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Piping Schematics
Chapter 13 Piping Schematics Piping Schematic Level 1 Control • Water heater • Closed system • Single-temperature radiant floor heating What to look for: • Bypass loop – A bypass loop is not required when using a water heater with radiant heat. Water Heater Closed System • Radiant Low Temperature loop circulator – A circulator (P1) has been added in the radiant loop. This circulator is necessary to insureP1 flow through the radiant panel. Where: All low-temperature radiant applications (< 145˚F) Why: This illustration shows a • Isolation valves – Isolation dedicated water heater supplying valves are recommended at water for a single radiant manifold. the supply and return radiant The water heater provides the manifolds to facilitate purging required supply water temperature and service. Isolation valves or directly to the radiant panel, flanges are recommended at with the water temperature all circulators for easy service. controlled by the water heater’s • Pressure-relief valve – When internal aquastat. As a result, using a water heater as a heat no additional water temperature Water source, install a 30-pound relief control device is needed. Heater valve in the near heat source Important: Consult local piping. Ensure there is NO building codes prior to isolation between the relief valve installing a water heater and the water heater. as a heat source for Water Heater radiantClosed heating. System ost water heaters come M equipped with a Temperature and Pressure (T&P) Valve. Do not remove this valve from the water heater, as it provides additional temperature safety. • Pressure-reducing valve – Uponor recommends installing a pressure-reducing valve in the fresh water makeup line to the water heater. This is necessary to properly set the system fill pressure for additional safety. • Zoning options – See pages 127-131. • Specific wiring schematic – See pages 182-183. Legend Low Temperature Manifold with Telestats P1 Manifold without Telestats Manifold with Valves P1 Circulator Expansion Tank and Air Separator Water Heater Ball Valve Zone Valve Legend Pressure Temperature Gauge Manifold with Telestats Complete Design Assistance Manual — Chapter 13 – Piping Schematics Manifold without Telestats Manifold with Valves 139 Piping Schematic Level I Control • Modulating-condensing boiler • Single-temperature radiant floor heating Where: All radiant and snow melt applications Why: This illustration shows a condensing boiler supplying water to a single radiant manifold for space heat or snow melting. Condensing boilers are designed to operate safely and efficiently at low return water temperatures. As a result, no additional water temperature control device is required. The boiler operating control is set up to provide the Condensing Boiler correct supply water temperature Single Temperature to the radiant panel. When using a condensing boiler in radiant and snow melt applications, consult the boiler manufacturer’s installation and operation instructions for specific near-boiler piping information and return water temperature limitations. What to look for: • Bypass loop – A bypass loop is not required when using a condensing boiler with radiant heat. • Boiler circulator – Many condensing boilers are packaged with an internal circulator (BP), but require an additional system circulator (P1). Consult the boiler manufacturer’s installation and operation instructions for specific requirements. If the boiler is equipped with a system circulator, flow (gpm) and head requirements for the radiant panels may exceed the capacity of that circulator. Review radiant flow requirements and size the system circulator appropriately. • Isolation valves – Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options – See pages 137-131. • Specific wiring schematic – See page 163. Legend Manifold with Telestats Legend Manifold without Telestats Manifold with Telestats Manifold with Valves Manifold without Telestats P1 Circulator Manifold with Valves P1 Circulator Expansion Tank and Air Separator Ball Valve Expansion Tank and Air Separator Ball Valve BP Zone Valve P1 Pressure Temperature Gauge Zone Valve Pressure Temperature Gauge Modulating-condensing Boiler Modulating-condensing Boiler 140 Chapter 13 – Piping Schematics — www.uponorpro.com Piping Schematic Level I Control temperature to the radiant panel. When using a condensing boiler in radiant and snow melt applications, consult the boiler manufacturer’s installation and operation instructions for specific near-boiler piping information and return water temperatures limitations. • Modulating-condensing boiler • Single-temperature radiant floor heating • Multiple manifolds Where: All radiant and snow melt applications Why: This illustration shows a condensing boiler supplying water to multiple radiant manifolds operating at the same supply water temperature. Condensing boilers are designed to operate safely and efficiently at low return water temperatures. As a result, no additional water temperature control device is required. The boiler operating control is set up to provide the correct supply water Condensing Boiler Single Temperature Multiple Manifolds What to look for: • Bypass loop — A bypass loop is not required when using a condensing boiler with radiant heat. • Boiler circulator — Many condensing boilers are packaged with an internal circulator (BP), but require additional system circulators (P1). Consult the boiler manufacturer’s installation and operation instructions for specific requirements. If the boiler is equipped with a system circulator, flow (gpm) and head requirements for the radiant panels may exceed the capacity of that circulator. Review radiant flow requirements and size the system circulator appropriately. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 178-179. Legend Manifold with Telestats Legend Condensing Boiler Single Temperature Multiple Manifolds Manifold without Telestats Manifold Manifold with with Telestats Valves P1 Manifold without Telestats Circulator Manifold with Valves Expansion Tank P1 and Air Separator Circulator P1 P2 BP Ball Valve Expansion Tank and Air Separator Zone Valve P1 BP P2 Ball Valve Pressure Temperature Gauge Zone Valve Modulating-condensing Boiler Pressure Temperature Gauge Modulating-condensing Boiler Complete Design Assistance Manual — Chapter 13 – Piping Schematics 141 Piping Schematic Level I Control • Modulating-condensing boiler • Dual-temperature radiant floor heating • Three-way tempering valve Where: Multiple temperature radiant applications Legend Manifold with Telestats Manifold without Telestats Why: This illustration shows a condensing boiler supplying water to multiple radiant panels requiring dramatically different supply water temperature, or having different installation methods (i.e. concrete vs. Joist TrakTM). Condensing boilers are designed to operate safely and efficiently at low return water temperatures. As a result, no additional water temperature control device is required for the higher temperature radiant. The boiler operating control is set up to provide the correct supply water temperature to the high temperature radiant panel. For the low-temperature radiant panel, an Uponor Three-way Tempering Valve (T1) will mix hotter boiler water with cooler radiant return Condensing Boiler water to achieve the selected 3-way Tempering Valve Temperature radiantLow supply water temperature High Temperature per the valve setting (See Chapter 12 for details on Three-way Tempering Valve operation). A Three-way Tempering Valve allows the radiant supply water temperature to be adjusted from 80°F to 160°F. When using a condensing boiler in radiant applications, consult the boiler manufacturer’s installation and operation instructions for specific near boiler piping information and return water temperature limitations. What to look for: • Bypass loop — A bypass loop is not required when using a condensing boiler with radiant heat. temperature, closing the hot (+) port of the valve. • High-temperature radiant loop circulator — Many condensing boilers are packaged with an internal circulator (BP), but require an additional system circulator (P2). Consult the boiler manufacturer’s installation and operation instructions for specific requirements. If the boiler is equipped with a system circulator, flow (gpm) and head requirements for the radiant panel may exceed the capacity of that circulator. Review radiant flow requirements and sized the system circulator appropriately. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Low-temperature radiant loop circulator — Circulators (P1) have been added on the radiant loop side of the Threeway Tempering Valve. This circulator is necessary to insure flow through the radiant panel. Without this circulator, flow through the radiant panel would stop once the tempering valve senses the supply water has reached the desired • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 178-179. Legend Manifold with Telestats Manifold with Valves Manifold without Telestats P1 Circulator Manifold with Valves P1 Circulator P1 Expansion Tank and Air Separator Ball Valve Expansion Tank and Air Separator Ball Valve Zone Valve P2 BP Zone Valve Pressure Temperature Gauge T1 Pressure Temperature Gaug Modulating-condensing Boiler Modulating-condensing Bo 142 Chapter 13 – Piping Schematics — www.uponorpro.com Piping Schematic Level I Control radiant applications, consult the boiler manufacturer’s installation and operation instructions for specific near-boiler piping information and return water temperature limitations. • Electric boiler • Single-temperature radiant floor heating Where: All radiant applications What to look for: Why: This illustration shows an electric boiler supplying water to a single radiant panel. Electric boilers are designed to operate safely and efficiently at low return water temperatures. As a result, no additional water temperature control device is required. The boiler high limit is set to provide the maximum supply water Electric Boiler Single Temperature temperature to the radiant panel. When using an electric boiler in • Bypass loop — A bypass loop is not required when using an electric boiler with radiant heat. • Boiler circulator — Electric boilers are not typically packaged with a circulator, and therefore require the installation of a system circulator (P1). Review radiant flow requirements (gpm and head) and size the system circulator appropriately. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See page 163. Legend Manifold with Telestats Manifold without Telestats Manifold with Valves P1 Legend P1 Circulator Manifold with Telestats Electric Boiler Single Temperature Expansion Tank Telestats Manifold without and Air Separator Manifold with Valves Ball Valve P1 P1 Circulator Zone Valve Pressure Temperature Gauge Expansion Tank and Air Separator Ball Valve Electric Boiler Zone Valve Pressure Temperature Gauge Electric Boiler Complete Design Assistance Manual — Chapter 13 – Piping Schematics 143 Piping Schematic Level I Control • Electric boiler • Single-temperature radiant floor heating • Multiple manifolds Where: All radiant applications Why: This illustration shows an electric boiler supplying water to multiple radiant panels operating at the same supply water temperature. Electric boilers are designed to operate safely and efficiently at low return water temperatures. As a result, no additional water temperature control device is required. The Electric Boiler Single Temperature Multiple Manifolds boiler high limit is set to provide the maximum supply water temperature to the radiant panel. When using an electric boiler in radiant applications, consult the boiler manufacturer’s installation and operation instructions for specific near-boiler piping information. What to look for: • Bypass loop — A bypass loop is not required when using an electric boiler with radiant heat. • Boiler circulator — Electric boilers are not packaged with a circulator, and therefore require the installation of additional system circulators (P1 and P2). Review radiant flow requirements (gpm and head) and size the system circulators appropriately. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic See pages 178-179. Legend Manifold with Telesta Legend P1 Manifold without Telest Manifold with Telestats Manifold with Valves Manifold without Telestats P1 Circulator Manifold with Valves P2 P1 Circulator Expansion Tank and Air Separator Ball Valve Expansion Tank and Air Separator Zone Valve Ball Valve Pressure Temperature Ga Zone Valve Electric Boiler Pressure Temperature Gauge Electric Boiler 144 Chapter 13 – Piping Schematics — www.uponorpro.com Piping Schematic Level I Control using an electric boiler in radiant applications, consult the boiler manufacturer’s installation and operation instructions for specific near boiler piping information and return water temperature limitations. • Electric boiler • Multiple-temperature radiant floor heating • Three-way tempering valve Where: Multiple temperature radiant applications What to look for: • Bypass loop — A bypass loop Why: This illustration shows an is not required when using an electric boiler supplying water to electric boiler with radiant heat. multiple radiant panels requiring dramatically different supply • Low-temperature radiant water temperatures, or having loop circulator — A circulator different installation methods (P1) has been added on the (i.e. concrete vs. Joist Trak). radiant loop side of the ThreeElectric boilers are designed to way Tempering Valve. This operate safely and efficiently at circulator is necessary to insure low return water temperatures. flow through the radiant panel. As a result, no additional water Without this circulator, temperature control device is flow through the radiant panel required for the higher temperature would stop once the Three-way radiant. The boiler high limit is Tempering Valve senses the set to provide the maximum supply water has reached the supply water temperature to the desired temperature, closing the Electric Boiler Electric Boiler 3-Way Tempering Valve hot (+) port of the valve. high temperature radiant panel. 3-Way Valve LowTempering Temperature For the low temperature radiant LowHigh Temperature Temperature High Temperature panel, an Uponor Three-way Tempering Valve is used to mix hot boiler water with cooler radiant return water to achieve the selected radiant supply water temperature per the valve setting (see Chapter 12 for details on Three-way Tempering Valve operation). A Three-way Tempering Valve allows the radiant supply water temperature to be adjusted from 80°F to 160°F. When T1 T1 • High-temperature radiant loop circulator — Electric boilers are not packaged with circulators, and therefore require an additional system circulator (P2). Consult the boiler manufacturer’s installation and operation instructions for specific requirements. Review radiant flow requirements and size the system circulator appropriately. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 178-179. Legend Legend P2 P2 Manifold with Telestats Manifold with Telestats Manifold without Telestats Manifold without Telestats Manifold with Valves Manifold with Valves P1 P1 P1 Circulator P1 Circulator Expansion Tank and AirTank Separator Expansion and Air Separator Ball Valve Ball Valve Zone Valve Zone Valve Pressure Temperature Gauge Pressure Temperature Gauge Electric Boiler Electric Boiler Complete Design Assistance Manual — Chapter 13 – Piping Schematics 145 Piping Schematic Level II Control • Non-condensing boiler • Three-way tempering valve Where: All low-temperature radiant applications (< 160° F) Legend Manifold with Telestats Why: This illustration shows a non-condensing boiler supplying water to a single radiant panel. The Uponor Three-way Tempering Valve (T1) is used to mix hot boiler water with cooler radiant return water to achieve the selected radiant supply water temperature per the valve setting (see Chapter 12 for details on Three-way Tempering Valve operation). In low-temperature (< 160°F) radiant heating applications using a noncondensing boiler, the boiler supply water temperature must be reduced to the proper radiant supply water temperature. A Three-way Tempering Valve allows the radiant supply water temperature to be adjusted from 80°F to 160°F. Non Condensing Boiler 3-Way Tempering Valve What to look for: r adiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. Non-condensing boilers require minimum return water temperatures of 140°F or higher (see boiler manufacturer’s installation instructions for specific requirements) to prevent flue gas condensation, potential internal corrosion, and potential thermal shock. The bypass loop allows an amount of hot boiler water (depending on bypass valve position) to circulate through the boiler to maintain return water temperatures above the minimum, preventing the boiler’s flue gasses from condensing. Condensed flue gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Radiant loop circulator — A circulator (P1) has been added on the radiant loop side of the Three-way Tempering Valve. This circulator is necessary to insure flow through the radiant panel. Without this circulator, flow through the radiant panel would stop once the Three-way Tempering Valve senses the supply water has reached the desired temperature, closing the hot (+) port of the valve. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Bypass valve setting — At system startup, position a suitable valve (V1) in the half-open position. If the • Specific wiring schematic — See page 163. Legen Manifold with Manifold without Telestats Manifold withou Manifold with Valves P1 Manifold with P1 Circulator P1 Circulato T1 Expansion Tank and Air Separator V1 Expansion T and Air Sepa Ball Valve Ball Valv Zone Valve BP Zone Val Pressure Temperature Gauge Pressure Tempera Non-condensing Boiler Non-condensin 146 Chapter 13 – Piping Schematics — www.uponorpro.com Non-condensing boiler Three-way tempering valves Dual temperature radiant floor heating Legend Piping Schematic Level II Control • Non-condensing boiler • Three-way tempering valve • Dual-temperature radiant floor heating Where: All low-temperature radiant applications (< 160°F) Why: This illustration shows a non-condensing boiler supplying water to a multiple radiant panels requiring dramatically different supply water temperatures, or having different installation methods (i.e. concrete vs. Joist Trak). The Uponor Three-way Tempering Valves (T1 and T2) will mix hot boiler water with cooler radiant return water to achieve the selected radiant supply water temperatures per the valve settings (see Chapter 12 for details on Three-way Tempering Valve operation). In low-temperature (< 160°F) radiant heating applications using a non-condensing boiler, the boiler supply water temperature must be reduced to the proper radiant supply water temperature. A Three-way Tempering Valve allows the radiant supply water temperature to be adjusted from 80°F to 160°F. return water temperatures above the minimum, preventing the boiler’s flue gasses from condensing. Condensed flue T1 gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Bypass valve setting — At system startup, position aT2 suitable valve (V1) in the halfV1 open position. If the radiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. P1 • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — P2 See pages 127-131. • Specific Wiring Schematic — See pages 178-179. Manifold with Valves P1 Circulator Expansion Tank and Air Separator Zone Valve Pressure Temperature Gauge Non-condensing Boiler Legend P1 Manifold with Telestats Manifold without Telestat T1 Manifold with Valves P1 Circulator P2 What to look for: • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. Noncondensing boilers require minimum return water temperatures of 140°F or higher (see boiler manufacturer’s installation instructions for specific requirements) to prevent flue gas condensation, potential internal corrosion, and potential thermal shock. The bypass loop allows an amount of hot boiler water (depending on bypass valve position) to circulate through the boiler to maintain Complete Design Assistance Manual Manifold without Telestats Ball Valve BP • Radiant loop circulator — Circulators (P1 and P2) have been added on the radiant boiler loopNon-condensing sides of each ThreeThree-way tempering valves way Dual Tempering Valve. These temperature radiant floor heating circulators are necessary to insure flow through the radiant panels. Without these circulators, flow through the radiant panels would stop once the Three-way Tempering Valves sense the supply water has reached the desired temperature, closing the hot (+) port of the valve. Manifold with Telestats — T2 Expansion Tank and Air Separator V1 Ball Valve Zone Valve BP Pressure Temperature Gaug Non-condensing Boiler Chapter 13 – Piping Schematics 147 Piping Schematic Level II Control • Non-condensing boiler • Three-way tempering valve • Dual-temperature radiant floor heating • High-temperature radiation Where: All low-temperature radiant applications (< 160°F), with high-temperature radiation Why: This illustration shows a non-condensing boiler supplying water to multiple radiant panels requiring dramatically different supply water temperatures or having different installation methods (i.e. concrete vs. Joist Trak) plus high-temperature radiation (baseboard, panel radiators, fan coils, etc.). The Uponor Three-way Tempering Valves (T1 and T2) are used to mix hot boiler water with cooler radiant return water to achieve the selected radiant supply water temperature per the valve settings (see Chapter 12 for details on Three-way Tempering Valve operation). In low-temperature (< 160°F) radiant heating applications using a noncondensing boiler, the boiler supply water temperature must be reduced to the proper radiant supply water temperature. A Three-way Tempering Valve allows the radiant supply water temperature to be adjusted from 80°F to 160°F. The hightemperature radiation is supplied directly with boiler water. 148 What to look for: • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. Noncondensing boilers require minimum return water temperatures of 140°F or higher (see boiler manufacturer’s installation instructions for requirements) to prevent flue gas condensation, potential internal corrosion, and potential thermal shock. The bypass loop allows an amount of hot boiler water (depending on bypass valve position) to circulate through the boiler to maintain return water temperatures above the minimum, preventing the boiler’s flue gasses from condensing. Condensed flue gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Bypass valve setting — At system startup, position a suitable valve (V1) in the halfopen position. If the radiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. • Radiant loop circulator — Circulators (P1 and P2) have been added on the radiant loop sides of the Three-way Tempering Valves (T1 and T2). These circulators are necessary to insure flow through the radiant panels. Without these circulators, flow through the radiant panels would stop once the Three-way Tempering Valves sense the supply water has reached the desired temperatures, closing the hot (+) port of the valves. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Baseboard zone control — In this schematic, the baseboard loop(s) are controlled with a zone valve (M1), which operates independently of the radiant heat. • Zoning options — See pages 127-131. • Specific Wiring Schematic — See pages 174-175. Chapter 13 – Piping Schematics — www.uponorpro.com Non-condensing boiler Three-way tempering valves Dual temperature radiant floor heating High temperature radiation Legend Manifold with Telestats Non-condensing boiler Three-way tempering valves Dual temperature radiant floor heating High temperature radiation Legend P1 Manifold without Telestats Manifold with Telestats Manifold with Valves T1 P1 Manifold without Telestats P1 Circulator Manifold with Valves T1 P2 M1 P1 Circulator Expansion Tank and Air Separator P2 T2 M1 V1 Ball Valve Expansion Tank and Air Separator T2 V1 Ball Valve Zone Valve Zone Valve BP Pressure Temperature Gauge BP Pressure Temperature Gauge Non-condensing Boiler Non-condensing Boiler Baseboard Baseboard Complete Design Assistance Manual — Chapter 13 – Piping Schematics 149 Piping Schematic Level II Control • Non-condensing boiler • Heat exchanger Where: All radiant and snow melt applications Why: This illustration shows a non-condensing boiler supplying water to a heat exchanger (HX1) to provide water temperature control and isolation where necessary. Water temperature for the radiant panel or snow melt system is controlled by a sensor (S1), either immersion type or strapon type, placed on the supply outlet of the heat exchanger. The sensor is wired to a set-point controller or aquastat, which is set for the desired supply water temperature. When the supply water temperature drops below the desired level, the set-point controller or aquastat will fire the boiler circulator and/or boiler to send hot water through the boiler side of the heat exchanger. The radiant supply water temperature will increase until the desired level is reached, shutting off the boiler circulator and/or boiler. Besides controlling water temperature, a heat exchanger can be used for isolating the boiler and its ferrous (corrodible) components when Uponor AquaPEX (non-barrier) tubing is used on the radiant or snow melt side of the heat exchanger. A heat exchanger will also protect non-condensing boilers from thermal shock and low return water temperatures, and allows for glycol to be added to the radiant/snow melt portion of the system only. 150 What to look for: • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. Noncondensing boilers require minimum return water temperatures of 140°F or higher (see boiler manufacturer’s installation instructions for specific requirements) to prevent flue gas condensation,, and potential thermal shock potential internal corrosion. The bypass loop allows an amount of hot boiler water (depending on bypass valve position) to circulate through the boiler to maintain return water temperatures above the minimum, preventing the boiler’s flue gasses from condensing. Condensed flue gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Expansion tank — An expansion tank and air separator are added to the radiant/snow melt side of the heat exchanger. This is required for proper air elimination and thermal expansion due to isolation from the boiler loop by the heat exchanger. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See page 163. • Bypass valve setting — At system startup, position a suitable valve (V1) in the half-open position. If the radiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. • Radiant loop circulator — A circulator (P1) has been added on the radiant loop side of the heat exchanger (HX1). This circulator is necessary to insure flow through the radiant panel. Chapter 13 – Piping Schematics — www.uponorpro.com Legend Non-condensing boiler Heat exchanger Manifold with Telestats HX1 S1 Manifold without Telestats P1 Manifold with Valves V1 P1 Circulator Expansion Tank and Air Separator BP Legend Ball Valve ndensing boiler changer Manifold with Telestats Zone Valve HX1 S1 Manifold without Telestats Pressure Temperature Gauge P1 Manifold with Valves V1 P1 Circulator Non-condensing Boiler Expansion Tank and Air Separator BP Ball Valve Zone Valve Pressure Temperature Gauge Non-condensing Boiler Complete Design Assistance Manual — Chapter 13 – Piping Schematics 151 Piping Schematic Level II Control What to look for: • Wood boiler • Mixing tank • Single-temperature radiant floor heating Where: All radiant applications Legend Manifold with Telestats Manifold without Telestats Why: This illustration shows a wood boiler supply water for a single radiant panel, using a mixing, or “buffer”, tank as a tempering device. The wood boiler supplies hot boiler water to the tank that will mix with the cooler radiant return water to deliver the proper radiant supply water temperature. An aquastat (AQ1), either an immersion type or strap-on type, controls the tank temperature. When the aquastat senses the radiant supply water temperature has dropped below the desired level, it starts the boiler pump (P1), mixing hot boiler water into the tank until the desired temperature has been reached. In all radiant applications using a wood boiler, a buffer tank must be used to control the radiant supply water temperature, and to protect Non-condensing boiler excessive the radiant panel from Buffer tank boiler water temperatures. Single-temperature • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. The installation of a bypass will allow an amount of hot boiler supply water (depending on bypass valve position) to circulate through the boiler to prevent low boiler return water temperatures, preventing the boiler’s flue gasses from condensing. Condensed flue gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Bypass valve setting — At system startup, position a suitable valve (V1) in the half-open position. If the radiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. • Radiant loop circulator — A circulator (P1) has been added on the radiant loop side of the buffer tank. This circulator is necessary to insure flow through the radiant panel. • Aquastat — An aquastat (AQ1) is used to sense and control water temperature inside the buffer tank. The aquastat is set to the desired radiant supply water temperature, and is wired to a relay that controls the boiler circulator (P1). • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 180-181. Legend Manifold with Telestats Manifold without Telestats Manifold with Valves Manifold with Valves P1 Circulator V1 Expansion Tank and Air Separator P1 Circulator AQ1 Ball Valve Buffer Tank Expansion Tank and Air Separator P1 BP Ball Valve Zone Valve Zone Valve Pressure Temperature Gauge Pressure Temperature Gaug Non-condensing Boiler Non-condensing Boiler 152 Chapter 13 – Piping Schematics — www.uponorpro.com Piping Schematic Level II Control tank temperature. When the aquastat senses the radiant supply water temperature has dropped below the desired level, it starts the heat pump circulator (P1), mixing warmer heat pump water into the tank until the desired temperature has been reached. Some geothermal manufacturers make buffer tanks and controls available for their equipment in radiant applications. Refer to the manufacturer’s installation and operation instructions for specifics. • Heat pump • Mixing tank • Single-temperature radiant floor heating Where: All low-temperature radiant applications (< 120°F) Why: This illustration shows a geo-thermal heat pump supplying water for a single radiant panel, using a mixing, or “buffer”, tank as a tempering device. The geo-thermal heat pump supplies warm water to the tank that will mix will cooler radiant return water to deliver the proper radiant supply water temperature. An aquastat (AQ1), either an immersion type Heat Pump or strap-on type, controls the Buffer Tank What to look for: • Radiant loop circulator — A circulator (P1) has been added on the radiant loop side of the buffer tank. This circulator is necessary to insure flow through the radiant panel. Single Temperature • Aquastat — An aquastat (AQ1) is used to sense and control water temperature inside the buffer tank. The aquastat is set to the desired radiant supply water temperature, and is wired to a relay that controls the system circulator (P1). • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 180-181. Legend Manifold with Telestats Manifold without Telestats Legend Manifold with Valves P1 Circulator Manifold with Telestats Heat Pump Buffer Tank Single Temperature AQ1 Buffer Tank P1 Manifold without Telestats Expansion Tank and Air Separator Manifold with Valves Ball Valve P1 Circulator HPP Zone Valve AQ1 Buffer Tank P1 Expansion Tank and Air Separator Pressure Temperature Gauge Ball Valve HPP Heat Pump Zone Valve Pressure Temperature Gauge Heat Pump Complete Design Assistance Manual — Chapter 13 – Piping Schematics 153 Piping Schematic Level III Control • Non-condensing boiler • Three-way modulating valve • Single-temperature radiant floor heating Where: All radiant and hydronic applications where full outdoor reset with a weather-responsive reset control is desirable Why: This illustration shows a non-condensing boiler supplying water to a single radiant panel. The radiant loop supply water temperature is controlled by the use of the Climate Cŏntrol Multifunction Controller and Three-way Modulating Valve. The Multifunction Controller is a weather-responsive reset controller that senses changes in outdoor temperatures and adjusts the radiant supply water temperature accordingly, while providing adequate heat to satisfy the structure’s heat loss requirements (see Chapter 12 for further information on weather responsive reset control). The Multifunction Controller also controls the radiant loop circulator and the boiler loop circulator, and also enables the boiler. 154 What to look for: • Bypass loop — This piping schematic includes a “bypass” loop at the boiler. Noncondensing boilers require minimum return water temperatures of 140°F or higher (see boiler manufacturer’s installation instructions for specific requirements) to prevent flue gas condensation and potential internal corrosion. The bypass loop allows an amount of hot boiler water (depending on bypass valve position and Three-way Modulating Valve position) to circulate through the boiler to maintain return water temperatures above the minimum, preventing the boiler’s flue gasses from condensing. Condensed flue gasses are highly corrosive and will shorten the boiler’s life and may void the boiler’s warranty. The bypass valve (V1) should never be left in the full open position during normal operation. • Bypass valve setting — At system startup, position a suitable valve (V1) in the half-open position. If the radiant supply water does not reach the desired temperature, continue to close the valve in small increments until that temperature is reached. • Radiant loop circulator — A circulator (P2) has been added on the radiant side of the Three-way Modulating Valve (MV1). This circulator is necessary to insure adequate flow through the radiant panel. Without this circulator, flow through the radiant panel would vary based on the position of the Three-way Modulating Valve. • Sensors — Strap-on sensors (S1 and S2) are placed on the piping between the MIX port of the Three-way Modulating Valve and the radiant manifolds, on the boiler return piping (S3) near the boiler return inlet, and outdoors (OAS) on the north side of the structure, preferably out of direct sunlight. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific Wiring Schematic — See pages 186-187. Chapter 13 – Piping Schematics — www.uponorpro.com Legend Non-condensing boiler Three-way modulating valve Manifold with Telestats S1 Manifold without Telestats Legend P1 Manifold with Valves Non-condensing boiler Three-way modulating valve S2 S1 Manifold with Telestats P1 Circulator Manifold without Telestats P1 Manifold with Valves Expansion Tank and Air Separator BP OAS S2 Place outdoor sensor above the snow line on north-facing wall P1 Circulator Ball Valve Zone Valve Expansion Tank and Air Separator BP OAS Place outdoor sensor above the snow line on north-facing wall Pressure Temperature Gauge Ball Valve Zone ValveBoiler Non-condensing Pressure Temperature Gauge Three-way Modulating Valve (0-10v) Non-condensing Boiler Three-way Modulating Valve (0-10v) Complete Design Assistance Manual — Chapter 13 – Piping Schematics 155 Piping Schematic Level III Control • Non-condensing boiler • Dual-temperature radiant floor heating • Variable-speed injection mixing Where: All radiant and other hydronic applications where two separate temperatures of full outdoor reset with a weatherresponsive control is desirable, using primary/secondary piping Why: This illustration shows a noncondensing boiler supplying water to multiple radiant panels requiring dramatically different supply water temperatures, or having different installation methods (i.e. concrete vs. Joist Trak). The Climate Cŏntrol Multifunction Controller separately controls the radiant loop temperatures based on outdoor temperatures. The controller senses changes in outdoor weather conditions and changes the supply water temperatures in each radiant manifold independently using variable-speed injection mixing (see Appendix I for information on variable-speed injection mixing), while providing adequate heat to satisfy the structure’s heat loss requirements (see Chapter 12 for further information on weatherresponsive reset controls). The Multifunction Controller controls each radiant loop circulator (SP1 and SP2) independently based on calls for heat, and varies the speed of each injection circulator (IP1 and IP2) based on the required supply water temperature for each radiant loop. The Multifunction Controller also enables the boiler and fires the primary circulator (PP1). 156 What to look for: • Bypass loop — Even though a non-condensing boiler is used in this applications, an additional bypass loop is not required. The Primary loop will suffice as a bypass loop. The Climate Cŏntrol Multifunction Controller uses primary sensors (S5 and S6) to provide boiler operation, maintaining return water temperatures above the boiler manufacturer’s recommended minimum and preventing flue gas condensation in non-condensing boilers. • Primary loop circulator — The primary circulator (BP) should be sized to meet the flow (gpm) demands of the entire heating system. The primary pump head should be sized to the pressure drop of the primary loop only, plus associated valves and fittings. • Radiant loop circulators — These circulators (SP1 and SP2) have been added to the secondary loops. These circulators are necessary to insure flow through the radiant panels. These are considered secondary circulators, and should be sized to the flow (gpm) and head loss of the secondary loops only. • Injection circulators — These circulators (IP1 and IP2) are used to inject hot water from the primary boiler loop into the secondary radiant loops. Based on input from the Multifunction Controller, the speed of the circulators will vary. This variable speed injection mixing will change the radiant supply water temperature based on outdoor weather conditions. • Thermal traps — Thermal traps are required in the injection piping to prevent thermal migration of hot water from the Primary loop into the secondary loops, possibly effecting radiant supply water temperature control. • Balancing valves — Balancing valves (BV1 and BV2) are required on the return legs of the injection piping to balance flow through the injection legs and to maximize circulator operation. • Tee spacing — Spacing between supply and return tees off the boiler primary loop and off the secondary loop should not exceed 6 inches. This will eliminate pressure drop between the tees. As a result, flow will only occur in the secondary loop when the secondary circulator is in operation. • Sensors — Strap-on sensors (S1 and S2) are placed on the boiler supply and return piping near the boiler, on the secondary radiant loops (S3 through S6) and outdoors (OAS) on the north side of the structure, preferably out of direct sunlight. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring Schematic — See pages 188-189. Chapter 13 – Piping Schematics — www.uponorpro.com Non-condensing boiler Three-way modulating valve Legend S3 Non-condensing boiler Three-way modulating valve Manifold with Telestats Legend SP2 OAS S4 S3 1 Manifold without Telestats Manifold with Telestats SP2 2 IP1 OAS S4 1 2 IP1 S1 Note: • Spacing between tees not to exceed 6" • Thermal trap minimum 12" 1 1 S1 Note: • Spacing between tees not to exceed 6" • Thermal trap minimum 12" 1 S2 2 BV2 P1 S2 1 IP2 Place outdoor sensor above the snow line on north-facing wall Place outdoor sensor above the snow line on north-facing wall Manifold with Valves Manifold without Telestats P1 Circulator Manifold with Valves P1 Circulator Expansion Tank and Air Separator Ball Valve Expansion Tank and Air Separator S5 2 BV2 1 IP2 Zone Valve Ball Valve SP2 S6 S5 P1 1 Pressure Temperature Gauge Zone Valve SP2 S6 Pressure Temperature Gauge Non-condensing Boiler Non-condensing Boiler Complete Design Assistance Manual — Chapter 13 – Piping Schematics 157 Piping Schematic Level III Control • Non-condensing boiler • Multiple-temperature radiant floor heating and snow melting • Variable-speed injection mixing Where: All single-temperature radiant floor heating or other hydronic applications, plus integrated snow melting where full outdoor reset with a weatherresponsive control is desirable, using primary/secondary piping. Why: This illustration shows a non-condensing boiler supplying water to a single radiant panel. The Climate Cŏntrol Multifunction Controller controls the radiant loop temperature. The controller senses changes in outdoor weather conditions and changes the supply water temperature in the radiant loop using variablespeed injection mixing (see Appendix I for information on variable-speed injection mixing), while providing adequate heat to satisfy the structure’s heat loss requirements (see Chapter 12 for further information on weather-responsive reset controls). The Multifunction Controller also controls an integrated snow melting system, using variable-speed injection mixing in conjunction with a heat exchanger (HX1). The Multifunction Controller controls the radiant and snow melt circulators (SP1 and SP2) independently based on calls for heat, and varies the speed of each injection circulator (IP1 and IP2) independently, based on the required supply water temperatures for the radiant and snow melt loops. The Multifunction Controller also enables the boiler and fires the primary circulator (P1). 158 What to look for: • Bypass loop — Even though a non-condensing boiler is used in this application, an additional bypass loop is not required. The primary loop will suffice as a bypass loop. The Multifunction Controller uses boiler sensors (S1 and S2) to provide boiler operation, maintaining return water temperatures above the boiler manufacturer’s recommended minimum and preventing flue gas condensation in non-condensing boilers. • Primary loop circulator — The primary circulator (BP) should be sized to meet the flow (gpm) demands of the entire heating system. The primary pump head should be sized to the pressure drop of the primary loop only, plus associated valves and fittings. • Radiant and snow melt loop circulators — Circulators (SP1 and SP2) have been added to the secondary loops. These circulators are necessary to insure flow through the radiant panels. These are considered secondary circulators and should be sized to the flow (gpm) and head loss of the secondary loops only. • Injection circulators — These circulators (IP1 and IP2) are used to inject hot water from the primary boiler loop into the secondary radiant loops. Based on input from the Climate Cŏntrol Multifunction Controller, the speed of these circulators will vary. This variable-speed injection mixing will change the radiant and snow melt supply water temperatures based on outdoor weather conditions (see Appendix I for injection pump sizing). • Thermal traps — Thermal traps are required in the injection piping to prevent thermal migration of hot water from the primary loop into the secondary loops, possibly affecting radiant supply water temperature control (see Appendix I for variable-speed injection mixing piping detail). • Balancing valves — Balancing valves (BV1 and BV2) are required on the return legs of the injection piping to balance flow through the injection legs and to maximize circulator operation. • Tee spacing — Spacing between supply and return tees off the boiler primary loop and off the secondary loops should not exceed 6 inches. This will eliminate pressure drop between the tees. As a result, flow will only occur in the secondary loop when the secondary circulator is in operation. • Sensors — Strap-on sensors (S1 and S2) are placed on the boiler piping near the boiler, on the secondary radiant/snow melt loops (S3 through S6) between the secondary loop circulators and the radiant manifolds, and outdoors (OAS) on the north side of the structure, preferably out of direct sunlight. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. Chapter 13 – Piping Schematics — www.uponorpro.com Non-condensing boiler Radiant floor heating and snow melting Injection pumping Dual temperature Legend S3 Non-condensing boiler Radiant floor heating and snow melting Injection pumping Dual temperature Manifold with Telestats SP2 Legend S4 1 S3 Manifold without Telestats Manifold with Telestats SP2 OAS 2 IP1 S4 1 Manifold with Valves Manifold without Telestats P1 Circulator OAS Place outdoor sensor above the snow line on north-facing wall 2 IP1 S1 1 1 S1 S2 Note: • Spacing between tees not to exceed 6" • Thermal trap minimum 12" 1 2 BV2 1 2 Note: • Spacing between tees not toS5 exceed 6" • Thermal trap minimum 12" IP2 BV2 SP2 Ball Valve Ball Valve Zone Valve S5 SP2 S6 • Expansion tank — An expansion tank and air separator are added to the snow melt side of the heat exchanger. This allows for proper air elimination and thermal expansion, as the snow melt loop is isolated from the boiler loop by the heat exchanger. Zone Valve Pressure Temperature Gauge S6 HX1 P1 P1 ExpansionCirculator Tank and Air Separator Expansion Tank and Air Separator IP2 HX1 P1S2 Place outdoor sensor above the snow line on north-facing wall Manifold with Valves Pressure Temperature Non-condensing Boiler Gauge Non-condensing Boiler • Zoning options — See pages 127-131. • Specific wiring Schematic — See pages 190-191. Complete Design Assistance Manual — Chapter 13 – Piping Schematics 159 Piping Schematic Level III Control • Non-condensing boiler • Three-way modulating valve • Dual-temperature radiant floor heating • High-temperature radiation • Domestic hot water • Primary/secondary piping Where: All low-temperature radiant applications (< 160°F), with high-temperature radiation and indirect domestic hot water using primary/secondary piping Why: This illustration shows a non-condensing boiler supplying water to multiple radiant panels requiring dramatically different supply water temperatures or having different installation methods (i.e. concrete vs. Joist Trak) plus high temperature radiation (base board, panel radiators, fan coils, etc.) and an indirect hot water tank using a single pipe primary/secondary boiler piping arrangement. All elements are controlled by the Climate Cŏntrol Multifunction Controller. The Three-way Modulating Valves (MV1 and MV2) are used to mix hot boiler water from the primary loop with cooler radiant return water from the secondary loop to achieve the selected radiant supply water temperature per the valve settings. The radiant panel loop(s) become the secondary piping. Hot boiler water off the primary boiler loop will feed the Secondary loops for both the high- temperature radiation and the domestic hot water tank. Primary/secondary boiler piping allows for simplified piping in multiple temperature applications, protects the boiler against low return water temperature, possible flue gas condensation and possible short cycling. In low-temperature (< 160°F) radiant heating 160 applications using a non-condensing boiler, the boiler supply water temperature must be reduced to the proper radiant supply water temperature. A Three-way Modulating Valve allows the radiant supply water temperature to be mixed from 80°F to 160°F. The high-temperature radiation is supplied directly with boiler water. What to look for: • Bypass loop — Even though a non-condensing boiler is used in this application, an additional bypass loop is not required. The primary loop will suffice as the bypass loop and will protect the boiler. • Primary loop circulator — The primary circulator (PP) should be sized to meet the flow (gpm) demands of the entire heating system. The primary pump head should be sized to the pressure drop of the primary loop only, plus associated valves and fittings. • Radiant loop circulator — Circulators (SP1 and SP2) have been added on the radiant loop side of the Three-way Modulating Valves (MV1 and MV2). These circulators are necessary to insure flow through the radiant panels. Without these circulators, flow through each radiant panel would stop once the Three-way Modulating Valves sense the supply water has reached the desired temperatures, closing the hot (+) port of the valves. These are considered secondary circulators, and should be sized to the flow (gpm) and head loss of the secondary loops only. Multiple high-temperature zones may be controlled by multiple circulators or zone valves. • Tee spacing — Spacing between tees off the boiler Primary loop and off the secondary loop should not exceed 6 inches. This will eliminate pressure drop between the tees. As a result, flow will only occur in the secondary loop when the secondary circulator is in operation. • Sensors — Strap-on sensors (S1 and S2) are placed on the boiler piping near the boiler, on the secondary radiant/snow melt loops (S3 through S6) between the secondary loop circulators and the radiant manifolds, and outdoors (OAS) on the north side of the structure, preferably out of direct sunlight. • Isolation valves — Isolation valves are recommended at the supply and return radiant manifolds to facilitate purging and service. Isolation valves or flanges are recommended at all circulators for easy service. • Zoning options — See pages 127-131. • Specific wiring schematic — See pages 192-193. • Baseboard control — In this schematic, the baseboard loop(s) is controlled with a circulator (ZP1), which will provide flow through the high-temperature radiation during a call for heat. Chapter 13 – Piping Schematics — www.uponorpro.com Non-condensing boiler Three-way modulating valves Multi-temperature radiant floor heating High-temperature radiation Domestic hot water Primary/secondary piping Manifold with Telestats Manifold without Telestats Manifold with Valves S3 S3 Legend P1 Circulator S3 S3 Non-condensing boiler Three-way modulating valves Multi-temperature radiant floor heating S3 High-temperature radiation Domestic hot water Primary/secondary S3piping Manifold with Telestats Note: • Spacing between tees not to exceed 6" S3 1 1 1 1 S3 Ball Valve Manifold with Valves S3 S3 1 S3 S3 S3 S3 S3 Expansion Tank Manifold Telestats and Airwithout Separator P1 Circulator Zone Valve S3 S3 S3 OAS S3 1 1 1 Expansion Tank and Air Separator S3 Place outdoor sensor above S3 the snow line on north-facing wall 1 1 S3 Pressure Temperature Gauge Note: • Spacing between tees not to exceed 6" S3 S3 S3 Ball Valve Non-condensing Boiler Zone Valve Domestic Hot Water Tank Pressure Temperature Gauge S3 Three-way Modulating Valve (0-10v) OAS Place outdoor sensor above the snow line on north-facing wall Baseboard Boiler Non-condensing Domestic Hot Water Tank Three-way Modulating Valve (0-10v) Baseboard Complete Design Assistance Manual — Chapter 13 – Piping Schematics 161 162 Chapter 13 – Piping Schematics — www.uponorpro.com
