DESIGN & INSTALLATION GUIDE - Infloor

1 IIDESIGN & INSTALLATION because it s ir doesn t mean it s Infloor Cha pter1 Cha pter2PG3 ..Intr oduction4 ..Advantages of anIn oor HeatingSys tem5 .. Tubing6 ..4-WayMixing Valves7 ..Res idential/Light CommercialMani foldsCopper Manifolds andBrassMani folds8 ..Site Preparation9 ..ConcreteSlabsWood Sub oorsPrecastConcreteSub oors, In oorboard, Warmboard, Emission plates12 .. HeatLoss13 .. Required FloorOutputFloorCoverings14 .. ActualFloorOutputand Del iveryWaterTemperature15 .. TubeSpac ing andTotal Tube RequiredNumberand Length of Tube Circuits16 .. WaterFlowsCircuitHeadPressure17 .. ManifoldIns tal lat ion CopperManifolds,Res idential/Light Commercial ManifoldsManifold Assembly, Manifol d/Tu bing18 .. Manifold Assembly/Tubing Connection/Brass Manifolds19 .. Tube LayoutIns tall T ube20 .. Calculations21 .. TubePres sureTestSpl ice Instructions23 .. ControlStr ategyCast Iron Boilers24.

2 High-E ciencyCon densingBoilers25 .. WaterHea tersGrou nd-Source heat Pumps26 .. Wood/CoalFiredBoi lersAlternativeSys tems27 .. SolarGainZoningDESCRIPTION/APPLICATIONSC hapter1C OMPONENTSC hapter2 SITE PREPARATIONC hapter3 SYSTEMDESIGNC hapter4I NSTALLATIONC hapter5C ONTROL OPTIONSC hapter6 PGI NFLOOR RESIDENTIAL/LIGHTCOMMERCIALT able of Contents28 .. SWC 5 Control Box29 .. Wiring Options30 .. In oor Single Zone Switching RelayThermostat: Heating System Applications31 .. Thermostat: Warm Floor Applications32 .. PurgingSystem Treatment33In oor System Treatment, Formula 10 ,34 .. Thermal Mass35 .. Suspended FloorsExisting Concrete Slab36 .. Concrete Slab On or Below GradeFloor Coverings37 .. Installing Tile or Marble over Therma-Floor Installing In oor Heating Systems in Mortar BedsInstalling Hardwood Floors Over In oor Heating Systems38 .. Glue-Down Laminated HardwoodFloating FloorSolid Hardwood39.

3 Nail-Down Sleeper SystemSingle-Layer Nail-Down SystemDual-Layer Nail-Down System40 .. Carpet and Pad41 .. Tube Speci cations42 .. Head Loss Tables with water and 50% Propylene Glycol45 .. Friction Loss Chart for Copper Pipe46 .. Non-Condensing BoilerMulti-Zone with 4-Way Mixing Valve, Multi-Zone with Variable Speed Injection Pump, Multi-Zone with 3- & 4-Way Mixing Valve, High/Low Temp Zones with 4-Way Mixing Valve, High/Low Temp Zones & DHW51 .. Condensing High-E ciency Boiler52 .. Ground Source heat Pump Multi-Zone53 .. Wood/Coal Boiler Multi-Zone with 4-Way Mixing Valve54 .. water Heater Closed-Loop Multi-Zone,, heat -Exchanger Multi-Zone57 .. Electric Control Box, In oor System Control58 .. In oor SWC 5 Control Box Wiring Diagrams59 .. Dual-Sensing Thermostat Wiring Diagrams61 .. Copper Manifold Dimensions62 .. Floor Covering Transition Details63 .. De nitions65 .. CSI Recommended Speci cationsWIRINGC hapter 7 SYSTEM START-UPChapter 8 THERMAL MASS & FLOOR COVERINGSC hapter 9 APPENDIXC hapter 10 PGChapter 1 INTRODUCTIONR adiant oor heating isn t a newconcept.

4 The ancient Romans usedcrude wood res built under their oors to heat their structures. Usingwarm oors to heat their homesproved very e ective. Nearly everyone now agrees that aradiant oor is the world s mostcomfortable heating system. Thatmakes oors wonderfully warm. Thesystem does not circulate dust orallergens. The system operates moree ciently than conventional sys-tems. These types of bene ts aren tonly limited to speci c kinds ofstructures. Today, radiant heatingsystems are capable of heatinghomes, custom and standard residen-tial, businesses, warehouses, com-mercial hangars, and snowmelt sys-tems. In oor Heating Systems o ers hotwater systems that are perfect Any residential, com-mercial or industrial building cannow take advantage of all the bene- ts radiant oor heating has to o projects can be new construc-tion, remodel, small additions, retro- t, industrial and snowmelting oor residential system compo-nents may be used for space heatingor warm oor applications.

5 Each dif-ferent type of application has a veryspeci c DESIGN criterion. This manu-al has been provided to assist thedesigner/installer with the necessaryguidelines to DESIGN , select, andinstall the proper In oor compo-nents for residential/ light commer-cial 1 ADVANTAGES OF ANINFLOOR HEATING SYSTEMoor Heating Systems er the customerand dealer various options when selecting aradiant heating system. Ioor s Residential /Light Commercial Systems include coppermanifolds, brass manifolds, mixing valvesand related controls, zoning controls withdomestic hot water priority, pre-piped andwired control panels, hydraulic separators,pumping stations, emission plates, andoorboard. Inoor oers all the relatedcomponents for a complete system with theexception of the heat source. has pro-vided general diagrams to include severalheat plant options. Manufacturers specca-tions of the heat source should be selecting tubing, it is important tocompare pressure and temperature ratings aswell as the wall thickness for heat transferand durability.

6 The application environmentor method of INSTALLATION , the need for barrieror non-barrier tubing, y and weightare additional considerations. Whether theinstallation method requires PEX tubing orAL PEX tubing for proper INSTALLATION . Inoorhas all of these products available to meet allthe types of INSTALLATION practicesfound in radiant LAYOUT COMPONENTS5 TUBINGI noor tubing is available in 3 con-ations: non-barrier tubing fromcross-linked polyethylene (PEX), oxy-gen barrier tubing from cross-linkedpolyethylene (BPEX), and pex alu-minum pex tubing from cross-linkedpolyethylene (PEX-AL-PEX). Thesetubes provide excellent performancein radiant applications and providethe system designer with the great-est options for component selectionto best t the Inoor tubing is rated for 100 psi(689 kPa) at 180 F (82 C). Theseconditions far exceed those normallyfound in radiant heating applications where system operating pressures are usually 12 to 20 psi (82 to 138 kPa)with maximum temperatures usual-ly reaching 140 F (60 C).

7 Whenoxygen diusion barriers arerequired, Inoor tubing meets theGerman DIN 4726 ion ofless than gram of oxygen percubic meter per day. Chemical compatibility varies withthe various tubing. While all tubesare not ected by normal system and additives, some operatingenvironments may indicate a needfor a c tube preference. PEX(13mm) (13mm) (16mm) (689 kPa)(82 C)(270m)BPEX(10mm)(10mm) (13mm) (689 kPa)(82 C)(180m)(13mm) (13mm) (16mm) (689 kPa)(82 C)(270m)Chapter 2 CROSS-LINKING CREATESBONDS BETWEEN INDIVIDUALMOLECULAR STRANDS,GREATLY ENHANCING THETUBE S TEMPERATURE ANDCHEMICAL Part# Size L Press. Temp. ASTM DIN Length Weight250503/8 3/8 1/2 100 psi180 F F-876600 27 lbs(10mm)(10mm)(13mm) (689 kPA)(82 C)(180m)250601/2 1/2 5/8 100 psi180 F F-876900 50 lbs250003/8 3/8 1/2 100 psi180 F F-876600 27 lbs250101/2 1/2 5/8 100 psi180 F F-8764726900 50 lbsCOMPONENTSC hapter 2In oor tubing may be installed in the concreteslab, on top of a sub oor and embedded inTherma- oor, a light weight gypsum cementthat provides excellent thermal mass whileadding sound control and re protection to the oor assembly, on top of an existing slab witha layer of insulation between the slab and thegypsum cement encased tubing, attached to awood sub oor by using In oorboard, andWarmboard applications requires our AL PEXproducts.

8 Retro t applications staple up withemission plates may be used, however closeattention needs to be paid actual room heatloss and supplemental heat may still berequired in colder MIXING VALVEST hese valves provide tempering of water tothe radiant zones. While there are variations inthe use of these components, their main pur-pose is to provide the proper temperature tothe radiant zone when the water temperaturefrom the heat source is higher than therequired water temperature for the radiantzone. Four-way valves are typically used totemper water for the whole radiant AT IONS M AY B EUSED INRETROFITAPPLICATIONSBUTREQUIRECLOS E AT TENTION TO DESIGN ANDINSTA L L ATION PARAMETERSFORPROPER (OPTIONAL)INSULATIONCONCRETESLABCONCRETE SLABTHERMA-FLOOR OVERCONCRETETHERMA-FLOOR OVERWOODSUBFLOOR10 SUPPLY TO FLOOR RETURNFROM FLOORHOT FROMBOILERRETURNTO BOILERMIXINGVALVEDIAGRAMMIXINGVALVEM ultiple valves may be used in a systemthat requires multiple water valves may be controlled by set pointcontrol that will modulate the valve, or canbe controlled by an actuator motor that hasindoor/outdoor reset control which will basethe delivery water temperature to the ooron outdoor actual " AIR SPACE INFLOORTUBINGFOIL FACEDINSULATIONFLOOR JOISTSUBFLOORHEAT EMISSION PLATEUNDERFLOORDIAGRAMCOMPONENTSC hapter 27 COPPER MANIFOLDSC opper Manifolds provide a low-cost mani-fold option for use with In oor HeatingSystems.

9 These manifolds are o ered inmany con gurations. These manifolds con-sist of 1 (25mm) mains with (13mm)outlets, and are available in valved and non-valved con gurations of 2 and 3 outlets. Thevalved version include (13mm) brass fullport ball valve with stainless steel ball, forpositive shut o on the outlets. (1-1/4 and1-1/2 mains with outlets and with andwithout valves are available as custom orderitems.)The manifolds are standard 1 (25mm) cop-per pipe size and may be joined using a stan-dard 1 copper coupling to increase the num-ber of outlets per manifold assembly. A 1 (25mm) copper cap is used to seal the end ofthe manifold, or a purge 90 with vent endpiece (#28400) may be used instead for easierpurging. The tube outlets are brazed to themains to allow for soldering of adjoiningmanifolds and ttings. Ball Valves are sol-dered to the MANIFOLDSFor residential and commercial heating sys-tems In oor Brass manifolds provide com-plete control over each loop and will precise-ly regulate the ow and allow for individualloop control as well as isolation, air elimina-tion, and purging are PEX crimp or PEX compression.

10 These ttings are available in (13mm) male coppersweat x either 3/8 (10mm) or (13mm) crimp orcompression. Compression ttings require no spe-cial tools for tightening onto tubing. PEX crimptool or Oetiker crimp system must be used withPEX crimp ttings. Solder ttings to the outlets onthe manifolds before attempting to attach tubing. COPPER MANIFOLDSTUBING CONNECTIONST hese manifolds consist of a supply andreturn manifold with mounting brack-ets completely assembled. Supply mani-fold complete with micrometric balanc-ing valves with ow curve manifold complete with shuto valves that can utilize thermo actua-tors. Pair of shut o valves one on thesupply manifold and one on the returnmanifold with color-coded handles forsupply and return. End tting assembly,which consist of a drain valve ttingand an automatic air vent. The supplyand return manifolds have a maintrunk size that will accommodateeither 1 or 1-1/4 ttings.