at least the prevailing frost line. The system design should specify the type and thickness of edge insulation. If edge insulation to the prevailing frost line is impossible or impractical, at the very least, edge insulation should fully cover the exposed slab edge and extend into the ground at least a few inches. Remember if the design specifies edge insulation to the frost line and that recommendation is not followed, the slab will experience higher edge heat loss, may not perform properly and system efficiency will suffer. In extreme cases, failure to install edge insulation where the system design calls for it could result in enough additional heat loss to overrun the boiler output. When attaching insulation to the slab forms prior to pouring, adjust the form position outward the thickness of the insulation so that the outer wall does not sit partially on the insulation. 14 TYPES OF FLOOR CONSTRUCTION When setting insulation prior to pouring a mono-pour slab/ foundation, adjust the width of the trench and the placement of the forms to accommodate the additional thickness of the insulation so that the outer wall does not sit on the insulation. TO FROST LINE Perimeter insulation is also recommended to promote efficient operation and to minimize heat loss. Perimeter insulation should extend a minimum of 4 feet inward from the outside slab edges and be installed around the entire outside perimeter of the slab. Edge and perimeter insulation will minimize the majority of heat loss; however, certain conditions may require full under-slab insulation to further minimize downward heat loss. Those conditions include high water table, high slab heat-load, and high R-value floor coverings. If there is a question as to the need for full under-slab insulation, consult the system design and/or the system engineer. ADJUST FOR INSULATION THICKNESS TO FROST LINE 4 FT. OR PER DESIGN The top of exposed edge insulation should be angled to provide water run-off and should be covered with flashing or other metal trim to prevent degradation of the foam. 15 TYPES OF FLOOR CONSTRUCTION When using full underslab insulation and securing the PEX loop tubing directly to the foam insulation, the R-value of the covering over the tubing increases and system response and required water temperature will be affected. An increase in the thickness of covering over loop tubing results in higher required water temperature and can cause sluggish system response to changing heat loads. The system control type or control parameters may require adjustment to accommodate the delay in system response time. FOR COVER > 2” COVERING THICKNESS > 2” OVER LOOP TUBING RESULTS IN HIGHER WATER TEMPERATURES AND CAN CAUSE SLUGGISH RESPONSE If fastening the PEX tubing directly to the foam insulation, see Over an Existing Slab for fastening instructions. In some rare instances, the PEX tubing must be placed in the sand backfill below the slab. Use caution with this method as system response time and required water temperature is significantly affected. Also, water temperature must not exceed 140° F to prevent crystallization of the sand which leads to very poor heat transfer. Do not place the tubing in the sand below the slab unless the system design specifies it directly. DO NOT PLACE PEX TUBING LOOPS IN THE SAND BED BELOW A SLAB UNLESS THE DESIGN SPECIFIES IT PEX tubing must be sleeved at all expansion joints and every point where it enters, exits or penetrates the slab. For expansion joints that are to be cut, the tubing must be dipped below the slab to prevent damage. HRCSL3 OR HRCSL4 Plastic Turnout: HRSL3 or HRSL4 Plastic Snap-on Sleeve: HRCSL3 or HRCSL4 SLEEVE PEX TUBING AT ALL EXPANSION JOINTS WITH HRCSL3 OR HRCSL4 SLEEVE EVERY POINT WHERE THE PEX TUBING ENTERS OR EXITS CONCRETE. USE HRSL3 OR HRSL4 ELBOWS OR HRCSL3 OR HRCSL4 SLEEVING FOR CUT EXPANSION JOINTS, DIP THE TUBING BELOW THE SLAB TO A SAFE DISTANCE AT THE CUT LINES 16 TYPES OF FLOOR CONSTRUCTION OVER AN EXISTING SLAB For existing or new applications, a new slab can be installed over an existing one to provide for a radiant heating panel. Insulation should be installed between the new and existing slabs (1” minimum recommended) that helps drive the heat upwards and insures that the system reacts properly to changes in the temperature of the living space. This is very important when coverings such as carpet and pad are used over the new slab. If insulation between the slabs is omitted, the thermal mass increases substantially and the system will be sluggish in responding to changes in room temperture. For the most part, a slab over slab is installed like a Slab system except that the new slab, since itis generally only about 2 inches thick, may not contain steel reinforcement and the tubing loops may be attached directly to the insulation with the methods described in this section. Please note, if the thickness of the new slab over the tubing will be substantially more than 2”, the system design must be consulted. Too much slab thickness over the tubing will cause sluggish response to changes in room temperature. NOTE: Omission of insulation between the new slab and the old slab will substantially increase the thermal mass, making response times very sluggish. Pour a minimum 3/4" of 3/4” slab thickness over the loop tubing. (See text) When installing the tubing in a poured slab over an existing slab, the tubing can be anchored by: 1. Attaching to re-mesh or re-bar laid over the existing slab as described in the Slab installation section. 2. Attaching directly to the insulation with staples (Vanguard Part No. STAP1 and STAP2) or screw-in clips (Vanguard Part No. CLC3). . WHEN USING STAP1 OR STAP2 STAPLES, DOUBLE STAPLE ON BOTH SIDES OF EACH TURN AND SINGLE STAPLE IN THE MIDDLE OF THE ARC FOR TURNS GREATER THAN 90°. 3. Attaching Snap-Trak (Vanguard Part No. CLMR3 or CLMR4) to the insulation with fasteners or adhesive and snapping the Vanex PEX tubing into the provided slots as shown in the illustration to the right. The remaining instructions for a slab over an existing slab follow those for a Slab installation on pages 13 through 16. However since insulation between the new and existing slabs is recommended, and the new slab will likely be only about 2” thick, then the tubing can be fastened directly to insulation laid over the entire surface of the existing slab. Attach the tubing to the insulation with foam staples (Vanguard Part No. STAP1 or STAP2), screw-in tubing clips (Vanguard Part No. CLC3 for 1/2” only) or install CLMR3 or CLMR4 Snap-Trak to the insulation and snap the tubing into the supplied slots. The distance between tubing fasteners shall be the same as shown in the Slab installation section. 17 TYPES OF FLOOR CONSTRUCTION POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR When installing a poured floor underlayment/thin slab over a suspended wood floor, attach the Vanex PEX tubing directly to the wood sub-floor with staples or clamps every 2 to 3 feet along straight runs. At turns, attach within 12" on both sides of each turn and also in the middle of the arc for turns greater than 90°. When using staples, do not use staples with sharp edges and do not drive them to a depth that deforms or crushes the PEX tubing. Clamps must also be free of sharp edges that could cut or damage the tubing. Thin Slab Insulation Subfloor WHEN USING STAP1 OR STAP2 STAPLES, DOUBLE STAPLE ON BOTH SIDES OF EACH TURN AND SINGLE STAPLE IN THE MIDDLE OF THE ARC FOR TURNS GREATER THAN 90°. Install only continuous loops of tubing into the poured underlayment/thin slab. Starting at the manifold location and leaving sufficient tubing to make the manifold connections run each loop continuously through the loop layout and back to the manifold location. DO NOT connect several shorter lengths of tubing together the make a complete loop. Vanguard supplies Vanex PEX in numerous coil lengths to minimize waste. To provide for a costeffective installation, order coil lengths that are either close to the required loop lengths or that can be cut into lengths that will minimize the length of “tails” to be cut off. There must be at least 3/4" of poured underlayment/thin slab over the top of the tubing. Do not drill or drive fasteners into the poured floor as you can puncture the tubing causing a leak. Inform the other construction trades of the presence of the tubing to minimize the risk of damage during further construction. 18 3/4" CORRECT INCORRECT STAPLES MUST NOT BE DRIVEN TOO DEEP AND DEFORM THE TUBE. THERE WILL BE A SLIGHT AMOUNT OF PLAY BETWEEN THE TUBING AND THE STAPLE WHEN PROPERLY DRIVEN. TYPES OF FLOOR CONSTRUCTION If interior walls are to be set on the poured underlayment/thin slab, keep the PEX tubing at least 3" away from wall locations. Before laying out the tubing loops, mark out the wall locations on the sub-floor to insure accurate placement. The joist spaces below the heated floor must be insulated. If the floor is over an unheated space, install a minimum R19 insulation. Foil faced insulation is preferred and the foil face is installed towards the heated side. If the space below is heated, install a minimum R11 insulation. As a general rule, the R-value of insulation below a suspended panel should be at least 4 times the R-value of the material covering the tubing (including the poured material and any floor coverings). NOTE! Insulating below a radiant floor panel is important even when the space below it is heated. The insulation “drives” the heat upwards since radiant heat emits from both sides of the heated panel. If no insulation is installed, the panel will emit radiant energy equally in both directions and the space above the floor will not be heated properly. Foil faced insulation or a separate radiant barrier can significantly improve insulation performance since it reflects infrared waves directly. 3” MARK WALL LOCATIONS ON THE SUBFLOOR AND KEEP PEX TUBING LOOPS AT LEAST 3 INCHES AWAY FROM THEM. FOIL FACING OR RADIANT BARRIER INSULATION - R11 TO R19 (SEE TEXT) NOTE! Install plastic elbows (HRSL3 or HRSL4) or sleeving (HRCSL3 or HRCSL4) to direct the tubing loops up to the manifolds. A 1x4 installed between studs provides a surface to clamp to. Staple or clamp tubing to sub-floor every 3-4 feet along straight runs and within 12 inches on each side of turns and in the middle of the arc for turns greater than 90°. 19 TYPES OF FLOOR CONSTRUCTION POURED UNDERLAYMENT/THIN SLAB OVER SUSPENDED FLOOR WITH SLEEPERS (OR NAILERS) Thin Slab When the finished floor over the heated panel requires nailing (such as hardwood), 2x2 sleepers are installed between the tubing runs and the underlayment/thin slab is poured over the tubing and screed level with the sleepers. Sleeper Other than the attachment of sleepers to the sub-floor, installation of this type of panel is identical to the Poured Underlayment/Thin Slab Over Suspended Floor. Insulation Subfloor Leave sufficient space between sleeper ends to make turns and supply/return runs to and from manifolds Insulation of a thin-slab with sleepers floor is identical to thin/slab without sleepers. (See page 19 for details.) 20 FOIL FACING OR RADIANT BARRIER INSULATION - R11 TO R19 (SEE TEXT) TYPES OF FLOOR CONSTRUCTION INSTALLATION BELOW THE SUB-FLOOR Vanex PEX tubing is installed under the sub-floor using the Vanguard Part No. HRTP3 Heat Emission Plate. Normally, two tubes will be installed into each joist space but check the system design, as some will only require one. The heat emission plates are used to fasten the tubing against the underside of the sub-floor and help distribute the heat more evenly. Subfloor Heat Emission Plates Insulation The illustration above shows the most common method of pulling the PEX tubing through holes drilled through the joists and into the joist spaces. After sufficient tubing has been pulled into all of the joist spaces, attach the tubing by nailing, stapling or screwing the heat emission plates to the underside of the sub-floor with shingle nails, staples or screws. Fasten each plate every 4-6 inches along each side of tubing-groove placing fasteners about 1/2” away from each side of the groove as shown in the figure at right. 21 TYPES OF FLOOR CONSTRUCTION Holes through joists for tubing bundles must be sufficiently sized to allow free movement of the tubing. Single tubes or a bundle must NOT fit tight in holes through joists or noise may occur during expansion and contraction. Holes must not be so large as to compromise the strength of the joist. Check the building code for allowable hole size. It may be necessary to have more, smaller bundles if required hole size exceeds that allowable. Bundle PEX tubes with only nylon cable ties (zip-ties) such as Vanguard Part No. HB14120. DO NOT bundle tightly. Leave the ties slightly loose to allow the tubes to freely expand and contract. DO NOT use tape to bundle. BUNDLE TUBES WITH ZIP-TIES. DO NOT USE TAPE. CAUTION! The fasteners must not be too long as they can protrude through the finished floor. Be aware of the thickness of the flooring and use the appropriate length fasteners. WRONG RIGHT FOIL FACE OR RADIANT BARRIER Install insulation in the joist cavity below the PEX loops leaving a 1 to 2 inch air gap. A foil faced insulation or a separate radiant barrier will improve heat flow towards the heated space. For floors over unheated spaces, install as much insulation as practical but at least R19. Insulate even if the floor is over a heated space with R11 to drive the heat upwards. 1-2” AIR GAP R11 MINIMUM OVER HEATED SPACE, R19 MINIMUM OVER UNHEATED SPACE 22 MANIFOLD LOCATION Since most whole-house radiant heating systems will require numerous tubing loops and at least one radiant manifold, consideration must be given to the location of the manifold or manifolds in relation to the water heating unit and the heating zones served by each. Some systems also require more than one delivered water temperature and may also require remote on/off control of one or more manifolds or even of individual loops. For systems requiring more than one delivered water temperature, separate manifolds are required for each water temperature. Of course, with very large residential or commercial systems there may be multiple manifolds for each delivered water temperature. It is not required to install manifolds in a dedicated space such as the mechanical room. While that arrangement may work for some systems, there are many times when the manifold(s) will be installed throughout the structure in accessible but unobtrusive locations such as in a closet, a wall or under a cabinet. Manifolds can be covered with a simple duct grate or more elaborate cover. They must, however, remain accessible and must not be permanently concealed behind Sheetrock or plaster. RADIANT MANIFOLDS CAN BE MOUNTED WITHIN A 2X6 WALL CAVITY BEHIND A DOOR OR REMOVABLE COVER. NOTE: Mounting the manifolds near the area they are intended to serve will more accurately heat those areas and be a more efficient use of the tubing. It also reduces the risk of unintentionally over heating a supply and return tubing pathway from the manifold to the area it is serving, such as a hallway leading to several remote rooms. RADIANT MANIFOLD LOCATIONS SOME SYSTEMS REQUIRE THAT RADIANT MANIFOLDS BE INSTALLED IN SEPARATE LOCATIONS. 3/4” OR 1” VANEX PEX IS USED AS SUPPLY/RETURN TUBING TO THE REMOTE MANIFOLD(S). 23 MANIFOLD CONNECTIONS RADIANT MANIFOLDS Vanguard offers several lines of send/return manifolds specifically for hydronic radiant heating systems. While each manifold type serves the same essential function, there are distinctions that make them more or less applicable to some applications. COMAP MANIFOLDS Air Vent The Comap line of radiant manifolds is a modular system that consists of an end connection kit, a balancing module, a actuator module and the loop fitting. The manifold is field assembled by connecting the required number of balancing and actuator modules with an end connection kit. Any manifold from 2 to 12 ports can be constructed from the modular components. Changes to the number of loops can be done quickly simply by inserting or removing balancing/ actuator modules. The end connection kit features manifold isolation valves, air vents and thermometers and includes mounting brackets to attach the manifolds. The main inlet/outlet connection to manifold supply tubing is 1" female NPT. The balancing and actuator modules look identical but are distinguished by the color of the adjustment knob. The balancing (or supply) module (HRCMSM) has a black adjustment knob and the actuator module (HRCMRM) has an orange adjustment knob. Also available is a return module with a built-in flow meter (HRCMFLM) so that adjustments in the flow of individual loops can be visually monitored. Wireform Module Connector Termination Module with Fill Purge Connection Wireform Module Connector Crimpsert Loop Fitting (requires crimp ring) Manifold Connection with Temperature Gauge Manifold Isolation Valve with 1” FPT Connection Send and Return Module (Black Knob - Balancing) (Orange Knob - Actuator) Return Module with Flow Meter Euro Style Compression Fitting Loop connections are available in Euro-compression (1/2" and 5/8") that require only a wrench to connect and CRIMPSERT (1/2" and 3/4") that use the standard PEX black-copper crimp rings and crimping tools. For systems requiring on/off control of individual loops, the HRLA24V loop actuator mounts directly on the actuator module and also provides an end switch to activate other system control functions. For each loop using a loop actuator, balancing is done through the built-in valve on the supply module. 24 HRLA24V Mounted on Return Module for Individual Loop Actuation Wireform Module Connector MANIFOLD CONNECTIONS SIMPLEX MANIFOLDS The Simplex line of radiant manifolds is a modular system that consists of an end connection kit, a balancing module, a actuator module and the loop fitting. The manifold is field assembled by connecting the required number of balancing and actuator modules with an end connection kit. Any manifold from 2 to 12 ports can be constructed from the modular components. Changes to the number of loops can be done quickly simply by inserting or removing balancing/actuator modules. Manifold Connector with 1” FPT Connection Termination Module with Fill Purge Connection The end connection kit features a 1" female NPT for manifold balancing connections, port to install the optional air vent (HRSMAV), fill/drain port and includes mounting brackets to attach the manifolds. Optional Air Vent (HRSMAV) Recommended Manifold Isolation Valve (not included with manifold) Actuator Module (Black Plastic Cap) Lock Ring The balancing and actuator modules look similar but are distinguished by the fact that the balancing module (HRSMSM) has a brass cover over the isolation valve and the actuator module (HRSMRM) has a black plastic adjustment knob. Also available is a return module with a builtin flow meter (HRSMFLM) so that adjustments in the flow of individual loops can be visually monitored. Loop connections are available in Eurocompression (1/2" and 5/8") that require only a wrench to connect and Crimpsert (1/2" and 3/4") that use the standard PEX black-copper crimp rings and crimping tools. For systems requiring on/off control of individual loops, the HRLA24V loop actuator mounts directly on the actuator module and also provides an end switch to activate other system control functions. For each loop using an actuator, balancing is done through the built-in valve on the balancing module for that loop. Balancing Module (Brass Cap) Return Module with Flow Meter Crimpsert Loop Fitting (requires crimp ring) Euro Style Compression Fitting HRLA24V Mounted on Return Module for Individual Loop Actuation 25 MANIFOLD CONNECTIONS COPPER MANIFOLDS The copper manifold line is available for those systems that require a minimum of zone and/or loop control. They are offered with Crimpsert connections on the inlet/outlet and loop connections for systems that require no loop isolation or balancing function and as buildup models that require the installer to join the manifold body, inlet/outlet fittings and loop valves by sweat soldering the components together. The Crimpsert copper manifolds are best used where all of the loops connected to a manifold pair are identical in length (maximum 10% variation) and will provide the most equal loop-to-loop flow-rate when connected in a reverse-return configuration (first in is last out and last in is first out). This method yields the most consistent pressure drop through all loops connected to the same manifold pair. No more than 12 loop tubes should be connected to a single manifold pair. The buildup models feature isolation valves and balancing valves for individual loop balancing control. Loop balancing is required when the length of loops connected to a single manifold pair vary by more than 10% and/or one or more loops connected to a manifold pair are used to heat non-contiguous areas. Loop balancing is also required for rooms with higher heat loads at outside walls (due to a large window area or outside door(s)), or when more than one room is served by a manifold pair, especially when each room has a significantly different heat load requirement. Crimpsert Copper Manifolds Loop isolation and Closed-end Model balancing valves are available with either Crimpsert loop connections (assembled with black copper crimp rings Flow-through Model and crimp tools) or with compression fittings that require only a wrench to connect. Crimp rings required for Crimpsert Connections Buildup Manifolds Crimpsert Transition Fitting Euro Compression Isolation and Balancing Valves 26 Crimpsert Isolation and Balancing Valves Crimp rings required for Crimpsert Connections Copper Manifolds Shown Mounted in 2x6 Wall with Mounting Brackets (HRM5 or HRM7) SYSTEM PRESSURE TESTING The system must be pressure tested before the loops are embedded in the slab or otherwise covered. As a minimum, the internal system pressure should be raised to 100 psig and held for at least 30 minutes. If it is a warm day and the sun has warmed the PEX tubing loops, there will be a slow expansion of the tubing that will show as a pressure decrease in the system. Depending on the ambient temperature, the pressure decrease could be significant and may require re-pressurizing the system back to 100 psig and maintaining for longer than 30 minutes. As long as the temperature remains relatively constant, the pressure will stabilize if the system is leak-free. If, after 2 hours test time the pressure cannot be stabilized, then there is probably a leak. Find and repair the leak and retest. It is paramount to system integrity that the loops are leak-free before covering. If a loop tube has been damaged during installation it is recommended to replace the entire loop and not install a repair coupling. Repair couplings are intended as a “last resort” repair during the pour when it is impossible to replace a damaged loop. When pouring the floor covering, pressurize the system with 30 to 50 psig of air so that any damage occurring during the pour will immediately be evident and a repair can be made. Use only a Vanguard Crimpsert repair coupling of the correct size with heat shrink sleeve covering for loop repair. The crimps must be checked with a Go/No-Go gauge and the system must be re-pressurized and the repair checked for leaks before shrinking the heat-shrink tubing over the coupling and crimp rings and burying the repair in the slab. CAUTION! Overnight testing is not recommended as it results in erroneous test results. Large swings in ambient temperature will show dramatic changes in test pressure as the loop tubes expand and contract with temperature. Even the air inside the loops expands and contracts with temperature and will lead to erroneous readings that could be indicative of a leak when no leak exists. Always start the test when the ambient temperature will remain relatively constant for the test duration. CAUTION! If water is used for system pressure testing it must be protected from freezing if there is even a remote possibility that the ambient temperature will drop to freezing or below before the structure is completed and the system is operating. The antifreeze must be of sufficient concentration to protect the system at least to the lowest expected temperature. Antifreeze and water must be mixed well before filling the system. Failure to protect the system from freezing will result in ruptured tubing loops within the slab and at expansion joints and can crack the slab severely. Repair is very costly and must be avoided. 27 SYSTEM FILLING AND AIR ELIMINATION After all of the loops have been connected to the manifolds, that portion of the system can be filled and purged of air. Alternately, the system can be pressurized with compressed air for leak detection and to maintain pressure on the system during the slab pour (see page 27) and the entire system (including transfer piping and the hot-water source) can be filled and purged at one time. Whether done in one or several stages, purging is a critical step since air entrapped in the system will inhibit or prevent fluid flow through some or possibly all of the loops, zone piping or transfer piping. The system must have at least one air vent device (Vanguard part# HRSMAV) and, for large-scale systems, there may be several air vents at key points in the system. The primary air-vent should be located between the water heating device and the circulator pump. This should be the point of lowest pressure in the system. Open the vent to the atmosphere while filling/purging the system to allow free escape of air. When fluid begins to escape from the air vent, close it and continue filling/purging the system It is recommended that the system be filled only with a water/antifreeze mixture of sufficient concentration to protect the system from freezing down to at least the lowest expected temperature. Please realize that construction schedules can change and a poured slab may sit for some indeterminate amount of time before the building is erected and an unprotected system can freeze resulting in catastrophic damage to the PEX tubing loops, manifolds and the slab. Loop and zone valves are important for purging as it allows individual control of purge flow to develop the needed fluid velocity to force out air. To affect the most efficient purging, each zone and loop should be purged individually. The key to purging is to create a highvelocity flow through the tubing to force air out of the system. Circulation pumps are generally low flow and may not provide the needed velocity. Purging is best accomplished with a purge cart. A purge cart is basically a container for mixing the water/ antifreeze solution and a pump capable of developing a minimum velocity of 5 feet/second in the piping being purged. The fluid is pumped into the system and is returned back to the mixing container until the return fluid is essentially free of air bubbles line. Enough fluid must be kept in the mixing container at all times during purging to prevent re-introduction of air into the system. Absolute air removal at the purging stage may not always be practical but removing as much air as possible during this step will help to ensure a properly operating system. The Comap and Simplex manifolds have built in fill/purge connections to fit a standard garden hose fitting. Other manifold types will need to be filled/purged through a different type of connection. For purposes of filling/purging, a flexible hose can be connected with a Crimpsert fitting using ordinary hose clamps. Connect the pressure side of the purge pump to the supply manifold and another line that returns to the mixing container to the return manifold. Close all of the loop isolation 28 Connect the supply and return lines from the filling/purging system to the built-in fill/drain connections on the manifolds. COMAP SIMPLEX Fill/Purge Garden Hose Fittings Fill/Purge Garden Hose Fittings Other manifold types require separate fittings to connect the filling/purging system. SYSTEM FILLING AND AIR ELIMINATION valves on both manifolds and start the purge pump. Working one loop at a time, open the isolation valves on the supply and return manifolds and watch the return water flow back into the mixing container. Continue to pump fluid until there is little, if any air bubbles in the return fluid stream. Close both isolation valves for that loop and open the valves for the next one. Continue this process for each loop on each zone. When all manifolds and loops have been purged, the system can then be pressurized for leak tightness testing (see page 27) and then a lower pressure can be held on the system during the pour so that any incidental loop damage can be located immediately and repaired. If when the pour is complete and some time will pass before the supply/return piping is connected, depressurize the system and close all loop isolation valves and all zone isolation valves. When the remainder of the system is connected, filling and purging is done in exactly the same fashion as above but the zone isolation valves will be used to purge individual parts of the system instead of loop isolation valves. When filling/ purging supply/return piping, leave all of the loop isolation valves closed to concentrate the fluid flow through the supply/return piping and manifolds. After all of the zones have been filled and purged, the loop isolation valves can then be opened. If filling/purging will be done only after all of the piping is in place, follow the same procedure as outlined above but work one loop on one zone at a time using the isolation valves. When system purging is complete, the purge pump can be used to pressurize the system to 15-20 psig. Small amounts of air remaining in the system will eventually vent, however; too much air can congregate into a larger bubble and stop pumping action altogether. Also, some boilers can be damaged by excessive air in the system. A flow meter in the transfer tubing is a good diagnostic tool and will show not only that fluid is flowing but will also show air bubbles (for clear meters) in the system. Remember that air in the system should be eliminated to the greatest extent possible before startup to prevent operational problems later. Each system must have an expansion tank to provide for expansion and contraction of the fluid as it is heated and cooled. Open expansion tanks are not recommended since they will introduce air into the system continually. Use a tank with a flexible bladder that separates the air-charge from the fluid. Charge the air side of the tank 2 to 3 psig below the system charge pressure. A simple fill/purge system consists of a container for mixing the water and antifreeze, a motor-driven pump and hoses to connect to the radiant system. 29 SYSTEM CONTROLS Even the simplest system requires some form of control to sense the temperature of a room or rooms and turn the circulation pump on and off as required to maintain the proper temperature. All of the Vanguard control systems operate on low voltage 24 volt AC current. The number and location of thermostats, zone or loop valves, temperature sensors, etc. must be known so that the necessary wiring can be installed throughout the structure prior to the wall finishing being applied. Typical control wiring is 18 AWG solid wire but the local electrical code may have different requirements. Control wiring must not be run parallel with telephone or AC lines or other sources of electromagnetic noise as this can affect the signal and may result in faulty operation. Twisted-pair or shielded cable, or running the wiring through grounded metal electrical conduit are options to prevent interference. Due to size of some systems or necessity of control features, there can be a substantial number of control wires routed back to the mechanical room or other control location. Each wire (or pair as the case may be) must be marked as to the function that it serves. A mass of unmarked wires coming from different parts of a structure is a nightmare to sort out. Always mark each wire run as it is being installed to prevent unneeded problems. One key to system comfort in large structures is providing sufficient controls to provide on/off operation of not only the entire system but also of individual zones and even individual loops. South facing rooms with ample glass may require a separate thermostat to turn off the zone (or zones) when radiant gain from the sun is high. This on/off action can be provided by zone valves (or loop actuators) or individual circulation pumps. Since each system is different, there are potentially thousands of control schemes and it is impossible to illustrate them all within the scope of this installation guide. Instead, we recommend that you contact Vanguard or the control system supplier for a detailed guide for the control unit(s) being utilized. The wiring schematics for the particular control being used must be consulted to ensure the proper wiring is installed. Outdoor Sensor Whole House Control Zone or Room Thermostats Boiler Sensor Circulators and/or Motorized Zone Valves Simplified control schematic illlustrates how multiple Zone or Room thermostats and outdoor and boiler temperature sensors provide feedback for automatic control of circulator(s) and/or Motorized Zone Valve(s). While not all systems will require this level of feedback and control, even simple systems need some form of thermostatic control to turn the system on and off. 30 PIPING SCHEMATICS While there are any number of ways to pipe a radiant floor heating supply/return system, and it would be impossible to illustrate every potential configuration, the schematics on the following pages represent several ideas that can be used "as is" or modified to suit individual system needs. Also, there are some basic guidelines that should be followed to prevent operational problems with modified piping layouts. 1) Each system or isolated part of a system needs an expansion tank. As the fluid in the system is heated and cooled, and during the off-season, there is a volume differential in the system that is best accommodated with a bladder expansion tank. The charge pressure in the air-side of each expansion tank should be a few psig below the static system pressure. 2) Expansion tanks are best placed upstream of circulators. 3) An air vent or, preferably, an air separator, should be installed at a point in the system or each isolated part of a system where the pressure is the lowest (upstream of circulator) and the fluid temp is the highest (just downstream of the water heating unit). This provides the most efficient air removal. 4) Isolation valves at each circulator and manifold will facilitate filling and purging and simplify replacement of a failed or worn-out component. 5) Zone circulators are preferred to motorized zone valves in multiple-zone systems. Installing a circulator on each zone provides for partial system operation in the event of a single circulator failure. 6) Using a single circulator and motorized zone valves on a large multiple-zone system may require a pressure activated bypass loop to prevent excessive head-pressure during single zone operation. 7) Never connect the system to the potable water system with an auto-fill valve. This is especially important for snow-melt systems. Unknowingly filling a leaky system with plain water can dilute the antifreeze concentration to a dangerously low level and can result in a system freeze-up. If an auto-fill is required, use a separate pressure tank with a water/antifreeze mixture of sufficient concentration. Charge the tank above the static system pressure and connect it through a pressure-reducing valve (PRV). 8) Non-condensing boilers may require the addition of a manually or automatically controlled bypass loop to maintain return water temperature above the boiler manufacture’s recommendations to prevent condensation of flue gases and acid production. 9) Size the circulator(s) for the portion of the system it (they) will be supplying. The primary circulator in a primary/secondary-circulator system must be sized for the total demand it must supply through the total length of piping in the primary piping circuit. Schematics Legend The illustrations below are used throughout the schematics section to define system components. Flow Check Valve Air Elimination Device Expansion Tank Circulator Pump Manifolds and Radiant Panel Loops Motorized Zone Valve Isolation or Balancing Valve 3-Way Thermostatic Mixing Valve 31 PIPING SCHEMATICS Single Zone Simple System For small, single-zone systems using a condensing boiler, water heater, or when supplied from the domestic hot-water supply, the system can be piped similar to the schematic below. The floor panel supply water tempering is through a manually-set, 3-way thermostatic mixing valve. System on-off control can be accomplished through a single thermostat or may also incorporate outdoor and floor temperature sensors to offer more even room temperature. When the radiant panel is supplied from the domestic hot-water system (when allowed by code), the expansion tank and air elimination device may be omitted. Some systems will require a balancing valve in the loop return to provide for return-side flow resistance to assure adequate return supply to the thermostatic mixing valve.. When supplying the radiant system from the domestic hot water system, expansion tank and air elimination device may be omitted. Hot Mixed Cold Condensing Boiler Water Heater or Supply from the Domestic Hot Water System 32 Balancing valve is optional but may be required to provide return-side flow resistance PIPING SCHEMATICS Single Zone Using Simply Radiant (HRZCP1) Control Box The HRZCP1 Control Box simplifies installations for single-zone systems up to 30,000 BTU. The zone pump, mixing valve and temperature control are all housed within the Control Box. The provided wall thermostat connects to the control box and provides on/off control by sensing room air and floor temperatures. The control also provides for high/low floor temperature limits. When the system is supplied from the domestic hot-water system (when allowed by code), the expansion tank and air elimination device may be omitted. Some systems will require a balancing valve in the loop return to provide for return side flow resistance to assure adequate return supply to the thermostatic mixing valve. When supplying the radiant system from the domestic hot water system, expansion tank and air elimination device may be omitted. Supplied Wall Thermostat Senses Room Air Temperature and Floor Temperature HRZCP1 Zone Control Condensing Boiler Water Heater or Supply from the Domestic Hot Water System Balancing valve is optional but may be required to provide return-side flow resistance 33 PIPING SCHEMATICS Multiple Zones Using Simply Radiant (HRZCP1) Control Boxes For larger systems with multiple zones, several HRZCP1 Simply Radiant Control Boxes can be supplied from a primary circulation loop off the hot water source. Each zone served by a Control Box then has its own floor and air temperature sensors to provide space temperature control. Please note, the diagram shown is not suitable for a noncondensing boiler. (See the diagram on page 40 for non-condensing boiler primary loop piping.) When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops. Some points to remember when installing this type of system - Check valves must be installed on the supply side of each secondary loop and optionally on each return side - Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia. of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop. HRZCP1 Zone Control Secondary Loop 8 x pipe dia. min. Hot Water Source (if boiler, must be condensing type) 6” max. Primary Loop Secondary Loop HRZCP1 Zone Control 34 4 x pipe dia. min. Supplied Wall Thermostat Senses Room Air Temperature and Floor Temperature PIPING SCHEMATICS Multiple Zone Single-Temperature System Using Motorized Zone Valves Installation Multiple heating zones requiring a single zone supply temperature using motorized zone valves in place of zone circulators can be piped similar to the schematic below. By using a 3-way thermostatic mixing valve on the primary boiler loop and then adding secondary zone loops as needed, the system can provide a single supply temperature to all connected secondary loops. Zone valve systems should be piped with supply and return manifolds on the primary loop to insure proper circulation in the secondary loops. Please note that by relying on a single circulator pump only on the primary loop, that partial system operation in the event of a pump failure is not possible. For even pressure balancing between secondary loops, the connection of the secondary supply and return lines to the primary manifolds should be piped in a first-out/last-in fashion where the first secondary loop on the supply manifold (closest to the supply pipe) is the last loop on the return manifold (furthest from the return pipe). Additional zones can be added provided the heat source and the main circulator are properly sized for the entire demand. However, as the primary circulator size is increased, the need may arise to install a bypass loop in the primary circuit to prevent excessive pressure when only some of the secondary circuits are in operation. The system shown below can also be piped to supply different temperatures to each secondary loop. By removing the thermostatic mixing valve from the primary loop and installing one on each secondary loop as required. Service Valves (Optional) NOTE! Large systems with numberous zones may require pressure controlled primary bypass loop to prevent excessive pressure. Hot Condensing Boiler Water Heater or Supply from the Domestic Hot Water System Cold Mixed Supply Return Balancing valve is optional but may be required to provide return-side flow resistance 35 PIPING SCHEMATICS Multiple Zone Single-Temperature System Installation Multiple heating zones requiring a single zone supply temperature can be piped similar to the schematic below. By using a 3-way thermostatic mixing valve on the primary boiler loop and then adding secondary zone loops as needed, the system can provide a single supply temperature to all connected secondary loops. When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops. Some points to remember when installing this type of system - Check valves must be installed on the supply side of each secondary loop and optionally on each return side - Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia. of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop. Secondary Loop 8 x pipe dia. min. Hot Mixed 6” max. 4x pipe dia. min. Condensing Boiler Water Heater or Supply from the Domestic Hot Water System Cold Primary Loop Secondary Loop Balancing valve is optional but may be required to provide return-side flow resistance 36 PIPING SCHEMATICS Multiple Zone Multi-Temperature System Installation Multiple heating zones requiring multiple zone supply temperatures can be piped similar to the schematic below. By using a primary boiler loop and then adding secondary zone loops as needed, the system can provide two or more zone temperatures by installing a 3-way thermostatic tempering valve on each secondary loop that requires a different temperature than the primary loop. When supplying secondary loops from the primary loop, the supply/return tees for each secondary loop must be spaced no further than 6 inches apart. This is necessary to prevent unwanted circulation in the secondary loops when the primary circulation pump is in operation. Additional secondary loops can be supplied from the primary loop. Please note that the hot water source must be capable of supplying the needed heat output and that the primary piping loop must be sized according to the total system demand of all secondary loops. Some points to remember when installing this type of system - Check valves must be installed on the supply side of each secondary loop and optionally on each return side - Tees for each secondary loop must be spaced closely together and there must be at least 8 x pipe dia. of clear pipe upstream of the supply tee and 4 x pipe dia. downstream of the return tee. This applies to each secondary loop. Hot Multiple supply water temperatures are achieved with 3-way thermostatic mixing valves as needed for different supply temperatures. Mixed Cold Secondary Loop 6” max. 8 x pipe dia. min. Primary Loop 4x pipe dia. min. Condensing Boiler Water Heater or Supply from the Domestic Hot Water System Secondary Loop 37 PIPING SCHEMATICS 4-Way Mixing Valve Installation A motorized 4-way mixing valve provides automatic control of both loop supply water temperature and return boiler water temperature and is best suited to a non-condensing boiler but can also be used on condensing boilers. By sensing the temperatures of the loop supply and boiler return, the control adjusts the position of the 4-way valve through the 4-way valve motor. Loop supply and boiler return are constantly adjusted to maintain the correct temperatures. The 4-way valve must be connected to the primary circulation loop through closely spaced tees not more than 6” apart. The control may also be equipped with an outdoor sensor to provide anticipation control based on outdoor temperatures. Outdoor Sensor (if equipped) Heated Loop Supply Supply Sensor Control Valve Motor Cooled Loop Return Condensing Boiler 4-Way Valve Boiler Return Sensor 38 PIPING SCHEMATICS Variable Speed Injection Pump Installation A Variable Speed Injection Pump is another method of providing tempered water from higher temperature boiler water. Injection mixing can be used to temper an entire single temperature primary loop by connecting it to a circulating boiler loop, or can be used to temper a secondary loop when connected to a primary loop. The injection pump is controlled by a temperature sensor on the tempered loop and the speed of the pump is varied to inject enough higher temperature water into the cooled return water to achieve the desired mix. A flow restriction valve is generally required on the injection return line to increase headloss in the circuit to match the pump’s output curve. Temperature Sensor Loop or Zone Supply Variable Speed Injection Pump Heated Supply Primary or Secondary Loop Primary or Boiler Loop Boiler Return Flow Restriction Valve Loop or Zone Return 39 PIPING SCHEMATICS Non-Condensing Boiler Installation Conventional, non-condensing boilers need protection of the return water temperature to prevent fluegas condensation that can result in corrosion and lead to premature boiler failure. For non-condensing boilers, a 3-way thermostatic mixing valve can be piped as shown above. The mixing valve can be set to provide a tempered return water to the boiler to prevent flue-gas condensation from too cold return water. Consult the boiler manufacturers recommendations to set the mixing valve. The remainder of the simple or primary/secondary system is piped the same as shown on the proceeding schematics. Heated primary loop supply Hot Cold Mixed Non-condensing Boiler 40 Cooled primary loop supply PIPING SCHEMATICS Thermal Trap Installation While not required, flow-check valves on the return side of secondary loops will further prevent unwanted circulation of the secondary loop during off-times even though the primary loop is operating. As an alternative to a flow check on the return side only, a thermal trap as shown below can be installed. The leg must dip at least 18 inches below the primary loop line to be effective. Whether a thermal loop is used or not, the same close spacing of secondary loop supply/return tees must be followed (maximum 6 inches). Also, a drain fitting may be fitted to the bottom of the thermal trap to facilitate draining. Heated primary loop supply 18” Min. Thermal traps can replace flow-check valves on secondary loop return lines. 41 APPENDIX A MAKING CRIMPSERT CRIMP CONNECTIONS Follow these instructions carefully to ensure proper crimp connections. 1. 4. 2. The tubing should be cut squarely and evenly without burrs. Uneven, jagged or irregular cuts will produce unsatisfactory connections. Slide the correct size crimp ring over the tubing end. 90° 1 3. /8 to 1/4” CORRECT Insert the fitting into the pipe to the shoulder or tube stop. Position the ring 1/8” to 1/4” from the end of the tubing. INCORRECT 5. 4. The ring must be attached straight. Center the crimping tool jaws exactly over the ring. Keep the tool at 90° and close the handles completely. DO NOT CRIMP TWICE. 6. When checking crimps with a GO/NO GO gauge, push the gauge STRAIGHT DOWN over the crimped ring. NEVER slide the gauge in from the side. Do not attempt to gauge the crimp at the jaw overlap area. The overlap area is indicated by a slight removal of the blackening treatment. You have a good crimp if the GO gauge fits the ring and the NO GO does not. You have a bad crimp if the GO gauge does not fit the ring or the NO GO gauge does fit. Bad crimps must be cut out of the tubing and replaced. If you check the crimps with a micrometer or caliper, use the dimensions shown below. CRIMP DIAMETER DIMENSIONS Crimp outside diameters should fall within these dimensions when measured with a micrometer or caliper. RING SIZE 3/8” 1/2” 5/8" 3/4” 1” 1 1/4” 42 MINIMUM 0.580” 0.700” 0.815" 0.945” 1.175” 1.431 MAXIMUM 0.595” 0.715” 0.830" 0.960” 1.190” 1.445 APPENDIX B DAILY TOOL CALIBRATION CHECK Check tool calibration at least twice daily. Vanguard recommends at least the first and last crimp of the day. Accurately adjusted crimping tools are critical to the success of this fitting system. If the crimped rings do not gauge properly, the tool needs adjustment. The method for checking the crimping tool for proper calibration is: 2. 4. Slide the correct size “GO” side of the crimp gauge over the crimp ring in at least FOUR places. DO NOT gauge the crimp at the jaw overlap area. If the “GO” side slides over the crimp ring, attempt to slide the correct size “NO GO” side of the gauge over the crimp ring in at least four places. DO NOT gauge the crimp at the jaw overlap area. 1. Assemble and crimp a fitting (see page 5). 3. If the “GO” side of the gauge fails to slide over the ring, the crimp tool requires calibration (ring is under crimped). REMEMBER: A crimp tool which has worn parts may not calibrate. Return worn tools for repair or replacement. 5. If the “NO GO” side of the gauge slides over the crimp ring, the crimp tool requires calibration (ring is overcrimped). REMEMBER: A crimp tool which requires frequent calibration may require repair or replacement. 43 APPENDIX C ADJUSTING “HCM” TOOLS The HCM compact crimp tools are generally not capable of over-crimping (the “NO GO” gauge fits over the crimped ring). However, normal wear may cause the crimp size to increase to above the maximum allowed (the “GO” gauge does NOT fit). Tools manufactured prior to December 1996 must be returned for calibration if they do not crimp to the dimensions shown on page 5. Tools manufactured after that date have an adjustment feature built in and are easily identified by a hex head on the back-pin, see Figure 1. These tools may be adjusted to decrease the crimp diameter up to five times. When an HCM crimp tool requires adjustment to a smaller crimp dimension, note the number to which the line on the hex head of the back pin points. (See Figure 1) Carefully remove the retaining clip by inserting a small flat blade screwdriver in the loop of the clip and turning the screwdriver. Figure 1 Remove Back Pin Retaining Clip From the clip end of the back pin, push it towards the tool body until the hex head on the other end of the pin just clears the body. CAUTION! The retaining clip is made from spring steel and may fly off of the pin if not removed carefully, possibly causing eye damage and loss of the clip. Rotate the pin until the line on the hex head points to the next higher number on the frame. Push the pin back into the frame and replace the retaining clip. To reduce crimp size, rotate Back Pin to Next Higher Number Crimp a test joint and check the crimped ring for proper sizing with a GO/NO GO gauge or by measurement (see page 5). Severely worn tools may require further adjustment. As the tool continues to wear with use, simply repeat these instructions as required. 44 APPENDIX D ADJUSTING “HAR” TOOLS An accurately adjusted crimping tool is critical to the success of this fitting system. If the crimped rings do not gauge properly, the tool needs adjustment. HAR TOOL The method for adjusting the HAR tool is: 1. 2. Open the tool handles. Note the position of the notched head of the adjustment cam in relation to the Phillips-head retaining screw. Retaining Screw Adjustment Cam 3. 4. Carefully remove the retaining screw and rotate the cam counter-clockwise slightly until the retaining screw can be installed in the other threaded hole. This Reinstall Retaining provides about 1/2 Screw notch of adjustment. Test the tool by crimping a joint and checking the crimped ring with the “GO” gauge. If the “GO” gauge slides over the ring then no further adjustment is needed. If the “GO” gauge will not slide over the crimped ring, then repeat the adjustment by rotating the adjustment screw counterclockwise an additional 1/2 notch and reinstalling the retaining screw in the other threaded hole. A tool adjusted to the middle of the crimp diameter range may reduce the frequency of calibrations. 45 APPENDIX E ADJUSTING “HAR34ST” TOOL An accurately adjusted crimping tool is critical to the success of an insert fitting system. If the crimped rings do not gauge properly, the tools need adjustment. HAR34ST TOOL The method for adjusting the HAR34ST tool is: 1. Open the han- 2. dles and loosen the BOTTOM adjustment screw with the correct size hex key wrench. 3. If the “GO” portion of the gauge will not slide over the ring (crimp is too large) or the crimp measures larger than the maximum dimension (page 5), tighten the TOP adjustment screw 1/4 turn. Then tighten the BOTTOM adjustment screw. 4. If the “NO GO” gauge slides over the ring (crimp is too small) or if the crimp measures smaller than the minimum dimension (page 5), loosen the TOP adjustment screw 1/4 turn. Then tighten the BOTTOM adjustment screw. Crimp a new joint after each adjustment. Repeat the adjustment as necessary to calibrate the tool. The “GO” gauge shall slide over the crimped ring, the “NO GO” shall not slide over the crimped ring, or the crimp measures within the dimensions shown on page 5. A tool adjusted to the middle of the crimp diameter range may reduce the frequency of calibrations. 46 APPENDIX F VANEX SERIES PEX REPAIR KIT The Vanguard XLHRK3 (1/2”) and XLHRK4 (3/4”) field repair kits are for Vanex series PEX tubing in slab-on-grade installations. While the best policy is to use only continuous lengths of tubing for plumbing lines, extenuating circumstances may dictate that a line be repaired due to a kink, puncture or other damage. If the line is damaged in more than one location, we strongly recommend that the entire line be replaced. Undamaged lengths of the replaced line can be further utilized by cutting out the damaged section and using the remaining length(s) for other, shorter line(s). Please read and understand these instructions before attempting a repair. Failure to follow these guidelines may result in leakage or failure of the repair. It is the responsibility of the user to read and understand these instructions in their entirety prior to attempting a repair. 1) Make a clean cut on both sides of the damaged area. Cut the tubing cleanly and square. 2) Slide the provided, 1” heat shrink tubing onto one end of the cut PEX and back a few inches. Slide the provided crimp rings onto each end of the cut PEX and insert the fitting into both tubes until the ends contact the tube stop on the fitting. Position each crimp ring 1/8” to 1/4” from the end of the tubing. See Figure 1 Figure 1 connection. Recheck the crimps with the GO/NOGO gauge. Do not proceed until both of the crimps pass the gauging test. 4) Pressurize the repaired loop and check for leaks. We recommend a pressure of 100 psig and a minimum time of 15 minutes. If the joint passes both a gauging and a pressure test proceed to the next step. If the connection fails either test, cut out the connection, make any necessary tool adjustment and remake the connection. 5) Slide the length of heat-shrink tubing over the repair joint so that it is approximately centered. See Figure 2 Figure 2 6) Using a heat-gun on the low setting, apply heat to the shrink tube evenly with a constant motion. Never use an open flame! Continue heating until the shrink tube conforms to the shape of the joint and pulls down snugly around the tubing. See Figure 3. Figure 3 7) The repair should be allowed to cool for a few minutes before final placement of tubing. 3) Using the correct size PEX crimping tool, crimp each ring while holding the tool at a 90° angle to the tube with the jaws of the tool centered over the ring. After completing both crimps, check each one using the GO/NO-GO gauge (HAC34),. The GO portion of the gauge must slide over the crimped ring (except at the jaw overlap area) and the NO-GO portion of the gauge must not slide over the ring. If either or both of the completed crimps fail to pass a GO/NO-GO gauging, the connection must be cut out completely and replaced. Use a new fitting and crimp rings and trim back the PEX tubing on both sides to eliminate the previously crimped portions. Make any necessary adjustments to the crimp tool and remake the 47 CONTINENTAL UNITED STATES 1-800-775-5039 OUTSIDE UNITED STATES 888-747-3739 FAX 1-800-775-4068 www.vanguardpipe.com 901 N. Vanguard Street McPherson, KS 67460 QHMN02VS 7.05 48