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Controls ● Pumps ● Wiring

Part No. 650-000-240/1098

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Part Number 650-000-240/10982

AlumiPAlumiPAlumiPAlumiPAlumiPeeeeexxxxx® ® ® ® ® Radiant TRadiant TRadiant TRadiant TRadiant Tubingubingubingubingubing

The following defined terms are used throughout this Guide to bring attention to the presence ofhazards of various risk levels, or to important information concerning the life of the product.

Read this page first

This Guide is provided for general information only. The building or heating system designer isresponsible for all design details and for compliance with all building codes, local and national.

Refer to AlumiPex Technical Information sheets for specific certifications and listings of AlumiPexRadiant Tubing.

AlumiPex Radiant Tubing is not certified for potable water applications.

Consult local requirements before installing a radiant heating system. Install AlumiPex tubingfollowing all of the applicable codes and all specifications and methods prescribed by the buildingdesigner and heating system designer.

Indicates special instructions on installation, operation or maintenance thatare important but not related to personal injury or property damage.

Indicates presence of hazards that will or can cause minor personal injury orproperty damage.

Indicates presence of hazards that can cause severe personal injury, death orsubstantial property damage.

Indicates presence of hazards that will cause severe personal injury, death orsubstantial property damage.

Do not expose AlumiPex Radiant Tubing to petroleum products or solvents.

Finished flooring: Use only finished flooring approved by the flooringmanufacturer for use with heated floors. Failure to follow this guidelinecould result in substantial property damage.

Use only AlumiPex Fittings with AlumiPex Tubing. Use of any other methodcan result in severe personal injury, death or substantial property damage.

Do not use AlumiPex Radiant Tubing in potable water or in systems whichuse boiler system water for potable use.

The tubing is not approved for domestic water use.

In combination space heating/potable water heating applications, chemicalor biological contamination in the system water is possible and could resultin severe personal injury, death or substantial property damage.

Install all equipment in accordance with the equipment manufacturer’sinstructions and all applicable codes. Failure to do so could result in severepersonal injury, death or substantial property damage.

Hazard definitions

Codes and standards

Do not use AlumiPex Radiant Tubing to conduct natural gas. Such anapplication could result in severe personal injury, death or substantialproperty damage.

Material referenced in this Guide is subject to change without notice. Reviewall equipment installation instructions for compatibility before installing.

Part Number 650-000-240/1098 3

Controls ● Pumps ● Wiring — Installation Guide

Contents

I Overview .................................................................................................................................. 4

II Piping & control methodsThree temperature control ...................................................................................................... ..................................................... 5Exceptions .................................................................................................................................................................................... 6Piping/ controlling methods ......................................................................................................................................................... 6Method 1 - Variable speed injection mixing ............................................................................................................................... 7Method 2 - Dual three-way valves .............................................................................................................................................. 9

III Primary/secondary pipingWhy use primary/secondary piping? ........................................................................................................................................ 10Primary/secondary piping tips ................................................................................................................................................... 12

IV Zoning radiant heating systemsCombining spaces for zoning ..................................................................................................................................................... 15Using zone valves and/or valve actuators ................................................................................................................................ 15Combining circuits on manifolds ............................................................................................................................................... 16Control circuit transformer sizing ............................................................................................................................................... 16

V Control strategies – generalOutdoor reset .............................................................................................................................................................................. 20Constant circulation .................................................................................................................................................................... 21

VI Injection mixing componentsWeil-McLain IPC Injection Pump Control ................................................................................................................................... 22Weil-McLain IPP-150 Injection Pump Panel .............................................................................................................................. 24

VII Determining flow ratesPrimary circuit flow rate ............................................................................................................................................................. 26Injection pump flow rates .......................................................................................................................................................... 30Secondary circuit flow rates ...................................................................................................................................................... 31

VIII Determining head lossEquivalent length .............................................................................................................. .......................................................... 32Head loss (series circuits) .................................................................................................... ...................................................... 32Determining head losses for circuits in parallel ............................................................................... ......................................... 35Head losses for AlumiPex tubing circuits ....................................................................................... .......................................... 36

IX Selecting pumpsMethod 1 - select pump from pump curve ............................................................................................................................... 39Method 2 - select pump from quick selector curves ................................................................................................................ 41

X Piping radiant circuits ........................................................................................................... 46

XI Domestic water heating ....................................................................................................... 52

XII Radiant heating system examples ...................................................................................... 54System CP-1 Adding a small zone of radiant heating to an existing baseboard heating system........................................................................................................... 56SystemC P-2 GV boiler supplying an injection pump panel ................................................................................................................................................................. 60SystemC P-3 Conventional boiler supplying an injection pump panel .................................................................................................................................................. 64SystemC P-4 Two-temperature radiant heating system using two injection pump panels ................................................................................................................... 68System CP-5 Two-temperature radiant heating system using one injection pump panel and a mixing valve ...................................................................................... 72SystemC P-6 Radiant heating and domestic water heating with conventional boiler - DHW as a secondary circuit ............................................................................ 76SystemC P-7 Radiant heating and domestic water heating with GV boiler - DHW as a secondary circuit ............................................................................................ 80SystemC P-8 Radiant heating and domestic water heating with conventional boiler - independent DHW operation ........................................................................... 84System CP-9 Radiant heating and domestic water heating with GV boiler - DHW through diverting valve.......................................................................................... 88System CP-10 Radiant heating, domestic water heating and baseboard heating with conventional boiler ............................................................................................ 92System CP-11 Radiant heating, domestic water heating and baseboard heating with GV boiler ........................................................................................................... 98System CP-12 Radiant heating, domestic water heating and baseboard heating with multiple boilers ................................................................................................ 104

XIII Appendix .............................................................................................................................. 110

Part Number 650-000-240/10984


What’s in this guide?

I Overview

We intend this Guide to provide system designers withthe information needed to select and specify controls,pumps and piping for AlumiPex radiant heating systems.

The most important message in thisguide is the need to control not justspace and supply water tempera-tures, but to design and installsystems that regulate the boilerreturn water temperature.

Piping & control methods provides you a choice oftwo basic piping/control designs which meet the needsof AlumiPex® radiant heating systems and the needs ofnoncondensing boilers. These are —

• Variable speed injection mixing (preferred method)

• Dual three-way valves (alternate method)

Though other designs can accomplish similarperformance, we have chosen to concentrate on a limitedselection to assure coverage in depth.

Primary/secondary piping outlines the reasons for usingprimary/secondary piping and some suggestions on howto apply it.

Zoning radiant heating systems provides guidelinesfor combining spaces in zoning and how to applyAlumiPex zoning components.

Control strategies – general presents the case foroutdoor reset and discusses continuous (or extended)circulation in radiant heating, along with some guidelinesfor setting up reset controls.

Injection mixing components gives a brief introductionto the Weil-McLain Injection Pump Control, the IPC,and the Injection Pump Panel, the IPP. For furtherinformation on these components, refer to the InjectionPump Panel/Injection Pump Control (IPC) Installationand Operating Manual.

Determining flow rates provides suggestions on howto calculate the flow rates needed for each type of circuitin a radiant system - for multiple purpose systems aswell as for radiant heating only.

Determining head loss provides means for calculatinghead losses in copper and steel piping and in AlumiPexradiant tubing circuits.

Selecting pumps provides pump curves for commonpumps. This section includes a new approach to pumpsizing - curves for ½”, ¾” and 1” AlumiPex tubing and ¾”through 2” copper piping that show pump GPM vssystem equivalent length for common circulators(pumps). This allows you to directly select a pump basedon your system equivalent length and flow rate, or to seewhat will happen if you place a different pump on yoursystem, without having to draw a system curve.

Piping radiant circuits and Domestic water heatingintroduce the final section of this guide, devoted to specificmethods for piping and controlling radiant systems andmultiple purpose systems (radiant heating plus domesticwater heating and baseboard heating). These sectionsprovide the background for the radiant heating pipingexamples which follow.

Radiant heating examples includes 12 examples ofradiant heating systems, including multiple purposesystems for domestic water and baseboard heating. Thesedo not represent all of the possibilities, but show someeffective applications of the principles discussed in thisGuide. Note, in particular, the emphasis on three-temperature control – control the boiler returnwater temperature (to protect the boiler) in additionto space and supply water temperatures.

This guide does not include radiant heating heat losscalculations or tubing placement design. These arehandled in separate publications. Weil-McLain currentlyprovides a computer-based sizing system — theAlumiPex Radiant Expert program. We recommendusing the A.R.E. in combination with this guide for themost comprehensive coverage of radiant heating designwith our products.

Part Number 650-000-240/1098 5


Piping and control designs must not only regulate space comfort - they must also:• assure the correct water supply temperature to the heating system.• protect noncondensing boilers from flue gas condensation and thermal shock.

So, piping and controls must regulate three temperatures —① Space temperature② System supply temperature③ Boiler return temperature

Regulate the space temperature by:· sensors located in the space and outside (if outdoor reset is used)· correct placement of radiant tubing and other heating units· regulation of heating water temperature and flow

Regulate the system supply temperature by:· using a control designed for radiant heating· using primary/secondary piping as described in this guide· using variable speed injection mixing or a correctly placed three-way valve

Regulate the boiler return water temperature by:· using primary/secondary piping as described in this guide· using a variable speed injection mixing system or correctly placed three-way valve

Why regulate the boiler return water?

· Flue gases contain water and acid vapors. When the flue gases contact a surface below thedewpoint temperature, acid and/or water will condense on that surface. This could damagethe boiler and lead to premature failure. Controlling the return water at or above 130 °F willprovide protection for most boilers.

· Radiant heating systems typically operate with supply water below 130 °F and return waterfrom 90 to 110 °F. Water this cool will cause condensation damage and may cause thermalshock as well.

Three temperaturecontrol

II Piping & control methods

The controls and piping must be designed and installed to return water to a noncondensing boilerat or above 130 °F to prevent condensation and possible thermal shock. Failure to follow thisguideline could result in substantial property damage.

Part Number 650-000-240/10986


II Piping & control methods - continued

The most common heating source for radiant heatingsystems is a noncondensing boiler. The boiler may becast iron, steel or copper, but will usually require aminimum return water temperature, as specified by theboiler manufacturer. If the manufacturer states aminimum return temperature - regardless what thattemperature is - the piping and controls must assurethe water temperature does not return to the boiler belowthe minimum.

The risk of not controlling the temperature is damage tothe equipment - ranging from minor corrosion tocomplete failure of the heat exchanger.

Exceptions

There are exceptions to the need for return watertemperature control - but ONLY for cases where the returnwater temperature will naturally remain above theminimum specified by the boiler manufacturer.

An example is the special case of floor heating using tubingsuspended in the joist bays (not stapled to the floor). Forsuch systems, the supply water temperature is usually160 °F or higher. Moreover, the radiant system has lowmass because the tubing is not in contact with the floor.So, these systems will behave similarly to finned tubebaseboard systems - return water temperature will nearlyalways be above 130 °F, and any periods of lower returntemperature will be brief.

Such exceptions are not illustrated in this Guide (exceptfor System CP1, discussed below) to avoid confusing theissue. Most radiant heating installations requirereturn water control because most of the heatingsources require a minimum.

You will find an exception to regulated return temperaturein Radiant heating system examples, System CP1.This special case applies to a small radiant circuit addedto an existing baseboard heating system. For this situation,return water protection is unnecessary because the radiantcircuit will not reduce the return water temperaturesignificantly.

Piping/controlling methods

This Guide focuses on the two preferred methods ofregulating space, supply water and return watertemperatures -

Method 1 - Variable speed injection mixing.

Method 2 - Dual three-way mixing valves.

Method 2 may, in some cases, have a lower first cost thanMethod 1. But Method 2 cannot provide outdoor resetcontrol without motorized valves - this could causeMethod 2 to be more costly than Method 1.

Alternative piping/controllingmethods

This Guide addresses only these two methods in order toprovide coverage in depth. Other methods can be usedand are covered in supplementary documents.

No alternative is as effective or flexible, however, asMethod 1 - variable speed injection mixing. The Weil-McLain IPP Injection Pump Panel and IPC Injection PumpControl provide exceptional control and a wide range ofcontrol options.

Interchangeability

Figures 2 and 3 are simplified schematics of Methods 1and 2, respectively.

Note the piping contained in the dotted rectanglesof these schematics. Wherever an IPP Injection PumpPanel (Method 1) is shown in piping diagrams in thisGuide, you can substitute the piping in the dottedrectangle in Figure 3. That is, the dual three-way mixingvalves, piped as shown, will provide the same regulationand protection as Method 1.

Bear in mind, if outdoor reset is desired with Method 2,a motorized valve and appropriate controls will berequired.

Part Number 650-000-240/1098 7


Method 1 — Variable speed injection mixing

Injection mixing uses a pump to inject hot water fromthe primary (boiler) circuit into the secondary (radiantheating) circuit. The amount of heat injected is regulatedby varying the pump speed — and hence the flow rate.

Figure 1 is a simplified injection mixing circuit.

• The injection pump pulls hot water from the primaryloop at C.

• This water (at temperature TH) is injected into thesecondary (heating) circuit at A, where it mixes withthe cooler return water (temperature TR). The resultis heating circuit supply water at temperature TS. Ifthe injection flow rate, FI, is increased the supply watertemperature will increase. If the injection flow rate isdecreased the supply water temperature will decrease.

AA

CC TH

TH

FI

FS

TS

TR BB

DD

Boiler loopsupply

Boiler loopreturn

System supplySystem return

Injectionpump

Balancingvalve

Figure 1

Radiant heating Method 1 –Injection mixing

• For each GPM of water injected at A, an equal amountof water exits the heating circuit at B, and mixes withthe primary (boiler) loop supply water at D.

• So the injection pump “pulls” heat from the boiler(primary) loop and injects it into the secondary(heating) circuit.

The return water from the secondary (heating) circuitlowers the water temperature returning to the boiler. Sothe IPC Injection Pump Control monitors boiler returnwater temperature (see Figure 2) as well as heating circuitsupply water temperature. Should the boiler circuit returnwater temperature approach 130 °F, the IPC slows downthe injection pump. This raises the temperature returningto the boiler because less cool heating circuit water isinjected into the boiler (primary) circuit.

Part Number 650-000-240/10988


Method 1 — Variable speed injection mixing

II Piping & control methods - continued

Figure 2

Radiant heating Method 1 –Injection mixing, typical

(The piping enclosed in thedotted rectangle represents

the components included in aWeil-McLain IPP Injection

Pump Panel)

Figure 2 is a typical piping schematic for injection mixingin a radiant heating system. Injection pump speed iscontrolled by the Injection Pump Control —

• Pump speed is increased when the system supplytemperature drops below target value.

• The pump is slowed as the system supplytemperature rises or when the boiler return watertemperature drops below the preset limit.

• The balancing valve in the injection circuit is used toprovide some pressure drop against the injectionpump, improving flow control.

Maximum required injection pump flow rate, F1, isrelated to system flow rate, FS, system temperature

Fill

Expansion tank IPCInjection PumpControl

Boiler

Boiler returnsensor

Boiler loop pump

Radiantloops

Manifolds

Inje

ctio

n pu

mp

Systemsupplysensor

Heating systempump

2 to 4 pipediameters


Outdoorsensor

(optional)

F1= FS xDTS

(TH – TR)

F1= FS x10°

(180° - 100°)

drop (DTS), system return temperature (TR) and supplywater temperature (TH) available from the boiler. Theformula for F1 is –

Injection pumps are generally much smaller than systempumps. For example, for 110 °F system supply and 10 °Fsystem drop (100 °F return temperature), with 180 °Fboiler supply temperature, the injection flow rate is only1/8 as much as the system flow rate, since —

Refer to Section VI, Injection mixingcomponents, for application and sizing information.

Part Number 650-000-240/1098 9


Method 2 — Dual mixing valves

Figure 3 is a schematic of the dual three-way mixingvalve system. This is intended as an alternate to injectionmixing. We suggest using this method only if a costanalysis indicates a noticeably reduced installed cost.

The three-way mixing valves can be self-contained, remotebulb operated or operated by an actuator (electric orpneumatic, for example).

As shown if Figure 3, the heating loop incorporates amixing valve piped to regulate the system supplytemperature. If the mixing valve is motor-operated, itcan be used to provide outdoor reset of the supplytemperature to the system.

The mixing valve in the boiler loop regulates the returnwater to the boiler. This valve should normally be set at130 °F (or as specified by the boiler manufacturer).

Figure 3

Radiant heating Method 2 –Dual mixing valves

(The piping enclosed in thedotted rectangle can be

substituted for an IPP InjectionPump Panel wherever the IPP

is shown in this guide)

Fill

Expansion tank

Boiler loop pump

Radiantloops

Manifolds

Heating system pump

Hot

Mixed

Mixed

Cold

Cold

2 to 4pipediameters

Hot

With the piping as shown, the heating system may operateat any desired temperature without risk of causingcondensation in the boiler. Likewise, the boiler supplytemperature may be set as high as desired without causingexcessive temperature in the heating system because theheating system three-way valve controls the temperaturesent to the system.

Exception: Control of boiler return temperature shouldnot be necessary for finned tube baseboard heatingsystems which have a small, low mass radiant loop asshown in example system CP-3. “Small” means theradiant circuit load must not exceed 10% of the boileroutput. This radiant application must only be forsuspended floor applications – not for slab applications(neither thick nor thin slab).

Part Number 650-000-240/109810


Why use primary/secondary piping?

III Primary/secondary piping

Traditional piping for residential hydronic heating uses series loop or two-pipe piping. Commercial

systems are usually two-pipe design. These piping designs lack the versatility and efficiency needed

for today's systems, particularly for radiant heating. Use primary/secondary piping for radiant

heating (and for any system using outdoor reset or energy management).

Look at Figures 4 through 7 for a comparison of a traditional two-pipe system to a primary/

secondary system.

Notice that the system pump must provide all the flow needed for every branch in a traditional

two-pipe system. But the flow in each secondary circuit (branch) of the primary/secondary

system is individually controlled by the loop components.

The need for a pump in every secondary circuit could be deemed a disadvantage. On the other

hand, the individual pumps provide primary/secondary systems with their versatility.

Disadvantages

Loop operations are

independent

Simple isolation for service

Piping and pump sizing

more efficient

No by-pass pressure regulator

Multiple boiler advantages

• The operation of pumps and control valves in a secondary circuit has no effect on pressure in

other secondary circuits of a primary/secondary system. There is no concern of over-pressuring

the control valve seats. In a traditional two-pipe system the pressure on control valves increases

as other loop valves close because the reduced flow causes the system pump to shift up on its

pump curve.

• Since closure of a secondary circuit has no impact on other secondary circuits, any circuit can

be isolated for service without impacting the rest of the system.

• Secondary circuit piping and components (pumps and valves) are sized only for the needs of

that circuit – not for the system as a whole.

• The flow and head loss through the primary pump never changes and the flow circuit is never

interrupted due to closure of control valves. On traditional two-pipe systems, the flow rate

changes constantly due to action of the control valves. And a by-pass pressure regulator is

needed to protect the pump from high head conditions (dead heading) as branch control

valves close.

• With multiple boilers on secondary loops, there is no flow through idle boilers. So stand-by

loss is virtually eliminated. Individual boilers can be isolated for service without affecting the

rest of the system.

Advantages This discussion emphasizes the advantages of primary/secondary piping in radiant heating systems.

You should see that the versatility of primary/secondary designs and the ability to more easily

control temperatures and flows in each loop make this approach essential.

Part Number 650-000-240/1098 11


Fill

Secondarypump

Flow/checkvalves

Expansiontank

BOILER

Primarypump

LOAD

LOAD

LOAD

LOAD

Secondarypump

Secondarypump

Secondarypump

Flow/checkvalves

Flow/checkvalves

Flow/checkvalves

Fill

Expansiontank

Balancingvalves

Controlvalves

By-passpressureregulator

Pump

LOAD

LOAD

BOILER

Figure 7

Primary/secondary branch loop

Figure 6

Primary/secondary system, typical

Figure 5

Two-pipe system load branch

LOAD

2 to 4pipe

diameters

Primary piping

Secondary piping

Common piping

Primary pipingSupply manifold Return manifold

LOADBalancing

valveControlvalve

Figure 4

Traditional two-pipe system, typical

Part Number 650-000-240/109812


See Figure 8 for guidelines for the piping connections used in primary/secondary systems. SeeFigure 13 for placement of the pump relative to an air separator.

Common piping (piping between secondary circuit tees) —

• Common piping must be sized for the larger of the primary or secondary piping.

• Continue this pipe size at least —

8 pipe diameters upstream of the first secondary circuit tee.

4 pipe diameters downstream of the second tee.

Secondary loop tees —

• Size the secondary circuit tees for whichever flow is larger – the primary or the secondarycircuit.

• Space secondary circuit tees no wider than 4 common piping pipe diameters. The teesmust be spaced closely to minimize the pressure difference caused by flow through theprimary circuit. This pressure difference, if too large, would induce flow in the branch.

• Secondary pump should flow into secondary circuit (away from primary piping) — toraise pressure in the secondary circuit when pump comes on.

• Thoroughly ream copper piping between tees to prevent causing a pressure drop or turbulencedue to burrs.

Preventing gravity flow —

• Where secondary loop piping is above the secondary circuit tees, use two flow/check valves(Figure 9) or one flow check on the supply and a minimum 18 inch thermal trap on the return(Figure 10). Note – you can use a swing check valve in place of the flow/check valve on thereturn piping if piped horizontally.

• Where secondary circuit piping is below the branch tees at least 18 inches, no traps or checkvalves are needed (Figure 11).

• With an injection mixing circuit piped below the primary piping at least 18 inches, as inFigure 12, no additional thermal trapping or flow/check valves are required, provided theinjection pump is turned off when connected branches are satisfied. Do not install flow/checks in injection risers.

• Boiler loop piping (for boiler piped on a secondary loop) — no flow/check valves are neededif primary piping is below the boiler(s). Otherwise, use a flow/check valve on the supply line.

• Indirect water heaters – refer to Figure 14. Use a flow/check valve in the piping when thewater heater is located below the primary. This will prevent gravity flow caused when thewater heater water is hotter than the primary loop.

Circuit sequencing —

• When possible, sequence the secondary circuits off of the primary with the circuitsrequiring the hottest water first and those requiring the coolest water last. This will reducethe flow rate required in the primary circuit.

Primary/secondarypiping tips

III Primary/secondary piping - continued

Part Number 650-000-240/1098 13


Figure 9

Use two flow/check valves when branch piping

Figure 10

Alternate — use a flow/check valve in thebranch supply line and a thermal trap belowthe primary as below.

LOAD

Flow/check orswing check valve


Secondarypump

Flow/checkvalve

LOAD

18"Min

Secondarypump

Flow/checkvalve


4 pipediametersminimum


Nearest componentor fitting

Nearestcomponent

or fitting

To secondarycircuit

Primary circuit

Commonpiping

Secondary circuit tees

Primary circuit


Figure 8

Primary/secondary pipingdefinitions

Part Number 650-000-240/109814


Figure 13

Provide minimum 8 pipe diameters between airseparator and pump inlet connection as shownbelow.

Fill Pump


Air separator

Figure 14

Use a flow/check valve in the return line whenan indirect water heater is piped below theprimary piping to prevent gravity circulation.

Indirectwater heater

flow/checkvalve


Figure 12

No flow/check valves are needed wheninjection pump piping is installed below theprimary as below.

Figure 11

No flow/check valves or thermal traps areneeded when branch piping is below theprimary.

LOAD

Secondarypump


18”min

LOAD

18"Min

Secondarypump

InjectionpumpBalancing

valve

PrimaryPrimary



III Primary/secondary piping - continued

Part Number 650-000-240/1098 15


IV Zoning radiant heating systems

A zone is defined as a heating circuit or group of heating circuits controlled by a commonthermostat (or other temperature sensing/regulating method). Radiant heat zoning is similar toother hydronic systems, but the versatility of radiant tubing applications introduces the need fordifferent supply temperatures to spaces – and different spaces may have very different needs.

When combining spaces for a zone, make sure they are similar with respect to —

❏❏❏❏❏ The type of radiant heat application in the space must be similar —• Slab on grade, thin slab, below floor, above floor, etc. — don’t mix system types on the

same zone.• Below floor applications usually require higher water temperature than other types.• The mass of a slab system responds differently from a low mass suspended floor system

(above floor or below floor tubing installation).

❏❏❏❏❏ Supply water temperatures required must be similar —• Select radiant circuits requiring similar water temperatures when combining in common

zones.• Availabe floor area will affect the supply temperature required. So floor area available in

spaces must be considered when combining on a zone.

❏❏❏❏❏ Internal and solar gain variations should be similar —• Kitchens, sun rooms and rooms with large window areas have different needs from

family rooms, bathrooms and bedrooms, for example.• Entry areas will have different responses because of the influx of cold air as doors are

opened.

❏❏❏❏❏ Finished flooring (tile, carpet, wood, etc.) should have similar R-values —• Carpet acts as an insulator, requiring higher water temperature to the tubing. Tile, on the

other hand, is a heat conductor and requires lower supply water temperature. Both havedifferent needs from wood or linoleum.

❏❏❏❏❏ Usage patterns should be similar —• Bedrooms should be zoned separately from high usage living areas, for example.

Combining spacesfor zoning

Using zone valvesand/or valve

actuators

Zone valves or valve actuators allow independent operation of zones. This provides a smarter,more adaptive system. Even the best designed radiant heating system may cause uncomfortablespace conditions if the space thermostat can't regulate the heat input to the space. With AlumiPexnickel-plated brass manifolds, optional valve actuators (2-wire or 4-wire) are available.

Use zone valves or valve actuators whenever possible, with the exception of some constantcirculation applications. Some zones of constant circulation systems should never have the flowstopped — for example, zones heating warehouse spaces adjacent to loading dock doors. (Keepthe water moving in these zones to reduce the potential for freeze-up should the heating source beoff while the loading doors are opened.)

When using constant circulation with zone valves or valve actuators, install a by-pass pressureregulator in the piping to provide a water path should all zones close for a time (see Figure 65).This will protect the circulator from cavitation caused by high head/low flow operation.

Use 4-wire valve actuators to allow the actuators to signal the heating system of the need for heat.For spaces with multiple tubing circuits, use one "master" 4-wire valve actuator on one of thecircuits, with 2-wire zone valve actuators on the remaining circuits (as shown in the examples atthe end of this Guide).

Try to combine small zones as “slave” zones to larger ones to prevent a small zone from being theonly heat zone during a call for heat to the boiler. (Using a buffer tank will also help to reducecycling of the boiler during light loads.)

Part Number 650-000-240/109816


When combining radiant circuits on manifolds, make sure the supply temperature requirementsof the connected circuits are similar (maximum 10 °F difference in design temperature). If circuitlengths vary by more than 10% from one another, provide means for flow balancing, preferablyAlumiPex® Manifolds with integral valves plus AlumiPex® Flow Indicators.

Suggestions for combining circuits at manifolds —

❏❏❏❏❏ Combined flow rate of all connected circuits on any manifold no greater than12 gpm.

❏❏❏❏❏ Maximum difference between design supply temperature in any two circuitsis 10 °F.

❏❏❏❏❏ Locate manifolds centrally to the heated spaces to reduce leader lengths.

❏❏❏❏❏ Limit leader length to approximately 50 feet, using multiple manifolds indifferent locations if necessary to accomplish this.

❏❏❏❏❏ Use a zone valve (or valve actuator) on each circuit to allow adaptive control.See Figures 16 and 17 for typical uses of zone valves and valve actuators.These diagrams also show the use of multiple manifolds – either where neededbecause of the zone size or because multiple temperatures (differing by morethan 10 °F) are required on the same or multiple zones.

❏❏❏❏❏ When using zone valves with constant circulation systems, install by-passpressure regulator between manifold supply and return to provide a flowpath for the circulator when all zone valves are closed.

Combining circuitson manifolds

Ensure that the control circuit transformer is large enough for the connected zone valves (or valveactuators) and controls. The rule of thumb is to allow 10 va plus 6 va for each connectedAlumiPex manifold valve actuator. See Figure 15, below, for suggested sizing. Be sure to addcapacity for controls not considered below, such as other types of zone valves.

The AlumiPex manifold valve actuator is available ONLY with a 24 VAC coil.

Control circuittransformer sizing

Figure 15

Suggested control circuittransformer sizing when using

AlumiPex manifold valveactuators

Transformer24 vac

Minimum va

1 202 to 3 304 to 5 40

6 507 to 8 60

9 to 11 7512 to 15 100

Number ofAlumiPex

Valve actuators

IV Zoning . . . continued

Part Number 650-000-240/1098 17


Figure 16

Zoning components — manifolds, operators, actuators and zone valves

•••

•

•

•

Available with 2, 3 or 4 take-offs.

Can be joined together for up to 8 take-offs.

Use these manifolds only when the lengths ofall connected loops are within 10% of oneanother. If loops differ in length more than10%, use only manifolds with integral valves— to allow flow balancing.

Shown with optional purge valves & airvents.

Always connect supply end of circuit tobottom manifold.

Always connect return end of circuit to topmanifold.

AlumiPex manifoldswithout integral valves

•

•

•••

•

•

Integral valves can be used with manualoperators (shown, standard) or electric valveactuators.

Valves have adjustable stops, used to setpressure drop for flow balancing.

Available with 2, 3 or 4 take-offs.

Can be joined together for up to 8 take-offs.

Shown with optional purge valves & airvents.

Shown with optional flow indicators —recommended to simplify balancing.

Always connect supply end of circuit tobottom manifold.

Always connect return end of circuit to topmanifold.

•

AlumiPex®

manifoldswith integral valves

2-wireactuator2-wire

actuator4-wire

actuator4-wire

actuatorManualoperator

(standard)

Manualoperator

(standard)

•

•

Use electric actuators for individual flowcontrol on each attached tubing loop.

When using multiple actuators on the samezone, use only one 4-wire actuator per zone.Use 2-wire actuators for the remaining loops— only one end-switch signal is needed perzone.

AlumiPex®

manifoldsoperators & actuators

••

Any zone valve may be used where shown.

When using 3-wire zone valves, pay specialattention to connections — to avoiddamaging controls due to stray voltages.

Zone valves(typical)

,

Part Number 650-000-240/109818


Figure 17a

Manifolds supplying a single zone – flow control methods

End switch wiring(to boiler, IPC, etc.)

Thermostat


Thermostat


Thermostat

Return

Supply

Zone valve

Return

Zone valve

Supply

Return

Return

Zone valve

Zone valve

Supply

Supply


Thermostat

Return Return

Supply Supply

Zone valve Zone valve

••

•

Use a manifold without integral valves.Tubing loop lengths should be similar;i.e., lengths should not vary more than10% — otherwise, use a manifold withintegral valves to allow flow balancing.Use a zone valve to regulate flow, asshown.

❏

❏

❏

One zone per manifoldOne or more tubing loops per zoneLoop lengths uniform within 10%

••

Use manifolds with integral valves.Tubing lengths vary more than 10%, sothe integral valves are needed to allowflow balancing. The optional flowindicators shown are recommendedbecause they simplify balancing andreduce time required.

❏

❏

❏

One zone per manifoldOne or more tubing loops per zoneLoop lengths vary more than 10%

••

•

Use manifolds without integral valves.If design supply temperature forconnected loops varies more than ± 5°F,provide separate manifold(s) as needed.

Use flow indicators to simplify balancingand reduce time required.

• Tubing loop lengths should be similar;i.e., lengths should not vary more than10% — otherwise, use a manifold withintegral valves to allow flow balancing.

❏

❏

❏

❏

Multiple rooms per zoneMultiple temperatures neededOne or more tubing loops per manifoldLoop lengths uniform within 10%

• Same as above, except use manifoldswith integral valves to allow balancingflow. Use flow indicators to simplifybalancing and reduce time required.

❏

❏

❏

❏

Multiple rooms per zoneMultiple temperatures neededOne or more tubing loops per manifoldLoop lengths vary more 10%

Temp 2Temp 1

IV Zoning . . . continued

Part Number 650-000-240/1098 19


Figure 17b

Manifolds supplying multiple zones – flow control methods


ThermostatZone 1

Zone 1

Zone 2

ThermostatZone 2

Return

Supply

SUPPLY

Zone valve


ThermostatZone 1

Zone 1

Zone 2

Temperature A Temperature B

Temperature B

ThermostatZone 2

Return Return

Supply Supply

SUPPLY

RETURNRETURN

4-wireactuator

2-wireactuator

SUPPLY

RETURN

4-wireactuator

2-wireactuator

SUPPLY

Zone valve

Return

Supply

RETURN

Alternate arrangementfor loop lengths all within10% of one another

••

•

Use a manifold with integral valves.Provide a 4-wire actuator for each zoneplus 2-wire actuators as needed foradditional loops on the same zone.If tubing loop lengths in a zone differ bymore than 10%, provide flow indicatorsto simplify balancing and reduce timerequired.

❏

❏

Multiple zones per manifoldOne or more tubing loops per zone

••

•

•

Use manifolds with integral valves.If design supply temperature forconnected loops varies more than ± 5°F,provide separate manifold(s) as needed.Provide a 4-wire actuator for each zoneplus 2-wire actuators as needed foradditional loops on the same zone.If tubing loop lengths in a zone differ bymore than 10%, use manifolds withintegral valves and provide flowindicators to simplify balancing andreduce time required.

❏

❏

❏

❏

Multiple rooms per zoneMultiple temperatures neededOne or more tubing loops per zoneLoop lengths vary more than 10%

Part Number 650-000-240/109820


Supply

wat

er t

emper

ature

Outdoor temperature

R=1.5(1.5 to 1 Ratio)

R=1(1 to 1 Ratio)

R=0.67(1 to 1.5 Ratio)

70 -1070

100

130

160

190

103050

V Control strategies - general

The purpose of a heating system is to match the heat input to each space to the heat lost from

that space. But the design point for a heating system is based on maximum load conditions, to

assure adequate heat for the coldest days of the heating season. Consequently, the heating

system components are often oversized for the majority of the heating season.

When it is warmer outside than design conditions, water supplied to the radiant tubing at the

design temperature will cause the heat input to exceed the heat loss. This causes cyclic operation

of the heating system, resulting in increased swings in room temperature and wasted heat.

Outdoor reset means the temperature of the supply water to the system is adjusted based on

the outdoor temperature. As the outdoor temperature rises above the design point, the supply

water temperature to the system is reduced. Heat input to the radiant floor or panels is directly

related to water supply temperature. So reducing the supply water temperature allows matching

heat supplied to heat needed.

The Weil-McLain IPC Injection Pump Control provides outdoor reset capability as well as

adjustments in reset ratio and outdoor reference temperature, allowing fine tuning of your

heating system. See the discussion following.

Outdoor reset

Figure 18

Typical outdoor reset curves –Notice that supply watertemperature drops as outdoortemperature rises.

Outdoor reference temperatureis usually 70 °F, but can bechanged on the IPC InjectionPump Control if needed. Sup-ply water temperature will equalthe outdoor temperature whenthe outdoor temperaturereaches the reference tempera-ture. This is the point at whichthere is zero heat loss, so noheat will be added to the space.

The reset ratio is the change insupply water temperature foreach degree change in outdoortemperature. To calculate theright ratio, determine the sup-ply temperature needed at theODT (outdoor design tempera-ture) for the location. For a 70°Foutdoor reference, the ratio is:R = (Supply temp -70)/(70-ODT).

R =Supply temp – 70

70 - ODTwhere• 70 = Outdoor reference temperature

(point of no heat requirement)• ODT = Outdoor design temperature for

the location• Supply temp = water supply temperature

needed at outdoor design temperature

Part Number 650-000-240/1098 21


Advantages of outdoor reset• Fewer cycles of the heating components (boiler, zone controls and pumps).

• Smaller changes in room temperature.

• Floors will feel more comfortable because floor temperature variations will be smaller.

• Reduced thermal stressing of wood flooring over heated slabs. Wood is less prone to cuppingor cracking when undergoing gradual temperature changes.

• Reduced expansion noise in distribution piping.

• Reduced heat loss from distribution piping because of lower supply temperature.

• From 10% to 15% reduction in fuel usage due to reduced cycling and lower distributiontemperature.

• Can also be used effectively with baseboard and panel radiation.

Advantages of fixed temperature control• Faster warm-up from cold start conditions in mild weather.

• Faster reaction to sudden influx of cold air into the space.

• Fewer control adjustments required.

• Can be done with relatively low cost three-way or two-way temperature regulating valves(provided the boiler return piping protects the boiler from condensation and thermal shock).

In general, the best performance for the radiant system will come from using outdoor reset with

zone valves on each zone. With the outdoor reset control correctly adjusted, and flow rates and

supply temperatures for each zone set properly, it will probably not be necessary to set the

circulator for constant operation because the matching of heat input to heat loss will keep the

circulator on most of the time anyway.

Summary

Constant circulation Constant operation of the distribution circulator throughout the system reduces temperature

swings in the floor and the heated space. Consider using constant circulation for wood floor

applications because it will reduce thermal stressing of wood flooring.

Use constant circulation on zones supplying heat to warehouse areas adjacent to load dock

doors. With constant circulation in the tubing, the possibility of freeze-up is reduced, even for

times when the door is open and the boiler is off. This is because the circulating water can take

stored heat from other floor areas to replace the high heat loss near the door.

A note on application of constant circulation —

Since zone valves are generally not used on constant circulation systems, all zones must have

similar requirements; i.e., if some zones have significant solar gain, these zones may be overheated

in a constant circulation system. If you plan to use constant circulation on such systems, provide

zone valves to segment the system and a by-pass pressure regulator to protect the pump from

running with no flow should all zone valves close at the same time.

Part Number 650-000-240/109822


Figure 19

Weil-McLain IPC Injection Pump Control

The Weil-McLain IPC InjectionPump Control is microprocessor-based, and is designed to controltemperatures (system supply andboiler return) by providing variablespeed output to an injection pump.

The IPC can either maintain a fixedradiant supply temperature - FixedTemperature system - or can varythe radiant supply temperaturebased on outdoor temperature -Outdoor Reset system. The IPCcontrol logic provides PID control/response methodology; i.e., thecontrol regulates its reaction to atemperature change based on howfast as well as how much the systemresponds.

The IPC also provides 120 VAC for anon/off heating system pump. Foradded flexibility, the control caninterface with a zone controller oraccept the inputs from an indoortemperature sensor.

LR 58223NRTL/C

OutdoorTempShutoff

Press to TestLamps &Pump Controls

Refer to inside ofcover for installationdefault values

BoilerSupply Temp. Max. Supply Temp.

Supply TempRatio

Outdoor TempSystem Shutoff

185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump

Min BoilerReturn Temp

Call ForHeat

%

%

%

%

%

Power

REQUIRED SENSORSRESET INPUTS

Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply

OutdoorSensor Signal wiring

must be ratedat least 300V

Power: 120 V 50/60 Hz 1500 VA120 V (ac) 2.4 A 1/5 hp.

120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput

ContinuousSystem Pump

Injectionpump

Systempump

ORZonecontrol

Indoorsensor

Outdoorsensor

Call for heat(24 vac or 120 vacsignal — not usedwhen indoor sensoris installed)

Supplytemp

Boilerreturntemp

Boiler

POWER120 VAC

VI Injection mixing components

Part Number 650-000-240/1098 23


Adjusting the outdoor resetheating line

When the IPC is operated in reset mode, the heating linecan be adjusted to match the specific requirements of thedistribution system. Two adjustments are used to set theheating line. The dial labeled Outdoor Temp SystemShutoff sets the starting point of the heating line (shownas 70 °F in Figure 18). The dial labeled SupplyTemperature Ratio sets the reset ratio - the slope of theheating line. These two adjustments are independent ofeach other. Used together they allow a wide range ofadjustment to the heating line.

When the IPC is used without an indoor sensor itcontinually calculates the desired supply watertemperature based on the following formula incombination with its dial settings:

Tsupply = Tstarting + (reset ratio) x (Tstarting – Toutside)

where: Tstarting = Outdoor Temp System Shutoff dial setting

reset ratio = Supply Temperature Ratio dial setting

Adjusting the starting point of the heating line issometimes referred to as parallel shifting the line. Figure20 shows the results of shifting a typical heating curve.

IPCoperation

Supp

ly w

ater

tem

pera

ture

Outdoor temperature

70, 70

60, 60

80, 80

Reset ratioReset ratio is the

slope of theheating line.

The heating lineshifts with thestarting pointtemperature.

Starting pointStarting temp

shifts along thisline when being

adjusted.

Curve for st

arting point o

f 80, 80 °F

Curve for st

arting point o

f 70, 70 °F

Curve for st

arting point o

f 60, 60 °F

Figure 20

Heating curve changes with changes in startingpoint temperature

Using an indoor sensor with theIPC

The IPC can use an indoor sensor (connected to terminals7 and 8) in lieu of a powered heat demand signal (24 or120 vac at terminals 15 and 16). An indoor sensorprovides a proportional signal to the IPC, telling it exactlywhat the room temperature is. This allows the IPC tosense small changes in room air temperature and toinitiate minor corrective actions before the roomoverheats or cools off.

The indoor sensor causes automatic adjustment of theheating line because the IPC detects changes in room airtemperature and adjusts heating accordingly. Set thedesired indoor temperature on the dial labelled OutdoorTemp System Shutoff when using an indoor sensor.

Single and multiple zones usingindoor sensors

The indoor sensor provides a single room temperaturefeedback to the IPC. Thus, it provides single zone control.This is suitable for buildings with "open" floor plans thatdo not experience widely varying internal heat gains indifferent parts of the heated space.

If multiple independent heating zones are needed, the IPCcan be interfaced with several zone controls (such as thetekmar® #367 and #368 controls). A zone control receivesa signal from a room sensor in each zone, then processesthe information to provide feedback to the IPC.

Part Number 650-000-240/109824


The Weil-McLain IPP Injection Pump Panel simplifiesradiant system design and installation. The IPP protectsagainst low return temperatures at the boiler whileproviding the radiant system the proper supplytemperature. This is accomplished by varying the speedof an injection pump while monitoring both the systemsupply and boiler return temperatures.

IPP components

The heart of the IPP is the Weil-McLain IPC InjectionPump Control. (This control can be also be used tocontrol a field-supplied injection pump and heatingsystem pump.) Included with the IPP are sensors forheating system water, boiler return water and outdoortemperature.

The IPP-150 is factory packaged with both the injectionpump, 1, and the heating system pump, 2, pre-pipedand pre-wired on the common panel.

Also included is a memory stop set manual balancingvalve — used to adjust the pressure drop in the injectionpump circuit, thus providing accurate control even atlow injection flow rates.

IPP advantages

When evaluating alternatives for temperature regulationin radiant heating systems, consider the advantages ofthe IPC Injection Pump Control and IPP Injection PumpPanel —

Simplicity

No additional components are needed to assuretemperature regulation for the radiant heating circuit aswell as the boiler return water.

The IPP includes the secondary (heating) circuit pumpas well as the operating control and the injection pump.

VI Injection mixing components – continued

IPPpanels

Both pumps are pre-piped, simplifying installation.

Reliability

Long term protection - Boiler return water protectionis fixed by the IPC, unlike manual by-pass arrangements,which can be defeated by incorrect adjustment ofbalancing valves. Manual by-pass systems cannot beapplied effectively when outdoor reset is desired.

Energy efficiency

The IPC, combined with injection mixing, allows watersupply temperature regulation to be "matched" toradiant heating system response by adjusting thesettings of the reset ratio and starting temperature. Thispays off in reduced energy usage because roomtemperature swings will be reduced - particularly whencompared to fixed temperature control provided by mostmixing valve systems.

Using the indoor sensor or zone control option couldalso reduce heating energy usage due to the improvedresponsiveness to room temperature.

Injection mixing does not introduce a head loss in theprimary or distribution circuits, whereas a mixing valvewill cause a noticeable head loss, often requiring largerpumps.

Versatility

The IPC provides outdoor reset capability (moredifficult and costly to accomplish when using mixingvalves). To obtain outdoor reset with mixing valves,motorized valves must be used. In addition, an outdoorreset controller or electronic control must be added.

The IPC allows future modifications, such as changingto zone control or indoor temperature sensors whensystem performance indicates the need.

Part Number 650-000-240/1098 25


Figure 21

Weil-McLainIPP-150InjectionPump Panel

Part Number 650-000-240/109826


VII Determining flow rates

Use a flow rate in the primary circuit that will:

Rule 1 Provide no lower than 140 °F waterreturning to the boiler.

Rule 2 Provide the minimum required watertemperature to each secondary circuit.

Pay close attention to the minimumtemperature needed at the injectionpump for variable speed injection systems. SeeTable 2 in this Guide for the minimumtemperature needed at the IPP-150 InjectionPump Panel, based on Btuh load and radiantcircuit return water temperature.

To calculate a flow rate when you know the temperaturedrop and heat load —

Equation 1

Flow rate, GPM = Btuh / (K1 x DT)

where DT is the temperature drop

K1 = 494 for water; 449 for 50/50 glycol/water

Alternatively, use Table 1 in place of Equation 1.

If you know the flow rate and want to find the temperaturedrop (or rise) —

Equation 2

DT = Btuh/(Flow rate x K1)

where DT is the temperature drop

K1 = 494 for water; 449 for 50/50 glycol/water

Flow rate is in GPM

Procedure for determining primaryProcedure for determining primaryProcedure for determining primaryProcedure for determining primaryProcedure for determining primaryflow rate –flow rate –flow rate –flow rate –flow rate –

Step 1 – Estimate minimum primary loop supplytemperature.

• For an initial estimate, assume a supply temperature• no lower than the temperature required at the

Primary circuit flow rate

first secondary circuit — and —• at least 20 °F higher than highest of any other

required secondary supply temperature.

Step 2 - Consider Rule 1.

• Use Equation 1 or Table 1 to find the minimum flowrate that will ensure return water to the boiler at noless than 140 °F. The Btuh value is the total of allsecondary heating loads.

• Determine maximum temperature drop — DT =Supply temperature - 140 °F

• Select K1 (494 for water; 449 for 50/50 glycol)• Calculate minimum flow rate from Equation 1 —

Minimum flow rate = Btuh/(K1 x DT); or use Table1 to select the minimum flow for this temperaturedrop.

• The primary loop flow rate must be no less than thisvalue. A lower flow rate would cause a greatertemperature drop, and the return water to the boilercould be low enough to cause condensation orthermal shock.

Step 3 - Consider Rule 2.

• Find a flow rate which will ensure each secondarycircuit the minimum supply water temperatureneeded.

• Assume a trial flow rate equal to the minimum flowrate determined in Step 2.

• Calculate the temperature drop caused by the firstsecondary circuit using the assumed flow rate inEquation 2.

• Subtract this temperature drop from the primaryloop supply temperature to determine the supplytemperature available to the next secondary circuit.

• Then calculate the temperature drop caused by thissecondary circuit and subtract the number from theprimary loop temperature to determine thetemperature available to the third secondary circuit.

• Repeat this process for the entire system to verifythat each secondary circuit will receive the minimumrequired water temperature.

• If the assumed flow rate results in one or moresecondary circuits not receiving adequate supplywater temperature, increase the initial primary supplytemperature or increase the flow rate, or both, untilthe selected flow rate and temperature satisfy bothRule 1 and Rule 2.

Part Number 650-000-240/1098 27


Table 1

Minimum water only (not glycol) flow rates – use this table to find the minimum flow rate required for a givenmaximum temperature drop, °F

TIP If the required Btuh is not listed in the table, you can add multiples together. For example —300,000 Btuh is 50,000 plus 250,000 – so you could add the flow rate for 50,000 to the flow ratefor 250,000 to determine the flow for 300,000 Btuh.

Btuh 2 4 6 8 10 15 20 25 30 40 50 60 70 80 90 100

2,000 2.0 1.0 0.7 0.5 0.4 0.3 0.2 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0

4,000 4.0 2.0 1.3 1.0 0.8 0.5 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0.1 0.1 0.1

5,000 5.1 2.5 1.7 1.3 1.0 0.7 0.5 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0.1 0.1

10,000 10.1 5.1 3.4 2.5 2.0 1.3 1.0 0.8 0.7 0.5 0.4 0.3 0.3 0.3 0.2 0.2

15,000 15.2 7.6 5.1 3.8 3.0 2.0 1.5 1.2 1.0 0.8 0.6 0.5 0.4 0.4 0.3 0.3

20,000 20.2 10.1 6.7 5.1 4.0 2.7 2.0 1.6 1.3 1.0 0.8 0.7 0.6 0.5 0.4 0.4

25,000 25.3 12.7 8.4 6.3 5.1 3.4 2.5 2.0 1.7 1.3 1.0 0.8 0.7 0.6 0.6 0.5

30,000 30.4 15.2 10.1 7.6 6.1 4.0 3.0 2.4 2.0 1.5 1.2 1.0 0.9 0.8 0.7 0.6

35,000 35.4 17.7 11.8 8.9 7.1 4.7 3.5 2.8 2.4 1.8 1.4 1.2 1.0 0.9 0.8 0.7

40,000 40.5 20.2 13.5 10.1 8.1 5.4 4.0 3.2 2.7 2.0 1.6 1.3 1.2 1.0 0.9 0.8

45,000 45.5 22.8 15.2 11.4 9.1 6.1 4.6 3.6 3.0 2.3 1.8 1.5 1.3 1.1 1.0 0.9

50,000 50.6 25.3 16.9 12.7 10.1 6.7 5.1 4.0 3.4 2.5 2.0 1.7 1.4 1.3 1.1 1.0

60,000 60.7 30.4 20.2 15.2 12.1 8.1 6.1 4.9 4.0 3.0 2.4 2.0 1.7 1.5 1.3 1.2

75,000 75.9 38.0 25.3 19.0 15.2 10.1 7.6 6.1 5.1 3.8 3.0 2.5 2.2 1.9 1.7 1.5

90,000 91.1 45.5 30.4 22.8 18.2 12.1 9.1 7.3 6.1 4.6 3.6 3.0 2.6 2.3 2.0 1.8

100,000 101.2 50.6 33.7 25.3 20.2 13.5 10.1 8.1 6.7 5.1 4.0 3.4 2.9 2.5 2.2 2.0

125,000 126.5 63.3 42.2 31.6 25.3 16.9 12.7 10.1 8.4 6.3 5.1 4.2 3.6 3.2 2.8 2.5

150,000 151.8 75.9 50.6 38.0 30.4 20.2 15.2 12.1 10.1 7.6 6.1 5.1 4.3 3.8 3.4 3.0

200,000 202.4 101.2 67.5 50.6 40.5 27.0 20.2 16.2 13.5 10.1 8.1 6.7 5.8 5.1 4.5 4.0

250,000 253.0 126.5 84.3 63.3 50.6 33.7 25.3 20.2 16.9 12.7 10.1 8.4 7.2 6.3 5.6 5.1

Minimum GPM required for temperature drop ( F) of no more than

Part Number 650-000-240/109828


Example system, Figure 22— Primary circuit feeds three branch circuits —

Circuit 1 Domestic water – 25,000 Btuh, requires supply water at 180 °F minimum.

Circuit 2 Baseboard heating circuit – 40,000 Btuh, require supply water at 180 °F minimum.

Circuit 3 Radiant heating circuit – 35,000 Btuh, requires supply water at 140 °F.

Determine the example system flow rate and primary loop supply temperature, T1 —

Step 1• Secondary circuit 1 requires 180 °F, so the primary loop supply temperature must be at least

180 °F.• Secondary circuit 2 requires 180 °F, the highest of the remaining circuits. Add 20 °F to this for

an initial estimate of the primary loop supply temperature, T1, of 200 °F .

Step 2• Determine the temperature drop in the primary loop if the water returns to the boiler at the

minimum allowable temperature of 130 °F —

DT = 200 °F - 130 °F = 70 °F.

• Total heating load, all branches = 25,000 + 40,000 + 35,000 = 100,000 Btuh

• Determine minimum flow rate from Equation 1 -

• Minimum flow rate = 100,000/(494 x 70) = 2.89 GPM (or 2.9 GPM if taken from Table 1.)

• The primary loop flow rate must be at least 2.89 GPM to satisfy Rule 1.

Step 3• Assume a flow of 2.89 GPM (from Step 2).

• Temperature drop due to Branch 1 —

• DT = 25,000/(494 x 2.89) = 17.5 °F.

• T2 = T1 - 17.5 °F = 200 °F - 17.5 °F = 182.5 °F.

• This exceeds the minimum required temperature at branch 2 of 180 °F, so the flow rate isacceptable for branches 1 and 2. Continue checking for branch 3.

• Calculate the temperature drop caused by branch 2 —

• DT = 40,000/(494 x 2.89) = 28.0 °F.

• T3 = T2 - 28 °F = 185 °F - 28 °F = 157 °F.

• This exceeds the minimum temperature required by branch 3, so the flow rate of 3.37 GPMis acceptable for all three branches.

Selection• Provide a flow rate in the primary circuit of at least 2.89 GPM.• Provide a supply water temperature of at least 200 °F.

Comments - extended example

• Note that, if the load in branch circuit 1 had been 60,000 Btuh, for example, the flow rate of2.89 GPM would not have been high enough to provide branch circuit 2 with water at 180 °F.The temperature drop due to branch 1 would have been 60,000/(494 x 2.89) = 42 °F. And thesupply temperature, T2, to branch 2 would have been 200 °F - 42 °F = 158 °F.

• To find the necessary flow rate — the maximum allowable temperature drop due to branch1 is 20 °F in order to provide 180 °F to branch 2. (Because DT = 200 °F - 180 °F = 20 °F.) So,from equation 1, the minimum flow rate would be 60,000/(494 x 20) = 6.07 GPM. (Thiswould be 6.1 GPM if taken from Table 1.)

VII Determining flow rates - continued

Primary circuit flowrate calculation –

example, Figure 22

Part Number 650-000-240/1098 29


Secondarypump

Flow/checkvalves

Flow/checkvalves

Fill

Expansiontank

BOILER

Primarypump

T1 T4T2 T3

Rule 1T4 no less than 130 °F

Rule 2T1, T2 and no less thanrequired at branches 1, 2and 3, respectively.

T3

180 °F min180 °F min 140 °F min

130 °F min

LOAD LOAD

Secondarypump

Secondarypump

125,000 Btuh 35,000 Btuh

Flow/checkvalves

Flow/checkvalves

LOAD

240,000 Btuh

Flow/checkvalves

Secondarypump

3

Figure 22

Primary circuit flow rateexample

Part Number 650-000-240/109830


VII Determining flow rates - continued

Injection pump flowrates

The injection pump only has to inject enough hot water from the primary loop into the heatingcircuit loop to raise the heating circuit return temperature to the desired supply temperature. Theformula for the injection pump flow rate when you know the heating load (Btuh), the heatingcircuit return temperature (TR), and the temperature of the water supplied to the injection circuit,(TS) is —

Equation 3 Injection flow, GPM = Btuh / [(TS - TR) x K1]

where DT is the temperature drop and K1 is taken from the following table —

When applying an IPP-150 Injection Pump Panel, ensure that the supply water temperatureavailable at the panel will be no less than the temperatures given in Table 2 If the supply temperatureis lower than the number shown, the panel will not be able to deliver enough hot water to theradiant circuit to achieve the heat load required. (Table 2 is based on a full load flow rate in theinjection riser of 4.5 GPM.)

Injection pump flow rate exampleA radiant heating circuit has a load of 50,000 Btuh. The supply temperature reaching the injectionpump will be 160 °F. And the radiant circuit requires water at 100 °F, returning at 90 °F. UseEquation 3 (with K1 = 495 for 100 °F) –

Injection flow rate = 50,000 / [(160 - 110) x 495] = 2.0 GPM

Table 2

Minimum supply watertemperature needed at an

IPP-150 Injection Pump Panel

��

��

90 100 110 120 130 140 150 160

10 94 104 114 124 134 144 154 16420 99 109 119 129 139 149 159 16930 103 113 123 133 143 153 163 17340 108 118 128 138 148 158 168 17850 112 122 132 142 152 162 172 18260 117 127 137 147 157 167 177 18770 121 131 141 151 161 171 181 19180 126 136 146 156 166 176 186 19690 130 140 150 160 170 180 190 200100 135 145 155 165 175 185 195 205110 139 149 159 169 179 189 199 209120 144 154 164 174 184 194 204130 148 158 168 178 188 198 208140 153 163 173 183 193 203150 157 167 177 187 197 207

HeatLoad

(MBH)

Minimum supply temperature to IPP-150 Injection Pump Panel with radiant circuit return temperature ( F) of -

Fluidtemperature

K1Water only

K130% glycol

K150% glycol

100 F 494 478 449140 F 491 479 453180 F 486 479 454

Part Number 650-000-240/1098 31


Secondary circuitflow rates

Domestic water circuitsDetermine the flow rate for domestic water heating based on the recommended flow rate given bythe water heater manufacturer. Weil-McLain PLUS and GOLD Plus water heater literature includesthis information.

Baseboard circuitsThe flow rate for baseboard circuits is usually based on a 20 °F drop and can be calculated usingEquation 1 or read directly from Table 1.

Radiant circuitsDetermine the flow rate for the radiant loops using the AlumiPex Radiant Expert computerprogram or AlumiPex Design Guide (when available). As a rule of thumb, the flow rate per loopwill generally be 1 gpm or less for ½” tubing (higher for larger tubing).

The radiant circuit pump must deliver water to all of the circuits piped off of the manifold. So thetotal flow rate required from the pump is the sum of the flows in all connected circuits.

The flow rate may also be determined from the desired temperature drop and heat load, usingEquation 1 or Table 1.

Estimate the total flow for a radiant heating circuit by assuming some typical conditions —

• Temperature drop = 10 °F.

• Fluid in circuit is water (no glycol).

Radiant heating circuit flow rate exampleDesign conditions —

• Heat load = 15 Btuh per square foot.

• Loop length 300 feet of tubing.

• Tubing layout at 12 inches on center.

• Water only (no glycol).

• Temperature drop = 10 °F, from 100 °F to 90 °F.

Determine the estimated heat load for the loop —

• To determine how many square feet of floor the 300 feet of tubing will cover, consider that, at12 inch center to center tube spacing, there will be one linear foot of tubing to each square footof floor space. (For any other tubing spacing, divide 12 by the tube spacing in INCHES to findthe number of feet of tubing per square foot of floor. For example, 6 inch tube centers wouldrequire two linear feet of tubing per square foot of floor; i.e., 12/6 = 2.)

• Since there is 1 linear foot of tubing per square foot for this example of 12 inch centers, the 300foot tubing loop will cover 300 square feet of floor.

• The loading is 15 Btuh per square foot of floor, so the total load of the loop is 300 feet times15 Btuh per square foot, or 4,500 Btuh total.

Determine the estimated flow rate —

• Use Equation 1 (or Table 1) — Flow rate = 4,500/(495 x 10) = 0.91 GPM.

Part Number 650-000-240/109832


VIII Determining head loss

Equivalent length

Determine the pipe size for each circuit based on therequired flow for that circuit (in GPM), and the desiredhead loss. Avoid high head losses where possible. Highhead losses require more energy to pump the water,resulting in higher electrical costs and higher costs for thepumps. You can use the following method to determinehead losses in the system, boiler and water heater circuits.

• The head loss through a length of pipe is directlyproportional to its length.

• For any fitting or valve, there is an equivalentstraight length of pipe which would cause the samehead loss as the fitting or valve. This length of pipeis the equivalent length for that fitting. See Table 5for equivalent lengths of copper and threadedfittings.

• The Total Equivalent Length (TEL) for a circuit isthe sum of the length of the piping plus theequivalent lengths of all fittings in the circuit.

The equivalent length depends on pipe size. So begin byestimating the TEL as 1.5 times the length of the piping.In fact, for small systems, this estimate is usually adequatefor the head loss calculation. This is because the circuitlengths are relatively simple and short, and the head lossesare low. Example: if the circuit contains 130 feet of straightpipe, estimate the TEL as: TEL = 1.5 x 130 = 195 feet.

Head loss (series circuits)

Table 3 provides the means of calculating head losses inpiping circuits. It also provides recommended maximumand minimum flow rates for each size AlumiPex or coppertubing, or steel pipe. The maximum is intended tominimize noise and prevent erosion. The minimum isintended to assure adequate movement of air throughthe system.

Procedure —

Select a trial pipe size from Table 3 based on the designflow rate, in GPM, for the circuit. For any given copper

or steel pipe size, select the corresponding “a”, “b”, and“c” from the table. Use a value of c =1 except wheretemperature is closer to 100 °F or 180 °F than to 140 °F,where the appropriate value of c from the table may beused to adjust the pressure loss. Calculate the pipingcircuit head loss, in feet, as:

Equation 4 H = (TEL/100) x a x (GPM)b x c

Add to the piping head loss the head losses for boilers,water heaters, baseboard, heat exchangers or any othercomponents of this sort in the circuit. Refer to theinstructions or literature on these components for theestimated head loss.

TIPS • Estimate ¾" baseboard as if it werejust a straight length of ¾" pipe.

• For cast iron boilers — estimate a headloss of 1 to 2 feet for residentialboilers and 2 to 5 feet for commercialboilers.

If the head loss based on the trial pipe size is acceptable(usually between 5 and 15 feet), check the actual equivalentlength of the circuit using the pipe size you selected. Obtainthe equivalent lengths of all valves and fittings from Table5. If the TEL is different from your estimate, use the new,calculated, TEL in the head loss formula, Equation 4. Ifthe result is acceptable, use the required flow andcalculated head loss to select a pump. If not, increase (ordecrease) the pipe size as indicated and redo thecalculation.

Glycol/water systems

For systems filled with propylene glycol/water, first dothe calculations as if the system were filled with wateronly. Then apply the correction factors given in Table 4.You will see from the table that the flow rate for glycol/water must be from 14% to 16% higher than water onlyto achieve approximately the same heat transfer. The headloss for any give flow rate will be higher for the glycol/water mixture than for water only.

Part Number 650-000-240/1098 33


Table 3

Head loss data and minimum/maximum flowrecommendations

Table 4

Correction factors when using50/50 glycol/water in place ofwater only

AlumiPex tubing - head loss data - water @ 140 F

¹⁄₂¹⁄₂¹⁄₂¹⁄₂ 0.55 2.19 3.9087 1.750 1.00 4.00 0.472 1.095 0.930

⁵⁄₈⁵⁄₈⁵⁄₈⁵⁄₈ 0.91 3.65 1.1507 1.750 1.00 4.00 0.610 1.095 0.930

³⁄₄³⁄₄³⁄₄³⁄₄ 1.52 6.07 0.3379 1.750 1.00 4.00 0.787 1.095 0.930

1111 2.56 10.26 0.0865 1.750 1.00 4.00 1.024 1.095 0.930

Copper Tubing, Type M - head loss data - water @ 140 F

¹⁄₂¹⁄₂¹⁄₂¹⁄₂ 1.189 3.17 1.588 1.750 1.50 4.00 0.569 1.095 0.930

³⁄₄³⁄₄³⁄₄³⁄₄ 2.41 6.44 0.295 1.750 1.50 4.00 0.811 1.095 0.930

1111 4.09 10.90 0.085 1.750 1.50 4.00 1.055 1.095 0.930

1 ¹⁄₄1 ¹⁄₄1 ¹⁄₄1 ¹⁄₄ 6.12 16.32 0.0324 1.750 1.50 4.00 1.291 1.095 0.930

1¹⁄₂1¹⁄₂1¹⁄₂1¹⁄₂ 8.56 22.83 0.0146 1.750 1.50 4.00 1.527 1.095 0.930

2222 14.82 39.52 0.00397 1.750 1.50 4.00 2.009 1.095 0.930

2¹⁄₂2¹⁄₂2¹⁄₂2¹⁄₂ 36.16 91.08 0.00113 1.812 2.37 5.98 2.495 1.071 0.947

3333 58.00 146.11 0.000478 1.812 2.67 6.72 2.981 1.071 0.947

Steel pipe, schedule 40 - head loss data - water @ 140 F

¹⁄₂¹⁄₂¹⁄₂¹⁄₂ 1.42 3.79 0.378 1.771 1.50 4.00 0.622 1.087 0.936

³⁄₄³⁄₄³⁄₄³⁄₄ 2.49 6.65 0.140 1.771 1.50 4.00 0.824 1.087 0.936

1111 4.04 10.77 0.0595 1.771 1.50 4.00 1.049 1.087 0.936

1 ¹⁄₄1 ¹⁄₄1 ¹⁄₄1 ¹⁄₄ 6.99 18.65 0.0225 1.771 1.50 4.00 1.380 1.087 0.936

1¹⁄₂1¹⁄₂1¹⁄₂1¹⁄₂ 9.52 25.38 0.0130 1.771 1.50 4.00 1.610 1.087 0.936

2222 15.69 41.83 0.00538 1.771 1.50 4.00 2.067 1.087 0.936

2¹⁄₂2¹⁄₂2¹⁄₂2¹⁄₂ 34.32 84.50 0.00105 1.858 2.30 5.66 2.469 1.053 0.960

3333 60.57 149.11 0.000366 1.858 2.63 6.47 3.068 1.053 0.960

c

c

PipeID

Correction@ 100 F

Correction@ 180 F

Velocity@

Min. fps

Velocity@

Max. fps

SizeMinimum

Flow, GPMMaximum Flow, GPM a b

Velocity@

Min. fps

Velocity@

Max. fps

Size

PipeID

Correction@ 100 F

Correction@ 180 F

Correction@ 180 F

c

PipeID

Correction@ 100 F

Minimum Flow, GPM

Maximum Flow, GPM a b

bVelocity

@Min. fps

Velocity@

Max. fpsSize

Minimum Flow, GPM

Maximum Flow, GPM a

Glycol/water correction factorsAverage

glycol/watertemperature

Multiply belowtimes water onlyflow rate forsame heat transfer

Multiply belowtimes water onlyhead loss for30% glycol/water

Multiply belowtimes water onlyhead loss for50% glycol/water

100 F 1.16 1.24 1.44140 F 1.15 1.19 1.36180 F 1.14 1.17 1.31220 F 1.14 1.15 1.27

Part Number 650-000-240/109834


Table 5

Equivalent lengths, feet of pipe, for common copper and steel valves and fittings

Copper fitting equivalent lengthsCopper fitting equivalent lengthsCopper fitting equivalent lengthsCopper fitting equivalent lengths

Copper sizeCopper sizeCopper sizeCopper size ‰ 1 1… 1‰ 2 2‰ 3 490 degree elbow 1.00 2.00 2.50 3.00 4.00 5.50 7.00 9.00 12.50

45 degree elbow 0.50 0.75 1.00 1.20 1.50 2.00 2.50 3.50 5.00

Tee (straight run) 0.30 0.40 0.45 0.60 0.80 1.00 0.50 1.00 1.00

Tee (side port) 2.00 3.00 4.50 5.50 7.00 9.00 12.00 15.00 21.00

B&G Monoflofi tee n/a 70.00 23.50 25.00 23.00 23.00 n/a n/a n/a

Gate valve 0.20 0.25 0.30 0.40 0.50 0.70 1.00 1.50 2.00

Globe valve 15.00 20.00 25.00 36.00 46.00 56.00

Angle valve 3.10 4.70 5.30 7.80 9.40 12.50

Ball valve (standard port) 1.90 2.20 4.30 7.00 6.60 14.00

Swing check valve 2.00 3.00 4.50 5.50 6.50 9.00 11.50 14.50 18.50

Flow-check valve (B & G) n/a 83.00 54.00 74.00 57.00 177.00 n/a n/a n/a

Butterfly valve 1.10 2.00 2.70 2.00 2.70 4.50 10.00 15.50 15.00

Threaded fitting equivalent lengths

Nominal pipe size ‰ 1 1… 1‰ 2 2‰ 3 490 degree elbow 1.55 2.06 2.62 3.45 4.03 5.17 6.17 7.67 10.10

Long radius 90, & 45 std. elbow 0.83 1.10 1.40 1.84 2.15 2.76 3.29 4.09 5.37

Standard tee, through flow 1.00 1.40 1.80 2.30 2.70 3.50 4.10 5.10 6.70

Standard tee, branch flow 3.10 4.10 5.30 6.90 8.10 10.30 12.30 15.30 20.10

Close return bend 2.59 3.43 4.37 5.75 6.71 8.61 10.30 12.80 16.80

45 deg. 2.60 3.10 3.80 5.00

90 deg. 10.30 12.30 15.30 20.10

Gate valve, full open 0.41 0.55 0.70 0.92 1.07 1.38 1.65 2.04 2.68

Globe valve, full open 17.60 23.30 29.70 39.10 45.60 58.60 70.00 86.90 114.00

Angle valve, full open 7.78 10.30 13.10 17.30 20.10 25.80 30.90 38.40 50.30

Swing check valve, full open 5.18 6.86 8.74 11.50 13.40 17.20 20.60 25.50 33.60

Butterfly valve 7.75 9.26 11.50 15.10

Mitre bend

VIII Determining head loss - continued

Part Number 650-000-240/1098 35


Determining head losses for circuits in parallel

Flowing liquids will seek the path of least resistance. Forparallel branches this means that flow will favor the lowerhead loss branches. Where the design head losses ofparallel branches differ more than 10%, use balancingvalves to assure proper flow distribution. The balancingvalves are used to increase the head loss in lower lossbranches. Ideally, the valves are closed off enough thatthe head loss in every branch is the same as the branchwith the highest design head loss.

The required flow for a pump feeding parallel branchesis the sum of the design flow rates for each connectedbranch.

The required pump head for a pump feeding parallelbranches equals the highest design head loss of anyconnected branch plus the head loss through thedistribution piping .

For example, see Figure 23.

• This simplified circuit has three parallel branches.The design flow and head loss for each branch isgiven in the figure.

• The branch with the highest design head loss isnumber 2, where the head loss at design flow of 2GPM is 7.0 feet water column.

• If the balancing valves were not closed down onbranches 1 and 3, they would receive higher thantheir design flows and branch 2 would receive lessthan design flow because the fluid flow will alwaysseek the path of least resistance. The balancing valvesare closed off until the head loss through the branch

Figure 23

Flow in parallel circuits

1.5

GPM

@ 4

.5 fe

et

Distribution piping - Head loss = 3.0 feetFlow = 1.5 + 2 + 2 = 5.5 GPM

2 G

PM@

7.0

feet

2 G

PM@

5.5

feet

1 2 3

Balancingvalves

TEL for varying pipe sizes

You must determine the TEL (total equivalent length) for each pipe size, then calculate the head loss for that piping

segment. The equivalent length data cannot be combined between pipe sizes.

(1 or 3) is the same as the pressure drop throughbranch 2.

• When the balancing valves are set properly, the headloss across all branches will be approximately 7.0 feetwater column.

• The total flow required of the pump is 5.5 GPM (sumof all three branch design flows).

• The pump head required of the pump is the sum ofthe highest branch design head loss plus the headloss in the distribution piping, or 3.0 feet plus 7.0 feet= 10.0 feet.

Part Number 650-000-240/109836


Head losses for AlumiPex tubing circuits

The majority of the head loss in AlumiPex radiant heating circuits is in thetubing itself. It is not necessary to consider the head loss in the AlumiPexmanifolds separately. To determine the head loss in an AlumiPex radiantheating circuit, calculate the head loss in the piping, valves and fittings in thesupply and return piping to the manifolds using the methods given in thisGuide for piping.

Then add the loss in the AlumiPex tubing, using Equation 5. The designhead loss used for a group of AlumiPex loops piped off a single manifoldassembly must be the highest design head loss for any loop connected to the

Figure 24 is a typical manifold arrangement with fourtubing loops connected. In this example, we will determinethe pump and piping required to supply the manifold.(The heating system designer wants a temperature dropof 13 °F — from 105 °F to 92 °F.)

When possible, do a tubing layout drawing for thebuilding using a computer drafting program for the mostaccurate means of determining tubing loop length. Usethe following method to estimate the required length oftubing when a tubing layout drawing is not available.

The heating load for the spaces in the example is 15 Btuper square foot, with tubing to be spaced on 9 inch (0.75foot) centers. With the tubing at this spacing, there isapproximately 1.33 linear feet of tubing per square footof floor space. Use this to determine the approximatelength of tubing needed for each space.

Add to the tubing needed for the space the length oftubing required to extend from the supply and returnmanifolds to the space (called the leader lengths). Thenadd an additional 5% to provide for variations in actuallayout.


AlumiPex tubing flow rate calculation – example, Figure 24

manifold. The head losses for the other loops must bemade equal to this highest head loss by closing down onthe manifold valves. This is how the system is balanced.(Glycol data is for propylene glycol/water mixtures inthe ratios shown.)

Equation 5, Head loss in AlumiPexfeet head = K2 x L (feet) x GPM1.75

where L is the total length of tubing in a loop and K2 is

a constant from the table 6, below —

The floor areas and leader lengths for the loops are:

Loop 1 175 square feet of floor space; total leader length needed = 40 feet.Requires 175 x 1.33 = 233 feet of tubing for space plus 40 feet = 273 feet.Add 5% allowance = 14 feet. Total length of loop = 287 feet.



Loop 4 150 square feet of floor space; total leader length needed = 30 feetRequires 150 x 1.33 = 200 feet of tubing for space plus 30 feet = 230 feet.Add 5% allowance = 12 feet. Total length of loop = 242 feet.

Table 6

Values of K2 for Equation 5 Fluid Temp ¹⁄₂¹⁄₂¹⁄₂¹⁄₂ Tubing ⁵⁄₈⁵⁄₈⁵⁄₈⁵⁄₈ Tubing ³⁄₄³⁄₄³⁄₄³⁄₄ Tubing 1 Tubing100 F 0.0428 0.0126 0.00370 0.000947140 F 0.0391 0.0115 0.00338 0.000865180 F 0.0364 0.0107 0.00314 0.000804100 F 0.0529 0.0154 0.00455 0.001164140 F 0.0466 0.0137 0.00402 0.001030180 F 0.0492 0.0145 0.00425 0.001089100 F 0.0617 0.0181 0.00533 0.001365140 F 0.0547 0.0161 0.00473 0.001211180 F 0.0650 0.0191 0.00562 0.001438

50% Glycol

K2 - Factor for AlumiPex tubing head loss

Water

30% Glycol

Part Number 650-000-240/1098 37


287

feet

½”

AP

tubi

ng

279

feet

½”

AP

tubi

ng

300

feet

½”

AP

tubi

ng

242

feet

½”

AP

tubi

ng

Distribution piping - 1” copper tubing, type MTotal equivalent length = 175 feet

1 2 3 4

Manifold valves

Manifold valves

Supply manifold

Supply manifold

Return manifold

Return manifold

1 2

3 4

287 feet, ½” AlumiPex 279 feet, ½” AlumiPex

300 feet, ½” AlumiPex 242 feet, ½” AlumiPex

TUBING LOOPS

SCHEMATIC DIAGRAM OF TUBING BRANCHES

Figure 24

Example AlumiPex manifolds with tubing circuits and pump

Part Number 650-000-240/109838


Now determine the flow rate required for each of the loops.

• The heating system will be filled with water (no glycol).• The temperature drop is to be 13 °F (from 105 °F to 92 °F).• Calculate the heat load for each loop by multiplying 15 Btuh per square foot by the area (in

square feet) heated by the loop.• Apply Equation 1 to calculate the flow rate in each loop.

For the example in Figure 24:

• Loop 1 Heat load = 15 x 175 = 2625 Btuh; Flow rate = 2625/(494 x 13) = 0.41 GPM• Loop 2 Heat load = 15 x 185 = 2775 Btuh; Flow rate = 2775/(494 x 13) = 0.43 GPM• Loop 3 Heat load = 15 x 200 = 3000 Btuh; Flow rate = 3000/(494 x 13) = 0.47 GPM• Loop 4 Heat load = 15 x 150 = 2250 Btuh; Flow rate = 2250/(494 x 13) = 0.35 GPM• Total Total flow rate for pump = 0.41 + 0.43 + 0.47 + 0.35 = 1.66 GPM.

Determine the head loss for each AlumiPex tubing loop at design flow rate using Equation 5 (usingthe K2 value for ½” tubing and 100 °F, since the water ranges from 105 °F to 92 °F). For theseconditions, the K2 value is 0.0428.

• Loop 1 Head loss = .0428 x 287 x 0.411.75 = 2.58 feet• Loop 2 Head loss = .0428 x 279 x 0.431.75 = 2.73 feet• Loop 3 Head loss = .0428 x 300 x 0.471.75 = 3.43 feet (highest head loss)• Loop 4 Head loss = .0428 x 287 x 0.351.75 = 1.96 feet• Note that the manifold valves would have to be partially closed on loops 1, 2 and 4 to cause

the head losses for these loops to match that of loop 3, the branch with the highest loss.

Determine the pipe size and head loss in the distribution piping.

• The flow in the distibution piping will be 1.66 GPM. Find a pipe size in Table 3 which is suitablefor this flow. The flow is within the range of ½” copper tubing, so select this as the pipe size.

• The example system has (12) 90-degree elbows (not shown) and (2) gate valves plus 150linear feet of piping. Find the equivalent lengths of these fittings for ½” copper from Table 5(1.00 feet per elbow; 0.20 feet per gate valve). The TEL for the distribution piping is –

TEL = 150 + (12 x 1.00) + (2 x 0.20) = 162 feet.• The head loss for the distribution piping using ½” copper tubing, at 1.66 GPM would be

(from Table 3) –Head loss = (162/100) x 1.588 x 1.661.75 = 6.25 feet.

Determine total required head for the pump —

• The highest loop head loss for any of the AlumiPex loops is 3.43 feet.• Add this to the distribution piping loss of 6.25 feet, for a toal head loss of 9.68 feet.

Solution — Select a pump capable of 1.66 GPM at a head loss of 9.68 feet.

AlumiPex tubingflow rate calculation

– example, Figure 24,continued


Note – If the loading required of a tubing loop requires too high a flow rate (or pressure drop), considerincreasing the tube diameter, provided the flow rate in the tubing is within the recommended flowrate range (between the minimum and maximum recommended flow rates).

Part Number 650-000-240/1098 39


IX Selecting pumps

The design flow rate and head loss for a circuit are calledthe design point. Calculate the design point using theprocedures given in this guide. Then select a pump whosecurve passes close to (preferably slightly above or on thedesign point). See Figure 25.

Figure 26 combines the pump curves for some commonTaco, Grundfos and Bell & Gossett pumps. Use Figure 26or another pump curve to select the pump required.

Example –

The previous example on pages 36 through 38 resulted ina design point of 1.66 GPM at a head loss of 9.68 feet(when using ½” AlumiPex tubing with ½” distributionpiping).

Find a pump (or pumps) using Figure 26 which couldaccomplish this design point.

The Taco 007 pump could provide 1.7 GPM at a head ofapproximately 10.5 feet. This is probably an acceptablepump selection.

The Taco 0010 pump could provide 1.7 GPM at a head ofapproximately 11.5 feet. This would probably be anacceptable selection as well.

None of the other pump curves passes close to the designpoint.

To determine what each of these selected pumps wouldactually do on the circuit, draw a system curve on thepump curve. A system curve is a line which representswhat the head loss in the system will be as the flow ratechanges. Flow rates below the design point will causelower head losses. Flow rates above the design point willcause higher head losses.

The head loss at any flow rate can be estimated from thedesign point flow rate by –

Equation 6

Head loss = Design head loss x (Flow rate/Design flow rate)1.75

where Flow rate is the rate at which the head loss is to be estimated

Design head loss and Design flow rate are the known Design Point data

Method 1 – Calculate flow rate and head loss - select pump from pump curve

Design pointSys

tem

curv

eS

yste

m c

urv

e

The system curvewill always passthrough the designpoint.

0010

0012

007

Figure 25

Drawing a system curve to determine pumpperformance

Apply Equation 6 for several flow rates in the desiredrange. Then draw these points on the pump curve andconnect with a line as shown in the pump curve segmentin Figure 25, below.

The design flow rate for the example circuit is 1.66 GPMand the design head loss is 9.68 feet. The system pointsused in Figure 25 are:

• 1.66 GPMwhere pressure drop = 9.68 feet (design point)

• 2 GPMwhere pressure drop = 9.68 x (2/1.66)1.75 = 13.4 feet

• 1 GPMwhere pressure drop = 9.68 x (1/1.66)1.75 = 4.0 feet

The flow rate and head loss for any pump is the pointat which the system curve crosses the pump curve.

• The Taco 007 pump would provide about 1.8 GPMat 10.6 feet.

• The Taco 0010 pump would provide about 1.9 GPMat 11.5 feet.

Part Number 650-000-240/109840


IX Selecting pumps - continued

Figure 26

Pump curves for some typical residential/light commercial circulators (Taco 007, 0010, 0011, 0012 and 0014;Grundfos 15-42, 26-64 and 43-75; B & G NRF-22, PL-30 and PL-50) See Appendix for pump curve equations.

0

5

10

15

20

25

30

0 10 20Flow rate (gpm)

Feet head

30 40 50

007

NRF-2215-42

0010 0012

43-75

0011

PL-50

0014

PL-30

26-64

Part Number 650-000-240/1098 41


Figures 27 through 30 are quick selector curves forselecting pumps based on a known flow rate and circuitlength.

The pumps included in these curves are —

• Taco 007, 0010, 0011, 0012, 0014.

• Grundfos 15-42, 26-64, 43-75.

• Bell & Gossett NRF-22, PL-30, PL-50.

• (See Appendix for pump curve equations.)

Use these curves only when the pipe diameter is the samethroughout the circuit being analyzed.

This method will work well for determining both pipesize and pump selection for primary circuits andbaseboard heating secondary circuits.

To select a pump using this method –

• Calculate the required flow rate based on the heatingload (Btuh) and the desired temperature drop usingEquation 1: GPM = Btuh/(494 x DT).

• Select a trial pipe size using Table 3 — that is, a pipesize for which the flow rate falls between the minimumand maximum recommended.

• Determine the linear feet of piping expected for thecircuit.

• Multiply this number by 1.5. The result is yourapproximate TEL (total equivalent length) for thecircuit.

• Select the Figure from Figures 27 through 30 for thepipe size you have selected.

• Select the pump which can deliver the flow rate andTEL you need.

Method 2 – Calculate flow rate and select pump from quick selector curves

• If you can't find a good pump selection, try anotherpipe size.

• You can refine and verify your selection by calculatingthe actual TEL for your circuit using the equivalentlength data in this Guide.

Example:

• A circuit with 300 linear feet of piping; heating load200,000 Btuh; using water from 180 °F to 160 °F.

• Estimate the TEL at 1.5 times 300, or 450 feet.

• Using Equation 1, the required flow rate for a 20 °Fdrop would be:

Flow rate = 200000/(494 x 20) = 20.2 GPM

• From Table 3, either 1½” or 2” copper pipe would beusable (though the pressure drop would be higher in1½” pipe). Use 1½” copper pipe for the trial size.

• From Figure 30, with 1½" copper pipe at a TEL of450 feet, a Taco 0011 or 0014 would deliver about19.5 GPM at 450 feet TEL. Or a B & G model PL-50would deliver about 21.3 GPM.

• At 19.5 GPM, the temperature drop would be (fromEquation 2) —

200000/(494 x 19.5) = 20.8 °F. So the Taco 0011 or0014 would probably be an adequate selection.

• Note, from Figure 30, that a model 0010, 0011, PL-30or 26-64 would be the likely choices if the pipe sizewere increased to 2” copper pipe. These pumps woulddeliver about 25 GPM.

• Verify the pump selection by doing a completecalculation of the TEL, using the data in this Guide.

Part Number 650-000-240/109842


Figure 27

Quick selector pump curves for ½” and ¾” AlumiPex tubing

0 100 200 300 400 500 600 700 800 900 10000.5

1.0

1.5

2.0

2.5

Flo

w r

ate, G

PM

Pump performance, ½" AlumiPex

Circuit equivalent length, feet

007

001000110012

43-75

15-42

PL-30

PL-50

0014

26-64

NRF-22

0 100 200 300 400 500 600 700 800 900 10001

2

3

4

5

6

7

Flo

w r

ate, G

PM


Pump performance, ¾" AlumiPex

007

0010

00110012

43-75

15-42

PL-30

PL-50

0014

26-64

NRF-22


Part Number 650-000-240/1098 43


0 100 200 300 400 500 600 700 800 900 10003

4

5

6

7

8

9

10

12

11

Flo

w r

ate, G

PM


Pump performance, 1" AlumiPex

0011

43-75

PL-30

PL-50

0014

26-64

007

0010

0012

15-42

NRF-22

Flo

w r

ate, G

PM


Pump performance, ¾" copper tubing

2

3

4

5

6

7

100 200 300 400 500 600 700 800 900 1000

PL-50

0014

NRF-22

PL-30007

Figure 28

Quick selector pump curves for 1” AlumiPex tubing and ¾” copper tubing

Part Number 650-000-240/109844


Figure 29

Quick selector pump curves for 1” and 1¼” copper tubing


4

5

6

7

8

9

10

11

12

100 200 300 400 500 600 700 800 900 1000

Flo

w r

ate, G

PM


Pump performance, 1" copper tubing

15-42

NRF-22

007

0010

0011

0012

43-75

PL-30

PL-50

0014

26-64

Flo

w r

ate, G

PM


Pump performance, 1¼" copper tubing

100 200 300 400 500 600 700 800 900 10006

7

8

9

10

11

12

13

14

15

16

17

18

007

0010

NRF-22

15-42

0012

0011

43-75

PL-50

0014

PL-30

26-64

Part Number 650-000-240/1098 45


Flo

w r

ate, G

PM


Pump performance, 1½" copper tubing

100 200 300 400 500 600 700 800 900 10009

10111213141516171819202122232425

007

0010NRF-22

15-420012

0011

43-75

PL-50

0014

PL-30

26-64

Flo

w r

ate, G

PM


Pump performance, 2" copper tubing

100 200 300 400 500 600 700 800 900 1000

40

15

20

25

30

35

007

0011NRF-22

15-42

0010

0012

43-75

PL-50

0014

PL-3026-64

Figure 30

Quick selector pump curves for 1½” and 2” copper tubing

Part Number 650-000-240/109846


X Piping radiant circuits

Higher temperature radiant circuits

The piping (and associated wiring) suggestions shown in the following pages

all provide some means of protecting the boiler from cold return water

temperatures. The special case of system CP-1 — adding a small radiant zone

to a baseboard heating system — does not provide return water temperature

regulation because the radiant zone is too small to cause unusually low return

temperatures.

Some radiant heating applications operate with temperatures similar to those

of finned tube baseboard systems – for example, where the tubing is suspended

in the joist bay, or for suspended floor applications with the tubing underneath

and carpet on the floor. In these cases, the supply temperature at design

conditions will often be 160 °F or higher.

For those suspended floor radiant heating applications requiring at least 160

°F supply water, the return water temperatures will be similar to finned tube

baseboard applications. Consequently, it would not usually be necessary to

provide return water temperature protection for the boiler in such

applications. These radiant heating zones can be installed as secondary circuits

directly connected to the primary, without using a mixing valve or injection

mixing system to protect the boiler.

The following sections provide suggested piping and wiring methods for

radiant heating systems and for hybrid systems which provide domestic

water and/or baseboard heating as well as radiant heating.

The radiant heating circuits illustrated in this Guide are all shown with injection

mixing. But you can substitute dual temperature mixing valves for the injection

mixing arrangement in all of the examples given. Follow the piping guidelines

for dual mixing valve circuits given in previous section II, Piping and control

methods, Method 2 - Dual three-way valves.

Overview

Part Number 650-000-240/1098 47


Alternative piping configurations

Most of the examples shown in this Guide utilize Weil-McLain IPP Injection Pump Panels and IPC

Injection Pump Controls. You will also find that we have given an alternative piping arrangement

for example systems CP-2 through CP-12 in Radiant heating system examples.

This Guide does not exclude other engineered systems that protect the system and the boiler (as

directed by the boiler manufacturer). We have concentrated on injection mixing and mixing valve

piping configurations in order to provide you with as complete an analysis and guide for their

applications as possible. Weil-McLain can provide you with supplementary materials for other

specific piping alternatives. Also refer to the boiler (heating source) manufacturer’s instruction

manuals and design information for their requirements and specific suggestions.

Pump location

In the following system examples, the primary circuit pump is shown mounted in the supply

piping, with the expansion tank and air separator on the inlet side of the pump (with the exception

of GV boiler systems). This is the preferred location for all pumps, and the only recommended

location for commercial system pumps.

Many packaged residential boilers are supplied with the pump on the return line to the boiler.

This is acceptable for residential applications and for multiple boiler systems using residential

packaged boilers. See the Caution statement below regarding location of the expansion tank and

fill connection.

Always connect the fill line at the expansion tank.

Locate the expansion tank (diaphragm or bladder type) on the inlet side of

the pump, even if the pump is mounted on the boiler return line.

When using a compression tank (expansion tank in which air is exposed to

the water), mount the compression tank and fill connection in the supply

piping, regardless of the location of the pump.

Failure to follow these guidelines could result in damage to the boiler and

system components.

Part Number 650-000-240/109848


P2

P1

IPP-150Injectionpumppanel

IPCInjectionpumpcontrol

Manifoldlocation A

Manifoldlocation B

Returntemperaturesensor

Primary loop(from boiler)

Roomtemperaturesensor or thermostat

Purge valves& air vents

Supply temperaturesensor

Valve actuators optional


Purgingvalves

Prad.cdr

Figure 31a

Typical radiant circuit piping - single supplytemperature

Single supply temperature — using injection mixing

The piping examples in this Guide utilize the Weil-McLainIPP Injection Pump Panel. This assures three-temperaturecontrol for the system; i.e., protecting the boiler fromcondensation while controlling system water and spacetemperatures. For those applications which are too largefor the IPP-150, install your own injection pump and usethe IPC Injection Pump Control to regulate it.

For most of the examples in this Guide, you can use thedual three-way valve option (see Section II) in place ofvariable speed injection, though the three-way valvemethod is much less versatile.

Whatever piping method you use, it must provide controlof the return water temperature to the boiler.

AlumiPex manifolds are shown in the example diagramsin this Guide with and without manifold valve actuators.Use actuators when you wish to provide zone control.

When using actuators and continuous operation of thepump, install a by-pass pressure regulator across thesupply and return connections of the circuit. This willprotect the pump from cavitation when the zone valvesclose off.

When all manifolds in a circuit must receive the sametemperature water, use the basic piping shown in Figure31a or Figure 31b.

For applications involving multiple manifolds that re-quire different supply temperatures, use the piping shownin Figure 32 or Figure 33, on the following pages.

NOTE: You can substitute dual mixing valves, piped as inFigure 3 of this Guide, for the IPP. See Figure 31b for aspecific example of substituting dual mixing valves forthe IPP of Figure 31a.

X Piping radiant circuits - continued

Part Number 650-000-240/1098 49


Manifoldlocation A

Manifoldlocation B


Thermostat




Purgingvalves

Pradmv.cdr

Mixing valve arrangementsubstituted for IPP panel

Heating systempump

Hot

Hot

Mixed

Mixed

Cold


Cold

Figure 31b

Typical radiant circuit piping – single supplytemperature – substituting dual mixing valvesfor the IPP Panel of Figure 31a

Single supply temperature — using dual mixing valves

Figure 31b is an example of directly substituting a dualmixing valve configuration for the IPP panel. The pipingschematics for Systems CP-2 through CP-12 in Radiantheating system examples all indicate how to substitutethe mixing valve arrangement. Note the special case ofSystem CP-4, in which two radiant circuits are suppliedoff of the primary circuit. When substituting mixing valvesfor the IPP in this case, note that only one boiler protectionmixing valve is needed – not two.

Other piping methods are possible if designed andinstalled to meet the requirements of the system and theboiler used. Whatever piping method you use, it mustprovide control of the return water temperature to theboiler if the boiler manufacturer specifies a minimumreturn water temperature.

The mixing valves may be either self-contained, remotebulb or motorized. If motorized, they may be operatedby an electronic control, allowing outdoor reset if desired.

AlumiPex manifolds are shown in the example diagramsin this Guide with and without manifold valve actuators.Use actuators when you wish to provide zone control.

When using actuators and continuous operation of thepump, install a by-pass pressure regulator across thesupply and return connections of the circuit. This willprotect the pump from cavitation when the zone valvesclose off. (See Figures 65 and 67 for examples.)

When all manifolds in a circuit must receive the sametemperature water, use the basic piping shown in Figure31a or Figure 31b.

For applications involving multiple manifolds that re-quire different supply temperatures, use the piping shownin Figure 32 or Figure 33, on the following pages.

Part Number 650-000-240/109850


P2

P1

IPP-150Injectionpumppanel


ManifoldAlocation

(low temp)



Max 4 pipediameters

Balancing valve

Mixingvalve

H

C

M

Circulator

1


Valve actuators required

ManifoldBlocation

(high temp)


2

Purgingvalves


Prad2.cdr


Figure 32

Typical radiant circuit piping - multiple supplytemperatures from single injection pump panel

Multiple supply temperatures

Use piping as shown in Figure 32 when multiple supplytemperatures are needed. In this example, the loopsconnected to Manifold location B require hotter waterthan those connected to Manifold location A. The mixingvalve reduces the IPP output temperature — to give twotemperature control.

The injection pump panel provides water to the heatingcircuit at the temperature needed for the radiant loopsconnected to Manifold location B, the highertemperature circuit.

Manifold location A, the lower temperature circuit,is connected to a crossover bridge containing a balancingvalve, item 1. This valve provides a pressure drop in thebridge to match the pressure drop through the loopsconnected at Manifold location B. Partially close the valveuntil the required flow is achieved through the Manifoldlocation B loops.

Lower temperature water is supplied to the Manifoldlocation A loops by the mixing valve, item 2. This valvemixes cooler return water with the supply water from thecrossover bridge to provide the desired temperature. (Youcan substitute a two-way valve combined with a manualbalancing valve for the 3-way mixing valve.)

Outdoor reset response –

If the IPC is operated in reset mode, it will reset the supplytemperature at the location of the IPC supply sensor. So,the reset will be based on the supply temperature andreset curve needed for the higher temperature radiantcircuit.

The low temperature circuit will not be reset until theheating curve drops below the setpoint of the lowtemperature circuit mixing valve.

Example:

The high temperature circuit is set for a reset ratio of 1and a starting point temperature of 70 °F.

The low temperature circuit mixing valve is set for atemperature of 100 °F.

The IPC supply temperature to the radiant circuits will beabove 100 °F except when the outdoor temperature is40 °F or higher. (Since the supply temperature is –

Tsupply= Tstarting + reset ratio x (Tstarting - Toutside)

= 70 °F + 1 x (70 °F - 40 °F) = 100 °F

At lower outside temperatures, the supply temperaturewill always be above 100 °F, so no reset will be seen inthe low temperature circuit.

NOTE: You can substitute dual mixing valves, piped as inFigure 3 of this Guide, for the IPP Injection Pump Panel.

X Piping radiant circuits - continued

Part Number 650-000-240/1098 51


P2

P1

IPP-150Injection pump panel


This diagramis schematic only.It does not indicatevertical placementof components.Flow/check valvesare omitted becausevertical placement isunspecified. Locateflow/check valves asneeded when applying.

ManifoldBlocation

(low temp)


Sup

ply

tem

pera

ture

sens

or

Balancing valve

Mixingvalve

H

C

M

Circulator

Max 4 pipediameters

1

Balancing valve

Max 4 pipediameters

1

Balancing valve

Max 4 pipediameters

1




ManifoldClocation

ManifoldAlocation


2

Purgingvalves


Prad3.cdr


Figure 33

Typical radiant circuit piping - multiple supply temperatures from single injectionpump panel, using primary/secondary piping in radiant circuits

Multiple supply temperatures

Figure 33 is a system similar to thatshown in Figure 32. In this case,however, each of the radiant circuitsis connected to a crossover bridge offa primary supply from the injectionpump panel.

With this arrangement, all of theradiant circuits have access to thehottest supply water from the pumppanel. This maximizes the outputfrom the IPP and reduces the flowrequired in the radiant primary loop.

Each of the radiant circuits requiresits own circulator for this system towork.

Manifold valve actuators areoptional.

Adjust the balancing valves (item 1)to regulate the amount of supply wterflowing through each of thecrossover bridges.

Use this piping design for largerbuildings with widely spacedmanifolds.

Outdoor reset response –

Response will be similar to thediscussion regarding Figure 32. TheIPC will control the supplytemperature and reset based on theneeds of the highest temperaturecircuit.

The low temperature circuit (withmixing valve) will only reset for thosetimes when the IPC supplytemperature is regulated below thesetting of the mixing valve.

All other circuits will experience someeffects of reset because the flow rateis fixed by the balancing valve andthe circuit pump. As the water supplytemperature drops, the temperatureto each circuit will drop as well,resulting in a reset effect even forlower temperature circuits.

NOTE: You can substitute dual mix-ing valves, piped as in Figure 3 of thisGuide, for the IPP Injection PumpPanel.

Part Number 650-000-240/109852


XI Domestic water heating

Many of the example systems in this Guide include pipingfor indirect water heaters. The Weil-McLain PLUS andGOLD Plus indirect water heaters provide high recoveryrates and efficient supply of domestic water. They can beinstalled effectively in radiant heating systems as shownby the examples.

Domestic priority

Domestic priority means the indirect water heater receivespriority over all other heating functions when the domestic

120 VAC

24 VAC

DHW tankaquastat

DHW

TDR

24 vac to throughvalve actuator endswitches

- or -24 vac to baseboardpump relay throughzone valve endswitches

IPC

Primary pump and/orbaseboard pump orpump relay

Override priority relay by connecting therelay contacts across the DHW Priority relaycontacts as shown below . . .

TDR

DHW1

TDR1 (call-for-heat-disable override)

TDR2 (pump-disable override)

DHW2

call-for-heat disable

heating pump disable

Figure 34

Priorityoverride relay

water storage tank calls for heat. Using domestic prioritygenerally allows a smaller boiler, since there is no overlapin heating and domestic water heating. Most residentialinstallations work well with domestic priority becausethe domestic water and space heating peaks occur atdifferent times.

Several methods are shown in the example systems,including -

• Diverter valve method (suggested for use with GVboilers only), as shown in Figure 37 and in systemCP-8. The diverter valve diverts all heating water flowto the water heater when it calls for heat. The divertervalve method has a slight disadvantage over othermethods shown because the pressure drop throughthe diverter valve reduces flow available to the system.

• First-in-line priority (can be used with all boilers),as shown in system CP-6 through CP-7. The pipingstrategy of Figure 36 always provides this priorityoption because the supply water is taken directly fromthe boiler supply piping.

For first-in-line priority, the heating water supply tothe indirect water heater is taken before it reachesother heating sources. This isn't true priority unlessthe flow to the other heating applications istemporarily interrupted on a call for heat from theindirect water heater. This can be done using the IPCcontrol and relays as shown in the correspondingwiring diagrams for systems CP-6, CP-7, and CP-9through CP-11.

• Flow interruption priority - can be applied in any ofthe systems CP-6 through CP-11 by using relays asshown in the wiring diagrams. When the indirectwater heater calls for heat, the relay(s) stops thepumps feeding other heating applications.

Priority override option —

If the building is frequently unoccupied (weekendhouse, f or example), consider installing a time delayrelay to prevent the possibility of extended no-heatperiods should the domestic priority system fail forany reason.

This relay, usually selected as a one-hour delay, can beintroduced to the DHW relay circuit to allow systemheating should the DHW relay remain activated longerthan the time period of the relay. See Figure 34.

Part Number 650-000-240/1098 53


Figure 37

Diverter valve domestic waterheater piping

Figure 36

Water heater piped directlyacross suppy and return

Figure 35

Water heater piped assecondary circuit

The following domestic water heating piping alternativescan be applied in most radiant heating applications. Theyare shown here separated from the remainder of thepiping for ease of discussion.

Piping strategies

The indirect water heater can be connected to theprimary/secondary piping in several ways, depending onthe desired operating characteristics. For conventionalboilers we recommend only the methods of Figure 35and 36. For GV boilers use only the methods of Figures35 or 37.

Figure 35 shows the water heater connected as asecondary circuit off of the primary. You will find thismethod used in systems CP-6 and CP-7. System CP-12uses a similar approach, but takes the secondary circuittees from the boiler supply water before it reaches theprimary loop. These systems require water to be flowingin the primary loop (or boiler supply piping for systemCP-12) in order to heat the indirect water heater. This

GOLD Pluswater heater

DHWoutlet

coldwater

inlet

Max 4 pipe diameters

flow/checkvalve

Circulator


flow/checkvalve

DHWoutlet

coldwater

inlet

Cir

cula

tor


DHW diverter valve

common

from boiler return

to s

yste

m

normallyopen

normallyclosed

DHWoutlet

coldwater

inlet

means hot water must flow throughout the primarypiping even during the summer.

Figure 36 provides a means of circulating water onlythrough the indirect water heater circuit during the non-heating months. Water is taken from the boiler supplyand returned directly to the boiler return. The primarypump does not have to operate during domestic waterheating cycles. This eliminates heat loss from the primarypiping during non-heating periods. For installations inwhich the primary piping runs throughout the building,this method can save considerable energy. You will findthis method used in systems CP-8 and CP-10.

Note re Figure 36 – For systems piped with zone valvezoning rather than circulator zoning, substitute a zonevalve for the pump.

Figure 37 uses a diverting valve to switch water flowfrom the heating circuit to the domestic water heaterduring a DHW heating cycle. It provides domestic priorityand prevents flow of hot water through the heating circuitsduring non-heating periods. This method is used insystem CP-9.

Part Number 650-000-240/109854


XII Radiant heating system examples

System System description Boiler Applications Pages

CP-1Adding a small zone of radiant heating to an existing baseboard heating system.

ConventionalFinned tube baseboardSmall radiant circuit

56 - 59

CP-2 GV boiler supplying an injection pumping panel

GV boiler Radiant heating only 60 - 63

CP-3 Conventional boiler supplying an injection pumping panel

Conventional Radiant heating only 64 - 67

CP-4Two-temperature radiant heating system using two injection pumping panels


CP-5Two-temperature radiant heating system using one injection pumping panel and a mixing valve


CP-6Radiant heating and domestic water heating with conventional boiler - DHW as a secondary circuit

ConventionalRadiant heatingDomestic hot water heating

76 - 78

CP-7Radiant heating and domestic water heating with GV boiler - DHW as a secondary circuit

GV boilerRadiant heatingDomestic hot water heating

80 - 83

CP-8Radiant heating and domestic water heating with conventional boiler - independent DHW operation


84 - 87

CP-9Radiant heating and domestic water heating with GV boiler - DHW through diverting valve


88 - 91

CP-10Radiant heating, domestic water heating and baseboard heating with conventional boiler

ConventionalRadiant heatingDomestic hot water heatingBaseboard heating

92 - 97

CP-11Radiant heating, domestic water heating and baseboard heating with GV boiler

GV boilerRadiant heatingDomestic hot water heatingBaseboard heating

98 - 103

CP-12Radiant heating, domestic water heating and baseboard heating with multiple boilers

ConventionalRadiant heatingDomestic hot water heatingBaseboard heating

104 - 109

Part Number 650-000-240/1098 55


Figure 38

Symbol legend for system piping drawings

To expansiontank

Cold water fill line detail

Automatic air vent

Air separator

Flow/check valve

Circulator or pump

Ball valve

Drain cock

Globe valve

Gate valve

Mixing valve

Diaphragm expansiontank

Pressure gauge

Pressure reducing valve

Backflow preventer

Balancing valve

Swing check valve

Part Number 650-000-240/109856


Radiant heating system examplesXIISystem CP-1

(pages 58 – 59)Adding a small zone of radiant heating to anexisting baseboard heating system

Purpose• This system shows two methods of adding a small radiant heating zone to an existing

baseboard heating system. The radiant heating zone must be small and low mass - it cannotbe a slab on grade installation. Use only for small zone thin slab or suspended floor radiantplate systems.

• This example is the only exception to the requirement for control of the boiler return temperature(other than high temperature radiant applications for suspended floor heating as discussedon page 46.) Return water temperature regulation is not needed in this example because theradiant load is small and low mass, so the radiant load won't greatly reduce the returntemperature.

• Two alternatives to piping the radiant zone are illustrated -

Alternate 1a - "slave" operation• The radiant branch must be connected as close to the end of the baseboard loop as possible,

to avoid reducing the water temperature (and output) to baseboards downstream.

• Install the radiant branch as a secondary circuit off of the baseboard loop. This pipingmethod will make no change in the flow of the primary (baseboard) loop.

• This piping option is called a "slave" zone because heat can be supplied to the radiant heatingcircuit only when the baseboard loop pump operates. Since the baseboard zone thermostatcontrols the boiler and the baseboard loop pump, the radiant zone can only operate when thebaseboard thermostat is calling for heat. Use this piping option when you are sure thebaseboard zones will always need heat at the same times as the radiant zone.

• Flow of hot water from the baseboard loop into the radiant circuit is controlled by the non-electric thermostatic valve (mixing valve). This valve may be remote bulb, as shown, or self-contained.

Operation - Alternate 1a• On call for heat from the radiant zone thermostat, a pump relay is activated, powering the

radiant circuit pump, P2.

• The boiler and baseboard loop pump will operate only when there is a call for heat from thebaseboard thermostat.

Part Number 650-000-240/1098 57


Alternate 1b - "independent" operation• This option takes the radiant heating water directly across the boiler supply and return,

allowing it to operate independently of the baseboard circuit pump. You must install a flow/check valve in the baseboard circuit if not already installed when using this option, to preventshort circuiting the flow of the radiant pump.

• Use this alternative when you want the radiant zone to be capable of operation even whenthere is no demand from the baseboard zones. Do not use alternate 1b with a GV boiler - flowthrough the boiler can only be controlled by the integral pump.

• The non-electric thermostatic valve (mixing valve) regulates flow of hot water from thebaseboard circuit into the radiant circuit. This valve may be remote bulb, as shown, or self-contained.

Operation - Alternate 1b• The baseboard pump operates on call for heat from the baseboard thermostat, powered

through the pump relay. This relay also provides the call for heat signal to the boiler.

• A second relay is operated by the radiant zone thermostat. On call for heat from this thermostat,the radiant circuit pumps are activated – pump P2 (boiler pump that circulates water throughthe crossover bridge from boiler supply to return) and pump P3 (pump that circulates waterthrough the radiant tubing).

System CP-1

Part Number 650-000-240/109858


Figure 39 - System CP-1

Adding a small zone of radiantheating to an existingbaseboard heating system

XII Radiant heating system examples – CP1

To fill line

Boiler

P1

P2

P2

P3

Existing baseboard circuit

"Slave" floorheating zone(alternate 1a)

"Independent" floorheating zone(alternate 1b)

Saf

ety

cont

rols

(as

requ

ired

by lo

cal c

odes

)

Primary pump





Non-electricthermostat valve(set for designwater temp.)

Non-electricthermostat valve(set for designwater temp.)

Capillary

Flow/checkvalve (add if usingalternate 1b)

Sensorbulb

Sensorbulb

Note 2

Note 2

Purgingvalves

Purgingvalves

Notes1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does

not represent that this drawing meets any particular mechanical or building codes. The installer is responsiblefor inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing.The installer is responsible for proper sizing/selection of all hardware shown on this diagram.

2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the teesthoroughly to prevent turbulence. The pipe or tubing connected to the first tee should be at least 8 pipediameters long.

3. See Weil-McLain installation instructions for specific details on installing the boiler and injection pumppanel.

Part Number 650-000-240/1098 59


L1 N

C1

B2

T

TC2

B1H

N

G

120VAC

24VAC

120 V

ACS

ervi

cesw

itch

Burner

Radiant zonethermostat

Baseboard zonethermostat

Floor heating pump

Baseboardpump

Boiler

Radiantpumprelay

NOTE — Floor heating pump, P2, canbe operated by wiring in parallelwith pump P1. This would eliminatethe transformer, pump relay andradiant zone thermostat.

Safety controls, if req’dby local codes

Transformer120vac/24vac

P2

P1

Figure 40a - System CP-1a

“Slave” floor heating zoneschematic wiring - 24 VACzone valve

When using the optional radiantcircuit pump relay, inform theowner that the thermostat onlycontrols the pump. It cannotoperate the boiler. Heat will beavailable to the radiant circuit onlywhen the baseboard thermostat(s)is calling for heat. The radiantthermostat only serves the purposeof limiting the heat input to theradiant zone.

Notes1. This drawing is conceptual only. It shows representative system wiring. Weil-McLain does not represent that

this drawing meets any particular mechanical, electrical, or building codes. All wiring must be installed inaccordance with:

• In the USA - the latest version of the National Electrical Code (N.E.C.), as well as any other National, Stateor Local code requirements having jurisdiction.

• In Canada - CSA C22.1 (C.E.C.) Part 1, as well as any other National, Provincial or Local code requirementshaving jurisdiction.

The installer is responsible for inclusion of all required safety devices, or other miscellaneous hardware notshown on drawing.

2. The minimum wire gauge used for all low voltage circuits shall be 18 AWG unless otherwise required bycode(s) having jurisdiction.

Figure 40b - System CP-1b

“Independent” floor heatingzone schematic wiringdiagram

L1 N

C1

B2

TT

C2

B1

H

N

G

120VAC

24VAC

120 V

ACS

ervi

cesw

itch

Burner

baseboardzonethermostat

floor heatingzonethermostat

Floor heating pump

Baseboard pump

Boiler pump

BoilerSafety controls,

if required bylocal codes

Transformer120vac/24vac

P1

P2

P3

relay

relay

Part Number 650-000-240/109860


Radiant heating system examplesXIIGV boiler supplying an injection pump panelSystem CP-2

(pages 62 – 63)

Purpose• Provide heating water to radiant circuits, using a control and injection pump that regulate

radiant circuit supply temperature and maintain minimum boiler return temperature.

Pumps and piping

Primary circuit

• The GV integral pump provides primary circuit flow.

Radiant circuits

• The Injection Pump Panel (IPP) includes the injection pump and radiant circuit pump. (Forapplications larger than the capacity of the IPP, use multiple IPP panels or use an IPC InjectionPump Control with an injection pump and radiant circuit pump sized for the flow rates andpressure drops needed.)

Radiant heating circuits• System CP-1 shows two manifold locations. The same piping design can be used for multiple

manifolds.

• Manifold valve actuators are optional, but recommended as discussed in Zoning radiantheating systems, section IV of this Guide. When actuators are not used, provide the call forheat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zonethermostat or a dry contact that closes on a call for heat. Alternatively, use an indoor sensoror zone control.

Part Number 650-000-240/1098 61


System CP-2

Controls and wiring

Injection pump control (IPCIPCIPCIPCIPC)

• The IPC is included with the IPP panel (or purchased separately when using field-constructedinjection mixing systems).

• The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor).You can connect an indoor temperature sensor or tekmar® zone control to the IPC toprovide room temperature feedback, allowing heating circuit regulation based on spacetemperature response.

• The IPC controls the injection pump (P2) and radiant circuit pump (P3). The GV boilerintegral pump (P1) operates with the boiler (activated by the GV controls).

• Use IPC dip switch 2 to set radiant circuit pump (P3) operation - DOWN for intermittentoperation, UP for continuous pump operation. With continuous radiant pump operation,either use no manifold valve actuators or install a differential pressure by-pass valve (asshown in system CP-12) to protect the pump from dead heading when the manifold valveactuators close.

• Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or anindoor sensor is connected to the IPC.

Operation• On call for heat from a radiant zone thermostat or actuator, the IPC activates the injection

pump (P2), the radiant circuit pump (P3), and the boiler. The boiler activates the integralpump (P1), initiating flow in the primary circuit.

• The IPC regulates the flow rate of the injection pump (P2), increasing flow to raise the supplytemperature, or lowering flow to reduce it.

• If boiler return temperature drops below the preset limit (130 °F), the IPC reduces injectionflow (reducing the temperature drop in the primary circuit).

Part Number 650-000-240/109862


Fill

GV Boiler

P1

P3

P2

Manifold

Alocation

Manifold

Blocation

Primary circuitS

afet

y co

ntro

ls (a

sre

quir

ed b

y lo

cal c

odes

)

Return temperaturesensor



Air separator



Purgingvalves

Alternate piping

IPPSubstitute for panel(using mixing valves)

Heating systempump

Return fromheatingsystem

Supply toheatingsystem

Primarycircuitsupply

Primarycircuitreturn

Hot

Hot

Mixed

Mixed

Cold


Cold


IPPInjectionpumppanel

Figure 41 - System CP2

GV boiler supplying aninjection pump panel

Notes1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any

particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware notshown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram.

2. See Weil-McLain installation instructions for specific details on installing the boiler and injection pump panel.

3. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel. See separate publication for suggested wiring forthis piping alternative.


Part Number 650-000-240/1098 63


LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

T T

L

N

G

P1

120 VAC

120

VAC

Ser

vice

sw

itch

Transformer120vac/24vacMinimum rating10 va plus 6 vaper AlumiPexvalve actuatorconnected

Roomthermostat

Roomthermostat

P2

P3

Valveactuator

Valveactuator

See note 3

Seenote 3

These pumpsare mounted andpre-wired on the

panel.IPPOutdoor sensor,required only ifusing outdoor reset.

Supply &returnsensors

To additionalactuators

Safety controls,if required bylocal codes

GV Boiler

Valveactuator

24 VAC

2-wireactuator

4-wireactuator

Indoor sensor(if used in lieu of

zone t-stats)

Notes1. This drawing is conceptual only. It shows representative system wiring. Weil-McLain does not represent that this drawing meets any particular mechanical,

electrical, or building codes. All wiring must be installed in accordance with:

• In the USA - the latest version of the National Electrical Code (N.E.C.), as well as any other National, State or Local code requirements havingjurisdiction.

• In Canada - CSA C22.1 (C.E.C.) Part 1, as well as any other National, Provincial or Local code requirements having jurisdiction.The installer is responsible for inclusion of all required safety devices, or other miscellaneous hardware not shown on drawing.

2. The minimum wire gauge used for all low voltage circuits shall be 18 AWG unless otherwise required by code(s) having jurisdiction.

3. Multiple valve actuators may be powered through a common thermostat for rooms/zones having multiple radiant circuits. End switches are optional on allbut one valve actuator wired in this manner.

4. See Weil-McLain installation instructions for specific details on installing the boiler, and injection pump panel.


Schematic wiring diagram

Part Number 650-000-240/109864



(pages 66 – 67)Conventional boiler supplying an injection pumppanel

Purpose• Provide heating water to radiant circuits, using a control and injection pump that regulate

radiant circuit supply temperature and maintain minimum boiler return temperature.

Pumps and piping

Primary circuit

• The primary pump can be as supplied with the boiler or purchased separately.

• Residential packaged boilers may have the pump mounted on the return piping at the boiler.The pump can be used in this location provided the expansion tank or compression tank andfill line are correctly located.

Radiant circuits

• The Injection Pump Panel (IPP) includes the injection pump and the radiant circuit pump.(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPCInjection Pump Control with an injection pump and radiant circuit pump sized for the flowrates and pressure drops needed.)

Radiant heating circuits• System CP-2 shows two manifold locations. The same piping design can be used for multiple

manifolds.


Part Number 650-000-240/1098 65


System CP-3

Controls and wiring


• The IPC (Injection Pump Control) is included with the IPP panel (or purchased separatelywhen using field-constructed injection mixing systems).

• The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor).You can connect an indoor temperature sensor or tekmar® zone control to the IPC toprovide room temperature feedback to the control, allowing heating circuit regulation basedon space temperature response.

• The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump(P1) operates with the boiler (activated by the boiler controls).

• Use IPC dip switch 2 to set radiant circuit pump (P3) operation - DOWN for intermittentoperation, UP for continuous pump operation. With continuous radiant pump operation,either use no manifold valve actuators or install a differential pressure by-pass valve (asshown in system CP-12) to protect the pump from dead heading when the manifold valveactuators close.


Operation• On call for heat from a radiant zone thermostat or actuator, the IPC activates the injection

pump (P2), the radiant circuit pump (P3), and the boiler. The boiler activates the primarypump (P1), initiating primary circuit flow.

• The IPC regulates the flow rate of the injection pump (P2), increasing flow to raise the supplytemperature, or lowering flow to reduce it.


Part Number 650-000-240/109866


Fill

Boiler

P1

P2

Primary circuit

Primary pump

P3

Manifold

Alocation

Manifold

Blocation

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)






Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold




Conventional boiler supplyingan injection pump panel






Part Number 650-000-240/1098 67


2-wireactuator

4-wireactuator

LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

T

C1

B2

T

C2

B1

L

N

G

P1

120 VAC

120

VAC

Ser

vice

sw

itch

Roomthermostat

Roomthermostat

P2

P3

Valveactuator

Valveactuator

See note 3

Seenote 3

These pumpsare mounted andpre-wired on the

panel.IPPOutdoor sensor,required only ifusing outdoor reset.



PrimaryPump

Burner


Oil-firedBoiler

Indoor sensor(if used in lieu of

zone t-stats)

Valveactuator

24 VAC











Part Number 650-000-240/109868



(pages 70 – 71)Two-temperature radiant heating system usingtwo injection pump panels

Purpose• Provide heating water to two radiant circuits - each requiring a different temperature. The

controls and injection pumps regulate radiant circuit supply temperature and maintainminimum boiler return temperature.

Pumps and piping

Primary circuit



Radiant circuits


Radiant heating circuits• Install the injection pump panel for the higher temperature subsystem upstream of the lower

temperature circuit injection pump panel to assure hotter supply water. This is illustrated insystem CP-4, where Circuit #1 is the higher temperature circuit.

• System CP-4 shows two manifold locations for Circuit #2 and one for Circuit #1. The samepiping design can be used for multiple manifolds.


Part Number 650-000-240/1098 69


System CP-4

Controls and wiring


• An IPC is included with each IPP panel (or purchased separately when using field-constructedinjection mixing systems).


• The IPC's control the injection pumps (P2 and P4) and radiant circuit pumps (P3 and P5).The primary pump (P1) operates with the boiler (activated by the boiler controls).

• On each IPC, use dip switch 2 to set radiant pump operation - DOWN for intermittentoperation, UP for continuous pump operation. With continuous radiant pump operation,either use no manifold valve actuators or install a differential pressure by-pass valve (asshown in system CP-12) to protect the pump from dead heading when the manifold valveactuators close.


Operation

• On call for heat from a radiant zone thermostat or actuator, the corresponding IPC activatesits injection pump, radiant circuit pump and the boiler. The boiler activates the primarypump (P1), initiating primary circuit flow.

• The IPC's regulate the injection pump flow rates, increasing flow to raise the supply temperature,or lowering flow to reduce it.


Part Number 650-000-240/109870


Fill

Boiler

P1

P3 P5

P2 P4

IPPInjectionpumppanel #2

IPPInjectionpumppanel #1



Manifold

Alocation

Manifold

Alocation

Manifold

Blocation

Primary circuit

#1#2

#2 #1

IPP #1, with HIGHER supplytemperature requirement, isinstalled upstream on theprimary circuit (in order toreceive the highest watertemperature).

NOTICE

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)


Outdoorsensor


Primary pump



Valve actuators optionalNo valve actuators are shownhere in order to provide forcontinuous circulation.

No valve actuators are shownhere in order to provide forcontinuous circulation.


Purgingvalves

Purgingvalves

Heating systempump

Heating systempump







H HM M

M

C C

CH

Note 2Note 2

Alternate piping

IPP(using mixing valves)

Substitute for panels


Two-temperature radiantheating system using twoinjection pump panels





3. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pump panel.See separate publication for suggested wiring for this piping alternative.

Part Number 650-000-240/1098 71


L1 N

T

C1

B2

T

C2

B1

L

N

G

P1

120 VAC

120

VAC

Ser

vice

sw

itch

Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

See note 3

Seenote 3

2-wireactuator

4-wireactuator

NOTE that IPC #1 is set up forthermostat operation.

IPC #2 is set up for use withindoor sensor and continuousoperation circulator. Thisconfiguration does not requirea voltage applied to terminals15 and 16.


Primarypump

Burner


Oil-firedBoiler

Valveactuator

24 VAC


Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64

Required sensorsZone

orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On

On/Off System PumpIndoor Sensor

Zone ControlContinuous Pump

Reset inputs

P2

P3

P3 and P4 are mounted andpre-wired on the panel.IPP

Outdoorsensor,used onlyfor resetoperation


Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

P4

P5


Outdoorsensor,used forreset ifdesired


Indoorsensor,if usedin lieuof zonet'stats

Indoorsensor,used inlieu ofzonet'stats

IPC #1 IPC #2

Figure 46 -System CP4

Schematicwiring diagram








Part Number 650-000-240/109872



(pages 74 – 75)Two-temperature radiant heating system usingone injection pump panel and a mixing valve

Purpose• Provide heating water to two radiant circuits - each requiring a different water supply

temperature. The control and injection pump provide water hot enough for the highertemperature radiant circuit, and maintain a minimum boiler return temperature. A mixingvalve regulates the supply water to the lower temperature circuit.

Pumps and piping

Primary circuit



Radiant circuits


• Pipe the radiant circuit requiring the higher water temperature (Circuit #2 in system CP-5)directly off of the radiant supply line as shown.

• Install a bridge for connection of the lower temperature radiant circuit (Circuit #1 in systemCP-5). Install a balancing valve in the bridge as shown. Throttle the valve enough to push therequired water through radiant Circuit #2.

• Provide a pump and a three-way mixing valve for the lower temperature circuit (Circuit #1 inCP-5). Assure that the pump is sized to handle the mixing valve pressure drop.

• System CP-5 shows one manifold location for each of the radiant circuits. The same pipingdesign can be used for multiple manifolds.


Part Number 650-000-240/1098 73


System CP-5

Controls and wiring


• An IPC (Injection Pump Control) is included with the IPP panel (or purchased separatelywhen using field-constructed injection mixing systems).


• The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump(P1) operates with the boiler (activated by the boiler controls).

• The low temperature radiant circuit pump (P4) operates when the low temperature circuitrelay is activated through the actuator end switches.

• On each IPC, use dip switch 2 to set radiant pump operation - DOWN for intermittentoperation, UP for continuous pump operation. Because of the bridge in the radiant circuitpiping, the radiant circuit pump always has a flow path, even if manifold valve actuators areused. This eliminates the need for a differential pressure by-pass valve when using manifoldvalve actuators with continuous pump operation.


Operation• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection

pump, radiant circuit pump and the boiler. The boiler activates the primary pump (P1),initiating primary circuit flow.

• On call for heat from one of the low temperature circuit actuator end switches, the lowtemperature circuit relay is activated. This activates pump P4 and signals the IPC for heat.

• The IPC regulates injection pump flow rate, increasing flow to raise supply temperature - orlowering flow to reduce it. Set the IPC supply temperature as needed for the higher temperaturecircuit (Circuit #2 in CP-5). The mixing valve will automatically regulate the supply temperatureto the lower temperature circuit (Circuit #1 in CP-5).


Part Number 650-000-240/109874


Fill

Boiler

P1

P2

P4

Primary circuit

Primary pump

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)


P3

Circuit #1(lower temp)


Note 2

Balancing valve

Mixingvalve

H

C

M

Pump

1


Valve actuators required

Circuit #2(higher temp)


2

Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold




Two-temperature radiantheating system using oneinjection pump panel and amixing valve




2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubingconnected to the first tee should be at least 8 pipe diameters long.



Part Number 650-000-240/1098 75


Indoorsensor,if usedin lieuof zonet'stats

L1 N

T

C1

B2

T

C2

B1

L

N

G

P1

P4

120 VAC

120

VAC

Ser

vice

sw

itch

Roomthermostat

Roomthermostat

Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

Valveactuator

Valveactuator

Valveactuator

Valveactuator

See note 3

See note 3

Seenote 3

Seenote 3

2-wireactuator

2-wireactuator

4-wireactuator

4-wireactuator

To additionalactuators(high temp circuit)

To additionalactuators(low temp circuit)

Primarypump

Low tempcircuitpump

Burner


Oil-firedBoiler

24 VAC


Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

P2

P3


Outdoorsensor,used forreset ifdesired


IPC #2

Low temperature zones . . . .

High temperature zones . . . .

Low tempcircuitrelay










Part Number 650-000-240/109876



(pages 78 – 79)Radiant heating and domestic water heating withconventional boiler - DHW as a secondary circuit

Purpose• Provide radiant heating and domestic water heating (with optional domestic priority). The

control and injection pump regulate radiant circuit supply temperature and maintainminimum boiler return temperature.

Pumps and piping

Primary circuit



Radiant circuits

• The Injection Pump Panel (IPP) includes the injection pump and the radiant circuit pump.(For applications larger than the capacity of the IPP, use multiple IPP panels or use an IPCInjection Pump control with an injection pump and radiant circuit pump sized for the flowrates and pressure drops needed.)

• System CP-6 shows two manifolds location for the radiant circuits. The same piping designcan be used for multiple manifolds.


Water heater circuit

• Provide a pump with the domestic water heater, sized to give the required flow through theheater for the supply water temperature available.

• Pipe the domestic water circuit as the first branch off the primary circuit. This assures thehottest possible supply water temperature.

Part Number 650-000-240/1098 77


System CP-6

Controls and wiring

Radiant heating controls

• An IPC (Injection Pump Control) is included with the IPP panel (or purchased separately when using field-constructed injection mixing systems).

• The IPC can be set for fixed supply temperature or outdoor reset (requires outdoor sensor). You can connect anindoor temperature sensor or tekmar® zone control to the IPC to provide room temperature feedback to thecontrol, allowing heating circuit regulation based on space temperature response.

• The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump (P1) operates withthe boiler (activated by the boiler controls).

• Use IPC dip switch 2 to set radiant circuit pump operation - DOWN for intermittent operation, UP for continuouspump operation. With continuous radiant pump operation, either use no manifold valve actuators or install adifferential pressure by-pass valve (as shown in system CP-12) to protect the pump from dead heading when themanifold valve actuators close.

• Do not connect a 24 volt or 120 volt signal to terminals 15 and 16 if either a zone control or an indoor sensor isconnected to the IPC.

DHW controls

• Provide a DHW relay as shown in the wiring diagram.

Operation

Domestic water heating

• The primary pump must operate to provide heating water to the domestic water heater. Heating water must flowthrough the primary piping during any domestic water heating cycle, including non-heating season periods. Thisapproach is best used on systems with short primary circuit piping, to minimize non-heating season pipinglosses. See systems CP-7 and CP-8 for alternate designs that do not require primary circuit operation duringdomestic water heating cycles.

• On call for heat from the water heater tank aquastat, the DHW relay is activated. This relay activates the boiler andthe DHW pump (P2). The boiler, in turn, activates the primary pump, P1. If wired for domestic priority, the DHWrelay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P3). The radiantcircuit pump (P4) will turn off as well unless IPC dip switch #2 is set for continuous pump operation.

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump, radiant circuitpump and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary circuit. If theDHW relay is wired for domestic priority, the IPC will not sense the call for heat until the domestic water heatingcycle is completed.

• The IPC regulates injection pump flow rate, increasing flow to raise the supply temperature, or lowering flow toreduce it.

• If boiler return temperature drops below the preset limit (130 °F), the IPC reduces injection flow (reducing thetemperature drop in the primary circuit).

Part Number 650-000-240/109878


Fill

Boiler

P1

P3

Primary circuit


Primarypump

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)

P4

Manifold

Alocation

Manifold

Blocation





Purgingvalves


P2

note 2

flow/checkvalve

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold



DHWoutlet

coldwaterinlet


Radiant heating and domesticwater heating withconventional boiler - DHW asa secondary circuit






Part Number 650-000-240/1098 79


2-wireactuator

4-wireactuator

LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

T

C1

B2

T

C2

B1

L

N

G

120 VAC

120

VAC

Ser

vice

sw

itch

P3

P4These pumpsare mounted andpre-wired on the

panel.IPP

Outdoor sensor,required only if

using outdoor reset.


Burner


Relay shown wiredfor domestic priority.Add jumper, shownin red above, toremove priority.

Oil-

fired

Boile

r

Indoor sensor,if used in lieu of

zone t-stats

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

DHW relay

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator P1P2

Primarypump

DHWpump










Part Number 650-000-240/109880



(pages 82 – 83)Radiant heating and domestic water heating withGV boiler - DHW as a secondary circuit



Pumps and piping

Primary circuit

• System CP-7 uses the integral pump in the GV boiler for primary loop circulation. If a higherflow rate is required, pipe the GV boiler and water heater on a secondary circuit and providea separate pump for the primary circuit.

Radiant heating circuits


• System CP-7 shows two manifold locations for the radiant circuits. The same piping designcan be used for multiple manifolds.




• Pipe the domestic water circuit as the first branch off of the primary. This assures the hottestpossible supply water temperature.

Part Number 650-000-240/1098 81


System CP-7

Controls and wiring




• The IPC controls the injection pump (P2) and radiant circuit pump (P3). The primary pump (P1) is integral to theGV boiler, and is activated by the boiler controls.



DHW controls

• Provide a DHW relay, as shown in the wiring diagram.

Operation


• The primary pump (P1, integral to the GV boiler) must operate to provide heating water to the domestic waterheater. Heating water must flow through the primary piping during any domestic water heating cycle, includingnon-heating season periods. This approach is best used on systems with short primary circuit piping, to minimizenon-heating season piping losses. See systems CP-7 and CP-8 for alternate designs that do not require primarycircuit operation during domestic water heating cycles.

• On call for heat from the water heater tank aquastat, the DHW relay is activated. This relay activates the boiler andthe DHW pump (P2). The boiler, in turn, activates the primary pump (P1). If wired for domestic priority, theDHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P3). Theradiant circuit pump (P4) will turn off as well unless IPC dip switch #2 is set for continuous pump operation.

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P3), radiantcircuit pump (P4) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. If theDHW relay is wired for domestic priority, the IPC will not sense the call for heat until the domestic water heatingcycle is completed.



Part Number 650-000-240/109882



Fill

GV BoilerP1

P3

P2

Primary circuitS

afet

y co

ntro

ls(a

s re

quir

ed b

ylo

cal c

odes

)


note 2

flow/checkvalve

P4

Manifold

Alocation

Manifold

Blocation





Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold



coldwaterinlet

DHWoutlet


Radiant heating and domesticwater heating with GV boiler -DHW as a secondary circuit




2. Space branch tees no more than 4 pipe diameters apart. Ream the pipe or tube stub between the tees thoroughly to prevent turbulence. The pipe or tubingconnected to the first tee should be at least 8 pipe diameters long.



Part Number 650-000-240/1098 83


2-wireactuator

4-wireactuator

T T

L

N

GP2P1

LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

120 VAC

120

VAC

Ser

vice

sw

itch

P3

P4


Primary circulator relay(24 VAC coil)





zone t-stats

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

DHWpump

DHW relay

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator

Safe

ty c

ontro

ls, i

fre

quire

d by

loca

l cod

es

GVBoiler

Relay shown wired forDHW priority. To removepriority, add red jumperwhere shown above.










Part Number 650-000-240/109884



(pages 86 – 87)Radiant heating and domestic water heating withconventional boiler - independent DHW operation



• This system allows domestic water heating without flow in the primary circuit, reducingpiping losses during non-heating season periods.

Pumps and piping

Primary circuit



Radiant circuits






• Include a flow/check valve in the primary and water heater circuits, as illustrated, to preventflow short circuiting.

• Connect the DHW supply directly off of the boiler supply piping. This assures the hottestpossible supply water temperature. Connect the DHW return to the boiler return piping.

Part Number 650-000-240/1098 85


System CP-8

Controls and wiring







DHW controls


Operation


• On call for heat from the water heater tank aquastat, the DHW relay is activated. This relay activates the boiler andthe DHW pump (P2). The boiler, in turn, activates the primary pump, P1. If wired for domestic priority, the DHWrelay turns off the primary pump (P1) and interrupts the heating signal to the IPC, causing the IPC to turn off theinjection pump (P3).

• The radiant circuit pump (P4) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P3), radiantcircuit pump (P4) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primarycircuit. If the DHW relay is wired for domestic priority, the primary pump will not be powered and the IPC will notsense the call for heat until the domestic water heating cycle is completed.



Part Number 650-000-240/109886


Fill

Boiler

P1

P2

P3IPCInjectionpumpcontrol

Primary circuit


Primarypump

coldwaterinlet

DHWoutlet

DH

W p

ump GOLD Plus

water heater

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)

Flow/checkvalve

Flow/checkvalve

P4IPPInjectionpumppanel

Manifold

Alocation

Manifold

Blocation





Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold


Radiant heating and domesticwater heating withconventional boiler -independent DHW operation






Part Number 650-000-240/1098 87


2-wireactuator

4-wireactuator

LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

T

C1

B2

T

C2

B1

L

N

G

120 VAC

120

VAC

Ser

vice

sw

itch

P3


panel.IPP




Burner


Relay shown wiredfor domestic priority.Add (2) jumpers, shownin red above, to removepriority.

Oil-

fired

Boile

r


zone t-stats

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

DHW relay

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator P1P2

Primarypump

DHWpump










Part Number 650-000-240/109888



(pages 90 – 91)

Purpose• Provide radiant heating and domestic water heating with domestic priority. The control and

injection pump regulate radiant circuit supply temperature and maintain minimum boilerreturn temperature.

• This system provides domestic water heating without flow in the primary circuit, reducingpiping losses during non-heating season periods.

Pumps and piping

Primary circuit

• The GV boiler integral pump must provide flow for the water heater and primary circuits.

Radiant circuits


• System CP-9 shows two manifold location for the radiant circuits. The same piping designcan be used for multiple manifolds.

• Manifold valve actuators are optional, but recommended as discussed in Zoning radiantheating systems, section IV of this Guide. When actuators are not used, provide the call forheat signal to the IPC (24 volt or 120 volt signal to terminals 15 and 16) through a zonethermostat or a dry contact that closes on a call for heat.


• The 3-way diverting valve is normally open to the radiant heating circuit (primary). It directsflow through either the primary or domestic water circuit.

Radiant heating and priority domestic water heatingwith GV boiler – DHW through diverting valve

Part Number 650-000-240/1098 89


System CP-9

Controls and wiring







DHW controls


Operation


• On call for heat from the water heater tank aquastat, the diverting valve directs flow to the water heater and theDHW relay is activated. This relay activates the boiler. The boiler, in turn, activates the primary pump, P1. TheDHW relay interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P2). Theradiant circuit pump (P3) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P2), radiantcircuit pump (P3) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primarycircuit. When the DHW relay is activated, the IPC will not sense the call for heat until the domestic water heatingcycle is completed.



Part Number 650-000-240/109890


Fill

GV Boiler


DHW diverter valve

P1

P2

Primary circuitS

afet

y co

ntro

ls(a

s re

quir

ed b

ylo

cal c

odes

)

common

normallyclosed

normallyopen


P3

Manifold

Alocation

Manifold

Blocation





Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold



DHWoutlet

cold waterinlet


Radiant heating and domesticwater heating with GV boiler -DHW through diverting valve






Part Number 650-000-240/1098 91


2-wireactuator

4-wireactuator

T T

H

N

G

P1

LR 58223NRTL/C

OutdoorTempShutoff




Supply TempRatio


185 °F 185 °F

100 °F

85 °F 85 °F

40 °F

0.2 3.6

3

21

140 °F 140 °F

70 °F

InjectionPumpSpeed

10

30

90

70

50

SystemPump


Call ForHeat

%

%

%

%

%

Power


Zone orIndoor

InjectionPumpN L

SystemPumpN L

PowerN L

120 V (ac)

BoilerReturn

FromRadiantT-stat

ToBoiler

T-T

Made inCanada

RadiantSupply




120 V (ac) 5 A 1/6 hp.

120 V (ac) 10 A 1/3 hp.

24 to 120 V (ac) 2 VA

fuse T2.5 A 250 V

pilot duty 240 VA

Inj. Pump:

Sys. Pump

T-stat:BLR Relay:

®

3 7 11 151 8 12 162 5 9 13 176 10 14 184

FOR

RESET

ONLY

1 2 3

Reset Off

Reset On

On/OffSystem Pump

IndoorSensor Input

Zone ControlInput


L1 N

120 VAC

120

VAC

Ser

vice

sw

itch

P2


panel.IPP




Indoor sensor,(if used in lieu of

zone t-stats)

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

24VAC DHW diverter valve(energized on call for DHW)

DHW relay

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator


GV Boiler










Part Number 650-000-240/109892



(pages 94 – 97)Radiant heating, domestic water heating andbaseboard heating with conventional boiler

Purpose• Provide multiple heating functions - radiant heating and baseboard heating plus domestic

water heating (with optional domestic priority). The control and injection pump regulateradiant circuit supply temperature and help maintain minimum boiler return temperature.

• This system provides domestic water heating without flow in the primary circuit, reducingpiping losses during non-heating season periods.

• Two versions are shown – one for baseboard zoning with zone valves (CP-10a) and the otherfor baseboard zoning with pumps (CP-10b).

Pumps and piping

Primary circuit



Radiant circuits






• Connect the DHW supply directly off of the boiler supply piping. This assures the hottestpossible supply water temperature. Connect the DHW return to the boiler return piping.

• Include a flow/check valve in the primary and water heater circuits, as illustrated, to preventflow short circuiting.

Baseboard circuits

• The system illustration shows several options for baseboard circuit piping. Provide thepumps needed for the baseboards. Each baseboard branch circuit off of the primary willrequire at least one pump, even if zoning with zone valves. Use flow/check valves in thebaseboard circuits as illustrated. A flow/check is required in every loop when zoning withpumps. A flow/check is required on the return piping when the piping is above the primaryunless a thermal trap is provided as shown.

Part Number 650-000-240/1098 93


System CP-10

Controls and wiring

Baseboard and DHW controls

• Baseboard heating and domestic water heating are operated through a Multi-zone relay center, illustrated basedon zoning the baseboard heating with pumps. If zoning with zone valves, replace the thermostats shown connectedto the relay center with the zone valve end switches. If domestic water heating priority is desired, add the DHWrelay.




• The IPC controls the injection pump (P10) and radiant circuit pump (P11). The primary pump (P1) operateswith the boiler (activated by the boiler controls).



Operation


• On call for heat from the water heater tank aquastat, the DHW circulator is activated by the relay center and theDHW relay (optional) is activated. If wired for domestic priority, the DHW relay turns off the primary pump (P1)and interrupts the heating signal to the IPC, causing the IPC to turn off the injection pump (P10). The radiantcircuit pump (P11) will turn off as well unless IPC dip switch 2 is set for continuous pump operation.

Baseboard heating

• On call for heat from a baseboard zone, the relay center activates the zone pump and turns on the boiler. Theboiler, in turn, activates the primary pump (P1). If domestic water priority is installed, the primary pump will notoperate during a water heating cycle.

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P10), radiantcircuit pump (P11) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. Ifdomestic water priority is installed, the primary pump will not be powered and the IPC will not sense the call forheat until the domestic water heating cycle is completed.



Part Number 650-000-240/109894



Fill

P1

P11

P10

P2

IPP Injectionpump panel


Manifold

Alocation

Manifold

Blocation

Primary circuit





flow/checkvalve

flow/checkvalve

Boiler

Saf

ety

cont

rols

(as

requ

ired

bylo

cal c

odes

)

Purgingvalves

Purgingvalves

Purgingvalves

P3

P3

P3

Baseboard zones(when above primary)

Baseboard zones(when below primary)

note 2

Zonevalves

Zone valves

Zonevalves

note 2

Thermaltrap - 18" min.

Alternate piping to circuit at left, usingflow/check valve on return line in placeof thermal trap

Use minimum 18" thermal trapas alternate to flow/check valve


Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold

DHWoutlet

coldwaterinlet

Figure 57 - System CP10a

Radiant heating, domesticwater heating and baseboardheating with conventionalboiler - baseboard zoning withzone valves







Part Number 650-000-240/1098 95


Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

2-wireactuator

4-wireactuator

L1 N

TC1

B2

TC2

B1

L

N

G

120 VAC

120

VAC

Ser

vice

sw

itch

Burner


Oil-firedBoiler

24 VAC

Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

DHW pump

DHW relay

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator

P1

P2

Primarypump

P10

P11


Outdoorsensor,if used Supply &

return sensors

Transformer120vac/24vacMinimum rating 10 va plus6 va per AlumiPex valveactuator connected, plustotal va load of all zonevalves connected

∗ Relay shown wiredfor domestic priority.Add (2) jumpers, shownin red, to remove priority.

Baseboardthermostats

Zone valves

P3

Baseboardpump

Baseboardrelay

Indoorsensor,if usedin lieuof valveactuators

Figure 58 -System CP10a









Part Number 650-000-240/109896



Fill

P1

P11

P10

P2

Manifold

Alocation

Manifold

Blocation

Primary circuit





flow/checkvalve

flow/checkvalve

Boiler

Saf

ety

cont

rols

(as

requ

ired

bylo

cal c

odes

)

Purgingvalves

P4

P4

P4

P5

P5

P5

P6

P6

P6

Flow/check valves Flow/check valves

Flow/check valves


P3



note 2

note 2





Purgingvalves

Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold



DHWoutlet

coldwaterinlet

Figure 59 - System CP10b

Radiant heating, domesticwater heating and baseboardheating with conventionalboiler - baseboard zoning withpumps


Notes1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain

does not represent that this drawing meets any particular mechanical or building codes. The installer isresponsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shownon drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram.



4. Alternate piping shown for use of two mixing valves, piped as shown, in lieu of using injection pumppanel. See separate publication for suggested wiring for this piping alternative.

Part Number 650-000-240/1098 97


2-wireactuator

4-wireactuator

L1 N

T C1

B2

T C2

B1

L

N

G

120 VAC

120

VAC

Ser

vice

sw

itch

Burner


Oil-firedBoiler

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

Multi-zone relay center

DHW relay - use if DHW priority req’d120 VAC coil(supplied by installer)

DHW pump

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator

P1

P2 P4 P5 P6

Primarypump

Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

P10

P11



returnsensors

See control manufacturer's instructions for DHW priority activation

Baseboard zonethermostats

Power

Isolatedboilercontact

T1

T N T T PR PR C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 C6 C6

T1 T3T3T2T2 T4T4 T5 T5 T6 T6


Figure 60 -System CP10b









Part Number 650-000-240/109898



(pages 100 – 103)Radiant heating, domestic water heating andbaseboard heating with GV boiler

Purpose• Provide multiple heating functions - radiant heating and baseboard heating plus domestic

water heating (with optional domestic priority). The control and injection pump regulateradiant circuit supply temperature and help maintain minimum boiler return temperature.

• Two versions are shown - one for baseboard zoning with zone valves (CP-11a) and the otherfor baseboard zoning with pumps (CP-11b).

Pumps and piping

Primary circuit

• The GV integral pump provides flow in the primary circuit. If more flow is required, installthe GV boiler as a secondary circuit off the primary and provide an appropriately sizedprimary pump.

Radiant circuits






• Connect the water heater in the first secondary circuit off of the primary. This assures thehottest available supply water.

Baseboard circuits

• The system illustration shows several options for baseboard circuit piping. Provide the pumpsneeded for the baseboards. Each baseboard branch circuit off of the primary will require atleast one pump, even if zoning with zone valves. Use flow/check valves in the baseboardcircuits as illustrated. A flow/check is required in every loop when zoning with pumps. A flow/check is required on the return piping when the piping is above the primary unless a thermaltrap is provided as shown.

Part Number 650-000-240/1098 99


System CP-11

Controls and wiring

Baseboard and water heating controls

• Baseboard heating and domestic water heating are operated through a Multi-zone relay center, illustrated basedon zoning the baseboard heating with pumps. If zoning with zone valves, replace the thermostats shown connectedto the relay center with the zone valve end switches. If domestic water heating priority is desired, add the DHWrelay.




• The IPC controls the injection pump (P10) and radiant circuit pump (P11). The primary pump (P1) is integral tothe GV boiler (activated by the boiler controls).



Operation


• On call for heat from the water heater tank aquastat, the DHW circulator is activated by the relay center and theDHW relay (optional) is activated. If wired for domestic priority, the DHW relay interrupts the heating signal tothe IPC, causing the IPC to turn off the injection pump (P10). The radiant circuit pump (P11) will turn off as wellunless IPC dip switch 2 is set for continuous pump operation.

Baseboard heating

• On call for heat from a baseboard zone, the relay center activates the zone pump and turns on the boiler. Theboiler, in turn, activates the primary pump (P1).

Radiant heating

• On call for heat from a radiant zone thermostat or actuator, the IPC activates its injection pump (P10), radiantcircuit pump (P11) and the boiler. The boiler activates the primary pump (P1), initiating flow in the primary. Ifdomestic water priority is installed, the IPC will not sense the call for heat until the domestic water heating cycle iscompleted.



Part Number 650-000-240/1098100

AlumiPAlumiPAlumiPAlumiPAlumiPeeeeexxxxx® ® ® ® ® Radiant TRadiant TRadiant TRadiant TRadiant TubingubingubingubingubingS

afet

y co

ntro

ls(a

s re

quire

d by

loca

l cod

es)

P1

P11

P10



Manifold

Alocation

Manifold

Blocation

Primary circuit






Purgingvalves

Fill

GV Boiler


DHWoutlet

coldwaterinlet

P2

note 2

flow/checkvalve

P3

P3

P3



note 2

Zonevalves

Zonevalves

note 2




Zone valves

Purgingvalves

Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold


Radiant heating, domesticwater heating and baseboardheating with GV boiler -baseboard zoning with zonevalves







Part Number 650-000-240/1098 101



Zone valves

2-wireactuator

4-wireactuator

L1 N

120 VAC

120

VAC

Ser

vice

sw

itch

24 VAC

Transformer120vac/24vacMinimum rating 10 va plus6 va per AlumiPex valveactuator connected, plustotal va load of all zonevalves connected

Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator

Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

P10

P11

P3



returnsensors

T T

L

N

G

P1

Safety controls, ifrequired by local codes

GVBoiler

DHW tankaquastat

DHW pump

Integralpump

DHW relay

Baseboardpump

Baseboardrelay

P2

∗ Relay shown wired for domestic priority.Add jumper, shown in red, to remove priority.











Part Number 650-000-240/1098102

AlumiPAlumiPAlumiPAlumiPAlumiPeeeeexxxxx® ® ® ® ® Radiant TRadiant TRadiant TRadiant TRadiant TubingubingubingubingubingS

afet

y co

ntro

ls(a

s re

quir

ed b

ylo

cal c

odes

)

P1

P11

P10

Manifold

Alocation

Manifold

Blocation

Primary circuit






Purgingvalves

Fill

GV Boiler


P2

note 2

flow/checkvalve

P4

P4

P4

P5

P5

P5

P6

P6

P6

Flow/check valves Flow/check valves

Flow/check valves

P3



note 2

note 2




Purgingvalves

Purgingvalves

Alternate piping


Heating systempump





Hot

Hot

Mixed

Mixed

Cold


Cold



DHWoutlet

coldwaterinlet


Radiant heating, domesticwater heating and baseboardheating with GV boiler -baseboard zoning with pumps






Part Number 650-000-240/1098 103


2-wireactuator

4-wireactuator

L1 N

120 VAC

120

VAC

Ser

vice

sw

itch

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

Multi-zone relay center

DHW relay - use if DHW priority req’d120 VAC coil(supplied by installer)

DHW pump

See note 3

Seenote 3

To a

dditi

onal

act

uato

rs

Valveactuator

P2 P4 P5 P6

Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

P10

P11



returnsensors

See control manufacturer's instructions for DHW priority activationPower


T1

T N T T PR PR C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 C6 C6

T1 T3T3T2T2 T4T4 T5 T5 T6 T6

T T

L

N

GP1

Safety controls, ifrequired by local codes

GVBoiler

Baseboard zonethermostats











Part Number 650-000-240/1098104


• System CP-12 shows three manifold locations forthe radiant circuits. The same piping design can beused for multiple manifolds.

• Manifold valve actuators are optional, butrecommended as discussed in Zoning radiantheating systems, section IV of this Guide. Whenactuators are not used, provide the call for heat signalto the IPC (24 volt or 120 volt signal to terminals 15and 16) through a zone thermostat or a dry contactthat closes on a call for heat.


• Provide a pump with the domestic water heater, sizedto give the required flow through the heater for thesupply water temperature available.

• Connect the DHW as a secondary circuit directly offof the multiple boiler supply manifold. This assuresthe hottest possible supply water temperature.

Baseboard circuits

• The system illustration shows two options forbaseboard circuit piping (see also system CP-10 foradditional options). Provide the pumps needed forthe baseboards. Each baseboard branch circuit offof the primary will require at least one pump, even ifzoning with zone valves. Use flow/check valves in thebaseboard circuits as illustrated. A flow/check isrequired in every loop when zoning with pumps. Aflow/check is required on the return piping when thepiping is above the primary unless a thermal trap isprovided as shown.

Controls and wiring

Baseboard and domestic water heating controls

• Baseboard heating and domestic water heating areoperated through a Multi-zone relay center,illustrated based on zoning the baseboard heatingwith pumps. If zoning with zone valves, replace the

Radiant heating system examplesXIISystem

CP-12(p.106 – 109)

Radiant heating, domestic water heating and baseboardheating with multiple boilers

Purpose

• Use a multiple boiler system to provide multipleheating functions - radiant heating and baseboardheating plus domestic water heating (with optionaldomestic priority). The control and injection pumpregulate radiant circuit supply temperature and helpmaintain minimum boiler return temperature.

• This system provides domestic water heating withoutflow in the primary circuit, reducing piping lossesduring non-heating season periods. Flow is onlyrequired in the multiple boiler secondary pipingduring domestic water heating cycles.

• Two versions are shown - one for baseboard zoningwith zone valves (CP-12a) and the other forbaseboard zoning with pumps (CP-12b).

Pumps and piping

Primary circuit

• Provide a primary pump sized for the flow needed.

Multiple boiler circuits

• Provide a pump and flow/check valve for each boiler(or use factory-packaged pump, if applicable).

• Residential packaged boilers may have the pumpmounted on the return piping at the boiler. The pumpcan be used in this location provided the expansiontank or compression tank and fill line are correctlylocated.

Radiant heating circuits

• The Injection Pump Panel (IPP) includes the injectionpump and the radiant circuit pump. (For applicationslarger than the capacity of the IPP, use multiple IPPpanels or use an IPC Injection Pump Control with aninjection pump and radiant circuit pump sized forthe flow rates and pressure drops needed.)

Part Number 650-000-240/1098 105


System CP-12

thermostats shown connected to the relay center withthe zone valve end switches.

Radiant controls

• An IPC (Injection Pump Control) is included withthe IPP panel (or purchased separately when usingfield-constructed injection mixing systems).

• The IPC can be set for fixed supply temperature oroutdoor reset (requires outdoor sensor). You canconnect an indoor temperature sensor or tekmar®zone control to the IPC to provide room temperaturefeedback to the control, allowing heating circuitregulation based on space temperature response.

• The IPC controls the injection pump (P2) and radiantcircuit pump (P3). The primary pump (P1) operateswith the boiler (activated by the boiler controls).

• Use IPC dip switch 2 to set radiant circuit pumpoperation - DOWN for intermittent operation, UPfor continuous pump operation. With continuousradiant pump operation, either use no manifold valveactuators or install a differential pressure by-passvalve (as shown in system CP-12) to protect the pumpfrom dead heading when the manifold valve actuatorsclose.

• Do not connect a 24 volt or 120 volt signal to terminals15 and 16 if either a zone control or an indoor sensoris connected to the IPC.

DHW controls

• Provide the DHW relay shown is domestic priority isdesired or to prevent flow in the primary pipingduring non-heating season domestic water heatingperiods.

• Multiple boiler controller.

• Install multiple boiler control, as illustrated. Themultiple boiler control shown has provision foractivation of the DHW pump on a signal from theDHW relay.

Operation


• On call for heat from the water heater tank aquastat,the DHW relay is activated. The relay activates theboiler and signals the multiple boiler control toactivate the DHW pump. The multiple boiler controlsequences boilers on as needed to meet the demand.If wired for domestic priority, the DHW relay turnsoff the primary pump (P4) and interrupts the heatingsignal to the IPC, causing the IPC to turn off theinjection pump (P12). The radiant circuit pump (P13)will turn off as well unless IPC dip switch 2 is set forcontinuous pump operation.

Baseboard heating

• On call for heat from a baseboard zone, the relaycenter activates the zone pump and sends a call forheat to the multiple boiler control. The multiple boilercontrol, in turn, activates the primary pump (P1)and sequences boilers on as needed to meet demand.If domestic water priority is installed, the primarypump will not operate during a water heating cycle.

Radiant heating

• On call for heat from a radiant zone thermostat oractuator, the IPC activates its injection pump (P10),radiant circuit pump (P11) and sends a call for heatto the multiple boiler control. The multiple boilercontrol activates the primary pump (P1), initiatingflow in the primary, and sequences boilers on asneeded to meet demand. If domestic water priority isinstalled, the primary pump will not be powered andthe IPC will not sense the call for heat until thedomestic water heating cycle is completed.

• The IPC regulates injection pump flow rate, increasingflow to raise the supply temperature, or loweringflow to reduce it.

• If boiler return temperature drops below the presetlimit (130 °F), the IPC reduces injection flow (reducingthe temperature drop in the primary circuit).

Part Number 650-000-240/1098106


Differential pressureby-pass valve - requiredif using manifold valves andcontinuous pump operation

swing check valve(to prevent heat migration)

Heating systempump





H

H

M

M

C

C

Note 2Alternate piping


Substitute for panel


DHWoutlet

coldwater

inlet

System pump

Expansiontank

To additional boilers

Fill

P4

P3

PB1 PB2

P13

P12

P5

P5

IPC Injectionpump control

Primary circuit

Baseboardzones



Supplytemp.sensor




note 2

note 2

flow/checkvalve

flow/check valve

Alternate piping to circuit atleft, using flow/check valveon return line in place ofthermal trap

Use minimum 18” thermal trapas alternate to flow/check valve

Boiler Boiler

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)

Purgingvalves


Manifold

Alocation

Manifold

Blocation

Manifold

Clocation


Radiant heating, domesticwater heating and baseboardheating with multiple boilers –baseboard zoning with zonevalves

XII Radiant heating system examples – CP12a






Part Number 650-000-240/1098 107


Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

2-wireactuator

4-wireactuator

L1 N

TT

C1C1

B2B2

TT

C2C2

B1B1

L L

N N

G G

120 VAC

120

VAC

Ser

vice

sw

itch

BurnerBurner



Boiler #1Boiler #2

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHWpump

DHWpriority

relay

Primary circulator

See note 3

To a

dditi

onal

act

uato

rs

Valveactuator

PB1

P4

P3

PB2Boiler

CirculatorBoiler

Circulator

Multipleboiler

control

spaceheatdemand

DHWheatdemand

systemcirculator

Boiler 2 Boiler 1

DHWcirculator

L1

N

P12

P13


Outdoorsensor,if used



Relay shown wiredfor domestic priority.Add (2) jumpers,shown in red above,to remove priority.

Baseboardpump

Baseboardrelay


Zone valves

DHW tankaquastat










Part Number 650-000-240/1098108


Differential pressureby-pass valve - requiredif using manifold valves andcontinuous pump operation

swing check valve(to prevent heat migration)

Alternate piping


Substitute for panel


DHWoutlet

coldwater

inlet

System pump

Expansiontank

To additional boilers

Fill

P4

P3

PB1 PB2

P13

P12

P5 P5

P6 P6

P7 P7

Primary circuit

Baseboardzones



Supplytemp.sensor




note 2

note 2

flow/checkvalves

flow/checkvalve

flow/check valve

Alternate piping to circuit atleft, using flow/check valveon return line in place ofthermal trap.

Use minimum 18” thermal trapas alternate to flow/check valve

Boiler Boiler

Saf

ety

cont

rols

(as

requ

ired

by

loca

l cod

es)

Purgingvalves

Manifold

Alocation

Manifold

Blocation

Manifold

Clocation

Heating systempump





H

H

M

M

C

C

Note 2

IPC Injectionpump control



Radiant heating, domesticwater heating and baseboardheating with multiple boilers -baseboard zoning with pumps

XII Radiant heating system examples – CP12b






Part Number 650-000-240/1098 109


Multi-zone relay centerPower


T1

L N T T PR PR C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 C6 C6

T1 T3T3T2T2 T4T4 T5 T5 T6 T6

Supply Temp.


InjectionPumpSpeed

InjPump

SysPumpPower

120 V (ac)

31 2 5 64


orIndoor

BoilerReturn

RadiantSupply

OutdoorSensor

7 118 129 1310 14

FromRadiantT-stat

ToBoiler

T-T15 16 17 18

Max. Supply Temp.

Supply TempRatio

Reset Off

Reset On



Reset inputs

2-wireactuator

4-wireactuator

L1 N

TT

C1C1

B2B2

TT

C2C2

B1B1

L L

N N

G G

120 VAC

120

VAC

Ser

vice

sw

itch

BurnerBurner



Boiler #1Boiler #2

24 VAC


Roomthermostat

Roomthermostat

Valveactuator

Valveactuator

DHW tankaquastat

DHWpump

DHWpriority

relay

Primary circulator

See note 3

To a

dditi

onal

act

uato

rs

Valveactuator

PB1

P4

P3

PB2Boiler

CirculatorBoiler

Circulator

Multipleboiler

control

spaceheatdemand

DHWheatdemand

systemcirculator

Boiler 2 Boiler 1

DHWcirculator

L1

N

P4 P5 P6

P12

P13



returnsensors


Relay shown wiredfor domestic priority.Add (2) jumpers, shownin red above, to removepriority.











Part Number 650-000-240/1098110


Pump curve equations

To calculate the Feet head for any flow rate for the pump curves given in Figure 26, you can use the followingpolynomial equations. Use only for the flow rate range shown in the curves.

Taco 007 Feet head = 10.932555 - 0.16875578xGPM - 0.01521757xGPM2 + 0.00020748122xGPM3




Taco 0014 Feet head = 21.973589 - 0.48933166xGPM - 0.00063109078xGPM2 – 0.00011604224xGPM3

Grundfos 15-42 Feet head = 16.852408 - 0.59616561xGPM - 0.012300406xGPM2 + 0.0000404xGPM3

Grundfos 26-64 Feet head = 21.973589 - 0.48933166xGPM + 0.00063109078xGPM2 – 0.00011604224xGPM3

Grundfos 43-75 Feet head = 26.387423 - 0.41974859xGPM - 0.003483614xGPM2 + .00000606xGPM3

B & G NRF-22 Feet head = 15 - 0.68182xGPM

B & G PL-30 Feet head = 25.141238 - 0.61869764xGPM - 0.0069084819xGPM2 – 0.00000221388xGPM3

B & G PL-50 Feet head = 17.366568 - 0.084338498xGPM - 0.0023640365xGPM2 – 0.000052571345xGPM3

XIII Appendix

Part Number 650-000-240/1098 111


Quick selector curve equations

The curves shown in Figures 27 through 30 can also be directly calculated using the formula and the chart below. Useonly in the flow rate ranges shown in the quick selector curves.

GPM = x xa bTEL

TELc

007 0010 0012 0014 15-42 26-64 43-75 NRF-22 PL-30 PL-50

a 20.977506 23.949589 26.724723 31.648593 25.160229 32.548114 36.067917 23.053464 33.244621 30.128854

b 0.9999193 0.9999884 0.999995 0.99998 0.9999484 0.999969 0.9999864 0.99994541 0.9999744 0.9999939

c -0.546243 -0.566845 -0.568391 -0.553786 -0.539398 -0.54395 -0.558151 -0.53630256 -0.549257 -0.567042

a 47.282097 83.654266 98.227686 93.893487 56.91038 32.513578 115.98578 51.346672 90.532778 112.76368

b 0.9995437 0.999942 0.9999694 0.9999269 0.9998195 0.9999679 0.9999606 0.99979985 0.9999122 0.9999824

c -0.426158 -0.539835 -0.551448 -0.505463 -0.443727 -0.543695 -0.524145 -0.43772596 -0.488098 -0.554712

a 75.153462 124.66566 172.66094 132.81573 44.919189 102.76405 175.50699 51.754916 106.20044 201.74157

b 0.9997386 0.9998432 0.9999264 0.9998754 0.9995672 0.9998416 0.9999229 0.99965195 0.9998299 0.999942

c -0.396225 -0.473094 -0.515583 -0.441545 -0.274307 -0.392628 -0.471034 -0.31668162 -0.394699 -0.522198

a 71.379514 97.515613 112.68287 109.82208 64.567699 100.35663 131.28224 61.643267 105.56214 128.15213

b 0.9998936 0.9999686 0.9999806 0.9999566 0.9998539 0.9999435 0.9999674 0.99987245 0.9999436 0.9999854

c -0.499304 -0.546292 -0.553938 -0.513679 -0.448395 -0.488876 -0.524849 -0.4548061 -0.496315 -0.555043

a 79.99001 138.55373 192.92987 154.57651 57.748169 122.83323 192.50008 64.069652 129.29073 226.29686

b 0.9997583 0.999878 0.9999562 0.9999245 0.9997203 0.999904 0.9999398 0.9997766 0.9998997 0.9999686

c -0.39971 -0.483946 -0.526506 -0.461537 -0.320622 -0.41861 -0.478421 -0.35422024 -0.424158 -0.533449

a 64.967808 126.50711 228.88302 152.62247 37.056987 106.04502 204.08838 48.05632 106.69447 295.9619

b 0.9996432 0.9997491 0.9998911 0.9998716 0.9995942 0.9998456 0.9998984 0.99965962 0.999835 0.9999352

c -0.281352 -0.376797 -0.46497 -0.380913 -0.173726 -0.321963 -0.408756 -0.23103054 -0.318881 -0.490197

a 58.008279 83.121812 225.94646 99.75135 27.252814 65.834312 168.76916 36.458671 59.002982 281.5639

b 0.9996916 0.9996014 0.9998454 0.99976 0.9996179 0.9997318 0.9998486 0.99963654 0.9997032 0.9998785

c -0.214147 -0.23636 -0.394833 -0.249847 -0.084596 -0.188388 -0.318849 -0.13868336 -0.165534 -0.413095

a 51.44484 62.224837 113.27687 53.9907 22.343917 40.881309 61.072713 25.510536 36.801943 91.875092

b 0.9998399 0.9997454 0.9996836 0.9997668 0.9998137 0.9997681 0.9996566 0.99973669 0.9997716 0.9996731

c -0.145029 -0.12866 -0.182626 -0.089707 -0.027987 -0.061195 -0.070971 -0.03819045 -0.044815 -0.132512

"AlumiPex

‰"AlumiPex

1"AlumiPex

Pump model number

1‰"Copper

2"Copper

Tube size

"Copper

1"Copper

1…"Copper

Part Number 650-000-240/1098112

Price $20

weil mclain radiant heat

Documents

severe personal

installation

injection

p3note 2alternate

substantial

indirect water

fillreturn

test lamps